{"id":17329,"date":"2023-10-06T09:25:37","date_gmt":"2023-10-06T14:25:37","guid":{"rendered":"https:\/\/blog.wika.com\/us\/\/?p=17329"},"modified":"2025-06-11T14:49:40","modified_gmt":"2025-06-11T19:49:40","slug":"tubeskin-temperature-measurement-how-to-improve-tubeskin-thermocouple-accuracy-on-a-butter-pad","status":"publish","type":"post","link":"https:\/\/blog.wika.com\/us\/products\/temperature-products\/tubeskin-temperature-measurement-how-to-improve-tubeskin-thermocouple-accuracy-on-a-butter-pad\/","title":{"rendered":"Tubeskin Temperature Measurement: How to Improve Tubeskin Thermocouple Accuracy on a Butter-Pad"},"content":{"rendered":"<p><strong>WIKA conducted a series of tests \u2013 both in the field and using computational fluid dynamics \u2013 to evaluate the accuracy of tubeskin thermocouples (TSTCs) when installed on a butter-pad vs. on a bare tube. We also varied the\u00a0weld material\u2019s\u00a0orientation (transversal vs. longitudinal), its emissivity values (\u03b5 = 0.45, 0.67, and 0.85), and subjected the sensors to different operating\u00a0conditions (firing at 6.9 MMBtu\/hr and 12.7 MMBtu\/hr).<\/strong><\/p>\n<p>Based on the data, we arrived at several conclusions as well as two ways to improve the accuracy of TSTCs when the sensors are not installed directly on a bare furnace tube.<\/p>\n<h2><strong>How Butter-Pads Impact Tubeskin Thermocouple Accuracy: Observations and ways to improve accuracy<\/strong><\/h2>\n<p style=\"font-weight: 400\">From the data, we observe the following:<\/p>\n<ul>\n<li>Regardless of the butter-pad\u2019s emissivity value, the product installed on a butter-pad read higher as compared to when it is installed on a bare tube. The magnitude of deviation from the actual is product-specific.<\/li>\n<li>We can infer that TSTC products designed to read accurately on bare tubes will read higher when installed on a butter-pad, and the magnitude of temperature deviation will be determined by the butter-pad\u2019s emissivity, dimension, and thermal conductivity.<\/li>\n<\/ul>\n<p style=\"font-weight: 400\">We hypothesized two ways to improve the product\u2019s performance when installed on a butter-pad:<\/p>\n<ul>\n<li>Vary the butter-pad\u2019s thermal conductivity through the use of different weld materials.<\/li>\n<li>Reduce the butter-pad\u2019s emissivity through surface preparation.<\/li>\n<\/ul>\n<p style=\"font-weight: 400\">For the following CFD simulation, we:<\/p>\n<ul>\n<li>Increased the butter-pad\u2019s thermal conductivity by 20%.<\/li>\n<li>Reduced the emissivity value from 0.67 to 0.45.<\/li>\n<\/ul>\n<p style=\"font-weight: 400\">The TSTC product and the butter-pad\u2019s dimensions remain unchanged.<\/p>\n<p style=\"font-weight: 400\">We found that increasing the butter-pad\u2019s thermal conductivity and decreasing its emissivity resulted in significantly better accuracy of the unshielded product (see Table 6), from +20\u00b0F to +5\u00b0F (\u2206 15\u00b0F) and from +26\u00b0F to +2\u00b0F<span>\u00a0 <\/span>(\u2206 24\u00b0F). For the shielded product, the improvement was marginal, from +22\u00b0F to +19\u00b0F (\u2206 3\u00b0F) and from +21\u00b0F to +16\u00b0F<span>\u00a0 <\/span>(\u2206 5\u00b0F).<\/p>\n<p style=\"font-weight: 400\"><strong>Table 6: Temperature deviation of unshielded vs. unshielded TSTC on <\/strong><strong><span>\u03b5<\/span> = 0.45 butter-pad and thermal condition = 1.2, CFD simulation<\/strong><\/p>\n<table style=\"font-weight: 400;width: 87.975672%\" width=\"563\">\n<tbody>\n<tr>\n<td style=\"width: 7.746479%\" width=\"39\">\n<p><strong>No.<\/strong><\/p>\n<\/td>\n<td style=\"width: 17.557727%\" width=\"92\">\n<p><strong>Firing (MMBtu\/hr)<\/strong><\/p>\n<\/td>\n<td style=\"width: 19.894605%\" width=\"97\">\n<p><strong>Bare tube<br \/>\ntemperature*<\/strong><\/p>\n<\/td>\n<td style=\"width: 16.533008%\" width=\"114\">\u00a0<\/td>\n<td style=\"width: 19.254097%\" width=\"114\">\n<p><strong>Temperature reading*<\/strong><\/p>\n<\/td>\n<td style=\"width: 48.767606%\" width=\"108\">\n<p><strong>Temperature deviation*<\/strong><\/p>\n<\/td>\n<\/tr>\n<tr>\n<td style=\"width: 7.746479%\" rowspan=\"2\" width=\"39\">\n<p>1<\/p>\n<\/td>\n<td style=\"width: 17.557727%\" rowspan=\"2\" width=\"92\">\n<p>6.9<\/p>\n<\/td>\n<td style=\"width: 19.894605%\" rowspan=\"2\" width=\"97\">\n<p>797\u00b0F<\/p>\n<\/td>\n<td style=\"width: 16.533008%\" width=\"114\">\n<p><em>unshielded TSTC<\/em><\/p>\n<\/td>\n<td style=\"width: 19.254097%\" width=\"114\">\n<p><span>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 <\/span><span>\u00a0\u00a0\u00a0<\/span><span>\u00a0<\/span><span>\u00a0<\/span><span>\u00a0<\/span>802\u00b0F<\/p>\n<\/td>\n<td style=\"width: 48.767606%\" width=\"108\">\n<p><span>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 <\/span>+5\u00b0F<\/p>\n<\/td>\n<\/tr>\n<tr>\n<td style=\"width: 16.533008%\" width=\"114\">\n<p><em>\u00a0 \u00a0 shielded<br \/>\n\u00a0 \u00a0 TSTC<\/em><\/p>\n<\/td>\n<td style=\"width: 19.254097%\" width=\"114\">\n<p><span>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 <\/span><span>\u00a0\u00a0\u00a0\u00a0<\/span><span>\u00a0<\/span>816\u00b0F<\/p>\n<\/td>\n<td style=\"width: 48.767606%\" width=\"108\">\n<p><span>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 <\/span>+19\u00b0F<\/p>\n<\/td>\n<\/tr>\n<tr>\n<td style=\"width: 7.746479%\" rowspan=\"2\" width=\"39\">\n<p>2<\/p>\n<\/td>\n<td style=\"width: 17.557727%\" rowspan=\"2\" width=\"92\">\n<p>12.7<\/p>\n<\/td>\n<td style=\"width: 19.894605%\" rowspan=\"2\" width=\"97\">\n<p>1,002\u00b0F<\/p>\n<\/td>\n<td style=\"width: 16.533008%\" width=\"114\">\n<p><em>unshielded TSTC<\/em><\/p>\n<\/td>\n<td style=\"width: 19.254097%\" width=\"114\">\n<p><span>\u00a0\u00a0\u00a0\u00a0\u00a0 <\/span><span>\u00a0\u00a0\u00a0\u00a0<\/span>1,003\u00b0F<\/p>\n<\/td>\n<td style=\"width: 48.767606%\" width=\"108\">\n<p><span>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 <\/span>+2\u00b0F<\/p>\n<\/td>\n<\/tr>\n<tr>\n<td style=\"width: 16.533008%\" width=\"114\">\n<p><em>\u00a0 \u00a0 shielded<br \/>\n\u00a0 \u00a0 TSTC<\/em><\/p>\n<\/td>\n<td style=\"width: 19.254097%\" width=\"114\">\n<p><span>\u00a0\u00a0\u00a0\u00a0\u00a0 <\/span><span>\u00a0\u00a0\u00a0\u00a0<\/span>1,018\u00b0F<\/p>\n<\/td>\n<td style=\"width: 48.767606%\" width=\"108\">\n<p><span>\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0\u00a0 <\/span>+16\u00b0F<\/p>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p style=\"font-weight: 400\"><em>* Values are rounded<\/em><\/p>\n<h2><strong>Conclusions and Next Steps<\/strong><\/h2>\n<p style=\"font-weight: 400\">Installing a thermocouple on a butter-pad is a good move for metallurgical reasons, but it comes with a penalty on accuracy. That being said, for products that normally read lower than actual, they would read higher than before on a butter-pad; depending on the product design, they may even come closer to actual or read higher than actual. Similarly, for products that normally read higher than actual, the temperature deviation is even greater when the thermocouple is installed on a butter-pad.<\/p>\n<p style=\"font-weight: 400\">Varying the butter-pad\u2019s physical properties, such as its emissivity and overlay material, can improve a TSTC\u2019s accuracy. However, these measures\u2019 effectiveness is unique to the product being installed; testing and CFD analyses would be necessary to arrive at an optimal solution.<\/p>\n<p><span style=\"font-weight: 400\">The ultimate goal, of course, is to use the information and learnings from this project to guide customers in designing temperature measurement solutions for their specific fired heaters, operating conditions, furnace tubes, and tubeskin thermocouples.<\/span><\/p>\n<p>This is a continuation of <a href=\"https:\/\/blog.wika.com\/us\/products\/temperature-products\/how-butter-pad-affects-tubeskin-thermocouple-accuracy\/?doing_wp_cron=1696356459.5636730194091796875000\">&#8220;How Butter-Pad Affects Tubeskin Thermocouple Accuracy&#8221;<\/a><\/p>\n<h2><strong>WIKA, Expertise in Tubeskin Temperature Measurement<\/strong><\/h2>\n<p style=\"font-weight: 400\">WIKA is a global leader in temperature measurement solutions for downstream applications in the <a href=\"https:\/\/www.wika.com\/en-us\/oil_and_gas_up_mid_and_downstream.WIKA\" rel=\"external\" target=\"_blank\">oil and gas industry<\/a>. In addition to manufacturing and\u00a0<a href=\"https:\/\/www.wika.com\/en-us\/engineered_solutions_temperature.WIKA\" rel=\"external\" target=\"_blank\">customizing<\/a>\u00a0high-quality <a href=\"https:\/\/www.wika.com\/en-us\/tubeskin_thermocouples.WIKA\" rel=\"external\" target=\"_blank\">tubeskin thermocouples<\/a>\u00a0and\u00a0<a href=\"https:\/\/www.wika.com\/en-us\/multipoint_thermometers.WIKA\" rel=\"external\" target=\"_blank\">multipoint thermocouples<\/a>\u00a0for refinery units, we provide several services designed to improve a plant\u2019s operations:<\/p>\n<ul>\n<li><a href=\"https:\/\/www.wika.com\/en-us\/field_service.WIKA\" rel=\"external\" target=\"_blank\">Thermocouple installation<\/a>, including supervision, weld work, troubleshooting, and inspections<\/li>\n<li style=\"font-weight: 400\"><a href=\"https:\/\/blog.wika.com\/us\/\/products\/temperature-products\/wika-thermocouple-verification-service\/\">Thermocouple verification<\/a> during turnarounds<\/li>\n<li><a href=\"https:\/\/blog.wika.com\/us\/\/products\/temperature-products\/thermocouple-replacement-temperature-monitoring\/\">Thermocouple replacement<\/a><\/li>\n<\/ul>\n<p>Contact us for more information about how WIKA USA can increase your facility\u2019s safety and profitability.<\/p>\n<p>&nbsp;<\/p>\n<p><span>[contact-form-7 id=&#8221;14552&#8243; title=&#8221;Blog Contact Form&#8221;]<\/span><\/p>\n","protected":false},"excerpt":{"rendered":"<p>WIKA conducted a series of tests \u2013 both in the field and using computational fluid dynamics \u2013 to evaluate the accuracy of tubeskin thermocouples (TSTCs) when installed on a butter-pad vs. on a bare tube. We also varied the\u00a0weld material\u2019s\u00a0orientation (transversal vs. longitudinal), its emissivity values (\u03b5 = 0.45, 0.67, and 0.85), and subjected the [&hellip;]<\/p>\n","protected":false},"author":190,"featured_media":17335,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[5,221],"tags":[],"class_list":["post-17329","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-knowhow","category-temperature-products"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.2 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Tubeskin Thermocouple: Bare Tube vs: Butter-Pad - WIKA blog<\/title>\n<meta name=\"description\" content=\"WIKA conducted a series of tests \u2013 both in the field and using computational fluid dynamics \u2013 to evaluate the accuracy of tubeskin thermocouples (TSTCs)\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/blog.wika.com\/us\/products\/temperature-products\/tubeskin-temperature-measurement-how-to-improve-tubeskin-thermocouple-accuracy-on-a-butter-pad\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Tubeskin Thermocouple: Bare Tube vs: Butter-Pad - 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