Asphalt plant maintenance holds paramount importance in ensuring uninterrupted production and supply, minimizing any potential losses incurred due to equipment failure during the production process. However, many failures arise due to inadequate maintenance practices, which can be mitigated if addressed early on. This brings us to the crucial question: How can we effectively and diligently maintain the equipment and ensure optimal daily upkeep? Notably, a survey reveals that 60% of equipment failures stem from insufficient lubrication, while 30% result from improper fastening. With these insights, the primary focus of daily machinery and equipment maintenance lies in anti-corrosion measures, lubrication, precise adjustments, and secure fastening.
Asphalt Plant Maintenance: Batching Station
(1) In each working shift,
check whether the bolts of vibration motor are loose;
Check whether the bolts of each component of the batching station are loose;
Check whether each roller has the phenomenon of belt jamming/non-rotation;
Check whether the belt has runaway.
(2) After 100 working hours,
check the oil level and leakage, replace damaged seals and add grease (ISO viscosity VG220 mineral oil) if necessary;
Cleaning the breather holes;
Apply grease to the belt machine tensioning screw.
(3) After 300 working hours,
grease the main and driven pulley bearings at both ends of the feed belt with calcium-based grease (just see oil coming out);
( batching station )
Asphalt Plant Maintenance: Drum Dryer
(1) After 100 working hours,
check the oil level and leakage, replace damaged seals and add grease (ISO viscosity VG220 mineral oil) if necessary;
Cleaning of the air permeability holes;
Check whether the four supporting wheels are in good contact with the drying drum.
(2) After 300 working hours,
roller and limit wheel support bearing oil (grease), note: feel a sense of pressure saturation can be;
(3) drying drum lubrication cycle: new machine working 200-300h,
replace (for the first time) reducer lubricant, add to half of the oil mirror on;
Later 1500h, replace the (first) reducer lubricant, add to half of the oil mirror can be.
Note: The ambient temperature will affect the type of oil used, and the lubricant should be replaced with various oils of lower viscosity grade one type in the northern winter construction.
(Dry drum)
Asphalt Plant Maintenance: Dust collector
(1) In each working shift, check whether the bolts of each part of dust collector are loose;
Check whether each cylinder moving is normal; check whether each cylinder action is normal and
whether there is leakage in each gas circuit;
Check whether the induced draft fan has any strange sound, whether the belt is suitable for tightening and whether the adjusting dampers are flexible.
2） After 300 working hours, inject 2# lithium grease into the gravity valve bearing;
Ash discharge spiral bearing injected with 2# lithium grease;
Inject 2# lithium grease into the bearing of induced draft fan damper; Note: Open bearing can be seen with oil coming out.
Spiral bearing injected with 2# lithium grease;
The main shaft bearing of the induced draft fan is injected with 2# lithium grease; Note: it is enough to feel the pressure saturation.
The induced draft fan damper joint is coated with calcium-based grease.
(3) dust removal system lubrication cycle: new machine work 200-300h, replace (for the first time) reducer lubricant, add to half of the oil mirror on;
Later 1500h, replace (for the first time) the reducer lubricant, add to half of the oil mirror on it.
Note: The ambient temperature will affect the oil type used, and the lubricant should be replaced with the same type of oil of lower viscosity level when constructing in winter in the north.
(Dust collector)
Asphalt Plant Maintenance: Vibrating Screen
1) It is best to stop regularly when working to minimize the loss of vibrating screen. The shutdown frequency is 8 hours of work and 1 hour of rest, which can prolong the service life of the vibrating screen.
2) To determine the screen aperture by the laboratory according to the condition of the aggregate.
3) Because the vibrating screen works under high-speed rotation and vibration conditions, the bolts and nuts should be tightened at least once a week. Especially the initial month of starting the machine should be checked daily.
(4) The size of the excitation force adjustment is: you can adjust the percentage of eccentric block, but if it is too large, it will damage the bearing.
5) Before the equipment is shut down, all the aggregate in the vibrating screen should be discharged.
(Vibrating screen)
Asphalt Plant Maintenance: Hot Material Bin
In each work shift, check whether the hot material bin door is stuck, open the door flexibly and the cylinder moves normally;
Check whether the overflow pipe is blocked or not;
Check whether the pneumatic butterfly valve is flexible to open the door and whether the cylinder action is positive.
(Hot material bin)
Asphalt Plant Maintenance: Mixing Host
(1) In each working shift, check whether the air pressure is normal and 0.7Mpa.
Check whether there is air leakage in each air circuit;
Check whether there is oil in the oil mist gas and add it if necessary;
Check whether the mixing mainframe parts are running normally;
Check whether there is any loosening of the bolts of the main machine;
Touching and checking the temperature, whether there is any abnormal temperature rise during work;
Check the liner, blade and mixing arm bolts tightening, no loose bolts, no scraping between the blade and the liner;
Check whether there is any leakage of asphalt at the end of the shaft.
(2) 200-250 working hours, check to adjust the mixing host switch door connecting rod end nut is loose, under normal circumstances the discharge door can be completely open or closed;
Observe whether the sealing devices of the hole, various material ports and discharge port are effective, and give repair or replacement if necessary.
(3) 10 working hours: the shaft end seal stuffing box is manually added with 3-5ml oil;
50 working hours: stirring main bearing manually add 20ml oil, discharging door bearing seat manually add 5-10ml oil.
1500-2000 working hours: check the wear of blades and liners, if they are worn to 2/3 of the original area, they should be replaced;
Check the wear and tear of v-belt, replace the whole group if necessary;
Listen to the reducer operation, if loose, impact or noise, should be disassembled, adjust the gap or replace the wear parts;
Clean the reducer breathable cap.
(4) mixing host lubrication cycle: new machine work 300h: replace (first) reducer lubricant, add to half of the oil mirror on;
The next 1500h: replace (for the first time) the reducer lubricating oil, add up to half of the oil mirror.
NFLG asphalt plant mixing mainframe
Asphalt Plant Maintenance: Aggregate Elevator
(1) In each working shift, check whether the chain is loosened and tightened properly;
Check whether the bearings have any jamming, strange noise and abnormal temperature rise; check whether the chain bucket has any deformation.
(2) 30 working hours: inject grease into the active sprocket bearing;
Inject grease into the bearing of the driven sprocket
(3) 100 working hours: grease the sprocket tensioning screw
4）Aggregate/powder material elevator lubrication cycle: 300h for new machine: replace (for the first time) reducer lubricating oil, add to half of the oil mirror; 1500h later: replace (for the first time) reducer lubricating oil, add to half of the oil mirror.
Aggregate/powder elevator
NFLG GLB5000 asphalt mixing plant + RLB2000 thermal regeneration plant applied in Linyi Municipal Engineering Co.
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