Manual Penyelenggaraan Bahagian Tanaman Asfalt Lengkap: Liputan mendalam mengenai prosedur penyelenggaraan terperinci untuk setiap komponen

Masa pelepasan: 2025-11-27

Pengenalan


Bahagian tumbuhan asfalt mewakili pelaburan modal yang signifikan untuk mana -mana syarikat pembinaan. Menjaga komponen ini dalam keadaan optimum melalui penyelenggaraan sistematik memastikan pengeluaran yang boleh dipercayai, kualiti campuran yang unggul, keselamatan pekerja, dan jangka hayat peralatan lanjutan. Loji asfalt yang dikendalikan dengan baik dapat mengurangkan penggunaan bahan api sehingga 10 peratus, meminimumkan downtime yang tidak dirancang, dan memberikan hasil yang konsisten yang memenuhi jangkaan pelanggan.

Manual penyelenggaraan yang komprehensif ini merangkumi prosedur terperinci untuk setiap komponen kritikal tumbuhan pencampuran asfalt moden, dari protokol pembersihan harian kepada teknik pembaikan khusus. Sama ada anda mengendalikan loji batch, pengadun drum, atau sistem mudah alih, panduan ini menyediakan pengetahuan teknikal yang diperlukan untuk melaksanakan program penyelenggaraan yang berkesan.


Bahagian 1: Memahami Rangka Kerja Penyelenggaraan Tanaman Asfalt


Mengapa perkara penyelenggaraan bahagian tumbuhan asfalt

Proses pengeluaran asfalt panas (HMA) melibatkan beribu-ribu bahagian bergerak yang beroperasi di bawah keadaan yang melampau-suhu tinggi, bahan-bahan yang kasar, dan tekanan mekanikal yang berterusan. Mengabaikan penyelenggaraan membawa kepada:

  • Kecekapan pengeluaran yang dikurangkan: Komponen tersumbat dan bahagian yang dipakai memaksa tumbuhan untuk bekerja lebih keras, memakan lebih banyak bahan bakar

  • Degradasi Kualiti: Pencampuran yang tidak konsisten, pemanasan yang tidak sekata, dan pencemaran kompromi spesifikasi asfalt

  • Bahaya Keselamatan: Pengikat longgar, galas gagal, dan kerosakan elektrik mencipta bahaya tempat kerja

  • Kos Pembaikan Meningkatkan: Masalah Kecil Menjadi Kegagalan Bencana yang Memerlukan Penggantian Komponen Lengkap

  • Ketidakpatuhan Alam Sekitar: Penyelenggaraan Baghouse yang lemah meningkatkan pelepasan; bahan api pembakar tidak mencukupi bahan api sisa bahan api

Membangunkan Jadual Penyelenggaraan Anda

Penyelenggaraan yang berkesan memerlukan pendekatan berstruktur dengan selang waktu yang jelas:
Penyelenggaraan Harian: Pembersihan, Pelinciran, dan Pemeriksaan Visual Penting dilakukan setiap peralihan
Penyelenggaraan Mingguan: Pemeriksaan Komponen Terperinci dan Tugas Pembersihan Sederhana
Penyelenggaraan Bulanan: Penentukuran Sistem Komprehensif dan Penilaian Keadaan Bahagian
Penyelenggaraan tahunan/bermusim: Pembersihan yang mendalam, pemeriksaan utama, dan penggantian bahagian pakaian yang dijadualkan

Kebanyakan pengeluar menyediakan jadual asas, tetapi selang penyelenggaraan khusus anda harus disesuaikan berdasarkan penggunaan tumbuhan, ciri -ciri bahan tempatan, dan persekitaran operasi.


Bahagian 2: Komponen tumbuhan asfalt kritikal dan prosedur penyelenggaraan terperinci


Drum Pengeringan: Jantung tumbuhan asfalt anda

Drum pengeringan beroperasi di teras pengeluaran asfalt, pemanasan dan pencampuran agregat kepada spesifikasi yang tepat. Komponen ini mengalami tekanan terma dan mekanikal yang melampau dan memerlukan perhatian yang paling.

Penyelenggaraan dram pengeringan setiap hari

Pemeriksaan dan Pembersihan Shell

  • Periksa secara visual shell drum luaran untuk retak, karat, atau corak haus yang tidak biasa

  • Keluarkan serpihan, habuk, dan pembentukan asfalt dari permukaan luar

  • Semak penerbangan dalaman (pencampuran bilah) untuk kerosakan yang boleh dilihat melalui pelabuhan akses

  • Kosongkan bahan terkumpul berhampiran salur masuk yang boleh menyebabkan penyambungan

  • Syarat shell dokumen dalam log penyelenggaraan anda untuk analisis trend

Pemantauan suhu dan prestasi

  • Gunakan termometer inframerah untuk mengukur suhu shell pada selang masa yang tetap (kira -kira setiap 3 kaki di sepanjang panjang gendang)

  • Ambil bacaan pada kadar maksimum dan dikurangkan untuk menubuhkan prestasi asas

  • Pengagihan suhu yang tidak normal menunjukkan haus dalaman atau kemerosotan penerbangan

  • Catat semua data suhu untuk mengenal pasti anomali haba lebih awal

Pelinciran komponen dram

  • Lubricate Drive Motor Bearings Menurut Spesifikasi Pengilang Menggunakan Grease Tinggi Tinggi yang sesuai

  • Sapukan pelincir ke galas roda trunnion yang menyokong drum berputar

  • Garam semua galas yang boleh diakses pada sistem pengurangan gear

  • Periksa bahawa titik pelinciran tidak disekat oleh serpihan atau karat

  • Jangan sekali-kali melinfikasikan, kerana gris yang berlebihan menghasilkan haba dan menarik pencemaran

Penyelenggaraan dram pengeringan bulanan/bermusim

Pemeriksaan dan Penggantian Penerbangan
Sebelum memulakan kerja penerbangan, lakukan tinjauan komprehensif mengenai konfigurasi anda yang sedia ada:

  • Ukur dan gambar semua penerbangan yang dipasang sekarang -kedudukan, kuantiti, jarak, dan keadaan mereka

  • Bandingkan konfigurasi sebenar dengan lukisan kilang dan rekod penyelenggaraan

  • Menganalisis prestasi pembakar dengan memantau suhu saluran keluar pada selang waktu 8-10 inci

  • Sekiranya penerbangan dipakai lebih daripada 1/3 ketebalan asalnya, jadilah penggantian

Prosedur Penggantian Penerbangan

  • Tuangkan semua bahan bakar dan kuasa ke bawah sistem menggunakan prosedur penguncian/tagout yang betul

  • Benarkan dram sejuk sepenuhnya (biasanya minimum 4-8 jam)

  • Keluarkan baut yang mengamankan penerbangan yang dipakai menggunakan set sepana soket

  • Pasang penerbangan baru menggunakan spesifikasi yang sepadan -konfigurasi penerbangan yang sukar mengurangkan kecekapan

  • Ketatkan semua pengikat dalam corak silang untuk memastikan tempat duduk

  • Periksa kimpalan dan sambungan untuk integriti sebelum kembali ke perkhidmatan

Roda trunnion dan penyelenggaraan galas

  • Periksa cincin trunnion untuk corak haus yang tidak sekata yang menunjukkan misalignment

  • Semak mainan galas dengan cuba menggerakkan drum yang kemudiannya -Excentive Movement menunjukkan galas yang dipakai

  • Sekiranya memakai melangkaui titik pengerasan atau menunjukkan pengapungan logam yang teruk, penggantian jadual

  • Perhimpunan Trunnion Lubricate pada selang waktu yang dijadualkan menggunakan perlawanan khas untuk aplikasi yang tepat

  • Ganti minyak dalam pengurangan pemacu semasa tempoh penyelenggaraan yang dijadualkan

Perkhidmatan Perhimpunan Pembakar (ditutup secara terperinci dalam bahagian pembakar)

  • Kepala pembakar, muncung, dan pembakaran yang bersih dalam

  • Ganti muncung bahan api (tidak dapat dibersihkan dengan berkesan sebaik sahaja dikeluarkan)

  • Periksa tetingkap sel CAD untuk kejelasan

  • Semak elektrod pencucuhan untuk jurang dan kebersihan yang betul

  • Sahkan bentuk api dan warna semasa menembak ujian


Silinder Mixer/Pencampuran: Peralatan Penggabungan Ketepatan


Pengadun menggabungkan agregat yang dipanaskan dengan pengikat asfalt kepada spesifikasi yang tepat. Ketepatannya secara langsung mempengaruhi kualiti produk dan konsistensi akhir.

Penyelenggaraan Pengadun Harian

Pintu Pintu dan Sistem Pengedap

  • Periksa keadaan meterai pintu untuk air mata, keretakan, atau kemerosotan

  • Permukaan pengedap bersih asfalt terkumpul dan bahan agregat

  • Sahkan bahawa pintu dibuka dan ditutup dengan lancar tanpa mengikat

  • Periksa bahawa mekanisme penyebaran memegang pintu dengan selamat semasa operasi

  • Ganti meterai jika kebocoran diperhatikan semasa kitaran pencampuran

Pemeriksaan galas dan meterai

  • Dengarkan bunyi pengisaran, squealing, atau bunyi yang tidak biasa yang menunjukkan masalah galas

  • Periksa kebocoran asfalt atau air di sekitar meterai aci

  • Pantau suhu galas dengan sentuhan (selepas penutupan) atau termometer inframerah

  • Sekiranya galas berasa panas atau getaran meningkat, merancang penyelenggaraan segera

Penilaian Keadaan Bilah dan Liner

  • Buka Pintu Akses Mixer semasa downtime dan periksa semua bilah pencampuran secara visual

  • Semak ketebalan bilah -gambarkan bilah jika dipakai lebih daripada 1/3 ketebalan asal

  • Periksa titik kimpalan bilah untuk retak atau pemisahan

  • Periksa pelapik pengadun (salutan laras dalaman) untuk pematuhan dan haus

  • Dokumen bilah dan syarat pelapik untuk meramalkan masa penggantian

Penyelenggaraan Pengadun Bulanan

Galas bawah dan pengganti meterai (prosedur lengkap)
Alat yang diperlukan: Set soket (termasuk soket berukuran berukuran), penarik galas, tukul, obor (untuk galas yang dirampas), tang cincin snap, kain bersih, gris pelincir
Penggantian langkah demi langkah:

  1. Kuasa ke bawah dan gunakan lockout/tagout

  2. Benarkan pengadun sejuk sepenuhnya

  3. Buka Panel Akses Mixer Bawah

  4. Sekiranya galas dirampas: Berhati -hati menggunakan obor pemotongan untuk memotong perlumbaan (pakai PPE yang betul)

  5. Gunakan penarik galas dengan soket yang sesuai untuk mengeluarkan perlumbaan galas luar

  6. Keluarkan bolt yang memegang pemasangan meterai bawah

  7. Slaid galas dan meterai dengan teliti

  8. Orientasi meterai nota sebelum penyingkiran

  9. Sapukan minyak pelincir ke anjing laut baru sebelum pemasangan

  10. Tekan meterai baru ke kedudukan dengan tekanan walaupun digunakan untuk pemasangan tri-clamp

  11. Masukkan penyesuai berulir dan ketatkan bolt dalam corak x, bertukar 1 giliran penuh setiap bolt pada setiap pas

  12. Putar pemasangan dengan tangan untuk mengesahkan operasi lancar sebelum ditutup

  13. Pasang semula Perumahan dan Panel Akses Tutup

Penggantian meterai aci

  • Periksa kedua -dua meterai berakhir untuk kebocoran atau kerosakan

  • Gantikan anjing laut O-ring jika dipakai, retak, atau terdegradasi

  • Sapukan gris vakum untuk mengelak permukaan sebelum pemasangan

  • Pastikan bahagian rata muka meterai pusat batang

  • Pelincir o-cincin sebelum menekan ke dalam pemasangan

Perkhidmatan Motor dan Gearbox

  • Periksa tahap minyak dalam kotak gear menggunakan kaca penglihatan atau dipstick

  • Tukar minyak kotak gear setiap tahun atau setiap jadual pengeluar

  • Pantau suhu gear semasa operasi

  • Periksa corak bunyi atau getaran yang tidak biasa

  • Semak bukaan pengudaraan motor untuk penyumbatan

  • Sahkan motor disambungkan dengan betul untuk memandu gandingan dengan pengikat selamat


Pemungut Habuk Baghouse: Perlindungan dan Kecekapan Alam Sekitar


Baghouse menangkap pelepasan habuk dan pulih denda yang boleh digunakan, berfungsi sebagai "paru -paru" tumbuhan asfalt anda. Operasi Baghouse yang lemah secara langsung mengurangkan kecekapan loji dan meningkatkan liabiliti alam sekitar.

Penyelenggaraan Baghouse harian

Pemeriksaan dan kebersihan beg

  • Periksa secara visual semua beg penapis untuk air mata, lubang, atau kerosakan

  • Periksa beg yang betul duduk di dalam sangkar mereka tanpa jurang

  • Sahkan beg menunjukkan pemuatan habuk tanpa pembentukan pekat di kawasan tertentu

  • Ketegangan beg pemeriksaan tempat dengan menyentuh dengan teliti (apabila selamat) untuk menilai ketegasan

  • Cari perubahan warna kain yang menunjukkan kerosakan haba atau serangan kimia

  • Dokumenkan mana -mana beg yang rosak untuk penggantian

Pemantauan Tekanan Berbeza (Penunjuk Kritikal)

  • Semak dan rekod tekanan perbezaan (penurunan tekanan merentasi sistem penapis) setiap hari

  • Perbezaan tekanan operasi biasa: 3-4 inci air

  • Tekanan pembezaan yang berlebihan (> 6 inci) menunjukkan ketepuan penapis

  • Tekanan pembezaan rendah (<2 inci) mencadangkan beg koyak atau pembersihan yang tidak betul

  • Mengekalkan Log Penjejakan Bacaan Tekanan Harian untuk Analisis Trend

  • Sekiranya tekanan perbezaan meningkat secara konsisten, penyiasatan sebab sebelum kegagalan berlaku

Sistem Pelepasan Hopper dan Pembersihan

  • Periksa corong untuk pengumpulan habuk dan pelepasan yang betul

  • Sahkan bahawa injap pelepasan beroperasi dengan lancar dan meterai sepenuhnya

  • Periksa bahawa habuk dikeluarkan dari aliran corong dengan bebas ke titik pengumpulan

  • Kawasan bersih di sekitar corong untuk mengelakkan pemadatan bahan

  • Sahkan sistem udara termampat yang menyediakan pembersihan nadi mempunyai tekanan yang mencukupi

Pemerhatian timbunan untuk pelepasan yang kelihatan

  • Secara visual perhatikan tumpukan ekzos semasa operasi

  • Sebarang pelepasan habuk yang kelihatan menunjukkan beg yang rosak atau kerosakan sistem

  • Sekiranya debu berlaku, hentikan tumbuhan dan siasat segera

  • Gunakan monitor kelegapan jika dilengkapi untuk mengesahkan pengukuran pematuhan

Penyelenggaraan Baghouse Bulanan

Prosedur penggantian beg penapis

  1. Catat kedudukan dan konfigurasi semua beg sebelum penyingkiran

  2. Kuasa ke bawah sistem pembersihan nadi dan biarkan udara termampat untuk dilepaskan

  3. Baghouse depressurize menggunakan injap berdarah

  4. Benarkan sistem sejuk (biasanya 30-60 minit)

  5. Buka Pintu Akses Baghouse menggunakan prosedur ruang terkurung yang betul

  6. Keluarkan beg yang rosak dengan meluncur ke atas dari sangkar

  7. Periksa struktur sangkar untuk kerosakan yang mungkin menyebabkan kegagalan beg

  8. Pasang beg pengganti baru dengan meluncur ke jawatan sangkar

  9. Pastikan beg duduk sepenuhnya tanpa kelainan atau lipatan

  10. Sahkan pengedap lengkap antara asas beg dan sangkar

  11. Tutup pintu akses dengan gasket dan tork pengikat yang betul

  12. Pulihkan tekanan sistem secara beransur -ansur sebelum meneruskan operasi

Perkhidmatan Sistem Injap dan Pembersihan Pulse

  • Periksa solenoid injap nadi untuk kerosakan atau kakisan

  • Operasi injap nadi ujian dengan mendengar kitaran membersihkan

  • Semak Pulse Cleaning Timing -Bag harus mengembang pada selang masa yang diprogramkan

  • Sahkan injap yang dicapai udara termampat mempunyai tekanan yang mencukupi (biasanya 80-100 psi)

  • Ganti kit diafragma jika kebocoran udara dikesan di sekitar batang injap

  • Periksa sambungan syarikat penerbangan untuk kelengkapan atau kebocoran yang longgar

  • Ganti kartrij pengering udara dalam sistem udara termampat setiap bulan

  • Semak elemen penapis udara di unit udara termampat untuk tepu

Pemeriksaan Baghouse dan pembersihan yang mendalam

  • Lakukan pemeriksaan visual di dalam Baghouse menggunakan prosedur ruang terkurung yang betul

  • Dokumenkan sebarang serpihan, kakisan, atau kerosakan beg yang dapat dilihat di pedalaman

  • Periksa dalaman corong habuk untuk pengumpulan bahan atau merapatkan

  • Periksa plat pengedaran untuk menyumbat atau aliran udara yang tidak sekata

  • Bersihkan semua permukaan dalaman jika pengumpulan habuk berat diperhatikan

  • Periksa operasi injap mengangkat dan keadaan meterai gasket

  • Sahkan peredam pintasan (jika dilengkapi) beroperasi dengan betul untuk melindungi beg semasa permulaan


Sistem pembakar dan pembakaran: penjanaan haba dan kawalan


Sistem pembakar memanaskan agregat kepada suhu yang tepat. Prestasi pembakar secara langsung mempengaruhi kecekapan bahan api, pelepasan, dan kualiti campuran. Penyelenggaraan pembakar profesional perlu dilakukan setiap tahun oleh juruteknik yang berkelayakan.

Penyelenggaraan pembakar harian

Pemerhatian api dan penilaian pembakaran

  • Perhatikan api pembakar melalui kaca penglihatan (gunakan perlindungan mata yang betul)

  • Api mestilah biru (tidak kuning/oren) yang menunjukkan pembakaran lengkap

  • Bentuk api harus berbentuk kerucut dan stabil, tidak berkedip atau berdenyut

  • Perhatikan sebarang warna api yang tidak biasa yang menunjukkan masalah nisbah bahan api/udara

  • Periksa isyarat pengesan api pada sistem kawalan yang menunjukkan pencucuhan yang betul

  • Dokumentasikan keabnormalan untuk siasatan juruteknik

Pemeriksaan sistem bahan api

  • Sahkan pam bahan api beroperasi secara normal tanpa bunyi yang luar biasa

  • Periksa tahap tangki bekalan bahan api dan pastikan bekalan yang mencukupi

  • Periksa talian bahan api untuk kebocoran pada sambungan dan sepanjang penghalaan

  • Pastikan bakul penapis bahan api tidak disekat (pemeriksaan visual jika boleh diakses)

  • Periksa bacaan tolok tekanan bahan api (jika dilengkapi) terhadap julat operasi biasa

  • Perhatikan sebarang bau bahan api atau tumpahan yang memerlukan perhatian segera

Kawasan perumahan dan akses pembakar

  • Keluarkan serpihan dan habuk yang boleh diakses dari kepala pembakar

  • Periksa bolt pelekap dan pengikat sama ada ketat

  • Sahkan penunu boleh bergerak dengan lancar dalam pendakap pelekap jika boleh laras

  • Periksa penghalaan hos bekalan bahan api untuk kerosakan atau pendedahan haba yang berlebihan

  • Semak bahawa kelegaan penunu dari peralatan masih mencukupi

Perkhidmatan Pembakar Suku Tahunan/Tahunan

Penggantian Nozel Lengkap
Muncung tidak boleh dibersihkan dengan berkesan dan mesti diganti daripada diperbaharui.
Prosedur Penggantian:

  1. Pastikan penutupan dan penyejukan sistem lengkap (minimum 30 minit)

  2. Gunakan lockout/tagout pada semua sumber tenaga

  3. Cari sambungan talian bahan api ke perumahan penunu

  4. Putuskan sambungan talian bahan api dari tiub penghantaran bahan api menggunakan sepana boleh laras

  5. Tanggalkan plat yang memegang keseluruhan sistem penghantaran ke perumahan penunu

  6. Pemasangan sistem penghantaran slaid keluar melalui bahagian atas perumahan penunu

  7. Menggunakan dua sepana boleh laras, keluarkan muncung dari tiub penghantaran:

    1. Satu sepana memegang tiub dengan mantap

    2. Sepana kedua memusingkan muncung mengikut arah jam

  8. Jangan cuba membersihkan muncung yang dikeluarkan—buang dengan selamat

  9. Rawat muncung baharu hanya apabila sepana bersentuhan (sama seperti langkah berjaga-jaga mentol lampu halogen—muncung kerosakan minyak kulit)

  10. Pasang muncung baru menggunakan prosedur terbalik, rentap dengan kuat tetapi tidak terlalu ketat

  11. Sambung semula sistem penghantaran bahan api dan plat pelekap selamat

  12. Sambung semula saluran bahan api dan sahkan tiada kebocoran

  13. Lakukan ujian tembakan dan sahkan corak nyalaan yang betul

Pemeriksaan Elektrod dan Pencucuh

  • Keluarkan kepala penunu untuk mengakses komponen penyala

  • Periksa elektrod untuk pitting, fouling atau terbakar

  • Periksa jurang elektrod sepadan dengan spesifikasi penunu (biasanya 3-4mm)

  • Bersihkan permukaan elektrod menggunakan kertas pasir halus atau berus dawai

  • Sahkan penyalaan menghasilkan percikan apabila kitaran penunu

  • Gantikan penyala jika percikan lemah atau tiada

  • Periksa tetingkap sel CAD (pengesan api) untuk mengesan jelaga atau perubahan warna

  • Bersihkan sel CAD menggunakan kain lembut dan aseton jika tercemar

Penapis Bahan Api dan Penyelenggaraan Skrin

  • Cari bakul penapis bahan api di antara tangki dan pam bahan api

  • Putar injap tutup bahan api untuk mengasingkan tangki

  • Keluarkan mangkuk perumah penapis menggunakan sepana

  • Keluarkan bakul dan periksa sama ada serpihan, air atau karat

  • Jika pencemaran jelas, bersihkan bakul dengan udara termampat atau berus

  • Toskan sebarang air dari mangkuk penapis

  • Keringkan bakul dengan teliti sebelum memasang semula

  • Sapukan pengedap gasket kalis bahan api pada benang sebelum memasang semula

  • Pulihkan bekalan bahan api dan periksa kebocoran

Penentukuran dan Pengujian Nisbah Udara-Bahan Api

  • Prosedur ini memerlukan peralatan dan latihan khusus

  • Hubungi juruteknik penunu yang diberi kuasa untuk penentukuran profesional

  • Pelarasan udara-bahan api yang tidak betul meningkatkan pelepasan dan mengurangkan kecekapan

  • Peralatan analisis pembakaran mengukur kandungan oksigen dalam gas ekzos

  • Pembakaran yang ideal mengekalkan 2-3% oksigen dalam gas serombong

  • Dokumen tarikh penentukuran dan tetapan dalam rekod penyelenggaraan


SISTEM TALI PINGGANG PENGHANTARAN: Pengangkutan Bahan


Tali pinggang penghantar mengangkut agregat daripada suapan sejuk melalui sistem pengering. Kegagalan tali pinggang menyebabkan penutupan loji serta-merta dan boleh merosakkan komponen sekeliling.

Penyelenggaraan Penghantar Harian

Penilaian Keadaan Tali Pinggang

  • Berjalan sepanjang tali pinggang pada kedua-dua belah pihak

  • Cari koyak, berjumbai, pemisahan jahitan atau lencongan tepi

  • Periksa sama ada tergelincir atau semput yang luar biasa semasa operasi

  • Perhatikan penjejakan tali pinggang-ia harus kekal berpusat pada takal

  • Perhatikan sebarang pembentukan atau tumpahan bahan di sepanjang sistem

  • Periksa kerosakan lembapan atau degradasi getah

  • Dengar bunyi mengisar yang menunjukkan takal tidak jajaran

Pengesahan Ketegangan dan Penjejakan

  • Sahkan tali pinggang menunjukkan ketegangan yang betul dengan menggunakan tekanan tangan pertengahan rentang

  • Tali pinggang harus mempunyai sedikit pesongan (biasanya 10-15mm di bawah tekanan sederhana)

  • Tali pinggang yang terlalu longgar tergelincir; tali pinggang yang terlalu ketat menyebabkan kehausan galas pramatang

  • Perhatikan penjajaran tali pinggang berbanding dengan tepi takal

  • Jika tali pinggang melayang ke arah satu sisi, laraskan bolt pengesan secara berperingkat

  • Jangan sekali-kali laraskan kedua-dua belah secara serentak—laraskan satu bahagian sahaja setiap syif

Pemeriksaan Pengikat

  • Periksa semua bolt, nat dan pengikat yang kelihatan di sepanjang bingkai penghantar

  • Ketatkan sebarang pengikat yang longgar dengan segera

  • Cari karat atau kakisan yang memerlukan penggantian

  • Periksa sambungan sambatan tali pinggang jika tali pinggang diganti baru-baru ini

  • Sahkan bolt pelekap takal kekal selamat

Penyelenggaraan Penghantar Bulanan

Pelarasan Ketegangan Tali Pinggang (Prosedur Lengkap)
Alat yang diperlukan: Pita pengukur, bicu atau alat penegang, sepana, pen penanda

  1. Bersihkan katil penghantar dari semua serpihan dan bahan

  2. Sahkan motor MATI dan terkunci

  3. Pasang tali pinggang ganti jika tali pinggang lama menunjukkan kerosakan

  4. Sapukan ketegangan awal (pra-tegangan) supaya tali pinggang hanya bergerak dengan tekanan tangan

  5. Pastikan semua penggelek adalah empat segi kepada laluan tali pinggang

  6. Tandakan dua titik pada tali pinggang dengan jarak tepat 100 inci, berserenjang dengan garis tengah

  7. Tingkatkan ketegangan secara beransur-ansur menggunakan bicu atau peranti penegang

  8. Ukur jarak antara tanda apabila ketegangan meningkat

  9. Gunakan ketegangan sehingga markah mencapai jarak yang dikira bagi setiap spesifikasi pengeluar

  10. Contoh: Jika 0.5% ketegangan dinyatakan, ketegangan kepada 100.5" (0.5% daripada 100")

  11. Setelah ketegangan yang betul dicapai, sahkan tali pinggang kekal persegi dan berpusat

  12. Jalankan tali pinggang perlahan-lahan untuk mengesahkan pengesanan yang betul sebelum meneruskan operasi biasa

  13. Periksa semula ketegangan selepas 24 jam beroperasi (tali pinggang baharu meregang pada mulanya)

Pemeriksaan Takal dan Penggelek

  • Tanggalkan tali pinggang atau akses bahagian bawah (jika selamat dan peralatan dimatikan)

  • Periksa semua takal untuk kehausan tertinggal atau kemerosotan getah

  • Periksa keadaan galas takal—dengar bunyi pengisaran atau bunyi luar biasa

  • Sahkan permukaan takal licin tanpa retak atau retak

  • Gantikan pulley lagging jika haus melebihi 50% daripada ketebalan asal

  • Lubricate pulley dan roller bearing mengikut jadual

  • Periksa penjajaran penggelek berserenjang dengan laluan tali pinggang menggunakan tepi lurus

  • Gantikan galas yang menunjukkan permainan atau kerosakan yang berlebihan

Pemeriksaan Motor Pandu

  • Periksa bolt pelekap motor untuk kesesakan

  • Sahkan bukaan pengudaraan motor tidak disekat

  • Periksa sambungan elektrik untuk kakisan atau kelonggaran

  • Periksa keadaan galas motor dengan mendengar bunyi yang luar biasa

  • Sahkan gandingan aci motor selamat

  • Semak cabutan arus motor berbanding garis dasar

  • Pastikan motor mempunyai pelinciran yang mencukupi mengikut jadual pengilang


SKRIN BERGETAR: Pemisahan dan Penggredan


Skrin bergetar mengelaskan agregat ke dalam saiz yang diperlukan, secara langsung mempengaruhi kualiti campuran akhir dan pengasingan.

Penyelenggaraan Skrin Harian

Pemeriksaan dan Pembersihan Mesh

  • Bersihkan jaringan skrin semua bahan antara setiap pengeluaran

  • Keluarkan bahan berlapis menggunakan berus atau udara termampat

  • Periksa jaringan secara visual untuk koyak, lubang atau ubah bentuk

  • Periksa lampiran mesh pada tepi bingkai untuk keselamatan

  • Cari apertur yang disekat yang mengurangkan kecekapan penyaringan

  • Perhatikan corak haus yang tidak sekata yang menunjukkan salah jajaran

Pemeriksaan Bingkai dan Pengikat

  • Periksa semua sambungan bolt untuk kelonggaran yang disebabkan oleh getaran

  • Ketatkan sebarang bolt yang longgar dengan segera menggunakan sepana yang sesuai

  • Cari keretakan pada kimpalan atau struktur rangka

  • Semak bahawa bingkai skrin kekal segi empat sama semasa operasi

  • Sahkan mata air pelekap dan sesendal pengasingan adalah utuh

  • Dengar bunyi berderak luar biasa yang menunjukkan komponen dalaman longgar

Pemeriksaan Unit Sipi/Penggetar

  • Periksa suhu exciter/vibrator dengan pengukuran inframerah selepas operasi

  • Suhu yang berlebihan menunjukkan masalah galas atau salah jajaran

  • Dengar bunyi pengisaran luar biasa daripada unit getaran

  • Sahkan bolt pelekap unit getaran kekal ketat

  • Periksa tahap pelinciran dalam galas penggetar jika boleh diakses

Penyelenggaraan Skrin Bulanan

Prosedur Penggantian Mesh

  1. Matikan skrin dan gunakan lockout/tagout

  2. Benarkan skrin sejuk (biasanya 15-30 minit)

  3. Tanggalkan bolt yang mengikat mesh ke bingkai menggunakan sepana soket

  4. Angkat jaring haus dari bingkai dengan berhati-hati

  5. Bersihkan tepi bingkai daripada sisa bahan menggunakan berus dan udara termampat

  6. Letakkan jejaring baharu pada bingkai memastikan penjajaran sekata

  7. Ketatkan sebahagian semua bolt dalam corak silang untuk memegang mesh buat sementara waktu

  8. Sahkan mesh adalah rata dan segi empat sama berbanding bingkai

  9. Ketatkan bolt sepenuhnya secara progresif, seli seli untuk mengekalkan tekanan yang sekata

  10. Pastikan jaring terletak rata pada bingkai tanpa kedutan atau lipatan

  11. Putar skrin secara manual untuk mengesahkan operasi lancar sebelum dihidupkan

  12. Berlari pada kelajuan rendah pada mulanya untuk mengesahkan tempat duduk mesh yang betul

Spring dan Pemeriksaan Pengasingan Getaran

  • Periksa spring/pengasing getah sama ada retak atau rosak

  • Gantikan spring jika keretakan kelihatan atau getah hancur

  • Semak bahawa sistem pengasingan skrin mengurangkan penghantaran getaran ke bingkai tumbuhan

  • Sahkan spring dimuatkan dengan betul dengan jarak yang betul

  • Pastikan bolt pemasangan spring ketat

Perkhidmatan Penguja/Penggetar

  • Periksa permainan bearing vibrator dengan cuba menggerakkan aci

  • Permainan yang berlebihan menunjukkan bearing haus yang memerlukan penggantian

  • Sahkan bolt pelekap unit getaran selamat

  • Periksa aras minyak dalam penggetar jika reka bentuk galas tertutup

  • Dengar semasa operasi untuk mengisar atau berderak yang menunjukkan masalah

  • Gantikan galas yang menunjukkan permainan yang berlebihan atau bunyi yang luar biasa


SISTEM PENYIMPANAN DAN PEMANASAN BITUMEN


Sistem penyimpanan bitumen mengekalkan pengikat asfalt pada suhu yang tepat untuk pengaliran dan penggunaan yang betul.

Penyelenggaraan Sistem Bitumen Harian

Pemantauan dan Kawalan Suhu

  • Semak bacaan termometer untuk mengesahkan suhu tangki dalam spesifikasi (biasanya 140-180°C)

  • Sahkan sistem kawalan suhu mengekalkan titik tetapan yang betul

  • Perhatikan sebarang turun naik suhu atau ralat instrumen

  • Periksa bahawa sistem pemanasan hidup/mati seperti biasa

  • Perhatikan bahawa penebat tangki kekal utuh tanpa kerosakan

Pemeriksaan Kebocoran dan Pengesahan Bahan Api

  • Periksa semua sambungan paip, injap dan tangki untuk kebocoran

  • Periksa tahap bekalan bahan api dan perhatikan jika penggunaan adalah normal

  • Sahkan talian bahan api dan sambungan selamat tanpa kerosakan

  • Dengar bunyi luar biasa daripada komponen sistem pemanasan

  • Perhatikan paip untuk kemerosotan atau kerosakan penebat

Penilaian Tangki Visual

  • Periksa keadaan tangki luaran untuk karat, kakisan atau kerosakan

  • Sahkan sokongan tangki dan asas kekal kukuh

  • Periksa sama ada tangga akses dan susur tangan adalah selamat

  • Perhatikan penunjuk aras tangki untuk operasi yang betul

  • Sahkan sistem penggera tahap tinggi berfungsi jika dilengkapi

Penyelenggaraan Sistem Bitumen Bulanan

Pemeriksaan Sistem Minyak Terma (Untuk Tangki Dipanaskan Minyak)
Prosedur untuk Perkhidmatan Dandang Minyak Terma:

  1. Benarkan sistem menyejuk ke suhu ambien (minimum 4-8 jam)

  2. Sapukan lockout/tagout pada sistem pemanasan

  3. Cari kaca penglihatan aras minyak pada dandang

  4. Semak bahawa paras minyak berada dalam julat yang betul (biasanya kaca penglihatan tengah)

  5. Jika rendah, tambah cecair terma tertentu (jangan sekali-kali mencampurkan jenis minyak)

  6. Sahkan warna minyak—jika sangat gelap atau berubah warna, rancang penukaran minyak

  7. Periksa semua sambungan saluran minyak untuk kebocoran atau rembesan

  8. Periksa penebat di sekeliling paip minyak untuk kerosakan atau kemerosotan

  9. Gantikan penebat yang rosak untuk mengekalkan kecekapan

Pemeriksaan Pam dan Injap

  • Sahkan pengedap pam bitumen tidak bocor asfalt

  • Periksa bacaan tolok tekanan pelepasan pam (jika dilengkapi)

  • Dengar bunyi pam luar biasa yang menunjukkan masalah peronggaan atau galas

  • Sahkan semua injap pengasingan beroperasi dengan lancar

  • Periksa sama ada injap pelega tekanan berfungsi (rujuk juruteknik jika tidak pasti)

  • Periksa penapis talian untuk sekatan

  • Gantikan elemen penapis jika penurunan tekanan berlebihan

Perkhidmatan Elemen Pemanas atau Pembakar (Untuk Sistem Kebakaran Terus)

  • Periksa kepala penunu untuk kebersihan dan penembakan yang betul

  • Periksa bahawa nyalaan pembakar berwarna biru dan stabil semasa operasi

  • Sahkan bekalan bahan api dan campuran udara pembakaran dengan betul

  • Bersihkan muncung penunu jika pengumpulan karbon diperhatikan

  • Periksa pemasangan penunu untuk keselamatan dan kedudukan yang betul

Pemeriksaan Dalaman Tangki (Prosedur Tahunan)

  1. Rancang pemeriksaan tangki tahunan semasa penutupan loji

  2. Toskan tangki sepenuhnya menggunakan injap nyahcas

  3. Benarkan bahagian dalam tangki sejuk kepada suhu persekitaran

  4. Buka lubang dan perhatikan keadaan dalaman

  5. Keluarkan lebihan sedimen dan serpihan dari bahagian bawah tangki

  6. Periksa permukaan dalaman untuk kakisan atau degradasi

  7. Periksa gegelung/tiub pemanas untuk mengesan pembentukan skala atau kakisan

  8. Gunakan berus dawai untuk menghilangkan kakisan ringan atau skala

  9. Siram bahagian dalam jika berlaku pengumpulan sedimen

  10. Bersihkan dan periksa muncung masuk/keluar

  11. Isi semula tangki dengan bitumen segar dan sahkan operasi sistem pemanasan


AGREGAT SUKAN SEJUK DAN SISTEM TIMBANG


Pemeteran dan penimbangan agregat yang tepat memastikan reka bentuk campuran yang konsisten dan menghalang pengasingan.

Penyelenggaraan Makanan Sejuk Harian

Pengesahan Pembukaan Pintu

  • Sahkan secara visual bahawa semua pintu penyuap agregat berada pada bukaan yang betul

  • Bandingkan kedudukan gerbang semasa dengan pelekat carta penentukuran

  • Perhatikan sebarang hanyut dari kedudukan yang ditentukan

  • Periksa bahawa pagar bergerak dengan lancar tanpa melekat atau mengikat

  • Dengar bunyi luar biasa daripada penggerak pintu

Penilaian dan Pemantauan Aliran

  • Perhatikan bahan yang mengalir dari setiap tong suapan sejuk ke dalam lif

  • Sahkan semua bahan yang mengalir pada kadar yang konsisten (tiada lonjakan atau hentian)

  • Semak bahawa bahan bergabung secara seragam tanpa pengasingan

  • Pantau penyumbatan bahan di kawasan pembuangan tong

  • Periksa penunjuk aras tong untuk ketepatan

Pemantauan Tahap Bin

  • Sahkan semua tong mempunyai bahan yang mencukupi pada penanda suku mata

  • Semak bahawa penggera tahap rendah diaktifkan sebelum tong sampah kosong sepenuhnya

  • Pastikan pengisian semula tong berlaku sebelum penutupan suapan bahan

  • Pantau untuk penyambungan bahan atau kerak dalam pelepasan tong

  • Semak sama ada penderia aras berfungsi dengan betul

Penyelenggaraan Makanan Sejuk Bulanan

Prosedur Penentukuran Gerbang Pengumpan
Penentukuran memerlukan mewujudkan kadar aliran bahan asas:

  1. Hentikan semua pengeluaran dan biarkan peralatan diselesaikan

  2. Pastikan tong sampah diisi secukupnya dengan bahan yang akan ditentukur

  3. Buka pintu pagar bahan ke kedudukan yang ditentukan setiap carta penentukuran

  4. Benarkan bahan mengalir ke dalam tong pengumpul atau penimbang untuk tempoh masa (biasanya 1-5 minit)

  5. Timbang bahan yang dikumpul atau ukur isipadu

  6. Kira kadar aliran sebenar dalam paun atau tan seminit

  7. Jika aliran sebenar tidak sepadan dengan sasaran dalam toleransi yang boleh diterima (biasanya ±5%), laraskan kedudukan get

  8. Uji semula dan laraskan sehingga kadar aliran sepadan dengan carta penentukuran

  9. Pelarasan pintu selamat dan sahkan tetapan kekal stabil

  10. Dokumen tetapan penentukuran akhir dan tarikh dalam log penyelenggaraan

Penentukuran Skala dan Pengesahan Ketepatan
Penimbang mesti mengekalkan ketepatan ±0.5% untuk reka bentuk campuran yang betul:

  1. Matikan loji dan gunakan lockout/tagout pada sistem skala

  2. Menggunakan pemberat ujian yang diperakui atau pautan rantai, letakkan berat yang diketahui pada platform skala

  3. Baca paparan skala dan bandingkan dengan berat sebenar

  4. Jika ralat melebihi ±0.5%, hubungi juruteknik skala bertauliah

  5. Sahkan semua sel beban berfungsi dengan ujian berat pada setiap kedudukan

  6. Periksa serpihan atau pengumpulan bahan pada mekanisme skala

  7. Lubricate titik pangsi skala dan komponen slaid mengikut jadual pengeluar

  8. Sahkan paparan digital skala dibaca dengan tepat dan kemas kini dengan betul

  9. Uji penghantaran data untuk mengawal sistem jika data skala digunakan untuk pengesahan resipi

Pengujian dan Penentukuran Penderia Tahap

  • Sahkan semua penderia aras tong berfungsi dengan memerhati paparan penunjuk

  • Uji penggera aras tinggi dan aras rendah dengan menaikkan/menurunkan aras bahan

  • Bersihkan kanta penderia daripada habuk atau kelembapan terkumpul

  • Sahkan kurungan pelekap sensor selamat

  • Periksa sambungan elektrik untuk kakisan atau kelonggaran

  • Jika bacaan tidak tepat, hubungi pengeluar penderia untuk penentukuran semula

Pemeriksaan Tali Pinggang dan Lif (Lihat bahagian Penghantar untuk prosedur terperinci)


SISTEM KAWALAN DAN KOMPONEN ELEKTRIK


Loji asfalt moden bergantung pada sistem kawalan berkomputer untuk mengurus resipi kumpulan yang tepat dan penjujukan peralatan.

Pemantauan Sistem Kawalan Harian

Status Sistem dan Penggera

  • Sahkan semua lampu status pada panel kawalan menunjukkan operasi normal

  • Semak bahawa tiada lampu penggera atau mesej ralat dipaparkan

  • Semak paparan sistem kawalan untuk sebarang penunjuk amaran

  • Perhatikan sebarang mesej yang memerlukan perhatian dan dokumen dalam log

  • Sahkan bahawa semua input sensor (suhu, tekanan, aliran) berada dalam julat normal

Pengesahan Skrin dan Paparan

  • Sahkan skrin paparan kawalan loji boleh dibaca tanpa gangguan

  • Sahkan semua data yang berkaitan (suhu, aliran, kiraan kelompok) dipaparkan dengan tepat

  • Periksa bahawa kawalan penggantian manual bertindak balas dengan sewajarnya apabila diuji

  • Pastikan butang berhenti kecemasan boleh dilihat dengan jelas dan boleh diakses

  • Sahkan navigasi melalui menu kawalan berfungsi dengan lancar

Sistem Merekod Data

  • Sahkan kilang sedang merekodkan data kelompok dan log pengeluaran

  • Sahkan ketepatan cap masa semua data yang direkodkan

  • Semak bahawa sistem sandaran berfungsi untuk data kritikal

  • Perhatikan sebarang jurang data atau ralat rakaman

  • Pastikan pangkalan data tidak menghampiri had kapasiti storan

Penyelenggaraan Sistem Kawalan Mingguan

Pemeriksaan Panel Elektrik

  1. Matikan loji menggunakan prosedur penutupan yang betul

  2. Gunakan lockout/tagout pada sistem elektrik

  3. Buka kabinet/panel kawalan elektrik

  4. Periksa secara visual semua komponen dalaman untuk pengumpulan habuk

  5. Periksa bahawa semua sambungan terminal adalah ketat tanpa kakisan

  6. Cari wayar yang longgar atau penebat yang rosak

  7. Sahkan semua pemutus litar dan fius selamat

  8. Periksa sesentuh penyentuh sama ada berlubang atau terbakar (rujuk juruelektrik jika teruk)

  9. Periksa operasi kipas penyejuk dan bersihkan penapis pengambilan

  10. Tutup panel dengan selamat

Pemeriksaan Penderia dan Pendawaian

  • Sahkan semua kabel penderia disalurkan dengan betul tanpa kekusutan atau kerosakan

  • Periksa sama ada penyambung terpasang sepenuhnya dan bebas daripada kakisan

  • Ketatkan sebarang bolt atau pengikat sambungan yang longgar

  • Cari penebat wayar yang dipotong atau melecet yang memerlukan penggantian

  • Sahkan sambungan pembumian adalah bersih dan ketat

Semakan PLC dan Sistem Komputer

  • Perhatikan masa operasi sistem dan sebarang tetapan semula atau but semula yang tidak dijangka

  • Periksa suhu sistem dalaman dan operasi sistem penyejukan

  • Sahkan semua lampu penunjuk modul input/output berfungsi dengan betul

  • Semak sebarang log ralat untuk isu berulang

  • Sandarkan data sistem jika tidak disandarkan secara automatik

Penyelenggaraan Sistem Kawalan Bulanan

Kemas Kini Perisian dan Prosedur Sandaran

  • Hubungi pengeluar sistem kawalan untuk sebarang kemas kini perisian yang tersedia

  • Semak nota keluaran kemas kini untuk penambahbaikan atau pembetulan pepijat

  • Jadualkan kemas kini semasa tempoh masa henti untuk mengelakkan gangguan pengeluaran

  • Sandarkan konfigurasi sistem semasa sebelum memasang kemas kini

  • Selepas kemas kini pemasangan, sahkan semua fungsi beroperasi dengan betul

  • Mengekalkan sandaran data sistem kritikal yang berasingan daripada storan utama

Diagnostik Sel Beban dan Sistem Penimbang

  • Sahkan bacaan skala sepadan dengan berat yang digunakan untuk semakan kelinearan

  • Uji tindak balas skala dengan menambah berat secara berperingkat

  • Semak bahawa rujukan sifar skala adalah betul sebelum pengeluaran dijalankan

  • Sahkan penghantaran data skala untuk mengawal sistem

  • Jika ralat skala dikesan, hubungi juruteknik skala bertauliah

Pengesahan Penderia Suhu dan Tekanan

  • Bandingkan bacaan instrumen dengan meter mudah alih sekunder jika ada

  • Semak masa tindak balas sensor dengan memantau perubahan semasa pengeluaran

  • Sahkan isyarat keluaran penderia dalam julat voltan yang dijangkakan (biasanya 4-20mA)

  • Bersihkan blok penentukuran sensor atau titik rujukan

  • Hubungi pengeluar penderia jika bacaan secara konsisten di luar spesifikasi


Bahagian 3: Penyelenggaraan Penutupan Bermusim dan Lanjutan


Prosedur Permulaan Pramusim (Musim Bunga)

Sebelum menyambung semula pengeluaran selepas penutupan musim sejuk:
Pemeriksaan Sistem Komprehensif

  • Periksa semua komponen struktur utama untuk kerosakan atau kemerosotan

  • Periksa semua sambungan bolt dan pengikat di seluruh loji

  • Sahkan penutup pelindung atau pengedap kekal utuh

  • Uji semua interlock keselamatan dan sistem kecemasan

  • Jalankan melalui urutan permulaan sistem kawalan lengkap

Pemeriksaan Peralatan

  • Kitar semua motor, pam dan penggerak melalui rangkaian penuh gerakan

  • Periksa paras bendalir dalam semua kotak gear, motor dan sistem hidraulik

  • Sahkan semua tali pinggang dan rantai mempunyai ketegangan yang betul

  • Uji semua sistem penggera dan amaran

  • Lakukan kitaran tumbuhan penuh pada kelajuan yang dikurangkan sebelum pengeluaran penuh

Penyediaan Sistem Bahan Api dan Bahan

  • Siram garisan bitumen dan sahkan aliran lancar

  • Gantikan mana-mana penapis bahan api yang disimpan semasa musim sejuk

  • Sahkan tong agregat sejuk kering dan tidak mengandungi lembapan

  • Uji semua laluan aliran bahan untuk mengesahkan tiada sekatan

Prosedur Penutupan Musim Gugur/Musim Sejuk (Di Luar Musim)

Semasa menyediakan loji untuk penutupan lanjutan:
Pembersihan Dalam dan Penyingkiran Sisa

  • Bersihkan semua komponen bahagian panas dengan teliti termasuk pengadun, pengering dan paip

  • Keluarkan asfalt dan timbunan agregat untuk mengelakkan pengerasan

  • Bersihkan saluran bitumen dan sistem pam untuk mengelakkan salutan

  • Toskan semua bahan sisa dari pusat akses dan bah

  • Sistem pengumpulan habuk bersih termasuk baghouse dan kerja saluran

Prosedur Saliran

  • Toskan semua air dari sistem udara menggunakan blowdown udara termampat

  • Pemisah air longkang dalam unit udara termampat

  • Tutup semua injap saliran selepas saliran lengkap

  • Toskan saluran minyak bahan api jika bahan api diesel digunakan (bahan api gel sejuk musim sejuk)

  • JANGAN mengalirkan minyak terma daripada sistem pemanasan (rujuk pengilang mengenai kaedah pemeliharaan)

  • Toskan air dari penghantar dan kawasan penangkapan air yang lain

Perlindungan Peralatan

  • Sapukan minyak anti karat pada semua permukaan keluli terdedah dan pengikat

  • Tutup motor dan komponen elektrik dengan penutup pelindung

  • Tutup bukaan untuk mengelakkan kelembapan dan pencerobohan perosak

  • Tanggalkan bahagian kecil (bolt, pengikat, instrumen) yang terdedah kepada kehilangan

  • Dokumen penyingkiran item untuk pemasangan semula musim bunga

  • Letakkan paket bahan pengering di kawasan tertutup untuk mengurangkan kelembapan

  • Tutup bahagian atas tong sampah untuk mengelakkan kemasukan hujan

Penutupan dan Pengasingan Sistem

  • Tutup semua injap bekalan bahan api

  • Tutup sistem udara termampat dan simpan dengan betul

  • Tutup semua injap pengasingan bahan

  • Gunakan label kunci keluar/tagout pada semua sumber tenaga

  • Dokumen prosedur dan status penutupan dalam log penyelenggaraan

Pemeriksaan Lanjutan Semasa Masa Henti

  • Lakukan pengukuran ketebalan terperinci pada cangkerang dram pengering dan penerbangan

  • Ukur kehausan cincin trunnion menggunakan alat ultrasonik atau angkup

  • Periksa asas konkrit untuk retak atau mendap

  • Periksa keluli struktur untuk perkembangan karat atau kerosakan

  • Periksa semua kimpalan untuk retak tegasan yang berlaku semasa musim

  • Dokumen semua penemuan untuk perancangan penyelenggaraan musim depan


Bahagian 4: Topik Penyelenggaraan Lanjutan


Pembangunan Program Pelinciran

Pelinciran yang betul memanjangkan hayat peralatan dan mengurangkan kos operasi dengan ketara.
Prinsip Pelinciran

  • Pelinciran mengurangkan geseran antara bahagian yang bergerak, meminimumkan haus

  • Jenis dan kelikatan pelincir yang betul mesti sepadan dengan reka bentuk galas dan suhu operasi

  • Pelinciran berlebihan menyebabkan haba yang berlebihan dan menarik pencemaran

  • Kurang pelinciran mempercepatkan kehausan dan kegagalan galas

  • Persekitaran suhu tinggi memerlukan gris dengan takat lebur yang lebih tinggi

Membangunkan Jadual Pelinciran Anda

  1. Rujuk dokumentasi pengilang untuk semua peralatan

  2. Buat senarai semua titik pelinciran termasuk lokasi, jenis pelincir dan kuantiti

  3. Tetapkan selang pelinciran berdasarkan waktu operasi peralatan

  4. Berikan tanggungjawab kakitangan khusus untuk tugas pelinciran

  5. Buat senarai semak yang menunjukkan lokasi, jenis pelincir dan tarikh perkhidmatan terakhir

  6. Latih kakitangan tentang teknik pelinciran yang betul (sapukan pada bearing, bukan kawasan sekeliling)

Titik Pelinciran Biasa pada Loji Asfalt

  • Galas penggelek tali pinggang penghantar (biasanya 1-2 auns gris setiap galas setiap bulan)

  • Galas motor pemacu pengering dan pengedap aci

  • Kotak gear pemacu mixer (tukar minyak setiap tahun, semak setiap bulan)

  • Galas penguja/vibrator skrin bergetar

  • Sistem penghantar suapan sejuk di seluruh

  • Semua pemacu rantai di seluruh loji

  • Galas kipas penyejuk kabinet sistem kawalan

  • Pengedap pam pada sistem bitumen dan asfalt

Memilih Pelincir yang Sesuai

  • Gunakan pelincir yang ditentukan oleh pengilang peralatan (ikut tepat cadangan OEM)

  • Aplikasi suhu tinggi (berhampiran pengering): gris NLGI Gred 2 atau 3 berkadar kepada 200°C+

  • Galas suhu biasa: gris litium pelbagai guna NLGI Gred 2

  • Pelinciran rantai: minyak rantai automatik atau pelincir rantai menembusi

  • Galas motor: pelincir berasaskan minyak dengan bahan tambahan untuk perlindungan haus

  • Jangan sekali-kali mencampurkan jenis pelincir pada aplikasi yang sama

Penyelenggaraan Ramalan Menggunakan Pemantauan Keadaan

Program penyelenggaraan moden semakin menggunakan pemantauan keadaan peralatan untuk meramalkan kegagalan sebelum ia berlaku.
Analisis getaran

  • Getaran yang berlebihan menunjukkan kehausan galas, salah jajaran atau ketidakseimbangan

  • Gunakan meter getaran pegang tangan untuk mengukur tahap getaran relatif

  • Bandingkan ukuran dari semasa ke semasa untuk mengenal pasti aliran getaran yang semakin meningkat

  • Wujudkan ukuran garis dasar apabila peralatan baru atau baru diservis

  • Memberi amaran kepada juruteknik apabila getaran meningkat melebihi julat normal

  • Jadual penggantian sebelum kegagalan galas bencana

Termografi (Pengukuran Inframerah)

  • Kamera inframerah mengukur suhu permukaan mendedahkan masalah dalaman

  • Galas terlalu panas menunjukkan pelinciran yang tidak mencukupi atau kegagalan yang akan berlaku

  • Titik panas pada sambungan elektrik menunjukkan sambungan longgar atau rintangan tinggi

  • Pemprofilan suhu dram pengering menunjukkan haus atau pembentukan penerbangan dalaman

  • Pengimejan terma membantu mengenal pasti kerosakan penebat atau penutup yang hilang

Analisis minyak

  • Pensampelan minyak berkala dari kotak gear mendedahkan kandungan logam yang menunjukkan kehausan

  • Zarah besi yang meningkat menunjukkan kehausan galas atau gear

  • Kandungan air menunjukkan kebocoran meterai atau masalah pemeluwapan

  • Perubahan keasidan atau kelikatan menunjukkan kemerosotan minyak

  • Analisis biasa menetapkan parameter biasa untuk perbandingan

Pemeriksaan Auditori

  • Juruteknik yang berpengalaman boleh mengenal pasti masalah dengan mendengar peralatan

  • Bunyi pengisaran menunjukkan masalah galas atau haus dalaman

  • Mencicit menunjukkan pelinciran yang tidak mencukupi atau salah jajaran

  • Berdentum menunjukkan komponen atau pengikat yang longgar

  • Corak bunyi yang luar biasa harus mendorong penyiasatan dan dokumentasi

Pengurusan Inventori Alat Ganti

Mengekalkan inventori alat ganti yang sesuai meminimumkan masa henti sementara mengelakkan kos inventori yang berlebihan.
Alat Ganti Kritikal untuk Stok

  • Kit sambatan tali pinggang penghantar dan tali pinggang gantian (kira panjang yang diperlukan)

  • Bilah pengadun dan pelapik (20-30% daripada set gantian)

  • Beg penapis baghouse (minimum set ganti lengkap)

  • Muncung penunu dan elektrod pencucuhan (2-3 setiap jenis)

  • Tali pinggang pemacu untuk semua motor dan kipas

  • Kit galas dan pengedap untuk motor dan pengadun

  • Berus motor untuk motor elektrik dengan berus

  • Fius elektrik dan komponen pemutus litar

  • Penderia suhu dan tekanan

Amalan Terbaik Penyimpanan Alat Ganti

  • Simpan alat ganti dalam persekitaran yang kering dan terkawal suhu

  • Susun inventori mengikut komponen tumbuhan (pengering, pengadun, penghantar, dll.)

  • Mengekalkan senarai inventori terperinci dengan nombor bahagian dan kuantiti

  • Putar stok menggunakan prinsip FIFO (First In First Out).

  • Periksa bahagian yang disimpan secara berkala untuk kemerosotan

  • Simpan maklumat pembelian dan butiran hubungan pembekal yang dikemas kini

  • Tetapkan tahap stok minimum yang mencetuskan pesanan semula

  • Mengekalkan dokumentasi waranti dan maklumat jangka hayat


Bahagian 5: Menyelesaikan Masalah Biasa


Kualiti Campuran Lemah dan Pengasingan

Simptom: Campuran asfalt tidak konsisten, sesetengah kawasan lebih keras/lembut, pemisahan agregat boleh dilihat
Penyiasatan dan Penyelesaian:

  • Kalibrasi penyuap agregat menggunakan prosedur yang ditetapkan (terperinci di atas)

  • Sahkan semua bacaan skala dalam ketepatan ±0.5%.

  • Periksa pengadun untuk bilah haus yang menjejaskan keseragaman adunan

  • Periksa konsistensi suhu alur keluar pengering sepanjang panjang dram

  • Sahkan bitumen digunakan secara sama rata pada campuran

  • Periksa operasi pintu pelepasan pengadun—pastikan pelepasan lengkap

  • Sahkan pengurusan tong penyimpanan yang betul tanpa masa yang berlebihan

Penggunaan Bahan Api Berlebihan

Simptom: Kos bahan api meningkat berbanding volum pengeluaran
Penyiasatan dan Penyelesaian:

  • Sahkan nisbah udara-bahan api penunu ditentukur dengan betul (memerlukan profesional)

  • Periksa penerbangan dram pengering untuk kehausan mengurangkan kecekapan pemindahan haba

  • Periksa penebat kulit dram untuk kerosakan atau kemerosotan

  • Sahkan penapis baghouse tidak tersumbat secara berlebihan sekatan yang semakin meningkat

  • Periksa ketegangan tali pinggang penghantar (ketegangan berlebihan meningkatkan beban motor)

  • Periksa kebocoran bahan atau tumpahan yang memerlukan peningkatan tekanan sistem

  • Sahkan pam bitumen tidak berongga atau memerlukan tekanan yang berlebihan

  • Sahkan kecekapan terma tidak terdegradasi oleh pembentukan skala

Getaran dan Bunyi Peralatan

Simptom: Getaran luar biasa, pengisaran, pencicitan, atau bunyi gemeretak
Penyiasatan dan Penyelesaian:

  • Periksa semua pengikat di seluruh tumbuhan untuk kelonggaran—ketatkan secara sistematik

  • Periksa mainan bearing menggunakan ujian pesongan tangan—gantikan jika berlebihan

  • Sahkan penjajaran gandingan motor/gear menggunakan tepi lurus

  • Periksa penjejakan tali pinggang penghantar dan pusat semula jika tidak sejajar

  • Periksa pengadun jika ada halangan dalaman atau bilah patah

  • Periksa haus trunnion dram pengering menggunakan alat ukuran

  • Sahkan ketegangan beg baghouse dan tempat duduk yang betul

  • Gunakan meter getaran untuk mewujudkan garis dasar dan menjejaki perubahan

Isu Api Pembakar

Gejala: Nyalaan tidak menyala, nyalaan tidak stabil, kuning/oren dan bukannya biru
Penyiasatan dan Penyelesaian:

  • Sahkan bekalan bahan api mencukupi dan mencapai penunu

  • Periksa penapis bahan api sama ada tersumbat—gantikan jika tersumbat

  • Periksa tekanan bahan api terhadap spesifikasi

  • Sahkan elektrod pencucuhan bersih dan dicelah dengan betul

  • Periksa tetingkap sel CAD (pengesan api) untuk mencari jelaga

  • Sahkan bekalan udara pembakaran mencukupi tanpa tersumbat

  • Periksa muncung bahan api untuk pengumpulan karbon (memerlukan pembersihan/penggantian profesional)

  • Sahkan kedudukan pelekap penunu tidak beralih yang menjejaskan campuran udara/bahan api

Isu Perbezaan Tekanan Baghouse

Gejala: Tekanan perbezaan terlalu tinggi (>6 inci air) atau terlalu rendah (<2 inci)
Penyiasatan dan Penyelesaian:
Tekanan Berbeza Tinggi:

  • Periksa beg penapis untuk tersumbat atau kerak habuk

  • Sahkan sistem pembersihan nadi beroperasi pada frekuensi yang betul

  • Gantikan elemen penapis pemampat udara jika tekanan bekalan rendah

  • Periksa solenoid injap nadi beroperasi dengan betul

  • Periksa saluran salur masuk baghouse jika ada tersumbat

  • Periksa beg untuk melihat tempat duduk yang buruk yang membenarkan pintasan

  • Sahkan suhu masuk tidak berlebihan (di atas spesifikasi)

Tekanan Berbeza Rendah:

  • Cari koyak atau lubang dalam beg penapis menggunakan pemeriksaan visual

  • Semak awan habuk keluar dari timbunan yang menunjukkan kebocoran

  • Sahkan pengedap gasket utuh pada semua pintu akses rumah bag

  • Periksa sangkar beg untuk kerosakan yang membenarkan pintasan

  • Periksa operasi injap angkat jika dilengkapi

  • Periksa plat pengedaran untuk tersumbat


Bahagian 6: Dokumentasi Penyelenggaraan dan Penyimpanan Rekod


Sistem Log Penyelenggaraan

Rekod penyelenggaraan yang komprehensif membolehkan analisis trend dan penjejakan kos.
Maklumat untuk Dokumen:

  • Tarikh dan masa tugas penyelenggaraan

  • Komponen atau sistem diservis

  • Juruteknik atau operator yang menjalankan penyelenggaraan

  • Kerja yang dilakukan dan penemuan

  • Bahagian diganti (nombor bahagian dan kuantiti)

  • Tempoh masa henti (jika berkenaan)

  • Kos bahagian dan buruh

  • Tarikh penyelenggaraan berjadual seterusnya

  • Sebarang cadangan untuk perhatian masa hadapan

Penyimpanan Rekod Penyelenggaraan

  • Mengekalkan kedua-dua sandaran digital dan fizikal rekod kritikal

  • Simpan rekod boleh diakses oleh semua kakitangan penyelenggaraan

  • Kemas kini rekod serta-merta selepas kerja siap

  • Semak rekod secara berkala untuk mengenal pasti isu yang berulang

  • Menganalisis data trend untuk mengoptimumkan selang penyelenggaraan

Membangunkan Sejarah Peralatan

Jejaki sejarah peralatan komprehensif yang mengenal pasti masalah berulang:
Faedah Analisis Sejarah:

  • Mengenal pasti komponen bermasalah kronik yang memerlukan penggantian

  • Mendedahkan selang penyelenggaraan yang memerlukan pelarasan

  • Menunjukkan corak yang menunjukkan isu punca utama

  • Mewajarkan keputusan naik taraf atau penggantian peralatan

  • Menyokong tuntutan waranti dengan dokumentasi terperinci

  • Membantu juruteknik baharu mempelajari sejarah peralatan


Kesimpulan


Penyelenggaraan sistematik komponen loji asfalt mewakili salah satu pelaburan pulangan tertinggi dalam pengurusan peralatan. Tumbuhan yang diselenggara dengan baik mencapai:

  • Kualiti Produk Unggul: Reka bentuk campuran yang konsisten, tiada pengasingan, kawalan suhu yang betul

  • Kos Operasi yang Dikurangkan: Kecekapan bahan api yang optimum, pembaikan kecemasan yang minimum, hayat komponen yang dilanjutkan

  • Keselamatan yang Dipertingkatkan: Peralatan berfungsi dengan betul dengan bahaya yang telah dihapuskan

  • Pematuhan Kawal Selia: Piawaian alam sekitar dipenuhi melalui pengumpulan habuk dan kawalan penunu yang berkesan

  • Peningkatan Keuntungan: Kadar pengeluaran yang lebih tinggi, kepuasan pelanggan yang lebih baik, keupayaan penetapan harga premium

Melaksanakan prosedur penyelenggaraan terperinci yang digariskan dalam manual ini memastikan loji asfalt anda memberikan prestasi yang boleh dipercayai dan hasil yang konsisten sepanjang hayat operasinya. Perhatian tetap kepada setiap komponen kritikal menghalang kegagalan yang mahal sambil memaksimumkan kecekapan dan keuntungan.
Mulakan hari ini dengan tugas pembersihan dan pemeriksaan harian, maju ke penilaian komponen mingguan, dan jadualkan penyelenggaraan bermusim yang komprehensif semasa tempoh masa henti. Komitmen anda terhadap kecemerlangan penyelenggaraan loji secara langsung diterjemahkan kepada kejayaan perniagaan dan kebolehpercayaan operasi.

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Jangan tunggu sehingga kerosakan: Amaran awal untuk bahagian tumbuhan asfalt

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Panduan Lengkap untuk Peningkatan Bahan Bahagian Tanaman Asfalt: Bagaimana Komponen Komponen Komponen Komponen Komponen Tinggi dan Komponen Seramik Tinggi
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