Built for - Gencor Industries, Inc.

Fall/Winter 2010
A publication from Gencor Industries, Inc.
Speed
Built for
E. Tetz & Sons’ quick turnaround
A cost-saving ‘trend’
Proper reports can make your offseason productive
Importance of Good Flighting
Seven steps help you maximize plant efficiency
One Company
•
One Source
•
One Solution
MANAGEMENT MESSAGE
Partnering for Success
4
IN THIS ISSUE
S
uccess in any business usually involves good partnerships, and Gencor is no exception.
Much of what we have achieved over the last 50 years is due to our relationships with
HMA Contractors who share our philosophy of honesty, integrity, and exceptional
service above and beyond. We believe in being a good partner not just in good times, but more
importantly when it’s needed most—never compromising your principles nor forgetting the
reason why you are in business in the first place.
Marc Elliott
President
Gencor Inc.
4
Built for Speed
Plant designed to quickly serve customers
In this issue, we feature two Gencor customers who learned first-hand that Gencor is more
than just an equipment manufacturer, but also a resource that can assist in whatever business
challenges surface along the way.
For example, E. Tetz & Sons had many impediments along the route to installing its new Gencor
Ultraplant. Gencor provided the much needed support throughout the permitting process by
providing technical engineering solutions and support to bring this decade long dream of Gary
Tetz to fruition.
We at Gencor take great pride in customer success stories because they underscore what we are
really all about: a solutions provider.
8
A Cost-Saving ‘Trend’
Proper reports make your off-season productive
8 14
Importance of Good Flighting
Seven steps help you maximize plant efficiency
18
An Ongoing Philosophy
The Best Just Keeps
Gencor training provides plant independence
Getting Better!
Visit Gencor Industries at
ConExpo - Con/AGG
March 22-26, 2011
2
Outdoor Booth# 730 Silver Lot 2
Las Vegas Convention Center
18
Innovations™ is published by High Velocity Communications Inc.. Publisher, Ken Snover • Editor, Pete Kennedy • Art Director, Jason France •
Director of Client Services, Kris Matz. Every attempt has been made to ensure specifications are accurate. Because specifications are subject to
change without notice, check with us for the latest information. Some photography provided courtesy of Gencor Industries Inc. Gencor, its respective logos and corporate and product identity used herein and Innovations are trademarks of Gencor Industries Inc. and may not be used without
permission. Phone (407) 290-6000. High Velocity Communications Inc., 2444 North Grandview Blvd., Waukesha, WI 53188. Phone (262) 544-6600.
© 2010 Gencor Industries Inc.. All rights reserved. Printed in the U.S.A. Volume 4 Number 1.
CUSTOMER PROFILE
Speed
Built for
Plant designed, built to
quickly serve customers
T
here are times when all the planning and homework
still aren’t enough. That’s the situation E. Tetz & Sons
Inc. found themselves in when they pursued a permit to
open a hot mix plant.
For more than a decade, the Middletown, N.Y.-based
company had fought endless legal challenges and lawsuits that
repeatedly stalled any momentum on the project.
Most contractors would have given up, but Gary Tetz is
not one of them. “We knew we could succeed in the asphalt
business, and we weren’t about to let someone else tell us we
couldn’t,” said Tetz, CEO of the company.
That determination was a great starting point, but
challenges remained. Specifically:
1. Obtaining the permit.
2. Luring prospective customers away from their existing
suppliers.
The Permit
Industry veteran shares knowledge about purchasing the right product
at a glance
Name: E. Tetz & Sons Inc.
Headquarters: Middletown, N.Y.
Opened: 1955
4
Employees: 135
Products: Asphalt, sand and gravel, concrete
Plants: 8, including one asphalt plant, which opened in 2009
Tetz knew from the start that obtaining a permit would be
a challenge. “One plant provider wouldn’t even give us a quote
on equipment,” Gary Tetz said. “They said, ‘Get the permit
first, then give us a call.’”
Gencor was more helpful from the beginning, and played a
key role in obtaining the proper permitting. “Their experience
was extremely valuable,” Gary Tetz said. “We hadn’t been
through this type of permitting before.”
The process was involved, and highly technical questions
were asked about emissions, sound and even aesthetics.
“Gencor stuck by us,” Gary Tetz said. “When there were public
hearings, they had their people there—and they didn’t ask for
any compensation. They came to a number of public hearings
and represented us well.”
E. Tetz & Sons also was able to show the regulators how
similar operations worked, as well as their environmental
impacts. “I visited several Gencor plants in Florida, and all of
the on-site people were very receptive,” Gary Tetz said. “They
let us go through their plants and conduct noise studies so
we knew what we were buying, and how our new plant would
sound when it was up and running.”
That eliminated any guesswork on the part of community
planners. “We were able to give the planning board here actual
readings from a comparable plant,” Gary Tetz said.
E. Tetz & Sons also found an outstanding lawyer in
Rosemary Stack of Syracuse, N.Y., who represented them well
throughout the process. Stack proved persistent and hardworking—which were essential to gaining the approval.
Continued on page 6
5
CUSTOMER PROFILE
Eventually, the permit was issued.
E. Tetz & Sons understood the business basics, having
run quarry and aggregate operations for decades. Asphalt
production was an obvious area of expansion, but it still
required expertise that the company hadn’t yet developed.
Specifically, Tetz needed to know what to buy and where to
put it. The “what to buy” part was relatively easy: Tetz decided
on a skidded Ultraplant. It included a 400-ton-per-hour
Ultradrum, Ultraflo baghouse, seven cold feed bins, two RAP
bins, six silos, three Hy-Way AC tanks and a state-of-the-art
control center with full Ultralogiks automation.
The ability to purchase the entire plant from one
manufacturer “helped us to jump in with both feet,” said Joe
Tetz, General Manager at the company. “We decided that if we
were going to do this, there was no going half-way.”
Starting from scratch has its benefits—particularly when
it comes to setting up the plant. There were no existing
foundations or equipment to work around.
“Setting up the plant was something we did right,” said
John Duffus, Plant Supervisor. “Gencor is exceptional at that.
We had never set up a plant before; we were totally green. They
set it up and used all their experience. The plant is efficient,
the loading is efficient, you can get the trucks in and out of
there fast.”
Speed as the differentiator
That plant design isn’t just a matter of convenience; it also
provides a competitive edge. The plant was designed and built
for speed, with six silos and two scales to quickly transition
customers in and out. “I hate the word ‘wait’,” Gary Tetz said.
Tetz also instituted a remote ticketing system. A wireless
network, which runs through the Gencor load-out system,
sends order details to a remote scale house location. The ticket
is printed and handed to the driver, helping him transport the
hot mix to the jobsite more quickly.
The result of all these efforts—multiple silos, quick
ticketing and fluid design—build on E. Tetz & Son’s
longstanding commitment to customer service. Customers
who gave the new plant a try were in and out in five
minutes, instead of 45 minutes (and often longer) wait times
experienced elsewhere. They left with a quality product, too.
It didn’t take long for word to spread about the new plant.
E. Tetz & Sons delivered on the same promise that had helped
the company grow for more than 50 years.
“This business has been based on quality and service since
my grandfather started it in the 1950s,” Joe Tetz said. “We
quickly earned that reputation in concrete and aggregates.
With Gencor’s help, it didn’t take us very long to earn that
same reputation in asphalt. Their service and ours are second
to none.”
Surviving
the Startup
Down the road
E. Tetz & Sons produced 180,000 tons of asphalt in its first
year and expects to increase that substantially this year—to a
total approaching 300,000 tons.
“We have converted a lot of customers from our
competitors, and think that having these customers with us all
year will help us reach that goal,” Duffus said.
The early financial returns on the plant have been good.
“I’ve never worked with people with so much determination,”
said Duffus. In addition to Gary and Joe Tetz, that list also
includes family members Skip, Denise and Corinne Tetz.
“They dug their heels in. I couldn’t be any more proud to
work here, and be a part of this family.”
Expanding a business and opening a plant is exciting.
It also can be challenging. So what should new asphalt
producers do to improve their chances of success? E. Tetz
& Sons suggests these start-up necessities.
Demand outstanding customer support. “You need
to have some outside expertise, and support of your
equipment,” said John Duffus, Plant Supervisor with
E. Tetz & Sons. “Gencor engineers and customer support
staff helped ease the situation. They had an engineer with
us when we set the plant up, right through the first day
that we ran it.”
Other customer support and software questions were
handled quickly over the phone. “They’ll work through
whatever you need to in person, or on the phone,” Duffus
said. “They can access our equipment through the Orlando
location. If need be, they actually can run the plant from
Orlando.”
Keep your word, no matter what the cost. Promises
are made during the permitting process. Make sure you
are ready and able to keep them when your doors open.
After all, the skeptics will be paying close attention.
“People are definitely watching,” said Gary Tetz, CEO of
E. Tetz & Sons.
“The efforts don’t have to be excessive. We were able
to keep our environmental promises by using Gencor
equipment. We also opted for features such as drum
insulation for sound attenuation and the silo blue smoke
capture system.”
Look ahead. “We added Gencor’s Advance RAP entry
system to allow 50 percent recycled material into the
product,” said Duffus. He also sees warm mix playing
an increasingly larger role. “In the next five years, we’re
going to see that the majority of mix will be warm mix,”
he predicted.
6
7
PRODUCT SUPPORT
NEW TECHNOLOGY
NEW
HEADLINE
A Cost-Saving
‘Trend’
By John Hynes
Product Support Technician
Gencor Inc.
Subhead can go here as reference
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8
reventative maintenance is nothing new to HMA
contractors and is typically part of the planning
process for virtually all plants. But have you ever
considered predictive maintenance? It’s a separate, yet
valuable process that involves analyzing your equipment and
processes and includes preparing for potential problems.
Why practice predictive maintenance? Because this early
planning enables you to obtain parts and establish procedures
that can be enormous cost-savers. In fact, predictive
maintenance costs less than preventative maintenance.
What, specifically, are the differences between preventative
and predictive maintenance? Preventative maintenance
involves a scheduled rebuild of equipment—whether or not
it actually needs to be rebuilt. It’s planned more around
schedules and total operating hours rather than actual
replacement need. While unplanned downtime is avoided,
parts that still have life left are replaced; virtually throwing
away money in the process.
Are we saying that you shouldn’t practice preventative
maintenance? Absolutely not. While every situation is
unique, the best approach is a combination of predictive and
preventative maintenance.
Predictive
Predictive maintenance involves analyzing your equipment
through the use of technology and observations by experienced
plant personnel. Key to this process is “Trending”—and key to
Trending is keeping thorough reports.
The individual responsible at your plant needs to routinely
record all variables, such as dust, moisture, and equipment
exposed to harsh environments. Trending labor is another key
indicator, alerting you to areas where your personnel spend a
disproportionate amount of time. These reports can be spread
out over the entire season, or recorded over shorter terms such
as weekly or monthly.
It is crucial to undertake a year-end Trending of the
equipment before winter sets in. This examination should
occur when the plant is running at full production so that you
can compare it to similar circumstances when full production
resumes in spring. (A quarterly report is best for those plants
that don’t shut down over the winter months.)
Infrared temperature guns
What kind of reports should you keep, and how do you
gather the information? You can start with the ground man
you rely on when starting the plant daily.
Continued on page 10
9
PRODUCT SUPPORT
Equip your plant man with an infrared temperature gun
and have him take readings around the plant. You could
use a very expensive thermal-imaging device to track the
temperatures, but all that’s really needed is a notebook, pen
and the infrared gun. Begin recording the temperatures
of bearings, gearboxes, electrical J-boxes, MCC bucket
components and any other key plant components on a
regularly scheduled basis. These readings should be recorded
in a plant diary for future reference.
Why is this important? Well, assume the bearing on a
trunnion assembly consistently reads 135º F. Then one day,
that temperature climbs to 145º F. Such an increase might
simply mean the bearing needs to be greased. However, a
temperature that continues to climb after greasing is a sign of
a failing bearing. Your personnel should contact Gencor and
make arrangements for a replacement bearing. Catching the
problem early enables you to order the part, and schedule the
replacement, without facing a catastrophic shutdown.
Keep a similar watch on gearboxes and other components.
The fluctuation could indicate something as simple as a faulty
wire—or something much bigger, like a failing component.
With winter approaching, now is the time to address any of
these significant temperature fluctuations.
10
Decibel meter
Noise is another indicator of potential trouble with
components. Unfortunately, vibration analysis tools can be
costly, but a simple decibel meter test can be an equally
effective tool.
Run only one piece of equipment, and use a decibel
meter to record the db level. You then can record the sound
level in your plant diary. You should repeat the db test for
all gearboxes, motors and other individual components.
Any increase in db levels over time is a good indication of a
looming problem. Although these tests are not as accurate
as an expensive vibration meter, they will give you a good
indication of potential problems for a lot less money.
The megger meter
These earlier tests can be performed relatively easily by
plant personnel, but the process can be more complex when
dealing with electrical issues. Due to the dangers involved,
you will need to have an experienced and well-trained person
familiar with high-voltage electricity to help you with the
Trending of plant components.
The last thing you want to do is to buy a new motor when
the old one is still good. Regular testing with a megger meter
should help avoid this. Megger meters are reasonably priced
and available from equipment supply houses. A 25 percent
difference is a warning, a 50 percent change an alarm and
a 75 percent discrepancy means it’s time for a replacement
motor. It’s also important to note how long it took for this
change to occur. If it Trends over several years, it’s simply the
result of time. A quicker change—over a single season for
example—could be a sign of other problems.
Aging or failing wiring can cause a lot of misdiagnosis
with plant equipment as well. An insulation test should be
followed up with an OHM balance test across the windings
of the motor (or whatever other components the electrician
is testing). In fact, all plant wiring should be included in the
electrician’s Trend report. Keep in mind that a bad test should
be confirmed by subsequent tests. Cumulative data from these
tests with a megger meter and OHM resistance test are a good
way to confirm results. Plant voltage tests should also be done
to assess the power company or transformer differences over
the season.
There is no crystal ball for all HMA plants, therefore, you
have to become familiar with how your plant operates under
normal conditions. Trending a typical operation is the best way
to predict trouble on the horizon and give you the “Predictive”
advantage to keep your plant running efficiently for the long
haul.
Ready for Winter?
Off-season storage techniques, page 12
11
PRODUCT SUPPORT
Ready for Winter?
Here are some storage techniques to take into consideration as you
prepare for the upcoming off-season
WINTER STORAGE FOR INACTIVE GEAR REDUCERS
Preparation for Storage
1.If a reducer is to be stored or is inactive after installation, fill
the reducer with the correct type and amount of lubricant.
Add a rust inhibitor such as Mobil Vaprotec Concentrate to the
lubricant.
2.Seal the reducer completely; replace the vent plug with a solid
pipe plug to keep air out.
3.After approximately three months, rotate the input shaft such
that the output shaft rotates a full 360 degrees. This will insure
that all internal parts will remain coated and will also keep
the bearings from becoming lacquered. (Non-compliance with
this procedure may cause bearing damage during start-up.)
4.Inspect the stored or inactive reducer every six months and add rust
inhibitor if necessary. Dry, indoor storage is recommended.
Preparation For Start-up
Rotate shafts until the bearings move freely. This is to ensure
that the bearings have not become lacquered. Reducer may be
operated without draining the lubricant.
WINTER AND SPARE MECHANICAL PARTS STORAGE
1.On receipt of spare parts, unpack and spray or dip the parts
in a rust preventative such as Mobilarma 524, or equivalent.
2.Place parts on a wood pallet in a dry place. Cover loosely
with plastic. DO NOT wrap or store parts in newsprint as it is
corrosive.
3.Re-spray parts every six months. (Spray parts every three
months if high humidity exists.)
4.If rust develops, remove rust with a medium grit emery cloth
and re-spray with rust preventative.
5.When ready to install parts, make sure all parts rotate
freely. Clean all grime from the parts before installation.
12
SO FUEL EFFICIENT,
IT MAKES YOUR HYBRID
LOOK LIKE A MONSTER TRUCK.
INSULATION RESISTANCE CHECKING FOR AN
ELECTRIC MOTOR
1.Disconnect motor from power supply before making any
insulation resistance measurement.
2.To avoid electric discharge risks, discharge the terminals
right after performing the measurement.
3.Measure the insulation resistance before operating the motor
and/or when there is any sign of moisture in the winding.
4.The resistance measured at 77ºF (25ºC) must be: Ri ³ (20 x
U) / (1000 + 2P) [MW] (measured with a MEGGER at 500 V
d.c.) where U = voltage (V); P = power (kW).
5.If the insulation resistance detected is less than 2 mega
ohms, the winding must be dried according to the following
procedure:
A. Warm it up in an oven at a minimum temperature
of 176ºF (80ºC) increasing 41ºF (5ºC) every hour
until reaching 105ºC (221ºF), remaining under this
temperature for at least one hour.
B. Check if the stator insulation resistance remains
constant within accepted values. If not, stator must
be re-impregnated. If necessary, replace bearings
and seals.
WINTER AND LONG-TERM MOTOR STORAGE
1.If motors are not immediately installed, they must be
stored in dry areas, free of dust, vibrations, gases, corrosive
smokes, under constant temperature and in normal position
free from other materials.
2.Motor storage temperature must remain between 41º F to 140º
F, with relative humidity not exceeding 50 percent.
3.If motors are stored for more than two years, bearings
must be replaced or the lubrication grease must be totally
removed after cleaning.
Gencor Industries recommends rotating the shaft (by hand) at
least once a month, and measuring the insulation resistance
before installing, if motors are stored for more than 6 months,
or when subject to high humidity areas.
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TIPS FROM THE EXPERTS
Combustion and Drying Zones
The Combustion Zone provides the space for the burner
flame to properly expand in an area free of impingement by
falling aggregate. By means of the combustion flights, material
travels along the sides of the
dryer.
The combustion volume
flights allow the aggregates
to be heated as they travel
through the intense heat of
the combustion chamber. This
not only adds efficiency to
the drying process, but also
reduces the shell temperature
of the drum.
The Drying Zone typically is designed with five rows of
Converta veiling flights. They can be positioned to optimize the
efficiency of the drying process.
7
14
John Price
Service Manager
for Global Combustion
Gencor Inc.
A
Inlet Temperature Curve
Remember that the baghouse inlet temperatures will be
high at low production rates because the flights are not full
and the material veil is thin. As the tons per hour (TPH) is
increased, the temperature will drop as the flights fill and a
full veil is established.
As the production rate increases beyond this point, the
baghouse inlet temperature also increases, as there is no rise
in veil.
At this point, inspect the flighting and make a diagram of
the flight position. Next inspect the flighting to determine if
there has been any buildup of materials on the flights. Check
mixes for signs of internal moisture such as AC stripping, large
stone bubbling at the discharge chute, and large temperature
drops between the discharge chute and the truck.
Seven steps optimize plant efficiency.
GOOD FlightING
n “efficient” plant can be described in simple terms: It dries material to
a specifically targeted temperature. That target, in turn, is the lowest
baghouse temperature that prohibits moisture condensation.
Much of the burden for achieving this efficiency rests with the drum flighting
arrangement. No standard setting will work on all aggregates at all locations. There are just
too many factors to allow a one-size-fits-all approach including the aggregates utilized, mix
design and moisture levels. For these
reasons, the Ultradrum is equipped
with adjustable “Converta-flights”
that provide the flexibility to deliver
optimum performance under any set
of conditions.
Heating the material takes
place with two specialized flights
in the combustion zone and the
drying zone.
A log book will help you evaluate plant efficiency. Notes
on the performance should include the mix designs, RAP
percentages, aggregate moisture levels and production rates.
Optimizing Efficiency
The Importance of
7 steps help you
maximize plant
efficiency
•A low stack temperature means increased fuel economy.
•The material must be thoroughly dried.
•Plant capacity cannot be limited due to high baghouse
inlet temperatures.
•Temperature must be maintained to the baghouse to
prevent moisture condensation.
1. Leakage – Inspect the plant for any potential leakage
of air into the equipment. Air leaks can limit production,
substantially lower gas temperatures and distort readings.
Common air leak sources that rob plant efficiency are inlet
flop gates, drum seals, and duct seals.
Converta-flights
The drying zone of a typical Ultradrum is designed with
five rows of Converta-flights. The veiling flights are adjustable
as shown, with five distinct positions. In addition, a piggyback
flight can be added to increase the veiling capacity of the
flights.
When each plant is shipped, the flighting pattern
corresponds to an arrangement that is effective with most
aggregates and mix designs. Each row has the Converta-flights
positioned alternately in position 1 and position 3.
Efficiency
The goal, of course, is plant efficiency. There are a number
of factors to consider in optimizing flighting adjustments,
including:
Here’s a tip: An analyzer typically will indicate 7
percent oxygen in the drum. Oxygen readings at the stack
more than 3 percent higher than the drum are cause for
concern.
2. Draft Control – Leakage and the plant’s performance
are dependent on being able to maintain a consistent draft
at the burner. A properly functioning Automatic Damper
Positioner (ADP) should be on the plant and adjusted for
minimal suction at the burner without creating any puffing
at the seals and other locations. Normally a draft reading
between 0.2 and .05 wc is sufficient.
Continued on page 16
15
TIPS FROM THE EXPERTS
# 1 (the burner end) and moving back each row toward
the feed end of the dryer. If the shell temperature drops
significantly before rows #4 and #5, then the flights in rows
#1 and #2 are veiling too heavily to allow heat to reach the
rear of the drum.
Flight Adjustments
Flight adjustments should not be made in radical steps.
Converta-flights are easy to adjust. Unless you encounter a
serious problem with performance (such as critically low or
high temperatures), the best approach is to adjust no more
then one row of flights at a time. After the adjustments are
made, a day’s run should determine the effects of the change
and confirm that an improvement has been made.
Be sure to stagger flighting row to row. If you have a
position #5 flight in row one, then a position #5 flight in row
two would not properly align. For maximum efficiency, you
should stagger each consecutive flight beginning from row
one’s position #5 flight. This forces the heat to snake side to
side, thereby avoiding a tunnel of heat down the drum.
Be sure to install washers on each attachment, tighten and
tack weld the nuts.
Baghouse temperatures
What if the baghouse temperature is off target? Here are some
steps to take.
If the baghouse inlet temperature is too low:
1. Check for air leaks at the flop gate and duct seals, as
they can drastically reduce baghouse inlet temperatures.
Correct all leaks before flight modifications.
3. Flight Buildup – Flighting with material buildup
should be manually cleaned to enhance capacity and
make proper evaluation possible. Buildup and a low inlet
baghouse temperature are indicative of too much veiling
at the burner end of the drum. Adjusting the flighting to
allow more heat to the feed-end will increase efficiency and
keep the flights free of buildup.
4. Burner Adjustment – The burner should be tuned for
low carbon monoxide emissions. In addition, the excess air
in the drum should be at the 7 percent oxygen target to
insure air flow is not excessive.
16
5. Evaluation – Review the log sheet temperatures for
the baghouse. Record the temperatures at several different
production rates and on different mix designs. The
baghouse inlet temperature is the most critical item in
evaluating the performance of the flighting. The baghouse
temperature may be so high that production is limited.
High baghouse temperatures reduce efficiency and shorten
component life. More typically, baghouse temperatures
are too low because of modern, overly efficient flight
design. Temperatures below dew point will allow moisture
condensation to occur in the baghouse. This can lead to
mud formation and blinded bags.
6. Cold Feed Breech Temperatures – Using a
temperature probe and measuring the temperature from
one side of the breeching to the other can pinpoint hot and
cold zones, indicating the need for flighting adjustment.
7. Drum Shell Temperature (uninsulated drums only)
– Using an infrared thermometer gun, measure the shell
temperature at each row beginning with veiling flight row
2. Remember: The flights at the cold feed end of the
drum (rows 4 and 5) control the baghouse temperature.
Increasing the veil or decreasing the veil in these rows
dramatically changes the baghouse inlet temperature.
3. If there is no heat available at the rear of the drum (due
to heavy veiling at the flights in rows 1 and 2) then setting
flights in the last two rows to position #5 (closed) will
have no effect. The drum shell temperature as previously
described will indicate if there is adequate heat at the cold
feed end of the drum.
4. If the burner-end flighting (rows 1 and 2) veil is too
heavy, change 25 percent of the flights in row 1 to position
#5. Next move 25 percent of row 2 flights to position #5.
(Note: Flights changed from a veiling position (#1, #2, #3 or
#4) to the #5 position will cause less material to be carried
up into the veil. This allows heat to pass by the flight.
If the baghouse inlet temperature is too high:
Rows 4 and 5 (cold feed end) in #1 position can be changed
to the #4 position, causing more material to be carried into
the air stream. Piggybacking flights will also dramatically
increase the veil and reduce baghouse inlet temperatures.
Retained moisture problems
Retained moisture in the mix can be the result of items
such as the following:
1. Drum slope is too steep, causing material to flow
through the drying zone too quickly.
2. Insufficient flight carrying capacity is allowing material
to roll down the drum length without proper heat exposure.
3. Excessive RAP moisture is present.
4. Excessive RAP gradation is making it difficult to heat.
5. Flighting is improperly adjusted.
Flighting modifications
Often, retained moisture problems are the result of a heavy
veiling condition at rows 1 and 2. It is preferable to adjust the
flighting to allow more heat to penetrate farther into the drum
cavity. This will start the aggregate heating process at row 5.
This effectively increases the residual or dwell time that the
aggregate is exposed to heat.
This can be accomplished by reducing the veil toward the
burner end of the drum. Some of the flights in rows 1 and 2
closest to the combustion volume zone flights should be placed
in the #5 position. In some special applications (including the
use of aggregate dryers) it may become necessary to impede
the flow of the material through the drum by reversing kickers
or other means.
Breech temperatures
Here are some tips for overcoming breech temperature
disparities.
• The temperature at rear breeching is high on the
downhill side. Change flights in the #3 position to the #4
position. This will carry more material over the top,
making the veil heavier on the down side.
• The temperature at rear breeching is too low on the lift
side. Flights that are in the #1 position can be changed
to the #2 position to veil the material later as the
material is lifted.
• The temperature is low on the uphill side and the
downhill side—but high in the middle. Flights in #1
position can be changed to the #4 position, causing a
more even distribution of the material and heavier veil
in the middle.
Gencor Industries’ Product Support Department is a great
resource with a wealth of information on dryer flighting
techniques to address any particular challenge you may have.
If you need assistance with your dryer, we would like to help.
After all, optimizing the performance of your plant is a great
way to increase your operation’s efficiency and profits.
17
TRAINING
An
ongoing philosophy
NEW THIS YEAR!
Gencor training provides plant independence
Y
ears ago, Gencor introduced a self-help philosophy when
it came to “plant-downs.” We believed that well prepared
plant operators were best equipped to respond quickly,
thereby minimizing downtime and returning plants to
production. This approach also made operators less dependent
on expensive service calls. Of course, the Gencor service team is
always available to help with diagnosis and repair.
Today, Gencor continues forward with this philosophy, and as
a result has earned a reputation for conducting the leading handson training curriculum for plant operators and superintendents.
Our training is built on the same course materials used to teach
our own service technicians, creating the optimum learning
experience for asphalt producers.
“This will be our 41st year of training,” said Larry Miles,
Director, Product Support, at Gencor. “We continually adjust to
challenges our customers are facing, but one thing never changes:
Our hands-on approach. Those who go through our training
programs benefit from real experience with real equipment.”
Basic Course
Our 5-day comprehensive hands-on training program addresses
the most common areas affecting the production of hot mix plants.
All demonstrations and classes include hands-on interaction with
actual equipment.
Topics include:
•Plant operation and maintenance
•Plant controls
•Combustion testing and training
•Thermal fluid systems training
•Exhaust system operation
•Electrical schematics
•Load cells
•Variable speed drives
•Trouble-shooting techniques
Advanced Course
During these five days of intensive hands-on training, our
experts systematically take you through all the areas of the plant
that affect production, cost efficiencies, trouble shooting and
proper plant operation.
The course registration is flexible, enabling customers to pick
and choose the equipment they are most interested in learning
about and maximizing hands-on trouble shooting.
It’s your opportunity to listen and learn from the experts
through the use of control simulators and actual equipment. You’ll
see demonstrations of the latest industry techniques, combined
with interaction and hands-on participation.
A special seminar course is included, with a different speaker
each day addressing plant management and efficient plant
operation.
Custom Course at Your Site
Two- and three-day customized courses also are available.
Our training professional will travel to your site and conduct a
customized training workshop of your choice. You can select topics
that will provide the most benefits for your team and operation
including dryer operation and maintenance; plant controls;
combustion testing and training; thermal fluid systems training;
exhaust system operation; variable speed drives; and others.
If you have any questions about training or wish to discuss
your specific needs for a custom program conducted at your site,
please call us at 407.290.6000, ext. 342.
2011 Training Classes
Location: Orlando, Fla.
Registration: SAVE $100 if you register by Friday, Dec. 17
All details can be found at www.gencor.com/training
Or call 407.290.6000, ext. 342
Schedule of Monday 8 a.m. start dates:
18
Basic Course, Jan. 17
Advanced Course, Jan. 24
Advanced Course, Jan. 31
Advanced Course, Feb. 7
Advanced Course, Feb. 14 (special group class)
Our training week is divided into our core and elective courses.
Our core courses are:
• Plant operation and maintenance, including plant/burner
efficiency, airflow, plant controls, management and cost
control, and plant capacity analysis (four instructors in four
days).
• Burner test stand, combustion testing, and troubleshooting.
• Thermal fluid systems with hands-on burner set up.
Our elective courses are:
AC & fuel storage tanks
Function and controls, demonstration and set up of transducer and
level readouts.
Basic electrical troubleshooting and schematic reading
You will use a volt meter to troubleshoot basic electrical circuits used
in an asphalt plant environment.
BC200/BC250
Function, set up and troubleshooting.
Burner installation
How to retrofit a burner to your plant.
Control van MCC/PLC
Function of control van MCC and PLC with troubleshooting.
Operation of actual equipment from control van. Load cell set up.
Drum flighting/baghouse
The basics of drum flighting to control baghouse inlet temperature,
function and troubleshooting of counter flow baghouse.
Drum trunnion adjustment
The theory behind adjusting the trunnion rollers on a drum mixer
and applying the theory in a practical situation using our 400 TPH
Ultradrum; how to avoid costly downtime from improper adjustment.
Fuel preheaters, management and burning reclaimed oil
Operation and troubleshooting of preheaters and burner set up.
Gen 3D™/Vector™
Functions of the Gen 3D, and the tools within the system to help
troubleshoot problems in the control and flame management
system. Also, how to set up a chart recorder and basic system
troubleshooting.
Gen III/Astraflame
Functions and troubleshooting of the Gencontrol III and the
Astraflame using a training simulator. Course covers set up of TC
amp and control cards along with hands-on troubleshooting.
Load cells
Set up for scale belts and weigh hoppers, including digitizer set up.
Micromotion
Set up of micromotion meter and the AC pump drive. Set up using
Hart communicator and laptop.
Silo/transfer/batcher
Operation, troubleshooting and maintenance. Includes loadout
demonstration of Quick Draw™ silo.
SL300/SL400
Function, set up and troubleshooting.
Stack test
How to prepare your plant for a particulate or gaseous emission test.
Ultralogiks loadout
Function and operation.
Ultralogiks plant controls
Function and operation.
Warm mix asphalt controls
What is warm mix asphalt? How is it different from hot mix
asphalt? What are the benefits?
Check out gencor.com/training for more information.
You will have the opportunity to choose your elective
classes during the registration process. Gencor Industries
Service Training programs are designed specifically
for hot mix asphalt producers that own and operate
HMA facilities. These courses are not open to industry
vendors, suppliers or consultants. To derive the most
from these courses, one must own, operate and maintain
an HMA plant.
19
5201 North Orange Blossom Trail
Orlando, Florida 32810
(407) 290-6000
gencor.com