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0% found this document useful (0 votes)
469 views55 pagesOperational Maint. Manual-Apollo-Hotmix Plant-DM50
ApolIo hot mix plant
Uploaded by
ohrisanjay30Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
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GUJARAT APOLLO.
EQUIPMENTS LIMITED
OPERATING INSTRUCTIONS
MANUAL
gh"
DRUM MIX PLANT
(DM 50)
OFFICE: “PARISHRAM’ 5-B, RASHMI SOCIETY,
MITHAKHALI CIRCLE,RAILWAY CROSSING ROAD ,
NAVRANGPURA - AHMEDABAD — 380 009
‘@: 079-6444597/6444598
FAX : 91-079-6564705
WORKS: DITASAN, STATE HIGHWAY.
POST ~ JAGUDAN , DIST- MEHSANA 382 710
‘: 02762 — 85344-345-346
FAXNO: 02762-51609/85359
Gug- 28) FOREWARD
This operating instructions & manual, a guide to
successful operation and servicing, is required
to be carefully read and followed by the
operator and supervisor a like in ensuring
efficient and trouble-free operation of the unit
The manual is required to be caretully
preserved for all the time, so that, whenever it
become necessary to carryout overhaul
operations, the recommeded procedures can be
easily followed, correct and genuine spares
ordered. Apart from the above the manual can
be always referred for operational pre-requisites
and routine maintenance in addition to all the
more important recommended maintenance
schedule, which must be strictly followed. The
latter is the most important part for the customer
and this cannot be overlooked for any reasons,
In conclusion, it may be mentioned that an
efficient spares and service organization is at
the disposal of the customer, in the event any
additional information or guidance is required for
the operation of the unit. GUJARAT APOLLO EQUIPMENTS LIMITED
GUARANTEE
We guarantee to replace or make good for
period of six months irom the date of despatch,
free of charge any defect arrising in goods
supplied or our own manufactured due solely to
faulty design or defective materials _or
workmanship, provitied always that immediated
notice be given and any such alled defective
works or material be immediately returned
carriage paid to our work by the purchaser. Any
guarantee expressed or implied hereunder shall
be limited to a period of six months to date form
the date of despatch by us and we undertake
no fiability in respect to any consequential
damage. No other guarantee is given by us and
this general guarantee is deemed to take the
place of any guarantee or other liability in either
expressed or implied. RECEIVING MACHINE
Your APOLLO Mixer was thoroughly tested,
carefully inspected, and properly loaded at the
factory. The entire shipment including loose
parts was thoroughly checked before it was
released to the transportation company.
Upon receipt of the machine, before unloading,
carefully inspect for any loss or damage that
may have occured during transportation. It
would be well to check it against your freight
bill, or against the packing list which will be
found in the too! box.
if any loss or damage is discovered, you will
save time by immediately notifying the
transportation company’s agent who will give
you the proper forms for making a claim.
Your dealer service department will instruct you
personnel in the correct operation and care of
this new machine, at no additional cost to you.
Should the machine not have started operation
at the time of delivery, your dealer will consider
ita favour if you will contact him when ready to
operate so he can supervise the initial
operation.
A tew days advance notice, if possible, will help
him greatly in his planning. SAFETY FIRST
Most accidents are caused by someone's failure
to follow simpie and fundamental safety rules or
precautions.
Regardless of the care used in the design and
construction of the machinery, there are many
points that cannot be completely safeguarded
without interfering with accessibility and efficient
operation.
A careful operator is the best insurance against
an accident
“THE COMPLETE OBSERVANCE OF ONE
SIMPLE RULES WOULD PREVENT MANY
THOUSANDS OF SERIOUS ACCIDENTS
EACH YEAR.
THAT RULE IS :
Never attempt to clean Oil, or adjust any
Machine while it is in Motion. THE SECRET TO
LONGER BELT LIFE THE SECRET TO LONGER BELT LIFE
SYMPTOMS CAUSES CURES
Belt Edges Rubbing due to :
Edges worn or frayed.
a. Defective joint a. Rectify Joint.
A b. Misaligned b. Check conveyor
Q running. alignment and
ees, ‘ re-align belt.
te eee
loading chute
to feed load
centrally.
Off centre loading.
d. Defective self- d. Rectify or
aligning idler. replace
faulty idler.
at
SN Sa e. Inadequate edge e. Minimum
clearance. recommended
ce clearnace
between
belt edge and
structure is
75mm.
f£. Belt too stiff for Install a
A belt which does not adequate troughing laterally
rough adequately will more flexible
cause misaligned running, belt.
resulting in severe belt
edge wear and material
spillage.
Repair or paint
edges
18 Across the Belt width +
tT, Top Cover
Exnéssive uniform a, Cover under-specified a. Specify
wear. or incorrect quality. thicker
covers of
correct grade
depending on
See loading cycle
BY =e and material
& carried.
VS b. Worn or seized return b. Install
i idlers. cleaning
devices or
rubber disc
idlers. Check
periodically
if all idlers
Return run of belt rotate
rubbing against spilled freely.
material. Replace
seized idlers
with new
ones.
¢. Spilled material under c. Increase
tail pulley setting up clearance
abrasion. between tail
pulley and
floor, fit
decking to
avoid
spillage.
d. Return run of belt a. Prevent
rubbing against spilled spillage
material along the along the run
conveyor. of the
conveyor.
Check return
idler spacing
and belt
tension.
Ensure all
spilled
material to
be removed
immediately.
19 SYMPTOMS CAUSES CURES
Narrow Central Section.
Speed is too high Redesign drive at
thereby belt carries a reduced speed,
a "thin" load. check chutes and
skirt boards to
ensure that the
load is fed on to
the belt uniformly
across its
effective width.
At t he
commencement. skirt
boards may be
placed about two-
A. Excessive cover wear. thirds of the belt
width apart and B.
B. “Thin” load, speed may be high. they should widen
out in direction
of travel to
ensure uniform
load distribution
across the width.
2. Cuts or stripping a. Naterial jamming a. Adjust skirt board
Of cover, or groovey between belt and rubber to provide
or patchy wear beneath skirt. minimum clearnace,
the skirt board. and install
cushion idlers to
hold belt against
skirt.
tne b. Skirt board rubber b. Use only plain
too hard and stiff | rubber strips of
or use of old belting correct
pieces. hardness.
c. Skirt board c. Skirt board should
incorrectly set. flare up slightly
(say 1 in 42) in
direction of
running of belt to
prevent wedging of
material between
belt and skirt.
Phe metal or
wooden skirt board
Entrapment of material should under no
between tip of chute circumstances come
and belt. in contact with
the belt.
20 d. Jamming of material d.Redesign and widen
in chute. chute. In case the
jamming is at the
loading chute,
reduce rate of
loading or
increase belt.
speed.
Worn or seized e.Replace all
return idler roll. unserviceable
idlers with new
idlers.
» Handling of wet
Install proper
sharp material cleaning
through tripper facilities
pulleys in the before belt
absence of proper wraps the
belt cleaning second tripper
facilities . pulley.
3. Cover gouging Impact of Heavy Lumps +
a. Face rubber cover a. Redesign cover
of inadequate and grade based
thickness. on loading cycle
and size of
material
carried.
Incorporate
breaker, if
necessary.
b. No cushion idlers b. Use impact idlers
at impact section at loading point
7 on height of fall and install
too great. "Grizzly Screen”
to ensure that
fines are
deposited first ®
the belt and Ht larger
lumps then A, Height of fall too great.
fall on belt,
Reduce the height B.
No rubber impact idlers. of fall of
i material to a
minimum.
al SYMPTOMS CAUSES " CURES
c. Roll back of mate- c. Reduce speed,
-rial on inclines. ensure loading on
horizontal, avoid
if possible,
loading large
lumps without
small material
accompanying
them.
Tl. Back Cover
Severe cover wear and
peeling off cover. a. Slippage of drive a. Adjust tension,
pulley, sand thrown lag the drive
between belt and pulley, increase
drive pulley. are of contact.
b, Carrying idlers b. Lubricate idlers
seized. regularly,
2 svat replace seized
~! idlers.
c. Excessive forward c. Adjust to not
tilt of carrying more than 2°
idler. from vertical.
Material spillage on to
return of belt.
d. Material spillage d. Install decking
on to return run plates or use
of belt which is endless belt.
ground between belt Use scrapers at
belt and pulley. tail end
section, Proper
rubber strips
; and not old
belting pieces
should be used
with scrapers
or
ploughs.
e. Bolt head in the case e. Tighten bolts,
of lagged drums pro- Replace worn
~truding. lagging. SYMPTOMS CAUSES CURES
N. General Cover Problems +
T. Surface cracks Exposure to sunlight protect belt.
or ozone for long suitably, part-
periods. icularly in
storage and
when idle on
the conveyor
for long
periods.
2, Cover softening and Oil contamination. avoid oil or
. bulging. grease
contamination.
. Cover hardening and = Material carried too Quench material
cracking prematurely. hot. carried or use
better heat
resistant grade
belting.
4. Bulging of cover at ‘Fine material working Immediate
places and the same into cuts or punctures repair of cuts
extending along belt in the rubber cover. and punctures
length. to prevent
ingress of fine
dust, etc.
. Belt Carcass
1, Breaks in the carcas a.Impact of large heavy a.Use cushion
ye material. idlers, Keep
a height of fall
to a minimum
and load in
line with the
belt at a speed
equal to belt
speed.
Entrapment of material at c.Material build up on ¢-Use belt,
at take-up pulley. pulley. cleaning device
and install
scraper on
pulley.
2. Transverse breaks a. Belt edges folding a. Use limit
at edge. up due to misalign~ switches to
ed running. stop excessive
running out and
He investigate
reasons for
running out.
23 6.
Lengthwise carcass
break with covers
intact.
Fastener pull out or
transverse carcass
breaks.
transverse breaks
immediately behind
fasteners.
Longitudinal rip
partially or through
CAUSES
b. Incorrect positioning
of idler next to head
pulley-too close or
too high.
Belt running off-
centre and folding
over.
b. Longitudinal exten-
sion of impact
damages.
a. Too much tension.
b. Incorrect size of
fastener or impro-
per joining.
c. Direct-on-Line
starting.
Fastener plates too
long for pulley
diameter.
a. Belt running off
and snagging on
entire belt thickness. structure.
b. @ramp iron jamming
in structure and
ripping belt apart.
cuRES
b. Relocate or
readjust idler
or pulley
position.
a. Use limit
switches and
determine
reasons for
running out.
b. Reduce impact
as explained
earlier.
a. Reduce tension.
b. Use correct
fasteners.
c. Use graduated
starting.
Change to shorter
fasteners or
increase diameter
of pulley.
Ensure true
running of
belt.
b. Redesign chute
to prevent
jamming.
24 SYMPTOMS,
7
Ply separation
CAUSES
Fasteners working
loose jamming in
structure and ripping
pelt apart.
Belt. lifting off at d.
vertical concave curve,
particularly at
starting, and becoming
damaged by intervening
skirt boards, chutes,
etc.
Mildew or dust pene- a
tration into carcass.
pulley diameters too b.
small.
Oil contamination. Cc.
Too many reverse a
bends.
Edge wear due to e.
rubbing and penetration
of moisture and grit.
CURES
Use correct
fastener and
periodically
examine joint &
rectification.
Use heavier belt
and if problem
remains, calculate
and rectify
structure for safe
vertical curve
radius.
Prevent cuts etc.
Arrange for
immediate repairs.
Increase pulley
diameter or
install synthetic
duck belting.
Remove source of
contamination.
Use more flexible
belt.
correct misalign-
ment or remove
obstruction.
25 vi. General Operating Problems +
i, Belt wanders Too stiff, does not Use belt with more
at random. conform to contour transverse flexi-
idlers. bility.
Belt runs off- | Wind pressures and Use Covers and
centre at effect of sun on wind deflectors
certain times. | conveyor frame. and self-aligning
idlers.
Belt stretches Excessive starting Increase speed
excessively. and operating tensions. keeping tonnage
same or reduce
tonnage keeping the speed same,
there by tensions will be reuced
Lag drive pulley or increase arc
of contact. Use minimum counter—
weight in take-up. Replace with
lower elongation or higher
strength belt.
26 a)
(2)
(4)
INDEX
DESCRIPTION
General Desciption
Erection
Belt Conveyor
{@) Installation & Operation
(b) Maintenance
(¢) Preventive Instructions
(d) Belt Training
(e) Secret to Longer Belt Life
(f) Idlers, Pulleys & Bearing
Belt Scale System
Fluid Coupling (If apply)
Worm Reduction Gears
Burner
Rotary Twin-Lobe Compressors (Roots-
Biowers)
Spare Part List DM-50 is a highly poratble, continous mix
plants. The system consists of a_ total
proportional controlled feed system which feeds
onto a slinger type charging conveyor. The
asphalt proportion enters the drum mixer
simultaneously with aggregate.
Aggregate is fed to the slinger conveyor by the
Feeder. The slinger conveyor feeds the
aggregate into the charging chute of the Drum
Mixer where it is sprayed with asphalt from the
asphalt system.
Mixer Drum
The parallel tlow drum mixer is a large rotating
cylinder that is supported by two steel tires
bolted to the outside of the drum, The drum is
driven from the main gear box by the drum
chain to a large sprocket bolted to the outside of
the drum,
As the aggregate discharges from the slinger
conveyor into the drum mixer charging chute the
asphalt is introduced. The asphlat cools very
fast and balls up with the fine aggregates and
dyst.
/ The first section of flights are ‘spirals that
prevent material from moving backwards to the
end of the drum. This prevent spillage. The
‘second set of flights are angles that gently roll
the material with a minimum amount of
exposure to the direct flame. The final set of
flights are cupped shaped. These are carrying
flights that lift the material from the bottom to
the top of the drum, discharging it in a veil
through the hot gasesft is at this point that the
softened asphalt will, foam and quickly spread
over the seareey/ GENERAL DESCRIPTION
Introduction
For a modern industrialised country, road and
highways network is a most now-a-days
because a natural earth track can neither
support modern wheel loads nor provide an
adequate riding surface. It has now become a
standard practice to use bitumen bound material
in the construction of heavy duty streets, roads
and airports ete.
Hot Mix Plant
To prepare hot asphalt mix for the base and
surface courses, both aggregate and the
bitumen are heated and then alongwith filler
material they are mixed thoroughly in the hot
mix-plant. It's functions are
(1) Rough proportioning of the aggregate
(2) Heating & Drying the aggregate.
(3) Heating the bitumen.
(4) Mixing the proportioned aggregates,
bitumen to produce a homogenous mix.
Hot Mix Plant mainly consists of
(1) Dryer unit complete with Blower
Exhauster, Burner.
(2) Load out conveyor with Discharge
Hopper/Silo & Elevator.
(3) Slinger Conveyor with Leadcell
(4) 3-Bin Feeder/4-Bin Feeder (PN-30)
(6) AC, DC Control Panel-Wiring diagram
operating Instructions manual.
(7) Bitumen tank with Automatic Burner. Optional Consists of:-
a)
(2)
(3)
(4)
6)
Wet Dust Collector.
Vibrating Screen.
Mineral Filler
Hot Oil Tank.
Fuel Tank.
Combustion Chamber
It consists of a refractory fire brick lined ste!
cylinder mounted at the charging end of the
mixer. The function of the cone is to obtain
complete combustion of the fuel. After a few
minutes operation, the combustion chamber
In the case of oil, the
atomized spray of fuel from the burner, passing
through the chamber, comes in contact with the
intense heat which converts the atomized spray
to a gas. Once in a gaseous form, the fuel
becomes very hot
burns instantly. ERECTION
The important factors to be considered for the
Selection of Plant Site are :
(1)
(2)
(3)
(4)
Size of the Plant Site
Stability of the ground
The Plant site should be such that an
adequate drainage can be provided.
Location of truck loading drive way.
After selecting the suitable site for plant erection
the following procedure should be adopted io
erect the Plant
(1)
(2)
(3)
Level off the area of ground over which
plant is to be erected.
Tow the different units of plant into exact
position since itis very difficult to change
their position once they are jacked up.
After towing the different units into
position set the two jack legs near the
towing side such that the units stand on
those two jack legs and tyres, the chassis
slightly inclined towards the towing side
Place a hydraulic or mechanical jack of
suitable capacity at the other end of the
units. Place the jack on a piece of heavy
timer to prevent the base of jack being
forced into the ground. Perform jacking
operation til the tail end of the units are
raised through a height of about 10cm.
Hold the units in this position by lowering
the jack legs near the tail end. Now
perform the jacking operation near towing
end till the chassis becomes horizontal
Repeat this operation till the different
units are lifted to their working heights. In
case of the units which are to be lowered
i.e. the working heights of the unit is less
than its towing height. Proceed as follows :-
Jack up the unit slightly as explained above so
as (0 relieve the tyres of the weight of the unit
Remove the tyres along with wheel rim to store
them indoor safely. Place a hydraulic or
mechanical jack of suitable capacity at one end
of the unit and perform jacking operation to
raise that end by Scm so that jack legs nearer
to the jack are relieved of load. Raise these jack
legs and lower this end of the unit gradually by
about 10m by operating jack. Hold the unit in
this position by lowering the jack legs. Perform
the jacking operation at the other end till the
chassis becomes horizontal. Repeat this
operation till the units are lowered to their
working height
To establish an absolutely rigid contact
between units and the ground, Preventing them
from swaying while in operation, the different
units should be supported in a raised position
by building a timber cribbing from the ground
upto the chassis of the units.
With the aid of the foundation drawings of
different units, the foundation work should be
down very precisely for each unit.
To ensure that the chassis of each units be
horizontal perfactly both cross wise and
lengthwise, check them by means of a accurate
spirit level MAINTENANCE AND ADJUSTMENTS
MAINTENANCE AND ADJUSTMEN
‘Trunnion Rollers
The function of the trunnion rollers is to support
the revolving mixer drum and when properly
adjusted, to neutralize the downhill thrust of the
drum. The natural tendency of the drum, while
rotating is to work downhill.
By skewing the trunnion assemblies a
Counteracting thrust is developed as a result of
friction between the trunnion rollers and the
drum tires.
NOTE In order to maintain this friction, the
drum tires and trunnion roller surfaces must
never be greased or oiled.
When the trunnions are properly adjusted, the
drum tire should contact either thrust roller only,
slightly causing them to turn intermittently
If the thrust roller bearings should overheat,
excessive thrust against that roller is indicated
and the trunnion should be adjusted
immediately to relieve this condition.
In order to simplify the adjustment of each
trunnion, a brass instruction plate (Figure G-1)
is attached to each trunnion support frame. This
plate shows which way to skew the trunnion to
shift the drum, either up-hill or down-hili, and
has a scale to show the distance that the
trunnion assembly has been skewed. The scale
has a Zero Point which denotes no skew. On
either side of the Zero Point the scale is
calibrated in eighth and sixteenths of a inch “2
The eighths are numbered 1,2,3 and 4. The
Sixteenths marks are not numbered, A Chisel
mark in the trunnion pivot frame, directly above
the instruction plate, serves as an indicator to
show the amount of skew.
Adjustment of the trunnion should be made with
the mixer fully loaded and in operation.
1, Assume that the drum is riding downhill with
the forward drum tire riding hard against the
lower thrust roller.
2With the Mixer Operating, skew one front
(charging end) trunion, not to exceed 1/16 in.
and observe the results. If this is sufficient to
cause the drum to shift uphill to the proper
position, then this trunnion should be returned
4/2 the distance moved and the opposite
trunnion moved the same amount, giving the
same amount of skew to each trunnion.
CAUTION
