Quick Connect Temperature Sensor Assembly for Refining Downtime
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Solution Overview
Problem
Temperature sensing devices in high-temperature environments, such as petrochemical and refining processes, face challenges in providing accurate and long-lasting measurements due to extreme temperatures, leading to frequent replacements and costly processing downtime.
Innovation Solution
A temperature sensing assembly comprising a thermocouple device with a contact portion and a docking device that increases the contact area with the surface, positioning the temperature sensing junction point away from the docking device to minimize its influence on measurements, and using magnetic or nonmetallic materials for the docking device that can withstand high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the temperature sensor is fixedly attached to the structure surface by welding, then the sensor can provide temperature measurements, but the sensor's useful life is limited and frequent replacements are required due to extreme temperatures
Solution Approach 1:
The temperature sensing assembly is divided into separable components: a thermocouple sensor portion and a docking device portion. The sensor can be detached from the docking device and replaced without removing the entire assembly from the structure, enabling quick sensor replacement during operational maintenance windows and reducing processing downtime.
Solution Approach 2:
The docking device acts as an intermediary between the temperature sensor and the structure surface. It provides a stable magnetic attachment to the structure while allowing the sensor to be easily coupled and decoupled. This intermediary enables sensor replacement without direct welding or permanent attachment, extending sensor useful life and reducing replacement time.
2Measurement precision
If the temperature sensor is replaced or added, then accurate temperature measurements can be obtained, but costly shutdown of the refining process is required
Solution Approach 1:
The assembly transitions from a static welded configuration to a dynamic, reconfigurable system. The magnetic docking device allows the sensor to be coupled and decoupled on-demand, enabling maintenance and calibration activities during brief operational pauses rather than requiring extended process shutdowns, thus maintaining productivity while ensuring measurement precision.
Solution Approach 2:
The docking device is pre-installed on the structure surface before sensor replacement is needed. This preliminary action prepares the mounting infrastructure in advance, so when sensor replacement or addition is required, only the sensor portion needs to be swapped rather than performing full installation procedures, minimizing process shutdown time.
3Measurement precision
If the contact area between the sensor and surface is increased, then measurement accuracy is improved, but the docking device may influence the temperature measurement
Solution Approach 1:
The temperature sensing function is extracted and separated from the docking device. The thermocouple sensor is positioned such that its sensing junction contacts the structure surface directly, while the docking device's magnetic attachment point is spaced apart from the measurement location. This extraction eliminates the docking device's thermal influence on the measurement while maintaining large contact area for accurate temperature detection.
Solution Approach 2:
Different portions of the assembly have specialized functions: the sensor contact portion is designed for optimal thermal contact with the structure surface to ensure measurement accuracy, while the docking device portion is designed for magnetic attachment. The spatial separation creates local optimization where each component performs its function without interfering with the other, allowing large contact area without docking device interference.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The assembly provides enhanced accuracy and longevity of temperature measurements by increasing the contact area and reducing the impact of the docking device on the measurement, thereby reducing downtime and maintenance costs in high-temperature applications.
Implementation Method 1
a temperature sensing junction point disposed within an elongate sheath to measure the temperature of the surface of the structure at a desired location
Implementation Method 2
using magnetic or nonmetallic materials for the docking device that can withstand high temperatures
Data Source
AI summary
In one aspect, a temperature sensing assembly for measuring temperature of a surface of a structure includes a thermocouple device and a docking device. The thermocouple device includes a temperature sensing junction point disposed within an elongate sheath to measure the temperature of the surface of the structure at a desired location. The thermocouple device further comprises a contact portion configured to contact the surface of the structure. The docking device has a bottom surface to attach to the surface of the structure adjacent the desired location. A line extends through the center of the sheath and the sheath has a cross-sectional area in a plane perpendicular to the line. The contact portion is configured such that, when the docking device is coupled to the surface, an area of contact between the contact portion and the surface of the structure is greater than the cross-sectional area of the sheath.