MALAVIYA NATIONAL INSTITUTE

OF TECHNOLOGY, JAIPUR

DEPARTMENT OF CHEMICAL
ENGINEERING
PROCESS INSTRUMENTATION
Session 2018-19
 THERMOCOUPLES

SUBMITTED BY:-
TEJAS GUPTA SUBMITTED TO:-
2017UCH1321 SHIV OM MEENA
DHARMENDRA (ASSISTANT
KUMAR PROFESSOR)
2017UCH1324
 CONTEXT

What is a thermocouple sensor ?

Basic principle.
Practical thermocouple construction.
Thermocouple working
Thermocouple characteristics
Advantages and Disadvantages
Selecting a Temperature Sensor
What are thermocouples?
 Most frequently used method to measure temperatures
with an electrical output signal
 Thermocouples operate under the principle that a circuit made
by connecting two dissimilar metals produces a measurable
voltage (emf-electromotive force) when a temperature
gradient is imposed between one end and the other.

 They are inexpensive, small, rugged and accurate when used

with an understanding of their peculiarities.
Thermocouples Principle of Operation
 In,1821 T. J. Seebeck observed the existence of an
electromotive force (EMF) at the junction formed between two
dissimilar metals (Seebeck effect).
◦ Seebeck effect is actually the combined result of two other
phenomena, Thomson and Peltier effects.
 Thomson observed the existence of an EMF due to
the contact of two dissimilar metals at the junction
temperature.
 Peltier discovered that temperature gradients along
conductors in a circuit generate an EMF.
 The Thomson effect is normally much smaller than
the Peltier effect.
Let’s take a look at this circuit
CONSTRUCTION
A thermocouple is composed of a junction
formed by two metal alloys. One portion of
the junction is placed on a source whose
temperature is to be measured, while the
other end is maintained at a constant
reference temperature in accordance with
the zeroth law of thermodynamics. Older
thermocouples use ice water baths as their
temperature source, but modern day ones use
a solid state temperature sensor.
CONSTRUCTION
Thermocouples are valuable in science and engineering
due to their accuracy, fast reaction time, small size, and
ability to measure extreme temperatures. The latter
ability is based on the metal combinations used; a
nickel-nickel combination can measure -50oC to
1410oC, while a rhenium-rhenium combination can
measure 0oC to 2315oC. The most common
combinations are iron-constantan, copper-constantan,
and chromel-alumel. The disadvantages of
thermocouples are that the signals produced may be
non-linear, and thus they need to be calibrated carefully
MODERN THERMOCOUPLE
OLD THERMOCOUPLE
 How thermocouples work
 It is generally
reasonable to assume
that the emf is
generated in the wires,
not in the junction.
The signal is generated
when dT/dx is not zero.
 When the materials are
homogeneous, e, the
thermoelectric power,
is a function of
temperature only.
 Two wires begin and
end at the same two Generally, a second order Eqn. is used.
temperatures.
E   (T  To )   (T  To )2
CHARACTERISTICS
What thermocouple materials should be used?

Depends on requirements:
◦ Temperature range
◦ Required accuracy
◦ Chemical resistance issues
◦ Abrasion or vibration resistance
◦ Installation requirements (size of wire)
◦ Thermal conduction requirements
Thermocouple Material Vs EMF
Types T, J, and K are most commonly used thermocouples
Material EMF versus Temperature
Chromel With reference to
the characteristics
of pure Platinum
Iron
emf Copper
Platinum-Rhodium

Alumel

Constantan
Temperature
Simple TC Model “EMF-Temperature Sketch”
Two materials
1
◦ Material A (+)
◦ Material B (-)
 Plus and minus refers 3 2
to how the emf changes
with temperature.
3
Number junctions around circuit and draw
B
Measured 2
emf

Emf
A

1
T meter T junction
Temperature
 Law of Intermediate Metals
Insertion of an intermediate metal
into a thermocouple circuit will
not affect the emf voltage output
so long as the two junctions are at
the same temperature and the
material is homogeneous.
Permits soldered and welded joints.
 Law of Intermediate Temperatures
If a thermocouple circuit develops a net
T2 T1 emf1-2 for measuring junction
temperatures T1 and T2, and a net emf2-3
for temperatures T2 and T3, then it will
develop a net voltage of emf1-3 = emf1-2 +
T3 T2
emf2-3 when the junctions are at
temperatures T1 and T3.

T3 T1
emf1-2+ emf2-3= emf1-3
If a thermocouple circuit of materials A and C generates a net emf A-C when
exposed to temperatures T1 and T2, and a thermocouple of materials C
and B generates a net emfC-B for the same two temperatures T1 and T2,
then a thermocouple made from materials A and B will develop a net
voltage of

emfA-B = emfA-C + emfC-B

between temperatures T1 and T2.

 Sometimes useful in the calibration of different thermocouple wires.

Advantages of Thermocouple
The following are the advantages of the
thermocouples.
1. The thermocouple is cheaper than the
other temperature measuring devices.
2. The thermocouple has the fast response
time.
3. It has a wide temperature range.
Disadvantages of Thermocouple
The following are the disadvantages of the
thermocouples.
1. 1. The thermocouple has low accuracy.
2. The recalibration of the thermocouple is
difficult.
 APPLICATIONS
 Steel Industry
 Gas appliance Safety
 Thermopile radiation sensors
 Manufacturing
 Power production
 Thermoelectric cooling
 Process plants
 Thermocouple as vacuum gauge
 Heaters
Selecting a Thermocouple
Type Application Information
E Recommended for continuously oxidizing or inert atmospheres. Sub-zero limits
of error not established. Highest thermoelectric output of the common
thermocouple types.
J Suitable for vacuum, reducing or inert atmospheres, oxidizing atmospheres with
reduced life. Iron oxidizes rapidly above 1000°F (538°C) so only heavy gauge
wire is recommended for high temperature. Bare elements should not be exposed
to sulfurous atmospheres above 1000°F (538°C).
K Recommended for continuous oxidizing or neutral atmospheres. Mostly used
above 1000°F (538°C). Subject to failure if exposed to sulfur. Preferential
oxidation of chromium in positive leg at certain low oxygen concentrations
causes “green rot” and large negative calibration drifts most serious in the 1500 -
1900°F (816 1038°C) range. Ventilation or inert sealing of the protection tube
can prevent this.
T Usable in oxidizing, reducing, or inert atmospheres as well as vacuum. Not
subject to corrosion in moist atmospheres. Limits of error published for sub-zero
temperature ranges
THANK YOU