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Thermocouples

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Thermocouples

Thermocouples have been the preferred temperature sensors in industries where precision is vital for operations. Thermocouples can detect temperatures ranging from -200°C to 2320°C across extreme industrial conditions. At Tempsens, our journey as one of the top thermocouple manufacturers has been about building trust through uncompromising performance.

 Tempsens’ range features base metal thermocouples, MI thermocouples, noble metal thermocouples, refractory thermocouples, and tailored assemblies for high-vibration, high-temperature, and hazardous environments.

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Working Principle of Thermocouple

Thermocouple sensors operate on the Seebeck Effect fundamental. Thermocouples measure temperature by utilizing a pair of dissimilar metal wires coiled together at one end, known as the measuring point or hot junction, and the other end, usually a cold junction, connects to a copper wire to maintain a stable ambient temperature.

∇V = -S(T) ∇T

Where S(T) is the Seebeck coefficient.

It is important to note that a thermocouple measures only the differential temperature, not the absolute temperature. This is why a cold junction is essential for a thermocouple; it ensures that ambient temperature does not affect the actual results, thereby providing an accurate reading on the display.

Thermocouple Working Principle

 

Features of Tempsens Thermocouple Sensors

 

 Our thermocouples serve professionals who demand zero compromise on performance—because the cost of failure is too high.

 

Applications of Thermocouples – Operational Challenges and Solutions 

 

Industry Operational Challenge Tempsens Thermocouple Solution
Steel Industry High-temp exposure, signal drift in furnaces Base metal, noble metal thermocouples with Inconel sheath
Cement Industry Sensor burnout in kilns, dust ingress, poor temp control MI thermocouples with thermowell with HRS 446 sheath
Pharma Industry Traceability, sterilization accuracy Certified RTD + thermocouple assemblies; NABL traceable
Oil & Gas Industry Corrosive gas exposure, sensor failure in flare stacks/reactors Noble metal thermocouples with glass sealing & purging with various tubes like KER 710 (C-799), Hexoloy, inconel sheathed, explosion proof heads
Glass & Ceramics Industry Sensor life loss at high temps, platinum migration, high corrosive environment Type S/R/B thermocouple temperature range up to 1600°C with Pt/ Pt Alloy Thimble ceramic tube and HWT ceramic sheaths
Power Plants Vibration failures, temperature spike in turbines, rapid thermal cycling MI thermocouples with sheath, vibration-proof
Chemical Plants Acid/corrosive damage, temp imbalance in reactors Titanium/Incoloy sheathed thermocouples with various coating: PTFE, Ceramics, TMT, Stellite, Carbide, etc.

 

Why Tempsens

Choosing the right Thermocouple manufacturer isn’t just about the sensor—it’s about the system. Here’s why global OEMs, EPCs, and engineers choose Tempsens:

Tempsens is also a leading thermocouple wire manufacturer. We help you with better, safer, smarter processes.
 

Types of Thermocouple

Tempsens manufactures a comprehensive range of thermocouple types, each designed for particular application areas:
 

Base Metal Thermocouple with Thermowell

 

  • These are the thermocouples most frequently utilized across different industries.
  • N Type & K Type Thermocouple: The industry preferred thermocouple  for oxidizing environments like the steel industry and furnaces.
  • T Type Thermocouple: Optimized for cryogenic applications.
  • J & E Type Thermocouple: Optimized for specific conditions based on their application and industry.
  • Thermowells provide durability and protection against harsh conditions.

 

 MI Thermocouples (Mineral Insulated)

 

  • Often referred to as Magnesium Oxide (MgO) thermocouples, they find extensive use in numerous operations and research applications. 
  • Flexible, vibration-resistant, and durable
  • Available in various sheath materials 
  • Exposed, grounded, and reduced tip styles
  • Perfect for compact spaces and fast response times
  • Superior insulation resistance and mechanical strength

 

Noble Metal Thermocouple

 

  • Made from precious metals like Platinum & Rhodium (Type R, S, B)
  • These sensors are fragile and must be used in oxidizing or inert applications with ceramic tubes. 
  •  

Refractory Thermocouple

 

  • Made of exotic metals like Tungsten and Rhenium for ultra-high thermocouple temperature range (up to 2320°C)
  • Designed for vacuum furnaces and non-oxidizing environments
  • Tempsens is a leading thermocouple supplier providing type G, C, and D thermocouples.

 

Special Thermocouples

 

  • Custom designs for critical applications in project-specific environments like Multipoint, Skin type, Vanstone thermowell with thermocouple, etc.

PRODUCTS

Our Thermocouples Catalog

FAQ

Frequently Asked Questions

Find answers to frequently asked questions related to Thermocouples.

A thermocouple is a sensor formed by joining two dissimilar metals that generate voltage with temperature changes, based on the Seebeck Effect.

Choose the thermocouple type based on temperature range, environment (oxidizing, reducing), sensor shape, and process compatibility.

Thermocouples offer faster response and wider ranges; RTDs are more stable over time. Thermistors are limited to low temps and require complex electronics.

  • Hot junctions in thermocouples are formed using TIG or laser welding to ensure conductivity and stability.

Tempsens thermocouples follow IEC 60584, ASTM E230, and ANSI MC96.1 for EMF output and material consistency.

  • Thermocouples (R, S, B) are made with platinum-rhodium for high-temperature measurements where a temperature of more than 1200° is required and up to 1750°C.

  • Refractory Metal Thermocouples are manufactured from exotic metals like Tungsten and Rhenium. These metals are expensive, difficult to manufacture, and brittle. These are utilized in high-temperature environments and under reducing or vacuum atmospheres, functioning at temperatures up to 2300°C.

     

Used in industries like:

  • Steel
  • Glass
  • Cement
  • Oil & Gas
  • Power
  • Petrochemical
  • Nuclear & Defence
  • Chemical
  • Aerospace 
  • Laboratories

Key traits include: 

  • Quick response time
  • Wide temperature range
  • Compatibility with many industrial controllers and PLCs.

MI thermocouples provide:

  • High flexibility
  • Fast response
  • High insulation resistance
  • Ideal for rugged installations.

 

  • Thermocouple uses in the steel industry are:
    • Blast Furnace
    • Annealing Furnace
    • Sinter Plants
    • Tundish
    • Billet reheating
    • Rolling mill temperature monitoring.
    • Mold Casting

Thermocouple uses in the cement industry are:

  • Clinker zone 
  • Pre-heaters
  • Rotary kilns
  • Boilers

Thermocouple uses in the pharma industry are:

  • Autoclaves
  • Lyophilizers
  • Sterilizers
  • Cleanroom validation
  • Distillation Columns
  • Process- Tank, boiler, reactor, dryer, granulation, distillation column, etc 

 

Thermocouple uses in the petrochemical industry where corrosion-resistant and high-temperature sensors are critical:

  • Reactor; Fire Tube & Heat exchangers
  • Reformers
  • Naphtha Cracker unit 
  • Pipelines
  • Sulphur Recovery Unit (SRU)
  • Vibrations & Bearing applications
  • Fluid Catalytic Cracking unit

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