High-Temperature Thermowell Upgrade for Biomass Plant
Background
A straw-fired biomass power station in Cambridgeshire was experiencing ongoing reliability issues with temperature measurement within its high-temperature process. The site was replacing between three and four thermowells every year due to premature failure.
Each thermowell replacement required process intervention, and during removal the site had to compensate on its gas supply to ensure output did not fall below required levels. To prevent dips in supply, excess gas was used creating avoidable operational costs on top of the frequent replacement of failed units.
Challenge
The process operates at extremely high temperatures, creating harsh conditions that conventional thermowells were unable to withstand long term. Standard designs resulted in repeated failures, excessive vibration stress, and material degradation.
The customer required a robust temperature measurement solution capable of delivering consistent, accurate readings while significantly reducing maintenance frequency, replacement costs, and excess gas consumption.
Solution
To address the issue, we supplied a Thermo-Electra Helical Thermowell manufactured from Hexoloy material.
Hexoloy offers exceptional high-temperature resistance, capable of withstanding temperatures up to 1800 °C while maintaining a reduced wall thickness for faster, more accurate temperature response. The material’s superior mechanical strength compared to conventional thermowell materials provides greater durability and resistance to wear.
The unit was installed in early 2025 as a direct replacement within the existing process.
Result
Since installation, the thermowell has not failed or required removal. The site now benefits from consistent and reliable temperature measurement without repeated intervention.
The extended lifespan has eliminated the need for quarterly replacements, significantly reducing maintenance costs and freeing engineering resources for other priorities. Furthermore, by removing the need to compensate with excess gas during thermowell changeouts, the solution has delivered ongoing operational savings.
The biomass facility now operates with improved measurement stability, lower upkeep costs, and a far more sustainable long-term temperature monitoring solution.
