21/09/2017 What to Choose RTD or Thermocouple ?

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Home / Instrumentation Design / What to Choose RTD or Thermocouple ?

INSTRUMENTATION DESIGN TEMPERATURE MEASUREMENT

What to Choose RTD or Thermocouple ?

March 28, 2016 S Bharadwaj Reddy 1 Comment

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Thermocouples (TCs) and resistance temperature detectors (RTDs) are the most widely used temperature sensors in automation
and process control. They are found embedded in motors, valves, turbines, bearings, and a host of other devices. Most smart
instruments such as owmeters, pressure transmitters, and level transmitters also have an embedded temperature sensor-used
to correct the primary measured variable or for process control.

Theories of operation

A thermocouple consists of two wires of dissimilar metals, joined at both ends-at the reference point outside the process (cold Categor
junction) and at a junction at the point of measurement (hot junction). The metals react di erently to temperature changes and
generate an electromotive force (EMF) voltage based on the temperature di erential between the junctions (the Seebeck e ect). Select Ca
Aresistance temperature detectoris based on the principle that electrical resistance in a wire increases with temperature.

In both cases, the sensor is wired to a transducer or signal conditioner that has been calibrated to accept the input voltage or
resistance, calculate the correct temperature, and output it as a 4-20 mA, mV, or digital signal to an automation system.

The above is pretty basic, taught in every Instrumentation class. But it poses the rst question to consider when choosing a
sensor: How do you wire the sensor to the transducer, signal conditioner, or automation system? Such devices and systems, being
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21/09/2017 What to Choose RTD or Thermocouple ? Instrumentation Tools
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electronic in nature, need to be mounted in a reasonably safe location, away from high temperatures.
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TCs must be wired with thermocouple extension wire, which is the same as the wire used in the TC. For example, a Type K TC uses
a wire of nickel-chromium connected at the sensing junction to a wire of nickel-alumel. Extension wire must be the same
composition, that is, one nickel-chromium and one nickel-alumel wire. In general, longer runs of extension wire are discouraged, Ja
as the wires act as an antenna, making the measurement more susceptible to electromagnetic and radio frequency interference.
Cost may also be an issue when dealing with long extension wires, especially ones with exotic materials (e.g., Type R TCs). In Th
certain cases, a compensation cable made up of a less expensive material with similar EMF properties to the TC can be used.

RTDs, on the other hand, can be wired with standard cable for much longer distances; however, they are typically limited by issues
related to self-heating errors. In both cases, the extension wiring must be shielded against electrical noise in the plant. Note that
TC extension wire is more susceptible to noise than RTD cable.

Temperature Measuring Environments

Temperature sensing is often done in unfriendly environments, such as corrosive, oxidizing, or reducing atmospheres, often
accompanied by severe vibration and electrical noise. When selecting an RTD or TC, the environment must be taken into account.
If the process environment poses a high degree of risk of sensor failure, a thermowell made of a material that is suitable for the
process environment should be considered.

Vibration-Wire-wound RTDs are most susceptible to vibration. Wire-wound RTDs can fail from mechanical stress in high-vibration
applications and should not be used. Thin- lm RTDs have a higher tolerance for vibration, but they are not as good as TCs, which
Like our
have the highest resistance to vibration.

Electrical noise-As noted above, the extension wires for both RTDs and TCs are susceptible to electrical noise. In high-noise
environments, extension wires should be sheathed, shielded, grounded, and kept as short as possible. An RTD is a better choice in
high-noise environments. Like P

Harsh environments-When dealing with a harsh environment, check to see if the RTD or TC sensor manufacturer o ers protection
against adverse conditions. Wire-wound RTDs in their protective casings are quite rugged and immune to most environmental Latest C
problems. For additional protection, RTDs can be coated with per uoroalkoxy (PFA) polytetra uoroethylene for use in plating
baths, highly pressurized systems, or similar applications. RTD extension wires are available with polyvinyl chloride, PFA, or S Bharadw
Hi, Please
berglass insulation for protection.
Clear You

TUONGR
TCs, especially those with metal cases, are much more rugged than RTDs and better able to deal with corrosive or oxidizing
Hi Mr. Red
atmospheres. When exposed TC junctions are used, special care must be taken in harsh environments.
couple fav

S Bharadw
TCs are classi ed by type, i.e., Types E, J, K, N, T, S, R, and B. Each type is suitable for a speci c temperature range from -201C to Hi, Please
1700C, and the construction of each makes it suitable for use in various environments: HERE...

balakrish
Type E: suitable for vacuum, inert, mildly oxidizing, or reducing atmospheres Please sen
Type J: may be used, exposed or unexposed, where there is a de ciency of free oxygen bala1243@
Type K: typically requires metal or ceramic protection ANAS
Type N: resists oxidation where sulfur is present thank you
Type T: can be used in either oxidizing or reducing atmospheres informatio
Types S, R, B: should always be protected with a ceramic tube, a secondary tube of porcelain, and a silicon carbide or metal S Bharadw
outer tube as conditions require Check you
Connect H

Major Considerations involved in selecting a TC or RTD ANAS

thanks fo
con rm th
Measuring range: RTDs can measure temperatures up to 1000C, but it can be di cult to get accurate measurements from an
RTD at temperatures above 400C. TCs can measure up to 1700C. The generally accepted rule is: for temperatures below 850C,
use an RTD for accuracy; for temperatures above 850C, use a TC. Industrial measurements typically are 200C to 400C, so an
RTD may be the best choice in that range.

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21/09/2017 What to Choose RTD or Thermocouple ? Instrumentation Tools

Response time: While both sensors respond quickly to temperature changes, TCs are faster. In certain cases, however,
ALL ANIMATION BASICS MEASUREMENT CONTROL SYSTEMS Q & A ELECTRONICS ELECTRICAL TOOLS MORE
manufacturing processes allow for production of thin- lm RTDs with greatly improved response times.

Dimensions:Both sensors are fairly small, at about 0.5 mm diameter. If space is an issue for mounting a sensor, check with the
supplier for size and mounting options.

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Vibration: In general, TCs are less susceptible to vibration than RTDs. However, in certain manufacturing processes thin- lm RTDs
can be produced that are capable of much greater vibration resistance than standard RTDs.

Self-heating: An RTD is made of very ne wires or very ne coatings, and requires a voltage from a power supply-TCs do not Inst Too
require power. Although the power required is only 1 mA to 10 mA, it can cause the platinum element in the RTD to heat up, thus
a ecting accuracy of the measurement. If long extension wires are used, more power may be needed to overcome resistance in
the wires, thus increasing the self-heating problem.

Stability: The long-term stability of an RTD is very good, meaning that its readings will be repeatable and stable for a long time.
TCs, on the other hand, tend to drift. The EMF produced by a TC can change over time because of oxidation, corrosion, and other
changes in the metallurgical properties of the sensing elements. TC drift is irreversible, and some provision is needed to detect it,
Languag
such as software or testing for loop resistance.
Select La

Accuracy: As a general rule, RTDs are more accurate than TCs. RTDs can produce accuracy of 0.1C, while TCs are typically accurate
to only 1C.

Although not a technical issue, TCs are considerably less expensive than RTDs due primarily to lower production costs. Depending
on the number of sensors needed for a particular application, this could be a major factor.

Careful selection of the right temperature sensing technology is essential to ensure the best performance, reliability, and cost
e ectiveness. Suppliers that sell both TCs and RTDs are often good sources of information when deciding which type of sensor to
use.

Why choose RTD over Thermocouple ?

Better Accuracy & Repeatability

RTD signal less susceptible to noise

Better linearity
RTD can be matched to transmitter(Interchangeability error eliminated)
CJC error inherent with T/Cs; RTDs lead wireresistance errors can be eliminated

Better Stability

T/C drift is erratic and unpredictable; RTDs driftpredictably

T/Cs cannot be re-calibrated

Greater Flexibility
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21/09/2017 What to Choose RTD or Thermocouple ? Instrumentation Tools

Special extension wires not needed

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Dont need to be careful with cold junctions

Why choose thermocouple over RTD ?

Applications for Higher Temperatures

Above 1100F

Lower Element Cost

Cost is the same when considering temperaturepoint performance requirements

Faster response time

Insigni cant compared to response time for T-Welland process

Perceived as more rugged

Rosemount construction techniques produceextremely rugged RTD

RTD vs Thermocouple Comparison Chart

Also Read: How to Test a Thermocouple

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Author

S Bharadwaj Reddy
O cer - Instrumentation, GSPC - Oil & Gas, Kakinada, India.

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One comment

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21/09/2017 What to Choose RTD or Thermocouple ? Instrumentation Tools

sharnee 2 months ago

ALL ANIMATION BASICS MEASUREMENT CONTROL SYSTEMS Q & A ELECTRONICS ELECTRICAL TOOLS MORE
can you please tell me on the RTD chart. How much temperature is how much resistance?

Reply

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