TEMPERATURE MEASUREMENT IN THE INDUSTRY

WHAT, WHY AND HOW

PROJECT MEMBERS
Names (in order of appearance) Anish Majumder Sk. Md. Ashif Roll No. 37 03

Debdeep Mallick Subhajit Mondal Anik Ganguly Shambo Ray

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OUTLINE
Thermocouples
overview, reference junction, proper connections, types, special limits of error wire, time constants, sheathing, potential problems, DAQ setup

RTDs
overview, bridges, calibration, accuracy, response time, potential problems

Thermistors Infrared Thermometry

fundamentals, emissivity determination, field of view

Temperature Controllers Industrial Applications How to Choose

Standards, cost, accuracy, stability, sensitivity, size, contact/non-contact, temperature range, fluid type
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THERMOCOUPLES

THERMOCOUPLES
Seebeck Effect
If two wires of dissimilar metals are joined at both ends and one end is heated, current will flow.

If the circuit is broken, there will be an open circuit voltage across the wires.
Voltage is a function of temperature and metal types. For small DTs, the relationship with temperature is linear For larger DTs, non-linearities may occur.
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MEASURING THE THERMOCOUPLE VOLTAGE If you attach the thermocouple directly to a voltmeter, you will have problems.

You have just created another junction! Your displayed voltage will be proportional to the difference between J1 and J2 (and hence T1 and T2). Note that this is Type T thermocouple.

EXTERNAL REFERENCE JUNCTION

A solution is to put J2 in an icebath; then you know T2, and your output voltage will be proportional to T1-T2.

OTHER TYPES OF THERMOCOUPLES

Many thermocouples dont have one copper wire. Shown below is a Type J thermocouple.

If the two terminals arent at the same temperature, this also creates an error.

ISOTHERMAL BLOCK
The block is an electrical insulator but good heat conductor. This way the voltages for J3 and J4 cancel out. Thermocouple data acquisition set-ups include these isothermal blocks.

If we eliminate the ice-bath, then the isothermal block temperature is our reference temperature

SOFTWARE COMPENSATION

How can we find the temperature of the block? Use a thermistor or RTD.
Once the temperature is known, the voltage associated with that temperature can be subtracted off. Then why use thermocouples at all?
Thermocouples are cheaper, smaller, more flexible and rugged, and operate over a wider temperature range.

Most data acquisition systems have software compensation built in. for example, to use Labview, youll need to know if you have a thermistor or RTD.

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HARDWARE COMPENSATION

With hardware compensation, the temperature of the isothermal block again is measured, and then a battery is used to cancel out the voltage of the reference junction. This is also called an electronic ice point reference. With this reference, you can use a normal voltmeter instead of a thermocouple reader. You need a separate ice-point reference for every type of thermocouple.

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MAKING THERMOCOUPLE BEADS

Soldering, silver-soldering, butt or spot or beaded gas welding, crimping, and twisting are all OK. The third metal introduced doesnt effect results as long as the temperature everywhere in the bead is the same. Welding should be done carefully so as to not degrade the metals. If you consistently will need a lot of thermocouples, you can buy a thermocouple welder; you stick the two ends into a hole, hit a button, and the welding is done.

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TIME CONSTANT VS. WIRE DIAMETER

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TIME CONSTANT VS. WIRE DIAMETER, CONT.

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THERMOCOUPLE TYPES

If you do your own calibration, you can usually improve on the listed uncertainties.
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THERMOCOUPLE TYPES, CONT.

Type B very poor below 50C; reference junction temperature not important since voltage output is about the same from 0 to 42 C Type E good for low temperatures since dV/dT (a) is high for low temperatures Type J cheap because one wire is iron; high sensitivity but also high uncertainty (iron impurities cause inaccuracy) Type T good accuracy but low max temperature (400 C); one lead is copper, making connections easier; but watch for heat being conducted along the copper wire, changing your surface temp Type K popular type since it has decent accuracy and a wide temperature range; some instability (drift) over time Type N most stable over time when exposed to elevated temperatures for long periods
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SHEATHING AND SLE

Special Limits of Error wire can be used to improve accuracy. Sheathing of wires protects them from the environment (fracture, oxidation, etc.) and shields them from electrical interference. The sheath should extend completely through the medium of interest. Outside the medium of interest it can be reduced. Sometimes the bead is exposed and only the wire is covered by the sheath. In harsher environments, the bead is also covered. This will increase the time constant. Platinum wires should be sheathed in non-metallic sheaths since they have a problem with metallic vapor diffusion at high temperatures.
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SHEATHING, CONT.

From J. Nicholas & D. White, 2001, Traceable Temperatures: An Introduction to Temperature Measurement and Calibration, 2nd ed. John Wiley & Sons.

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POTENTIAL PROBLEMS
Poor bead construction
Weld changed material characteristics because the weld temperature was too high

Large solder bead with temperature gradient across it

Decalibration
If thermocouples are used for very high or cold temperatures, wire properties can change due to diffusion of insulation or atmosphere particles into the wire, cold-working, or annealing. Inhomogeneities in the wire: These are especially bad in areas with large temperature gradients; especially common in iron. Metallic sleeving can help reduce their effect on the final temperature reading.
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POTENTIAL PROBLEMS, CONT.

Shunt Impedance
As temperature goes up, the resistance of many insulation types goes down. At high enough temperatures, this creates a virtual junction. This is especially problematic for small diameter wires.

Galvanic Action
The dyes in some insulations form an electrolyte in the water. This creates a galvanic action with a resulting emf potentially many times that of the thermocouple. Use an appropriate shield for a wet environment. T Type thermocouples have less of a problem with this.

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POTENTIAL PROBLEMS, CONT.

Thermal shunting
It takes energy to heat the thermocouple, which results in a small decrease in the surroundings temperature. For tiny spaces, this may be a problem. Use small wire (with a small thermal mass) to help alleviate this problem. Small-diameter wire is more susceptible to decalibration and shunt impedance problems. Extension wire helps alleviate this problem. Have short leads on the thermocouple, and connect them to the same type of extension wire which is larger. Extension wire has a smaller temperature range than normal wire.

Noise
Several types of circuit set-ups help reduce line-related noise. You can set your data acquisition system up with a filter, too. Small-diameter wires have more of a problem with noise.
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POTENTIAL PROBLEMS, CONT.

Conduction along the thermocouple wire
In areas of large temperature gradient, heat can be conducted along the thermocouple wire, changing the bead temperature. Small diameter wires conduct less of this heat.

T-type thermocouples have more of a problem with this than most other types since one of the leads is made of copper which has a high thermal conductivity.

Inaccurate ice-point

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DATA ACQUISITION SYSTEMS FOR THERMOCOUPLES

Agilent, HP, and National Instruments are probably the most popular DAQ systems Example National Instruments DAQ setup for thermocouples and costs

* Approximately 2.05 lakhs

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THINGS TO NOTE DURING SYSTEM ASSEMBLY

Make sure materials are clean, especially for high temperatures. Check the temperature range of materials. Materials may degrade significantly before the highest temperature listed. Make sure you have a good isothermal junction. Use enough wire that there are no temperature gradients where its connected to your DAQ system. If youre using thermocouple connectors, use the right type for your wire.

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THINGS TO NOTE DURING SYSTEM ASSEMBLY, CONT.

If youre using a DAQ system, use the right set-up for thermocouples. Check the ice-point reference. Provide proper insulation for harsh environments.

Pass a hair-dryer over the wire. The temperature reading should only change when you pass it over the bead.
Mount a thermocouple only on a surface that is not electrically live (watch for this when measuring temperatures of electronics).

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RTDS (RESISTANCE TEMPERATURE DETECTORS)

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RTDS (RESISTANCE TEMPERATURE DETECTORS)

Resistivity of metals is a function of temperature.

Platinum often used since it can be used for a wide temperature range and has excellent stability. Nickel or nickel alloys are used as well, but they arent as accurate.
In several common configurations, the platinum wire is exposed directly to air (called a birdcage element), wound around a bobbin and then sealed in molten glass, or threaded through a ceramic cylinder. Metal film RTDs are new. To make these, a platinum or metal-glass slurry film is deposited onto a ceramic substrate. The substrate is then etched with a laser. These RTDs are very small but arent as stable (and hence not quite accurate). RTDs are more accurate but also larger and more expensive than thermocouples.
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RTD GEOMETRY

From Nicholas & White, Traceable Temperatures.

Sheathing: stainless steel or Inconel, glass, alumina, quartz Metal sheath can cause contamination at high temperatures and are best below 250C. At very high temperatures, quartz and high-purity alumina are best to prevent contamination.

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RESISTANCE MEASUREMENT
Several different bridge circuits are used to determine the resistance. Bridge circuits help improve the accuracy of the measurements significantly. Bridge output voltage is a function of the RTD resistance.

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RESISTANCE/TEMPERATURE CONVERSION

Published equations relating bridge voltage to temperature can be used. For very accurate results, own calibration can be done easily.
Several electronic calibrators are available. The most accurate calibration that you can do easily yourself is to use a constant temperature bath and NISTtraceable thermometers. You then can make your own calibration curve correlating temperature and voltage.

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ACCURACY AND RESPONSE TIME

Response time is longer than thermocouples; for a sheath, response time can easily be 10 s.

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POTENTIAL PROBLEMS
RTDs are more fragile than thermocouples.
An external current must be supplied to the RTD. This current can heat the RTD, altering the results. For situations with high heat transfer coefficients, this error is small since the heat is dissipated to air. For small diameter thermocouples and still air this error is the largest. Use the largest RTD possible and smallest external current possible to minimize this error. Be careful about the way you set up your measurement device. Attaching it can change the voltage.

When the platinum is connected to copper connectors, a voltage difference will occur (as in thermocouples). This voltage must be subtracted off.
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THERMISTORS

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THERMISTORS
Thermistors also measure the change in resistance with temperature. Thermistors are very sensitive (up to 100 times more than RTDs and 1000 times more than thermocouples) and can detect very small changes in temperature. They are also very fast. Due to their speed, they are used for precision temperature control and any time very small temperature differences must be detected.

They are made of ceramic semiconductor material (metal oxides).

The change in thermistor resistance with temperature is very non-linear.
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THERMISTOR NON-LINEARITY

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POINTS TO NOTE IN CASE OF THERMISTORS

Standard thermistors curves are not provided as much as with thermocouples or RTDs. You often need a curve for a specific batch of thermistors. No 4-wire bridge is required as with an RTD.

DAQ systems can handle the non-linear curve fit easily.

Thermistors do not do well at high temperatures and show instability with time (but for the best ones, this instability is only a few millikelvin per year)

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COMPARISONS

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*from Omega

INFRARED THERMOMETRY: PYROMETER

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INFRARED THERMOMETRY

Infrared thermometers measure the amount of radiation emitted by an object. Peak magnitude is often in the infrared region. Surface emissivity must be known. This can add a lot of error.

Reflection from other objects can introduce error as well.

Surface whose temp youre measuring must fill the field of view of your camera.

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BENEFITS OF INFRARED THERMOMETRY

Can be used for

Moving objects Non-contact applications where sensors would affect results or be difficult to insert or conditions are hazardous Large distances Very high temperatures

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FIELD OF VIEW

On some infrared thermometers, FOV is adjustable.

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EMISSIVITY
To find out temperature, surface emissivity must be known. You can look up emissivities, but its not easy to get an accurate number, esp. if surface condition is uncertain (for example, degree of oxidation). Highly reflective surfaces introduce a lot of error. Narrow-band spectral filtering results in a more accurate emissivity value.

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WAYS TO DETERMINE EMISSIVITY

1. Measure the temperature with a thermocouple and an infrared thermometer. Find out the emissivity. This method works well if emissivity doesnt change much with temperature or youre not dealing with a large temperature range. For temperatures below 500F, place an object covered with masking tape (which has e=0.95) in the same atmosphere. Both objects will be at the same temperature. Back out the unknown emissivity of the surface. Drill a long hole in the object. The hole acts like a blackbody with e=1.0. Measure the temperature of the hole, and find the surface emissivity that gives the same temperature. Coat all or part of the surface with dull black paint which has e1.0. For a standard material with known surface condition, look up e.
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2.

3. 4. 5.

SPECTRAL EFFECTS
Use a filter to eliminate longer-wavelength atmospheric radiation (since your surface will often have a much higher temperature than the atmosphere). If you know the range of temperatures that youll be measuring, you can filter out both smaller and larger wavelength radiation. Filtering out small wavelengths eliminates the effects of flames or other hot spots. If youre measuring through glass-type surfaces, make sure that the glass is transparent for the wavelengths you care about. Otherwise the temperature you read will be a sort of average of your desired surface and glass temperatures.

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PRICE AND ACCURACY

Prices range from $500 (for a cheap handheld) to $6000 (for a highly accurate computer-controlled model). Accuracy is often in the 0.5-1% of full range. Uncertainties of 6.6C are common, but at temperatures of several hundred degrees, this is small. Microprocessor-Based IR Thermometer

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EXTRAS: THE ALTERNATE WAYS

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EXTRA: NON-ELECTRONIC TEMPERATURE GAGES

Crayons You can buy crayons with specified melting temperatures. Mark the surface, and when the mark melts, you know the temperature at that time. Lacquers Special lacquers are available that change from dull to glossy and transparent at a specified temperature. This is a type of phase change. Pellets These change phase like crayons and lacquers but are larger. If the heating time is long, oxidation may obscure crayon marks. Pellets are also used as thermal fuses; they can be placed so that when they melt, they release a circuit breaker. Temperature sensitive labels These are nice because you can peel them off when finished and place them in a log book.
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EXTRA: NON-ELECTRONIC TEMPERATURE GAGES, CONT.

Liquid crystals They change color with temperature. If the calibration is known, color can be determined very accurately using a digital camera and appropriate image analysis software. This is used in a fair amount for research.

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CONTROLLERS

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TEMPERATURE CONTROLLERS
Consider the following when choosing a controller
Type of temperature sensor (thermocouples and RTDs are common) Number and type of outputs required (for example, turn on a heater, turn off a cooling system, sound an alarm) Type of control algorithm (on/off, proportional, PID)

On/off controllers
These are the simplest controllers. On above a certain set point, and off below a certain set point On/off differential used to prevent continuous cycling on and off. This type of controller cant be used for precise temperature control. Often used for systems with a large thermal mass (where temperatures take a long time to change) and for alarms.
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PROPORTIONAL CONTROLLERS
Proportional controllers
Power can be varied. For example, in a heating unit the average power supplied will decrease the closer one gets to the set point. Power is often varied by turning the controller on and off very quickly rather than using a VFD Some proportional controllers use proportional analog outputs where the output level is varied rather than turning the controller on and off.

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PID
Combines proportional with integral and derivative control. With proportional control, the temperature usually stabilizes a certain amount above or below the set point. This difference is called offset.

With integral and derivative control, this offset is compensated for so that you end up at the set point. This provides very accurate temperature control, even for systems where the temp. is changing rapidly.
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BLOCK DIAGRAM OF THE SYSTEM

Driver

Load / Motor

User Interface (screen, controller etc.)

Monitoring System

Sensor

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INDUSTRIAL APPLICATIONS

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INDUSTRIAL APPLICATIONS

Steel industry
Thermocouples or RTDs are used to measure temperatures of the furnace Infrared pyrometers and infrared cameras are used to measure the temperature of the metal itself

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INDUSTRIAL APPLICATIONS

Power industry
Thermocouples or RTDs are used to monitor the furnace and boiler temperatures

Infrared pyrometers are used to measure temperatures in various sections of the turbines, especially blades

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HOW TO CHOOSE A TEMPERATURE CONTROL DEVICE OR SYSTEM

Things to take into account
Standards Cost Accuracy Stability over time (esp. for high temperatures) Sensitivity Size Contact/non-contact Temperature range Fluid
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ENCLOSURE RATINGS
Type 1 general purpose indoor enclosure to prevent accidental contact

Type 2 indoor use, provides limited protection from dirt and dripping water
Type 3 outdoor use to protect against wind-blown dust, sleet, rain, but no ice formation Type 3R outdoor use to protect against falling rain but no ice formation Type 4 add splashing or hose-directed water to 3 Type 4x add corrosion Type 6 add occasional submersion to 4x etc.
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CHOICE BETWEEN RTDS, THERMOCOUPLES, THERMISTORS

Cost thermocouples are cheapest by far, followed by RTDs

Accuracy RTDs or thermistors

Sensitivity thermistors Speed - thermistors Stability at high temperatures NOT thermistors Size thermocouples and thermistors can be made quite small Temperature range thermocouples have the highest range, followed by RTDs Ruggedness thermocouples are best if your system will be taking a lot of abuse
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THANK YOU!