The long and short of connecting sensors to control rooms

Temperature sensors, more than most other types of instrumentation, can require specialized cabling and treatment to provide accurate data.


The choices made to get temperature measurements to the control room can have a profound impact on plant operation and costs. Temperature measurement can be found in control, monitoring, or logging situations, and quite often temperature is the most commonly measured variable in a plant. Every application has its own unique requirements for accuracy, reliability, and compatible system architecture. Matching these requirements with the right connectivity choice will ensure that the temperature measurement will provide the right performance for the right cost.

The ultimate objective is to get the temperature measurement to the control room with the accuracy, repeatability, and stability required for the application. In addition, the solution should offer ease of maintenance and the lowest practical cost of ownership. The design engineer must consider a number of technology, performance, and cost of ownership issues to make a proper decision.

As you begin evaluating an application, consider these questions:

  • Are the measurements made with an RTD (resistance temperature detector) or TC (thermocouple)?
  • How far are the measurement points (sensor locations) from the system connection?
  • How are the connections made at each end?
  • Are there junction boxes, conduits, or wire-ways?
  • How and where is the raw sensor signal converted to a useable measurement value?
  • Will using a transmitter help? If so, what kind of transmitter?
  • Where could a transmitter be mounted?
  • Is a wireless transmitter an option?
  • Will this be strictly analog, or is a digital device-level network (fieldbus) used in the plant? If so, which one?

Connection options

There are several options to consider in choosing a reliable method to get the signal from the field sensor to the control system in a way that delivers the performance levels required by the application. Figure 1 illustrates the most common choices.

There are many options for bringing sensor data to the host system. The difficulty is evaluating the differences and choosing the best for a given application. Courtesy: Emerson Process Management

Direct wiring – Connect field sensors directly to input card racks within control room systems. The signal is conditioned or converted into an analog signal or digital value representing the temperature measurement for use in that system.

Remote I/O – I/O cards, racks, and power supplies are positioned into field marshaling cabinets that are connected to the control system via a digital link. The same attributes as direct wiring apply, but the sensor wiring runs are shorter.

Multiplexors – Typically using either serial RS232C or RS485 communications or Ethernet, multiplexers communicate with the control system. The communications can be any of a number of host protocols such as Modbus, OPC, Profibus, or other proprietary protocol. While generally reliable, this is a dated approach that has seen a decline in use.

Locally mounted transmitters – A transmitter is usually located in a connection head or enclosure mounted integrally with the sensor or in very close proximity. The most basic is a simple 4-20 mA output version with limited options and features. HART-enabled transmitters, which are the most common, provide a high-performance and cost-effective option for most applications. Fieldbus architectures use either Foundation fieldbus or Profibus, allowing multiple transmitters to share a common two-wire signal cable to the control room. Adoption of either of these fieldbus architectures is usually a management decision that applies to the entire plant facility or to a unit operation. Wireless is a rapidly growing technology with WirelessHART (IEC62591) and ISA100.11a (IEC62734) growing in numbers of deployments. Wireless transmitters can provide the same process variable information and diagnostic capabilities as wired versions.

Critical factors

Each approach has its tradeoffs, and the best combination will depend on the needs of the process at that measurement point. Courtesy: Emerson Process ManagementThere are pros and cons to every technology, as shown in Figure 2. You should look for the solution that best matches your needs with the best cost-to-performance ratio.

Direct wiring using long sensor cables has to transmit low-level sensor signals that are very susceptible to interference. This electrical interference can come from sources such as pumps, motors, variable frequency drives (VFDs), and radios as well as sources of electrostatic discharge (welders and lightning) and other electrical transients. There is the potential for very large errors to be induced on the low-level sensor signals, and the longer the sensor lead wires, the greater the risk. Direct wiring may provide an adequate installation if the wire run distances are short and there is good separation and protection from interference sources. 

Remote I/O cabinets may be cost effective for high-density measurement locations and where adequate protection from interference can be provided. Remote I/O requires an operating power source, which typically needs redundancy or an uninterruptible power supply for critical applications. An installation may also require environmental protection. Situations where a large number of measurement points are centrally located may allow for relatively short wire runs, but the sensor wire length may still be an issue for noise susceptibility and potentially significant errors.

The best and most common alternative is to use a transmitter, either analog or fieldbus, that is designed to reject common mode and normal mode interference, as well as provide a high degree of immunity to electromagnetic interference (EMI), electrostatic discharge (ESD), and radio frequency interference (RFI). Where possible and practical, transmitters should be mounted close to the measurement point to minimize any potential noise pickup by the sensor leads. This is especially important for low-level TC signals, which are especially susceptible to noise. Such transmitters may be simple 4-20 mA analog or HART enabled. Fieldbus transmitters have the same characteristics with all-digital architecture. The use of transmitters is sometimes thought to be expensive, but when the cabling and lifecycle maintenance costs are taken into consideration, this balance shifts.

The wireless transmitter option may prove to be cost effective for many applications, particularly where it is difficult or expensive to install traditional instrument infrastructure. A highly robust wireless system, as is available today, is achieved by proper network design. This approach is suitable for just a few measurements, or a system can be designed for an entire process unit operation.

Transmitters vs. direct wiring

Consideration of the high-cost of installation of direct wired systems and their high cost of ownership including maintenance and performance issues strongly suggests that using a transmitter approach has a clear advantage for most applications.

  • Specifying a single temperature transmitter, sensor, and thermowell assembly to meet a specific performance goal simplifies purchasing and places responsibility on a single vendor.
  • Transmitters can provide higher accuracy performance, often reducing the accuracy percentage by half.
  • An individual sensor type can be changed from TC to RTD or to a different type of TC or RTD and the same transmitter can normally be reconfigured easily to the new sensor type. The output cable and the DCS input card stay the same. For direct-wired systems, the extension cable would likely need to be changed as well as the DCS input card.
  • The standard two-wire copper wiring used with transmitters is far less expensive than the TC extension wire or four-wire RTD extension cable used with direct wiring.
  • Higher performance is assured since a transmitter and sensor assembly may be calibrated as a system for optimal accuracy. This cannot be done with a direct-wired system and sensor. Extraordinary performance can be achieved by using the sensor-transmitter matching procedure inherent in high-end transmitters. While I/O subsystems (DCS or PLC input cards) have reasonable specifications, they are no match for the performance of today’s quality temperature transmitters.
  • A transmitter facilitates using all copper wiring in the field, eliminating the potential for wiring installation errors that come from using different types of TC extension wire.
  • A transmitter’s ability to work with multiple sensor types means that a user can often buy all its transmitters from the same manufacturer and likely even the same model, which minimizes spares.
  • A 4-20 mA signal or digital fieldbus data from a transmitter is far less susceptible to EMI, ESD, and RFI than the low-level signals from a sensor. Some transmitters also offer intelligent filtering options to protect data integrity. Such software may not even be available in the control system host.
  • Safety-related applications are by far best done in a transmitter-equipped system. In an SIS (safety instrumented system), an error in excess of 2% is considered an undiagnosed failure.
  • Some transmitters offer an option that supports local display in the field, either as a built-in readout or mounted externally. This can be a major advantage when troubleshooting or in situations where operators are routinely in the area.
  • Troubleshooting and maintenance time can be reduced by using the extensive transmitter diagnostics that are either not available or very limited in DCS input cards.
  • A single type of high-level input card is required for the control system instead of a mixture of high-level and more expensive low-level cards, reducing inventory.
  • Copper wire typically lasts for the life of the plant, eliminating the need to periodically replace degraded TC extension wire.

Good design yields cost-effective performance

When creating your instrumentation and networking design, always consider overall cost of ownership and not just purchase cost. Poor performance, higher maintenance costs, or more frequent replacement associated with low-cost products or deficient designs most often tilt the cost of ownership scale strongly in favor of a design using high-quality components.

Jim Cobb is a senior product manager for Emerson Process Management.

Key concepts:

  • Temperature sensors have more options for connecting them to a control system than most other types of instruments.
  • Various connection strategies have different trade-offs for durability and accuracy.
  • Using a transmitter at the sensor can eliminate many of the headaches that can go with other sensor wiring methods.


Read the first two parts of the temperature series below.

To learn more about measuring temperature, go to and order the Engineer’s Guide to Industrial Temperature Measurement.

Jonas , , 11/25/13 11:11 PM:

Digital communication does not have the limitations of 4-20 mA so for fieldbus and wireless there are multi-input transmitters available. For instance, for fieldbus you can get a transmitter accepting 8 inputs, and you can put 16 of those on the same bus, meaning 128 measurements on a single pair of wires (communication and power). This is ideal when temperature sensors are clustered together such as for monitoring temperature profiles in a reactor, column, boiler tubes, or gas turbine etc. Similarly there are wireless transmitters accepting 4 inputs and you can have 100 of those in a wireless networking, meaning 400 measurements on a single gateway. In most temperature monitoring applications, an update period of 4-16 seconds is acceptable. For a temperature control loop, a single or dual input fieldbus transmitter is much faster achieving.

Cabinet “breathing” in humid air as temperature changes from day to night can be a problem for system components in remote I/O cabinets. Providing redundant power can also be a challenge.

I agree that signal conditioning should be done as close to the sensor as possible. I personally think that digitization should also be done right at the sensor. That is, convert the sensor signal to a digital signal as early as possible, and then keep it digital all the way from that point without converting back to analog 4-20 mA. Fieldbus and wireless keeps the signal digital all the way, from the very “first meter”, plus provide real time status, ensuring high integrity and fidelity, and reducing spurious shutdowns. Both fieldbus and wireless enable multi-input transmitters as explained above, with each transmitter eliminating 8 (or 4) conventional transmitters, 8 (or 4) pairs of wires, and 8 (or 4) AI channels on the system. The cost savings are dramatic. Learn more about fieldbus here:

Advanced device diagnostics is a good example of where “always-on” digital adds great value over just a simple process variable measurement. The Fieldbus version has Statistical Process Monitoring (SPM). SPM is able to detect abnormal process behavior before operation constraints are reached, providing an early warning. SPM alerts provide process engineers with a better view of what is going on in the process. It may be used to detect hydrate formation in natural gas lines, scaling formation, and thermowell coating etc.

Learn more about how device diagnostics (from all kinds of field instruments and valves) can be incorporated into work practices to more effectively schedule daily maintenance and turnaround planning to reduce maintenance cost and downtime:

Wireless transmitters enable existing plants to be modernized. Wireless transmitters are best known for providing PROCESS EQUIOMENT diagnostics as opposed to for their own device diagnostics. That, is a wireless temperature transmitter can detect a faulty thermocouple or RTD element, but they are best known for applications where they perform temperature (as well as vibration, pressure, and DP etc.) measurements to diagnose the health of a piece of process equipment rather than themselves. This is known as “type 4” diagnostics. For instance, wireless transmitters may be used to determine the health of heat exchangers, pumps, blowers, air cooled exchangers (fin fans), and cooling towers etc. These are measurements that were never done in the plants in the past when they were built. We call them “missing measurements”. WirelessHART is ideal for providing a second layer of automation for pervasive sensing of these missing measurements which are beyond the P&ID. WirelessHART is ideal because it is easy to deploy in an existing plant since no signal wires and no power wires have to be run. That is, non-intrusive electrical installation, meaning minimal risk of damaging existing installation since cable trays and junction boxes need not be opened. Most of these applications beyond the P&ID do not need high accuracy enabling use of clamp-on sensors measuring the pipe or vessel surface temperature in case thermowells are not existing and cannot be installed. That is, non-intrusive mechanical installation too, minimal risk. Learn more from this blog post:
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
Safer human-robot collaboration; 2017 Maintenance Survey; Digital Training; Converting your lighting system
IIoT grows up; Six ways to lower IIoT costs; Six mobile safety strategies; 2017 Salary Survey
2016 Top Plant; 2016 Best Practices on manufacturing progress, efficiency, safety
Future of oil and gas projects; Reservoir models; The importance of SCADA to oil and gas
Big Data and bigger solutions; Tablet technologies; SCADA developments
SCADA at the junction, Managing risk through maintenance, Moving at the speed of data
What controller fits your application; Permanent magnet motors; Chemical manufacturer tames alarm management; Taking steps in a new direction
Commissioning electrical systems; Designing emergency and standby generator systems; Paralleling switchgear generator systems
Package boilers; Natural gas infrared heating; Thermal treasure; Standby generation; Natural gas supports green efforts

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Motion control advances and solutions can help with machine control, automated control on assembly lines, integration of robotics and automation, and machine safety.
This article collection contains several articles on creating and enhancing a safe workplace in manufacturing.
Maintenance Manager; California Oils Corp.
Associate, Electrical Engineering; Wood Harbinger
Control Systems Engineer; Robert Bosch Corp.
click me