Temperature Measurement: Prepared By: Dba

TEMPERATURE
MEASUREMENT
PREPARED BY: DBA

INDUSTRIAL TEMPERATURE MEASUREMENT
IN AN INDUSTRY, THERE IS ALWAYS A NEED TO MEASURE AND

MONITOR TEMPERATURE OF A PARTICULAR SPOT, FIELD OR
LOCALITY. THE INDUSTRIAL NAMES GIVEN TO SUCH TEMPERATURE
SENSORS ARE TEMPERATURE INDICATORS (TI) OR TEMPERATURE
GAUGES (TG).
TEMPERATURE IS A PHYSICAL QUANTITY EXPRESSING HOT AND

COLD. IT IS MEASURED WITH A THERMOMETER CALIBRATED IN ONE
OR MORE TEMPERATURE SCALES.
WHY TEMPERATURE IS IMPORTANT?
• MANY PHYSICAL PROCESSES ARE AFFECTED BY TEMPERATURE
• PHYSICAL PROPERTIES OF MATERIALS INCLUDING THE PHASE,
DENSITY, SOLUBILITY, VAPOR PRESSURE, ELECTRICAL
CONDUCTIVITY
• RATE AND EXTENT TO WHICH CHEMICAL REACTIONS OCCUR
• THE AMOUNT AND PROPERTIES OF THERMAL RADIATION
EMITTED FROM THE SURFACE OF AN OBJECT
• SPEED OF SOUND IS A FUNCTION OF THE SQUARE ROOT OF THE
ABSOLUTE TEMPERATURE
TYPES OF TEMPERATURE SENSOR TO BE DISCUSSED IN THIS CHAPTER
A. BIMETALLIC TEMPERATURE SENSOR
https://www.youtube.com/watch?v=6Am3lqOGCuA&t=190s
B. FILLED-SYSTEM TEMPERATURE SENSOR

https://www.youtube.com/watch?v=WID5xEHNSWg
C. RESISTANCE TEMPERATURE DETECTOR (RTD)

https://www.youtube.com/watch?v=IeOeh1d-U3w
D. THERMOCOUPLE
https://www.youtube.com/watch?v=3U2EA7U0NI8
E. THERMISTOR
https://www.youtube.com/watch?v=DDdlzDFnFu8
F. PYROMETER
Note: https://www.youtube.com/watch?v=yetXIqoEsn0&t=2s
All video links are optional, you may choose to access it or not, but I
believe the videos may help you to best appreciate the lesson.
A. BIMETALLIC TEMPERATURE SENSORS
• It uses the bimetallic strip which converts the temperature into the mechanical
displacement.
• This mechanical action from the bimetallic strip can be used to activate a
switching mechanism for getting electronic output. Also it can be attached to the
pointer of a measuring instrument or a position indicator.
Working Principle
• All metals change in dimension, that is expand or contract when there
is a change in temperature.
• The rate at which this expansion or contraction takes place depend on
the temperature co-efficient of expansion of the metal and this
temperature coefficient of expansion is different for different metals.
Hence the difference in thermal expansion rates is used to produce
deflections which is proportional to temperature changes.
Types:
1. HELICAL TYPE (HELIX TYPE)
2. SPIRAL TYPE
3. CANTILEVER TYPE
1. Helical Type
The helix type bimetallic strip is mostly used for industrial applications. In this
thermometer, the helix shape strip is used for measuring the temperature. The free
end of the strip is connected to the pointer. The deflection of the strip shows the
variation of temperature.
1. Helical Type

2. Spiral Type
In bimetallic strip thermometer, the spiral-shaped strip is used. This type of
thermometer is used for measuring the ambient temperature. Because of the
thermal expansion property of metal the deformation occurs in the spring with the
variation of temperature. The pointer and dials attached to the spring, which
indicates the variation of temperature.
2. Spiral Type
3. Cantilever Type
The bimetallic strip is in the form of a cantilever beam. An increase in
temperature will result in the deflection of the free end of the strip and this
deflection is linear and can be related to temperature changes.
3. Cantilever Type
Important properties a material should have to be selected for
bimetallic thermometers:
1. Coefficient of expansion.
2. Modulus of elasticity.
3. Elastic limit after cold rolling.
4. Electrical conductivity.
5. Ductility.
6. Metallurgical ability.
Commonly used metal in Bimetallic thermometers:
High expansion
1. Brass
2. Nickel-iron alloy with chromium and manganese.
Low Expansion
1. Invar (alloy of nickel and iron).
2. Iron
Application of Bimetallic Strips and Thermometers:
• The bimetallic thermometer is used in household devices likes oven,
air conditioner, and in industrial apparatus like refineries, hot wires,
heater, tempering tanks etc. for measuring the temperature.
• By far the most common application of the bimetallic strip is as a
thermostat switch used for temperature and energy control.
Advantages of Bimetallic Thermometers:
1. They are simple, robust and inexpensive.
2. Their accuracy is between + or - 2% to 5% of the scale.
3. They can with stand 50% over range in temperatures.
4. They can be used wherever a mercury–in-glass thermometer is used.
Limitations of Bimetallic Thermometer:
1. They are not recommended for temperature above 400°C.
2. When regularly used, the bimetallic may permanently deform, which in turn will
introduce errors.
3. Their sensitivity and accuracy is less at low temperature.
B. FILLED-SYSTEM TEMPERATURE SENSORS
• A thermometer which has a bourdon tube connected by a capillary tube to a
hollow bulb.
• The standard classifies filled-system thermometers by the type of fill fluid used,
it is either liquid, vapor or gas.
• Bulb Design
The bulb volume varies over a range of 100 to 1 depending on the fill fluid, the
temperature span, and the capilliary length.
Different bulb materials are available but when used in Thermowell, standard
materials can be used. Some of this materials are copper, bronze or stainless steel. In case
of atmospheric corrosion, stainless steel is preferred.
• Capillary Tubing and Armoring
Capillary tubing is a small diameter tubing, usually made of stainless steel. Armor
should always be specified mot only because of mechanical strength but also to
distinguish with other tubing. Armor material shall be also a stainless steel material.
Some case where in corrosive atmosphere, the armor should be plastic coated.
Working principle:
• Filled-system thermometers use the phenomenon of thermal
expansion of matter to measure temperature change.
• Filled-bulb systems exploit the principle of fluid expansion
to measure temperature. If a fluid is enclosed in a sealed
system and then heated, the molecules in that fluid will exert
a greater pressure on the walls of the enclosing vessel.
• There are different types of filled-system thermometer that are identified by
“Class Numbers”
CLASS I: LIQUID FILLED
• Liquid actuated, solid filled with a high volumetric
expansion organic liquid (not mercury) The elastic
element responds to volumetric expansion of liquid in the
bulb.
• Common fill liquids are hydrocarbons and silicone fluids
Bulb size is dependent on temperature span and fill
medium Liquid filled systems are sensitive to ambient
temperature changes on the elastic element and capillary
unless some means of compensation is employed
CLASS II: VAPOR FILLED
• It uses a volatile liquid/vapor combination to generate a
temperature-dependent fluid expansion.
• Vapour pressure systems are quite accurate and reliable.
This form of measurement is based on the vapour-
pressure curves of the fluid and measurement occurs at
the transition between the liquid and vapour phase.
• Methyl Chloride, Ethane and Ethyl Chloride are some
of the fluid used in this class.
CLASS III: GAS FILLED
• This type of measurement is quite simple and low cost.
• Nitrogen is quite commonly used with gas filled systems
because it does not react easily and is inexpensive. At
low temperature, helium should be considered.
• Gas filled systems do provide a faster response than the
other filled devices because it converts temperature
directly into pressure that is particularly useful in
pneumatic systems.
CLASS IV: GAS WITH ADSORBENT
• Gas actuated thermometer with an adsorbent (such as
activated carbon) in the bulb The adsorbent amplifies the
pressure temperature relationship providing a pressure change
greater than that of an equivalent range Class 3 thermometer
This permits the use of smaller bulbs and narrower
temperature spans Lower operating pressures minimize
ambient temperature errors
CLASS V: MERCURY FILLED
• Mercury expansion systems are
different from other liquid filled
systems because of the properties of
the metal. Mercury is toxic and can
affect some industrial processes
that's why it is used less in filled
system.
SOURCES OF ERRORS:
• Ambient temperature effect - The capillary tube and bourdon tube are exposed to surroundings and subjected to a
variable temperature widely different from that of the bulb, which results as an error in temperature measurement.
• Head or elevation effect - If the long capillary tube is used and thermometer bulb is placed at a different height
with respect to the bourdon tube, then due to elevation difference between bulb and bourdon tube deflecting end,
pressure head is created which results as an error in temperature measurement.
• Radiation effect - This error occurs due to temperature difference between the bulb and other solid bodies around
it.
• Immersion effect - If the bulb is not properly immersed or head of bulb is not properly insulated, then heat from
the bulb may be lost due to conduction from bulb and hence temperature at the bulb may be reduced, so that, it
indicates lower temperature than the actual.
• Barometric effect - The tip travel of a bourdon tube is due to pressure difference between atmosphere and filled
system pressure. So if any variation in atmospheric pressure from designed pressure, the bourdon tube tip travels
and can cause an error in temperature measurement.
Advantages:
- Simplicity in use - Low cost
- Portable device - Power source not require
- Checking physical damage is easy
Disadvantages:
- Can't use for automatic reading
- Time lag in measurement
- Fragile construction
- Some fluid used is toxic like mercury
A Resistance Thermometer or Resistance Temperature Detector is a
device which used to determine the temperature by measuring the
resistance of pure electrical wire. This wire is referred to as a
temperature sensor. If we want to measure temperature with high
accuracy, RTD is the only one solution in industries.
WORKING PRINCIPLE:
• A Resistance Temperature Detector (RTD) functions on the resistance and
temperature relationship in metals. It works on the principle of measurement
which states that “The resistance of a material changes with temperature”.
• When the metal’s temperature increases, the resistance to the electron’s flow
also increases. Similarly, as and when the temperature of element used in the
Resistance Temperature Detector increases, the resistance increases too.
• RTD’s resistance and the temperature can be determined by applying a
constant current and evaluating the occurrence of voltage drop through the
resistor.
• The figure shows the resistance-
temperature characteristics curve of
the three different metals. For
Platinum, its resistance changes by
approximately 0.4 ohms per degree
Celsius of temperature.
• Copper, Nickel and Platinum are
widely used metals.
• These three metals are having
different resistance variations with
respective to the temperature
variations.
Cu
∎ Why platinum? PRT Types
❑ Stable element
❑ Resists corrosion
❑ Easily workable
❑ High melting point
❑ Easily purified
PLATINUM TEMPERATURE
THERMOMETERS (PRT) are the
most common type of RTD
What are PT100 and PT1000 in RTD?
• In PT100 the ‘PT’ defines that the metal is Platinum and the ‘100’ is
the resistance in ohms at ice point (or 0°C). These are generally wire
wound and are quite common in industrial uses.
• PT1000 exhibits 1000Ω resistance at 0°C Celsius temperature. These
are generally thin film devices and are more expensive.
• 200 and 500 ohm Platinum RTD’s are available but are more
expensive and less common.
• PT100 (Platinum) Resistance table.
• Note: for PT 100, when the input
measurement is 0 deg C, the output
resistance is 100 ohms
Why is wire compensation needed in RTD?
• As RTD is a resistor, the ohm meter or the resistance measuring devices are
connected parallel to the lead wires of the RTD. The lead wire resistance adds
to the RTD resistance as the wires got resistance and this combined resistance
will be shown as the RTD resistance incorrectly. So that lead compensation
techniques are used in RTD connections.
• There are three connection circuits for RTD wire circuit:
• Two-wire circuit
• Three-wire circuit
• Four-wire circuit
RTD LEAD WIRE CONFIGURATION:
• Two Wire Configuration -It is the most simple one and has the chances
of errors. In this configuration, RTD is connected to a Wheatstone bridge
circuit using two wires. The voltage output is monitored to get the the
desired output.
• Three Wire Configuration - They are the most common ype of RTD
assembly. Typically, they are connected to standard bridge circuit, which
allows lead wire resistance to be compensated. They are more accurate
than two wire RTDs and are used in most industrial applications.
• Four Wire Configuration - Four wire Resistance Temperature Detectors
are even more accurate than Three wire RTDs as they are able to
completely compensate for the resistance of the wires without having to
pay attention to the length of each of the wires. This provides
significantly increased accuracy at low cost of increased copper
extension wire.
ADVANTAGES:
• Linearity over wide operating range
• Wide temperature operating range
• High temperature operating range
• Interchangeability over wide range
• Good stability at high temperature
DISADVANTAGES:
• Low sensitivity
• Higher cost than thermocouples
• No point sensing
• Affected by shock and vibration
• Requires three or four-wire operation
APPLICATIONS
 In Automotive  In Industrial
Industry – As audio Electronics – For gas
amplifiers and engine flow indicators and
oil temperature Plastic laminating
sensors. equipment.
 In Medical
Electronics – For
 In Communication blood dialysis
and Instrumentation equipment and Infant
– As temperature incubators.
sensors and amplifiers.
 In Consumer
Electronics – For
small appliance
controls and Fire
Detectors. NOTE: RTDs should be used when:
1. Stability and accuracy are a requirement
of the customer’s specification.
2. Accuracy extends over a wide temperature
range.
D. THERMOCOUPLE TEMPERATURE SENSOR
A Thermocouple is a sensor used to measure temperature.
Thermocouples consist of two wire legs made from different metals. The
wires legs are welded together at one end, creating a junction. This junction
is where the temperature is measured. When the junction experiences a
change in temperature, a voltage is created. The voltage can then be
interpreted using thermocouple reference tables to calculate the temperature.
The thermocouple principle mainly depends on the three effects namely Seebeck,
Peltier and Thompson.
See beck-effect - This type of effect occurs among two dissimilar metals. When the heat
offers to any one of the metal wire, then the flow of electrons supplies from hot metal wire
to cold metal wire. Therefore, direct current stimulates in the circuit.
Peltier-effect - This Peltier effect is opposite to the Seebeck effect. This effect states that
the difference of the temperature can be formed among any two dissimilar conductors by
applying the potential variation among them.
Thompson-effect - This effect states that as two disparate metals fix together & if they
form two joints then the voltage induces the total conductor’s length due to the gradient of
temperature. This is a physical word that demonstrates the change in rate and direction of
temperature at an exact position.
Types of Thermocouple:
Type K (Nickel-Chromium / Nickel-Alumel): The type K is the most common type of
thermocouple. It’s inexpensive, accurate, reliable, and has a wide temperature range
Type J (Iron/Constantan): The type J is also very common. It has a smaller temperature
range and a shorter lifespan at higher temperatures than the Type K. It is equivalent to
the Type K in terms of expense and reliability
Type T (Copper/Constantan): The Type T is a very stable thermocouple and is often
used in extremely low temperature applications such as cryogenics or ultra low freezers
Type E (Nickel-Chromium/Constantan): The Type E has a stronger signal & higher
accuracy than the Type K or Type J at moderate temperature ranges of 1,000F and lower.
See temperature chart (linked) for details.
Types of Thermocouple:
Type N (Nicrosil / Nisil): The Type N shares the same accuracy and temperature limits as the Type K.
The type N is slightly more expensive.
Type S (Platinum Rhodium - 10% / Platinum): The Type S is used in very high temperature
applications. It is commonly found in the BioTech and Pharmaceutical industries. It is sometimes used
in lower temperature applications because of its high accuracy and stability
Type R (Platinum Rhodium -13% / Platinum): The Type R is used in very high temperature
applications. It has a higher percentage of Rhodium than the Type S, which makes it more expensive.
The Type R is very similar to the Type S in terms of performance. It is sometimes used in lower
temperature applications because of its high accuracy and stability
Type B (Platinum Rhodium – 30% / Platinum Rhodium – 6%): The Type B thermocouple is used in
extremely high temperature applications. It has the highest temperature limit of all of the thermocouples
listed above. It maintains a high level of accuracy and stability at very high temperatures
Applications:
• These are used as the temperature sensors in thermostats in offices, homes,
offices & businesses.
• These are used in industries for monitoring temperatures of metals in iron,
aluminum, and metal.
• These are used in the food industry for cryogenic and Low-temperature
applications. Thermocouples are used as a heat pump for performing
thermoelectric cooling.
• These are used to test temperature in the chemical plants, petroleum plants.
• These are used in gas machines for detecting the pilot flame.
ADVANTAGES:
• Accuracy is high
• It is Robust and can be used in environments like harsh as well as high vibration.
• The thermal reaction is fast
• The operating range of the temperature is wide.
• Wide operating temperature range
• Cost is low and extremely consistent
DISADVANTAGES:
• Nonlinearity
• Least stability
• Low voltage
• Reference is required
• least sensitivity
• The thermocouple recalibration is hard
E. THERMISTOR TEMPERATURE SENSOR
• A Thermistor is a type of resistor used to
measure temperature changes, relying on
the change in its resistance with changing
temperature.
• Thermistor is a combination of the words
thermal and resistor
Working Principle:
A Thermistor does not actually “read”
anything, instead the resistance of a
thermistor changes with temperature. How
much the resistance changes depends on the
type of material used in the thermistor.
Unlike other sensors, thermistors are non-
linear, meaning the points on a graph
representing the relationship between the
resistance and temperature will not form a
straight line. The location of the line and how
much it changes is determined by the
construction of the thermistor.
Types of Thermistor:
Negative Temperature Coefficient (NTC)
• With NTC thermistors, resistance decreases as temperature rises. An NTC is
commonly used as a temperature sensor, or in series with a circuit as an
inrush current limiter.
Positive Temperature Coefficient (PTC)
• With PTC thermistors, resistance increases as temperature rises. PTC
thermistors are commonly installed in series with a circuit, and used to
protect against overcurrent conditions, as resettable fuses.
Note: NTC Types are used for Temperature measurement
Advantages:
• Small size and light in weight
• Inexpensive
• Very high sensitivity (Select range)
• Fast response
• Standard two wire connection system
• Made to be waterproof and bomb proof
Disadvantages:
• Not easily interchangeable
• Non linear
• It is not suitable for large temperature range
• Susceptible to self-heating errors
Applications:
• Microwave
For those who have used a microwave, you have used a thermistor. They are used in these machines to
determine and maintain internal temperature. Without the resistor in the microwave, there is a
possibility of overheating in the unit. This could lead to potential fires.
• Circuit Protector
If you have a power supply or surge protector in your home or office then you are also using a
thermistor. Without a thermistor in this product, surges of energy would be uncontrolled. This could
lead to overheating or too much electricity being pushed to whatever is plugged in. This could lead to
some of your electronics shorting out.
• Automotive
Cars, trucks, and buses all use thermistors. They are used to determine the temperature of oil and
coolants. This is how you are able to know if your car is overheating or not. The thermistors are
connected to indicators on the dashboard of the vehicle. Thermistors in cars do not prevent or regulate.
Instead, they are used to gather information. This allows a driver to fix their car or truck before
something serious happens.
Applications:
• Digital Thermometers
Have you ever wondered how digital thermometers are able to accurately gauge someone’s
temperature? This is possible because of thermistors. Just like with cars, these devices used to
gather information rather than helping to maintain temperature.
• Rechargeable Batteries
The ability to recharge a battery is only possible because of the help it gets. When you start
charging batteries, there is a tendency for things to get hot. The low resistance of the thermistor
allows it to stop the charging if things are getting too hot.
E. PYROMETER
Pyrometer also is known as an Infrared thermometer or
Radiation thermometer or non-contact thermometer used to detect
the temperature of an object’s surface temperature, which depends
on the radiation (infrared or visible) emitted from the object.
Pyrometers act as photo detector because of the property of
absorbing energy and measuring of EM wave intensity at any
wavelength.
E. PYROMETER
Types of Pyrometer:
1. Optical Pyrometers
Used to detect thermal radiation of the
visible spectrum. The temperature of the
hot objects measured will depend on the
visible light they emit.
Optical pyrometers are capable of
providing a visual comparison between a
calibrated light source and the targeted
object’s surface.
E. PYROMETER
Types of Pyrometer:
1. Optical Pyrometers
E. PYROMETER
Types of Pyrometer:
2. Infrared Pyrometers
Designed to detect thermal radiation in
the infrared region, which is usually at a
distance of 2-14um. It measures the
temperature of a targeted object from the
emitted radiation.
This radiation can be directed to a
thermocouple to convert into electrical
signals. Because the thermocouple is
capable of generating higher current equal
to the heat emitted.
E. PYROMETER
Applications:
• Suited especially to the measurement of moving objects or any
surfaces that cannot be reached or cannot be touched
Application in the areas of:
• Glass Production
• Cement Production
• Metal Production
• Food Production
• Products that are not stationary
E. PYROMETER
Main Components of Pyrometer:
• The Absorption Screen is used to pull in as much radiation energy as possible into
the system. This not only increases the amount of radiations entering inside but also
extends the measuring range of the instrument. The radiations from the absorption
screen are concentrated on a filament lamp.
• The filament lamp or detector is connected to a circuit, which measures the
intensity of radiations. The filament works similar to a thermocouple, providing the
exact temperature using an ammeter calibrated in units of temperature.
• The monochromatic filter is used to dissect the light into a single color, usually red,
to simplify the filament radiation calibrating process. Thus, the radiations from the
lamp and the heat source are almost the same, and the calibrated current through the
lamp is the measure of temperature of the heat radiating source.
E. PYROMETER
Main Components of Pyrometer:
E. PYROMETER
Advantages:
• It can measure the temperature of the object without any contact with the object.
• It has a fast response time
• Good stability while measuring the temperature of the object.
• It can measure different types of object’s temperature at variable distances.
Disadvantages:
• Expensive
• Human errors
• Not useful for measuring temperature of clear glass
• At high temperature filament erodes frequently
END

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TEMPERATURE

PREPARED BY: DBA

IN AN INDUSTRY, THERE IS ALWAYS A NEED TO MEASURE AND

TEMPERATURE IS A PHYSICAL QUANTITY EXPRESSING HOT AND

B. FILLED-SYSTEM TEMPERATURE SENSOR

C. RESISTANCE TEMPERATURE DETECTOR (RTD)

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