TM

INTRODUCTION

WAAREE has been manufacturing thermowells for over 10 years and has gained an expertise
that is unsurpassed in the industry. Waaree offers thermowells in a large variety of connections, bore
sizes, stem lengths and materials, including special materials, for all applications.

Thermowells :
Thermowells are used to provide an isolation between a temperature sensor and the
environment, either liquid, gas or slurry. Thermowells protect temperature sensors, including RTDs &
Thermocouples, from the high pressure & corrosive media. They are also used to isolate the temperature
sensors from the service line for repair or replacement.

Types :
Thermowells are closed-end tubes that are available in four different designsA) Straight type designs, which have the largest amount of surface area, do not call for extra machining and
are cost effective. They also represent the most common thermowell design.
B) Straight reduced tip shank thermowells, in comparison to straight type thermowells, provide smoother
speeds around the barrel because they have less surface area.
C) Tapered & partial tapered shank thermowells provide increased sensitivity and have the lowest surface
area of all other designs.

Selection :
Important factors to keep in mind when selecting a thermowell are stem length, bore diameter,
lagging extensions and the thickness of the matter in which the thermowell is rested. The tip thickness
is the distance between the bore and the end of the well. Bore diameter is the size of the opening that
the probe will be put in. Lagging extensions take into consideration the pipe fittings, insulation and walls
that the sensor will go through. Finally, the length from the connection to the bore represents the
Insertion length. The pressure-temperature ratings and selection of suitable thermowell material as
per the requirement of process media has to be taken care while selection.

Design Procedure as per PTC 19.3 :

The purpose of this design procedure is to enable the user to determine if a wall selected for
thermometry considerations is strong enough to withstand specific application conditions of temperature,
pressure, velocity and vibration. Well failures are caused by forces imposed by static pressure, steady
state flow and vibration. This design procedure does not allow for effects due to corrosion or erosion.

The Product Images Shown Inside the Catalogue are for Reference Purpose Only, the Original Product May Differ

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Design Procedure for Thermowells as per PTC 19.3

Figure 1.1 PerformanceTest Code Thermometer Wells
The purpose of this design procedure is to enable the user to determine
if a well selected for thermometry considerations is strong enough to
withstand specific application conditions of temperature, pressure,
velocity and vibration. Well failures are caused by forces imposed by
static pressure, steady state flow and vibration. Separate evaluations of
each of the above effects should be made in order to determine the
limiting condition. This design procedure does not allow for effects due
to corrosion or erosion.
The natural frequency of a well designed in accordance with figure 1.1
and of the dimensions given in table 1.3 is given by the following equation:

3/16"=4.76 mm
A

d
L

Table 1.3 Well dimensions in inches

fn = Kf / L

E/

(Equation 1)

Dimension

where fn = Natural frequency of the wall at use temperature, cycles per second

A (minimum)
B (minimum)
d (minimum)
d (maximum)

L = Length of well as given in figure 1.1

Nominal size of sensing element

1/4
3/8
9/16 11/16
7/8
13/16 15/16 1-1/11 1-1/4 1-7/16
5/8
0.75 15/16 1-1/16 1-1/4
0.254 0.379 0.566 0.691 0.879
0.262 0.387 0.575 0.700 0.888

E = Modulus of elasticity of well material at use temperature, psi

= Specific weight of well material at use temperature, lb per cu in.

Table 1.4 Values of Kf

Nominal size of sensing element
Well Length
L
1/4
3/8
9/16 11/16
7/8
2-1/2
2.06
2.42
2.97
3.32
3.84
4-1/2
2.07
2.45
3.01
3.39
3.96
7-1/2
2.08
2.46
3.05
3.44
4.03

Kf = A constant obtained from table 1.4

The wake or Strouhal frequency is given by:

fw = 2.64*V/B

(Equation 2)

10-1/2
16
24

where fw = Wake frequency, cycles per sec

2.09
2.09
2.09

2.47
2.47
2.47

3.06
3.07
3.07

3.46
3.47
3.48

4.06
4.08
4.09

V = Fluid velocity, fps

Table 1.5 Values of Stress Constants
Nominal size of sensing element
Stress
Constant
1/4
3/8
9/16 11/16
7/8
K1
0.412 0.334 0.223 0.202 0.155
37.5
42.3
46.8
48.7
50.1
K2
K3
0.116 0.205 0.389 0.548 0.864

B = Diameter at tip (figure 1.1), in.

The ratio of wake to natural frequency (fw/fn) shall not exceed 0.8, and
then this condition is met, the Magnification Factor, relationship of
dynamic to static amplitude is given by:
2

FM =(fw/fn) / 1-((fw/fn) = r /1-r

(Equation 3)

The maximum length that a thermometer well can be made for a given
service is dependent upon both vibratory and steady stste stress. The
necessity for keeping the frequency ratio at 0.8 or less imposes one
limitation on maximum length. The other limitation is one of steady state
stress considerations, as given by the following equation:

For r < 0.8

where
FM = Magnification factor, dimensionless

Lmax = K2/V

(S-K3Po)/1+ FM

(Equation 5)

r = Frequency ratio, (fw/fn), dimensionless

where
Stress Analysis
The maximum pressure that a thermometer wellcan withstand for a given
material at a given temperature shall be computed from the following:

V = Fluid velocity, fps

P= K1S

= Specific volume of the fluid, cu ft per lb

(Equation 4)

where

Lmax = Maximum values of L (as shown in Figure 1.1) for a given service, in.

S = Allowable stress for material at opening temperature as given in the

ASME Boiler and Pressure Vessel or Piping Codes, psi

P = Maximum allowable static gage pressure, psi

S = Allowable stress for material at opening temperature as given in the
ASME Boiler and Pressure Vessel or Piping Codes, psi

Po = Static operating gage pressure, psi

FM = Magnification factor

K1 = A stress constant obtained from table 1.5.

K2, K3 = Stress constants obtained from Table 1.5

II

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THERMOWELL TERMINOLOGY
Process Connection

External means to connect thermowell to process system. Wells can be threaded, bolted (to
matching flange), clamped, or welded in place.

Instrument Connection

Internal threads to connect temperature instrument to thermowell.

U Length

Length of thermowell immersed into process system. Measured from the base of the process
connection to the end tip of the well.

H Extension Length

Also called lagging extension. Extends length between the instrument and process
Connections to accommodate vessel or piping insulation.

G Minor Diameter

Also called tip diameter. Diameter of thermowell shank at the end tip of the thermowell. This
dimension may vary with process connection and/or shank design.

F Major Diameter

Also called root diameter. Diameter of thermowell shank below the process connection.
This dimension may vary with process connection and/or shank design.

D Bore Diameter

Dimension of internal bore to match the diameter of the instrument inserted into the
thermowell.

Straight Reduced Shank

Also called reduced tip. The shank O.D. is reduced at the end of the U dimension
from the standard root diameter.

Straight Shank

Thermowell O. D. is same throughout the U length.

Tapered Shank

Shank O.D. is gradually reduced from the root diameter (F Major Diameter) to the tip diameter
(G Minor Diameter). The tapered shank is recommended for heavy duty applications
characterized by high vibration, pressure, temperature, and/or velocity.

MANUFACTURING TOLERANCE FOR BAR STOCK THERMOWELLS

Spanner Slots
+0.00 / -0.50 mm
Major / Minor Diameter
0.25 mm
U Length
1.00 mm up to 1000 mm
5.00 mm above 1000 mm (Built - in Bar stock type)
Tip Thickness
+1.0 mm
- 0.0 mm
Bore Diameter
+0.20 mm
Head Size
0.20 mm for Round Head
0.20 mm for Hexagonal Head

III

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TABLE 1.1
SELECTION TABLE FOR HEAD SIZE & CONNECTION
T HERMOWELL
INST UMENT
CONNECT ION

T HERMOWELL PROCESS CONNECT ION

MINIMUM HEAD SIZE

HEX HEADED
ROUND HEADED
(mm)
(mm)
22
25
25
25
30
30
36
36
22
25
25
25
30
30
36
36

3/8"(F)
BSP, NPT , PF, R, G &
BSPT

3/8" BSP, NPT , PF, R, G & BSPT (M)

1/2" BSP, NPT , PF, R, G & BSPT (M)
3/4" BSP, NPT , PF, R, G & BSPT (M)
1" BSP, NPT , PF, R, G & BSPT (M)
M20 x 1.5(M)
M22 x 1.5(M)
M27 x 2(M)
M33 x 2(M)

1/2"(F)
BSP, NPT , PF, R, G &
BSPT

3/8" BSP, NPT , PF, R, G & BSPT (M)

1/2" BSP, NPT , PF, R, G & BSPT (M)
3/4" BSP, NPT , PF, R, G & BSPT (M)
1" BSP, NPT , PF, R, G & BSPT (M)
M20 x 1.5(M)
M22 x 1.5(M)
M27 x 2(M)
M33 x 2(M)

25
25
30
36
25
25
30
36

28
28
30
36
28
28
30
36

3/4"(F)
BSP, NPT , PF, R, G &
BSPT

3/8" BSP, NPT , PF, R, G & BSPT (M)

1/2" BSP, NPT , PF, R, G & BSPT (M)
3/4" BSP, NPT , PF, R, G & BSPT (M)
1" BSP, NPT , PF, R, G & BSPT (M)
M20 x 1.5(M)
M22 x 1.5(M)
M27 x 2(M)
M33 x 2(M)

32
32
32
36
32
32
34
36

34
34
34
36
34
34
34
36

The data provided above is just for reference purpose. Waaree does not guarantee for its accuracy & correctness.
However user has to refer the relevant standards to select the material.

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Thermowell Material Selection Guide - Chemical Application

Chemical Application
Acetic acid
10 to 50%, 21C
50%, 100C
99% 21 to 100C
Alcohol, ethyl, methyl
21 to 100C
Ammonia
All concentration 21C
Ammonium chloride
All concentration 100C
Ammonium nitrate
All concentration 21 to
100C
Ammonium sulphate,
10% to saturated 100C
Barium chloride, all concentration,
21C
Barium hydroxide, all concentration,
21C
Barium sulphite
Brines
Bromine
Butadiene
Butane
Butylacetate
Butyl alcohol
Calcium chlorate, dilute 21 to 66C
Calcium hydroxide
10 to 20%, 100C
50%, 100C
Carbolic acid, all, 100C
Carbon dioxide, wet or dry
Chlorine gas
Dry, 21C
Moist, -7 to 100C
Chromic acid, 10 to 50% 100C

Thermowell Material
Type 304, Hastelloy C, Monel
Type 316, Ha stelloy C, Monel
Type 430, Hast elloy C, Monel
Type 304
Types 304, 316 SS

Types 316 SS, Monel

Chemical Application

Thermowell Material

Formaldehyde
Formic acid, 5%, 21 to 66C
Freon
Gallic acid, 5%,21 to 66C
Gasoline, 21C
Glucose, 21C
Glycerine, 21C
Glycerol
Hydrobromic acid, 98%, 100C
Hydrochloric acid
1%, 5% 21C
1%, 5% 100C

Types 304 SS, 316 SS

Type 316 SS
Monel
Monel
Type 304 SS, low carbon steel
Type 304 SS
Type 304 SS
Type 304 SS
Hastelloy B

Type 316 SS

25%, 21 to 100C
Hydrofluoric acid, 60%, 100C
Hydrogen peroxide, 21 to 100C

Hastelloy C, Monel
Types 316 SS, 304 SS

Monel, Hastelloy C

Hydrogen sulphide, wet and dry

Type 316 SS

Low carbon steels

Iodine, 21C

Tantalum

Nichrome Hastelloy C
Monel
Tantalum, Monel
Type 304 SS
Type 304 SS
Monel
Type 304 SS

Lactic acid
5%, 21C
5%, 66C
10%, 100C
Magnesium chloride
5%, 21C
5%, 100C
Magnesium sulphate, hot and
cold
Muriatic acid, 21C
Naptha, 21C
Natural gas, 21C
Nickel chloride, 21C
Nickel sulphate, hot and cold
Nitric acid
5%, 21C
20% 21C

Type 304 SS
Type 304 SS, Hastelloy C
Type 316 SS, Hastelloy C
Type 316 SS
2017-T4 aluminum, Monel, nickel
Type 316 SS, Monel
Hastelloy C
Type 316 SS, Hastelloy C (all
concentrations)

Copper nitrate
Copper sulphate
Cresols
Cyanogen gas
Dow therm
Ether
Ethyl acetate
Ethyl chloride, 21C
Ethyl sulphate, 21C
Ferric chloride, 5%, 21C to boiling

Type 304 SS, Hastelloy C (all

concentrations)
Type 316 SS, Hastelloy C (all
concentrations)
Type 316 SS, Hastelloy C (all
concentrations)
Types 304 SS, 316 SS
Types 304 SS, 316 SS
Type 304 SS
Type 304 SS
Low carbon steels
Type 304 SS
Monel, Type 304 SS
Type 304 SS, low carbon steel
Monel
Tantalum, Hastelloy C

Ferric sulphate, 5%, 21C

Ferrous sulphate, dilute, 21C

Type 304 SS
Type 304 SS

15%, 100C
Concentrated, 100C

Hastelloy B

Type 316 SS

Citric acid
15%, 21C

Hastelloy C
Hastelloy B

Type 304 SS, 316 SS

Type 316 SS
Tantalum
Nickel, Monel,
Nickel
Monel
Tantalum
Type 304 SS
Types 304 SS, 316 SS, 317 SS
Type 304 SS
Type 304 SS
Types 304 SS, 316 SS
Types 304 SS, 316 SS

50% 21C

Types 304 SS, 316 SS

50% 100C

Types 304 SS, 316 SS

65% 100C

Type 316 SS

Concentrated, 21C

Types 304 SS, 316 SS

Concentrated, 100C
Nitrobenzene, 21C
Oleic acid, 21C
Oleum, 21C
Oxalic acid
5% hot and cold
10%, 100C
Oxygen 21C
Palmitic acid
Pentane

Tantalum
Type 304 SS
Type 316 SS
Type 316 SS
Type 304 SS
Monel
Steel
Type 316 SS
Type 340 SS

The data provided above is just for reference purpose. Waaree does not guarantee for its accuracy & correctness.
However user has to refer the relevant standards to select the material.

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Thermowell Material Selection Guide - Chemical Application

Chemical Application

Thermowell Material
Type 304 SS

Type 304 SS
Type 304 SS

Sodium sulphite, 30%, 66C

Sulphur dioxide
Moist gas, 21C
Gas, 302C
Sulphur
Dry molten
Wet
Sulphuric acid
5%, 21 to 100C)
10%, 21 to 100C
50%, 21 to 100C
90%, 21C
90% 100C
Tannic acid 21C
Tartaric acid
21C
150C

Potassium permanganate, 5%, 21C

Type 304 SS

Toluene

Potassium sulphate, 5%, 21C

Potassium sulphide, 21C
Propane
Pyrogallic acid
Quinine bisulphate, dry
Quinine sulphate, dry
Seawater
Salicylic acid
Sodium bicarbonate
All concentration, 21C
5%, 66C
Sodium carbonate, 5%, 21 to 66C
Sodium chloride
5%, 21 to 66C
Saturated, 21 to 100C
Sodium fluoride, 5%, 21C
Sodium hydroxide
Sodium hypochlorite, 5% still
Sodium nitrate, fused
Sodium peroxide
Sodium sulphate, 21C
Sodium sulphide, 21C

Types 304 SS, 316 SS

Types 304 SS, 316 SS
Type 304 SS, low carbon steel
Type 304 SS
Type 316 SS
Type 304 SS
Monel, Hastelloy C
Nickel

Turpentine
Whiskey and wine
Xylene
Zinc chloride
Zinc sulphate
5% 21C
Saturated 21C
25% 100C

Chemical Application
Phosphoric acid
1%, 5%, 21C
10%, 21C
10%, 100C
30%, 21 to 100C
85%, 21 to 100C
Picric acid, 21C
Potassium bromide, 21C
Potassium carbonate, 1%, 21C
Potassium chlorate, 21C
Potassium hydroxide
5% 21C
25% 100C
60% 100C
Potassium nitrate
5%, 21C
5%, 100C

Thermowell Material
Type 304 SS,
Type 316 SS
Hastelloy C
Hastelloy B
Hastelloy B
Type 304 SS
Type 316 SS
Types 304 SS, 316 SS
Type 304 SS
Type 304 SS
Type 304 SS
Type 316 SS

Type 316 SS
Types 304 SS, 316 SS
Type 304 SS
Type 316 SS
Hastelloy B, 316 SS
Hastelloy B
Hastelloy B
Hastelloy B
Hastelloy D
Type 304 SS, Hastelloy B
Type 304 SS
Type 316 SS
2017-T4 aluminium, low carbon
steel
Types 304 SS 316 SS
Type 304 SS, nickel
Copper
Monel
Types 304 SS, 316 SS
Types 304 SS, 316 SS
Types 304 SS, 316 SS

Type 304 SS
Types 304 SS, 316 SS
Types 304 SS, 316 SS
Type 316 SS
Type 316 SS, Monel
Monel
Types 304 S, 316 SS, Hastelloy C
Type 316 SS, Hastelloy C
Type 316 SS
Type 304 SS
Types 304 SS, 316 SS
Type 316 SS

The data provided above is just for reference purpose. Waaree does not guarantee for its accuracy & correctness.
However user has to refer the relevant standards to select the material.

VI

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Thermowell Material Selection Guide - Industrywise Application

Application
Heat Treating
`1Annealing
Up to 704C
Over 704C
Carburising hardening
Up to 816C
816 to 1093C)
Over 1093C
Nitriding salt baths
Cyanide
Neutral
High speed
Iron and steel
Blast furnaces
Downcomer

Thermowell Material

Application

Inconel 600, Type 446 SS

Silicon carbide, LT-1

Cement
Exit flues
Kilns, heating zone
Ceramic
Kiln
Dryers
Vitreous enamel ling
Paper
Digesters
Glass
Fore hearths and feeders
Lehrs
Tanks Roof and wall
Flues and checkers
Petroleum

Stove dome

Inconel 600

De-waxing

Hot blast main

Inconel 600

Towers

Stove trunk

Black steel

Transfer lines

Black steel
Inconel 600, Type 446 SS
Black steel, Type 446 SS
Inconel 600, Type 446 SS
Ceramic*
Type 446 SS
Nickel (CP)
Type 446 SS
Ceramic*

Stove outlet flue

Factioning column

Thermowell Material
Inconel 600, Type 446 SS
Inconel 600
Ceramic, and silicon carbide
Silicon carbide, black steel
Inconel 600, Type 446 SS
Type 316 SS, Type 446S
Platinum thimble
Black steel
Ceramic
Inconel 600, Type 446 SS
Types 304, 310, 316, 321, 347 SS, carbon
steel
Types 304, 310, 316, 321, 347 SS, carbon
steel
Types 304, 310, 316, 321, 347 SS, carbon
steel
Types 304, 310, 316, 321, 347 SS, carbon
steel
Types 304, 310, 316, 321, 347 SS, carbon
steel

Open hearth

Inconel 600, Type 446 SS

Bridgewall

Flues and stack

Checkers
Waste heat boi ler
Billet heating slab heating and butt
welding
Up to 1093C
Over 1093C

Inconel 600, LT-1

Inconel 600, Type 446 SS

Power
Coal-air mixtures
Flue gases

304 SS
Black steel, Type 446 SS

Inconel 600, Type 446 SS

Pre-heaters

Black steel, Type 446 SS

Silicon carbide, ceramic*

Steel lines
Water lines

Types 347 or 316 SS

Low carbon steels

Boiler tubes

Types 304, 309, or 31 0 SS

Bright annealing batch

Top work temperature
Bottom work temperature
Continuous furnace section
Forging
Soaking pits
Up to 1093C
Over 1093C
Nonferrous metals
Aluminum Melting
Heat Treating
Brass or bronze
Lead
Magnesium
Tin
Zinc
Pickling tanks

Not required (use bare Type J

thermocouple)
Type 446 SS
Inconel 600, ceramic*
Silicon carbide, ceramic*
Inconel 600
Silicon carbide, ceramic*

Hexoloy, Syalon, 1100, Cast, Iron

Black steel
Not required (use dip-type
thermocouple)
Type 446 SS, black steel
Black steel, cast iron
Extra heavy carbon steel
Extra heavy carbon steel
Chemical lead

Gas producers
Producer gas
Water gas
Carburetor
Superheater
Tar stills
Incinerators
Up to 1093C
Over 1093C
Food

Type 446 SS
Inconel 600, Type 446 SS
Inconel 600, Type 446 SS
Low carbon steels
Inconel 600, Type 446 SS
Ceramic (primary) Hexoloy (secondary)*

Baking Ovens

Slack Steel

Charretort, Sugar
Vegetables and fruit

Slack Steel
Type 304 SS

The data provided above is just for reference purpose. Waaree does not guarantee for its accuracy & correctness.
However user has to refer the relevant standards to select the material.

VII

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