TERM PAPER

OF
INDUSTRIAL MEasurement
ON
FABRICATION OF INDUSTRIAL
THERMOCOUPLES
In thermocouples industry

SUBMITTED TO:
SUBMITTED BY:
MR. abhishek srivastava Roufi
Williams
(dept. of ELECTRONICS)
Roll
no.:R0e156a12
REG. NO.:
10801345
 COURSE CODE:
ecE887
SECTION:
oe156
 ACKNOWLEDGEMENT

I would like to express my deep sense of gratitude and indebtness

to Mr. ABHISHEK KUMAR SEIVASTAVA, who
guided me at all stages in the preparation of this dissertation.
This project would not have been possible without his valuable
suggestion and encourages.

It would not be out of place to mention here that my revered

parents have always been a great source of inspiration to me. I
am thankful to all my friends and classmates who were readily
available for help. At last but not least I’ll also thankful to my God.

ROUFI WILLIAMS
ROE156A12
 Contents

 INTRODUCTION

 INDUSTRIAL THERMOCOUPLES

 APPLICATION

 TYPES

 CONCLUSION

 BIBLIOGRAPHY
 INTRODUCTION

THERMOCOUPLE:

A thermocouple is a junction between two different metals that produces a voltage related to
a temperature difference. Thermocouples are a widely used type of temperature sensor for
measurement and control and can also be used to convert heat into electric power. They are
inexpensive and interchangeable, are supplied fitted with standard connectors, and can measure a
wide range of temperatures. The main limitation is accuracy: system errors of less than one
degree Celsius (C) can be difficult to achieve.

Any junction of dissimilar metals will produce an electric potential related to temperature.
Thermocouples for practical measurement of temperature are junctions of specific alloys which
have a predictable and repeatable relationship between temperature and voltage. Different alloys
are used for different temperature ranges. Properties such as resistance to corrosion may also be
important when choosing a type of thermocouple. Where the measurement point is far from the
measuring instrument, the intermediate connection can be made by extension wires which are
less costly than the materials used to make the sensor. Thermocouples are usually standardized
against a reference temperature of 0 degrees Celsius; practical instruments use electronic
methods of cold-junction compensation to adjust for varying temperature at the instrument
terminals. Electronic instruments can also compensate for the varying characteristics of the
thermocouple, and so improve the precision and accuracy of measurements.

Thermocouples are widely used in science and industry; applications include temperature
measurement for kilns, gas turbine exhaust, diesel engines, and other industrial processes.
LAW FOR THERMOCOUPLES:
Law of homogeneous material:-
A thermoelectric current cannot be sustained in a circuit of a single homogeneous material by the
application of heat alone, regardless of how it might vary in cross section. In other words,
temperature changes in the wiring between the input and output do not affect the output voltage,
provided all wires are made of the same materials as the thermocouple.

Law of intermediate materials:-

The algebraic sum of the thermoelectric emfs in a circuit composed of any number of dissimilar
materials is zero if all of the junctions are at a uniform temperature. So If a third metal is inserted
in either wire and if the two new junctions are at the same temperature, there will be no net
voltage generated by the new metal.

Law of successive or intermediate temperatures:-

If two dissimilar homogeneous materials produce thermal emf1 when the junctions are at T1 and
T2 and produce thermal emf2 when the junctions are at T2 and T3 , the emf generated when the
junctions are at T1 and T3 will be emf1 + emf2 .
INDUSTRIAL THERMOCOUPLES:
Thermocouples are among the simplest temperature sensors for industrial applications.
Essentially, a thermocouple consists of two different metals (wires) joined together at one end
and open at the other end (Figure 1). The point at which the two wires are joined is called the
measuring junction, hot junction, or simply the junction. The point at which the thermocouple
wires are attached to the extension wires that lead to a temperature indicator is referred to as
reference junction or cold junction. If the measuring junction and the reference junction are at
two different temperatures, a voltage called electromotive force (EMF) is produced. The
magnitude of the EMF normally depends on the properties of the two thermocouple wires and
the temperature difference between the measuring junction and the reference junction. For
laboratory work and for calibrating thermocouples, the reference junction is usually kept in an
ice bath (at 0°C). However, in industrial applications, a circuit known as a cold junction
compensation circuit is normally used to automatically account for the temperature of the
reference junction.
 APPLICATION

Thermocouples for Industrial Applications:

• These are the most common type of thermocouple used in furnace applications. With a
metal or ceramic protection tube, they are appropriate for severe and demanding
environments. The heavy wall provides a long life for the thermocouple.

• Similar to the above. With a 90° bend, the hot leg protection tube is made of metal or
ceramic. Used in salt baths, heat treating, and molten metal applications.

• A general purpose thermocouple. The thin wall metal protection tube gives fast
response.
 • "MgO" thermocouple are insulated in magnesium oxide with a stainless steel or Inconel
sheath. This provides superior performance and longevity. The material can be bent to
nearly any desired shape without damaging the element. Diameters of 0.040” to 0.250”
are available.

• Elements are available in both base metal and noble metal. Base metal elements are used
directly for temperature sensing or as component items for insertion into a protection
tube.

Thermo Sensors Thermocouples:

Thermo Sensors Industrial thermocouples are
widely used in process industry applications.
Thermocouples are generally selected by
determining the particular conditions under
which it must perform. These conditions which
have recommended wire and material selections
and are grouped in types.
Thermo Sensors thermocouple element types include:

• Type E Chromel-Constantan Thermocouple

• Type J Iron-Constantan Thermocouple
• Type K Chromel-Alumel Thermocouple
• Type N Nicrosil-Nisil Thermocouple
• Type R Platinum-Platinum 13% Rhodium Thermocouple
• Type S Platinum-Platinum 10% Rhodium Thermocouple
• Type B Platinum 6% Rhodium-Platinum 30% Rhodium Thermocouple
• Type T Copper- Constantan Thermocouple

The wire gauge and recommended temperature ranges are of various sizes as well.

TYPE:
Thermocouple Types:

Thermocouples have different properties dependent upon the metals or conductors used. There
are several standard types that are given designations according to the materials used.

Type Materials Approx Sensitivit Comments

Designati Used Temperat y (uV/C)
on ure
Range (C)
B Platinum / Rhodium 50 to 1800 Gives same output at
0C and 42C making the
minimum useable
temperature around
50C
E Chromel / 68 Normally used for
Constantan cryogenic applications

J Iron / Constantan -40 to ~52 Should not be used

+750 above 760C as a
magnetic change will
permanently de-
calibrate the
thermocouple
K Chromel / Alumel -200 to 41 Good general purpose
1200 thermocouple, widely
used and cheap

N Nicrosil / Nisil 10 Becoming a

R Platinum / Rhodium
S Platinum / Rhodium
T Copper /
Constantan
replacement for type K
thermocouples
up to 1600 10 High cost and low
sensitivity restricts the
use. This thermocouple
is generally used for
high temperature
applications.
up to 1600 10 Very stable and
therefore used as a
standard of calibration
for the melting point of
gold (1064.43C). High
cost.
-200 to ~43 As both metals are non
350 magnetic, this type of
thermocouple is popular
for applications where
high magnetic fields
exists, e.g. for use with
electrical generators.

These thermocouples use a variety of different materials. The ones used in the thermocouples
mentioned above are all forms of metal alloys:

• Alumel Nickel 96%, manganese 2%, aluminium 2%

• Chromel Nickel 90%, chrome 10%
• Constantan Copper 55%, nickel 45%
• Nicrosil Nickel chrome silicon
• Nisil Nickel silicon

It is worth noting that thermocouple types B, R, and S are all made from noble metals and are
therefore more stable than other thermocouples. However they have a low level of sensitivity
(around 10 uV/C) and they are therefore normally used for higher temperatures.
 CONCLUSION

Thermocouples are widely used for measuring temperature in many applications. Although data
acquisition and process control make extensive use of them, they are also incorporated in many
stand alone thermometers. The type of thermocouple that is most widely used is the K type
thermocouple. This is also the type that is used in most portable instruments as it provides a high
output over the ranges most widely used. Nevertheless other types of thermocouple are still used
in other applications where more specialist requirements exist.

Thermocouples have many advantages when compared to other forms of temperature

measurement. They are small in size, and this makes them fast to respond to temperature
changes. Thermocouples also offer a wide temperature range, and they are also good for
measuring high temperatures. Finally they are comparatively cheap to manufacture. When
combined, these advantages make thermocouples an obvious choice for many temperature
measurement applications.
 Bibliography

Websites referred:-
http://en.wikipedia.org/wiki/thermocouple.htm

http://www.radio-electronics.com/info/receivers/thermocouple.php

http://www.radio-electronics.com

http://www.tpub.com/neets/book12/51d.htm

http://www.tpub.com/neets/book12/51e.htm

http://www.tpub.com/neets/book12/51f.htm

http://www.tpub.com/neets/book12/51c.htm