TC solve surface temperature measurement headache with fast response thermocouple design

Contents

1. Background to Project
2. Customer Pain Points
3. Temperature Measurement Challenges
4. Thermocouple Sensor Solution
5. Results and Conclusions

Background to Project

A customer approached us to address the challenge of reliably measuring the surface temperature of a pipe. The application required a compact and efficient temperature monitoring system that could deliver fast and consistent readings.

Surface temperature measurement can often be problematic, especially when dealing with space limitations and the need for quick responses to changes in temperature. The customer needed a more reliable method for monitoring the surface temperature of a pipe, which was proving difficult with their existing approach.

Customer Pain Points

The customer’s existing temperature measurement method was unreliable and resulted in erratic readings. Additionally, the space limitations in the application made it difficult to install alternatives. This highlighted the need for a different approach to sensor type and design.

Temperature Measurement Challenges

After assessing the application and the current sensor setup, we discovered that the customer was using a Pt100 sensor laid parallel to the pipe. However, a lack of insulation or lagging around the sensor, due to the limited space, was contributing to inaccurate temperature readings.

While Pt100 sensors offer high accuracy, thermocouples are often a more practical solution for many temperature measurement applications. After explaining the advantages and limitations of both sensor types, the customer agreed that thermocouples would be the best solution for their needs, particularly as they could easily change the inputs on their temperature controller to accept thermocouples.

Thermocouple Sensor Solution

Sensor Type – Adjustable Ring Thermocouple, Type T, Direct Contact style (No Lagging required).

Why this sensor? – The pipe temperature was around 135°C, so a type T thermocouple was well suited to this temperature range and has an accuracy of +/-0.5°C. We recommended a grounded junction as this provides an even quicker response time than an insulated junction. Grounded junctions are less common and if you were to have any potential electrical interference then this would not be the best option. On this occasion there was no problem with electrical noise.

Finally, as the sensor was designed for direct contact with the pipe, there was no need for insulation, making the installation process quicker and easier.

Results and Conclusions

The Type T thermocouple successfully served as proof of concept for this temperature measurement application. It has since replaced Pt100 sensors in similar setups, proving to be an easy-to-install, reliable, and cost-effective solution with fast response times. The thermocouples have significantly reduced costs and improved the overall efficiency of the temperature monitoring process.

Results:

• Reliable Temperature Monitoring: Consistent and accurate readings
• Quick Installation: No insulation needed, reducing installation time
• Cost-Effective: Reduced overall costs compared to Pt100 sensors

Final Thoughts

This solution resolved the customer's temperature measurement challenges and has been successfully rolled out across multiple applications. Given its ease of use, reliability, and quick response time, this thermocouple design has proven to be an excellent alternative to traditional Pt100 sensors.

Further Reading

Learn more about Surface thermocouples
Explore the unique thermocouple designs available for various surface temperature measurement applications.

See our range of thermocouples for demanding applications
Discover designs of thermocouples for use in diverse and challenging environments.

Why calibrate thermocouples in a UKAS Accredited Laboratory?
Understand the significance of calibration in achieving precise measurements.