Temperature Measuring

Instruments Selection &

Application

Rev. # – Mmm YYYY

Table of Contents
 Infrared Pyrometer
 Course Learning Objectives
 Temperature Control
 Introduction
 Petrofac Work Process
 Thermocouples (TC’s)
 Sample Data Sheet for Temperature
 RTD’s Gauge and Transmitter
 RTD’s & TC’s Comparison  Wake Frequency
 Thermistors  Lessons Learned
 Choice Between RTD’s TC’s &  QMS Documents
Thermistors
 Petrofac Documents
 Thermowells Design & Material
 International Standards
 Bimetallic Thermometer
 References
 Filled Thermal System
 Review
 Dial Thermometer

2
Course/Learning Objectives

3
INTRODUCTION

4
Introduction

 How to select a Temperature Control Device or System:

• Standards
• Cost
• Accuracy
• Stability over time (esp. for high temperatures)
• Sensitivity
• Size
• Contact/non-contact
• Temperature range
• Fluid
• Any particular functional requirements (like fast response, surface
temperature measurement, average temperature etc.)

5
THERMOCOUPLES (TC’s)

6
Thermocouples (TC’s)

 Standard Thermocouple Alloy Conductor Combinations:

7
Thermocouples (TC’s)

 A graph of temperature vs. voltage shows thermocouple characteristics

are not perfectly linear:

8
Thermocouple Resolution

 Temperature Change From 500 deg F to 510 deg F:

9
Thermocouple

 Response time comparison

among the different thermocouple
tip types:

10
Thermocouple

 TC Conductor Combinations, operating ranges and color coding:

11
Thermocouples- Application Notes
 As a general rule of thumb, the below listed thermocouple material
combinations should be selected for the temperatures indicated:

• Chromel Constantan, Type E for -200 to +1000°C

• Copper Constantan, Type T for -250 to + 400°C
• Iron Constantan, Type J for -200 to 700°C
• Chromel Alumel, Type K for -200 to 1372°C
• Plat/Plat 10% Rhodium, Type S for 0 to 1300°C
 All thermocouple secondary instruments such as transmitters, indicators,
and/or recorders shall have built-in cold junction compensation, burnout
protection features and thermocouple linearization. Generally
considerations for burnout protection is upscale for indicating
instruments and upscale or downscale for control loops depending on
the failsafe action of the final control element e.g. control valve.
Thermocouple linearization ensures that the thermocouple voltage is
adjusted to be linear with the temperature being measured.

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Advantages of Thermocouples

 Fast Response.

 Point sensitivity (not necessarily an advantage).

 Suitability for remote measurement.

 Wide Range.

 Freedom of effect by wire length and diameter provided that a high-

impedance secondary instrument is used.

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Disadvantages of Thermocouples

 Need for cold-junction compensation.

 Need for extension wire.
 Susceptibility to error from extension wire termination
temperature gradient.
 Possible sensitivity to signal noise.
 Need for secondary instrument.
 Need for thermocouple transmitter on long runs.
 Need to avoid intermediate junctions of dissimilar metals.
 Inability to accurately measure temperature over a narrow span.
 Unsuitability for bare use in electrically conducting substance.

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RTD’s

15
RTD Selection
 Temperature Notes
of turbine inlet steam whose design temperature is close
to the maximum allowable temperature for piping and equipment.

 Temperature of permanent turbine test points.

 Average temperature of nuclear reactor coolant.

 Average combustion turbine inlet air temperature.

 Condenser cooling water inlet to outlet temperature gain.

 Motor stator winding and bearing temperatures.

 Applications requiring high accuracy like Custody flow metering and Tank
gauging.

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Advantages of RTD
 High accuracy.

 Very-good-to-excellent stability and reproducibility.

 Interchangeability.

 Ability to be matched to close tolerances for temperature-difference

measurements.

 Ability to measure narrow spans.

 Suitability for remote measurement.

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Disadvantages of RTD
 Susceptibility to mechanical damage.

 Need for lead wire resistance compensation.

 Sometimes expensive.

 Susceptibility to self-heating error.

 Susceptibility to signal noise.

 Unsuitability for bare use in electrically conducting substance.

 Generally not repairable.

 Need for power supply.

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RTD – Types , Ranges, Accuracy

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RTD’s & TC’s COMPARISON

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RTDs and T/Cs : Properties Comparison

21
RTD vs TC Accuracy Overview

22
THERMISTORS

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Thermistors
 Thermistors also measure the change in resistance with temperature.

 Thermistors are very sensitive (up to 100 times more than RTDs and
1000 times more than thermocouples) and can detect very small
changes in temperature. They are also very fast.

 Due to their speed, they are used for precision temperature control and
any time very small temperature differences must be detected.

 They are made of ceramic semiconductor material (metal oxides).

 The change in thermistor resistance with temperature is very non-linear.

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CHOICE BETWEEN RTD’s TC’s & THERMISTORS

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Choice Between RTDs, Thermocouples,
Thermistors

 Cost – thermocouples are cheapest by far, followed by RTDs

 Accuracy – RTDs or thermistors
 Sensitivity – thermistors
 Speed - thermistors
 Stability at high temperatures – not thermistors
 Size – thermocouples and thermistors can be made quite small
 Temperature range – thermocouples have the highest range, followed by
RTDs
 Ruggedness – thermocouples are best if your system will be taking a lot
of abuse

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THERMOWELL DESIGN & MATERIAL

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Thermowell Design & Material
 Considerations for Thermo well selection:

• Process temperature

• Environment / Process media

• Fluid or gas pressure

• Pipe or vessel size

• Flow velocity

• Based on the above thermo well length and diameter are decided.

• Insertion length is normally within mid two third of the pipe inner diameter.
Smaller lengths are used for high velocity process stream.

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Thermowell- Application Notes
Interface
 In case, if material of construction (MOC) of Thermo well is different than
the pipe class material, the flange rating of Thermo well shall be suitable
& withstand pipe line design condition i.e. pressure & temperature.

 For example, if pipe class is Carbon Steel (CS) and MOC for Thermo
well is SS316, then Instrument Engineer should check the rating required
for Thermo well based on line design pressure & temperature.

 Incase if the flange rating of Thermo well is different than the pipe rating ,
it should be communicated to Piping & Process to take necessary action
at their end ( Provide nozzle with same rating as thermo well rating .)

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Thermowell- Application Notes
Interface
 Requirement of Insulating Gasket shall be communicated to Mechanical
and process in case material of construction for thermo well is different
than piping material.

 In case, if Thermo wells are with collar to protect it from failure due to
high vibration, then the nozzle ID shall be checked with respect to collar
diameter. This information should be communicated to Mechanical to
avoid any mismatch during installation.

 Care shall be taken when Thermo wells are selected with collars for lined
vessels and cladded vessels. In these cases nozzle ID shall be checked
with equipment drawings to avoid mismatch of Thermo well during
installation.

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Thermowell- Application Notes
Interface
 Additional nozzles due to SIL study: It is possible that SIL review may
demand additional temperature instrument for shutdown loops. As the
nozzles on the equipment are normally frozen much before the SIL
study, it is necessary to see whether the Feed documents like Feed
P&IDs which are used to prepare the detailed P&IDs have already
considered the recommendation of Feed stage SIL review.

 Requirement of Thermo well connections (Flanged, Threaded or

Welded) shall be checked as per specific project requirement.

 NDE requirement for Thermo well shall be checked and specify as per
piping requirement.

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Thermowell- Application Notes
Interface
 When the Thermo wells are installed on the equipment & vessel, care
shall be taken while deciding insertion length of these Thermo wells to
avoid fouling with equipment/vessel internals.
 Equipment/vessel internal arrangement drawing & nozzle location shall
be reviewed by Instrument engineer to avoid any mismatch.
 Otherwise it is necessary to review with the Process group for safety
critical applications where the P&IDs do not indicate multiple
temperature instruments participating in voting logic. If necessary
additional nozzles should be provided as spare for use in future in case it
is recommended by the SIL study at a later date.
 To meet the SIL level, two or more than two temperature elements may
be required in a safety protection loop. Duplex temperature elements
may be used for such purpose; however use of duplex temperature
element (i.e. two temperature elements in a single thermo well or
encapsulation) must be carefully reviewed, as the duplex element may
be more vulnerable to common mode failure than two simplex elements.

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Thermowell- Application Notes
Interface
 If the temperature to be measured is not required for automatic control,
recording, or indication in the control room, a bimetallic thermometer
should be used.

 Bimetallic thermometers are generally available with 2, 3, 4, 5 or 6-inch

concentric dials, preferably of the non-parallax type (i.e. not visually
misaligned or displaced), with external zero adjustment, and 1/2-inch
mounting thread.

 The stem should be of Stainless Steel SS316), having a 1/4-inch

diameter, and of a customized length to suit process requirements.

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Thermowell- Application Notes
Interface

 The dial orientation may be bottom or back, known as "straight" or

"angle", respectively. However, an all angle adjustable swivel connection
is preferred in order to enable the dial to be read from the most
convenient location.
 Bimetallic thermometers are not recommended for continued use above
426°C. The thermal stability of the bimetallic thermometer is an inherent
characteristic of the metals used and continued operation cannot be
assured above 471°C.

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BIMETALLIC THERMOMETERS

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Bimetallic Thermometers- Selection Notes

 Thermometers for auxiliary service applications (compressor lube oil,

etc.) & control valve/ESDV may be a 2” or 3" diameter when supplied as
a component in a package.
 Standard ranges shall be selected in order to avoid too many ranges in
specific project.
 The standard ranges available in the market almost cover all process
temperature measurement requirements. All Manufacturers have lists of
standard ranges that should be used to avoid extra charges for non-
standard ranges.

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FILLED THERMAL SYSTEM

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Filled Thermal System- Selection Notes
 Occasionally a temperature transmitter, recorder and/or controller has to
be installed in a location or under circumstances where electrical power
is not available or inconvenient to use, while instrument air (at 20 psig or
above) is present. Under these circumstances, a filled system
thermometer is an ideal choice because it can be combined with a
commercially available pneumatic transmitter, recorder and/or controller.

 If a local temperature measurement is in an inaccessible location so that

a bimetallic thermometer cannot be easily read, a filled system
thermometer is recommended because its capillary tubing can be led to
an indicator that can be installed/located in a convenient place. Armored
capillary tubing (generally of SS316), properly supported throughout its
length, to be used for connecting the bulb to the indicator.

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Filled Thermal System- Selection Notes

 A liquid filled thermometer should be considered for corrosive /

hazardous areas or where vibration is a problem.

 Where process lines are subject to vibration or run in inaccessible

locations, the use of a filled-system type indicating thermometers with
capillary extensions shall be considered.

 Project specific requirement such as dial size, stem material, stem

diameter, immersion length, accuracy etc shall be selected based on
specific project requirement.

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DIAL THERMOMETERS

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Dial Thermometers- Standard ranges

 Standard ranges shall be selected in order to avoid too many ranges in

specific project.
 Typical standard ranges listed in ASME B40.200 (B40.3), DIN 16203 and
BS EN 13190 is listed below:

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INFRARED PYROMETERS

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Infrared Pyrometer-Selection Notes
 The Infrared Pyrometer can measure temperatures in the range from
-100 to 3500 deg C (standard) and up to 5000 deg C with an accuracy of
± 1/2 % full scale. Therefore, it is used when a temperature
measurement must be made that is above the capability of
thermocouples.

 The Infrared Pyrometer is also useful when the temperature

measurement must be made at a location that is difficult to reach, either
because it is in a harsh (usually high temperature) environment or there
are no means of access to this particular location.

 Permanent installations of Infrared Pyrometers are usually made to

measure the high temperatures of flames, furnaces, kilns, etc. If the
installation is located near the point of measurement the Infrared
Pyrometer must be water or air cooled.

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Infrared Pyrometer-Selection Notes

 An infrared Pyrometer will measure the temperature of what it sees,

therefore it must be carefully aimed to read material temperature and not
vessel wall or flame temperature. Units are available with narrow to
broad target areas.

 If steam, dust or smoke partially obscures the target, such as in a kiln,

roll stand or coking furnace, a two-color ratio pyrometer can be used to
block out the effect of the interfering medium.

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TEMPERATURE CONTROL

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Basic Temperature Control

• Controlled variable: temperature (desired output)

• Input variable: temperature (measured by thermometer in theromostat)
• Setpoint: user-defined desired setting (temperature)
• Manipulated variable: natural gas valve to furnace (subject to control)

• Furnace
• House is too cold
• furnace turns on
• heats the house

• is • house temperature
temperature
• below
• measured
setpoint?

• setpoint = 72°F

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PETROFAC WORK PROCESS

47
PETROFAC WORK PROCESS
Temperature Measurement System
 Basic Data:
• Check tag no. of the temperature measuring instrument from P&ID. Example
– TIT-100 or TI/TG-100

• Check type of the application required i.e. local indication or Remote

indication/control from the P&ID & legend sheet. Select temperature gauge or
RTD or Thermocouple accordingly

• Check project instrument design philosophy document (if available) to verify

the instrument type required i.e. RTD or T/C for remote applications.

• Check suitability of the instrument with respect to the application. (This is an

optional check and may be carried out only if required.)

• Check with respect to process data such as temperature to decide RTD or

T/C.
48
PETROFAC WORK PROCESS
Temperature Measurement System
 Preparation of datasheet:
• Use PECIL's standard Instrument Data Sheets available in Intools for
preparation of datasheet for the particular instrument.

• To complete the Instrument data sheet, inputs related to process data is

required. This will be entered by the process group in the process module of
Intools.

• Check piping specification for the particular line in which the instrument is
being installed and enter the material of construction, flange rating, flange
facing etc for thermowells. MOC for thermowell shall be minimum SS316.
(Refer project Piping specification for this requirement.)

• Complete the datasheet by filling all other required details such as accuracy,
type of instrument, immersion length, output etc. (Piping & Instrument
interface drawing, Equipment internal arrangement drawings to be referred.).

49
PETROFAC WORK PROCESS
Temperature Measurement System

 Preparation of Inquiry Requisition (IR):

• Use PECIL's standard Inquiry Requisition Form for preparation of requisition
for the particular instrument.

• Complete the Inquiry Requisition by incorporating details such as scope of

supply for the vendor (example - manufacture, inspection, testing etc.), notes
and attaching relevant documents such as instrument datasheets,
specifications etc. Vendor Document Requirement (VDR) Form and Vendor
Quality Requirement (VQR) Form are mandatory attachments.

• Requirement of Wake Frequency calculation shall be indicated in the Inquiry

requisition. Fluid velocity shall be indicated in all the data sheets for thermo
wells.

50
TEMPERATURE GAUGE & TRANSMITTER DATA SHEET

51
Instrument Datasheet- Temperature Gauge

52
Instrument Datasheet- Temperature
Transmitter

53
WAKE FREQUENCY

54
Wake Frequency Calculation

 Example are illustrated to demonstrate the wake frequency calculation :

• wake frequency calculation.xls

 Some of parameter can increase the drag force are velocity and density
whereas Large thermo well surface areas and lengths also contribute to
increase this force. Calculations
• Thermowell
1) Ensure that:

55
LESSONS LEARNED

56
Lesson Learned- session 1

 Problem: Electrical Motor Bearing temperature RTD Cable routing

 Problem Statement: Motor Bearing RTD Cable routing was done by
Electrical due to its destination to Sub-station. Due to this the following
issues are faced
• RTD Cables are shown in Electrical Trench routing drawing along with
Electrical High Voltage cables by mistake.

• RTD Cables are laid inside Electrical Trench as per routing layout at Site.

• Error was identified during inspection & shifted to route in Instrument Trench

• Additional efforts & Man-hours are wasted to identify suitable route in

Instrument trench to match the cable cut length.

• Most of the Cables are re-ordered due to length mismatch when routed over
Instrument Trench.

57
Lesson Learned- session 1

 Problem Root Cause :Scope clarity and Implication of laying LV cable

along with HV cable was not evaluated during design.
 Highly reflective surfaces introduce a lot of error.

 Recommendation: Electrical Scope shall end in identifying the RTD

Cable quantities & its destination Cabinet. The Complete routing needs
to be done by Instruments & shall be reflected in Instrument Cable
Schedule. It,s the duty of Electrical to ensure & check Instrument Cable
Schedule for quantity of RTD Cable consideration along with providing
space in sub-station for routing this Cables with required segregation
from Other High-Voltage Cables.

58
Lesson Learned- session 2

 Problem: RTDs requirement for HV motors above 1000 KW

 Problem Statement: As per contract specification for HV/MV motors,
motor RTD protection is required only for motors above 1000kW rating.
Hence, RTD protection has not been considered for motors less than
1000kW rating during design engineering. However, it was observed that
all the HV/MV motor manufacturer provides RTD by default in their
design and their motor guarantee is valid only if the given RTD protection
is provided for the motors.
 Problem Root Cause :Restricting our scope within contract requirement.
 Recommendation: Irrespective of any clause specified in contract
specification, it is advisable to consider RTD protection for HV/MV
motors of all ratings, considering high ambient temp greater than 45
Deg.

59
QMS DOCUMENTS

60
QMS documents – Technical Bid evaluation

61
QMS documents – Datasheets

62
QMS documents – SUPPLIER DOCUMENT
REQUIREMENT LIST (SDRL)

63
PETROFAC DOCUMENTS REFERANCES

64
Petrofac Document References

65
INTERNATIONAL STANDARDS

66
International Standards

 North America
• NEMA (National Electrical Manufacturers Association), UL (Underwriters
Laboratories), CSA (Canadian Standards Association

67
References
 ISA MC 96.1: Temperature Measurement Thermocouples
 PIP PCETE001: Temperature Measurement Guidelines
 PIP PCFTE100: Thermo well Fabrication Details
 ASME PTC 19.3: Temperature Measurement
 ASME B40.200: Thermometers, Direct Reading and Remote Reading
 IEC751: Industrial Platinum Resistance Thermometers & Platinum
measuring Resistors.
 ISA-MC 96.1: Temperature Measurement Thermocouples
 WIKA Handbook for Pressure and Temperature Measurement.
 Liptak, Bela G. "Instrument Engineers' Handbook" : Process
Measurement.
 Claire Soares (McGraw-Hill) : “Process Engineering Equipment
handbook”

68
Review

Summary of topics covered.

69
QUESTIONS?

70