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Corrosive Service Guide to Materials for Thermowell Applications

Thermowells stand as guardians of precise accuracy, shielding temperature sensors from the potentially detrimental effects of corrosion. By utilizing these protective sheaths, industrial processes can continue to thrive in the face of corrosion's relentless forces.

Understanding Corrosion: A Complex Dance with Materials

Corrosion, in its essence, is a natural chemical reaction between materials and their surrounding environment. It involves the gradual degradation of metals and alloys due to various factors such as moisture, chemicals, temperature fluctuations, and exposure to gases. While corrosion can sometimes be harnessed beneficially, such as in the case of creating protective oxide layers, it more commonly poses a significant threat to industrial equipment and processes.

The Diverse Faces of Corrosion

The spectrum of corrosion mechanisms is vast and can include uniform corrosion, pitting corrosion, crevice corrosion, and stress corrosion cracking, among others. The selection of materials and protection strategies hinges on understanding the specific corrosion process taking place, the materials involved, and the unique demands of the application.

photo of a thermowell with data style backgroundRole of Temperature Sensors: Vital but Vulnerable

In the grand tapestry of industrial processes, the need for accurate temperature monitoring cannot be overstated. Yet, this precision must be achieved despite the often corrosive and hostile environments in which these processes occur.

Enter the Thermowell: Armor Against Corrosion

A thermowell, a critical component in temperature sensing systems, is a protective sheath designed to encase temperature sensors, ensuring their reliability and longevity in corrosive environments. Typically manufactured from corrosion-resistant materials like stainless steel, Inconel, or Hastelloy, thermowells act as a barrier, preventing direct contact between the sensor and the corrosive medium.

By intelligently selecting the proper thermowell material, design, and installation, industrial operations can effectively guard against corrosion-driven sensor failures, safeguarding their processes, maintaining efficiency, and ensuring product quality.

As industries continue to evolve and push boundaries, thermowells will remain a crucial element in maintaining efficiency, safety, and product quality. Through these unassuming protective sheaths, industrial processes can continue to thrive in the face of corrosion’s relentless forces.

The following chart lists the most common corrosion-susceptible materials used in thermowells. The second column lists the temperature in Fahrenheit at which it corrodes. The third column is the percentage of concentration, and the last column contains the corrosion-resistant materials that are recommended for use with these susceptible materials.

Thermowells can protect your temperature sensing systems from the challenges of corrosion. Additionally, with helical thermowell technology, companies can ensure even more accuracy and eliminate concerns about failure within high velocity environments. Some common helical thermowells are made from 304 stainless Steel, 316 stainless Steel, and Monel, but there are many materials to choose from according to your process needs.

Temp-Pro offers a wide range of temperature control equipment and services, including industrial temperature sensors such as RTDs, thermocouples, helical thermowells, and industrial electrical enclosures. Our team of experts is dedicated to meeting your unique needs and exceeding your expectations. Contact us today and get a customized solution to suit your business needs.

CORROSIVE TEMP F CONC. % RECOM. MATERIAL
Acetic Acid 212 ALL Monel
Acetic Anhydride 300 Nickel
Acetone 212 ALL 304 SS
Acetylene 400 304 SS
Alcohols 212 ALL 304 SS
Alum (Potassium or Sodium) 300 ALL Hast. C
Aluminum Chloride 212 ALL Hast. B
Aluminum Sulfate 212 ALL 316 SS
Ammonia, Dry 212 ALL 304, 316 SS
Ammonium Hydroxide (Ammonia, Aqua) 212 ALL 304, 316 SS
Ammonium Chloride 300 50% Monel
Ammonium Nitrate 300 ALL 304 SS
Ammonium Sulfate 212 ALL 316 SS
Amyl Acetate 300 ALL 304 SS
Aniline 75 Monel
Asphalt 250 304 SS
Atmosphere (Industrial and Marine) 304 SS
Barium Compounds SEE CALCIUM
Beer 70 304 SS
Benzene (Benzol) 212 Steel
Benzoic Acid 212 ALL 316 SS
Bleaching Powder 70 15% Monel
Borax 212 ALL Brass
Bordeaux Mixture 200 304 SS
Boric Acid 400 ALL 316 SS
Bromine 125 DRY Monel
Butane 400 ALL Steel
Butyl Alcohol SEE ALCOHOLS
Butyric Acid 212 Hast. C
Calcium Bisulphite 75 ALL Hast. C
Calcium Chloride 212 ALL Hast. C
Calcium Hydroxide 300 20% Hast. C
Calcium Hypochlorite SEE BLEACHING POWDER
Carbolic Acid SEE PHENOL
Carbon Dioxide, Dry 800 ALL Brass
Carbonated Water 212 ALL 304 SS
Carbonated Beverages 212 304 SS
Carbon Disulfide 200 304 SS
Carbon Tetrachloride 125 ALL Monel
Chlorine, Dry 100 Monel
Chlorine, Moist 100 ALL Monel
Chloracetic Acid 212 ALL Monel
Chloroform, Dry 212 Monel
Chromic Acid 300 ALL Hast. C
Cider 300 ALL 304 SS
Citric Acid 212 ALL Hast. C
Copper (10) Chloride 212 ALL Hast. C
Copper (10) Nitrate 300 ALL 316 SS
Copper (10) Sulfate 300 ALL 316 SS
Copper Plating Solution (Cyanide) 180 304 SS
Copper Plating Solution (Acid) 75 304 SS
Corn Oil 200 304 SS
Creosote 200 ALL 304 SS
Crude Oil 300 Monel
Ethyl Acetate SEE LACQUERS AND THINNERS
Ethyl Chloride, Dry 500 Steel
Ethanol SEE ALCOHOLS
Ethylene Glycol (Uninhibited) 212 ALL 304 SS
Ethylene Oxide 75 Steel
Fatty Acids 500 ALL 316 SS
Ferric Chloride 75 ALL Hast. C
Ferric Sulfate 300 ALL 304 SS
Formaldehyde 212 40% 316 SS
Formic Acid 300 ALL 316 SS
Freon 300 Steel
Flourine, Anhydrous 100 304 SS
Furfural 450 316 SS
Gasoline 300 Steel
Glucose 300 304 SS
Glue ph 6-8 300 ALL 304 SS
Glycerine 212 ALL Brass
Hydrobromic Acid 212 ALL Hast. C
Hydrochloric Acid (37-38%) 225 ALL Hast. B
Hydrogen Chloride, Dry 500 304 SS
Hydrocyanic Acid 212 ALL 304 SS
Hydroflouric Acid 212 60% Monel
Hydrogen Flouride, Dry 175 Steel
Hydrofluogilicic Acid 212 40% Monel
Hydrogen Peroxide 125 10-100% 304 SS
Kerosene 300 ALL Steel
Lacquers and Thinners 300 ALL 304 SS
Lactic Acid 300 ALL 316 SS
Lime 212 ALL 316 SS
Linseed Oil 75 Steel
Magnesium Chloride 212 50% Nickel
Magnesium Hydroxide (or Oxide) 75 ALL 304 SS
Magnesium Sulfate 212 40% 304 SS
Mecuric Chloride 75 10% Hast. C
Mercury 700 100% Steel
Methylene Chloride 212 ALL 304 SS Methyl Chloride, Dry
Milk, fresh or sour 180 304 SS Molasses
Natural Gas 70 304 SS
Nitric Acid 75 ALL 304 SS
Nitric Acid 110 ALL 316 SS
Oxygen 75 ALL Steel
Potassium Compounds SEE SODIUM COMPOUNDS
Propane 300 Steel
Rosin 700 100% 316 SS
Sea Water 75 Monel
Soap and Detergents 212 ALL 304 SS
Sodium Bicarbonate 212 20% 316 SS
Sodium Bisulphite 212 20% 304 SS
Sodium Bisulphate 212 20% 304 SS
Sodium Carbinate 212 40% 316 SS
Sodium Chloride 300 30% Monel
Sodium Chromate 212 ALL 316 SS
Salt or Brine SEE SODIUM CHLORIDE
Sodium Cyanide 212 ALL 304 SS
Sodium Hydroxide 212 30% 316 SS
Sodium Hypochlorite 75 10% Hast. C
Sodium Nitrate 212 40% 304 SS
Sodium Nitrite 75 20% 316 SS
Sodium Phosphate 212 10% Steel
Sodium Silcate 212 10% Steel
Sodium Sulfate 212 30% 316 SS
Sodium Sulfide 212 10% 316 SS
Sodium Sulfite 212 30% 304 SS
Sodium Thiosulfate 212 ALL 304 SS
Steam 304 SS
Stearic Acid SEE FATTY ACIDS
Sugar Solutions SEE GLUCOSE
Sulfur 500 304 SS
Sulfur Chloride 75 DRY 316 SS
Sulfur Dioxide 500 DRY 316 SS
Sulfur Trioxide 500 DRY 316 SS
Sulfuric Acid 212 10% 316 SS
Sulfuric Acid 212 10-90% Hast. B
Sulfuric Acid 212 90-100% 316 SS
Sulfuric Acid, Fuming 175 Alloy 20
Sulfurous Acid 75 20% 316 SS
Titanium Tetrachloride 75 ALL 316 SS
Tannic Acid 75 40% Hast. B
Toluene 75 Steel
Trichloracetic Acid 75 ALL Hast. B
Trichlorethylene 300 DRY Monel
Turpentine 75 316 SS
Varnish 150 Steel
Zinc Chloride 212 ALL Hast. B
Zinc Sulfate 212 ALL 316 SS
Marketing And Sales Specialist at Temp-Pro | Website | + posts

Nicole Chotain is a passionate marketing and sales specialist in the temperature sensor industry who finds it incredibly fulfilling to be involved in marketing and selling crucial components used in power generation and renewable energy. She takes great joy in creating remarkable campaigns, forging meaningful connections between Temp-Pro and its customers, and driving the growth of the brand.

Sales Engineer And Commercial Sales Manager at Temp-Pro | + posts

Neal Messier is a dedicated sales manager at Temp-Pro. With 17+ years of experience working with instrumentation in diverse industrial and process industries particularly power generation, he is passionate about the temperature sensor industry and uses his strong technical background and comprehensive industry knowledge to fulfill client’s temperature sensor needs.

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