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The importance of correct installation of thermocouples in melting furnaces

ELPRO experts, as an example of good practice, highlight the importance of correct installation of temperature sensors on melting furnaces

Experts ELPRO Adhesive , as an example of good practice, highlight the problem of incorrect assemblies of temperature sensors/thermocouples which leads to incorrect measurements and hazards in the metalworking industry, more specifically in the measurement of temperature in melting and maintenance furnaces. For similarities, see the following expert article “The importance of correct installation of thermocouples in melting furnaces”.

In the case shown in the picture below, it is an engineering product designed, manufactured and installed on an aluminium maintenance furnace by ELPRO experts .

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Figure: Example of ELPRO Adhesive good practice for mounting a thermocouple on an aluminium furnace

SOLUTION DESCRIPTION – Installation of thermocouples on melting furnaces

The bracket we have used allows quick and easy assembly and disassembly of the immersion thermocouple, without the need for additional tools. The latter is very important as this operation has to be carried out by workers who are present on site and who usually do not have the appropriate tools. The assembly or dismantling process is further complicated by the fact that the employees are in the vicinity of the aluminium melt, which has a high temperature of around 700 °C.

The key purpose of this installation is to ensure a good fit of the thermocouple, thus reducing the possibility of damage to the protection tubes, thus allowing longer lifetime of the thermocouples, less maintenance and a positive impact on sustainability.

ELPRO Lepenik offers you the EL-MARSH casting thermometer, a professional set for aluminium, copper and copper alloy melts.

Consequences of incorrect installation of thermocouples in melting furnaces

Poor attachment of temperature sensors/thermocouples is the main reason for the failure of immersion thermocouples in melts. If incorrectly fixed or not fixed, the thermocouple may fail out of the stove, causing the stove to heat up uncontrollably (the failed element indicates the temperature outside the stove). This can lead to overheating and destruction of the batch of melt, overheating and destruction of the furnace and heating elements, breakage of the graphite crucible and/or melt leakage and associated fire. Not to mention the threat to human life.

Usability of the ELPRO Adhesive

The same problems and hazards can occur in all industries, where the failure of an incorrectly attached or completely unattached temperature sensor can lead to uncontrolled heating or cooling. The latter leads to damage to machinery and equipment, structural elements, fires and/or explosions.

Another good feature of this solution is the easy dismantling of the immersion thermocouple, which is needed daily for filling the furnace with new material (e.g. aluminium), cleaning the furnace and servicing.

In practice, users make quite rigid beams (fixed fixing with screws). Dismantling them is time-consuming. As this also requires the appropriate tools, operators do not usually choose to dismantle the unit, so there is a high risk of damaging the thermocouple protection tube.

EXPERT ARTICLE: The importance of correct installation of thermocouples in melting furnaces

AUTHOR: Zoran Lepenik
23. 2. 2022

ELPRO production of temperature sensors is at your disposal for special versions of temperature sensors/thermocouples.

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