Reduce Plant Operation Costs with Proper Preventive

Reduce Plant Operation Costs with Proper Preventive Maintenance

Dennis Hunt Senior Vice President Gencor Industries, Inc.

© Copyright 2013 Gencor Industries Inc.

Safety First

PPE


Proper Tools


Proper Tools



Spare Parts

Check List • Plant maintenance

– Written schedule – Check list – Daily inspection – Keep records


Check List


Maintenance to be Performed Maintenance

Main Type of D=Daily W=Weekly BW=Bi-Weekly M=Monthly Y=Yearly A/D=As Directed Completed

Component Maintenance Part

Conveyor Visual Check all moving parts for proper operation or abnormalities D Conveyor Visual Guards Insure that all guards are in place D Conveyor Visual Check & fill ballast D Conveyor Visual Idlers Check all idlers for proper operation D Baghouse Visual Baghouse Walls Check for oily mist on walls - see manual if present D

Baghouse Visual Exhaust Fan Check for oily residue on housing or duct - see manual if present D

Baghouse Visual Exhaust Stack Check for blue smoke or black stacking - see manual if present D

Baghouse Visual Baghouse Dust Check if dust is gray or black - see manual if present D Baghouse Visual Housing Check for holes in ducts and worn seals D Baghouse Visual Electrical Cables Check for cuts, cracked, or abraded cables D Baghouse Visual Fans Check for correct rotation D Baghouse Visual Conveyor Check for correct rotation of motor and flow D

Hot Oil Heater Visual Gas Burner Check incoming and manifold reading D

Daily Plant Inspection • Pre shift inspection • Daily checks and maintenance • Post shift inspection • Keep records • Have a check list


Monitor The Plant


Daily Plant Inspection





















342°F 315°F 230°F 156°F


Veil in drum

263°F

151°F


Veil in drum

212°F

260°F




Keys to Proper Combustion

• Properly tuned burner • Properly sized burner • Properly sized combustion zone • Proper fuel viscosity


Causes of High CO

• Burner not properly tuned – Improper air/fuel ratio


Combustion Zone


Combustion Zone


Ductwork


Ductwork


Leakage Air

Leakage Air


Leakage Air


Leakage Air


Leakage Air

• Baghouse door gasket 5’ x ¼”

• 15 sq in. • Suction 5” • 908 CFM loss

Baghouse


Baghouse


Moisture in Baghouse


Asphalt Cement Pump


Trunnion Adjustment


Trunnion Adjustment


Trunnion Adjustment


Trunnions

112°F 93°F

100°F

69°F 77°F

93°F

105°F

Feed end

Discharge

125°F

Rotation


Trunnion Adjustment


• MAKE SURE ALL POWER SOURCES ARE

OFF AND LOCKED OUT BEFORE

ATTEMPTING TO ADJUST THE TRUNNIONS

• DO NOT UNDER ANY CIRCUMSTANCES TRY

TO PERFORM THIS MAINTENANCE WHILE

THE IS RUNNING

•WHENEVER MAINTENANCE IS DONE ,

ALWAYS NOTIFY THE OPERATOR

•FAILURE TO DO SO CAN RESULT IN SERIOUS

OR FATAL INJURY

TRUNNION ADJUSTMENT PROCEDURES


Trunnion Adjustment • A properly adjusted set of trunnion rolls will cause a

constantly loaded drum to “float” between the thrust rolls for weeks at a time, without the tire touching either of the thrust rolls

• Trunnions must be adjusted at the “average” production rate the drum/dryer produces on a daily basis

• Drum will run downhill empty – uphill loaded • If increased production rate is going to continue for

extended time periods, you will want to make an adjustment to compensate for the loading changes on the drum/dryer


Bearing Lubrication • Lubrication serves to:

– Carry away heat – Reduce wear and

friction – Minimize debris

problems – Protect wearing

surfaces for corrosion


Greasing • Proper greasing

– When bearing is running at operating temperature – Clean grease zerk before and after greasing – Following manufactures recommendations – Keep a greasing chart


Bearing Failure


Bearing Failure • 50% of all bearing

failures caused by lubrication – Insufficient lubrication – Excessive lubrication – Contamination


Bearing Failure • Overfilling a bearing with too much grease can cause

excess churning of the grease during operation and high temperatures, resulting in overheating and excess grease purging* (leaking). Overheating occurs because the heat generated cannot dissipate correctly, continually building until damage occurs. As the operating temperature of the bearing rises, the oxidation (breakdown) rate of the grease sharply increases – doubling every 18º F.


Bearing Failure • Under filling a bearing with grease can also have

adverse consequences. As in overfilling, heat can be generated but for different reasons. When the grease amount is low, a grease starvation condition may be created, causing heat generation or excessive metal wear during operation. If a bearing suddenly becomes noisy and/or the temperature increases, excessive wear may be taking place.


Check The Stack

• Look at the stack at least twice a day

• Monitor baghouse pressures


Check List FEED BINS • CONDITION OF FEEDER BELTS / SPLICES • CONDITION OF FEEDER BELT SKIRTING • OPERATION OF FEEDER NO FLOW DEVICES • CONSISTENT FEEDER DRIVE OUTPUT / CALIBRATION SCALE CONVEYOR • CONDITION OF BELT / HOW MUCH STRETCH • GRAVITY TAKE UP BOX WORKING CORRECTLY • TRACKING OF BELT • HISTORY OF LOAD CELL / LOAD CELL mv/V VOLTAGE RANGE • CONSISTENT SCALE CALIBRATION AGGREAGTE FEED CHUTE / CONVEYOR • NO AIR LEAKS AROUND FEED CHUTE OR FEED CONVEYOR DRYING FLIGHTS • CORRECT POSITION OF DRYING FLIGHTS • CONDITION OF DRYING FLIGHTS / WEAR COMBUSTION ZONE • CORRECT COMBUSTION ZONE LENGTH • CONDITION OF COMBUSTION FLIGHTS • HEAT DAMAGE FROM INCORRECT BURNER SET UP BURNER • IMPELLER CONDITION / BALANCE • DRIVE BELTS / SHEAVE ALIGNMENT • FUEL / AIR LINKAGE SETUP • MODULATING DRIVE MOTOR • PILOT IGNITION SYSTEM • CONDITION OF FLAME MANAGEMENT SYSTEM (SCANNERS) • CONDITION OF NOZZLE AND INTERNAL FUEL DISPENSING COMPONENTS • FUEL CONTROL VALVES • FLUE GAS ANALYZED • OIL FIRED BURNER / CHECK SYSTEM FROM FUEL TANK TO BURNER AND ALL COMPONENTS IN BETWEEN • GAS FIRED BURNER / CHECK SYSTEM FROM GAS MAIN TO BURNER AND ALL COMPONENTS IN BETWEEN


Driving Maintenance Efficiencies

• Train • Plan • Organize • Look • Listen • Report • Correct


Thank You


Documents

Reduce Plant Operation Costs with Proper Preventive