Instrumentation For Engineering Measurements Ch8
Instrumentation For Engineering Measurements Ch8
TABLE 8.3 Temperature Range, Sensors, and Interpolation Equations for the
International Practical Temperature Scale
Temperature
Range (°C) Sensor Fixed Point Equation
(8.2)
When error due to the neglect of nonlinear terms becomes excessive, either
linearizing circuits can be used to compensate for the nonlinearities, or additional
terms can be retained from Eq. (8.1) to relate the measured A.R to the unknown
temperature T. Retaining the temperature coefficients 71 and 72 from Eq. (8.1)
Nickel
Copper
o
0I2-1-1-1_1_I_
Figure 8.9 Deviation from linearity for a 50-0 RTD sensor with a 150-0 shunt resistor
when the sensor is bonded to 1018 steel. (Courtesy of Micro-Measurements.)
wire circuit (7?^ = 0.5 O) with a 50-0 nickel sensor will produce an apparent
temperature offset of only 0.2°C (0.4°F). All error due to lead wires can be
eliminated by using either the three- or four-wire circuits illustrated in Figs. 8.5
or 8.6.
Stability of the sensors is usually assured by aging of the elements during
the manufacturing process. Stability may become a source of error when the
upper temperature limit of the sensor is exceeded either by design or accident.
Anytime the upper temperature limit of a sensor is exceeded, any new temper¬
ature measurements should be repeated until stable and reproducible readings
are obtained. Stability can also be affected by the polymeric carrier used with
bondable RTDs. These carriers have a finite life and lose their strength at
temperatures in excess of 120°C (250°F).
Self-heating errors are produced when excitation voltages or currents are
used in the signal conditioning circuits. Usually there is no reason for large
excitation signals, since an RTD is a high-output sensor (a typical output is 0.9
mV/V • °C or 0.5 mV/V • °F). Self-heating errors can be minimized by limiting
the power dissipation in the RTD to less than 2 mW. In those applications where
small temperature changes are to be measured and very high sensitivity is re¬
quired, sensors with large surface areas should be employed. These sensors with
large surface areas can dissipate larger amounts of heat; therefore, higher ex¬
citation voltages can be used without introducing self-heating errors.
Bonded RTD sensors resemble strain gages and, in fact, they respond to
strain. Fortunately, the strain sensitivity of the sensor is small in comparison to
the temperature sensitivity. A bonded RTD with a nickel sensor exhibits an
apparent temperature change of 1.7°C (3°F) when subjected to an axial tensile
strain of 1000 |xm/m along the filaments of the gage grid. The magnitude of the
strain effect is such that it can be neglected in most applications.
Thermistors
Thermistors are temperature-sensitive resistors fabricated from semicon¬
ducting materials, such as oxides of nickel, cobalt, or manganese and sulfides
of iron, aluminum, or copper. Thermistors with improved stability are obtained
8.2 RESISTANCE THERMOMETERS 409
or
R = R,e^^^''^ - (8.4)
^R/R _ p (8.5)
AT '
small change in resistance of the lead wires due to the temperature variation.
Also, the resistance of the thermistor is very large relative to the resistance of
the lead wires {RjIRi^ ~ 1000); consequently, any reduction in sensitivity of the
sensor due to lead-wire resistance is negligible.
Errors may occur as a result of self-heating since the power {P — PRt)
dissipated in the thermistor will heat it above its ambient temperature. Rec¬
ommended practice limits the current flow through the thermistor to a value
such that the temperature rise due to the PRj power dissipation is smaller than
the precision to which the temperature is to be measured. A typical thermistor
with Rj- = 5000 ft is capable of dissipating 1 mW/°C above the ambient tem¬
perature. Thus, if the temperature is to be determined with an accuracy of 0.5°C,
the power to be dissipated should be limited to less than 0.5 mW. This limitation
establishes a maximum value for the current / at
The expansion (or contraction) per unit length A///of a material experiencing
an increase (or decrease) in temperature AT is given by the expression
Liquid-in-Glass Thermometers
The well-known and widely used glass thermometer provides a simple,
convenient, and inexpensive means for measuring temperature in many appli¬
cations. The thermometer consists of an indexed glass capillary tube with a bulb
at one end to hold a supply of fluid. The fluids commonly used are mercury and
8.3 EXPANSION THERMOMETERS 417
alcohol. Mercury can be used for temperatures between — 39°C ( —38°F) and
538°C (1000°F). When a lower temperature limit is needed, alcohol permits
measurements at temperatures as low as — 62°C ( —80°F); pentane can be used
for measurements as low as — 218°C ( —360°F).
Glass thermometers are designed for either partial or full immersion. As
the name implies, full-immersion thermometers are calibrated to read correctly
when the thermometer is completely immersed in the fluid whose temperature
is being measured. Partial-immersion types are marked and should be immersed
only to the depth indicated by the immersion mark.
The accuracy that can be achieved with a glass thermometer depends upon
the quality and range of the particular thermometer being used. Also, strict
attention must be paid to immersion requirements, since corrections must be
made when these requirements are not satisfied. With a good-quality, full-im¬
mersion thermometer having a range from 0°C to 100°C, the temperature can
be determined to within ±0.1°C.
Glass thermometers provide a low-cost means for measuring temperatures
with reasonable accuracy over the range from about -200°C to 500°C. Since
the readout is visual, they are not used in automatic data systems or in auto¬
matically controlled processes in industry.
Bimetallic Thermometers
The sensing element in a bimetallic thermometer consists of a bonded com¬
posite of two materials, as illustrated in Fig. 8.14. Materials is usually a copper-
based alloy with a large coefficient of thermal expansion, while material B is
usually Invar (a nickel steel), which has a very small coefficient of thermal
expansion. When the bonded bimetallic strip is subjected to a temperature
change, the differential expansion causes it to bend into a circular arc. The radius
of curvature of the arc is given by the expression
Bimetallic elements in the form of cantilever beams, spirals, washers, and helixes
are inexpensive and deform significantly with relatively small changes in tem¬
perature; therefore, they are used in a wide variety of temperature sensing and
temperature control devices. In thermostats, they are used to control temper-
~r
t
; Material A
' to Material B
1 ‘B
ature by switching the heat source on and off. As overload switches in electrical
equipment, they are activated by excessive current flows and turn off the equip¬
ment. Finally, they are often used in conjunction with a linear-displacement
sensor such as a potentiometer or linear variable-differential transformer (LVDT)
to provide a temperature indicating instrument.
The accuracy of bimetallic thermometers varies; therefore, they are usually
used in control applications where low cost is more important than accuracy.
For those applications where accuracy is important, high-quality bimetallic ther¬
mometers are available with guaranteed accuracies of about 1 percent.
Pressure Thermometers
A typical pressure thermometer, illustrated schematically in Fig. 8.15, con¬
sists of a bulb filled with a liquid such as mercury or xylene, a capillary tube,
and a pressure sensor. When the bulb is subjected to a temperature change,
both the bulb and the fluid experience a volume change. The differential volume
change AF^ is proportional to the temperature change AT. In a closed system
completely filled with liquid under an initial pressure, the pressure changes in
response to the differential volume change. The pressure is transmitted through
the capillary tube to a pressure measuring transducer, such as a bourdon tube,
bellows, or diaphragm. Movement of the bourdon tube or bellows can be trans¬
mitted through a suitable linkage system to a pointer whose position relative to
a calibrated scale gives an indication of the temperature. The bourdon tube or
bellows can also be used with a potentiometer or linear variable-differential
transformer (LVDT) to construct a temperature measuring and recording in¬
strument. Similarly, an electrical resistance strain gage on a diaphragm provides
the sensor for a temperature measuring and recording instrument.
The dynamic response of a pressure thermometer is poor because of the
thermal lag associated with the mass of fluid in the bulb; therefore, such in¬
struments cannot be used to measure temperatures in fluids undergoing rapid
changes in temperature. The pressure thermometer can, however, provide a
8.4 THERMOCOUPLES 419
8.4 THERMOCOUPLES
A thermocouple is a very simple temperature sensor, consisting essentially
of two dissimilar wires in thermal contact, as indicated in Fig. 8.16(3. The op¬
eration of a thermocouple is based on the Seebeck effect, which results in the
generation of a thermoelectric potential when two dissimilar metals are joined
together to form a junction. The thermoelectric effect is produced by diffusion
of electrons across the interface between the two materials. The electric potential
of the material accepting electrons becomes negative at the interface, while the
potential of the material providing the electrons becomes positive. Thus, an
electric field is established by the flow of electrons across the interface. When
this electric field becomes sufficient to balance the diffusion forces, a state of
equilibrium with respect to electron migration is established. Since the magnitude
of the diffusion force is controlled by the temperature of the thermocouple
junction, the electric potential developed at the junction provides a measure of
the temperature.
The electric potential is usually measured by introducing a second junction
in an electric circuit, as shown in Fig. 8.16^, and measuring the voltage across
one leg with a suitable voltmeter. The voltage across terminals M-N can be
Material A Material A
Material B M N
Figure 8.16 Thermocouple sensor and circuit for measuring the temperature difference
Tj - Tj. (a) Single junction, (b) Dual junction.
420 TEMPERATURE MEASUREMENTS
Material A Copper
Measuring
junction
Material B
Ip Copper
Reference Readout
junction
Figure 8.17 The ice bath method for maintaining a reference temperature at 0°C (32°F).
434 TEMPERATURE MEASUREMENTS
Temperature
sensor
-O E„0-
Figure 8.26 Two-terminal temperature sensor circuit with leadwire resistance and a
series output resistance with trim potentiometer for standardizing sensitivity.
mV/K or 10 mV/K. This trim adjustment also permits the sensor’s calibration
error at a given temperature to be adjusted so as to improve accuracy over a
given range of temperatures as shown in Fig. 8.27.
Unfortunately, the two-terminal integrated-circuit temperature transducer
is limited to use in the range of temperatures from -55°C to 150°C. In this
temperature range, it is an excellent temperature measuring device.
Temperature (°C)
Figure 8.27 Typical nonlinearity and calibration error for a two-terminal integrated-
circuit temperature transducer.
8.6 RADIATION METHODS (PYROMETRY) 435
2'nc^h (8.26)
1) - 1)
C, = 2ttc2/z = 3.75(10-16) yy ■ m-
X^ = 2891(10-6)/7’ (8.27)
436 TEMPERATURE MEASUREMENTS
The area under each of the curves in Fig. 8.28 is the total power W emitted at
the particular temperature T. Thus
1. The total power W increases as a function of the fourth power of the tem¬
perature.
2. The peak value of spectral radiation intensity VF;, occurs at shorter wave¬
lengths as the temperature increases.
Both of these physical principles are used as the basis for a measurement of
temperature.
the hot body and the filament of the pyrometer lamp is then passed through a
red filter with a sharp cutoff below X = 0.63 ixm. The light transmitted through
the filter is then collected by an objective lens and focussed for viewing with an
ocular lens. The image observed through the eyepiece of the pyrometer is that
of the lamp filament superimposed on a background intensity due to the hot
body. The current to the filament of the pyrometer lamp is adjusted until the
brightness of the filament matches that of the background. Under a matched
condition, the filament disappears (hence the commonly used name—^disap-
pearing-filament optical pyrometer), as illustrated in Fig. 8.296. The current
required to produce the brightness match is measured and used to establish the
temperature of the hot body. Pyrometers are calibrated by visually comparing
the brightness of the tungsten filament with a blackbody source of known tem¬
perature (e =1).
When the brightness of the background and the filament are matched, it is
evident from Eq. (8.26) that
8 1
(8.29)
^C2l\rT _ Y ~ QC2l\rT[ _ ^
temperature
low
b
Figure 8 29 Schematic illustration of the optical system and filament brightness ad¬
justment in an optical pyrometer, (a) Schematic illustration of an optical pyrometer. (6)
Filament brightness adjustment in an optical pyrometer.
438 TEMPERATURE MEASUREMENTS
When T < 4000°C (7200°F), the term » 1 and Eq. (8.29) reduces to
dT _ kT de
(8.31)
y“ ~ Q T
Since kTIC2 <0.1 for T< 2000°C (3630°F), errors in temperature determinations
are mitigated considerably with respect to errors in emissivity. For example, at
Tantalum 0.49 — 16 Cr