Development of Excalibur Thermocouple for Harsh

Environments
Jim Walker & Gerard Cassidy

ECEFast
26 Business Park Drive Notting Hill
AUSTRALIA 3168 www.ecefast.com.au

Abstract. Temperature measurement can represent a significant burden of cost, through replacement parts, installation
time and lost production when applied in difficult environments. The Excalibur was developed by combining a number
of existing technologies to address the problems of short life in high temperature, and aggressive or abrasive
environments.

INTRODUCTION EXCALIBUR THE CONTEXT

Thermocouples are extremely simple devices
essentially two wires joined at one end [hot junction],
and connected to a measuring instrument at the other
end [cold junction]. A significant part of the
technology associated with thermocouples, involves
ways of protecting the hot junction from physical and
chemical attack by the environment. The task is harder
at high temperatures, since chemical attack and
physical effects, such as erosion by hard particles, are
exacerbated. Our goal is to find a better way to do it.
Platinum based thermocouples have increased in cost
enormously, and in any case, are usually of ceramic
construction and fragile. So another reasonable goal is
to allow extension of the workable range of base metal
thermocouples to 1300C
Our experience in the solution of these problems is the
subject of this paper.
Identifying a Benchmark Application
No application better demonstrates these issues, than
the measurement of temperature in Anode Bake
furnaces [used in aluminum smelters]. These furnaces
operate at 1150C, with excursions to 1250C, and are at
the top limit for base metal thermocouples. They are
very large, having up to several hundred
thermocouples, and they run continuously. Previously
these furnaces used rare metal thermocouples, but now
use type N sensors almost exclusively. Type N
sensors have demonstrated long life and stability at
temperatures up to 1300C. [Reference 1]. The change
to N has reduced thermocouple costs significantly. In
spite of this, a typical furnace could use $US100K to
US150K in thermocouples per year.
This application was used as a benchmark to develop
and test the Excalibur

Analysis of the existing problem

Life is limited in these anode furnaces by deterioration

EXCALIBUR - THE CONTEXT
Figure 1 Excalibur 500mm long with Flange
of the protection tube, and by failure of the
thermoelectric elements. In the case of commonly used
8ga wire and bead construction in NB Inconel 600
Schedule 40 pipe, green rot is the mode of failure of
the N wires. To optimize material use and costs, the
expected life of wires and sheath should be the same,
but usually the elements will be replaced at least once
during the life of the protection tube. In some cases
6mm MIMS thermocouples are used in the heavy tube.
In addition, control systems benefit by electrical
isolation, coupled with quick thermal response and
wire and bead constructions are poor for both. In the
high temperature zones, smaller sheath diameters
[such as 10.8mm mineral insulated] often curl and
are more prone to physical damage.
Figure 2 Cross Sectional Sizes
Proposing a solution
The Outer Sheath
In metallic protection tubes the life of a given alloy
will depend on its homogeneity and its thickness. It is
important to select the correct alloy [discussed later]
and to make it as thick as possible.
The solution proposed is to use thick wall tubes with
cold welded ends to ensure homogeneity in the hottest
area. The OD is reduced and wall thickness increased
by swaging during manufacture. The starting size is
logically NB Sched. 40 tube, which is common,
and is already widely used in the application. For our
reference application, there are two alloys to consider.
Incotherm Alloy TD [Reference 2] which is an
evolution of Pyrosil C- [Previously Nicrobell C]
Reference 3 shows Nicrobell C gives long life and
low drift at high temperatures in MIMS construction
thermocouples. The difficulty with this alloy is its high
cost and limited availability.
The second choice is Inconel 601, [Reference 4].
This alloy has very high corrosion resistance at
temperatures over 1150C, and is moderately priced
and widely available.
The Hot Junction
This will be insulated to minimize noise and stray high
level voltages, and isolated from air to prevent
oxidation and green rot. The heat transfer from hot
junction to sheath will be enhanced. Thermoelectric
elements will be as large as possible. [Reference 1
shows that at high temperatures, conductor size is
directly related to life, and inversely related to drift]
The solution proposed is to use 2.7mm thermoelectric
elements insulated with 99.9% pure MgO. The size is
chosen to allow good electrical isolation in the finished
geometry [approx. 3mm of compressed MgO] and to
equalize the life of the hot junction and the sheath.
MgO is used in conventional MIMS cable. At very
high temperatures the life and stability of the
thermoelectric elements is very sensitive to the purity
of this insulation. Air is removed by compressing the
MgO during swaging of the OD and water is removed
by constantly heating the MgO during the filling
process. At each stage of production the open end of
the thermocouple is resealed with epoxy, and finally
with high temperature epoxy. Heat transfer at the hot
junction and sensor response time is enhanced by the
compression of the MgO.
Final Construction
.
The Excalibur sensor is manufactured with the
following steps. First the thermocouple wires are
straightened and a hot junction formed. The sheath
material is cleaned, and one end cold welded closed.
All thermocouple wires used are calibrated according
to NATA procedures in the ECEFast accredited
laboratory. The thermoelectric element is inserted to
correctly position the hot junction and the assembly
filled with pure MgO, compacted with constant
vibration, and with the wires positively positioned.
The diameter is swaged down to highly compress the
MgO, and the cold end sealed with epoxy. Depending
on the reduction in diameter, the sensor is then
annealed to eliminate the effects on thermocouple emf
of the cold working.
Insulation checks are used to ensure correct geometry.
Figure 3 Cutaway of
Junction
 Variations on a Theme
The Excalibur thermocouple is made in diameters of
14, 18, and 22mm with the normal variety of fittings
and terminations. The material can be bent with small
radius [like conventional MIMS] for elbowless right
angle assemblies. Lengths up to 2000mm are possible.
Not all materials can be cold welded, 310SS, Sandvik
253MA, Incotherm Alloy TD and others can be
readily used. For abrasion resistance for example in
the cement industry, the Excalibur can be plasma
sprayed with a ceramic coating. On the 14mm size a
second sheath can be swaged to a finished OD of
18mm and a wall thickness of almost 5mm.
In the following cases, performance of an 18mm
Excalibur N thermocouple, Inconel 601 [Type I] is
compared with that of 8Ga wire and ceramic bead
thermocouples in NB Schedule 40 Inconel 600 pipe
without powder fill.[Type II]
The numbers quoted refer to our internal testing. In
real life there is great variability in style and
construction of thermocouples and this would lead to a
range of possible results.

Results in the Benchmark Application

The benchmark application was the flue
thermocouples in Anode Bake furnaces in Aluminum
smelters. These operate in oxidizing and reducing
atmospheres, depending on the air/fuel ratio- which is
difficult to control - and at high temperatures, at the
limit of base metal thermocouples.

It was an ideal test site for product development

because of the large numbers of sensors involved, and
the extremely arduous work cycle. The smelter
operator cooperated in the early stages because they
always strive for improved efficiency, and saw
potential for reduced costs. In the latter stages, and in
spite of the difficulties experienced, they could see Figure 4 Excalibur Standard Alloy Head
clearly that the sensor design would deliver the lowest
cost for temperature measurement.

After some 5 years of work, the correlation of Insulation Resistance

materials, design and manufacturing methodology was
established, and consistent performance was achieved.
The average life of the sensors in this application is
between 1.5 and 2 times that of conventional designs,
while the cost is about 1.25 times higher.
During this time other applications in cement plants,
brick kilns, calcination furnaces and garbage
incinerators, were successfully tested. These tests were
to full term life and demonstrated that the product
significantly outlasted all previous base metal
solutions.
Many control systems can be adversely affected by
ground loops or interference, via the sensor input.
Sensor isolation can eliminate or reduce these
problems. Excalibur has larger spacing between the the
thermoelectric elements and the sheath, and this space
is filled with compressed magnesia [MgO]. In Type II
thermocouples there is usually no isolation at all [even
if the sensor is powder filled, there is no way to ensure
positioning of the junction] In all conventional MIMS
constructions the sensor is smaller, additionally the
powder fill cannot be compressed to remove air.

The refractory materials lose insulating properties at

CHARACTERISTICS OF EXCALIBUR
This is a new construction method for thermocouples,
and sensors of this design have been tested to
determine the performance of several characteristics
when compared with conventional designs.
high temperature. Tests on Excalibur indicate values of
above 100Mohm at more than 700C and 15Kohm at
1200C. This compares with a 6mm MIMS with
insulated junction which drops to 15Kohms at 650C.
 Speed of response
Whilst life is enhanced by larger physical size [in most
applications], the result is slower response, leading to a
less controllable process. Most high temperature
industrial processes are slow enough to allow larger
sensors, but for a given size, faster response means a
more controllable process.
Type II thermocouples have air surrounding the
junction, while Type I have compressed Magnesia
which has higher thermal conductivity than air.
ceramic bead and of improved oxidation resistance of
Inconel 601 compared with Inconel 600 and Incoloy
800.
Life testing indicates expected life of Type I will be
will be at least double that of Type II with long term
drift of approximately 1/3, being of the order of 3C
Testing was at 1150C in air. Type II sensor failed after
less than 2000 hours, Type I was still in good
condition when the test was terminated after 3000
hours.

Tests indicate a T90 time constant of around 30 Physical Strength

seconds for Type I compared with 4 minutes for a
Type II thermocouple. [water bath at 100C]
Useful Life
Extended life may be obtained in many applications by
correct selection of thermocouple type, design, and
protection tube materials. The papers quoted earlier
point to extended life and long term stability of Type
N elements when compared with K, - Of extended life
with MIMS construction compared with wire and
Excalibur will normally bring higher strength to an
installation, due in part to its thicker outer sheath, and
good thermal response [allowing the use of larger
diameters]. In addition, failure of the sheath does not
lead to loss of sealing integrity, because the MgO will
act as a barrier to escape of gases or liquids from the
process.
Given that bending strength increases as the 4th power
of diameter, the 22mm Excalibur will be more than 10
times the bending strength of a 10.8mm MI

ACKNOWLEDGEMENTS

Registered Trademark of Special Metals Ltd

Registered Trademark of Nicrobell Pty Ltd
National Association of Testing Authorities
Australia [equivalent to N.I.S.T in USA]

REFERENCES
Figure 5 Showing relative sizes of basic MI materials
from 22mm on left to 3mm diameter on right
1. Burley N.A., Hobson J.W., Paine A. Department of
Defence MRL-R-903 The Nicrosil vs Nisli Type N
Thermocouple A Commercial Reality 1983

2. Sizek H.W., Baker B.A., Smith G.D. Introduction of a Figure 6 Showing 18mm Excalibur hot junction in new
New High Temperature Alloy for Thermocouple condition from brick kiln 4000hrs at up to 1150C
Protection Sheathing published in Corrosion 2000
Paper 00255

3. Burley N.A. Advanced Integrally Sheathed Type N

Thermocouple of Ultra High Thermoelectric Stability
Published in Measurement Vol8 1990

4. Inco Alloys International INCONEL alloy 601

publication 5M8-92IAI-33 pp9-12