Temperature is often a critical measurement parameter in many industrial processes and operations. Prior to the advent and global availability of wireless technology, it was difficult and expensive to implement remote temperature monitoring of industrial operations, especially over long distances. In this article, I’ll discuss some examples of the many different types of industrial sites that benefit from remote temperature monitoring. I’ll then discuss some of the basic components used in remote monitoring systems.
Examples of Industrial Sites That Benefit from Remote Temperature Monitoring
Oil and Gas Facilities
Examples: Remote drilling rigs, pipeline stations, gas compression stations.
Why: Temperature affects pipeline integrity, equipment performance, and safety (e.g., fire or explosion risk).
Mining Operations
Examples: Surface mines, underground mines, mineral processing plants.
Why: High or low temperatures can impact machinery, explosives storage, and worker safety.
Renewable Energy Sites
Examples: Remote solar farms, wind turbine installations, geothermal plants.
Why: Temperature impacts energy production efficiency and equipment longevity (e.g., overheating solar inverters).
Telecommunications Towers
Examples: Rural cell towers, satellite uplink stations.
Why: Electronic equipment in shelters must stay within temperature specs to avoid failures.
Power Substations and Transmission Infrastructure
Examples: Remote substations, high-voltage switchyards.
Why: Transformers and switchgear can overheat, leading to outages or fires.
Water Treatment and Pumping Stations
Examples: Remote irrigation systems, wastewater treatment outposts.
Why: Temperature affects chemical reactions and equipment like pumps and motors.
Agricultural Operations
Examples: Greenhouses, cold storage units, livestock monitoring stations.
Why: Precise temperature control is vital for crops, food storage, and animal health.
Forestry and Environmental Monitoring Stations
Examples: Fire watch towers, weather stations, reforestation outposts.
Why: Ambient temperature data is crucial for predicting wildfire risks and conducting ecological studies.
Military and Defense Installations
Examples: Radar stations, remote surveillance posts.
Why: Electronics and stored equipment must be kept within operational temperature ranges.
Scientific Research Outposts
Examples: Arctic/Antarctic bases, volcanology stations, astronomy observatories.
Why: Extreme environments require tight control and monitoring to protect both instruments and personnel.
The Components of a Remote Temperature Monitoring System
There are three basic components required for any remote temperature monitoring system:
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Sensors: Convert temperature into an electrical signal, which can be sent via a transmitter to a remote location.
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Transmitters: Provide connection and communication between the sensor and remote receiving station.
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Remote Receiving System: Located remotely from the sensor, this is the device or system that provides display, monitoring, and/or control of the temperature.
Sensors
The most common sensors used for industrial temperature measurement are thermocouples and RTDs. Thermistors and infrared temperature sensors are also used, but less common.
Thermocouples: A simple but extremely versatile sensor. A thermocouple consists of two wires of dissimilar metals joined together to form a junction. Temperature is sensed at the junction point, which produces a low-level voltage that can be converted into temperature.
Advantages:
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Wide temperature range
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Low cost
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Durable
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Can be constructed in various mechanical configurations for different applications
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Very fast responding in certain configurations
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Self-powered, making them well-suited for battery-powered instruments
Disadvantages:
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Because they produce a low-level signal, they are susceptible to electrical noise
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Lower accuracy than some other sensors
RTDs (Resistance Temperature Detectors):
RTD sensors change resistance with temperature changes, allowing the resistance to be used to calculate temperature. RTDs may be made from wire wrapped around a ceramic or glass core, or constructed from thin-film metal. Platinum is one of the most common metals used for RTDs.
Advantages:
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Higher accuracy than thermocouples
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Temperature range is sufficient for many applications
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Less susceptible to electrical noise than thermocouples
Disadvantages:
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Higher cost than thermocouples
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Slower responding
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Limited in some applications due to their temperature range
Thermistors:
Similar to RTDs in that their resistance is used to calculate temperature. They are normally constructed from semiconductor material. Thermistors are very accurate but have a limited temperature range. Due to this, they are rarely used in industrial applications. Also, there are many types of thermistors, making them difficult to pair with off-the-shelf instruments. They are commonly used in OEM applications where the reader is designed to work with a specific thermistor.
Infrared Sensors:
These are non-contact sensors that measure solid or liquid surface temperature. Their cost and limited application preclude their use in most general temperature measurement applications, but they are the primary choice when the sensor can’t be in contact with the surface.
Transmitters
The transmitter converts the sensor’s output into a format that can be sent to a remote location. “Remote” is relative. For this discussion, it means a distance further than you’d typically want to run dedicated wire. This includes wireless transmitters as well as Ethernet transmitters.
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Ethernet: A good solution if there’s an established Ethernet network. It’s fast, reliable, and adds very little incremental cost. If connected to the internet, it can serve as a gateway to a wireless network.
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Wireless: The three most common wireless technologies are Wi-Fi, cellular, and private wireless networks.
Wi-Fi: Convenient and cost-effective. Transmission is limited to the local network, but with internet access, global reach is possible.
Cellular: Easiest to implement since it doesn't rely on other infrastructure, but it requires cellular coverage. Cellular service can involve recurring fees.
Private Wireless Networks: Includes Zigbee, LoRa, WirelessHART, 802.15.4, Z-Wave, and others. These may be used when:
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No other network is available
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Higher security and reliability are required
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Low power operation is needed, especially with battery-powered sensors
(Explore our full range of transmitters here to match your application.)
Remote Receiving System
This is the device or software that receives temperature data for display, recording, and/or control. Systems include:
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Cloud Platforms: Internet-accessible software systems that offer global access via browser or app. Advantages include minimal training/setup and low internal maintenance.
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Disadvantages: May have recurring costs; relatively slow response times (1 minute or more), making them unsuitable for real-time control.
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SCADA Software: SCADA (Supervisory Control and Data Acquisition) is software used to monitor and control industrial processes. While it can run on cloud platforms, this article focuses on SCADA systems installed on personal computers or on-premise servers. The advantages of SCADA include advanced functionality, a high level of control, and compatibility with a wide range of industrial data protocols. The disadvantages are that setup can be complex, the learning curve is steep, and often these systems can be expensive to implement and maintain.
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Dedicated Hardware Devices: These are primarily PLCs (programmable logic controllers) but may also include devices like simple meters or PID controllers with network/wireless capabilities. A dedicated hardware device generally provides a high degree of reliability because of their dedicated nature. Because they can be programmed for a very specific function, they tend to offer a simpler interface for operators than SCADA software and are much faster responding than cloud systems. They can be a good choice for real-time control.
For many applications, capturing and archiving temperature trends over time is just as important as real-time monitoring. That’s why integrating data logging is a smart addition—especially in regulated industries or for long-term equipment performance analysis.
Bringing It All Together
Wireless temperature monitoring is transforming how industrial sites manage remote operations, delivering greater visibility, efficiency, and control. With the right combination of sensors, transmitters, data logging, and receiving systems, even the most challenging environments can be monitored effectively.
IOThrifty offers a full range of these components—including data loggers and transmitters—to support your application and help you build a robust remote monitoring system.