TRAINING MANUAL - INSTRUMENTS DOC No.

: 29040-IC-UFR-0004

Rev. : R0
TEMPERATURE MEASUREMENT
Uhde India Limited Page : 0

CONTENTS

Page

0.0 Cover Sheet 0

1.0 Mechanical Thermometers
A Filled system Thermometers 1
B Bimetallic Thermometers 1-2
2.0 Electric Thermometer
A RTD Thermometers 2-4
B Thermocouple Thermometers 4-5
3.0 Thermowells 5
4.0 Temperature transmitters 5

Annexure: Slides 11 sheets

Applicable Revision:
Prepared: Checked: Approved:

Date: Date: Date:

First Edition: R0
Prepared: Checked: Approved:

R.K. KAMATH M.B.JOSHI N.C.JAIN

Date: 25/07/2000 Date: Date:

File Name: 537007344.docs Server: KUMUS 206

Directory: /conversion/tmp/activity_task_scratch/537007344.doc537007344.docs
 TRAINING MANUAL - INSTRUMENTS DOC No. : 29040-IC-UFR-0004

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1 MECHANICAL THERMOMETERS

The term mechanical thermometers are used for temperature measuring devices, which give a
local indication of the temperature measured. The commonly used types are 1) Filled system
thermometers 2) Bimetallic thermometers.

A) FILLED SYSTEM THERMOMETERS

A.1) Usage

They are used when accurate local temperature measurements are desired. Filled
thermometers are rugged when compared to bimetallic thermometers.

A.2) Construction

Filled systems consist of a fluid filled in a bulb, which when subjected to temperature expands /
contracts. This variation in volume is transmitted to a readout, which displays the temperature.

Filled systems can be Liquid, mercury, vapour or gas filled systems. Mercury filled or vapour
filled gauges is commonly used in industrial applications. In case of applications where a wider
measurement range is required, it may be necessary to use gas filled systems.

A.3) Range of use and accuracy

Range of use (Liquid filled systems) : (-) 80 to 315°C

Range of use (Mercury filled systems) : (-) 40 to 400°C
Range of use (Vapour filled systems) : (-) 30 to 300°C
Range of use (Gas-filled systems) : (-) 100 to 650°C

Accuracy (All the above systems) : 0.5 to 1% of span.

A.4) Limitations

It is difficult to achieve narrow measurement spans with filled systems. The speed of response
is slow.

Mercury filled thermometers are not generally preferred due to environmental reasons.
However, where the pipelines are subject to vibrations, mercury filled local temperature gauges
with capillary may be used to prevent damage to the gauge and maintain readability of
indication. Typical examples of this are suction and discharge temperature measurements of
compressors.

B) BIMETALLIC THERMOMETERS

B.1) Usage

These are used in applications where accuracy to the extent provided by filled system
thermometers is not required.

B.2) Construction

Two metals with different co-efficients of thermal expansion are fused together to form a
bimetallic element. This element, when subjected to temperature, distorts due to the difference
in expansion / contraction of the two elements forming the bimetal. This distortion is transferred
on to a readout, which in turn displays the temperature. Normally used bimetal are
manufactured by fusing together Invar / Ni-Fe alloy.
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B.3) Range of use and accuracy

Range of use (Bimetallic system) : (-) 70 to 550°C

Accuracy : 2% of span

B.4) Limitations

Bimetallic temperature gauges have a relatively poor accuracy. They cannot be used in services
that are prone to vibrations. Rough handling may result in drifting of calibration.

2 ELECTRIC THERMOMETERS

Electric thermometers are primarily used for remote indication of measured temperature. The
measurements obtained are more accurate than either Bi-metallic or filled system thermometers.
Following are two types of electric type thermometers commonly used in industrial applications:

a) RTD – Resistance Temperature Detector

b) T/C – Thermocouple

Electric systems basically consist of two parts, the sensor and the measurement system.

A) RTD THERMOMETERS

A.1) Usage

RTDs are used in applications where a high degree of measurement accuracy is desired,
associated with excellent stability of measurement, repeatability and sensitivity.

A.2) Construction

Resistance Thermometry is based on the principle that the resistance that electrical conductors
exhibit to the flow of an electric current is related to their temperature. The ideal resistance
thermometer should have high temperature of co-efficient of resistance and temperature co-
efficient of resistance shall be linear over wide range of temperature. Some metals that fulfil this
requirement are copper, gold, nickel, platinum and silver. Of all the metals, platinum has the
bast linear temperature co-efficient of resistance over wide range of temperature. Hence,
platinum resistance elements are most commonly used in industrial applications.

The sensors have platinum wires wound on glass or ceramic former that have similar
temperature v/s. expansion characteristics to that of the platinum wire. The windings are
secured with a coating of suitable cement or glaze. Platinum resistance sensor elements are
filled in protection tubes equipped with a small terminal blocks for connection to the copper
cable linking the instrument. The protection tube might be fitted into a thermowell for further
mechanical protection.
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A.3) Measurement system

The RTD is connected to control room instruments by following methods to measure change in
resistance and display it as temperature measurement.

Sr. Type of Principle of Error due to Cost of

Remarks
No. connection Measurement connecting wires Cable
1 Two wire Wheatstone Resistance of the Low cost of Not used in
RTD Bridge connecting wires is cable industrial
always included in applications.
measurement with
that of the sensor
leading to inaccuracy.
2 Three wire Wheatstone Here the two wires Medium cost Commonly
RTD Bridge connected to the of cable industrial
sensor are on either applications
side of the bridge and
thus partially cancel
the measurement
error due to
connecting wires,
while the third wire
functions as the
extended supply wire
to configure the
bridge.
3 Four wire Constant No error due to High cost of Used when high
RTD current source connecting wires cable accuracy is
required.

A.4) Range of use and accuracy (as per IEC-751)

IEC-751 defines the range of use and accuracy specifications of RTD with Platinum
measuring elements.

Range of use : (-) 60 to 650°C

(With class “A” accuracy)
: (-) 60 to 850°C
(With class “B” accuracy)

Accuracy : Class “A” =0.15 + (0.005 * Mod t)

: Class “B” =0.30 + (0.05 * Mod t)

Mod t is value of temperature being measured

without considering the sign.
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A.5) Limitations

RTD sensors are delicate and require careful handling. These sensors are generally not
recommended for applications subject to excessive vibrations such as compressor applications.
RTD sensors cannot cover a wide range of temperature. Sensors are larger in size when
compared to thermocouples and cannot be used if there is a limitation of clearance available.

B) THERMOCOUPLE THERMOMETERS

B.1) Usage

Thermocouples are widely used in industrial applications due to their wide temperature range
and robustness. Thermocouples have a high degree of accuracy and a reasonably good degree
of stability, repeatability and sensitivity.

B.2) Construction

Temperature measurement by thermocouple is based on the principle that circuit formed by

junctions of two dissimilar metals generates emf proportional to temperature difference between
two junctions. In industry, following types of thermocouples are used.

Type Range of use

Conductor Material
designation (°C as per IEC-584)
R Pt-13% Rh (+) 0 to 1600
Pt (-)
S Pt-10% Rh (+) 0 to 1600
Pt (-)
B Pt-30% Rh (+) 600 to 1700
Pt-6% Rh (-)
K Ni-Cr (Chromel) (+) (-) 200 to 1200
Ni-Al (Alumel) (-)
T Cu (Copper) (+) (-) 200 to 350
Cu-Ni (Constantan) (-)
Fe (Iron)
J (-) 40 to 750
(+)
Cu-Ni (Constantan) (-)
E Ni-Cr (Chromel) (+) (-) 40 to 750
Cu-Ni (Constantan (-)
N Ni-Cr-Si (+) (-) 200 to 1200
Cu-Si (-)

B.3) Measurement System

The best way of extending T/C circuits from the sensor to the reference unit is to connect cables
with same conductor materials to those of sensor. Alternatively, they may incorporate quite
different conductor materials which in combination develop similar outputs to those of the T/C
over the limited temperature range that are likely to be experienced at the T/C to the extension
wire connections. These are called compensating cables. Compensating cables are normally
used for thermocouples having expensive materials e.g. Platinum T/Cs.
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A T/C provides an output, which is related to the temperature of the two junctions. For it to
function as an absolute temperature measuring device, the reference junction must be at a
known and constant temperature. Variation of reference junction temperature causes errors in
temperature measurements. To overcome the error introduced due to this, “cold junction
compensation” is done. The most commonly used method is to provide software compensation
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in the DCS / control system, where a thermistor is used to measure the actual reference
junction temperature variations and its effect is nullified by means of software calculations.

B.4) Range of use and accuracy

The range of use is given above in section B.2. There are three accuracy classes defined in
IEC-584-2 for each type of thermocouple, which can be referred and the best choice of
thermocouple can be made. Class-1 has the highest accuracy and Class-3 has the least
accuracy.

B.5) Limitations

Thermocouple measurements need to have a stable reference for accurate measurements. In

case the reference system is not accurate, the accuracy of the measurement is compromised.
Extension cables required to transmit the signals to control room are expensive. The formation
of junctions due to terminations in panels causes voltage drops and this leads to errors in
measurements. Type “J” thermocouples are prone to corrosion of the positive element (Iron).

3 THERMOWELLS

Thermowells are metallic protective pockets to house the temperature sensory elements such
as RTDs, T/Cs, etc. and act as a physical interface.

THERMOWELL CONSTRUCTION

Thermowells are made from bar stock with suitable hollow cavity to house the temperature
element.

Thermowells of welded type, flanged type or screwed type are used in industrial applications.

Flanged thermowells are most commonly used. These are useful primarily in corrosive
applications or where it is necessary to disassemble thermowell for disassembly of equipment
for maintenance. The screwed thermowells have shorter immersion length and hence they are
less prone to vibrations due to high velocity. UIL practice is to use flanged thermowells in
general and screwed thermowell in case of velocity limitations.

For thermowell immersion length guidelines refer UIL standard drawing no. GENL-IC-UED-
0215.

4 TEMPERATURE TRANSMITTERS

Temperature transmitters commonly available are Head mounted type and Remote mounted type.
Head type transmitters are less accurate and less expensive than remote mounted versions.
These can be used with both RTDs and thermocouple sensing elements. When the
thermocouples are used in a plant, head mounted transmitters provide a cost effective solution as
they convert the millivolt signals to a conventional 24VDC, 4-20 mA 2-wire signal, thus allowing
usage of normal copper wires instead of expensive thermocouple extension cables.
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