Plant Control & Quality Innovations in Equipment & - - PowerPoint PPT Presentation

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Plant Control & Quality Innovations in Equipment & - - PowerPoint PPT Presentation

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Plant Control & Quality Innovations in Equipment & Technology: NCAUPG Technical Conference 2012 Indianapolis, IN Payne & Dolan Inc. Vertically Integrated Construction Company Operations Aggregates-Asphalt Overview Quality

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Plant Control & Quality Innovations in Equipment & Technology:

NCAUPG Technical Conference 2012 Indianapolis, IN

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Payne & Dolan Inc.

Vertically Integrated Construction Company

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Operations Aggregates-Asphalt

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Overview

Quality Assurance Forces Driving Quality Innovations in Quality over the years Quality/Production Relationship Future Expectations

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QA/QC

QA testing: Activities designed to ensure that the development process is adequate to ensure you meet given

  • bjectives-(Proactive QC)

QC testing: Activities designed to evaluate a developed product-(after the fact) Contractor Terms QA=Risk Management

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Factors Driving Quality

Economics

Reduction in virgin asphalt Reduction in virgin aggregates

Using high RAP/RAS

mixes saves money Vital to our industry Competitive edge Risk

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Asphalt vs. Concrete

Competition is getting stiffer Maintain economic advantage while providing superior quality Ensure Quality

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Economic forces Driving Quality

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Wisconsin Specifications

Allowable Combination Maximums Recycled Asphaltic Percent Binder Replacement Material Lower Layer Upper Layer RAS only 25 20 RAP & FRAP 40 (30) 25 (20) RAS & RAP & FRAP 35 (30) 25 (20) DPE Ratio 1.2 VMA (19.0-9.5) 13-15

(2010 Specifications)

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Typical Gradations

Mix w/25% RAP and 5% RAS requires all Virgin Aggregates <1% P200

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Washing Aggregates

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Controlling Size

Wisconsin DOT 2011

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Controlling Size

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Controlling RAP:

Agglomeration and Oversize

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Controlling Size

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Controlling Moisture

Measure Consistent and Accurately Moisture Probe vs stockpile sample (lab)

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Plant Capacity

Remove the Moisture

Know your moisture content

Moisture changes Your mix volumetric change Quality Changes Pay factors change Production

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Plant Capacity

500 TPH Plant

Capacity to Remove H2O?

25 ton H2O - Total per Hour 5 ton H2O - Mixing / Rap Entry

RAP Moisture 5.0% RAS Moisture 10.0% Virgin Aggregate 3.5%

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Plant Capacity

Mixing/Drying Capacity 500TPH Plant

Percent Recycle TPH 50% RAP 200 30% RAP 335 25% RAP, 5% RAS 285 20% RAP, 5% RAS 335

  • Controlling factor 5TPH of H20 removal after RAP

entry

  • Savings doesn’t take into account Plant efficiency
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Existing Plant Capacity

Counter Flow Parallel Flow

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Capital Costs:

Bigger Drums

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Capital Costs:

Aggregate Storage

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Infered Camera

25% RAP 5% RAS 15% RAP 3% RAS

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Drying/Flighting

Dramatically increasing Virgin Aggregate Temperatures(super heating) can increase aggregate degradation in your

  • drum. Knowing

temperatures can let help you predict absorption or degradation.

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Plant Inovations

RAP Entry Evaluation?

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Field Checks

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Controlling Variability when Sampling

Sampling… .When, Where & How?

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Controlling Variability Measuring Dust

Control Dust Surges from baghouse to Drum

  • Record by Mix / Plant amount of dust created in

Drum

  • Maintain constant dust flow through baghouse
  • Control Dust Surges within your system
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Plant Control Systems

Control Systems

Record / Graphing Telemetry Systems Multiple Weigh Point System vs Single

Weigh Point System

Capability to separate RAP on Inclines

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Measuring Weight

Incline (Combined Weights) vs Individual Bin

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Controlling Variability using Control Systems

Control System Logging – Real Time

  • Each Keystroke logged
  • All material calibrations stored
  • Mix changes / TPH ongoing
  • Fuel / Power Usage
  • AC / Additive Flow

ASPHALT PLANT ROOT CAUSE ANALYSIS

EVENT DATE PERSON PERFORMING INVESTIGATION CREW'S MANAGER/SUPERVISO INVESTIGATION DATE INDIVIDUALS INVOLVED ESTIMATED TIME SPENT TO COMPLETE REPAIR: HRS PRODUCTION STOPPED AT WHAT TIME: PRODUCTION RESUMED AT WHAT TIME: INVESTIGATION INCLUDED SITE VISIT: Yes No REPAIR DESCRIPTION CATEGORY CONTROL HOUSE CONVEYOR BELTS LOADER/SKIDSTEEER SILOS BAGHOUSE PLANT COMPUTER DRAG AC TANK(S) SCALES/LOADOUT SY DRUM BURNER FUEL TANK(S) SCHEDULING BURNER PUMPS PLANT MANAGEMENT FEDDER BINS METERS/TACHOMETERS AGGREGATE MANAG RECYCLE BINS GENERATOR OTHER: ___________ DESCRIPTION OF SITUATION (A brief explanation of how the event or situation (Breakdown) occurre ROOT CAUSES (why did the event occur?) Check all that apply.

PERSONNEL FACTORS SYSTEM/EQUIPMENT F

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Success Stories

STH 47 Wisconsin –WARRANTY PROJECT E-3 12.5mm

20% RAP 5% RAS

Average IRI 34

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Success Stories

STH 47 Wisconsin

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Wisconsin Outstanding Paving Award Winner

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Future Expectations

Plant efficiencies continue to get better for high recycle materials Plant Automation Systems

Real time QA results continual

Develop real time gradation Testing

Close to being perfected

Lower risk for our customer and contractor

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Questions

Thank You!

JBartoszek@crmanagement.com