What is a thermocouple and where is it used?

What is a thermocouple?

A thermocouple is a sensor that is used for measuring temperature. The sensor has two dissimilar metal wires joined at one end and is connected to a thermometer or another thermocouple-capable device at the other end. When they are correctly configured, they can provide temperature measurements across a broad range of temperatures.

Stable thermocouples are highly versatile as temperature sensors, and so are often used in various applications, from industrial use to a regular thermocouple you can find on utilities and standard appliances. There are many different models and technical specifications for thermocouples, so it’s very important to understand the basics of how it works, its structure, and its ranges to get a better insight into what type of thermocouple and material are right for your application.

How does a thermocouple work?

When two wires made of different metals are joined together at both ends and one of the ends is then heated, there is a consistent current which flows in the thermoelectric circuit. If the circuit breaks at the centre, the net open circuit voltage is a part of the junction temperature and composition of the two metals. This means that when heat or cold is applied to the junction of the metals a voltage is produced that can be linked back to the temperature.

Thermocouple types

Thermocouples can come in multiple different calibrations or combinations of metals. The most commonly used are the base metals referred to as N, T, E, J, and K types. As well as this there are high temperature calibrations called noble metals. These are types R, S, C, and GB.

Where are thermocouples used?

Thermocouples are the most commonly used temperature sensors in the world because they can measure a wide range of temperatures, are durable, and are relatively inexpensive. When it comes to high temperatures, fast response, small temperatures, and a high vibration, you will likely find a thermocouple wire collecting the temperature measurements. Below we’ll be looking at just a few examples of where these sensors are used, so you will know how they can be applied in your operations.

Food applications

Thermocouples are used in many different types of applications within the food and drink industry, such as:

  • Clean-in-place sensors
  • Penetration probes
  • Oven control
  • Food chain monitoring
  • Hotplate control and monitoring
  • Steam kettle temperature control

Extruders

Extruders need high temperatures and pressures. Also, they have a unique thread adapter that works to position the tip of the sensor in the molten plastic under the high-pressure conditions located there.

Measuring low temperature

Type E, K, T, and N thermocouples can all be used to record low temperatures, as low as -200C. However, the alloys used need to be specially chosen for use at these temperatures to meet the published accuracies.

Many manufacturers ensure their alloys are calibrated for use from 0C and above. The same alloys can be used to measure down to -200C, but the accuracy might change slightly from the established values. If you purchase individual calibrations, you can determine offset values.

Furnaces

The right thermocouple for this application will depend on the furnace conditions it will be exposed to. When deciding on the right thermocouple, some factors that will need to be considered are:

  • The temperature capabilities of the thermocouple cables
  • Temperature capabilities of the sheath or protective coating (metal or ceramic)
  • The environment it will be used in (air, reducing, oxidising)
  • The configuration for mounting

Molten metal

It is difficult to measure the temperature of molten metal due to the high temperatures and harsh conditions involved. The only option for getting contact measurements in this area is to use Type K or N Base Metal thermocouples, or Types R, S, and B Platinum thermocouples.

When base metal thermocouples are used, the wires are generally large in diameter, with ceramic insulators and ceramic and/or metal protection tubes. The increased diameter of the Type K or N wires degrade slower to enable enough time for measurements to be taken before the high temperature conditions break down the wires.

Platinum thermocouple wires, unlike the base metal Type K and N, will become soft instead of becoming corroded, due to long term annealing and ultimately fail because of grain growth.

Contact TRM today for help with temperature measurement solutions for your business’ operations.

Everything to know about trace heating

What is trace heating? 

Trace heating is when the temperature of pipes and vessels is maintained or increased via specifically engineered cables. Trace heating products exist in response to the winter season when temperatures become very cold and can drop below freezing levels. 

When this happens, businesses often look to trace heating as a solution to prevent their vessels and pipes from freezing during the coldest temperatures. This is when pipes can freeze over which might result in them bursting from the expanding ice applying too much pressure. So, the aim of a trace heating system is to stop frost from forming in water pipes by keeping temperatures at a certain level. 

Also, heat tracing can be applied in processes that need temperature maintenance like insulating steam pipes. Another example is where certain liquids need to be kept at a specific temperature so they can be safely transported. In these cases, heat tracing can still be applied even without cold temperatures. 

How does trace heating work? 

Trace heating is done by connecting specifically engineered cables made from a resistance element to the vessel or pipe. The electric cables then have the job of process temperature maintenance by swapping heat loss with their power output. Ohm’s law dictates that connecting a voltage with a wire or cable will lead to a supply of power, which is then changed into heat energy by the heat tracing system. 

Trace heating cables have two copper conductor wires that are the same length, which forms a heating zone with a resistance filament in position. With a supply of fixed voltage, a consistent wattage is generated which in turn heats up the zone. A thermostat monitors the trace heating cables to make sure that the correct amount of thermal energy is produced so the cable won’t underheat or overheat. 

What are the different types of trace heating UK? 

Series resistance trace heating 

A series resistance heating cable is made up of a high-resistance wire that is usually insulated and enclosed within a protective cover. Thermal energy is created from the resistance of the wire when it is powered at s specific voltage level. The main benefit of a series resistance heating cable is that it often costs less than other options and is capable of maintaining very high temperatures for longer lines. 

Therefore, series resistance trace heating cables are normally made to be a fixed length and can’t be shortened in the field. This is because any break or failure at any point along the line would lead the full cable to fail. So, series resistance trace heating cables are often used for longer pipeline heating procedures. 

However, the circuit still needs to be monitored and controlled as the resistance material could melt because of overheating. Series resistance trace heating is normally put in place when long pipeline process heating is required, for example on the quay side of load pipes on oil refineries and along oil pipelines. 

Constant wattage trace heating 

The design for constant wattage trace heating cables includes a heating element that is wrapped around two insulated, parallel wires. There are several points throughout the trace heating cable that experiences constant wattage. 

A notch is made in the insulation on opposite sides of the conductors. Then a small heating circuit is created by fusing the heating component to the exposed conductor wire and this is continued throughout the entirety of the cable. Next the parallel wires are separated from the grounding braid by an inner jacket. 

A key advantage of constant wattage trace heating, compared to series resistance heating, is that the former can still work even in the event of an issue somewhere on the cable. In addition, the length of the cable can be altered on site thanks to its parallel functionality, this cannot be done with series resistance trace heating. It’s for this reason that a lot of businesses and industries ask heat trace specialists to install constant wattage trace heating, because of the flexibility you get with it. 

Constant wattage trace heating cables always come with a thermostat when installed in order to monitor and regulate the power output of the cable. This is done to stop overheating and burning out, should the cable ever come into contact with itself. 

Self-regulating trace heating 

Self-regulating trace heating cables that can change depending on the temperature. On a basic level, when temperatures drop below a certain limit, the cable resistance will go down as well. However, the resistance of the cable will increase when the temperature goes above the specified level. 

Self-regulating trace heating cables are made from two equal wires encased in a semi-conductive polymer. The polymer is typically made with carbon which stops the current from overflowing at increased temperatures. The carbon inside the polymer can expand or contract to generate different levels of resistance and heat energy output. 

The length of the cables can be altered in the field. Also, the self-limiting capability of the cable enables it to be more energy efficient as it can lower its output at higher temperatures. Thanks to its feature of conserving energy when the temperature goes up, self-regulating cables can help businesses to save money as less power is used. 

Additionally, these cables have better levels of safety which is particularly desirable in hazardous locations. This is because the power output of the cables won’t go above a certain level as output decreases when the temperature increases. So, it’s not possible for the cables to overheat, which could have been dangerous, especially in areas with flammable gases and vapours. 

How can trace heating be applied? 

Freeze protection 

As previously mentioned, trace heating is often used to protect pipes and vessels from freezing by keeping the temperature at a set level above freezing point. This is done by providing heat energy to balance the level of heat lost through conduction. Keep in mind thermal insulation can only slow down the heat loss process, it can’t prevent it from happening completely. So, trace heating is a good solution to heat loss and frost protection. 

Gutter and de-icing roof 

Trace heating cables can be fitted to the roofs and in gutters to avoid the accumulation of ice or snow. Also, the cables function as a draining path for water from the melted ice to move through to stop overflowing in the rooftops and gutters. 

Overflowing can have a negative effect on the structural integrity of buildings as it can lead to water soaking into cracks or joints. Additionally, the extra weight from the gathering of snow or melted ice can cause indentations and depressions on the rooftops and gutters. So, trace heating is key to preventing unwanted water build-up. 

Anti-cavitation 

Trace heating helps to lower the chance of cavitation occurring in pipes as heating a liquid makes it thinner and reduces its viscosity. The term cavitation refers to the development of vapour bubbles in a liquid caused by fast changes in pressure.  

Shockwaves are created when the vapour bubbles or cavities in the liquid collapse or implode, which degrades the inside of the pipe over time. Also, cavitation can break up the flow of liquid within the pipes. So, putting heat tracing cables in place will lower the likelihood of cavitation as it helps to reduce the pressure difference in the liquid. 

Conclusion 

Thermal insulation doesn’t completely reduce heat loss, so heat tracing is needed for businesses to keep temperatures over a designated level. This is particularly important during the winter season when temperatures can go below freezing levels and frost heaving is likely to happen. 

As professional trace heating suppliers, TRM can help you with your trace heating needs. Contact our team today to discuss your requirements. 

 

What are the different types of temperature sensor?

It may not seem like a common thing, but we use temperature sensors every day to control the temperature in buildings, water temperature regulation, and to control refrigerators. Temperature sensors are also an essential part of several other applications including consumer, medical, and industrial electronics. In this article, we’ll be looking at each type of industrial temperature sensor in detail as well as their advantages and disadvantages. 

Thermocouples 

A thermocouple is the most commonly used type of temperature sensor. Thermocouples are widely utilised in industrial, automotive, and consumer applications. One of the key benefits of thermocouples is they are self-powered and don’t require any excitation, so they can work over a broad temperature range and have fast response times. 

Thermocouples work by attaching two dissimilar metal wires together, which causes a Seebeck Effect. The Seebeck Effect is where a temperature difference of two dissimilar conductors creates a voltage difference between the two substances. This voltage difference can then be measured and used to work out the temperature. 

There are many types of thermocouple sensors made from various materials, allowing for different temperature ranges and sensitivities. The types of thermocouples are distinguishable by the letters they are assigned. The one that is used most often is the K type. Despite there being many benefits to thermocouples, making them a frequently used temperature sensor, they do come with a few small disadvantages too. 

For example, measuring temperature can be difficult because of their small output voltage, which demands accurate amplification, exposure to external noise across long wires, and cold junction. Cold junction is the term used to describe the thermocouple wires meeting copper traces of the signal circuit. Another Seebeck Effect is created from this which needs to be compensated for with cold junction compensation. 

Resistance Temperature Detector (RTD) 

When temperature changes, the resistance of metal changes too. It is this difference in resistance that the concept of RTD temperature sensors was based on. An RTD is a resistor that has clear resistance vs. temperature features. The most common and precise metal used to make RTDs is platinum. 

Platinum RTDs are often utilised because they provide an almost linear response to temperature alterations, they are stable and reliable, they offer repeatable responses, and they have a vast temperature range. Resistance temperature detectors are mostly used in applications that require precision due to their high accuracy and easy repeatability.

RTD heat trace elements typically have increased thermal mass, and so don’t respond as quickly to changes in temperature as thermocouples do. Signal conditioning is key in RTDs. They also need an excitation current to flow through the resistance temperature detector, if you know the current, you can work out the resistance.

Configurations of RTDs can come in two, three, and four wire options. The two-wire is best used when the lead length is short enough that resistance doesn’t negatively impact measurement accuracy. 

A three-wire configuration includes an RTD probe that moves the excitation current. This offers a way to cancel wire resistance if necessary. Four-wire is the most accurate approach, as separate force and sense leads take away the effect of wire resistance.

Thermistors 

Thermistors share similarities with RTDs in the sense that temperature fluctuations cause resistance changes that can be measured. Thermistors are often manufactured from a polymer or ceramic material. In many cases, they are less expensive than RTDs but also aren’t as accurate. The majority of thermistors come in two wire configurations. 

The NTC (Negative Temperature Coefficient) thermistor is the most used for temperature measurement applications. The resistance of an NTC thermistor decreases as the temperature rises. Also, thermistors have a non-linear relationship with temperature resistance. A common way or using a thermistor, is by using it with a fixed value resistor to create a voltage divider with an ADC digitised output. 

Semi-conductor based ICs 

There are two different types of semi-conductor based temperature sensor ICs: local temperature sensor and remote digital temperature sensor. Local sensors are ICs that measure their own die temperature using the physical characteristics of a transistor. Remote digital sensors record the temperature of an external transistor.

Local temperature sensors can utilise analogue or digital outputs. Analogue outputs can only be either voltage or current whilst digital outputs can be seen in many formats. Local sensors feel the temperature on printed circuit boards or the natural air around it. 

Remote digital sensors work like local ones by using the actual features of a transistor. The difference with remote digital is the transistor is situated away from the sensor chip. Certain microprocessors and FPGAs have a bipolar sensing transistor to record the die temperature of the desired IC. 

Final thoughts 

Each of these types of temperature sensors has its own unique features and benefits that will best fit with different applications. Thermocouples are cheap, durable, and are able to measure a wide range of temperatures. RTDs provide a wide range of measurements as well as measurements that are accurate and repeatable, but they are slower, and they need an excitation current and signal conditioning. 

Thermistors are small and durable, but they aren’t as accurate as RTDs and demand more data corrections to translate temperature. Semi-conductor based ICs are open to implantation and can come in very small packages, but their temperature range is limited. 

For all your temperature sensor and heat trace needs, contact TRM today. Our specialist team are on hand to ensure your application needs are perfectly met. 

  

Fire Survival In Modern Buildings

The difficult job of making sure our modern buildings are as safe as they can be

Thermal Resources Management have a long history as MICC and BICC of supplying both the commercial and industrial construction industries. From the 1930’s BICC were manufacturing and installing the same seamless tube Mineral Insulated Fire Survival Cable as we make today in Churches across the UK… much of it is still working today!

The construction indThe ustry represents a unique challenge in terms of promoting our fireproof and heating cable products. To ensure our products are used correctly we work at all levels of the supply chain. This helps end users ensure they get the right product at the highest quality but also the best life time cost!

Please review the following sections on how we can specifically help each part of the construction supply chain.

End Users

When it comes to who has the ultimate responsibility for the safety of the people who will eventually use a new building the end users/owners must surely take on this mantle.

Why? Because they or the building in their building will be the ones who in the event of a disaster or major emergency like a large scale fire will be the first to face the trauma of it.

It’s their staff, tenants, guests, visitors, commuters, patients and even perhaps pupils that will experience things first hand and will rightly expect the building to have the very best lifesaving systems…. Regardless of cost the alarm, emergency lighting, ventilation, access, firefighting and suppression systems etc must do the job they are required to do… they simply must work!

Of course, the cost is a major influencer in all construction projects around the World but before the cost of a build comes the reason to build or job the building must succeed in doing. So it stands to reason that any product to be used in the building during or after construction needs the same approach… i.e. a simple method or thought process like the following is needed;

  1. What does it need to do?
  2. Can it do it?
  3. How much will it cost?
  4. When can we get it?
  5. Etc

There is clearly no use in reviewing products from the cost only angle. If it doesn’t work then it doesn’t matter what the price is, it just shouldn’t be used!

It is however unfair of course to give all the responsibility the end users/owners of the buildings, they trust the people they employ to help them design and build their project to the highest possible specification.

Owners and end users also must trust the governing bodies and standards associations to provide adequate tests to ensure the products used will perform the job they are required to do.

They must also trust the manufacturers to market their products correctly and truthfully, especially when it comes to potential life-saving equipment and technology.

Sadly the last two points cannot be guaranteed.

MICC provides a voice for the Mineral Insulated Cable Industry. In the Fire Survival Wiring section of our website, you will find open, honest and factual information concerning the performance of our MI cables in a real fire… the only one that matters.

Well before the sales process begins we offer free training and consultation, our aim is to make buildings around the World safer by advising on where MI fireproof cables should be used. The information we give is fact-based and backed up by industry experience and research.

Please contact us to arrange a seminar at your office, or leave your details so we can invite you to our next training seminar in your area. Let us help you make the right choice.

Consultants

After the End Users / Building Owners have decided to start a project very early on they appoint a design consultant. This may be a direct approach or for large scale projects may be in the form of a tender where a consortium of companies might win a package of work within the budget set by the client.

The key thing to note here is that the end users will look to the consultants for advice and expertise in what standards need to be employed in the building construction. Savvy end users may already have an idea of what they want but generally, their consulting partners will design the building based on their knowledge and experience, ensuring the building fits their client’s requirements.

With this in mind, it is vital that consultants know as much as possible about the potential life-saving systems they are recommending to be used in the building. So how do they gain this knowledge?…

It may be a mixture of some or all of the following; past experience, current local or international standards, product research and education / other training.

When looking specifically at the choices made for the Fireproof cabling in a modern building two important factors are usually considered; how long must the circuit work for and what standard must the product meet.

Once the egress time is decided, usually upwards of one hour to ensure the building users have time to escape with the lifesaving circuits still operational, a suitable standard is called for to ensure the products used fit for purpose.

It is of course not the consultants’ job to test the products themselves to give them and their client the peace of mind that they will do the job intended… The problem is the standards cannot always be 100% trusted to confirm the performance a product in question. Standard committees will only guarantee product performance based on the specific laboratory tests employed, they also usually have small print which must be understood before placing full trust in them. And finally, they say it is up to the Consultant to still make the right choice as they only provide a minimum guideline of potential performance.

This leaves consultants and indeed end users in a very difficult position, are they really expected then to conduct their own tests to ensure the products specified will perform the jobs intended? Well in the past this has been what has been needed to ensure the best / right products are installed… for example, the Kings Cross underground fire in 1987 where 27 people lost their lives. After this fire the London Underground developed their own test for fire performance cables known as BS6387 enhanced, the only cable to pass this test for a long time was MICC fire survival cables.

MICC works around the World to educate and consult on the proper use of fireproof cables. Using tried and tested methodologies and research we bridge the gap between real-world performance and current international standards.

Our training and consultation is free and simply designed to help save lives in the event of a fire or other serious event where a higher performing cable is required, for example, risk of terrorist attack.

Please contact us to arrange a seminar at your office, or leave your details so we can invite you to our next training seminar in your area. Let us help you make the right choice.

Contractors

When it comes to the actual construction of a building then the contractors employed are on the front line. Their knowledge and experience are vital to ensure the end users dream and the consultant’s plan are realised in the desired way.

However it is rarely a straight forward task, even the best-laid plans can need a little tweaking to ensure they work. The critical thing here though is the consultant, designer or architects and contractors are on the same page. If the contractor doesn’t know what a specified standard or product is they may not know how to use it correctly or where to even source it from. Sometimes what is not understood is feared and contractors rightly will do all they can to ensure they complete their part of the construction in the shortest time to the lowest possible cost.

It is vital then that contractors know as much as possible about current standards and where the relevant products fit in with them. Then they must know how to work with them properly to ensure there are no delays on site which could delay the project and increase its cost.

MICC understands how important contractors are and also hold training seminars with them regularly around the World to advise and demonstrate how Mineral Insulated Cables work, and how they should be used correctly to make installation quick and easy.

Please contact us to arrange a seminar at your office, or leave your details so we can invite you to our next training seminar in your area. Let us help you make the right choice.

Distributors

MICC believes that in order to have the greatest potential to save lives through better specification and use of fireproof cables all levels of the supply chain must understand the real-World situation.

As the pages in the Fire Survival Wiring section area of this website demonstrate, the fact is soft skin cables do not give the performance they or current standards infer. It is not that they are poor cables, more than they are often used incorrectly or relied upon to give survival times which they have no hope in meeting.

Distributors and wholesalers are vital to the construction industry and play a very important role in providing products quickly and to the required standard. They are also ideally placed to give an extra layer of advice/peace of mind to contractors / installers by being able to help recommend and demonstrate proper use of retailed products.

MICC support the wholesale and distribution industry by giving full training on the principle, technical specification and proper termination & installation of Mineral Insulated Fire Proof cables.

This holistic approach by supporting all levels of the construction supply chain is best way to ensure lives are less at risk in the event of a major incident including fire in any modern building.

Please contact us to arrange a seminar at your office, or leave your details so we can invite you to our next training seminar in your area. Let us help you make the right choice.

Brexit Help

At MICC we understand Brexit means new challenges for many of our European customers and partners at a time when nobody is in need of additional challenges.

We hope the attached document can help to explain the new processes we need to follow in the post-Brexit world and make the transition as straightforward as possible.

MICC are seasoned exporters with 20 years experience and are happy to support and guide our customers in any way we can. For any specific questions or concerns on how to do business with MICC from within the EU today, please contact our sales team here.

Brexit Help Document

Michael Lee Celebrates 20 Years with MICC

As part of MICC Group’s 20 Years celebration, we would like to say a special thank you to Michael Lee, who has been with MICC since the very beginning.

Through leading the shipping team with tremendous hard work and dedication, Michael has been at the heart of MICC’s growth into a global manufacturing brand.

Congratulations on 20 Years at MICC, Michael. Thank you for everything you have accomplished.

Even the Newcastle fans in the office hope Sunderland beat Oxford for you tomorrow… probably

Fire & Risk Management Publication

MICC’s regional manager for Asia/Pacific, Richard Hosier, has had an article published in the Fire & Risk Management Journal in October 2019.

Richard discusses is wiring for life safety and firefighting systems up to code in our buildings, and is this enough to ensure safety?

Read the article here

To learn more about the Fire & Risk Management Journal, please visit www.frmjournal.com/

MICC employee Shaun McIntosh qualifies for 2019 Bowls World Championship

Shaun McIntosh MICC

We are proud and delighted to announce that Shaun McIntosh has qualified for the 2019 Bowls World Championship!

Shaun is sponsored  by MICC and is one of our employees based in our Washington, Tyne & Wear, Mineral Insulated Cable factory HQ. After many years of hard work and great National success he has been able to qualify for the World Championships via becoming a member of the Professional Bowls Association (PBA).

We spoke to Shaun about his journey to the top of his sport and here’s what he had to say;

I had my first game of bowls when I was seven years old, I used to go along and watch my father regularly played to a high standard – I think this is where my love of the game came from.

After many hard years of practice I started to win junior event titles regularly, this caught the eye of the selection committee for the full men’s team at my local club Hebburn Bowls Association, at the age of 15 I won the men’s singles championship becoming the youngest in the clubs history to do so, after this win I received my first Durham County cap, I remained in the team for that season which ended with us being National Title Champions – since then I have went on to win four English Titles in total.

At the age of 18 I had my first England Under 25’s trial, on this occasion I did not make the team.

2019 has been my biggest season yet, securing sponsorship from MICC Ltd has given me the platform to join the Professional Bowls Association (PBA) which gave me the opportunity to qualify for the 2019 World Championships, after eleven hours on the green myself and my pairs partner qualified for the 2019 World Championships which will take place at Potters Hotel Norfolk in early 2019 – which is also a live televised event.

I look forward to 2019 and hope to achieve all my title goals”

We all wish Shaun the best of luck. For more details on the event please visit;

Daniel’s Mini Great North Run

Can you give little for a very good cause?

Please help Daniel raise money for Isabella and people like her with Williams Syndrome via his Mini Great North Run! https://zurl.co/KnQ8

Here is Daniel explaining why this is important to him in his own words.

Thanks for taking the time to visit my JustGiving page.

 

My name is Daniel, I am 5 years old and I am going to be running with my mammy (if she can keep up) in this year’s Mini Great North Run on the 8th September.

I am raising money and awareness for the Williams Syndrome Foundation UK.

Williams Syndrome is a rare congenital disorder  that occurs randomly
and affects around one in 18,000 people in the UK. It is non-hereditary
and causes distinctive facial characteristics and a wide range of learning difficulties. Infants often have delayed development and can develop physical and mental health problems, including anxiety and depression in  later life. All WS people tend to be talkative and excessively friendly towards adults.

My beautiful cousin Isabella will be 8 this October. Almost 3 years ago, in December 2015, she was diagnosed with Williams Syndrome.

Since then, my very brave Auntie Emma and Uncle Philip have been doing lots to raise awareness of William’s Syndrome and raising money for the Foundation, who have got them through some very difficult times in the last 3 years.

Now it’s my turn to help, I would love it and would be very grateful if you could donate as little or as much as you can to help raise funds for WSF UK as they are a charity very very close to our family’s heart.

Donating through JustGiving is simple, fast and totally secure. Your details are safe with JustGiving – they’ll never sell them on or send unwanted emails. Once you donate, they’ll send your money directly to the charity. So it’s the most efficient way to donate – saving time and cutting costs for the charity.

 

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