Process control systems make sure industrial processes are carried out efficiently, consistently

and with as little variation as possible. They're installed in industrial settings

 To help maintain throughput, quality, yield and energy efficiency
 Make sure working practices are carried out safely and profitably
Systems measure, monitor and control manufacturing processes and activities. They identify and
correct any abnormalities or variations from specified values, either manually or automatically.
The aim is to make sure that production is consistent and that as little energy is wasted as
possible.
lthough process control technology has advanced rapidly since the mid-1980s, the latest systems
still follow the traditional hierarchical or pyramid-like structure. The lowest level of the pyramid
works to make sure a particular process doesn't vary by more than an allowed amount. It
monitors the operation of each part of the process, identifies unwanted changes and initiates any
necessary corrective actions.

7 Basic Types of Temperature Measuring Sensors

How to Measure Temperature?

1. Thermocouples
Thermocouples are voltage devices that indicate temperature measurement
with a change in voltage. As temperature goes up, the output voltage of the
thermocouple rises - not necessarily linearly.

Often the thermocouple is located inside a metal or ceramic shield that protects
it from exposure to a variety of environments. Metal-sheathed thermocouples
also are available with many types of outer coatings, such as Teflon, for trouble-
free use in acids and strong caustic solutions.

2. Resistive Temperature Measuring Devices (RTDs)

Resistive temperature measuring devices also are electrical. Rather than using a
voltage as the thermocouple does, they take advantage of another characteristic
of matter which changes with temperature - its resistance. The two types of
resistive devices we deal with at OMEGA Engineering, Inc., in Stamford,
Conn., are metallic, resistive temperature devices (RTDs) and thermistors.

In general, RTDs are more linear than are thermocouples. They increase in a
positive direction, with resistance going up as temperature rises. On the other
hand, the thermistor has an entirely different type of construction. It is an
extremely nonlinear semi-conductive device that will decrease in resistance as
temperature rises.

3. Infrared Sensors

Infrared sensors are non-contacting sensors. As an example, if you hold up a

typical infrared sensor to the front of your desk without contact, the sensor will
tell you the temperature of the desk by virtue of its radiation–probably 68°F at
normal room temperature.

In a non-contacting measurement of ice water, it will measure slightly under

0°C because of evaporation, which slightly lowers the expected temperature
reading.

4. Bimetallic Devices

Bimetallic devices take advantage of the expansion of metals when they are
heated. In these temperature checking devices, two metals are bonded together
and mechanically linked to a pointer. When heated, one side of the bimetallic
strip will expand more than the other. And when geared properly to a pointer,
the temperature measurement is indicated.
Advantages of bimetallic devices are portability and independence from a power
supply. However, they are not usually quite as accurate as are electrical devices,
and you cannot easily record the temperature value as with electrical devices
like thermocouples or RTDs; but portability is a definite advantage for the right
application.

5. Thermometers

Thermometers are well-known liquid expansion devices also used for

temperature measurement. Generally speaking, they come in two main
classifications: the mercury type and the organic, usually red, liquid type. The
distinction between the two is notable, because mercury devices have certain
limitations when it comes to how they can be safely transported or shipped.

For example, mercury is considered an environmental contaminant, so breakage

can be hazardous. Be sure to check the current restrictions for air transportation
of mercury products before shipping.

6. Change-of-State Sensors

Change-of-state temperature sensors measure just that a change in the state of a

material brought about by a change in temperature, as in a change from ice to
water and then to steam. Commercially available devices of this type are in the
form of labels, pellets, crayons, or lacquers.

For example, labels may be used on steam traps. When the trap needs
adjustment, it becomes hot; then, the white dot on the label will indicate the
temperature rise by turning black. The dot remains black, even if the
temperature returns to normal.
Change-of-state labels indicate temperature measurement in °F and °C. With
these types of devices, the white dot turns black when exceeding the
temperature shown; and it is a nonreversible sensor which remains black once it
changes color. Temperature labels are useful when you need confirmation that
temperature did not exceed a certain level, perhaps for engineering or legal
reasons during shipment. Because change-of-state devices are nonelectrical like
the bimetallic strip, they have an advantage in certain applications. Some forms
of this family of sensors (lacquer, crayons) do not change color; the marks made
by them simply disappear. The pellet version becomes visually deformed or
melts away completely.

Limitations include a relatively slow response time. Therefore, if you have a

temperature spike going up and then down very quickly, there may be no visible
response. Accuracy also is not as high as with most of the other devices more
commonly used in industry. However, within the realm of application where
you need a non-reversing indication that does not require electrical power, they
are very practical.

Other labels which are reversible operate on quite a different principle using a
liquid crystal display. The display changes from black color to a tint of brown or
blue or green, depending on the temperature achieved.

For example, a typical label is all black when below the temperatures that are
sensed. As the temperature measurement rises, a color will appear at, say, the
33°F spot–first as blue, then green, and finally brown as it passes through the
designated temperature. In any particular liquid crystal device, you usually will
see two color spots adjacent to each other– the blue one slightly below the
temperature indicator, and the brown one slightly above. This lets you estimate
the temperature as being, say, between 85° and 90°F.

Although it is not perfectly precise, it does have the advantages of being a small,
rugged, nonelectrical indicator that continuously updates temperature
measurement.

7. Silicon Diode

The silicon diode sensor is a device that has been developed specifically for the
cryogenic temperature range. Essentially, they are linear devices where the
conductivity of the diode increases linearly in the low cryogenic regions.

Whatever sensor you select, it will not likely be operating by itself. Since most
sensor choices overlap in temperature range and accuracy, selection of the
sensor will depend on how it will be integrated into a system.

This article was originally published on Dec. 28, 2000. It has been revised for
clarity.

Benefits of an efficient process control system

Your business could benefit from a well-designed control system in many ways,
including:

Energy savings - energy wastage is reduced when your plant and machinery are
efficiently operated

Improved safety - control systems automatically warn you of any abnormalities

which minimises the risk of accidents
Consistent product qualities - variations in product quality are kept to a
minimum and reduce your wastage.

Lower manufacturing costs - detecting faults early means throughput, yield

and quality are maintained

Improved environmental performance - systems can give you an early

warning of a rise in emissions