Thermowell

Thermowells are tubular fittings used to protect temperature sensors installed in industrial processes. A thermowell
consists of a tube closed at one end and mounted in the process stream. A temperature sensor such as a thermometer,
thermocouple or resistance temperature detector is inserted in the open end of the tube, which is usually in the open
air outside the process piping or vessel and any thermal insulation. Thermodynamically, the process fluid transfers
heat to the thermowell wall, which in turn transfers heat to the sensor. Since more mass is present with a sensor-well
assembly than with a probe directly immersed into the process, the sensor's response to process temperature changes
is slowed by the addition of the well. If the sensor fails, it can be easily replaced without draining the vessel or piping.
Since the mass of the thermowell must be heated to the process temperature, and since the walls of the thermowell
conduct heat out of the process, sensor accuracy and responsiveness is negatively impacted by the addition of a
thermowell.[1]

To be representative of the average temperature of fluid, the thermowell must extend a few per cent of the inside
diameter of the process pipe or vessel (Normally 1/3 rd of the pipe inside diameter).[2] A rule of thumb that is
sufficient for most industrial applications (approximately 1% accuracy) is to ensure that the thermowell projects 5
times its own diameter into the process plus the length of its sensing element. So, for a grounded thermocouple
spring-loaded into a thermowell with a 1-inch-diameter shank and a tip thickness of .25 inch, a typical immersion
length would equal 5.5 inches (1 inch OD x 5 + .25 inch well tip thickness +.25 inch sensor wall thickness = 5.5
inches).[3]

A thermowell is typically machined from solid bar stock and gun-drilled to ensure a long straight bore that closely
approximates the diameter of the installed sensor (ex: a .260-inch bore matching a .250-inch sensor). A thermowell is
typically mounted into the process stream by way of a threaded, welded, sanitary cap or flanged process connection.
The temperature sensor such as a thermometer, thermocouple or resistance temperature detector is inserted in the
open end of the thermowell and typically spring-loaded to ensure that the outside tip of the temperature sensor is in
metal to metal contact with the inside tip of the thermowell.

Contents
1 Materials and construction
2 Flow forces
3 Standardization
4 See also
5 References
6 External links

Materials and construction

The thermowell protects the instrument from the pressure, flow-induced forces, and chemical effects of the process
fluid. Typically a thermowell is made from metal bar stock. The end of the thermowell may be of reduced diameter (as
is the case with a tapered or stepped shank thermowell) to improve the speed of response.

For low pressures and temperatures, Teflon may be used to make a thermowell; various types of stainless steel are
typical, with other metals used for highly corrosive process fluids.
Where temperatures are high and the pressure differential is small, a protection tube may be used with a bare
thermocouple element. These are often made of alumina or other ceramic material to prevent chemical attack of the
platinum or other thermocouple elements. The ceramic protection tube may be inserted into a heavy outer protection
tube manufactured from silicon carbide or other material where increased protection is required.

Flow forces
Thermowells are typically installed in piping systems and subject to both hydrostatic and aerodynamic forces. Vortex
shedding is the dominant concern for thermowells in cross-flow applications and is capable of forcing the thermowell
into resonance with the possibility of fatigue failure not only of the thermowell but also of the temperature sensor. The
conditions for flow-induced resonance generally govern the design of the thermowell apart from its pressure rating
and materials of construction. Flow-induced motion of the thermowell occurs both in-line with and transverse to the
direction of flow with the fluid forces acting to bend the thermowell. In many applications the transverse component
of the fluid forces resulting from vortex shedding tends to govern the onset of flow-induced resonance, with a forcing
frequency equal to the vortex shedding rate. In liquids and in high-pressure compressible fluids, a smaller but
nonetheless significant component of motion in the flow-direction is also present and occurs at nearly twice the vortex
shedding rate. The in-line resonance condition may govern thermowell design at high fluid velocities although its
amplitude is a function of the mass-damping parameter or Scruton number describing the thermowell-fluid
interaction.

For drilled bar-stock thermowells, the most common form of failure is bending fatigue at its base where the bending
stresses are greatest. In extreme flow conditions (high-velocity liquids or high-velocity, high-pressure gases and
vapors) catastrophic failure may occur with bending stresses exceeding the ultimate strength of the material. For
extremely long thermowells, the static component of the bending stresses may govern design. In less demanding
services, fatigue failure is more gradual and often preceded by a series sensor failures. The latter are due to the
acceleration of the thermowell tip as it vibrates, this motion causes the element to lift off the bottom of the thermowell
and batter itself to pieces. In cases where the acceleration stresses have been measured, sensor accelerations at
resonant conditions often exceed 250 Gs and have destroyed the accelerometer.

The natural frequencies of thermowell bending modes are dependent upon the dimensions of the thermowell, the
compliance (or flexibility) of its support, and to a lesser extent dependent upon the mass of the sensor and the added
mass of the fluid surrounding the thermowell.

The ASME Performance Test Code PTC 19.3TW-2016 ("19.3TW") defines criteria for the design and application of
thermowells. However, these thermowells must be manufactured from bar stock or forged material where certain
dimensional requirements and manufacturing tolerances are met. Coatings, sleeves, velocity collars, special machined
surfaces such as spirals or fins are expressly outside the scope of the 19.3TW standard.[4]

Standardization
A widely use Code for thermowells machined from bar stock and includes those welded to or threaded into a flange as
well as those welded into a process vessel or pipe with or without a weld adaptor is the ASME PTC 19.3 TW
Thermowells Standard.

See also
Bending
Timoshenko beam theory
Vibration
References
1. Thomas W. Kerlin & Mitchell P. Johnson (2012). Practical Thermocouple Thermometry (2nd Ed.) (http://www.isa.o
rg/Template.cfm?Section=Books3&Template=/Ecommerce/ProductDisplay.cfm&ProductID=12178). Research
Triangle Park: ISA. pp. 79–85. ISBN 978-1-937560-27-0.
2. H. M. Hashemian (ed), Sensor Performance and Reliability, ISA 2005 ISBN 1-55617-897-2, page 16
3. J.V. Nichols D.R. White(2nd ed) "Traceable Temperatures", John Wiley & Sons, Ltd. 2001 ISBN 0-471-49291-4,
page 136
4. Johnson, Mitchell P. & Gilson, Allan G. (August 2012). "Do Your Thermowells Meet the ASME Standard?" (http://w
ww.flowcontrolnetwork.com/measurement/temperature/article/do-your-thermowells-meet-the-asme-standard).
Flow Control. XVIII (8).

External links
PTC 19.3 Committee (http://cstools.asme.org/csconnect/CommitteePages.cfm?Committee=C91930000)
[1] (http://www.temperatures.com/twells.html)
Thermowells Sensors (http://www.instrumentationtoolbox.com/2011/01/sensors-used-in-industrial_25.html)

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This page was last edited on 3 July 2017, at 10:48.

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