Instrumentation

Temperature

Thermocouples

Introduction

It is the German physicist SEEBECK (1770 - 1831) who discovered

in 1821, the thermo-electric effect

It noted that, in a closed circuit, made up of two different metal wire,

joined at their ends, there was birth of an electric current if they were
carried two end of this circuit at different temperatures

Ni-Cr

Tjct.
100C

Tref.
0C

b
Ni-Al

Hot junction or measuring junction

Metal a b

Cold junction or reference junction

2

Thermocouples (cont.)

Correspondence and thermocouple choice

Two metals constituting the thermocouples are selected according to

temperature to be measured

In a thermocouple, the first metal named is always the positive one

Thermocouples Types
Thermocouple Type

B
C
E
J
K
N
R
S
T

( Quality vs Cost )

Names of Materials

Useful Range

Platinum30% Rhodium (+)

2500 -3100F

Platinum 6% Rhodium (-)

1370-1700C

W5Re Tungsten 5% Rhenium (+)

3000-4200F

W26Re Tungsten 26% Rhenium

(-)

1650-2315C

Chromel (+)

200-1650F

Constantan (-)

95-900C

Iron (+)

200-1400F

Constantan (-)

95-760C

Chromel (+)

200-2300F

Alumel (-)

95-1260C

Nicrosil (+)

1200-2300F

Nisil (-)

650-1260C

Platinum 13% Rhodium (+)

1600-2640F

Platinum (-)

870-1450C

Platinum 10% Rhodium (+)

1800-2640F

Platinum (-)

980-1450C

Copper (+)

-330-660F

Constantan (-)

-200-350C

Thermocouples (cont.)

Cold welding and compensation wire

The thermocouple is composed of 2 metal wire of different nature

One of the ends is welded, it is the junction or the hot welding. The
other end, the junction of reference or cold welding, is connected to
the measuring circuit

A difference in temperature between the hot welding and the cold

welding causes one potential difference (electromotive Force)
function of the variation in temperature. Temperature of the point of
measurement is then deduced starting from knowledge from
temperature of the junction of reference

It will thus be necessary to obtain a temperature cold welding as

constant as possible so to carry out only one correction

Thermocouples (cont.)

To obtain this result, we use cables of compensation which move the

welding cold of the probe head to their end and we use a corrector
unit or cold welding to obtain the true value

The A and B wires of the thermocouple constitute the sensor. The

connection between the junction intermediary T2 and the junction of
reference Tref. is ensured by the cables of compensation A' and B'
respectively associate with metals A and B.

Thermocouples (cont.)

Class and precision

The thermocouples follow the standard CEI 584 which defines the
allowed tolerances. There are several types of thermocouples for
various ranges of temperature, sensitivities and characteristics.

The thermocouple J is used for its high sensitivity but there is a

possible iron contamination in oxidizing atmosphere starting from
400C, we will avoid to use it.

The thermocouple T has strong sensitivity and is used for the

temperature measurement negative.

The thermocouple N or K has an excellent thermoelectric stability,

and no problem of oxidation at high temperature (range useful from 0
to 1000C)

The thermocouple R & S are used for the high temperatures

Thermocouples (cont.)

Accuracy Classes.

Pt100

Introduction

The principle of measurement of these sensors is the resistance

variation of the metal conductor according to the temperature

The platinum has a good linearity, precision, stability with the

advantage to be twist in very fine wire. This is why, the sensor with
platinum resistance, indicated by Pt, is generally used in industrial
environment

The wire used is very fine so we will take care to use an antivibratory system to avoid its damage.

Mini epoxy covered head

Working length

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Pt100 (cont.)

Norm and standard

International standard CEI 751, derived from DIN standard 43.760

defines the values nominal as well as the acceptable variations

The Pt 100 start with a resistance of 100 ohms at 0 C (from where

the Pt100 term). With 100C the resistance is of 138.51 Ohms

The standard defines two classes

Tolerance Classifies A: + (0.15 + 0.002 [T]) of - 200C with + 600C
Tolerance Classifies B: + (0.30 + 0.005 [T]) of - 200C with + 850C

The class A gives a precision approximately 2 times better than the

B. In general, the class B is for industrial use and the class A is for
laboratories.

The range of use in our installation: -50 + 400C

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Pt100 (cont.)

Measurement method and electric connection

The measuring accuracy is in particular influenced by the resistance

of the cable line . For this reasons, we found different types of
assembly according to the degree of accuracy . Measurement is
generally taken in Wheat stone bridge in assembly 2 or 3 wires. The
assembly 3 wires is the most usually used in industry. Assembly 4
wire is intended for the laboratories

In assembly 2 wire, the error due to the cable is of approximately

0.06C per meter for a section from 1 mm2

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Two Wire RTD connection

Simple & Cheap.

Inaccurate

For short distance

between sensor & Tx.

Using the 2-wire method, the two wires that provide the RTD with its
excitation current and the two wires across which the RTD voltage is
measured are the same. There is inaccuracy in using this method
that if the lead resistance in the wires is high, the voltage measured
VO, is significantly higher than the voltage that is present across the
RTD itself.
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Three Wire RTD connection

I
V

EX

R
R
R

More Expensive.

More Accurate.

L1

For long distances

between sensor & Tx.

L2

L3

Using the 3-wire method, there are 2 parallel wires connected to one
end of the variable resistance, Vo is taking the voltage drop across
one of the wires only , not both.

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Four Wire RTD connection

Very Expensive.

Completely Accurate.

For long distances

between sensor & Tx.

The 4-wire method has the advantage of not being affected by the
lead resistances because they are on a high impedance path going
through the device that is performing the voltage measurement;
therefore, you get a much more accurate measurement of the
voltage across the RTD.

15

Pt100 (cont.)

Norm and standard

As coeff. Temp is not constant , hence there is also table for PT100.

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17

Optical pyrometers

Introduction

The optical pyrometer is a method of measurement of the

temperature based on the relation between the temperature of a
body and the optical radiation (infra-red or visible) that it body emits.
Let us take for example, an electrical resistance, feed by a power
source. It is started black, but it starts to emit heat, it is the invisible
thermal radiation called infra-red. Then resistance becomes red and
emits a visible radiation

The interest of the optical pyrometer is to allow the determination of a

temperature without contact with the object: it is thus an adapted
method when the conditions installations do not allow the use a
traditional thermometric sensors

Very high temperature (> 1200C)

Measurements without contact
Very aggressive environment
Part moving
Localization of the hot spots.

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A Pyrometer, or radiation thermometer, is a non-contact instrument that detects an

object's surface temperature by measuring the temperature of the
electromagnetic radiation (infrared or visible) emitted from the object.
Pyrometers are essentially photo detectors which are capable of absorbing energy, or
measuring the EM wave intensity, at a particular wavelength or within a certain range of
wavelengths.

Typical Broadband Pyrometer

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The Electromagnetic Radiation Spectrum

Courtesy of the Advanced Light Source, Berkeley Lab
(Ernest Orlando Lawrence Berkeley National Laboratory)
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Instruments for Scanner

Kiln IR Scanner.
Kiln position Encoder.
3. Kiln rotation sensor ( Pulse Switch).
4. Tire Migration proximity switches.
5. Pyrometers for Tires.
1.
2.

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22

Resolution for T Scanner

Scanning frequency = 20 rev/sec

Kiln diameter = 5 meters
Kiln speed = 3 rev/ min hence 1 rev = 15.7metres in 20 sec
Scanner measures 20 lines in one sec.
Hence the scanner trace 400 lines in the whole circumference of kiln
Scanner can read line of [ 1570/(20 * 20) ] = 3.925 cms
Data for one scan is coded in 12 bit o/p for 360 deg.
FOV = 120 , hence we use 1/3 of the 4096units.
Minimum horizontal scanned distance is 7800/4096/3 = 5.71cms

15.7m

3.925cms

78m

5.71cms
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FOV and Kiln Geometry

Requested data :
FOV angle
Two Pass points in terms of angles and length from kiln reference
Girth Gear place from Kiln reference.
Tires place from kiln reference.
Kiln Diameter
Kiln Length

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Kiln Pulse Sensor

Inductive proximity switch / Mechanical switch ( Which is Better ? )

25

Live Scan cycle ( Raw Scan )

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Scanner Interface program

X Axis View , Temperature wise ( Peak , Minimum , Average )

Y Axis View , for ruler place on X- Axis view cross section temp. profile.
Image Plot , color interpretation for temperatures along whole kiln.
Live Ring migration Plot. For rollers slip measurement.
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Internal temperature, used to define the internal kiln temperature profile.

The internal temperature profile is used
for calculating the brick / coating thickness. As many temperature points
can be added as needed. The position of the first and last temperature
point cannot be modified. When adjusting the position and temperature
for a temperature point, the current brick and coating thickness are shown
to the right.

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Refractory Program
Historical Dbase for Kiln briking

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