Asphalt Production and Liquids Essentials
Starting last month, AsphaltPro now brings a new way to examine the equipment, products and services available in the marketplace to asphalt professionals. Of course we will still focus on the items relevant to an asphalt business, but we have a new approach to make the focus more useful to you, the reader and end user.
Notice this month that all equipment and services listed in the Product Gallery relate to the “production” side of the industry. Starting with an article on controls from Gencor of Orlando, Fla., the information contained herein pertains to the bitumen, aggregate, mix design and production portion of our industry. When you see the Asphalt Production and Liquids Essentials headline for our Product Gallery throughout 2015, you’ll know you have the latest and greatest for the production side of the asphalt game.
We’ll bring you paving and pavement maintenance essentials next month.
Gencor Controls Diagnose Themselves
By Keith Harper
Far from the days when asphalt just had to be hot and black, today’s asphalt production facilities make mix in fast paced, high-tech environments. Juggling multiple mix designs, ordering product and loading trucks, the plant operators have demanding jobs. Orders coming in on the phone, truckers calling on the radio, and production requirements changing all day long occupy the operator’s attention. When a problem occurs on the plant, the operator doesn’t have time to think through the possible causes. Until the day when controls can self-heal the plant, the operator needs a control that will guide him to the problem and give him instructions to resolve it.
One such product is the Gencor Vector® Burner Control. The original goals of the Vector Burner Control were to eliminate the mechanical linkage that created the fuel-to-air ratio for combustion and to achieve a cleaner burn with higher efficiency.
These goals were met with great success. However, the engineering team turned next to self-diagnostics.
Most operators want the control to tell what is wrong and how to fix it fast. Back in the old days, earlier concepts incorporated user manuals or electrical schematics that popped up at the touch of a button. In the midst of panic, with the plant down and trucks lining up for material, the last thing an operator wanted to do was sit down and read a manual or search through drawings.
Nowadays most of the safety sensors and limit switches are monitored directly by the independent Flame Safety controller responsible for safely shutting off the burner. The idea of designing a control that monitors all of these devices in parallel was the turning point for Gencor. Changing the hardware design to monitor all of these signals was fairly easy; now came the hard part. As the Flame Safety shuts down the burner, we needed a control that would immediately detect the cause of the shutdown and display it on the screen and also tell the operator what to do about the problem.
At Gencor, we refer to this as “in your face” help screens. In the event of a burner safety shutdown, the operator can see exactly what to do. He doesn’t even have to press any buttons to get the answer. When a shutdown occurs, the Gencor Vector Burner Control pops open a full screen message that details the steps to get the burner operational again. Only the conditions and components that could cause the given fault are listed. The components are listed from most likely to least and presented in a simple step by step procedure. The operator can print out the instructions as a guide to walk through each component that needs to be checked on the burner.
Gencor’s latest version of the Vector includes enhanced instructions with diagrams, pictures and video. The old adage about a picture is still true today, especially at hot mix plants. We have found that a photograph of the location of a sensor helps tremendously to speed up the troubleshooting process. If you don’t know where the sensor is, you can’t test it and you don’t have valuable time to waste looking for it.
Once the “troubleshooter” locates the component, instructions go into more detail showing close-ups and diagrams as needed. With this level of detail and precision, the need to call for outside assistance is almost zero. However, if the solution cannot be found using the “troubleshooter,” a second layer of technical assistance can be implemented.
The Vector Burner Control has the ability to be monitored remotely by trained Gencor staff. Both the operator screen and the PLC processor can be accessed remotely. The Gencor technician can see the plant Vector control screen on his own computer, and spot problems not apparent to the operator. He can watch and assist the operator in getting the system quickly operational again.
Additional control features include monitoring voltages at each analog input and the status of all digital inputs so a multimeter is no longer needed. If calibrations need to be performed or settings adjusted, the Gencor technician can readily see the existing settings and make recommendations for adjustment. This is also a time when additional training can occur.
Expensive field visits to train the operator are no longer necessary when remote monitoring is provided. With the operator on the phone and the Gencor technician logged in, they can go through all of the setup and operation procedures, and answer any questions the operator may have.
When the plant experiences a loss of signal from the primary fan pressure switch, the control will give the plant operator a help screen that shows him or her exactly where the switch is located at the plant.
D&H Blends Rubber
D&H Equipment, LTD, Blanco, Texas, is raising production capacity with its newest portable blending plant system. The plant has been designed for producing 50 tons per hour of asphalt rubber binder. It will be working hard next paving season producing binder for American Pavement Systems doing chip seal work in California. D&H has enhanced the controls to include new and improved reporting capabilities, allowing data to be more easily analyzed and shared either internally or with regulating agencies. Automated valving on the blender and reaction tank is designed to manage all aspects of the plant from precise metering of ingredients to the reaction time and temperature. The plant is also designed to meet California’s strict air quality guidelines by utilizing low NOx burners (less than 9 ppm) and redesigned finned condensers. A second hopper has been included with the system. The blender piping was designed for easy inclusion of a high shear mill. A 30,000-gallon, two-compartment reaction tank will accompany the rubber blending unit. A new Premier Automation Package replaces the manual valves and allows the PLC to automatically record an unprecedented amount of reaction tank data. Both compartments are heated by hot oil serpentine coils and include D&H’s unique top-mounted agitation system, which creates a high degree of agitation throughout the entire compartment while eliminating leaking caused by auger seals. A complete interlock variable speed pump system and high-performance Coriolis flowmeter records and meters the finished product as it leaves the reaction tank.
Masaba Side Dumps
Masaba, Inc., Vermillion, S.D., offers the Masaba Side Dump Truck Unloader, the newest addition to its full line of truck unloaders. This innovative solution eliminates dumping material on the ground and re-handling. This unit features an 8-foot by 40-foot hopper with a 30 cubic yard capacity. Under the 3/8-inch steel hopper is a 36-inch by 52-foot conveyor driven by heavy duty drives. Masaba’s Side Dump Unloader can be completely customized to meet specific operational needs. The unit may be stationary or skid-mounted and is easily placed to feed other equipment.
Telesmith Tracks Screening
Check out the 820 Track Screening Plant from Telsmith, Inc., Mequon, Wis. The plant includes an 8203 Telsmith TL Screen, 1372 mm feed conveyor, and 1829 mm under screen conveyor, all combined to process up to 907 MTPH. The 820 Track Screening Plant produces up to four products simultaneously and can be operated through a wireless remote control.
For more information, contact Chad McClaskey at (262) 242-6600.
Dana Expands Loader Solutions
Dana Holding Corp., Maumee, Ohio, offers a 23-ton drivetrain system for front-end loaders with the Spicer® TE18 powershift transmission side by side with the latest hydromechanical variable transmission (HVT) from Dana Rexroth Transmission Systems. The Spicer TE18 powershift transmission is engineered to supply front-end loaders with high input power capability and smooth, quiet operation. Rated from 200 to 260 hp, the TE18 is a four-speed transmission platform that uses internal components from Dana’s field-proven line of powershift transmissions already available for the off-highway market.
For more information, visit www.dana.com.
AEM Helps Get Components Up Safely
A new live-action crane safety video and extensively revised crane safety manual from the Association of Equipment Manufacturers (AEM) are now available to provide machine operators a well-rounded look at current industry best practices, including U.S. OSHA 1926:1400 crane standard requirements. Most plant personnel don’t use a crane daily, so this combo offers a useful training resource for portable facilities and those sites that perform maintenance and/or replacement of high components. The newly released AEM video and manual reflect changes in the crane industry and OSHA crane standards over the last decade since AEM produced its original crane safety manual and animated video. The live-action format of the DVD-video, and the manual, offer a convenient learning/reference program for the industry today. AEM developed the crane safety video and manual together; crane industry experts working through AEM’s Crane Technical Committee (CTC) provided content development and review. Certified trainers from the International Union of Operating Engineers (IUOE) demonstrated best practices in the DVD-video. The combo outlines tips on how to avoid accidents and create a safe construction site; how to prepare the machine for operation and reduce repair costs; and how to prepare the construction site for safe crane operation.
For more information, contact Bobby Hoffmann at (414) 298-4105 or firstname.lastname@example.org.
ADM Mixes in Goodies
Asphalt Drum Mixers, Inc., of Huntertown, Ind., uses counterflow technology in its Milemaker™ Series asphalt plants. The Milemaker now has the capability to introduce water or other chemicals into liquid asphalt entering the plant, thereby lowering the temperature to warm-mix specs, according to the manufacturer. Milemaker plants, which are available in portable or stationary versions, are designed to meet all federal and state specs while consistently producing quality asphalt. A wide range of components further customizes each plant for particular customer needs. Available individual components include cold feed bins, hot oil asphalt cement tanks (both horizontal and vertical), direct-fired horizontal tanks, portable and stationary baghouses, mineral filler systems, recycled asphalt pavement systems, self-erect and stationary silos, weigh and drag conveyors, weigh batchers and fuel oil tanks.
For more information, call (260) 637-5729 or visit www.admasphaltplants.com.
Process Heating Company Heats Tanks
Process Heating Company’s Lo-Density® Unitized Storage Tank Heaters are designed to be installed into any above-ground tank or vat, and then dissipate controlled heat as low as three watts per square inch on the heater’s sheath or prevent coking or damaging of temperature-sensitive material. Unitized Heaters feature the company’s unique drywell-style elements that reside inside the sheath, making the accessible from outside of the tank and eliminating the need to drain the tank to service the elements. UL-listed controls offer easy-to-use complete automation of temperature regulation. The main indicating temperature control regulates the product temperature and includes a high-limit control for safety. There is a main disconnect, and the individually fused heat circuits provide overcurrent protection. All components are mounted and prewired in a NEMA Type 4 enclosure. Custom control panels are also available.
For more information, call (866) 682-1582 or visit www.processheating.com.
Fairbanks Weighs In Technology
Fairbanks Scales, Inc., Kansas City, Mo., offers the Trident Truck Scale with Intalogix® technology. The fully electronic, heavy capacity Trident scale is built to produce a long-lasting scale. It’s built to federal bridge standards and can be shipped from the factory and installed in one day. The Trident’s open-bottom design creates a natural ventilation system, while the solid deck design resists deflection and metal fatigue. Armored stainless steel load cell cabling is provided for durability and load cells are hermetically sealed to protect them from moisture. The Trident also features encapsulated circuit boards. All Trident scales come with Fairbanks’ proprietary Intalogix technology. This digital technology achieves high levels of accuracy, reliability and surge protection, according to the manufacturer.
For more information, call (800) 451-4107 or visit www.fairbanks.com.
Astec Increases RAP Capacity
With the Voyager 120 and the RAP KING, Astec Industries of Chattanooga brings higher RAP percentages to your mix production. The Astec Voyager 120 is built around a counter flow drum featuring Astec V-flights, which are designed to provide greater uniformity of the aggregate veil during the drying process. The Voyager 120 offers a compact, highly portable design with the ability to run up to 30 percent RAP. Other features include a reverse pulse baghouse, a controls cab with fully automated PLC controls, gravity take-up with direct drive, air ride suspension and up to five cold feed bins and two RAP bins. If you need to run higher percentages of RAP, Astec Industries also offers the RAP KING™, which is designed to produce mixes with 100 percent RAP.
For more information, contact (423) 867-4210 or visit www.astecinc.com.
Tarmac Dries Rap
The counter flow dryers from Tarmac, Inc., Lee’s Summit, Mo., offer long combustion flights for optimum flame development and three RAP entry location options for higher RAP percentages in mixes. Dryers feature moving slinger belt to adjust gas temperature to the baghouse and come with trunnion or chain drive. The company supplies complete new plants, new components and replacement parts, as well as consulting and used equipment.
For more information, contact (816) 220-0700 or visit www.tarmacinc.com.
SKF Seals the Deal
SKF of Gothenburg, Sweden, has consolidated the range of hydraulic seals it offers. The seals are offered for both OEMs and the aftermarket, and in metric and imperial units. SKF has added the “S1S” polyurethane U-cup for heavy duty rod sealing systems and three new styles of polyurethane piston seals. SKF developed a new grade of SKF ECOPUR® polyurethane material in conjunction with the new product designs. The material was improved for seal function in heavy duty applications with high system pressure and temperature. The complete SKF hydraulic seals range includes thousands of standard articles from more than 40 different designs of rod seals, piston seals, wipers, static seals and guide rings, plus a broad range of design and material choices for tailor-made solutions.
Atlas Copco Drills, Pumps
Among the many offerings from Atlas Copco, the Secoroc AB branch based in Sweden released the COP 66 drill designed with reduced air consumption and a 30 percent shorter and lighter hammer than its predecessor. It’s designed for the newer generation of drill rigs—the Atlas Copco SmartROC and FlexiROC, which have air packages up to 435 psi. Stateside, Atlas Copco has more recently announced that Wilder Motor & Equipment of Nashville will offer the full line of WEDA electric submersible pumps. “Adding the Atlas Copco equipment allows us to offer a more complete lineup of pumps that can handle a greater variety of applications,” Jack Wilder said.
For more information, visit www.AtlasCopco.com.
Heatec’s colloid mill skid is designed to produce 60 tons per hour of emulsified asphalt. Included on the skid are an asphalt meter system, a latex pump, a control panel and the Barracuda™ colloid mill. The Barracuda mill is the feature component on the skid. It makes adjustments while it’s running.
For more information, contact Tom Wilkey at (423) 821-5200.
Hauck Burners Use Multiple Fuels
Hauck has announced the MegaStar multi-fuel burner. It employs variable frequency drive (VFD) technology for precise air flow control for energy and combustion efficiency. The burner package is compact and easy to install, yet is simple to service, according to the manufacturer. Linkages have been eliminated to make the burner easy to maintain and adjust. Available in sizes ranging from 50 to 150 million BTU/hour. The standard design can be applied to applications up to 1,500 degrees F. Custom lengths are also available for warm-mix applications.
For more information, contact Rick Carpenter at (717) 389-0416.
Bindicator Senses Material
The MP Series from Bindicator®, Spartanburg, S.C., is a microwave, pulse radar that is used to determine the level of bulk solids in solids or tanks. Used in some of the tallest silos, the MP70 model has a measuring distance of up to 230 feet. Transmitting at a frequency of 26GHz with a narrow beam angle of eight degrees, the MP Series radar is consistent and accurate in dusty environments, according to the manufacturer. The MP Series Radar is a non-contact device that uses “time of flight” to determine level in a vessel. The time it takes for an emitted microwave pulse to travel from the device to the material surface and back again is measured. This time is calculated into distance, which is then translated into a level measurement.
For more information, contact Tami Stribling at (864) 574-8060.