Thermowell Selection and Application Notes
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Burns Engineering Thermowell Selection and Appl ication
Thermowell Selection and Application
If you are experiencing audio problemsplease call the teleconference number below
1-408-600-3600Access code 660 637 935
Bill Bergquist, Sr. Applications EngineerJ eff Wigen, National Account Manager J effBill
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Burns Engineering Thermowell Selection and Appl ication
The thermowell used with your temperature sensor provides criticalprotection, access, and measurement integrity. Well shed some lighton how, why, and when to apply this important device.
Thermowell basics Purpose Types Process connection styles Materials, coatings and surface finish
Performance Wake frequency & strength Immersion length Time response
Custom designs Specifying
Definitions/codes Typical drawing Details Testing & certifications Options
Preventive Maintenance Selection Checklist
What Well Cover
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Burns Engineering Thermowell Selection and Appl ication
Why use a thermowell?
Protect the temperature sensor from:
Excessive pressures
Excessive material velocities & viscosities
Corrosion
Erosion
Simplify maintenance
Sensor replacement without draining the system Eliminate potential for contamination system stays closed
Protection increases potential life of the sensor
Improve temperature measurements
Thermowell Basics - Purpose
Athermowellsmainpurposeistoprotectthe
temperaturesensortoinsurelonglifeand
accuratemeasurement.Maintenanceisaidedby
allowingthesensortoberemovedwithout
havingtodrainthepipeortank. Sensorchanges
canbedoneonthefly.
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Burns Engineering Thermowell Selection and Appl ication
Thermowell types
Stepped
Tapered
Straight
Sanitary
Protection tube
Typically made from pipe
Usually not suited for RTDs
Thermowell Basics - Types
Thermowelltypesaredesignatedbythestyleof
stemorwettedportionofthewell. Protection
tubesaretypicallyusedforthermocouplesand
arenotsuitedforusewithRTDsbecausetheydo
notprovideenoughsupportforthesensor.
Mostthermowellsaremachinedfrombarstock
toinsure
integrity
for
high
pressure
applications.
Flangesarejoinedtoathermowellstemmost
commonlybyawelding process. Smallerwells
maybeconstructedfromtubingandhavethe
endweldedclosedandaprocessconnection
weldedon. Thesearetypicallyusedinlow
pressureapplications.
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Burns Engineering Thermowell Selection and Appl ication
Thermowell Basics - Stem Types
Stepped
Tapered
Straight
Stepped,sometimesreferredtoasreducedtip,
wellsareusuallydiameterandstepdownto
diameter
to
improve
time
response.
Tapered
wellsareabalancebetweenstrengthandtime
response. Straightwellsarespecifiedwhere
increasedlifeisdesiredduetocorrosionor
erosion.
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Burns Engineering Thermowell Selection and Appl ication
Connection styles
Flange ANSI B16.5
Van Stone
Socket weld
Weld-in
Threaded Sanitary flange
O-Ring
Thermowell Basics - Process Connections
Connectionstotheprocessareaccomplished
withtaperedpipethreadsoradaptationsofpipe
orsanitarytubingflangeconnections. Ablankor
blindflangeismodifiedtoacceptthethermowell
stemandtheneasilyattachestostandard
flanges.
Weldinstylesareusedforconvenienceorwhere
exposedthreadsmaycollectcontaminantssuch
asinfoodprocessingorpharmaceutical
production.
AspecialtytypeofconnectionincorporatesanO
ringtosealinsideasleeveweldedtoatank.
SometimesreferredtoasanIngoldfittingafter
thecompanythatinventeditforphandoxygen
sensors.
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Burns Engineering Thermowell Selection and Appl ication
Thermowell Basics - Process Connections
Thesearejustafewoftheseveralstyles
available. Anyimaginablepipeortubing
connectionstyleeitherhasbeenorcouldbe
adaptedtoathermowellprocessconnection.
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Burns Engineering Thermowell Selection and Appl ication
Sanitary Weld-In
Asanitaryweldinstylesuchasthisoneisusedin
sanitaryprocesstankswherecracksandcrevices
arenot
desired.
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Burns Engineering Thermowell Selection and Appl ication
Sanitary Flange
Thisisathermowellwithasanitaryflange
connectionwhichissometimesreferredtoasa
TriClampconnector. Itisthemostcommon
styleofsanitaryconnection. Thehighpolishand
largeradiusbetweenstemandflangeimprove
corrosionresistanceandmakecleaningeasier.
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Burns Engineering Thermowell Selection and Appl ication
Sanitary with Process & Instrument Flange
Anotherstyleofsanitarywellusesasanitary
flangeforattachmentofthetemperaturesensor.
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Burns Engineering Thermowell Selection and Appl ication
Sanitary Process and Instrument Flange
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Burns Engineering Thermowell Selection and Appl ication
Sanitary Easy Access Tri-Clamp
Notoolsarerequiredtoinstallorremovethe
sensorwhichmakesforeasiermaintenance.
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Burns Engineering Thermowell Selection and Appl ication
O-Ring
Themostcommonstyleofinstrument
connectionisaNPTfemalethreadasshown
hereonthisOringstylewell. Thisstylewell
installsintoasleeveweldedtoatankwhich
acceptsthewellandthethreadednutholdsitin
place. AtightfitinsuresthattheOringseals
securely.
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Burns Engineering Thermowell Selection and Appl ication
Process connection selection
Thread size Typically tapered pipe thread
Flange size and rating Gasket surface type
Raised
Flat
RTJ
Lag length Added thermowell length outside process to reach through
insulation
Brass or SS plug for test wells
Thermowell Basics - Process Connections
Whenselectingaprocessconnectionthereare
severalthingstoconsider. Threadedconnections
arethe
easiest,
flange
connection
require
a
flangesize,pressurerating,andgasketsurface
style.
Laglengthisanextensionofthenonwetted
portionofthewelltoreachthroughinsulationor
otherobstaclestoprovidewrenchaccess.
Typicallyspecifiedforthreadedwells.
Testwellsthatsitemptyforlongperiodsoftime
shouldhaveaplugintheinstrumentconnection
topreventdebrisfromentering.
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Burns Engineering Thermowell Selection and Appl ication
Factors to consider
Define the conditions Corrosion/erosion
Temperature
Pressure
Fluid Properties
Match the pipe or tank materials Refer to corrosion charts
Materials
Materialselectioncanbeassimpleaschoosing
thesamematerialasthetankorpipewhereitis
tobeinstalled. Thisworksmostofthetimebut
thereareexceptions. Inthecaseofcorrosionor
erosionanobjectplacedintoaflowismore
susceptibletothoseeffectsandadifferent
materialwillbenecessarytoprovidelongerlife.
Therearecorrosionchartsavailablefrom
thermowellmanufacturersthatlistthepreferred
materialforchemicalsatdifferentconditions.
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Burns Engineering Thermowell Selection and Appl ication
Materials Corrosion
Condition MaterialChemical
Materialselectiontablesareavailablefor
numerouschemicalsandconditions. Notethat
concentrationandtemperaturehavean
influenceontherecommendedmaterial. The
higherthetemperatureand/orconcentrationthe
morecorrosivethechemicalcanbe.
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Burns Engineering Thermowell Selection and Appl ication
Corrosion
Photo courtesy of Alloy Engineeringhttp://www.thermowells.com/library.html
Choosingthewrongmaterialcanresultinfailure
ofthewell. Herethetiphascorrodedawayand
allowedthe
process
fluid
to
leak
inside
the
well.
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Burns Engineering Thermowell Selection and Appl ication
Corrosion
Photo courtesy of Alloy Engineeringhttp://www.thermowells.com/library.html
Thisisaviewinsidethetipsectionshowing
corrosionontheinsidefromtheleakingprocess
fluid.
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Burns Engineering Thermowell Selection and Appl ication
Materials
Cobalt-Chromium (Stellite) Cobalt-Nickel (Wallex) Tungsten Carbide
Silicon Carbide (Hexoloy) Alumina
Materials - Erosion
Photo courtesy of LisaDanielson
Particlessuspendedinafluidorpowdered
materialscancauseerosionofthewellover
time. Thereareseveralmaterialsavailableto
slowdowntheerosion.Mostarehardmaterials
thatareappliedthroughaweldingorspraying
process. Sometimesjustpickingthecorrect
thermowellmaterial
is
sufficient
to
minimize
the
erosionaffects.
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Burns Engineering Thermowell Selection and Appl ication
Materials Metals
Plastic
Ceramic
Surface coatings Teflon
Tantalum
Ceramic
Hard facing
Surface finish Improved corrosion resistance
Sanitary applications Electropolish
Passivation
Materials - Selection
Avarietyofmaterialscanbeusedtoconstruct
thermowells. Surfacecoatingscanbeusedto
improvecorrosion
and
erosion
resistance.
PlasticssuchasTeflonarehighlycorrosion
resistantand ceramicsofferhightemperature
capabilitiesandcanbeagoodchoiceforerosive
applications.
Tantalumisusedforacidresistanceandcanbe
appliedasasleeveoritcanbebondedtothe
surfaceofnearlyanythermowellstyle.
Improvingthesurfacefinishwillincrease
corrosionresistanceandmakeiteasiertoclean.
Fewerridges
and
crevices
means
asmaller
surfaceareaforthecorrodenttoattack.
Electropolishingorpassivatingthesurface
furtherincreasescorrosionresistance.
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Burns Engineering Thermowell Selection and Appl ication
Materials
Sometimeslessexpensivematerialsturnoutto
bethebestchoice. OriginallyaTeflonplated
metalwellwasusedformonitoringthe
temperatureofanacidicwasteproduct. Teflon
platingiseasilydamaged(thinkofyourfrying
pan)and
the
acid
quickly
ate
away
the
metal
well
causingittoleak. Thesolutionwastouse
standard3PVCpipetoconstructthewellwhich
wasabout10ftlongandattachedwithaflange
connection. Aninternalwellwasmadewith
PVCtohousethetemperaturesensorallowingit
tostickoutacoupleinchesforbettertime
response.
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Burns Engineering Thermowell Selection and Appl ication
Positive Material Identification (PMI)
PositiveMaterialIdentification(PMI)referstothe
identificationandanalysisofvariousmetalalloys
basedontheirchemicalcompositionin
nondestructivetesting(NDT).Measurement
resultsareshownintheformofelemental
concentrationinpercentageorbyspecificalloy
namesuch
as
SS316L
or
Inconel
625.
PMI
is
afieldtestingmethodmadepossiblebythe
portabilityofmostPMIanalyzers.These
instrumentsalsocanbeusedinthelaboratory
TheXRayFluorescenceTechniqueXRF
XRFinstrumentsworkbyexposingasampletoa
beamofXrays.Theatomsofthesampleabsorb
energyfromtheXrays,becometemporarily
excitedandthenemitsecondaryXrays.Each
chemicalelementemitsXraysataunique
energy.Bymeasuringintensityandcharacteristic
energyof
the
emitted
Xrays,
an
XRF
analyzer
can
providequalitativeandquantitativeanalysis
regardingthecompositionofthematerialbeing
tested.
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Burns Engineering Thermowell Selection and Appl ication
Measurement accuracy
Wake frequency and strength calculations ASME PTC 19.3 TW-2010
Immersion length Elbow well
Time response Heat transfer paste
Bore and probe diameter
Performance
Measurementaccuracycanbeadverselyaffected
byathermowellunlessafewprecautionsare
taken.Wakefrequencyandstrengthcalculations
areprobably
the
most
important.
These
calculationswilltellyouhowlongthewellcanbe
immersedintoyourprocessbasedontheflow
conditions(moreonthislater). Thishastobe
balancedwiththeaccuracyneedsofthesensor
tobeimmersedsufficientlytopreventstem
conductionorimmersionerror.
Finally, timeresponseisslowerwiththeaddition
ofathermowellandforprocessesthatchange
temperaturerapidlythiscanbeasignificanterror
source.
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Burns Engineering Thermowell Selection and Appl ication
ASME PTC 19.3 TW - 2010
The long awaited PTC 19.3 TW-2010 is a completely new standard that establishes
the practical design considerations for thermowell installations in power and
process piping. This code is an expanded version of the thermowell section
contained in the PTC 19.3-1974, and incorporates the latest theory in the areas
of natural frequency, Strouhal frequency, in-line resonance and stress evaluation.
ASME responded to changing industry demands for a more comprehensive setof thermowell evaluations. Key enhancements over the 1974 edition include:
Expanded coverage for thermowell geometry
Natural frequency correction factors for mounting compliance,
added fluid mass, and sensor mass
Consideration for partial shielding from flow
Intrinsic thermowell damping;
Steady state and dynamic stress evaluations
Improved allowable fatigue limit definition.
ASME PTC 19.3 TW-2010
Excerpted from ASME website:http://staging.files.asme.org/Catalog/Codes/PrintBook/25750.pdf
Thenewreleaseofthethermowellsectionofthe
PowerTestCodeincorporatethelatesttheoryfor
wakefrequencyandstrengthcalculations. If
youreapipingdesignerallthisprobablymeansa
lottoyou. Forsomeoneselectingathermowell
itmaybealittlelikelearninghowtobuilda
chainsawto
cut
down
atree.
Interesting
but
not
reallynecessary. Yourthermowellsupplierwill
providethecalculationsbasedyourprocess
conditionsanddesiredthermowellconfiguration.
Youneedtoknowthatyouwantthecalculations
donetothenew2010versionofthestandard.
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Burns Engineering Thermowell Selection and Appl ication
Von Krmn vortex street, by [http://www.mcef.ep.usp.br/staff/jmeneg/cesareo/Cesareo_HomePage.htmlCesareo de La Rosa Siqueira
Von Krmn Vortex
Whenacylindricalobjectisplacedinaflowthere
isadisturbancecreatedonthedownstreamside
thatoscillates
back
and
forth.
The
frequency
of
theoscillationincreasesastheflowrate
increases. Iftheresonantfrequencyofthe
thermowellmatchesthefrequencyofthe
vorticesthewellwillstarttovibrateandwillfirst
damagetheRTDandthenthewellwillfail.
Therearealotofgoodillustrationsofthis
phenomenaontheinternet. Asearchforvon
karmanorwakefrequencywillreturnseveral.
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Burns Engineering Thermowell Selection and Appl ication
Thermowell Selection
Thisgraphshowstheacceptableflowratesfor
variousthermowelldesignsandadiameter
directimmersionRTD. Notethatashortincrease
inimmersionlengthhasalargeaffectonthe
allowableflowrate.
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Burns Engineering Thermowell Selection and Appl ication
Information Required
Thisistypicaloftheinformationthatisneeded
toperformthecalculations.
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Burns Engineering Thermowell Selection and Appl ication
Stress Crack
Photo courtesy of Alloy Engineeringhttp://www.thermowells.com/library.html
Anexampleofwhatcanhappenifthewake
frequencyandstrengthcalculationsarenot
done.This
well
incorporates
asupport
part
way
downthestemtoprovidesupportbutitwasnt
enough. Acrackformedasoutlinedaroundthe
stem.
ASMEPTC19.3doesnotrecommendtheuseof
supportssuchasthis. Shorterimmersionor
largerdiameterarethepreferredsolutions.
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Burns Engineering Thermowell Selection and Appl ication
Stress Crack
Photo courtesy of Alloy Engineeringhttp://www.thermowells.com/library.html
Alittlebetterviewofthecrackthatformed.
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Burns Engineering Thermowell Selection and Appl ication
Immersion Length
25C
Direct immersion RTDs require 10 x probe diameter plus sensitive length toavoid stem conduction errors. Thermowells require about 4.5.
200C
Aruleofthumbforminimumimmersionlength
toavoidstemconductionerroris10timesthe
probediameterplusthesensitivelengthofthe
probe.MostRTDshaveasensitivelengthof
approximately1.0. SoforadiameterRTDthe
minimumrecommendedimmersionis3.5.
Thermowellsrequire
about
4.5
as
aminimum
forbestaccuracy.
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Burns Engineering Thermowell Selection and Appl ication
Immersion Error for 200L05ANN135TT302
-5.00
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
0 2 4 6 8 10 12
Immersion Depth (Inches)
IndicatedError(%D
eltaT)
Ice Bath
100C OilB ath
200C OilB ath
Immersion Error
Athermowell/RTDassemblywasimmersedina
bathtodeterminethestemconductionat
variousdepths.
At
4.5
inches
most
of
the
error
hasdisappeared. Asyoucanseetheerroris
mostlyindependentofthebathtemperature
used. Theerrorisexpressedasapercentageof
thedeltaTbetweenambientandprocess
conditions.
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Burns Engineering Thermowell Selection and Appl ication
Specialty Elbow Wells
Whenlinesizedoesntallowforalongenough
immersionlengthaspecialtythermowellsuchas
thiscanbeused. Notetheflarearoundthe
internalthermowellwhichavoidsflow
restriction.
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Burns Engineering Thermowell Selection and Appl ication
Elbow Well Drawing
Forthoseapplicationsthatrequireathermowell,
theelbowstyleworkswellifsizedcorrectly. An
immersionlengthofatleast4formost
applicationsisnecessarytoprovideanaccurate
measurement. Shorterimmersionlengthsmay
workforsomeprocessfluidsandflowrates.
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Burns Engineering Thermowell Selection and Appl ication
Installation in a Tee
Fluid
SENSOR INSTALLEDPERPENDICULAR TO FLOW
SENSOR INSTALLEDPARALLEL TO FLOW
SENSOR INSTALLEDPARALLEL TO FLOW
Good
Better
Best
Insmalldiameterlinesthereistypicallynot
enoughroomtogettheproperimmersionlength
toavoid
stem
conduction.
This
illustrates
three
methodsofmodifyingthepipingtoprovideextra
room. Theoneontherightisthebestmethod
becauseitprovidesfortheflowcomingdirectly
atthetipofthesensorforlessstressonthe
probeanditalsowashesoutthedeadlagportion
ofthetee.
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Burns Engineering Thermowell Selection and Appl ication
Anti-Immersion?
Photo courtesy of Alloy Engineeringhttp://www.thermowells.com/library.html
Anotherinstallationmethodwhichwedont
recommend. Theresprobablyajokebehindthis
suchasitsforroomairtemperatureorit
makesanicehandhold. Likelyjustthe2nd
shift
crewhaving funwiththe1stshiftcrew. Inany
case,aremindertoalwaysdoublecheckyour
installation.
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Burns Engineering Thermowell Selection and Appl ication
Performance - Time Constant
Adding heat transferpaste cuts thesetimes nearly in half.
TimeConstantisdefinedasthetimeittakesfor
thesensortoindicate63.2%ofastepchangein
temperatureinwatermovingat3fps.
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Burns Engineering Thermowell Selection and Appl ication
Specialty Fast Response Tip
Time constant is about 4 seconds
Afewspecialtywellssuchasthisonecan
improvethetimeconstantsignificantlywitha
smalldiameter
tip,
heat
transfer
paste,
and
a
specialdesignRTD.
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Burns Engineering Thermowell Selection and Appl ication
Specialty Flow-Through Design
Thiswellprovidesprotectiontothesensorbut
allowsflowintothesensorforimprovedtime
response.
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Burns Engineering Thermowell Selection and Appl ication
Specialty Large Diameter Elbow
A3tubesanitaryelbowthermowellisshown
hereandrevealstheinternalthermowellwhichis
3/8diameterandhasa.260borediameter.
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Burns Engineering Thermowell Selection and Appl ication
Process connection P Immersion length U Lag length T Bore depth A usually overall length minus Tip diameter D Root diameter Q Stem style Instrument connection Material
Coatings
Bore diameter Surface finish Plug Testing Certifications
Specifying - Definitions/Codes
Standardvariablelettersareusedtodescribe
thermowelldimensions.
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Burns Engineering Thermowell Selection and Appl ication
Specifying Typical Drawing
OfthesetheimmersionlengthUandthebore
depthAaremostcommonlyusedforspecifying
thelengthofthesensor.
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Burns Engineering Thermowell Selection and Appl ication
Thread size
1/2 , 3/4, or 1 NPT
Socket weld
3/4 refers to O.D. of connection based on pipe size.
3/4 =1.05 OD of fitting
Flange 2.0 x 150 LB or class 150
1.5 x 300 LB
Sanitary flange
1.5 , 2, 2.5 etc.
Flange size refers to the tube size it is used to connect andnot the actual flange diameter. For example: 1.5 sanitaryflange measures 2.0 diameter
Specifying Some Need to Know Details
Someknowledgeofthevarioustypesofprocess
connectionsisrequiredtochoosethecorrect
size. ThreadedconnectionsareNPTandfairly
straightforward. Flangeconnectionsizesreferto
thesizepipeortubewhichtheyconnect.
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Burns Engineering Thermowell Selection and Appl ication
A few of the available certifications: Hydrostatic internal or external pressure testing per ASTM Dye penetrant testing per ASTM X-ray examination per ASTM Material certification Wake frequency and strength calculations Mechanical Surface Finish Certification Canadian Registration Number (CRN) Material Certificate of Conformance No ADM (Animal Derived Material) Certification that no polishing compound was used Certification of NACE Approval Electropolishand Surface Finish Certification Positive material identification (PMI) Inspection Certificate (ISO 10474, EN 10204, DIN 50049) 3.1B Passivation Weld Map - location & numerical identification of every weld
Specifying - Testing and Certifications
Thesearejustafewofthepossibleteststhatcan
beperformedonathermowell. Ofthese,the
mostcommon
are
material
certification,
wake
frequencycalculations,andpressuretesting.
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Burns Engineering Thermowell Selection and Appl ication
Some available options: Plug and chain
Marked with tag number (customer specific information)
Open ended thermowell
1/8 Diameter weep hole
Full weld penetration on flanged well, includes certification
British Standard Pipe process threads (BSP)
Deep Tap threads (for explosion proof applications)
Velocity collar (not recommended per the ASME standard)
Coatings for corrosion or erosion resistance
Flange facing options
Cleaned for oxygen service
Root and tip Q and D dimension options
Specifying - Options
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Burns Engineering Thermowell Selection and Appl ication
Preventive maintenance
Thermowell
; Bore cleaning
; Heat transfer compound
; Product buildup on wetted portion
; Cracks in flange weld or leaky gasket
; RTD bottoms in well and spring loads
An ounce of prevention
Thermowellstypicallyneedonlyminimal
maintenance,keepingthemcleaninsideandout
isusuallyallthatisrequired. Heattransferpaste
shouldberenewedifthesensorisremovedfor
calibrationorreplacement.
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Burns Engineering Thermowell Selection and Appl ication
Thermowell selection
Material selection
Corrosion
Erosion
Strength
Process connection style
Flange
Threaded
Welded
Sanitary
Stem style
Wake frequency and strength calculations
Immersion length
Surface finish
Time response
Thermowell Selection Checklist
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Burns Engineering Thermowell Selection and Appl ication
Thermowell basics Purpose Types Process connection styles Materials, coatings and surface finish
Performance Wake frequency & strength Immersion length Time response
Custom designs
Specifying Definitions/codes Typical drawing Details Testing & certifications Options
Preventive MaintenanceSelection Checklist
Summary
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Burns Engineering Thermowell Selection and Appl ication
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