この包括的なメンテナンス マニュアルでは、日常の清掃手順から特殊な修理技術に至るまで、最新のアスファルト混合プラントのあらゆる重要なコンポーネントの詳細な手順をカバーしています。バッチ プラント、ドラム ミキサー、またはポータブル システムを操作する場合でも、このガイドは効果的なメンテナンス プログラムを実装するために必要な技術的知識を提供します。
生産効率の低下: コンポーネントの詰まりや磨耗により、工場の作業がより困難になり、より多くの燃料が消費されます。
品質の低下: 不均一な混合、不均一な加熱、および汚染により、アスファルトの仕様が損なわれます。
安全上の危険: 留め具の緩み、ベアリングの故障、電気的故障は職場に危険をもたらします。
修理コストの高騰: 軽微な問題が、コンポーネントの完全な交換を必要とする致命的な障害に発展する
環境違反: バグハウスのメンテナンスが不十分な場合、排出量が増加します。不適切なバーナー調整により燃料が無駄になります
ほとんどのメーカーは基準スケジュールを提供していますが、特定のメンテナンス間隔は、プラントの利用状況、現地の材料特性、および動作環境に基づいてカスタマイズする必要があります。
外側のドラムシェルに亀裂、錆、または異常な摩耗パターンがないかを目視検査します。
外面からゴミ、ほこり、アスファルトの蓄積を取り除きます。
内部のフライト (混合ブレード) にアクセス ポートを通して目に見える損傷がないか確認します。
詰まりの原因となる可能性のある注入口付近に蓄積した物質を取り除きます。
傾向分析のためにシェルの状態をメンテナンス ログに記録します。
赤外線温度計を使用して、一定の間隔で (ドラムの長さに沿って約 3 フィートごとに) シェルの温度を測定します。
最大スループット レートと低下したスループット レートの両方で測定値を取得して、ベースライン パフォーマンスを確立します
異常な温度分布は内部摩耗または飛行劣化を示します
すべての温度データを記録して、熱異常を早期に特定します
適切な高温グリースを使用して、メーカーの仕様に従って駆動モーターのベアリングを潤滑します。
回転ドラムを支えるトラニオン車の軸受に潤滑剤を塗布します。
ギア減速システムのアクセス可能なすべてのベアリングにグリースを塗布します
潤滑ポイントがゴミや錆で詰まっていないか確認してください。
過剰なグリースは熱を発生させ、汚れを引き寄せるため、決して過剰に潤滑しないでください。
現在設置されているすべてのフライトの位置、数量、間隔、状態を測定し、写真を撮ります。
実際の構成を工場の図面やメンテナンス記録と比較する
出口ダクトの温度を8～10インチ間隔で監視してバーナーの性能を分析します
フライトが元の厚さの 1/3 以上摩耗している場合は、交換のスケジュールを立ててください。
適切なロックアウト/タグアウト手順を使用して、すべての燃料を排出し、システムの電源を切ります。
ドラムが完全に冷めるまで待ちます (通常は最低 4 ～ 8 時間)
ソケットレンチセットを使用して、摩耗したフライトを固定しているボルトを取り外します
一致する仕様を使用して新しいフライトをインストールします - 不適切なフライト構成により効率が低下します
すべてのファスナーを十字のパターンで締めて、均等に装着できるようにします。
使用を再開する前に、溶接部と接続部の完全性を検査します。
トラニオンリングの位置ずれを示す不均一な摩耗パターンがないか検査します。
ドラムを横方向に動かしてベアリングの遊びを確認します。過剰な動きはベアリングが磨耗していることを示します。
摩耗が硬化点を超えて広がっている場合、または重度の金属剥離が見られる場合は、交換のスケジュールを立ててください。
正確に塗布するための特別な治具を使用して、スケジュールされた間隔でトラニオン アセンブリに注油します
定期メンテナンス期間中にドライブ減速機のオイルを交換してください
バーナーヘッド、ノズル、燃焼室を徹底的にクリーン化
燃料ノズルを交換します (一度取り外すと効果的に洗浄できなくなります)
CAD セル ウィンドウを調べて明確にする
点火電極のギャップが適切で清潔であることを確認してください
テスト燃焼中に炎の形状と色を確認します
ドアシールの状態に破れ、亀裂、劣化がないか点検します。
蓄積したアスファルトと骨材のシール面をきれいにします
ドアが締め付けられることなくスムーズに開閉することを確認します。
動作中にラッチ機構がドアをしっかりと保持していることを確認してください
混合サイクル中に漏れが観察された場合はシールを交換してください
ベアリングの問題を示す異常な研削音、きしみ音、またはガタガタ音に注意してください。
シャフトシール周囲のアスファルトまたは水の漏れを確認します。
タッチ（シャットダウン後）または赤外線温度計でベアリング温度を監視
ベアリングが熱くなったり、振動が増加したりした場合は、すぐにメンテナンスを計画してください
ダウンタイム中にミキサーのアクセス ドアを開け、すべての混合ブレードを目視検査します。
ブレードの厚さを確認します。元の厚さの 1/3 以上摩耗している場合はブレードを交換します。
ブレードの溶接点に亀裂や剥離がないか検査します。
ミキサーライナー (バレル内部コーティング) の付着と摩耗を検査します。
ブレードとライナーの状態を記録して交換時期を予測する
電源を切り、ロックアウト/タグアウトを適用します
ミキサーが完全に冷めるまで待ちます
オープンボトムミキサーアクセスパネル
ベアリングが固着した場合: 慎重に切断トーチを使用してレースを切断します (適切な PPE を着用してください)。
適切なソケットを備えたベアリングプーラーを使用して、アウターベアリングレースを取り外します
ボトムシールアセンブリを固定しているボルトを取り外します
ベアリングをスライドさせて慎重にシールします
取り外す前にシールの向きに注意してください
取り付ける前に新しいシールに潤滑グリースを塗布してください
トライクランプフィッティングに均等な圧力を加えて、新しいシールを所定の位置に押し込みます。
ネジ付きアダプターを挿入し、ボルトを X パターンで締め、各パスでボルトごとに 1 回転させます。
アセンブリを手で回転させて、閉じる前にスムーズに動作することを確認します。
ハウジングを再組み立てし、アクセス パネルを閉じます
シールの両端に漏れや損傷がないか検査します。
Oリングシールが摩耗、亀裂、または劣化した場合は交換してください
取り付ける前にシール面に真空グリースを塗布してください
シールの平らな部分がシャフトの中心に面していることを確認してください
フィッティングに押し込む前に O リングに注油してください
サイトグラスまたはレベルゲージを使用して、ギアボックス内のオイルレベルを確認します
ギアボックス オイルは毎年、またはメーカーのスケジュールに従って交換してください
動作中のギアボックス温度を監視する
異常な騒音または振動パターンを検査します。
モーターの通気口に詰まりがないか確認してください
モーターがしっかりした留め具でドライブカップリングに正しく接続されていることを確認します
すべてのフィルターバッグに破れ、穴、損傷がないか目視検査します。
バッグがケージに隙間なく正しく収まっていることを確認します
特定の領域に集中して蓄積することなく、バッグに均等に粉塵が積載されていることを確認します。
(安全な場合に) 慎重に触ってバッグの張力をスポットチェックし、硬さを評価します
熱による損傷や化学的攻撃を示す生地の変色を探します。
交換のために破損したバッグを文書化します
差圧 (フィルターシステム全体の圧力降下) を毎日確認して記録します。
通常の動作圧力差: 3 ～ 4 インチ水柱
過度の差圧 (>6 インチ) はフィルターの飽和を示します
差圧が低い (<2 インチ) 場合は、袋が破れているか、不適切な洗浄が考えられます。
傾向分析のために毎日の圧力測定値を追跡するログを維持します
差圧が継続的に上昇する場合は、故障が発生する前に原因を調査してください
ホッパーに粉塵が蓄積していないか、適切に排出されているかを検査します。
排出バルブがスムーズに動作し、完全に密閉されていることを確認します。
ホッパーから除去されたダストが収集ポイントまで自由に流れることを確認します。
材料の圧縮を防ぐためにホッパーの周囲を清掃してください
パルス洗浄を行う圧縮空気システムが適切な圧力であることを確認します。
動作中の排気筒を視覚的に観察する
目に見える粉塵の放出がある場合は、バッグの損傷またはシステムの故障を示しています。
粉塵が発生した場合は、プラントを停止し、直ちに調査してください
不透明度モニターが装備されている場合は、コンプライアンス測定を検証するために使用します。
取り出す前にすべてのバッグの位置と構成を記録します。
パルス洗浄システムの電源を切り、圧縮空気を排出します。
ブリードバルブを使用してバッグハウスを減圧します。
システムを冷却します (通常は 30 ～ 60 分)
適切な密閉空間手順を使用してバッグハウスのアクセスドアを開ける
損傷したバッグをケージから上にスライドさせて取り除きます
バッグの破損の原因となった可能性のある損傷がないかケージの構造を検査します。
ケージポストにスライドさせて、新しい交換用バッグを取り付けます
バッグがねじれたり折れたりせずに完全に固定されていることを確認します
バッグのベースとケージの間が完全に密閉されていることを確認します。
適切なガスケットと留め具のトルクでアクセス ドアを閉めます
運転を再開する前にシステム圧力を徐々に回復してください
パルスバルブソレノイドに損傷や腐食がないか検査します。
クリアサイクルを聞いてパルスバルブの動作をテストします
パルス洗浄のタイミングを確認します。バッグはプログラムされた間隔で膨張する必要があります。
バルブに到達する圧縮空気が適切な圧力 (通常は 80 ～ 100 psi) であることを確認します。
バルブステムの周囲で空気漏れが検出された場合は、ダイヤフラムキットを交換してください
航空会社の接続部に緩みや漏れがないか点検します
圧縮空気システムのエアドライヤー カートリッジを毎月交換してください
圧縮空気ユニットのエアフィルターエレメントが飽和していないか確認してください
適切な密閉空間手順を使用して、バッグハウス内の目視検査を実行します。
内部に見える破片、腐食、またはバッグの損傷を文書化します。
ダストホッパーの内部に物質の蓄積やブリッジがないか確認してください
分配プレートの詰まりや空気の流れの不均一を検査します。
大量の塵の蓄積が見られる場合は、すべての内部表面を清掃してください
リフティングバルブの動作とガスケットのシール状態を確認してください
バイパス ダンパー (装備されている場合) が起動時にバッグを保護するために適切に動作することを確認します。
のぞき窓を通してバーナーの炎を観察します (適切な目の保護具を使用してください)
炎は完全燃焼を示す青色 (黄色/オレンジ色ではない) である必要があります。
炎の形状は円錐形で安定している必要があり、ちらつきや脈動はありません。
燃料/空気比の問題を示す異常な炎の色に注意してください。
制御システム上の火炎検出器信号が適切な点火を示していることを確認してください
技術者による調査のために異常を文書化します。
燃料ポンプが異常な騒音なく正常に動作していることを確認します。
燃料供給タンクのレベルを確認し、適切な量が供給されていることを確認してください
燃料ラインの接続部および配線に沿った漏れがないか検査します
燃料フィルターバスケットが詰まっていないことを確認します (アクセス可能な場合は目視検査)
燃料圧力計の読み取り値 (装備されている場合) を通常の動作範囲と比較して確認します。
燃料の臭いや流出にはすぐに注意する必要があることに注意してください。
バーナーヘッドからアクセス可能な破片やほこりを取り除きます
取り付けボルトと留め具がしっかり締まっているかを確認してください
調整可能な場合、バーナーが取り付けブラケット内でスムーズに移動できることを確認します。
燃料供給ホースの配線に損傷や過度の熱への曝露がないか点検します。
バーナーと機器の隙間が適切に保たれていることを確認してください
システムを完全にシャットダウンしてクールダウンすることを確認します (最低 30 分)
すべてのエネルギー源にロックアウト/タグアウトを適用する
バーナーハウジングへの燃料ライン接続の位置を確認します
調節可能なレンチを使用して燃料ラインを燃料供給チューブから外します
供給システム全体をバーナーハウジングに保持しているプレートを取り外します
送出システムアセンブリをバーナーハウジングの上部からスライドさせて外します
1 本のレンチでチューブをしっかりと固定
2 番目のレンチでノズルを反時計回りに回す
取り外したノズルは掃除しないでください。安全に廃棄してください。
新しいノズルは、レンチが接触する場所にのみ扱ってください (ハロゲン電球の注意事項と同じ - 皮膚の油分によりノズルが損傷します)
逆の手順で新しいノズルを取り付けます。しっかりとはめ込みますが、締めすぎないように注意してください。
燃料供給システムを再接続し、取り付けプレートを固定します
燃料ラインを再接続し、漏れがないことを確認します
テスト点火を実行し、適切な火炎パターンを確認します。
バーナーヘッドを取り外してイグナイターコンポーネントにアクセスします
電極に孔食、汚れ、または焼けがないか検査します。
電極ギャップがバーナーの仕様と一致していることを確認してください (通常は 3 ～ 4 mm)
目の細かいサンドペーパーまたはワイヤーブラシを使用して電極表面をきれいにします
バーナーのサイクル時にイグナイターが火花を生成することを確認します。
火花が弱いか消失している場合はイグナイターを交換してください
CAD セル (火炎検出器) の窓に煤や変色がないか確認してください。
CAD セルが汚れている場合は、柔らかい布とアセトンを使用して清掃してください
燃料フィルターバスケットをタンクと燃料ポンプの間に配置します
燃料遮断バルブを回してタンクを隔離します
レンチを使用してフィルターハウジングボウルを取り外します
バスケットを引き出し、破片、水、錆がないか検査します。
汚れが明らかな場合は、圧縮空気またはブラシでバスケットを掃除してください
フィルターボウルから水を排出します
再度取り付ける前にバスケットを完全に乾燥させてください
再組み立てする前に、ネジ山に耐燃料ガスケットシーラーを塗布してください。
燃料供給を再開し、漏れがないか確認します
この手順には特殊な機器とトレーニングが必要です
専門的な校正については認定バーナー技術者にお問い合わせください。
不適切な空燃比調整は排出量を増加させ、効率を低下させます
燃焼分析装置は排ガス中の酸素含有量を測定します
理想的な燃焼により、排ガス中の酸素が 2 ～ 3% 維持されます。
校正日と設定を保守記録に文書化する
ベルトの両側を全長に沿って歩きます
破れ、ほつれ、縫い目の剥がれ、端のカールがないか確認してください。
運転中に異常な滑りや鳴きがないか確認してください
ベルトのトラッキングを観察します。ベルトはプーリーの中心に留まるはずです。
システムに沿った物質の蓄積または流出に注意してください。
湿気による損傷やゴムの劣化がないか確認してください
プーリーの位置ずれを示す研削音を聞いてください
スパンの中間部に手を加えて、ベルトが適切な張力を示していることを確認します。
ベルトにはわずかなたわみがあるはずです (中程度の圧力で通常 10 ～ 15 mm)。
ベルトが緩すぎると滑ります。ベルトがきつすぎるとベアリングの早期摩耗が発生します
プーリーのエッジに対するベルトの位置合わせを観察します。
ベルトが片側にずれている場合は、トラッキングボルトを段階的に調整してください
両側を同時に調整しないでください。シフトごとに片側のみを調整してください。
コンベアフレームに沿って目に見えるすべてのボルト、ナット、および留め具をチェックします
緩んだ留め具がある場合はすぐに締めてください
交換が必要な錆や腐食がないか確認する
ベルトを最近交換した場合は、ベルトのスプライス接続を検査します
プーリー取り付けボルトがしっかりと固定されていることを確認します
コンベアベッドからすべての破片や材料を取り除きます
モーターがオフでロックアウトされていることを確認します
古いベルトに損傷がある場合は、交換用ベルトを取り付けます
ベルトが手の圧力だけで動くように、初期張力 (プリテンション) を適用します。
すべてのローラーがベルトの経路に対して直角であることを確認してください
中心線に対して垂直に、ベルト上に正確に 100 インチ離れた 2 つの点に印を付けます。
ジャッキや張力調整装置を使用して徐々に張力を高めます
張力が増加するにつれてマーク間の距離を測定します
マークがメーカーの仕様に従って計算された距離に達するまで張力を加えます
例: 0.5% 張力を指定した場合、張力は 100.5 インチ (100 インチの 0.5%)
適切な張力が得られたら、ベルトが直角で中心に保たれていることを確認します。
通常の操作を再開する前に、ベルトをゆっくりと動かし、適切なトラッキングを確認してください。
24 時間使用した後に張力を再チェックします (新しいベルトは最初は伸びます)。
ベルトを外すか、下側にアクセスします (安全で機器の電源がオフの場合)
すべてのプーリーに遅れ摩耗やゴムの劣化がないか検査します。
プーリーのベアリングの状態を確認し、磨耗や異常な音がないか確認してください。
プーリーの表面が亀裂やくぼみがなく滑らかであることを確認します。
元の厚さの 50% 以上摩耗したプーリーの遅れを交換する
スケジュールに従ってプーリーとローラーベアリングに注油します
直線エッジを使用して、ベルト パスに対して垂直なローラーの位置を確認します。
過剰な遊びや損傷があるベアリングを交換する
モーターの取り付けボルトが締まっているか確認してください
モーターの通気口がふさがれていないことを確認してください
電気接続に腐食や緩みがないか検査します。
異常なノイズを聞いてモーターのベアリングの状態を確認します
モーターシャフトカップリングがしっかりと固定されていることを確認してください
モーターの消費電流をベースラインと比較して確認します
メーカーのスケジュールに従ってモーターに適切な潤滑が行われていることを確認してください
生産実行ごとにすべての材料のスクリーン メッシュをクリーンアップします。
ブラシまたは圧縮空気を使用してこびりついた物質を除去します
メッシュの破れ、穴、変形を目視検査します。
安全のためにフレームの端にメッシュが取り付けられていることを確認してください
スクリーニング効率を低下させる詰まりのある開口部を探す
位置ずれを示す不均一な摩耗パターンを観察する
振動による緩みがないかすべてのボルト接続を検査します。
緩んだボルトがある場合は、適切なレンチを使用してすぐに締めてください
溶接部やフレーム構造に亀裂がないか確認してください
動作中にスクリーン枠が正方形のままであることを確認してください
取り付けスプリングと絶縁ブッシュが損傷していないことを確認します。
内部コンポーネントの緩みを示す異常なガタガタ音がないか確認してください。
運転後、赤外線測定により加振器・加振器の温度を確認する
過度の温度はベアリングの問題または位置ずれを示します
振動ユニットからの異常な研削音を聞いてください
振動ユニットの取り付けボルトがしっかりと締まっていることを確認します
アクセス可能な場合は、バイブレーターのベアリングの潤滑レベルを確認してください
画面の電源を切り、ロックアウト/タグアウトを適用します
画面が冷めるまで待ちます (通常は 15 ～ 30 分)
ソケットレンチを使用してメッシュをフレームに固定しているボルトを取り外します
摩耗したメッシュをフレームから慎重に持ち上げます
ブラシと圧縮空気を使用して、フレームの端に残った材料を取り除きます。
新しいメッシュをフレーム上に配置し、均一な位置に配置します。
すべてのボルトを十字パターンで部分的に締めて、メッシュを一時的に保持します
メッシュがフレームに対して平らで正方形であることを確認します
均等な圧力を維持するために、交互のコーナーでボルトを段階的に完全に締めます。
メッシュがしわや折り目がなくフレームにぴったりと密着していることを確認します。
電源を入れる前に画面を手動で回転させてスムーズな動作を確認してください
最初は低速で走行し、メッシュが適切に装着されていることを確認します。
ラバースプリング/アイソレーターに亀裂や劣化がないか検査します。
亀裂が見られる場合、またはゴムが分解している場合は、スプリングを交換してください。
スクリーン絶縁システムがプラントフレームへの振動伝達を軽減していることを確認します。
スプリングが正しい間隔で適切に負荷されていることを確認します
スプリング取り付けボルトがしっかりと締まっていることを確認してください
シャフトを動かしてみて、バイブレータのベアリングの遊びを確認します。
過度の遊びはベアリングが摩耗していることを示しており、交換が必要です
振動ユニットの取り付けボルトがしっかりと固定されていることを確認します
密閉型ベアリング設計の場合は、バイブレータ内のオイル レベルを確認してください。
動作中に音を聞いて、問題を示す研削やガタつきを確認します
過剰な遊びや異音が発生したベアリングを交換する
温度計の測定値をチェックして、タンク温度が仕様内であることを確認します (通常は 140 ～ 180°C)。
温度制御システムが適切な設定値を維持していることを確認する
温度変動や機器誤差に注意してください
暖房システムが正常にオン/オフを繰り返すことを確認します
タンクの断熱材が損傷なくそのままであることを確認します。
すべてのパイプ接続、バルブ、タンクに漏れがないか検査します。
燃料供給レベルを確認し、燃料消費が正常かどうかを確認します
燃料ラインと接続が損傷なくしっかりと固定されていることを確認します
暖房システムのコンポーネントからの異常なノイズに耳を傾けてください
配管に断熱材の劣化や損傷がないか観察してください
外部タンクの錆、腐食、損傷の状態を確認します。
タンクのサポートと基礎がしっかりしていることを確認します
アクセス梯子と手すりが安全であることを確認してください
タンクレベルインジケーターが正しく動作しているかどうかを確認してください
高度警報システムが装備されている場合は機能することを確認する
システムが周囲温度まで冷却されるまで待ちます (最低 4 ～ 8 時間)
暖房システムにロックアウト/タグアウトを適用する
ボイラー上のオイルレベルのぞき窓の位置を確認します。
オイル レベルが適切な範囲内にあることを確認します (通常はミッドサイト ガラス)
少ない場合は、指定されたサーマル流体を追加します（オイルの種類を決して混合しないでください）
オイルの色を確認します。非常に濃いまたは変色している場合は、オイルの交換を計画してください。
すべてのオイルライン接続に漏れや滲みがないか確認してください
オイル配管の周囲の断熱材に損傷や劣化がないか点検します。
効率を維持するために損傷した断熱材を交換してください
アスファルトにアスファルトが漏れていないことを確認します。
ポンプ吐出圧力ゲージの測定値を確認します (装備されている場合)
キャビテーションまたはベアリングの問題を示す異常なポンプノイズを確認します。
すべての隔離バルブがスムーズに動作することを確認します
圧力リリーフバルブが機能していることを確認します (不明な場合は技術者に相談してください)
ラインストレーナの詰まりを点検する
圧力降下が過度に大きい場合はストレーナエレメントを交換してください
バーナーヘッドが清潔かどうか、また点火が適切かどうかを検査します。
動作中にバーナーの炎が青色で安定していることを確認します。
燃料供給と燃焼用空気の混合が適切であることを確認します。
カーボンの蓄積が観察された場合は、バーナーノズルを掃除してください
安全性と適切な位置についてバーナーの取り付けを確認してください
プラント停止中の年次タンク検査を計画する
排出バルブを使用してタンクを完全に排出します
タンク内部が周囲温度まで冷えるまで待ちます
マンホールを開けて内部の状態を観察する
タンクの底に溜まった余分な沈殿物やゴミを取り除きます
内部表面の腐食や劣化を検査します。
加熱コイル/チューブにスケールの蓄積や腐食がないか確認してください
ワイヤーブラシを使用して軽い腐食やスケールを除去します。
堆積物が蓄積した場合は内部を洗い流してください
入口/出口ノズルの清掃と検査
タンクに新しいアスファルトを補充し、暖房システムの動作を確認します。
すべての骨材フィーダー ゲートが適切な開口部にあることを目視で確認します。
現在のゲート位置を校正チャートのプラカードと比較します
指定された位置からのずれに注意してください
ゲートが固着したり固着したりすることなくスムーズに動くことを確認します
ゲートアクチュエーターからの異常なノイズを聞く
原料が各低温飼料ビンからエレベーターに流れ込む様子を観察
すべての材料が一定の速度で流れていることを確認します (急増または停止がない)。
材料が分離せずに均一に結合していることを確認します
ビン排出エリアでの材料の詰まりを監視
ビンレベルインジケーターの精度を検査する
すべてのビンの 4 分の 1 マーカーの位置に適切な材料があることを確認します。
ビンが完全に空になる前に、低レベルのアラームが作動することを確認します
材料供給を停止する前にビンの補充が確実に行われるようにする
ビン排出時の材料のブリッジングまたは固化を監視
レベルセンサーが正しく機能していることを確認してください
すべての生産を停止し、設備を安定させる
ビンが校正対象の材料で適切に満たされていることを確認します
キャリブレーションチャートに従って指定された位置まで材料ゲートを開きます
材料を一定時間（通常は 1 ～ 5 分間）収集ビンまたは計量器に流し込みます。
収集した材料の重量を量ったり、体積を測定したりする
実際の流量をポンドまたは毎分トンで計算します
実際の流量が許容誤差 (通常 ±5%) 以内で目標と一致しない場合は、ゲート位置を調整します。
流量が校正チャートと一致するまで再テストして調整します
ゲート調整を確実にし、設定が安定していることを確認します
最終的な校正設定と日付をメンテナンスログに記録します。
プラントの電源を切り、スケールシステムにロックアウト/タグアウトを適用する
認定されたテスト分銅またはチェーンリンクを使用して、既知の分銅を秤プラットフォームに置きます
スケール表示を読み取り、実際の重量と比較します
誤差が ±0.5% を超える場合は、認定されたはかり技術者にご連絡ください。
各位置の重量テストにより、すべてのロードセルが機能していることを確認します。
スケール機構上の破片や物質の蓄積を確認します。
メーカーのスケジュールに従ってスケールのピボット ポイントとスライド コンポーネントに注油します
スケールのデジタル表示が正確に読み取られ、適切に更新されることを確認します。
レシピ検証にスケールデータが使用される場合、制御システムへのテストデータ送信
インジケーターの表示を観察して、すべてのビン レベル センサーが機能していることを確認します。
材料レベルを上げたり下げたりして、高レベルおよび低レベルのアラームをテストします
センサーのレンズに溜まったほこりや湿気を取り除きます
センサー取り付けブラケットがしっかりと固定されていることを確認します
電気接続に腐食や緩みがないか確認してください
測定値が不正確な場合は、センサーのメーカーに連絡して再調整してください。
コントロール パネルのすべてのステータス ライトが正常に動作していることを確認します。
アラームランプやエラーメッセージが表示されていないことを確認してください
制御システムの表示を確認して、警告インジケーターがないか確認してください。
注意が必要なメッセージをメモし、ログに記録します
すべてのセンサー入力 (温度、圧力、流量) が正常範囲内であることを確認します。
プラント制御表示画面が問題なく読めることを確認する
すべての関連データ (温度、流量、バッチ数) が正確に表示されていることを確認します。
テスト時に手動オーバーライド コントロールが適切に反応することを確認します。
緊急停止ボタンが明確に見え、アクセスできることを確認する
コントロール メニューのナビゲーションがスムーズに機能することを確認します。
プラントがバッチデータと生産ログを記録していることを確認する
すべての記録データのタイムスタンプの精度を検証する
重要なデータのバックアップ システムが機能していることを確認する
データのギャップや記録エラーに注意してください
データベースがストレージ容量の制限に近づいていないことを確認する
適切なシャットダウン手順を使用してプラントの電源をオフにします
電気システムにロックアウト/タグアウトを適用する
開いた電気制御キャビネット/パネル
すべての内部コンポーネントに埃が溜まっていないか目視検査します。
すべての端子接続が腐食がなくしっかりと接続されていることを確認してください
ワイヤーの緩みや絶縁体の損傷を探す
すべての回路ブレーカーとヒューズが安全であることを確認してください
コンタクタの接点に孔食や焼けがないか確認します (ひどい場合は電気技師に相談してください)
冷却ファンの動作を検査し、吸気フィルターを掃除します
パネルを確実に閉めてください
すべてのセンサー ケーブルがよじれや損傷がなく適切に配線されていることを確認します。
コネクタが完全に固定され、腐食がないことを確認してください
接続ボルトや留め具が緩んでいる場合は締めてください
交換が必要な切断または摩耗したワイヤ絶縁体を探します
接地接続がきれいでしっかりしていることを確認します
システムの稼働時間と予期しないリセットまたは再起動に注意してください。
システム内部の温度と冷却システムの動作を確認します。
すべての入出力モジュールのインジケーター ライトが正しく機能していることを確認します。
エラーログを確認して、再発する問題がないか確認してください
システムデータが自動的にバックアップされない場合はバックアップします
利用可能なソフトウェア アップデートについては、制御システムの製造元にお問い合わせください。
改善やバグ修正については、アップデートのリリース ノートを確認してください。
生産の中断を避けるために、ダウンタイム期間中に更新をスケジュールします。
アップデートをインストールする前に現在のシステム構成をバックアップする
アップデートのインストール後、すべての機能が正しく動作していることを確認します
重要なシステムデータのバックアップをメインストレージとは別に維持する
スケールの読み取り値が直線性チェックに適用された重量と一致することを確認します
重量を段階的に加えてスケールの応答をテストする
実稼働前にスケール ゼロの基準が正しいことを確認してください
制御システムへのスケールデータ送信を検証する
スケールエラーが検出された場合は、認定されたスケール技術者に連絡してください
可能であれば、機器の測定値を二次ポータブルメーターと比較します
生産中の変化を監視してセンサーの応答時間を確認する
センサー出力信号が予想される電圧範囲内 (通常 4 ～ 20mA) であることを確認します。
センサーの校正ブロックまたは基準点をきれいにします
測定値が一貫して仕様から外れている場合は、センサーのメーカーに問い合わせてください
すべての主要な構造コンポーネントに損傷や劣化がないか検査します。
工場全体のすべてのボルト接続と留め具を確認してください
保護カバーまたはシールが損傷していないことを確認します
すべての安全インターロックと緊急システムをテストする
完全な制御システム起動シーケンスを実行する
すべてのモーター、ポンプ、アクチュエーターを全可動範囲で循環させます。
すべてのギアボックス、モーター、油圧システムの液面をチェックします。
すべてのベルトとチェーンに適切な張力があることを確認します。
すべての警報および警告システムをテストする
完全な生産の前に、速度を落としてプラントサイクル全体を実行します
アスファルトラインをフラッシュし、スムーズな流れを確認する
冬の間に保管していた燃料フィルターは交換してください
冷骨材ビンが乾燥しており、湿気が含まれていないことを確認します。
すべての材料の流れ経路をテストして、詰まりがないことを確認します
ミキサー、ドライヤー、配管などのすべての高温側コンポーネントを徹底的に洗浄します。
アスファルトと骨材の蓄積を除去して硬化を防ぎます
コーティングを防ぐためにアスファルトラインとポンプシステムを清掃してください
アクセスポイントとサンプからすべての残留物を排出します
バッグハウスとダクトを含むクリーンな集塵システム
圧縮空気のブローダウンを使用して空気システムからすべての水を排出します
圧縮空気ユニットのドレン水分離器
完全に排水した後、すべての排水バルブを閉じます
ディーゼル燃料を使用する場合は、燃料オイルラインを排出します（冬季の寒さで燃料がゲル化する可能性があります）。
暖房システムからサーマルオイルを排出しないでください（保存方法についてはメーカーに問い合わせてください）。
コンベアやその他の水が溜まるエリアから水を排出します。
すべての露出したスチール表面と留め具に防錆油を塗布します。
モーターや電気部品を保護カバーで覆う
開口部を密閉して湿気や害虫の侵入を防ぎます
紛失しやすい小さな部品（ボルト、ファスナー、器具）を取り外します。
スプリングの再取り付けのためのアイテムの削除の文書化
湿気を減らすために、乾燥剤のパックを密閉された場所に置きます
開いたゴミ箱の上部をカバーして雨の侵入を防ぎます
すべての燃料供給バルブを閉じます
圧縮空気システムを停止し、適切に保管してください
すべての材料遮断バルブを閉じます
すべてのエネルギー源にロックアウト/タグアウト ラベルを適用する
シャットダウン手順とステータスをメンテナンスログに記録する
乾燥機のドラムシェルとフライトの詳細な厚さを測定します
超音波またはキャリパーツールを使用してトラニオンリングの摩耗を測定します
コンクリート基礎に亀裂や沈下がないか検査します。
構造用鋼に錆の発生や損傷がないか確認します
シーズン中に発生した応力亀裂がないかすべての溶接部を検査します。
来シーズンのメンテナンス計画のためにすべての結果を文書化する
潤滑により可動部品間の摩擦が軽減され、摩耗が最小限に抑えられます。
適切な潤滑剤の種類と粘度は、ベアリングの設計と動作温度に適合する必要があります
過剰な潤滑は過剰な熱を引き起こし、汚れを引き寄せます
潤滑不足はベアリングの摩耗と故障を加速します
高温環境ではより高い融点のグリースが必要です
すべての機器については製造元のマニュアルを参照してください
場所、潤滑剤の種類、量を含むすべての潤滑ポイントのリストを作成します。
装置の稼働時間に基づいて給油間隔を設定する
潤滑作業に対して特定のスタッフの責任を割り当てます
場所、潤滑剤の種類、最終サービス日を記載したチェックリストを作成する
スタッフに適切なグリース補給技術をトレーニングします (ベアリングの周囲ではなくベアリングに塗布します)
コンベヤー ベルトのローラー ベアリング (通常、ベアリングごとに毎月 1 ～ 2 オンスのグリースを塗布します)
ドライヤー駆動モーターのベアリングとシャフトシール
ミキサードライブギアボックス (オイルは毎年交換、毎月点検)
振動スクリーンエキサイター/バイブレーターベアリング
コールドフィードコンベアシステム全体
工場全体のすべてのチェーンドライブ
制御システムキャビネット冷却ファンベアリング
ビチューメンおよびアスファルトシステムのポンプシール
機器メーカーが指定した潤滑剤を使用してください (OEM の推奨事項に従ってください)。
高温用途 (乾燥機付近): NLGI グレード 2 または 3 グリース、定格 200°C+
常温軸受：NLGIグレード2多目的リチウムグリース
チェーン潤滑：自動チェーンオイルまたは浸透チェーン潤滑剤
モーターベアリング: 摩耗保護のための添加剤を含むオイルベースの潤滑剤
同じ用途で潤滑剤の種類を決して混合しないでください
過度の振動は、ベアリングの摩耗、位置ずれ、または不均衡を示します。
手持ち式振動計を使用して相対振動レベルを測定する
測定値を経時的に比較して、振動の増加傾向を特定する
機器が新品または新しく整備されたときにベースライン測定を確立する
振動が通常の範囲を超えて増加した場合に技術者に警告します
致命的なベアリング故障の前に交換のスケジュールを立てる
赤外線カメラで表面温度を測定し、内部の問題を明らかにします
ベアリングの過熱は、潤滑が不十分であるか、故障が差し迫っていることを示します
電気接続上のホットスポットは、接続が緩んでいるか、抵抗が高いことを示しています
乾燥機ドラムの温度プロファイリングにより、内部のフライト摩耗または蓄積が示されます
熱画像は断熱材の損傷やカバーの紛失を特定するのに役立ちます
ギアボックスから定期的にオイルをサンプリングすると、摩耗を示す金属含有量が判明します
鉄粒子の増加はベアリングまたはギアの摩耗を示します
水分含有量はシールの漏れまたは結露の問題を示します
酸性度または粘度の変化はオイルの劣化を示します
定期的な分析により、比較のための正常なパラメータが確立されます
経験豊富な技術者は機器の音を聞いて問題を特定できます
研削音はベアリングの問題または内部摩耗を示します
鳴きは潤滑不足または位置ずれを示唆します
ガタガタ音がする場合は、コンポーネントまたは留め具が緩んでいることを示します
異常なノイズパターンがある場合は、調査と文書化を促す必要があります
コンベヤ ベルト スプライス キットと交換用ベルト (必要な長さを計算)
ミキサーブレードとライナー (交換セットの 20 ～ 30%)
バグハウスフィルターバッグ (最低限必要な完全な予備セット)
バーナーノズルと点火電極（各2～3本）
すべてのモーターとファン用のドライブベルト
モーターおよびミキサー用のベアリングおよびシールキット
ブラシ付き電動モーター用モーターブラシ
電気ヒューズおよびサーキットブレーカーのコンポーネント
温度および圧力センサー
スペアパーツは乾燥した温度管理された環境に保管してください
プラントのコンポーネント (乾燥機、ミキサー、コンベアなど) ごとに在庫を整理します。
部品番号と数量を含む詳細な在庫リストを維持する
FIFO (先入れ先出し) 原理を使用して在庫をローテーションします。
保管されている部品が劣化していないか定期的に検査してください
購入情報とサプライヤーの連絡先詳細を最新の状態に保つ
再注文をトリガーする最低在庫レベルを設定する
保証文書と有効期間情報を維持する
所定の手順 (上記で詳しく説明) を使用して骨材フィーダーを校正します。
すべてのスケールの読み取り精度が ±0.5% 以内であることを確認します。
混合の均一性に影響を与える磨耗したブレードがないかミキサーを検査します
ドラムの長さに沿った乾燥機の出口温度の一貫性を確認します
アスファルトが混合物全体に均一に適用されていることを確認します
ミキサーの排出ゲートの動作を検査し、完全な排出を確保します
余分な時間を費やすことなく適切な保管箱管理を確認する
バーナーの空燃比が適切に校正されていることを確認します (専門家が必要です)
乾燥機ドラムのフライトに摩耗があり、熱伝達効率が低下していないか検査します。
ドラムシェルの断熱材に損傷や劣化がないか確認してください
バグハウスフィルターが過度に詰まっていないことを確認し、制限を増やします
コンベアベルトの張力を点検します（張力が過剰になるとモーターの負荷が増加します）
システム圧力の上昇を必要とする材料の漏れや流出がないか確認してください。
アスファルトポンプにキャビテーションが発生していないか、過剰な圧力が必要になっていないことを確認します。
スケール付着による熱効率の低下がないことを確認
工場全体のすべての留め具に緩みがないか検査し、計画的に締めます
手動たわみテストを使用してベアリングの遊びを確認し、過剰な場合は交換します
直線エッジを使用してモーター/ギアカップリングの位置を確認します
コンベアベルトのトラッキングを検査し、位置がずれている場合は中心を再調整します
ミキサーに内部障害物やブレードの破損がないかを調べます
測定ツールを使用して乾燥機ドラムのトラニオンの摩耗をチェックする
バッグハウスバッグの張力と適切な設置を確認してください
振動計を使用してベースラインを確立し、変化を追跡する
燃料供給が適切でバーナーに到達していることを確認します
燃料フィルターの詰まりを検査し、詰まっている場合は交換します
仕様に照らして燃料圧力を確認してください
点火電極が清潔で適切なギャップがあることを確認します
CAD セル (火炎検出器) ウィンドウに煤がないか検査します
燃焼用空気が詰まりなく十分に供給されていることを確認する
燃料ノズルにカーボンが蓄積していないか確認します (専門家による清掃/交換が必要です)
バーナーの取り付け位置がずれて空気と燃料の混合に影響を与えていないことを確認します。
フィルターバッグの詰まりや粉塵の固着を検査します。
パルス洗浄システムが正しい周波数で動作していることを確認する
供給圧力が低い場合はエアコンプレッサーのフィルターエレメントを交換してください
パルスバルブソレノイドが正しく動作していることを確認してください
バグハウスの入口ダクトに詰まりがないか調べます
バイパスを可能にする不適切な座席がないかバッグを検査する
入口温度が過剰ではないことを確認します（仕様を上回っています）
目視検査を使用してフィルターバッグの破れや穴を探す
漏れを示すスタックから出る塵雲を確認する
すべての袋室アクセス ドアのガスケット シールが損傷していないことを確認します。
バイパスを可能にする損傷がないかバッグケージを検査します
リフティングバルブが装備されている場合は動作を確認してください
分配プレートの詰まりを調べる
メンテナンス作業の日時
サービスを受けるコンポーネントまたはシステム
メンテナンスを行う技術者またはオペレーター
実行された作業と結果
交換した部品（部品番号と数量）
ダウンタイム期間 (該当する場合)
部品代と人件費
次回のメンテナンス予定日
今後の注意事項に関する推奨事項
重要な記録のデジタルと物理の両方のバックアップを維持する
すべての保守スタッフがアクセスできる保管記録
作業完了後すぐに記録を更新する
記録を定期的に確認して、再発する問題を特定する
傾向データを分析してメンテナンス間隔を最適化します
交換が必要な慢性的に問題のあるコンポーネントを特定します
調整が必要なメンテナンス間隔を明らかにする
根本原因の問題を示すパターンを表示します
機器のアップグレードまたは交換の決定を正当化する
詳細な文書で保証請求をサポートします
新しい技術者が機器の歴史を学ぶのを支援します
優れた製品品質: 一貫した混合設計、分離なし、適切な温度制御
運用コストの削減: 最適な燃料効率、最小限の緊急修理、コンポーネントの寿命の延長
安全性の向上: 危険を排除した適切に機能する機器
法規制への準拠: 効果的な集塵とバーナー制御により環境基準を達成
収益性の向上: 生産率の向上、顧客満足度の向上、プレミアム価格設定機能
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