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Embedded Elements
‘The temperature of the heat-generating conductor in an embedded element
consists of two components: the temperature drop between the element
surface and the environment, which depends on the element surface load
and the heat-dissipating conditions outside the element, and the tempera-
ture difference between the heat-generating conductor and the element sur-
face, which depends on the geometry (dimensions and shape) of the con-
ductor and the insulation, the thermal conductivity of the insulation, and
the surface load of the element.
‘The temperature may vary along the heat-generating conductor. The
highest temperature determines its life. When, for instance, the heat-
‘generating conductor is a coil of resistance wire, its temperature often
235236 Chapter 6
varies along the circumference of each wire tum. The part of the wire
which is situated closest to the element surface will reach a lower tempera-
ture than the part that is farthest away. The biggest imaginable tempera-
ture difference along one tum of wire is presented in Equation (6.38) of
Section 6.10.
In embedded heating elements the heat-generating conductor is en-
closed in insulating materials and not easily available for temperature mea~
surements. In Section 3.10 it has been explained how such a measurement
can be performed. The temperature of this conductor should not exceed a
certain limit in order to secure a long element life and satisfactory electrical
insulation. Equation (3.100) in Section 3.10 shows the connection between
the temperature of the heat-generating conductor, the element surface load,
and the element surface temperature, which is often easy to measure. It
follows from this equation that for embedded elements the maximum per-
missible element surface load and the maximum permissible element sur-
face temperature cannot be applied simultaneously. When the element sur-
face load is close to the permissible maximum the element surface
temperature has to be low, and when the surface temperature is close to
its permissible maximum the surface load has to be low.
Tin the embedded elements the resistance heating conductor is locked
and can in most elements not elongate permanently as it does for at least
Fe-Cr-Al alloys above 700°C in suspended and supported elements. This
implies that the rating remains more constant in embedded elements op-
crating above 700°C.
6.1. METAL-SHEATHED TUBULAR ELEMENT
6.1.1. General Description
‘A metal-sheathed tubular element usually consists of a coil of a resistance
heating alloy that is connected at each end to a terminal pin and is elec-
trically insulated from a concentric metallic tube. The construction
shown in Figure 6.1. The insulation between coil and tube normally con-
sists of ceramic material, often fused MgO powder. The tube ends are
frequently equipped with beads of insulating material such as ceramic or
silicone rubber. The aim is to increase the creepage distance (see Section
3.8.2.) between the tube and the terminal pin. If a ceramic bead is applied
there may in addition be a seal between the bead and the insulation in
‘order to avoid penetration of moisture into the element.
Metal-sheathed tubular elements with both or all terminals at the
same tube end may be classified as cartridge elements. A cartridge element
in this book is, however, a metal-sheathed tubular element that has allEmbedded Elements 237
ininal pln /End plug Sealing Insulation powder Coll
femeten pcan ne Ps
‘\ Metal tube
Ficune 61 Metal-sheathed tubular element with one coil having one ter-
minal at each tube end.
terminals at the same tube end, a straight tube, and a round cross section.
Powder-filled cartridge elements are treated in Section 6.2.
‘The cross section of the tubular element is usually round but may
instead be oval, rectangular, triangular, or square. If the cross section de-
viates from the round shape it may become more difficult to achieve a high
powder density and a high thermal conductivity of the embedding powder.
When it is important to keep a small temperature drop between wire and
tube, for instance when the tube surface load is very high and the heat
dissipation conditions at the tube surface are very good, the round cross
section may be best.
‘In some cases, however, the temperature difference between tube and
fluid outside the tube becomes more important for the element design than
the temperature drop between coil and tube, and in such cases it may
sometimes be better to choose an oval or flat cross section than a round
fone. At free convection, for instance, a horizontal tubular element with an
oval or flat cross section and with its width pointing in vertical direction
has, for the same tube surface load and the same circumference, a lower
tube temperature than a round tube,
The tubular element may be equipped with two or three parallel coils
instead of only one. These coils may have one terminal in each tube end,
or all the terminals may be at the same tube end. In the latter case the
other tube end is closed by welding. The cross section of such an element
‘may be flat, oval, triangular, or round. There may, for instance, be three
parallel coils joined together at the closed tube end, or there may be two
parallel coils and one terminal running all along the two coils. The terminal
is joined to the two coils at the closed tube end. In Figure 6.2 the two
alternatives are shown for a tubular elements with a flat or oval cross