Measurement and Instrumentations of temperature

Temperature measurement is very important in all spheres of life and especially so in the process industries. However, it poses particular problems, since temperature measurement cannot be related to a fundamental standard of temperature in the same way that the measurement of other quantities can be related to the primary standards of mass, length and time. If two bodies of lengths l1 and l2 are connected together end to end, the result is a body of length l1 + l2. A similar relationship exists between separate masses and separate times. However, if two bodies at the same temperature are connected together, the joined body has the same temperature as each of the original bodies.

1. 1
Measurement
and
Instrumentations
Temperature
Measurements

2. 2
Principles of temperature measurement
•Temperature measurement is very important in all spheres
of life and especially so in the process industries. However,
it poses particular problems, since temperature
measurement cannot be related to a fundamental standard
of temperature in the same way that the measurement of
other quantities can be related to the primary standards of
mass, length and time. If two bodies of lengths l
1
and l
2
are
connected together end to end, the result is a body of
length l
1 + l
2. A similar relationship exists between separate
masses and separate times. However, if two bodies at the
same temperature are connected together, the joined body
has the same temperature as each of the original bodies.

3. 3
•In the absence of such a relationship, it is necessary to establish
fixed, reproducible reference points for temperature in the form
of freezing and boiling points of substances where the transition
between solid, liquid and gaseous states is sharply defined.
The International Practical Temperature Scale (IPTS) uses this
philosophy and defines six primary fixed points for reference
temperatures in terms of:
•the triple point of equilibrium hydrogen _259.34°C
•the boiling point of oxygen _182.962°C
•the boiling point of water 100.0°C
•the freezing point of zinc 419.58°C
•the freezing point of silver 961.93°C
•the freezing point of gold 1064.43°C
(all at standard atmospheric pressure)
Principles of temperature measurement

4. 4
Instruments to measure temperature can be divided into
separate classes according to the physical principle on which they
operate. The main principles used are:
•Thermal expansion
•The thermoelectric effect
•Resistance change
•Sensitivity of semiconductor device
•Radiative heat emission
•Thermography
•Resonant frequency change
•Sensitivity of fibre optic devices
•Acoustic thermometry
•Colour change
•Change of state of material.
Principles of temperature measurement

5. 5
Thermal Expansion
•Expansion thermometers
Most solids and liquids expands when they
undergo an increase in temperature. The
direct observation of the increase of size, or of
the signal from a primary transducer detecting
it, is used to indicate temperature in many
thermometers.

6. 6
A: Expansion of Solids
•The change (δθ) of temperature is given by
δι= ια δθ
where, α is the coefficient of linear expansion, usually taken as
constant over a particular temperature range
The bonding together of two strip of metal having difference
expansion rate to form bimetal strip , as shown in Fig 1, causes
bending of the strip when subjected to temperature change.
Thermal Expansion
Fig 1: Deflection of a bimetal strip

7. 7
Expansion of Solids
•Referring to fig 1, let the initial straight length of the bimetal strip be ι
o at
temperature 0 °C, and α
A and α
B be linear expansion coefficients of materials A and
B respectively, where α
A < α
B,
•If the strip is assumed to bend in a circular arc when subjected to a temperature θ,
then
•If invar is used for strip A, then α
A
is virtually zero, and the equation becomes
A strip oflength expanded
B strip oflength expanded
r
dr


)1(
)1(


Ao
Bo
l
l



)(
)1(
AB
Ad
r





Bdr

8. 8
Exercise

A bimetal- strip has one end fixed and the other
free, the length of the cantilever being 40mm.
the thickness of each metal is 1mm, and the
element is initially straight at 20 °C. Calculate the
movement of the free end in a perpendicular
direction from the initial line when the
temperature is 180 °C, if one metal is invar and
the other is a nickel-chrome-iron alloy with a
linear expansion coefficient (α) of 12.5×10
-6
/ °C

9. 9
Expansion of liquids
Perfect gas thermometer
•The ideal- gas equation, PV=mRT, show that, for a given mass of
gas, the temperature is proportional to the pressure if the volume is
constant, and proportional to the volume if the pressure is
constant.
•It is much simpler to contain a gas in a constant volume and
measure the pressure than to measure the volume at constant
pressure; hence constant-volume gas thermometers are common,
whilst constant- pressure ones are rare.
•The simple laboratory type is illustrated in Fig 2
Fig 2: vapour- pressure thermometer

10. 10
•The industrial type illustrated in Fig 3, is filled usually with nitrogen,
or for lower temperature hydrogen, the overall range covered being
about -120 °C to 300 °C.
•At the higher temperature, diffusion of the filler gas through metal
wall is excessive, the loss of gas leading to loss of calibration.
Expansion of liquids
Fig 3: gas thermometer

11. 11
Thermoelectric effect sensors (thermocouples)
When two wires composed of dissimilar metals are joined at both ends and one of the
ends is heated, a continuous current flows in the “thermoelectric” circuit. Thomas
Seebeck made this discovery in 1821. This thermoelectric circuit is shown in Figure 4(a). If
this circuit is broken at the center, as shown in Figure 4(b), the new open circuit voltage
(known as “the Seebeck voltage”) is a function of the junction temperature and the
compositions of the two metals.
Fig 4: gas thermometer

12. 12
Thermoelectric effect sensors (thermocouples)
•Thermoelectric effect sensors rely on the
physical principle that, when any two different
metals are connected together, an e.m.f.,
which is a function of the temperature, is
generated at the junction between the metals.
The general form of this relationship is:
e = a
1
T+ a
2
T
2
+ a
3
T
3
+…….+a
n
T
n
……(1)
Where, e = the e.m.f generated and
T = the absolute temperature.

13. 13
•This is clearly non-linear, which is inconvenient for
measurement applications. Fortunately, for certain
pairs of materials, the terms involving squared and
higher powers of T (a
2T
2
, a
3T
3
etc.) are approximately
zero and the e.m.f.–temperature relationship is
approximately linear according to:
e ≈a
1T …….(2)
Thermoelectric effect sensors (thermocouples)
Wires of such pairs of materials are connected together at one
end, and in this form are known as thermocouples.
Thermocouples are a very important class of device as they
provide the most commonly used method of measuring
temperatures in industry.

14. 14
Thermocouples are manufactured from various
combinations of
•the base metals copper and iron,
•the base-metal alloys of alumel (Ni/Mn/Al/Si), chromel
(Ni/Cr), constantan (Cu/Ni), nicrosil (Ni/Cr/Si) and nisil
(Ni/Si/Mn),
•the noble metals platinum and tungsten, and
• The noble-metal alloys of platinum/rhodium and
tungsten/rhenium.
Thermoelectric effect sensors
(thermocouples)

15. 15
•Only certain combinations of these are used as thermocouples and
each standard combination is known by an internationally
recognized type letter, for instance type K is chromel–alumel. The
e.m.f.–temperature characteristics for some of these standard
thermocouples are shown in Figure 5: these show reasonable
linearity over at least part of their temperature-measuring ranges.
Fig. 5. E.m.f. temperature characteristics for some standard thermocouple materials.
Thermoelectric effect sensors
(thermocouples)

16. 16
Thermoelectric effect sensors
(thermocouples)

17. 17
•A typical thermocouple, made from one chromel wire and
one constantan wire, is shown in Figure 6(a). For analysis
purposes, it is useful to represent the thermocouple by its
equivalent electrical circuit, shown in Figure 6(b). The e.m.f.
generated at the point where the different wires are
connected together is represented by a voltage source, E
1,
and the point is known as the hot junction.
Fig. 6(a) Thermocouple; (b) equivalent circuit.
The temperature of the hot
junction is customarily shown as T
h

on the diagram. The e.m.f.
generated at the hot junction is
measured at the open ends of the
thermocouple, which is known as
the reference junction.
Thermoelectric effect sensors
(thermocouples)

18. 18
•In order to make a thermocouple conform to
some precisely defined e.m.f.–temperature
characteristic, it is necessary that all metals
used are refined to a high degree of pureness
and all alloys are manufactured to an exact
specification.
Thermoelectric effect sensors
(thermocouples)

19. 19
•It is clearly impractical to connect a voltage-measuring instrument at the
open end of the thermocouple to measure its output in such close
proximity to the environment whose temperature is being measured, and
therefore extension leads up to several metres long are normally
connected between the thermocouple and the measuring instrument.
•This modifies the equivalent circuit to that shown in Figure 7(a). There are
now three junctions in the system and consequently three voltage
sources, E
1, E
2 and E
3, with the point of measurement of the e.m.f. (still
called the reference junction) being moved to the open ends of the
extension leads.
Fig. 7 (a) Equivalent circuit for thermocouple with extension leads; (b) equivalent circuit for thermocouple and extension
leads connected to a meter.
Thermoelectric effect sensors
(thermocouples)

20. 20
•The measuring system is completed by connecting the extension
leads to the voltage measuring instrument. As the connection
leads will normally be of different materials to those of the
thermocouple extension leads, this introduces two further e.m.f.-
generating junctions E
4
and E
5
into the system as shown in Figure
7(b). The net output e.m.f. measured (E
m
) is then given by:
E
m
= E
1
+ E
2
+ E
3
+ E
4
+E
5
……….3
and this can be re-expressed in terms of E
1
as:
E
1
= E
m
̶ E
2
̶ E
3
̶ E
4
̶ E
5
……….4
Thermoelectric effect sensors
(thermocouples)

21. 21
•In order to apply equation (1) to calculate the
measured temperature at the hot junction, E
1 has to be
calculated from equation (4). To do this, it is necessary
to calculate the values of E
2, E
3, E
4 and E
5. It is usual to
choose materials for the extension lead wires such that
the magnitudes of E
2 and E
3 are approximately zero,
irrespective of the junction temperature. This avoids
the difficulty that would otherwise arise in measuring
the temperature of the junction between the
thermocouple wires and the extension leads, and also
in determining the e.m.f./temperature relationship for
the thermocouple–extension lead combination.
Thermoelectric effect sensors
(thermocouples)

22. 22
Zero Junction
•A zero junction e.m.f. is most easily achieved by choosing the
extension leads to be of the same basic materials as the
thermocouple,
•but where their cost per unit length is greatly reduced by
manufacturing them to a lower specification.
•However, such a solution is still prohibitively expensive in the case
of noble metal thermocouples, and it is necessary in this case to
search for base-metal extension leads that have a similar
thermoelectric behaviour to the noble-metal thermocouple.
•In this form, the extension leads are usually known as
compensating leads.
•A typical example of this is the use of nickel/copper–copper
extension leads connected to a platinum/rhodium–platinum
thermocouple.

23. 23
•Copper compensating leads are also sometimes
used with some types of base metal
thermocouples and, in such cases, the law of
intermediate metals can be applied to
compensate for the e.m.f. at the junction between
the thermocouple and compensating leads.
•To analyse the effect of connecting the extension
leads to the voltage-measuring instrument, a
thermoelectric law known as the law of
intermediate metals can be used.
Zero Junction

24. 24
•To analyse the effect of connecting the extension leads to
the voltage-measuring instrument, a thermoelectric law
known as the law of intermediate metals can be used.
•This states that “The e.m.f. generated at the junction
between two metals or alloys A and C is equal to the sum of
the e.m.f. generated at the junction between metals or
alloys A and B and the e.m.f. generated at the junction
between metals or alloys B and C, where all junctions are at
the same temperature”. This can be expressed more simply
as:
e
AC =e
AB + e
BC……………… (5)
Zero Junction

25. 25
Suppose we have an iron–constantan thermocouple connected by
copper leads to a meter.
We can express E
4
and E
5
in Figure 7 as:
E
4
= e
iron_copper
; E
5
= e
copper_constantan
The sum of E
4 and E
5 can be expressed as:
E
4 = e
iron_copper + e
copper_constantan
Applying equation (5):
e
iron_copper
+ e
copper_constantan
= e
iron_constantan
Zero Junction
Fig 8. Effective e.m.f. sources in a thermocouple measurement system.

26. 26
•Thus, the effect of connecting the thermocouple extension wires to
the copper leads to the meter is cancelled out, and the actual e.m.f.
at the reference junction is equivalent to that arising from an iron–
constantan connection at the reference junction temperature,
which can be calculated according to equation (1). Hence, the
equivalent circuit in Figure 7(b) becomes simplified to that shown in
Figure 8. The e.m.f. E
m
measured by the voltage-measuring
instrument is the sum of only two e.m.f.s, consisting of the e.m.f.
generated at the hot junction temperature E
1
and the e.m.f.
generated at the reference junction temperature E
ref. The e.m.f.
generated at the hot junction can then be calculated as:
•E
ref
can be calculated from equation (1) if the temperature of
the reference junction is known.
Zero Junction

27. 27
•In practice, this is often achieved by immersing the reference
junction in an ice bath to maintain it at a reference temperature of
0°C. (Fig 9)
Zero Junction
Figure 9. Thermocouple kept at 0°C in an ice bath.

28. 28
Thermocouple table
•Although the preceding discussion has suggested that the
unknown temperature T can be evaluated from the calculated
value of the e.m.f. E
1
at the hot junction using equation (1), this is
very difficult to do in practice because equation (1) is a high
order polynomial expression.
•An approximate translation between the value of E
1
and
temperature can be achieved by expressing equation (1) in
graphical form as in Figure 5
•However, this is not usually of sufficient accuracy, and it is normal
practice to use tables of e.m.f. and temperature values known as
thermocouple tables.

29. 29
•These include compensation for the effect of
the e.m.f. generated at the reference junction
(E
ref), which is assumed to be at 0°C. Thus, the
tables are only valid when the reference
junction is exactly at this temperature.
Thermocouple table

30. 30
•Example 1
If the e.m.f. output measured from a chromel–
constantan thermocouple is 13.419mV with the
reference junction at 0°C, the appropriate column
in the tables shows that this corresponds to a hot
junction temperature of 200°C.
Thermocouple table

31. 31
•Example 2
If the measured output e.m.f. for a chromel–
constantan thermocouple (reference junction at
0°C) was 10.65 mV, it is necessary to carry out linear
interpolation between the temperature of 160°C
corresponding to an e.m.f. of 10.501mV shown in
the tables and the temperature of 170°C
corresponding to an e.m.f. of 11.222 mV. This
interpolation procedure gives an indicated hot
junction temperature of 162°C.
Thermocouple table

32. 32
Resistance temperature detectors
(RTDs)

33. 33
RTDs
•Resistance temperature detectors
(RTDs) are temperature transducers
made of conductive wire elements.
The most common types of wires used
in RTDs are platinum, nickel, copper,
and nickel-iron. A protective sheath
material (protecting tube) covers
these wires, which are coiled around
an insulator that serves as a support.
Figure 1 shows the construction of an
RTD. In an RTD, the resistance of the
conductive wires increases linearly
with an increase in the temperature
being measured; for this reason, RTDs
are said to have a positive
temperature coefficient.
Figure 1. Resistance temperature detector.

34. 34
•The resistance of most
metals increases in a
reasonably linear way with
temperature (Figure 2) and
can be represented by the
equation:
Figure 2: Resistance variation with
temperature for metals
RTDs

35. 35
RTDs
Resistance temperature detectors (RTDs) are simple resistive elements in the form of coils of
metal wire, e.g. platinum, nickel or copper alloys.
Platinum detectors have
•high linearity,
• good repeatability,
•high long term stability,
• can give an accuracy of ±0.5% or
better,
•a range of about -200 °C to +850 °C,
•Can be used in a wide range of
environments without deterioration,
but are more expensive than the
other metals. They are, however, very
widely used.
Nickel and copper alloys are
•Cheaper but have less
stability, are more prone to
interaction with the
environment and cannot be
used over such large
temperature ranges

36. 36
•RTDs are generally used in a
bridge circuit configuration.
Figure 3 illustrates an RTD in a
bridge circuit. A bridge circuit
provides an output
proportional to changes in
resistance. Since the RTD is the
variable resistor in the bridge
(i.e., it reacts to temperature
changes), the bridge output
will be proportional to the
temperature measured by the
RTD.
Figure 3. RTD in a bridge circuit.

37. 37
•As shown in Figure 3, an RTD
element may be located away
from its bridge circuit. In this
configuration, the user must be
aware of the lead wire resistance
created by the wire connecting
the RTD with the bridge circuit.
The lead wire resistance causes
the total resistance in the RTD arm
of the bridge to increase, since the
lead wire resistance adds to the
RTD resistance. If the RTD circuit
does not receive proper lead wire
compensation, it will provide an
erroneous measurement.
Figure 3. RTD in a bridge circuit.
RTDs

38. 38
•Figure 4 presents a typical wire
compensation method used to
balance lead wire resistance. The
lead resistances of wires L
1
and L
2

are identical because they are made
of the same material. These two
resistances, R
L1 and R
L2, are added to
R
2 and R
RTD, respectively. This adds
the wire resistance to two adjacent
sides of the bridge, thereby
compensating for the resistance of
the lead wire in the RTD
measurement. The equations in
Figure 4 represent the bridge before
and after compensation. Note that
R
L3
has no influence on the bridge
circuit since it is connected to the
detector.
Figure 4. RTD bridge configuration with lead wire compensation.
RTDs

39. 39
Figure 4. RTD bridge configuration with lead wire
compensation.
RTDs
RTD
R
R
R
R
3
2
1

21
3
2
1
LLRTD
RRR
R
R
R


2
3
12
1
LRTDL RR
R
RR
R



Without lead wire consideration

Taking lead wire into
consideration (no compensation)

Taking lead wire into
consideration (with compensation)

40. 40
THERMISTORS
•Like RTDs, thermistors (see Figure 5) are
semiconductor temperature sensor that
exhibit changes in internal resistance
proportional to changes in temperature.
Thermistors are made from mixtures of metal
oxides, such as oxides of cobalt, chromium,
nickel, manganese, iron, and titanium. These
semiconductor materials exhibit a
temperature-versus-resistance behaviour that
is opposite of the behaviour of RTD
conducting materials. As the temperature
increases, the resistance of a thermistor
decreases; therefore, a thermistor is said to
have a negative temperature coefficient.
Although most thermistors have negative
coefficients, some do have positive
temperature coefficients.
Figure 5. Different types of thermistors.