Precision at the core
As someone who has spent over 40 years in temperature instrumentation product engineering, suppling solutions across the energy industrial sector, I’ve seen firsthand how critical rotating equipment – turbines, compressors, pumps, and large electric motors – are key to keeping industrial operations running smoothly especially in highly volatile environments like the oil and gas industry
Traditionally, we’ve relied heavily on vibration analysis for condition monitoring. But over time, I’ve come to appreciate that precise temperature measurement is just as vital, often providing a faster warning when things aren’t right. In my experience, those few degrees of thermal data can be the difference between a planned maintenance shutdown and an unexpected, costly breakdown.
THE THERMAL EARLY WARNING SYSTEM
In my work, I’ve found that temperature is one of the earliest and most reliable signs of emerging equipment issues, covering a wide range of failure modes. While vibration patterns can reveal mechanical wear weeks ahead of failure, temperature monitoring is unique in its ability to alert us to immediate operational dangers – like abnormal loading, lubrication breakdown, or cooling system faults – that may not show up in vibration data right away.
Take electric motors, for example. They’re responsible for about 70% of industrial electricity use, and I’ve seen that bearing problems cause a large percentage of motor failures. A temperature increase of just 20–30°F (11–17°C) above normal can indicate issues like grease breakdown or misalignment – long before a bearing seizes. By using continuous temperature sensors, I’ve helped shift teams from reactive fixes to proactive asset management. This prevents the nasty domino effect where heat leads to friction, oil breakdown, and, ultimately, catastrophic failure.
CRITICAL SPECIFICATIONS FOR OIL & GAS ENVIRONMENTS
To get meaningful results, temperature sensors must stand up to tough conditions. In my experience, high-precision Resistance Temperature Detectors (RTDs) – especially 100-ohm platinum (Pt100) Class A sensors – are the go-to choice for rotating equipment. They offer impressive stability and accuracy (around ±0.5°C), outclassing thermocouples for long-term reliability.
Typically, these sensors are spring-loaded into bearing housings to maintain solid contact with the bearing’s outer race, without interfering with the rotating shaft. I’ve noticed that standards like NEMA MG-1 and IEC 60034-1 now treat this data as essential, requiring bearing RTDs in motors over 200 HP (150 kW).
SOLVING THE ‘SILENT KILLER’ OF RELIABILITY
While the sensor element is vital, I’ve learned that the sensor’s lead wire system is a common – and often overlooked – failure point, especially in oil-lubricated bearings and gearboxes. Anti-wicking bearing sensors are a game changer for long-term reliability.
“Wicking” is the capillary action that draws oil or fluids up between wire strands and insulation. In pressurised or oil-mist environments, I’ve seen this action pull oil from the bearing housing straight into the conduit system – or worse, into the electric motor’s terminal box or the control cabinet.
WHY ANTI-WICKING MATTERS
Preventing motor contamination: Without anti-wicking, oil can migrate into the motor, saturating windings and causing insulation breakdown and severe electrical damage.
Eliminating maintenance headaches: I’ve dealt with oil leaking from sensor leads, which creates messy cleanup jobs and environmental risks, often forcing a full shutdown to replace contaminated cables.
Enhanced environmental sealing: Anti-wicking sensors use internal fluid blocks – special epoxies or fillers – to create barriers at the sensor head or along the cable, stopping fluids right at the entry point.
By specifying anti-wicking sensors, I’ve seen engineering teams eliminate a major source of secondary damage. This simple design feature ensures that the very instrument meant to monitor health doesn’t become the cause of failure.
MINIMISING BREAKDOWN MAINTENANCE
The financial argument for advanced temperature sensing is clear to me. For critical equipment where downtime costs are sky-high, investing in a quality RTD probe is a small price compared to replacing a motor and losing production.
Today’s condition monitoring platforms leverage machine learning to set “normal” thermal baselines, considering seasonal changes and production demands. When a bearing temperature spikes, these systems can trigger a safe shutdown automatically. I’ve seen how this protects assets from catastrophic damage and substantially cuts Mean Time to Repair (MTTR) by allowing technicians to zero in on a specific issue – rather than dealing with a full-blown mechanical failure.
In the evolution of the global oil and gas industry, precision temperature measurement has moved from an auxiliary check to a frontline defence. By pairing high-accuracy Pt100 sensors with robust anti-wicking cable technology, facilities can safeguard their most critical rotating assets. This dual approach not only provides the data needed for predictive maintenance but also ensures the physical integrity of the equipment, ultimately driving down costs and maximising uptime in an increasingly competitive industrial landscape.
Chris Chant is principal business & product development specialist at Daily Thermetrics.
www.dailyinst.com
