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Industrial Instrumentation and

Measurements

Temperature
Measurements

Assoc Prof Dr Nordin Saad


Department of Electrical & Electronics Engineering
Universiti Teknologi PETRONAS
Email: nordiss@petronas.com.my
Tel: 05-368 7835

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.6 Temperature-


Temperature- 1
Learning
Learning Outcomes
Outcomes Assessment
Assessment Criteria
Criteria
To achieve the following Learning Outcomes: Assessment criteria:
• Have knowledge and understanding of the various process To demonstrate student has achieved the learning
industry instruments, the concept of measurements, outcomes
calibration and configuration requirements and their
applications. • Describe the measuring principles, calibration and
configuration requirements of different process
• Be able to design and develop a control loop consisting the industry instruments and their applications.
process instruments, based on a prescribed requirement. • Design and develop a control loop using the relevant
. instruments to meet specifications

Process
Process ,, Industrial
Industrial Instrumentation
Instrumentation && Measurement
Measurement
Assessment criteria: Lab experiences Assessment criteria:
• Basic concepts of measurements • Calibration, • Signal Conditioning
configuration of
• Process control terminologies transmitters, • P,T,L,F to mA, V
• Calibration controllers, • V-V,V-mA,mA-V
recorders and
other peripherals,
wiring, selection
and installation.
Assessment criteria: Assessment criteria:
• Design and
• Applications and selections of sensors and actuators implementation of • Design and implement a simple control
used in industries a simple control loop.
• Pressure Level Temperature Flow loop.

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Types of Temperature measurements

Types of temperature measurements

– Thermometry based on thermal expansion

– Electrical Resistance Thermometry

– Thermoelectric

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Thermal expansion

üThermometry based on thermal


expansion

• Liquid in Glass Thermometers

• Bimetallic Thermometers

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Thermal expansion

• Liquid in Glass Thermometers

– measures temperature by virtue of the thermal


expansion of a liquid.
– Change of fluid to cause a detectable rise of the
liquid in the stem of the thermometer
– level of the liquid in the capillary is an
indication of the temperature

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Thermal expansion

• Complete immersion thermometer


– the entire thermometer is immersed in
the calibrating temperature
environment
• Total immersion thermometer
– the thermometer is immersed in the
calibrating temperature environment
up to the liquid level in the capillary
• Partial immersion thermometer
– the thermometer is immersed to a
predetermined level in the calibrating
environment

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Thermal expansion
• Bimetallic
Thermometers
– is the differential
thermal expansion of
two metals.
Thickness
of strip

rc d
α
[(Cα )A−(Cα )B](T 2 − T 1)

Application: Sensing Radius of curvature Temperature


and control element Thermal expansion rise
coefficient
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Thermal expansion

• Bimetallic Thermometers

Motion of bimetal
strip is quite small. To
amplify motions the
bimetal strip were
wound into a helix or
spiral.

The angular deflection of the pointer vary


nearly directly with temperature change
and the length of the coiled strip.

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Electrical Resistance
üElectrical Resistance Thermometry
ü as a results of the physical nature of the conduction of
electricity, electrical resistance of a conductor or semiconductor
varies with temperature
ü the physical basis for the relationship between resistance and
temperature is

resistivityx Length ρe × L
Resistance =
Cross section Area
R=
Ac

– There are two types of electrical resistance thermometry

• Resistance Temperature Detectors (RTD)


– Conductors
• Thermistors
– Semiconductors

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Electrical resistance
• Resistance Temperature Detectors, RTD

– The sensor is constructed by mounting a metal


wire on an insulating support structure

• To eliminate mechanical strains


• To prevent changes in resistance that due to
influences from the sensor’s environment

– The relationship between temperature and


resistance over specific small temperature ranges
is linear

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Electrical resistance

– Small increase of resistance with temperature


(prefer metal of large resistivity, eg. Pt, Ni, w)
– The approximation can be expressed as:-

R = Ro[1 + α (T − To )]
– Ro = reference resistance at temperature To
– α = coefficient of resistivity
– α should be chosen for the temperature range of
interest

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Electrical resistance
• Most common material used is platinum.

Platinum
Copper
Nickel
Balco (70% Nickel,
30% Iron)
Tungsten

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Electrical resistance
• Why Platinum?
– Available in nearly pure state, capable of being drawn
into very fine wire, and relatively high melting point.
– Exhibits a predictable and reproducible change in
electrical resistance with temperature (Linear
approximation for the relationship between temperature and
resistance over wide temperature range) . High accuracy and
precise measurement of temperature, -250oC to 800oC.
– Used today as interpolation standard from Oxygen point
(-182.96oC) to antimony (630.74oC)
– Suitable for use as a secondary temperature standard
Care:
– Must be protected from contamination to hydrocarbon
and silica (causes Platinum to become brittle).

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Electrical resistance

• RTD Resistance Measurement

– RTD must be energized from an


external power supply (accurate
and stable PS).
– Wheatstone bridge circuit are
commonly used for these
measurements, to obtain a zero
based output signal.
– When greater accuracy are
required three wire and four wire
bridge circuits can be used.

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Metal Film
RTD
-mass
produced
-small size

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Electrical resistance
• RTD Resistance Measurement

R1 R3
=
R 2 RRTD
Note:
Basic wheatstone bridge
circuit does not compensate
for the resistance leads in
measuring resistance of an
RTD - source of error in
electrical resistance
thermometers A 2-wire system

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Electrical resistance
RTD : A 3 wire system

Allows RTD to be
located at a far r

distance from R2

indicating RTD=R4

instrument s2
Power Supply

r G (Stable and
accurate)

Provides ambient s1

temperature R3 R1
compensation

( R 2 + s 2)( R 3 + r ) Disadvantage: not an accurate


R4 = −r
R1 + s1 technique
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A 3-wire system

A 4-wire system is
preferred

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Electrical resistance
• Thermistors
– The name derived from the words “thermally
sensitive resistors”. It is a semiconductor device.
– Mixtures of pure oxides of iron, nickel, copper,
cobalt, manganese and titanium. Temperature-
resistance relationship may be controlled by varying
the type of oxide used.
– The resistance of a typical thermistor decrease with
temperature: have very large negative temperature-
resistance characteristics, e.g., -4% per oC at 20oC.
– The functional relationship between resistance and
temperature is:-

R = Roe β ( 1 /T − 1 /To )
non-linear
Resistance at To Thermistor constant (K)
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Electrical resistance
1 dRT B
α= . = − 2 [unitin K]
RT dT T

Thermistor temperature
coefficient
The thermistor sensitivity varies greatly with temperature,
[-3%/oC to –6%/oC at room temperature]

The parameter β ranges from 3500 to 4600K, depending on the material,


temperature and individual construction for each sensor

Few electrons are available for conductance at low temperature. When


the temperature increases the kinetic energy possessed by the electrons
increases and this enables them to move from inner bound orbital band
to the outer conductive band. With more free electrons available the
resistance to current flow is reduced.
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Electrical resistance

The specific resistance of


curve thermistor-1 decreases
by a factor of 50 as the
temperature is increased
from 0 to 100oC. Over the
same temperature range, the
resistivity of platinum RTD
will increase by a factor of
1.39
Example:
Measuring range: -51 to 150oC,
resolution 0.6oC, accuracy 0.2oC.
Power supply 9V battery.

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Electrical resistance

– Thermistors generally are used when high sensitivity,


ruggedness,fast response times are required e.g. takes
– 15 ms to reach 63% of final Temperature, and 40ms to reach 90%
of final Temperature.
– Can also be used in corrosive or abrasive environment
– Suitable for narrow span measurements (due to v. large, non-
linear temperature-resistance characteristics).
– For wide temperature span, a wide range of thermistors must be
used.
– The zero-power resistance is the resistance value of the
thermistor with no flow of electric current.

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Thermoelectric

Thermoelectric Temperature
Measurement

ü The most common method of measuring and


controlling temperature uses a electrical circuit called
a thermocouple

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Thermoelectric

A thermocouple consists of two pieces of dissimilar metals with their


ends joined together (by twisting, soldering, or welding). When heat is
applied to the junction, a voltage, in (mV) is generated. Thermocouple is
said to be self-powered.
If temperature T1 is higher than T2, then the voltage generated at
Junction 1 is higher than that at Junction 2.

Circuit emf=Measurement emf – Reference emf

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Thermoelectric

Circuit emf=Measurement emf – Reference emf

A temperature transmitter is used to convert the emf generated to the


standard 4-20mA.

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Thermoelectric
üThermocouple Measurement
Principle

T1
T2 C
A
m EMF
n EAB(T2,T1) Measuring
B
Instrument
Hot junction
C
Cold junction

The metals A and B are two dissimilar metals, and are called the
thermocouple. The difference in temperature between point T2 and T1
generates the thermoelectromotive force, EAB(T2,T1).
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Thermoelectric
Reference Thermoelectromotive Force Table

Type: J Unit: lV
Temp. 0 -10 -2 0 -30 -40 -5 0 -60 -70 -8 0 -90 T emp.
( o C) ( o C)
-2 0 0 -7 890 -8 096 -200
-1 0 0 -4 632 -5 036 -5 426 -5 801 -6 159 -6 499 -6 821 -7 122 -7 402 -7 659 -100
0 0 -5 0 1 -995 -1 481 -1960 -2 431 -2 892 -3 344 -3 785 -4 215 0
Temp. 0 10 20 30 40 50 60 70 80 90 T emp.
( o C) ( o C)
0 0 507 1 019 1 536 2 058 2 585 3 115 3 649 4 186 4 725 0
100 5 268 5 812 6 359 6 907 7 457 8 008 8 560 9 113 9 667 10 222 100
200 10 777 11 332 11 887 12 42 12 998 13 553 14 108 14 663 15 217 15 771 200
300 16 325 16 879 17 432 17 985 18 537 19 089 19 640 20 192 20 743 21 295 300
400 21 846 22 397 22 949 23 501 24 054 24 607 25 161 25 7 16 26 272 26 829 400
500 27 388 27 949 28 511 29 075 29 642 30 210 30 782 31 356 31 933 32 513 500
600 33 096 33 683 34 273 34 867 35 464 36 066 36 671 37 280 37 893 38 510 600
700 39 130 39 754 40 382 41 013 41 647 42 283 42 922 43 563 44 207 44 852 7 00
800 45 498 46 144 46 790 47 434 48 076 48 716 49 354 49 989 50 621 51 249 800
900 51 875 52 496 53 115 53 729 54 341 54 948 55 553 56 155 56 753 57 349 900
1000 57 942 58 533 59 121 59 708 60 293 60 876 61 459 62 039 62 619 63 199 1000
1100 63 777 64 355 64 933 65 510 66 987 66 664 67 240 67 815 68 390 68 964 1100
1200 69 536 1200
o
Remark : Temperature of reference junction is 0 C.
o
When temperature of reference junction is 20 C, substract 1 019 lV from the value given in the above table.

Thermo-couple EMF graph


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Thermoelectric
Example:

Given a K-type thermocouple.


T3=500 oC, T2=20 oC, T1=0 oC. ü Law of successive temperatures

T3 T2 T1 EAB(T3,T1)=EAB(T3,T2)+EAB(T2,T1)

A
EAB(T3,T1),

EAB(T3,T2),
B
A

EAB(T2,T1),
B

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Thermoelectric
Reading from REFERENCE THERMOELECTROMOTIVE FORCE
Table
(IEC 584-1977, BS 4937-1973, JIS C 1602-1981, DINIEC 584-1984,
ASTM E230-1983, ANSI MC96.1-1982)

EAB(T3,T1)=20 640 lV, EAB(T2,T1)=798 lV.

EAB(T3,T1)=EAB(T3,T2)+EAB(T2,T1)

Accordingly, EAB(T3,T2) = EAB(T3,T1) - EAB(T2,T1) =19 842 lV.

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Thermoelectric

ü Practical use requires the following


qualities:
i. Good corrosion resistance, robustness against
gases, etc.
ii. Large thermo-electromotive force.
iii. Good heat resistance and ability to maintain
mechanical strength at high temperatures.
iv. Stable thermo-electromotive force even over long
periods of use, with small thermocouple loss.
v. Interchangeability: thermocouples of the same
type normally have the same characteristics.

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Thermoelectric
ü Features of Base Metal Thermocouples:
a. K-type (chromel-alumel)
-Can be used in an oxidizing environment
-Deteriorates slowly in a reducing environment
-Strong against metal vapors
-Good linearity of thermoelectromotive force
-Used for temperature 550oC to 1250oC.
b. E-type (chromel-constantan)
-Good resistance to corrosion and oxidation
- Deteriorates slowly in a reducing environment
-Large thermoelectromotive force
-High electrical resistance
-Little measurement lag
-Used for temperature up to 850oC.

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Thermoelectric
ü Features of Base Metal Thermocouples:
c. J-type (iron-constantan)
-Can be used in reducing environments
-Rusts easily
-Good linearity, relatively large thermoelectromotive force,
but exhibit hysterisis thermoelectromotive force at high
temperature (800oC)
-Used for temperature up to 850oC.
d. T-type (copper-constantan)
-Suited for use at low and extremely low temperatures
- Suited for use in reducing environments
-Large heat transfer error. -
-Used for temperature up to 400oC.

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Thermoelectric
ü Features of Noble Metal Thermocouples:
a. B-type (Platinum-30% rhodium), R-type (Platinum-13%
rhodium), S-type (Platinum-10% rhodium)
-Can be used continuously in an oxidizing environment, but
not suited for use in a reducing environment.
-Good resistance to corrosion and chemicals.
-Easily degenerated by hydrogen or metal vapors.
-Suited for measurement of high temperatures.
-Small thermo-electromotive force, especially the B-type.

e.g., Pt.40%Rh-Pt.20%Rh thermocouple can measure temperatures


near 1900oC., but has unusually low electromotive force.

Note: For noble metal thermocouple, the first mentioned material is the negative
polarity, and vice versa for base material.

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Thermoelectric
The reference junction (RJ), or the cold junction, is usually at 0oC.
If it is not possible to maintain RJ at 0oC, a correction must be made to
the mV values shown in the thermocouple tables.

The following eqn. can be used when RJ deviates from 0oC.


mV = MJ –RJ ,
where MJ is the measuring junction temperature (or the hot junction)
Calculation steps:
a. From thermocouple table, obtain the mV (based on 0oC RJ)
corresponding to the actual temperature of the thermocouple RJ.
b. Add algebraically the value in (a) to the mV read on the measuring
instrument.
c. Convert the mV obtained into terms of temperature directly from the
same table.
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Thermoelectric

Example:
Determine the measuring junction temperature when the output
of an iron-constantan thermocouple reads 13.275 mV and the
temperature at the reference junction is 20oC.

RJ=E at 20oC = 1.019 mV [Reading from Table]


Solution: mV=MJ –RJ i.e., 13.275=MJ-1.019
MJ=14.294mV

By interpolation, 270oC=14.663mV,
260oC=14.108mV.Gives, 0.055 mV per oC.
MJ=260oC+[(14.294mV-14.108mV)/0.055mV]=263.38oC.

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Comparisons of Temperature sensors

Thermistor –
R highly Thermocouple-
or sensitive RTD- stable wide range
V

800oC
Temperature

End
End of
of Lecture
Lecture notes
notes on
on Temperature
Temperature Measurement
Measurement

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.6 Temperature-


Temperature- 36

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