Thermocouple Wires and Extension Lead Issues

Instrumentation engineering root cause analysis of thermocouple wires and extension lead cables issues and their solutions.

Article Type:Root Cause Analysis (RCA)
Equipment Type:Sensors
Author:S. Raghava Chari

Note: This root cause analysis (RCA) is from real-time scenarios that happened in industries during the tenure of two or three decades ago. These articles will help you to improve your troubleshooting skills and knowledge.

Thermocouple Wires Issues

The author noticed that:

  1. Crew usually tack welds ½ m long shop made beaded thermocouples (TCs) measuring ends to the job and connect each TC using a single pair extension lead (EL) to a 5 m away table placed multi-point temperature recorder.
  2. Saving these small lengths thermocouple wires and extension leads (EL) is cumbersome; hence, these though very expensive and difficult to get reach the scrap after each use, and pose non-availability problems during rush stress relief jobs


The author insisted on tacking 10 m long beaded thermocouples ends to the job and connect the other end to a Table placed temperature recorder as usual.

Benefits Derived

Benefits Derived are:

  1. No extension lead use, hence no EL waste
  2. Saving the 10-m long beaded thermocouples TCs) for several re-uses is easy and practical. hence no TCs waste either
  3. Welding short length TC wires to make up the length is easy. Hence, the TCs are always usable waste free.

Author: S. Raghava Chari

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Thermocouple Wires and Extension Lead Issues

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