ELECTRICAL ENGINEERING DEPARTMENT

DEJ50063 - PROCESS MEASUREMENT

PRACTICAL WORK : 1 / 2 / 3 / 4 / 5 / 6

TITLE : Characterize the temperature sensor (RTD)

PROGRAMME : DJK5A

1. Tengku Nadzion Tengku Ibrahim

LECTURER :
2. Shellie Suzana Saad

GROUP REGISTRATION NO. STUDENTS' NAME

MEMBERS
S1 09DJK21F1011 MUHAMMAD ADAM HUSAINI BIN SHAHMINAN

S2 09DJK21F1017 HAZIQ HAZWAN BIN MAZLAN

S3 09DJK21F1029 ADI YUSNIZAM BIN SHAMSUL

S4

PRACTICAL SKILL EVALUATION (CLO2, PLO05)

ASPECT Excellent (5) Good (4) Average (3) Weak (2) Very Weak (1) Scale S1 S2 S3 S4
Student Student Student Student did notStudent did not
had/gathered all had/gathered had/gathered have/gather have/gather the
materials and most materials most materials, some of the needed
Student
was completely and do the however, they needed materials and
Preparedn X2
ready to do the practical work. needed extra materials to was nearly
ess [P2]
practical work. time to do so. perform unable to
practical work.perform the
practical work.
Followed Followed Nearly did not
Ability to Follow procedures with procedures with follow
Followed Usually followed
Procedures a high degree of limited procedures . X2
procedures. procedures.
[P3] effectiveness. effectiveness.

The task was The task was The task was The task was The task nearly
complete complete but complete but completed but was not
Task Completion according to the needed minor needed several needed several completed.
X4
[P4] criteria. modifications. minor major
modifications. modifications.

Student was Student was

Student was Student was Student was
able to able to able to unable to nearly unable to
Performing the
complete the complete the complete the complete task complete task
Practical Work X4
task without task with little
task with without major with assistance.
[P4]
assistance. assistance. moderate assistance.
assistance.
Display the Student is able Student is able Student is able Student is able Student is not
Complete to display the to to display the to display the able to display
Result [P4] complete result approximately complete result minimum result the result and
with an display the with a few with no no explanation X4
appropriate complete result explanation explanation given.
explanation with an
explanation
80%

B. LAB REPORT ASSESSMENT

Excellent (5) Good (4) Average (3) Weak (2) Very Weak (1) SCALE SCORE

Outstanding High level of Some ability to Minimal

ability to grasp ability to conceptualize Limited ability to awareness that
concepts and conceptualize essential ideas draw out external
Discussion Relate theory to essential ideas and relate concepts and concepts exist X3
practice and relate theory to relate theory to
theory to practice practice
practice
Conclusion Conclusion
includes Conclusion No conclusion
includes Conclusion
whether the includes what was included
whether the shows little
Conclusion findings was learned OR shows very X1
findings effort and
supported the from the general
supported the reflection.
objectives, experiment. statements only.
objectives and
 possible
sources of error, what was
and what was learned from
learned from the the experiment.
experiment
20%

STUDENTS S1 S2 S3 S4

Total marks 100%

 POLITEKNIK IBRAHIM SULTAN
JABATAN KEJURUTERAAN ELEKTRIK

Practical Work : 6

Assessment : Experiment 6

Topic : Characterize the temperature sensor(RTD)

Objective : To understand the working principle of RTD.

1. Study static and dynamic characteristics of RTD.
2. Study effect of various parameters on RTD performance.

Equipment : Simulator level tank

(www.vlab.co.in > Electrical Engineering > Sensors Modelling & Simulation Lab > List of
Experiments > Characterize the temperature sensor(RTD) > Find Simulator)

Theory :
Resistance Temperature Detector (RTD)

Resistance Temperature Detector (RTD), as the name implies, is a sensor used to measure temperature
by correlating the resistance with temperature. Most RTD elements consist of a length of fine coiled wire
wrapped around a ceramic or glass core. The element is usually quite fragile, so it is often placed inside a
sheathed probe to protect it. The RTD element is made from a pure metal as mentioned below. The material
property to have predictable change in resistance as the temperature changes, is used to determine
temperature.

Commonly used RTD Materials:

a. Platinum (most popular and accurate)

b. Nickel
c. Copper
d. Balco (rare)
e. Tungsten (rare)

Temperature calculations:

RTDs are manufactured from metals whose resistance increases with temperature. Within a limited
temperature range, its resistance increases linearly with temperature:

RT= Rref [1 + α (T - Tref)]

Where:

RT = resistance at temperature T
Rref = resistance at a reference temperature (Generally 0°C)
α = temperature coefficient of resistance (°C‾1)
Tref = setting to 0°C
T = temperature (°C)
Experiment 6A : Static Characteristics of RTD
Aim : Study the change in resistance of RTD probe depending on the process temperature.

Procedure :

a. Select the material of RTD you want to use. Temperature coefficient α for the same will be displayed
on the screen. Note this value.
b. Click on Rref to get the value of Rref for selected RTD. Note the same.
c. Click on Get Temperature. The temperature for which RT is to be found will be displayed.
d. Using formula calculate the value of RT and enter the answer in the box provided (up to 2 decimals
with rounding off). Submit the answer using submit button.
e. If your calculation is correct, go to step 3. Repeat the procedure min 3 times.
f. If your calculation is wrong, you will be asked to repeat the same. Please refer to GET FORMULA
tab and verify your calculations.
g. After finishing minimum 3 set of correct readings, you can see the graph by clicking on Plot.
h. When the graph is displayed click Next tab to repeat the procedure with different reference
resistance Rref value and with different materials.
i. Minimum 3 calculations are necessary to plot the graph.
j. Study the graphs for RTD performance with different reference resistance values and different
materials.

Experiment 6B: Dynamic characteristics

Aim : Study the dynamic response of RTD probe

In this experiment, Platinum RTD is used for calculating the time constant values. The response of RTD for
a step change in the input is plotted. The maximum temperature the RTD attains, is same as the
temperature displayed by Get Temperature tab.

Procedure :

1. Select the RTD as bare element (make it on). With the standard dimensions considered for bare
element, the time constant value will get displayed in the output box.
2. Verify this by using equation given under Get formula tab.
3. Now select the RTD dynamic performance with sheath. Select appropriate material and thickness
value. The time constant value will get displayed in the output box.
4. Verify this by using equation given under formula tab.
5. Observe the change in the time constant values with different materials with different thickness.
6. Now select the RTD dynamic performance with Thermowell. Select appropriate material, thickness
and filling material. The time constant value will get displayed in the output box when Thermowell
material, thickness and filling material is selected.
7. Verify this by using equation given under formula tab.
8. Observe the change in the time constant values with different materials with different thickness.
9. Also see the effect of change in filling material.
10. Click on plot button to observe the dynamic response (Time Vs Temperature).
11. Observe and verify response time of RTD which is generally 5 times the time constant value.
12. After completion of both the parts, you can proceed to Post Test to find out if you have understood
all aspects of the experiment.

Question :

1. What are different sources of errors in RTD measurement?

= Resistance Temperature Detectors (RTDs) serve as sensitive tools for measuring temperature,
yet several factors can introduce errors in their readings. Lead wire resistance, stemming from the
wires connecting the RTD to measurement devices, can add resistance to the circuit and skew
temperature measurements. Self-heating occurs when the current passing through the RTD
generates heat due to its resistance, potentially altering the measured temperature. Calibration drift, a
gradual change in the RTD's electrical properties over time, can result in inaccuracies. Environmental
influences, like temperature gradients, electromagnetic interference, or moisture exposure, may
impact accuracy. Mismatched or improperly calibrated transmitters and receivers could lead to
erroneous readings. Mechanical stress, caused by bending or stretching RTD wires, can alter
resistance and skew measurements. Non-linear characteristics, especially at extreme temperatures,
might deviate from expected linear behavior, affecting accuracy. Sensor aging due to prolonged use
or harsh conditions can also impact measurement precision. Insufficient excitation current supplied to
the RTD can cause resistance measurement inaccuracies, influencing temperature readings. Lastly,
issues within the measurement circuitry, such as inadequate shielding or grounding problems, can
introduce errors in the recorded values. Mitigating these errors involves using high-quality
components, regular calibration, proper installation, and implementing compensation techniques
where applicable to maintain accurate temperature measurements.

2. What is lead wire compensation?

= measurements caused by the resistance of the wires connecting the RTD sensor to the
measurement instrument. The electrical resistance of these connecting wires introduces inaccuracies
in the temperature readings, as it adds to the overall resistance in the circuit.

Lead wire compensation aims to negate these errors by employing a method that accounts for and
cancels out the resistance of the connecting wires. This compensation technique typically involves
using a three- or four-wire configuration in the RTD measurement setup.

In a three-wire configuration, the RTD sensor is connected to the measuring instrument using three
wires. Two of these wires carry the excitation current to the RTD, while the third wire measures the
voltage across the RTD. By measuring the voltage across the RTD using the third wire, the resistance
of the connecting wires can be accounted for and compensated, resulting in a more accurate
temperature measurement.

The four-wire configuration further refines this compensation method by using two sets of wires to
both apply the excitation current and measure the voltage across the RTD. This configuration
effectively eliminates the impact of the lead wire resistance on the accuracy of the temperature
measurement.

Lead wire compensation is an essential technique in RTD measurements, especially in situations

where accurate temperature readings are crucial. It helps mitigate errors caused by the resistance of
the connecting wires, allowing for more precise and reliable temperature measurements.

3. What is the significance of temperature coefficient of expansion (alpha) on the

measurement?
= The temperature coefficient of expansion (alpha) is a fundamental property of materials,
indicating how their dimensions change with temperature fluctuations. In the realm of temperature-
sensitive devices such as resistance temperature detectors (RTDs) and thermocouples, this
coefficient holds significant importance. It directly influences the physical changes in materials,
impacting their resistance, voltage, or other measurable properties in response to temperature
alterations. For instance, in RTDs, understanding the alpha value of the material used for the sensor
is crucial for calibrating the relationship between resistance and temperature accurately. This
knowledge aids in precise temperature measurements by accounting for how the material's
dimensions vary with temperature. Material selection for these devices is guided by alpha values, as
different materials exhibit varying coefficients of expansion. Moreover, the alpha value is crucial in
predictive maintenance, helping anticipate potential failures due to thermal expansion in industrial
settings. Additionally, it facilitates compensatory measures to correct for temperature-induced
changes, ensuring more accurate and reliable temperature measurements in diverse applications.
Overall, the temperature coefficient of expansion is pivotal for understanding material behavior in
response to temperature variations, guiding calibration, material selection, and maintenance
strategies in temperature-sensitive instruments.

4. Explain self-heating effect in RTD.

= The self-heating effect within Resistance Temperature Detectors (RTDs) stems from the electrical
current flowing through the RTD sensor, generating heat due to the sensor's inherent resistance. As
the current passes through the RTD, it encounters resistance in the sensor material, resulting in Joule
heating that raises the sensor's temperature above the ambient temperature being measured. This
additional heat, generated by the electrical current, can introduce inaccuracies in temperature
measurements, causing the sensor's temperature to deviate from the actual environment being
monitored. This effect is especially pronounced in high-precision applications or when dealing with
low-resistance RTDs. To minimize measurement errors due to self-heating, strategies include
reducing excitation currents, designing the RTD setup for efficient heat dissipation, and employing
calibration techniques that account for and compensate for the self-heating effect. Understanding and
addressing this phenomenon are crucial for achieving accurate temperature measurements and
ensuring the reliability of RTD-based temperature sensing systems.

5. Comment on: the selection criteria for RTD material?

= The selection criteria for Resistance Temperature Detector (RTD) materials revolve around several
key factors crucial for accurate and reliable temperature measurements. The material choice hinges
on the required temperature range, stability, linearity, and environmental considerations. RTD
materials, such as platinum (Pt), nickel (Ni), and copper (Cu), are evaluated based on their
Temperature Coefficient of Resistance (TCR), aiming for low values to ensure stable resistance-
temperature characteristics. Platinum-based RTDs, notably PT100 and PT1000 sensors, are popular
due to their exceptional stability, linearity, and low TCR, making them suitable for a wide range of
applications. Linearity and minimal drift over time are pivotal to enable straightforward calibration and
sustain accuracy throughout the RTD's lifespan. Chemical and mechanical stability, resistance to
environmental factors, repeatability, and cost-effectiveness also influence material selection, ensuring
the sensor withstands conditions encountered in its intended application. The final choice balances
performance requirements, availability, and cost considerations to deliver precise and consistent
temperature measurements. Ultimately, selecting the appropriate RTD material aligns with the specific
needs of the application, ensuring optimal performance and reliability in temperature sensing.

6. Give the applications of this transducer in related industry.

= Resistance Temperature Detectors (RTDs) are ubiquitous across diverse industries due to
their unparalleled precision and reliability in temperature measurement. In industrial
automation, RTDs ensure optimal conditions for chemical processing, pharmaceutical
manufacturing, food and beverage production, and plastics processing by accurately
monitoring temperatures, enhancing process efficiency, and ensuring product quality. HVAC
systems benefit from RTDs, maintaining comfortable and energy-efficient environments in
residential and commercial buildings by precisely controlling heating and cooling. These
sensors also play a critical role in automotive and aerospace applications, monitoring engine
and exhaust temperatures to ensure operational efficiency and safety. Power generation plants
rely on RTDs to monitor temperatures in boilers, turbines, and critical components, optimizing
energy production and ensuring safe operation. In healthcare and pharmaceuticals, RTDs
uphold accuracy in medical equipment, laboratories, and storage units, guaranteeing precise
temperature control for the safety and efficacy of medical procedures and product storage.
Additionally, RTDs contribute to environmental monitoring, food processing compliance, and
scientific research, underscoring their indispensable role in various industries where exact
temperature measurements are paramount for process control, quality assurance, and
research advancement.

Result :
1. Plot the graph for the answers as per request.
2. By using print screen/snipping tools, show your experiments in report.
MUHAMMAD ADAM HUSAINI BIN SHAHMINAN (09DJK21F1011)

PW6 PROCESS MEASUREMENTS

EXPERIMENT 6A

Material : Platinum α value: 0.00385

Temperature range : -200 to 850
TEMPERATURE Rt VALUE
159°C 38.79
735°C 382.98
705°C 371.43
EXPERIMENT 6B

Material : Platinum

Withsheath: Yes

Material: SS304

Thickness: 0.5mm

Thermowell: Yes

Material: SS304

Thickness: 1.0mm

Filling Material: Mg0 powder

HAZIQ HAZWAN BIN MAZLAN ( 09DJK21F1017 )
PW6 – PROCESS MEASUREMENT
EXPERIMENT 6A

Material : Balco
α value: 0.00518 Temperature range : -100 to 204

Temperature Rt Value
79º 140.92
154º 179.77
6º 103.11
EXPERIMENT 6B
Material : Platinum
Withsheath : Yes
Material : SS316
Thickness : 1.0mm
Thermowell : Yes
Material : SS316
Thickness : 1.0mm
Filling Material : Silicon Compound
ADI YUSNIZAM B SHAMSUL (09DJK21F1029)

PW6
Discussion : The static characteristics of an RTD refer to its behavior under constant or slowly
changing
temperature conditions. This includes the relationship between the resistance of the RTD and the
temperature it is exposed to. The resistance vs. temperature relationship of an RTD is well known
and repeatable over time. RTDs are typically built to standardized curves and tolerances, with the
most common being the 'DIN' curve, which describes the resistance vs. temperature characteristics
of a Platinum 100 ohm sensor. The accuracy of an RTD is determined by its base resistance
tolerance
and temperature coefficient of resistance tolerance. Static calibration involves determining the
mathematical model that describes the sensor's response under constant temperature conditions.
The dynamic characteristics of an RTD refer to its behavior in response to a changing temperature. In
the case of a signal that is changing with time (dynamic), a sensor that can keep up, or is fast enough,
is needed to accurately detect the change. The dynamic response of an RTD can be characterized by
its time constant, which is a measure of how quickly the sensor responds to a change in temperature.
Dynamic calibration involves determining the mathematical model that describes the sensor's
response to a changing temperature.In summary, the static characteristics of an RTD describe its
behavior under constant or slowly changing temperature conditions, while the dynamic
characteristics describe its behavior in response to a changing temperature.
The performance of a Resistance Temperature Detector (RTD) is affected by various parameters,
including linearity, stability, precision, accuracy, repeatability, response time, and cost. The linearity
of an RTD refers to its ability to respond to changes in temperature as they occur across the sensor. A
device with high linearity provides a resistance change that matches that of the device, resulting in
exceptional accuracy and reliability. The stability of an RTD is its ability to provide accurate and
precise readings over a long period, and close control and monitoring are required to maintain
optimal temperature. The precision and accuracy of RTDs make them a reliable means of achieving
that goal, but they are more expensive than other temperature measuring methods. The
repeatability of RTD sensors is high, and readings are constant, stable, and repeatable for longer than
any other form of temperature sensor. The response time of an RTD is determined by its time
constant, which is a measure of how quickly the sensor responds to a change in temperature.
Improvements to thin film Pt100s have substantially improved sensor response time. The accuracy of
an RTD is determined by its base resistance tolerance and temperature coefficient of resistance
tolerance, and the most common calibration temperature is 0°C. In general, RTDs are preferred over
thermocouples when high precision measurement is required.

Conclusion : A Resistance Temperature Detector (RTD) is a temperature sensor that measures

temperature by correlating the resistance with temperature. The RTD element is made from a pure
metal, usually platinum, and its resistance increases as the temperature of the sensor increases. The
resistance vs temperature relationship is well known and is repeatable over time. An RTD is a passive
device that does not produce an output on its own. External electronic devices are used to measure
the resistance of the sensor by passing a small electrical current through the sensor to generate a
voltage. Typically, 1 mA or less measuring current is used, and 5 mA is the maximum without the risk
of self-heating. RTDs are built to several standardized curves and tolerances, and the most common
standardized curve is the ‘DIN’ curve. The curve describes the resistance vs temperature
characteristics of a Platinum, 100 ohm sensor, the standardized tolerances, and the measurable
temperature range. The accuracy of an RTD is a combination of both base resistance tolerance
(resistance tolerance at the calibration temperature) and temperature coefficient of resistance
tolerance (tolerance in the characteristic slope). The most common calibration temperature is 0°C.