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

Preventative Maintenance

• 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

PM Schedules

Performing scheduled maintenance based on manufactures requirements will help eliminate “unscheduled” downtime.

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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

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

Turmac Maintenance List

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

Grease fittings

Gear Box

Mixer Maintenance

Grease Fitting

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

Mixer Maintenance

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

Mixer Maintenance

Hydraulic Coupling

Safety fuse. Rated for 356°

Mixer Maintenance

Spare safety fuse for the hydraulic coupling.

Breather for Gearbox. Filter should be cleaned weekly to keep pressure from building in gearbox.

Mixer Maintenance

Drain plug for gearbox oil

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

Mixer Maintenance

Rotating gear box

Seals

Prevents water and

concrete from penetrating

Oil drops from gear box

Outside casing

of gearbox

Lubricator

fittings

Guards

Grease pushes possible

impurities & moisture out

Mixer Gear Box

Mixer Maintenance

• Mixer Gear Box

• Above mixing spider

Grease pushes possible

impurities & moisture out

Lubricator fitting

Guard

Oil seals

Tightening

shim

Mixer Maintenance

• Mixer Gearbox

Mixer Maintenance

Proximity sensors on discharge door. • Must clear target

• Positioned correctly

• Must be kept clean

• Inspect weekly

Water Bar/Meter Maintenance

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

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

14,000 + yards

New shovel 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 approx-

imately 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.