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Temperature Sensor
High-accuracy Type K thermocouple and PT100 RTD sensors for drum discharge, bitumen line, and flue-gas monitoring in the AVL-DMP.
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At a glance
| Sensor types available | Type K thermocouple / PT100 RTD (2-wire or 4-wire) |
|---|---|
| Measurement range | −50 °C to +600 °C (Type K); −50 °C to +400 °C (PT100) |
| Accuracy | ±1.5 °C or ±0.4% rdg (Type K); Class A ±(0.15 + 0.002|t|) °C (PT100) |
| Thermowell material | 316L stainless steel (bitumen/aggregate); Inconel 600 (flue-gas) |
| Process connection | ½" BSP or ¾" BSP threaded |
| Response time t90 | <6 s in moving media |
| Enclosure (head) | Die-cast aluminium, IP67 |
| Cable insulation | PTFE with stainless-steel overbraid |
Overview
The AVL-DMP requires continuous temperature measurement at several critical process points simultaneously: the drum mix outlet (mix temperature, typically 150–185 °C), the bitumen storage tank and transfer lines (130–170 °C), the primary air/flue-gas duct upstream of the baghouse (typically 120–180 °C), and the aggregate pre-heat zone inside the drum. Avelta supplies both Type K thermocouple sensors and PT100 resistance temperature detectors (RTDs) suited to each location, complete with matching thermowells, connection heads, and extension cables.
Sensor selection is determined by the measurement location: PT100 RTDs are preferred where accuracy better than ±1 °C is required (bitumen dosing lines, mix outlet); Type K thermocouples are used in higher-temperature or vibration-intensive locations such as the flue-gas duct and drum shell proximity measurement. Both types feed analogue signals directly to the plant PLC for closed-loop burner and pump control.
Function
Temperature sensors provide the primary feedback signal that allows the PLC to modulate burner firing rate and bitumen pump speed to maintain target mix temperature. In a drum mix plant operating between 40 TPH and 160 TPH, aggregate moisture content and feed rate vary continuously; the temperature loop must respond within seconds to maintain mix within the specification window. An inaccurate, slow-responding, or failed sensor causes the control system to operate blind, resulting in mix temperature excursions — either cold mix with poor coating (below 145 °C) or overheated mix with bitumen carbonisation and smoke (above 195 °C). Both conditions are costly in material waste and can trigger regulatory non-compliance on emission limits.
Construction & quality
Sensing elements are manufactured to IEC 60584 (Type K thermocouple) or IEC 60751 Class A tolerances (PT100). Thermocouple wire is chromel–alumel, mineral-insulated (MI), with MgO mineral fill and seamless stainless-steel outer sheath. PT100 elements use platinum wire wound on a ceramic former, encapsulated in a stainless-steel sheath. Thermowells are machined from seamless 316L stainless-steel bar for bitumen and aggregate service, or from Inconel 600 for high-temperature flue-gas locations. Process connections are ½" BSP or ¾" BSP threaded, with hexagonal wrench flats for installation torque. Connection heads are die-cast aluminium, IP67-sealed, fitted with DIN 43722 terminal blocks and stainless-steel cable glands. Extension cables are PTFE-insulated with overall stainless-steel overbraid for chemical and mechanical protection.
When to replace
- Erratic or drifting temperature readings not attributable to genuine process changes, checked against a calibrated reference
- PLC open-circuit or out-of-range alarm persisting on the specific sensor channel after cable and connector checks
- Visible corrosion pitting, scaling, or physical impact damage on the thermowell body or sheath
- Slow response to known temperature step changes, indicating thermowell fouling with carbonised bitumen or slag
- Reading offset greater than ±5 °C versus a calibrated handheld reference under steady-state process conditions
Compatibility & fitment
Supplied for all AVL-DMP plant capacities from 40 TPH to 160 TPH; Avelta matches sensor type (TC or RTD), temperature range, process connection thread, insertion length, and cable termination to the plant's PLC analogue input card specification and existing junction-box wiring.
Why buy from Avelta
Avelta temperature sensors are individually calibrated and supplied with a calibration record, matched thermowell, and pre-wired extension cable, eliminating the loop errors and signal offsets that arise when sensors, thermowells, and cables are sourced separately. Batch stock availability ensures same-week despatch of common configurations.
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