Batch Plant Maintenance

Batch Plant Maintenance

Batch Plant Maintenance Preventative Maintenance PM Schedules Mixer (Haarup) Skip Hoist Cement Systems Pneumatic Valve Panels Water Systems Aggregate Bins & Equip Dust Collectors Cement Silos Automation/Database

Proper plant maintenance increases efficiency and profitability by decreasing unexpected costs associated with down-time. Key Components to PM include: (1) following the recommended maintenance schedules and procedures (2) understanding MTBF expectancy of the equipment - replace before failure (3) keeping a safety stock of critical parts to ensure minimal down time Preventative Maintenance

PM Schedules Turmac Maintenance List Performing scheduled maintenance based on manufactures requirements will help eliminate unscheduled downtime. Equipment Code Description How Who When Result Turmac Mixers & 1 Check moisture probe & clean visually operator all / shift Ensure proper operation Haarup Mixers 2 Check adjustment of proximity sensors on discharge doors visually operator 1 / day Ensure proper operation 2 Check adjustment of proximity sensors on discharge blade visually operator 1 / day Ensure proper operation 2 Clean all agitator arms & wear blades manually maintenance 1 / day Prevent build up and mixer damage 2 Clean all scraper blades manually maintenance 1 / day Prevent build up and mixer damage 4 Adjust all wear blades (side, door agitator) manually maintenance 1 / mo Prevent build up and mixer damage 2 Remove build-up on side-liners & bottom-liners manually maintenance 1 / day Prevent build up and mixer damage 2 Wipe all water bar spray nozzles inside of mixer manually maintenance 1 / day Ensure proper operation 3 Adjust thrust & trunion rollers manually maintenance 1 / wk Extend life of drive gear 3 Spray drive gear & pinion with lubricant manually maintenance 1 / wk Prevent failure and extend life 4 Check gear box oil level manually maintenance 1 / mo Prevent failure and extend life 4 Check rotating chute drive chain adjustment and bearing surface manually maintenance 1 / mo Prevent failure and extend life 3 Grease all fittings manually maintenance 1 / wk Extend life / prevent failure 3 Check air panel & empty water trap visually maintenance 1 / wk Detect leaks & assure free air flow For Haarup mixers refer to manual for further information as needed Skip Hoist 2 Check limit switches for proper adjustment visually operator 1 / day Prevent serious malfunction 3 Check the dead man and shackle at the skip winch visually maintenance 1 / wk Prevent failure 3 Check for wear on the skip hoist wheels visually maintenance 1 / wk Extend life of wheel 3 Check for wear on bucket cable pulley shaft and bushings visually maintenance 1 / wk Prevent failure and extend life 3 Grease skip bucket wheels manually maintenance 1 / wk Prevent failure and extend life 3 Grease skip buck cable pulley manually maintenance 1 / wk Prevent failure and extend life 3 Grease hoisting drum pillow blocks manually maintenance 1 / wk Prevent failure and extend life 3 Grease skip bucket door pillow blocks manually maintenance 1 / wk Prevent failure and extend life 4 Check skip winch gearbox oil level manually maintenance 1 / mo. Prevent failure and extend life 4 Check for spacing and wear on electric brake motor visually maintenance 1 / mo. Ensure proper function For Haarup skip hoist refer to manual for further information as needed Page: 3 of 6 Blending Belts 1 Check belt alignment visually maintenance all / shift Prevent belt wear 2 Clean holding hopper manually maintenance 1 / day Prevent belt wear & ensure proper function Adjust the tail pulley during break in manually maintenance as needed Prevent belt slip 1 Check for rocks wedged between the skirting and belt visually maintenance all / shift Prevent grooves forming in conveyor belting 3 Grease head pulley pillow blocks manually maintenance 1 / wk Prevent failure and extend life 3 Grease tail pulley pillow blocks manually maintenance 1 / wk Prevent failure and extend life 4 Grease troughing rollers and return idlers manually maintenance 1 / mo. For smooth belt operations 3 Check air panel & empty water trap visually maintenance 1 / wk Detect leaks & assure free air flow 3 Check vibrator mounts for stress fractures visually maintenance 1 / wk Prevent hopper from cracking 4 Check flow switch for wear and proper adjustment manually maintenance 1 / mo. Ensure proper functions 4 Check gearbox for proper fluid level visually maintenance 1 / mo. Prevent failure and extend life 42" Transfer Belt 1 Check belt alignment visually maintenance all / shift Prevent belt wear 1 Clean receiving hopper visually maintenance all / shift Prevent belt wear & ensure proper function Adjust the tail pulley during break in manually maintenance as needed Prevent belt slip 1 Check for rocks wedged between the skirting and belt visually maintenance all / shift Prevent grooves forming in conveyor belting 3 Grease head pulley pillow blocks manually maintenance 1 / wk Prevent failure and extend life 3 Grease tail pulley pillow blocks manually maintenance 1 / wk Prevent failure and extend life 4 Grease troughing rollers and return idlers manually maintenance 1 / mo. For smooth belt operations 4 Check for spacing and wear on electric brake on motor visually maintenance 1 / mo. Ensure proper function 3 Check Emergency stop for proper operations manually maintenance 1 / wk Ensure proper operations 3 Check for proper alignment on the scraper visually maintenance 1 / wk Prevent slippage and failure 4 Check gearbox for proper fluid level visually maintenance 1 / mo. Prevent failure and extend life 35" Transfer Belt 1 Check belt alignment visually maintenance all / shift Prevent belt wear 1 Clean receiving hopper visually maintenance all / shift Prevent belt wear & ensure proper function Adjust the tail pulley during break in manually maintenance as needed Prevent belt slip 1 Check for rocks wedged between the skirting and belt visually maintenance all / shift Prevent grooves forming in conveyor belting 3 Grease head pulley pillow blocks manually maintenance 1 / wk Prevent failure and extend life 3 Grease tail pulley pillow blocks manually maintenance 1 / wk Prevent failure and extend life 4 Grease troughing rollers and return idlers manually maintenance 1 / mo. For smooth belt operations 4 Check for spacing and wear on electric brake on motor visually maintenance 1 / mo. Ensure proper function 3 Check Emergency stop for proper operations manually maintenance 1 / wk Ensure proper operations 3 Check for proper alignment on the scraper visually maintenance 1 / wk Prevent slippage and failure 4 Check gearbox for proper fluid level visually maintenance 1 / mo. Prevent failure and extend life

Mixer Maintenance Proper Mixer Maintenance Increase the life of the mixer Increase the life of the liners Increase the life of the mixing tools Reduces risk of downtime Reduces cost of expedited parts

Mixer Maintenance Greasing the Seals Fluid Coupling Change GB Oil Sensor Adjustment Water System / Nozzles Mixing Tools

Mixer Maintenance Gear Box Grease fittings

Grease Fitting Mixer Maintenance

Mixer Maintenance Grease Fitting. Remove protective cap and insert grease Grease twice a month Fill until grease visible from GB seam Bump mixer and re-grease

Mixer Maintenance Grease Fitting. Remove protective cap and insert grease

Grease Fitting on housing for discharge door. Needs to be greased on a bi-weekly basis. Mixer Maintenance

Mixer Maintenance Hydraulic Coupling Safety fuse. Rated for 356

Mixer Maintenance Breather for Gearbox. Filter should be cleaned weekly to keep pressure from building in gearbox. Spare safety fuse for the hydraulic coupling.

Drain plug for gearbox oil Mixer Maintenance

Mixer Maintenance Inlet for filling oil. Oil level should be about half way up this gear. Oil must be changed after 500 hrs of operation and then every 5,000 hrs.

Haarup Technician: On-site PM Visit Inspect Motor Coupling Checks GB Alignment Adjusts Alignment shims (if required) Inspect Gears - check mesh Replace seals, bearings, coupling (if required) Change gearbox oil Replace / Adjust Mixing Tools Mixer Maintenance

Outside casing of gearbox Mixer Maintenance Mixer Gear Box Oil drops from gear box Lubricator fittings Guards Rotating gear box Grease pushes possible impurities & moisture out Seals Prevents water and concrete from penetrating

Mixer Maintenance Mixer Gear Box Above mixing spider Lubricator fitting Guard Grease pushes possible impurities & moisture out Oil seals Tightening shim

Mixer Gearbox Mixer Maintenance

Mixer Maintenance Proximity sensors on discharge door. Must clear target Positioned correctly Must be kept clean Inspect weekly

All inlets and outlets (water nozzles, cement, additives, etc..) should be cleaned on a daily basis. Meter Calibration Checked as needed or every 3 months Water Bar/Meter Maintenance

Mixer Maintenance Haarup mixing shovels should be adjusted/turned as required. Increase life of shovel Increase life of liners Decrease clean-up Maintain fast mixing cycles New shovel New 14,000 + yards 14,000 + yards

Mixer Maintenance Mixing shovels and side scrapers should be adjusted approximately 2-3mm from the liners. These should be inspected and adjusted on a monthly basis. Improper adjustment will lead to premature wear on liners and shovels.

Mixer Maintenance Protective sleeves are available for the mixing arms. These provide additional protection for a fraction of the cost of new arms. Bottom and Side Liners should be changed when the bolt head begins to shrink in size. This will allow plenty of time for the new plates to arrive for installation. Haarup recommends replacement when the bolt head reaches 17mm in diameter.

Skip Hoist Maintenance Skip Hoist Cable: inspected weekly, replaced with any visible damage (one strand broken) GB Oil Level: checked monthly, oil replaced after 5,000 hrs Skip Wheels: checked monthly

Skip Hoist Maintenance LUBRICATION & MAINTENANCE Every 3rd month: Grease the Flanged Bearing on the wire drum. Grease the Flanged Bearings on the charging chute for mixer. Grease the Skip Hoist wheels. Grease the Teflon Bearings and steering rollers at gate on skip hoist. Check the oil level in the gearbox. Every month: Clean and Lubricate the skip hoist cable (use B2 Sunspray or a very thin engine oil). Clean and Lubricate the fall safety device on the Haarup skip hoist. Clean and Lubricate all moveable parts.

Cement Batcher / Screw Conveyor Maintenance Cement Screw Conveyor Check GB Oil Level: Monthly Change GB Oil: 5,000 hrs Replace Hanger Bearings First Sign of Noise Cement Batcher Monitor cement sock for leaks: daily. Check Alignment of butterfly valves: weekly. Clean the inlet to mixer: daily. Check vibrator mounts and bolts: weekly. Check vent tubes: weekly.

Pneumatic Valve Panel Maintenance Valve panels should be checked daily for leakage. The water trap should be drained every day. One replacement valve should be kept in stock for every different type in use.

Aggregate Bin Maintenance Monitor high/low bin indicators for proper operation: daily Check the paddles on the bin indicators: monthly Check the cylinders / choking collars: weekly Grease the clam gates: monthly Check the vibrator mounts and bolts for fatigue: monthly

Aggregate Batching Belt Maintenance Check Belt Scraper Wear and Alignment Check Scraper is not too tight Grease Head / Tail Pulley Bearings: Monthly Check Gearbox Oil Level: Monthly Change Oil every 5,000 hrs

Dust Collector Maintenance The Dust Collectors should be inspected and cleaned on a monthly basis to assure proper operation. The cartridges should be removed from the dust collector body and cleaned. Failure to do so could cause the dust collector to clog up with cement and cause permanent damage to the body. Cartridges should be replaced approximately every 12-18 months. The Silotop dust collector should remain on at all times when the silo is being filled and remain on for at least 10-15 minutes after the silo has been filled.

Cement Silo Maintenance Check the pneumatic valve panel and empty water trap daily. Check for leaks at the same time. Check the dust collector cartridges on a monthly basis. Dust collectors should remain on the entire time the silo is being filled. Inspect bin indicators on a monthly basis. Check aeration pads when cement weighing becomes erratic. Clean and/or replace pads if they become clogged.

Automation/Database Maintenance The Batchmatic database has a capacity for 65,000 entries. To ensure optimum performance, the batch counter has been limited to 20,000 batches. Some printing lockups or slow computer performance can be attributed to database overload. It is recommended that a Turmac technician is contacted when the total batch count nears 20,000. An alarm can be installed to alert the batch operator to contact Turmac prior to the batch count reaching 20,000.