INTRODUCTION

• The accurate measurement of temperature is vital across abroad spectrum of human

activities,
 Including industrial processes Manufacturing;
(e.g. making steel)
 Health and safety.
• In fact, in almost every sector, temperature is one of the key parameters to be
measured.
• Different people will have different perceptions of what is hot and what is cold.
Temperature ?
• scalar quantity
• Degree of hotness or coldness
• Molecular K.E. increase = Temperature increase
Heat ?
• Form of energy.
• Measured in calories or BTUS[British Thermal Units].
How is heat transferred?
• Conduction
• Convection Convection is the movement of heat by a liquid or gas medium.
• Radiation Radiation, on the other hand, does not rely upon any contact between
the heat source and the heated object. Solar radiation is the most obvious example.
Scale
Temperature - measure of the thermal energy.
Measured in degrees [o]using scales.
• Fahrenheit.[oF]
• Celsius or centigrade. [oC]
• Kelvin .[oK] 
• In the year 1821, a physicist namely “Thomas Seebeck” revealed that when two
different metal wires were linked at both ends of one junction in a circuit when the
temperature applied to the junction, there will be a flow of current through the circuit
which is known as electromagnetic field (EMF).
• The energy which is produced by the circuit is named the Seebeck Effect.

What is a Thermocouple?
The thermocouple can be defined as a kind of temperature sensor that is
used to measure the temperature at one specific point in the form of the
EMF or an electric current. This sensor comprises two dissimilar metal
wires that are connected together at one junction. The temperature can be
measured at this junction, and the change in temperature of the metal wire
stimulates the voltages.

Thermocouple
The amount of EMF generated in the device is very minute (millivolts), so
very sensitive devices must be utilized for calculating the e.m.f produced in
the circuit. The common devices used to calculate the e.m.f are voltage
balancing potentiometer and the ordinary galvanometer. From these two, a
balancing potentiometer is utilized physically or mechanically.
Thermocouple Working Principle
The thermocouple principle mainly depends on the three effects namely
Seebeck, Peltier, and Thompson.
See beck-effect
This type of effect occurs among two dissimilar metals. When the heat
offers to any one of the metal wires, then the flow of electrons supplies
from hot metal wire to cold metal wire. Therefore, direct current stimulates
the circuit.
Peltier-effect
This Peltier effect is opposite to the Seebeck effect. This effect states that
the difference of the temperature can be formed among any two dissimilar
conductors by applying the potential variation among them.
Thompson-effect
This effect states that as two disparate metals fix together & if they form
two joints then the voltage induces the total conductor’s length due to the
gradient of temperature. This is a physical word that demonstrates the
change in rate and direction of temperature at an exact position.

Construction of Thermocouple
The construction of the device is shown below. It comprises two different
metal wires and that are connected together at the junction end. The
junction thinks as the measuring end. The end of the junction is classified
into three type’s namely ungrounded, grounded, and exposed junction.

Thermocouple Construction
Ungrounded-Junction
In this type of junction, the conductors are totally separated from the
protecting cover. The applications of this junction mainly include high-
pressure application works. The main benefit of using this function is to
decrease the stray magnetic field effect.
Grounded-Junction
In this type of junction, the metal wires, as well as the protection cover, are
connected together. This function is used to measure the temperature in
the acidic atmosphere, and it supplies resistance to the noise.
Exposed-Junction
The exposed junction is applicable in the areas where a quick response is
required. This type of junction is used to measure the gas temperature. The
metal used to make the temperature sensor basically depends on the
calculating range of temperature.
Generally, a thermocouple is designed with two different metal wires
namely iron and constantan that makes in detecting element by connecting
at one junction that is named as a hot junction. This consist of two
junctions, one junction is connected by a voltmeter or transmitter where the
cold junction and the second junction is associated in a process that is
called a hot junction.
How Does a Thermocouple Work?
The thermocouple diagram is shown in the below picture. This circuit can be
built with two different metals, and they are coupled together by generating
two junctions. The two metals are surrounded by the connection through
welding.
In the above diagram, the junctions are denoted by P & Q, and the
temperatures are denoted by T1, & T2. When the temperature of the
junction is dissimilar from each other, then the electromagnetic force
generates in the circuit.

Thermocouple Circuit
If the temperate at the junction end turn into equivalent, then the
equivalent, as well as reverse electromagnetic force, produces in the
circuit, and there is no flow of current through it. Similarly, the temperature
at the junction end becomes imbalanced, then the potential variation
induces in this circuit.
The magnitude of the electromagnetic force induces in the circuit relies on
the sorts of material utilized for thermocouple making. The entire flow of
current throughout the circuit is calculated by the measuring tools.
The electromagnetic force induced in the circuit is calculated by the
following equation
E = a (∆Ө) + b (∆Ө)2
Where ∆Ө is the temperature difference among the hot thermocouple
junction end as well as the reference thermocouple junction end, a & b are
constants
Thermocouple Types
In before going with a discussion of thermocouple types, it has to be
considered that thermocouple needs to be protected in a protective case to
isolate from the atmospheric temperatures. This covering will significantly
minimize the corrosion impact on the device.
So, there are many types of thermocouples. Let us have a detailed look at
those.
Type K – This is also termed as Nickel-Chromium/Nickel-Alumel type of
thermocouple. It is the most generally used type. It has the features of
enhanced reliability, preciseness, and inexpensive and can operate for
extended temperature ranges.

Type K Thermocouple
The temperature ranges are:
Thermocouple grade wire – -454F to 2300F (-2700C to 12600C)
Extension wire (00C to 2000C)
This K-type has an accuracy level of
Standard +/- 2.2C or +/-0.75% and the special limits are +/- 1.1C or 0.4%
Type J – It is a mix of Iron/Constantan. This is also the most used type of
thermocouple. It has the features of enhanced reliability, preciseness, and
inexpensive. This device can be operated only for lesser temperature
ranges and has a short lifespan when operated at a high range of
temperatures.
 J Type
The temperature ranges are:
Thermocouple grade wire – -346F to 1400F (-2100C to 7600C)
Extension wire (00C to 2000C)
This J-type has an accuracy level of
Standard +/- 2.2C or +/-0.75% and the special limits are +/- 1.1C or 0.4%
Type T – It is a mix of Copper/Constantan. The T type thermocouple holds
increased stability and is generally implemented for lesser temperature
applications like ultra-low temperature freezers and cryogenics.

T Type Thermocouple
The temperature ranges are:
Thermocouple grade wire – -454F to 700F (-2700C to 3700C)
Extension wire (00C to 2000C)
This T-type has an accuracy level of
Standard +/- 1.0C or +/-0.75% and the special limits are +/- 0.5C or 0.4%
Type E – It is a mix of Nickel-Chromium/Constantan. It has a greater signal
ability and improved accuracy when compared with that of Type K and J
thermocouples when operated at ≤ 1000F.
 E Type
The temperature ranges are:
Thermocouple grade wire – -454F to 1600F (-2700C to 8700C)
Extension wire (00C to 2000C)
This T-type has an accuracy level of
Standard +/- 1.7C or +/-0.5% and the special limits are +/- 1.0C or 0.4%
Type N – It is considered as either Nicrosil or Nisil thermocouple. The
temperature and accuracy levels of type N are similar to type K. But this
type is more expensive than type K.

N Type
The temperature ranges are:
Thermocouple grade wire – -454F to 2300F (-2700C to 3920C)
Extension wire (00C to 2000C)
This T-type has an accuracy level of
Standard +/- 2.2C or +/-0.75% and the special limits are +/- 1.1C or 0.4%
Type S – It is considered as either Platinum/Rhodium or 10%/Platinum
thermocouple. The S type of thermocouple is extremely implemented for
high-temperature range applications such as in Biotech and pharmacy
organizations. It is even used for lesser temperature range applications due
to its increased preciseness and stability.
 S Type
The temperature ranges are:
Thermocouple grade wire – -58F to 2700F (-500C to 14800C)
Extension wire (00C to 2000C)
This T-type has an accuracy level of
Standard +/- 1.5C or +/-0.25% and the special limits are +/- 0.6C or 0.1%
Type R – It is considered as either Platinum/Rhodium or 13%/Platinum
thermocouple. The S type of thermocouple is extremely implemented for
high-temperature range applications. This kind is included with a higher
amount of Rhodium than Type S that makes the device more costly. The
features and performance of type R and S are nearly similar. It is even
used for lesser temperature range applications due to its increased
preciseness and stability.

R Type
The temperature ranges are:
Thermocouple grade wire – -58F to 2700F (-500C to 14800C)
Extension wire (00C to 2000C)
This T-type has an accuracy level of
Standard +/- 1.5C or +/-0.25% and the special limits are +/- 0.6C or 0.1%
Type B – It is considered as either 30% of Platinum Rhodium or 60% of
Platinum Rhodium thermocouple. This is widely used in the higher range of
temperature applications. Of all the above-listed types, type B has the
highest temperature limit. At the increased temperature levels, the type B
thermocouple will hold increased stability and accuracy.
 B Type Thermocouple
The temperature ranges are:
Thermocouple grade wire – 32F to 3100F (00C to 17000C)
Extension wire (00C to 1000C)
This T-type has an accuracy level of
Standard +/- 0.5%
The types S, R, and B are considered noble metal thermocouples. These
are chosen because they can function even at high-temperature ranges
providing great accuracy and a long lifetime. But, when compared with
base metal types, these are more expensive.
While choosing a thermocouple, one has to consider many factors that suit
their applications.
 Check what are the low and high temperature ranges necessary for your
application?
 What budget of the thermocouple to be used?
 What percentage of accuracy to be used?
 In which atmospheric conditions, does the thermocouple is operated
such as inert gaseous or oxidizing
 What is the level of response that it is expected which means that how
quickly the device needs to respond to the temperature changes?
 What is the lifetime period that is required?
 Check before the operation that the device is immersed in water or not
and to which level of depth?
 Will the utilization of the thermocouple either to be intermittent or
continuous?
 Will the thermocouple be subjected to twisting or flexing all through the
device lifetime?
How Do You Know If You Have a Bad Thermocouple?
In order to know whether a thermocouple is working perfectly, one needs to
perform testing the device. Before going with the replacement of the
device, one has to check that it is actually functioning or not. To do this, a
multimeter and basic knowledge of electronics are completely enough.
There are mainly three approaches to testing the thermocouple using a
multimeter and those are explained as below:
Resistance Test
To perform this test, the device has to be placed in a gas appliance line
and the equipment required is digital multimeter and crocodile clips.
Procedure – Connect the crocodile clips to the sections in the multimeter.
Attach the clips on both ends of the thermocouple where one end will be
folded into the gas valve. Now, switch on the multimeter and note down the
reading options. If the multimeter displays ohms in small order, then the
thermocouple is in perfect working condition. Or else when the reading is
40 ohms or more, then it is not in good condition.
Open Circuit Test
Here, the equipment used is crocodile clips, a lighter, and a digital
multimeter. Here, instead of measuring the resistance, voltage is
calculated. Now, with the lighter heat up one end of the thermocouple.
When the multimeter displays voltage in the range of 25-30 mV, then it is
working properly. Or else, when the voltage is close to 20mV, then the
device has to be replaced.
Closed Circuit Test
Here, the equipment used is crocodile clips, thermocouple adapter, and
digital multimeter. Here, the adapter is placed inside the gas valve and then
the thermocouple is placed to one edge of the adapter. Now, switch on the
multimeter. When the reading is in the range of 12-15 mV, the device is in
proper condition. Or else when the voltage reading drops below 12mV, it
indicates a faulty device.
So, using the above testing methods, one can find out whether a
thermocouple is working properly or not.
Advantages & Disadvantages
The advantages of thermocouples include the following.
 Accuracy is high
 It is Robust and can be used in environments like harsh as well as high
vibration.
 The thermal reaction is fast
 The operating range of the temperature is wide.
 Wide operating temperature range
 Cost is low and extremely consistent
The disadvantages of thermocouples include the following.
 Nonlinearity
 Least stability
 Low voltage
 Reference is required
 least sensitivity
 The thermocouple recalibration is hard
Applications
Some of the applications of thermocouples include the following.
 These are used as the temperature sensors in thermostats in offices,
homes, offices & businesses.
 These are used in industries for monitoring temperatures of metals in
iron, aluminum, and metal.
 These are used in the food industry for cryogenic and Low-temperature
applications. Thermocouples are used as heat pumps for performing
thermoelectric cooling.
 These are used to test temperature in chemical plants, petroleum plants.
 These are used in gas machines for detecting the pilot flame.
What is the Life Span?
The lifespan of the thermocouple is based on the application when it is
utilized. So, one cannot specifically predict the thermocouple life period.
When the device is maintained properly, the device will have a long life
span. Whereas, after continual usage, they might get damaged because of
the aging effect.
And also, because of this, the output performance will be lowered and the
signals will have poor efficiency. The price of the thermocouple is also not
high. So, it is more suggested to modify the thermocouple every 2-3 years.
The measurement of thermocouple output can be calculated by using
methods like a multimeter, potentiometer, and amplifier by output devices.
The main purpose of the thermocouple is to build consistent & direct
temperature measurements in several different applications.