Fall 14.pdf
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Transcript of Fall 14.pdf
MANAGEMENT MESSAGE
Increased production, reduced costs, and better reliability are things we can all relate to in these challenging economic times for our industry. As Contractors, your everyday challenge has certainly been: how do you improve efficiencies and environmental compliance leading to a healthier bottom line?
This Special Show Edition of Gencor Innovations™ may provide the answers to your questions and give you a multitude of reasons to include Gencor in your plant operations. Whether a minor replacement, upgrade or a fully integrated new plant, this “Gencor Innovations At Work” edition is chock full of solutions that directly address your top-10 questions as asphalt producers.
Two customer success stories at opposite ends of the industry spectrum demonstrate the practical application of Gencor’s products and services in everyday situations across North America. Tilcon’s New Jersey Division implemented its master plan of consolidating three locations into one Gencor MegaPlant, while Asphalte Drummond sought greater efficiencies in a batch plant that could handle higher volumes of RAP to combat rising aggregate prices. The new plants provided both customers with solutions that addressed their primary needs, but also provided additional benefits including capacity for future growth.
You’ll also enjoy a story on a familiar pastime in our industry with a big game hunter, Gene Carrier of East Texas Asphalt, in our customer lifestyle segment.
You’ll find that Gencor’s full range of customer support capabilities and Gencor University training are worthwhile annual investments that pay dividends throughout the year. Technical how-to stories with simple tips about converting to natural gas and quickly solving a heater ignition problem make this edition of Innovations the reference tool you’ll want to keep handy as you begin the season.
I hope you enjoy this edition of Innovations and thank you for your loyalty to the many exceptional products and services of Gencor.
Marc Elliott President Gencor Inc.
Marc ElliottPresidentGencor Inc.
INNOvATIONS FOr YOu
Let Us Show You the Way
gencorinnovationS
at work
See How Innovations Make the Best Even Better!
Pages 20 - 37
Every attempt has been made to ensure specifications are accurate. Because specifications are subject to change without notice, check with us for the latest information. Gencor, its respective logos and corporate and product identity used herein and Innovations are trademarks of Gencor Industries Inc. and may not be used without permission. Phone 407.290.6000. ©2014 Gencor Industries Inc. All rights reserved. Printed in the u.S.A. Volume 6 Number 1. Innovations™ is published by High Velocity Communications Inc. Publisher, Warren Eulgen • Editor, Pete Kennedy • Creative Director, Jay Blazek • Director of Client Services, Kelly Pemper. High Velocity Communications Inc., 1720 Dolphin Drive, Suite D, Waukesha WI 53186. Phone 262.544.6600.
in thiS iSSUe
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4 Mega Decision Tilcon New Jersey Goes From Three Plants to One
10 Is the Timing right? Natural Gas Outlook Sparks Conversions
14 Turning Dreams into Reality ETA’s Gene Carrier Goes Safari Hunting
18 Making Customers Feel Exceptional Product Support Designed Around Your Needs
20 Why Talk with Gencor? Special Show Edition Highlights Innovations
38 Keeping Rising Costs in Check RAP, New Plant Reduce Asphalte Drummond Costs
43 uh-oh, Heater Not Lighting! System Understanding Key to Diagnosis
46 Training Investment Yields Huge returns Gencor university #1 for Hands-on Training
Spring 2014tM
ON THE COvErS Front - Tilcon New Jersey Division MegaPlantBack - Asphalte Drummond Batch Plant
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FALL
Tilcon New Jersey was at a crossroads three years ago. Volumes at the company’s three asphalt plants (one batch and two drum) had
been trending downward. The plants also were aging and in need of fairly extensive maintenance. In addition, the ages led to inefficiencies, particularly concerning energy consumption.
“There had been some conversations about the plants before, but in 2011 serious discussions started taking place,” said Scott Laudone, General Manager of Asphalt Operations and Quality Control, Tilcon New York Inc. – New Jersey Division.
The issues needed to be addressed. Yet the company’s leadership was hesitant to invest in plants with declining volumes.
“The discussions led us to consider combining the three plant operations into one location,” Laudone said.
Volumes could be more efficiently monitored and adjusted at a single location. There also was an expectation that volumes would improve with the development of a site that was easier for customers to access—and where their trucks were loaded more quickly.
“There were other efficiencies that just go with having one operation instead of three,” Laudone said.
Yet there were issues to work through. “We needed a very large plant,” Laudone said. “Our volumes were still high, and we expected them to remain so, and perhaps to grow.
“High volume was one need, but lower volume of specialized mixes was another. We were determined to continue to meet the needs of our smaller, specialized customers. We wanted a batch plant, too.”
crunching the numbersTilcon’s two drum plants each had 400 ton-per-hour capacity, while the third location was a 6-ton-per-hour batch plant. The company began taking a closer look at manufacturing options and future expectations.
“We estimated our volumes would be between 700,000-900,000 tons per year for the next few years,” Laudone said. “Our analysis showed a single plant should be able to provide that volume, while also delivering the efficiencies that would go with a single, centrally located operation. We determined there would be considerable energy savings as well.”
Three Plants to One
Continued on page 6
Part of the energy savings would result from new technology. In fact, that technology upgrade was another reason for making the switch. “We realized we would go from dated equipment to new, state-of-the-art systems,” Laudone said.
The decision was made to build a single plant. After reviewing several manufacturers, Tilcon selected Gencor and its “MegaPlant.” The production capabilities and technological advances were among the reasons, as was Gencor’s promise to provide a turnkey plant setup.
Building the plantThe plant construction was a team effort. Tilcon coordinated the site development, while Gencor handled plant construction and installation.
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MegaMegaMegaMegaMegaMegaDeciSion
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Tilcon used the site work as an opportunity to make the plant user-friendly. At the previous plants, customers sometimes had to drive 1.5 miles of gravel road to reach the loading site. The “MegaPlant” is near a main road. It also features three scales, with three silos near each for quick loading.
In fact, the entire flow of the new plant is designed to facilitate quick entry and exit for customers. In addition, drivers can load and process tickets without leaving their vehicles. “It’s a convenience and a safety effort,” Laudone said.
Lower-volume customers with more unique mix requirements also were kept in mind during the site planning. “Out of this one plant, we service the small driveway customer all the way to heavy highway construction crews,” Laudone said. “We’re able to produce many different types of mixes—and provide volume, too.”
The site’s nine silos play a crucial role in providing both volume and specialized mix. “It’s not the production capacity as much as the silo storage capacity,” Laudone said. “We have nine 300-ton silos. That keeps our customers supplied with the mix types they need.”
The “MegaPlant” is actually a high-volume version of the Gencor Ultraplant®. Crucial to that plant is the Ultralogiks® Plant Control System.
“The technology that really helps with efficiency is in that control system,” Laudone said. The system is easy to use, enabling operators to leverage its built-in benefits. Automated blending and load-out provide efficiencies as well.
the right Fit for others?Does Laudone advise others to switch to a “MegaPlant”? “It has to be looked at on an individual basis,” he said. “You have to consider your
A division of Tilcon New York
Provides construction materials and road construction services
Owned by Oldcastle® Materials Inc., a vertically integrated supplier of aggregates, asphalt, ready mixed concrete and paving services across the u.S.
Tilcon new Jersey
Continued on page 8
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The Gencor Ultraplant® In developing the “MegaPlant,” Tilcon utilized Gencor’s Ultraplant®—the most fuel-efficient, environmentally clean and lowest-maintenance design available to the hot mix industry. The ultraplant:
• Is an integrated drum concept that enables high-production, continuous mix with high-volume, high-moisture recycled material and the optional flexibility of feeding a batch tower, all in a unitized drum design.
• Has taken top honors year after year for being the only hot mix plant with a positive, volatile-capture-and-recovery system that eliminates blue smoke and asphalt odors from the process and feeds them to the combustion process as fuel.
• Has been accepted in the most stringent and environmentally sensitive areas of the country, producing high quality polymer and Superpave mixes.
• Combines simple design with the most advanced control technology and massive structural integrity—unmatched in the industry.
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market and decide if the capital expense is going to pay dividends in several years.”
If a consolidation is pursued, Laudone recommends finding a partner who can offer—and ultimately go beyond—turnkey services. “Gencor set up the plant, and it went very well,” Laudone said. “We had staff work with them, and the coordination of the plant and site development really came together.”
On-site operating training was provided during the setup and startup, with additional sessions available in the off-season. “That training helped our operators take full advantage of the technology available to them,” Laudone said.
Another key to the partnership was Gencor’s environmentally friendly equipment. “We care about emissions and recycling materials, and their equipment is very ‘green’ on both fronts,” Laudone said.
Up and runningThe “MegaPlant” has been in operation for about a year and is one of the largest, if not the largest, plants in the state. “It’s absolutely tremendous,” Laudone said. “It makes a high quality product and it’s very consistent. We’re very happy with the MegaPlant.”
Enhanced technology, gained efficiencies, improved customer service and excellent productivity—all at a single location. Three years after facing a tough decision, the crossroads are in the rearview mirror for Tilcon New Jersey.
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Gencor has been great about
meeting our needs. The products
and people deliver the benefits
as advertised. The 600 ton-per-
hour ratings capacity is asking
a lot, but the plant has proven it
can exceed that limit.
–Scott LaudoneGeneral Manager of Asphalt
Operations and Quality Control Tilcon New York Inc. New Jersey Division
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600-ton-per-hour insulated ultradrum®, which is warm mix and rAP compatible
Gencor ultralogiks® Plant Control System, an integrated automation package that manages and monitors all plant control functions
120,000 CFM baghouse with 400-hp variable-frequency drives
Ten 10'-by-16' cold feed bins, each with a capacity of 100 tons
Three 10'-by-15' RAP bins
Four 35,000-gallon vertical asphalt tanks
A 1,000-gallon calibration tank
Automatic sampling station for Quality Control
2,000-gallon anti-strip tank and automated metering pump
2 million BTu hot oil heaters
Nine 300-ton storage silos
The Mount Hope, n.J. Tilcon Plant
Gencor Ultralogiks® Plant control System • An integrated automation package that manages and
monitors all plant control functions with a Windows-based environment and graphical user interface.
• The hardware is an advanced PLC control platform that performs all plant operations, including blending and load-out functions.
• The graphical user interface is PC based, using a high-speed IBM compatible computer with a large-capacity hard drive.
• A backup computer and redundant hard drive assure complete security of the data and operating system in the event of a failure of the PC or the PLC.
• The main operating screens display a logical presentation of operating data through the use of segregated screen sections. The upper section displays items at the point of liquid asphalt injection, while the center section offers selectable views of Motors, Maintenance, or Event Log information as well as configuration settings and calibration screens.
• Detailed user screens for each equipment component are displayed by simply clicking on the equipment image.
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By John Price Service Manager General Combustion Corp.
iS THe TiMinG RiGHT?NATURAL GAS OUTLOOK SPARKS CONVERSIONS
The number of plant operators converting to natural gas and the number of inquires Gencor is receiving about the possibility
of converting have grown considerably throughout 2013 and early 2014. Setting aside the increased consumer and business demand prompted by the Polar Vortex-influenced winter of 2013-14, the long-term outlook for natural gas exploration, production, distribution and pricing remains very positive for all users—including asphalt producers.
While the topic of natural gas conversions was covered in the Spring 2009 issue of Gencor Innovations, the energy landscape has changed considerably for most producers since then. Perhaps you’re among those who have recently decided to take another look at your fuel options. If you are, you will likely find the following article to be of value in your evaluation and decision-making process.
Cut-away view of burner showing Natural Gas conversion installed.
Modulating Valve
ASK THE ExPERT
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A: The short answer to the question is no; it’s not difficult. However, there are steps you should follow that make the process easier and help ensure your expectations are met.
The biggest benefit to switching to natural gas is cost. Natural gas also extends baghouse life, and eliminates the need for fuel delivery schedules and fuel storage expenses. You should also consider some potential drawbacks. Depending on your situation, they might be substantial enough that you’ll want to continue utilizing your existing fuel source. Natural gas prices could rise rapidly and wipe out the savings. Even so, any rise in natural gas pricing is likely to parallel the trends for other fuels. Also, remember that gas is more sensitive and requires more safety equipment.
If you do decide to switch, make sure you avoid the most common mistake we see: undersizing gas supply pipes. In many cases, your gas supplier will not be familiar with the volume and pressure your plant requires. That lack of awareness too often leads the supplier to recommend small-diameter pipes that simply can’t do the job. If you’re not careful, you’ll end up with a grid of new piping—that can’t deliver an adequate fuel supply.
What’s the right decision for you? You’ll likely know when you ask the proper questions of your gas supplier, and have a thorough understanding of the factors involved in converting. You should also be aware that Gencor experience and insight are just a phone call away at 407.290.6000. In fact, many of our customers seek our input when weighing this decision. When you call, simply ask for our help desk. We’ll be glad to answer your specific questions. We’ll also encourage you to consider the following key factors:
1. GETTING STARTEDFact gathering should be your first step before engaging your natural gas supplier.
4 Know the BTU rating of your burner, and the corresponding consumption rate. For example, an Astraflame 100 is rated at 150 million BTUs per hour at maximum firing rate. That means it would consume 150,000 cubic feet per hour. Can your supplier handle this volume?
4 The burners have a 10:1 turndown. That means at low-fire, the burner will consume 10 percent of its rated capacity.
4 For the burner to operate efficiently—and the burner control to work in automatic—the gas supply pressure at the burner must be unquestionably consistent. (Or, as I tell customers, “rock solid.”)
4 The gas pressure at the burner manifold will be field adjusted to between 4-5 psi.
Normally, a Fisher model 1098 control regulator needs a minimum of 12 psi to function. We recommend a supply pressure of 20 psi to the Fisher regulator. (However, the Fisher regulator can be set up for pressures of 125 psi or more.)
2. MEETING WITH YOur GAS SuPPLIErWith the above specifics in hand, you’ll be ready to answer the questions your gas supplier asks—or should ask. Don’t hesitate to volunteer information and ask questions of your own. Agree on a plan of action. Making changes can be a costly process at later stages of the conversion. Questions you should ask include:
4 Is a gas pipeline extension needed? If so, who foots the bill? Some extensions are the responsibility of the gas company. In other cases, they might be willing to pay part of the bill—maybe even a substantial portion—if they are aware of your potential purchase volume.
4 Speaking of volume, can they deliver it? And can they do so at the pressure you require? As stated earlier, sometimes gas companies aren’t quick to comprehend the volume and pressure your plant will require. Be prepared to spell it out for them.
4 What equipment do they supply? The time to determine who pays for what is before the conversion begins. You’ll want to know who is responsible for costly equipment. Or maybe you can negotiate a cost-sharing arrangement as you explore using the gas company as a supplier.
4 Is the supply steady or will there be winter outages? If outages are a possibility, when will they most likely occur? Will you already be shut down? Ask for details—how frequently do shutdowns occur, how long do they typically last, under what circumstances?
4 Will the gas company swab or blow out the gas line after installation? This is an important task, as dirt, metal shavings and other impurities can quickly ruin a new gas regulator.
If you’re satisfied with the answers from the gas company, and have decided a natural gas conversion is in your best interests, following are a few tips to keep in mind:
4 All burners are manufactured with the gas ports in the burner head. If the burner was not purchased with the gas option, then the gas pipe and modulating valve need to be installed (FIGURE 1 on page 13). All of these parts can be ordered as a kit from Gencor’s Parts Department.
4 The burner conversion can be completed in one day. After the utility completes the stub-up supply line for the burner, the gas piping from the utility stub-up to the burner can be completed in two days.
QQ: is conversion a difficult process?this question is always at or near the top of the list when customers engage the gencor team in a discussion about the possibility of converting to natural gas.
ASK THE ExPERT
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4 The complete gas train can be purchased from Gencor’s Parts Department. The manual gas valve, gas trap, Fisher regulator and NFPA gas safety shut off valve complete the gas piping system—from the utility stub-up to the burner manifold (FIGURE 2).
4 Keep in mind that Canadian standards vary by province and may require block-and-vent, as well as manually operated firing valves in place of the standard manifold.
4 If you’re removing an LP or oil gun assembly, then 2-1/8" freeze plugs should be installed and tack-welded in the diffuser pipe. The gun assembly can remain in the burner and be retracted inside the diffuser pipe when gas is in use.
Final considerationsAs you can see, making the switch isn’t all that difficult when you ask the right questions—and consider all aspects of the conversion including the following:
4 The pilot for the burner must be piped in ahead of the last regulator (FIGURE 2). The pilot gas needs 12 psi for operation.
4 No modification is needed to convert the pilot from vaporized LP to natural gas.
Gas @ 1000/BTU/CF OIL/GPM 9.88 LP/GPM 14.581000CF/HR 80.10 OIL/GPH 593.00 LP/GPH 874.90THERM/TON 2.00 OIL/GPT 1.48 LP/GPT 2.19
a plant running 400 tph at 300° F mix temp with 3% moisture would consume fuel as shown below:
Natural gas Fuel Oil LP Liquid gas
4 Never undersize the gas supply pipe. If the schedule calls for a 6" line for your burner, maintain a 6" pipe from the Fisher regulator to the burner manifold—even though the regulator may be a 3" regulator bell sized to the 6" pipe. (See table at bottom of FIGURE 2.)
4 Install pressure taps with shut off-valves for gauges.
Safety FactorsGas-fired burners can be very safe to operate if normal safety interlocks and reasonable care are maintained. Safe operation of a natural-gas-fired burner operation only differs from other fuels as follows:
1. NFPA requires a low-pressure alarm shutdown.
2. You must have a high gas safety shutdown.
3. You must have proof of closure on the gas fuel valves.
Should you make the switch? Gencor customers are increasingly doing so—if for no other reason than to have options as fuel prices fluctuate so dramatically. But before converting, you’ll need to do your homework to make sure the switch pays off for your asphalt plant.
ASK THE ExPERT
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1/2” Minimum Size Pipe to Burner
Burner
GencorPrepiped
NFPA 86 Gas TrainGas Trap
**ManualValve Regulator
Pilot GasRegulator
60” Min
Site Installed Piping -Valve Train to BurnerSee table below forPipe Sizes
Site Installed Piping -Utility Supply
ModulatingValve1/2” Min
3/8”Min
PressureGauge
FIGurE 1
FIGurE 2
ASK THE ExPERT
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Pursuing many exotic animals in many exotic places
Adventure trips are supposed to create moments of introspection, and Gene Carrier certainly had one as he looked at the animal,
a few yards away, that could end his life with the swipe of a paw.
Carrier wasn’t just looking at the lioness. He also saw his son-in-law holding a camera, not a gun—and at 15 yards much closer to the action than had been planned.
And that’s when Carrier had his introspective moment and stopped fearing the lioness and started fearing something else. “I had this thought: ‘If my son-in-law gets hurt, my daughter is going to kill me,’” Carrier said.
The son-in-law, Jason Purke, didn’t get hurt—and Carrier did bag the lioness. But the adventure was a reminder that the line between hunter and hunted can become a bit blurred on a safari. No matter how many scouts or how big the gun, there is no such thing as a “safe” lion hunt.
Carrier, president of East Texas Asphalt, started hunting whitetail deer in Texas as a boy. His first big out-of-the-country experience was as an adult, when he went dove hunting in Argentina. He shot enough birds to (literally) feed a village. Yet he also found the time before and after the hunt just as captivating.
“I like to integrate into the community and see what’s going on,” he said.
He had talked about an African safari for years, but it remained a dream. Then in 2001 a friend turned the dream into reality. “He said, ‘We’re going to go this summer,’” Carrier said. And they did.
Carrier brought his son, Geno Carrier IV, along. A friend, Jim Huggins, also accompanied him. “Jim was going to stay for a week
and ended up staying three weeks,” Carrier said. Huggins also had a change of heart regarding hunting when he saw the action. “He was going to take pictures,” Carrier said. After a day tracking game he said, “I’m going hunting.”
Safari outfitters provide trackers, scouts, and highly trained and skilled professional hunters. All told about 60 staff took care of five hunters.
The trip was out of South Africa and focused on plains game: zebras, emus, wildebeest, kudos and elands. They donated the game to the locals, though Carrier does recall a succulent warthog appetizer being served at camp.
On that 2001 trip, another hunter was going after some dangerous game. It looked like fun and Carrier considered returning some day to hunt the dangerous animals.
“ “i had this thought: ‘if my son-in-
law gets hurt, my daughter is going
to kill me.’
TURninG DReAMS inTo ReALiTY
CuSTOMEr LIFESTYLE
–Gene Carrier
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He did so in July 2012, when both he and Geno (right) shot lionesses. And of course his son-in-law came along, too.
When it’s time to shoot, the guns are set on tripods because of their size and kick. Carrier was all set up when his targeted lioness moved. That meant moving the tripod away from the original spot, which was safer.
And that’s when he thought about his son-in-law, and his daughter’s patricide.
“It gets your heart going, there is no doubt about that,” he said.
That same trip included hunting the extremely unpredictable—and therefore dangerous—cape buffalo. “That was a beast,” Carrier said.
“
“
it gets your heart going, there
is no doubt about that.
–Gene Carrier
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cost: Gene Carrier estimates the cost for a one-week plains-game African safari to cost about the same as a trophy whitetail buck hunt of the same duration. That includes the crew, meals and accommodations, but does not include airfare.
crew: You need a good one. “You absolutely need professional hunters,” Carrier said. “It has to be someone reputable. Get references.”
if you go
(L-to-r) Gene Carrier, Jason Purke, Geno Carrier Iv and Jim Huggins relax around the campfire.
“My first shot went through its neck. It would have been a killshot for any other animal.”
The wounded animal was in a group with five or six others. At one point a rival, sensing the leader was injured, approached the animal, scooped it with its approximately 4-foot wide horns and tossed it over his head into the air—an amazing display of power considering the bulls weigh about 2,200 pounds.
It was another situation where circumstances dictated that the crew move away from its safest position, particularly since the other five bulls could have turned and charged.
It eventually took Carrier four shots to kill the animal. He was using high-powered ammo in the form of 400-grain bullets.
Carrier is not one to brag about his hunting skills, but he must be a good shot given the kudu hunt.
Carrier shot a kudu that came to rest in croc-infested waters. Most of the crew shook their heads “no” at the thought of going in, which would have been fine with Carrier. But a professional hunter told Carrier to cover him; he would go in and pull out the animal. Carrier was instructed to shoot if the crocs came too close.
All returned safely, with the exception of the kudu.
The majestic landscapes add to the experience. That’s been the case in Africa, Argentina and New Zealand, where Carrier recently hunted red stag and tahr, a long-haired sheep.
New Zealand was beautiful, but also difficult terrain to navigate. “I should have done that when I was 40,” Carrier said.
It seems like Carrier’s done just about everything. What’s next?
“Africa maybe,” he said. “There is amazing bird hunting over there. Some of the birds are two feet tall. I might try that.”
His daughter might be more approving of a bird hunt as well.
Gene Carrier estimates the cost for a one-week plains-game African safari to cost about the same as a trophy whitetail
f you gof you gof you go
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eTA Founded: 1958
Headquarters: Lufkin, Texas
Hotmix Plants: Lufkin, Center, Livingston and Paxton, Texas
Rail Sidings: Crockett, Tenaha, Lufkin and Livingston, Texas
Products: Hot mix asphalt, hot mix-cold laid asphalt, cement stabilized base material, super patch, limestone and granite base, agricultural lime, rip rap, crushed stone and pea gravel
environmental efforts: East Texas Asphalt incorporates rAP and rAS whenever possible. Other recycled materials include used tires.
Getting there: The trip can be grueling, with some major overseas flights combined with many smaller legs, too. He estimates 40 hours passed from the time he left camp until he reached his doorstep in Texas. “It’s worth it,” he said.
The reward: “For me, there is more to these trips than just hunting,” Carrier said. “Seeing new places, meeting new people, having new experiences—that’s the great part. Hunting is just an excuse.”
Founded:
Headquarters:
Hotmix Plants:and Paxton, Texas
Rail Sidings:and Livingston, Texas
Products:laid asphalt, cement stabilized base material, super patch, limestone and granite base, agricultural lime, rip rap, crushed stone and pea gravel
eAsphalt incorporates whenever possible. Other recycled materials include used tires.
Getting there: The trip can be grueling, with some major overseas flights combined with many smaller legs, too. He estimates 40
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At Gencor, everyone is focused on meeting the needs of our customers in a timely and cost efficient manner with one thought
in mind: make every customer feel exceptional, every day. Whether you purchased an entire plant or a single component, the confidence you place in Gencor is appreciated. Our product support department is designed around you, the Contractor, and how we can best meet your needs 24/7, starting with a simple phone call.
partsGencor OEM parts are high quality and designed to keep your equipment running at peak efficiency. More than 50,000 parts are in stock at two warehouse locations (Iowa and Florida) to assure fast response. Our project cataloging system assures you receive the right part to meet your specific needs. Gencor’s knowledgeable and friendly personnel are available 24/7 including holidays and weekends to assist you with your parts needs. If you need a custom shaft, a special dryer shell or some other unique part, our machining and fabrication shops will create what you need.
Making every cUStoMer Feel
parts trackerGencor has teamed up with several leading freight carriers to assure your parts are delivered where and when you need them including weekends and holidays. In most cases, Gencor offers same-day shipping through our special freight carriers.
Through Gencor’s exclusive parts tracking system, you can track your own parts shipments from our warehouse to your plant site at the click of a button.
• FedExTracking
• UPSTracking
• DHLTracking
• RoadwayExpressTracking
exceptional
product SupportGencor has assembled the highest quality technical talent in the industry with real-world, hands-on equipment knowledge. With over a century of experience in hot mix plants, our experts understand the demands that you place on your equipment and the need for the best support to keep you running efficiently.
24/7 help deskGencor’s help-desk provides 24/7 telephone technical support for both electrical and mechanical problems. All calls are logged into our customer database and monitored to assure you are connected to one of our experts for your particular problem. Most diagnostics, programming and software changes can be made remotely via Internet connection with our exclusive Ultralogiks network.
CuSTOMEr SErvICE
“Gencor went the extra mile and your representative even contacted me at home on Sunday to see if i received the parts. Your service was excellent as always and greatly appreciated.”
–James ZellerU.S. Asphalt
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turnkey erection ServiceGencor’s subsidiary company, ESGI, has experience with some of the largest and most complex site projects in the world and can provide complete turnkey management including site engineering, foundations, electrical, mechanical erection, start-up and training. Supplemental erection services and supervisory assistance are also available to complement your own staff.
permitting assistanceGencor’s Ultraplants coupled with Ultraflame burners have been exceeding environmental standards over the last 50 years and, as a result, are the cleanest-operating hot mix plants in the world. Over that time, we’ve learned plenty about the ever-increasing environmental requirements and how to best meet your needs as a hot mix producer. Whether you need permitting assistance or consulting services, Gencor provides expert advice and technical support for your new or upgraded hot mix plant.
regional techniciansGencor maintains a network of localized field service technicians in many regions of the country to assure faster response times to your plant site, when needed. Each service technician is a factory-trained graduate of Gencor University. Whether you need a burner tune-up or a major upgrade, Gencor has the specialized talent to make it happen.
“When problems do occur, we receive great service from Gencor. Technical help is always available around the clock with most parts arriving the same day. Gencor has assembled a talented team that equals the quality of its plants.”
–Robbie SaundersBasic Construction
CuSTOMEr SErvICE
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GencorGencor
2020
GencorGencorProduct InnovatIonsGencorFor those of you considering the purchase of a stationary or portable plant or modernizing one or more plant components, this Special Show Edition of Gencor Innovations provides you with information about some of the latest Gencor innovations at Work. From high-producing portables to our most sophisticated stationary plants, you’ll see how Gencor leadership provides rugged products and advanced technologies that will help keep you and your team operating at peak efficiency.
examples are evident in all areas of plant components and systems including:• PremiumandPortableSilos• Hy-WayStationaryandPortableACTanks• 400PortableUltradrum™ and 500 Ultradrum™ A.R.E.• MegabinsandColdFeederBins• Ultraflo182Baghouse• Equinox® Vector Burner 135 and Ultra II™ High-
Efficiency Burners• Equinox™ Vector Burner Control• Ultralogiks™ Plant Control System• GreenMachineUltrafoamGX2™ System• TurbocoilHYThermal-FluidHeater
Gencorwhy talk with gencor?
gencorinnovationS
at work
Top-10 ReasonsCustomers Talk with Gencor Customers and prospects come to Gencor with a variety of needs and business challenges. We’re here with answers and solutions. The following is a list of the top-10 reasons asphalt producers begin a conversation with Gencor:
1. Higher production: Gencor provides it.
2. Greater energy efficiency: Gencor has it.
3. increased use of RAP and/or RAS: Gencor has you covered.
4. Higher quality, more consistent mix: Gencor helps you drum up more business.
5. Great-neighbor environmental solutions: Gencor Green is your best choice.
6. increased automation: Gencor has proven solutions.
7. Stronger technology linkages: Gencor integrated systems perform.
8. Faster portable plant assembly and teardown: Gencor gets it done.
9. consolidating plant capacity: Gencor makes bigger better.
10. Higher reliability: Gencor offers unparal-leled uptime.
If you’re looking to make a quantum leap in one or more phases of your plant operations, Gencor professionals will design a tailored solution for you backed by the industry’s best parts, service, training and customer support. Every step of the way, Gencor puts customer needs first. To see how Gencor innovations at Work can make a big difference for your bottom line, turn the page.
21
Genc
or®
Genc
or®
Genc
or P
rem
ium
Silo
s®
Pre
miu
m S
ilos
®
Gencor® Premium Silos are designed for producers’ long-term or extended storage needs, while still retaining all of
the innovations and safety features you’ve come to expect from Gencor. Heavy-duty structural components—featuring wide-flange beams and massive leg frames—provide many years of dependable life and set Gencor Premium silos apart from others. Five capacities range from 150 to 350 tons.
All Gencor Premium silos have a steep, 60º-tapered cone that forms a 36" discharge opening for fast, smooth material flow. The cone is fully welded and gusseted around the perimeter to prevent bottoming out. The entire cone is enclosed and insulated using a subfloor that comprises the floor section and safety gates.
Gencor Premium silos are fully insulated against heat loss with 10" of industrial-grade insulation in the upper deck section and 6" of sidewall insulation. The floor section also has 6" of insulation, and the silo barrel is completely covered by a painted, 18-gauge, galvanized-steel skin for years of dependable service.
A dual, anti-segregation batcher with two opposing batcher gates charges the silo evenly without building a conical material pile in the center. A unique central splitter section provides a non-wearing surface that is virtually maintenance free. The main discharge gate is a single, independently driven clamshell that is fabricated from heavy steel and is electrically heated. A thermal-fluid, cone-heating system helps maintain mix temperature, avoiding hot spots and coking of the mix.
additional Features & Benefits:• A largeheatexchangecoilsurface
• Serpentineandhelicalcoildesignsforadequateexpansionandcontraction
• 4"ofhigh-qualityfiberglassinsulationtomaintaintheoptimumoperatingtemperature
• A safetysuctionsystemthatpreventstheliquidlevelfromdroppingbelowtheheatingcoil—yetallowscompleteemptyingofthetank
• Aninternalventandoverflowsystemtopreventoverfillingandcondensingvaporsfromcollectingininsulationduringtruckunloading
PRODUCT INNOVATIONS
BUilt For extended StoragegeNcOr® PreMiuM SiLOS
gencorinnovationS
at work
22
SE-75
1.
2.
3.
Gencor® SE-75 Self-Erecting Silo is ideal for Contractors on the move. The SE-75 is highly portable and can be erected in 10 minutes without a crane.
This self-erecting silo continues the Gencor tradition of building the strongest, most-innovative hot mix storage silo system in the industry.
An all-welded body provides enormous strength and maximum structural integrity to tolerate heat, vibration and frequent moves. The SE-75 has many of the same features that make Gencor stationary silos the industry standard—including a dual-flow, anti-segregation batcher. Leveling outriggers enable you to quickly set up on any stable surface and the 75-ton capacity and fast-loading, dual clam gates help keep trucks moving smoothly.
additional Features & Benefits:• Hydraulicliftsystemerectsinminutes
• 1/4"double-weldedbody
• Quick-disconnect,plug-inwiring
• Two-speedlandinggear
• Fifth-wheelpin
• Integrateddrag-slatconveyor
• Levelingoutriggers
• Dual-flow,anti-segregationbatcher
• Material-levelindicators
• Electricgateheat
• 3-pointloadcellsforpreciseweighing
PRODUCT INNOVATIONS
eaSily portaBle, 10-MinUte SetUp
Se-75 SeLF-erectiNg SiLO
gencorinnovationS
at work
23
30K-Gallon CTV Tanks
Hy-Way® asphalt and polymer storage tanks are the most innovative, energy-efficient tanks
available for your liquid storage requirements. All Hy-Way coil tanks feature the highest quality materials and construction for durability and maximum heat retention. Tanks are available in vertical and horizontal configurations with capacities from 1,000 to 50,000 gallons.
Hy-Way vertical storage tanks are a space-saving alternative to conventional tanks and provide higher efficiencies for polymer blend and emulsified liquids. Each tank is equipped with a unique triple-layer serpentine coil for maximum surface area and heat release into the product. An optional, low-watt density coil can be added for extra heat transfer.
Constructed of 1/4" plate, Hy-Way vertical tanks feature a standard, OSHA-compliant caged ladder and 20" manhole access to the top of the tank. Diamond-plate top-deck construction surrounded by a safety railing with kick plate provides a sturdy access platform. All tank controls and piping are easily accessible at grade and include 3" inlet and outlet flanges, and safety level cut-off switches as standard.
additional Features & Benefits:• Thelargestheat-exchangecoilsurface
• Serpentinecoildesignaccommodatesexpansionandcontraction
• 4"ofhighqualityfiberglassinsulationhelpmaintaintheoptimumoperatingtemperature
• Asafetysuctionsystempreventstheliquidlevelfromdroppingbelowtheheatingcoil,yetallowscompleteemptyingofthetank
• Internalventandoverflowsystempreventoverfillingandcondensingvaporsfromcollectingintheinsulationduringtruckunloading
PRODUCT INNOVATIONS
increaSed tank eFFiciency30K-gaLLON ctV taNKS
gencorinnovationS
at work
24
30K-Gallon Portable AC Tank
Hy-Way® portable asphalt tanks are the most energy-efficient tanks available for your liquid polymer storage requirements. All Hy-Way portable, coil tanks feature the highest-
quality materials and construction for durability and maximum heat retention. The rugged shell utilizes 1/4" butt-welded steel plate, and four inches of fiberglass insulation reduces conductive heat loss. You’ll find innovations in a variety of configurations and capacities from 1,000 to 50,000 gallons to accommodate any plant size. Setup and connectivity to your portable plant are fast and easy.
additional Features & Benefits:• A high-efficiency,closelywound,serpentinecoilincreasesoilcirculationandimprovesheat
transferforeventhemostviscousmaterials
• Supportframeconsistsofaseriesofintegralsaddlesmountedonheavy,twin12"I-beams
• Aneasilyset-to-gradesupportframewithswing-downlandinggearspeedssetup
• All-weather,scratch-resistant,18-gauge,embossedaluminumskinprovidesyearsofprotectionfromtheelements
• A skid-mountedhotoilheaterandACmeteringpumpformanintegratedmobilesystem
PRODUCT INNOVATIONS
go-anywhere tankS Match yoUr needS
30K-gaLLON POrtabLe ac taNKPortable AC Tank
gencorinnovationS
at work
25
400
Port
able
Ultr
adru
m™
400
Port
able
Ultr
adru
m™
400
Port
able
Ultr
adru
m
You can be up and running in a hurry with the rugged, yet agile 400 Portable Ultradrum™. Adjustable drum flighting maximizes
heat transfer and provides industry-leading fuel-efficiency. In addition to accommodating multiple fuel types and grades, the innovative Ultra II® burner provides total combustion air, destroys all hydrocarbon fumes and odors, and controls combustion inside the sealed drum for significant noise reduction. The 9'-9" diameter increases productivity, while lowering air velocity through the drum—effectively reducing dust carryout and wear on the ductwork, breechings and baghouse.
A separation wall segregates drying and mixing zones to protect the RAP and liquid asphalt from exposure to high combustion gases and radiant energy from the fire. The wall also prevents burning and distillation of the asphalt, leading to a higher quality mix.
Patented adjustable Converta-flights provide quick release of energy into the aggregate. Five-position adjustability facilitates tuning for specific aggregate sizes to optimize heavy-veil and heat-transfer efficiencies, even with varying moistures. Patented T-flights create the combustion volume needed to release energy effectively, while also protecting the drum from excessive heating.
additional Features & Benefits:• Wide-flangeI-beamconstructionprovidesextrastrengthand
durability,reducesvibration
• Thelighter3/8"X50'shell—crucialforaportableplant—isveryresistanttowear
• Replaceablewearplatesandahydraulicerectionpackageassureeasytransport/set-up
• Thefour-trunnion,independentfrictiondriveincreasesefficiencyandlongevity,reducesmaintenance
• Positivebluesmokesystemcapturesanddestroyshydrocarbons
• Hydraulicerectionpackageandskidsprovidefastset-up
• 50%RAPandRAScapability
PRODUCT INNOVATIONS
MoSt energy eFFicient, higheSt MoBility
400 POrtabLe uLtradruM™
gencorinnovationS
at work
26
500 Portable Ultradrum™500 Portable Ultradrum™500 Portable Ultradrum
The 500 Ultradrum™ A.R.E. (Advanced RAP Entry) facilitates increased use of high-moisture RAP or RAS (recycled asphalt
shingles) at 50% without additional energy input or loss of production. The result is high-production, high-quality hot mix—under extreme conditions.
The innovative A.R.E. concept utilizes the gases and convective heat of the combustion zone to preheat and advance the release of internal moisture in the recycled pavement. This advanced release of moisture results in higher production due to a more evenly staged release of water vapor in the drying process. RAP, virgin aggregate and baghouse dust combine in the mixing zone, away from the direct radiant zone. Asphalt cement (AC) is then added into the thoroughly dried mixture to form a fully coated and homogenous mix before exiting the drum.
The 500 Ultradrum A.R.E. flighting is designed for even greater productivity and reduced wear and maintenance, making it the industry’s highest-production, lowest-cost-per-ton drum. Some of the largest asphalt producers in North America are running applications in excess of 700 tons per hour while producing over 50% RAP.
additional Features & Benefits:• PatentedA.R.E.flightspre-heatRAP
• Patented,Converta-flightsreduceenergyconsumptionandstacktemperature
• Sweepingmaterialinletflightsprovideevendrumloading
• Self-cleaningRAPinletenablesuseofover50%recycledasphalt
• Largerdrumdiameterreducesairvelocityanddustcarry-out
• Friction-driventrunnionrollsreducenoise,maintenanceandenergyuse
• Positive,volatilereclaimsystemcapturesanddestroyshydrocarbons
PRODUCT INNOVATIONS
over 50% rap, high prodUction500 uLtradruM™ a.r.e.
gencorinnovationS
at work
27
Super-Sized Megabins
As the largest of their kind, Gencor Megabins are super-sized to meet the demands of large plants exceeding 600 tons per hour. Heavy, rugged design features such as 1/4" steel sidewalls and heavy-
duty leg supports make Megabins the most durable feed bins in the industry. This massive feed system stores as much as 105 tons of aggregate per bin making them the largest bins of their kind.
The innovative bin design provides steep-sided, tapered walls and a self-relieving throat that virtually eliminates the bridging and material-flow problems typically associated with large aggregate silos. A simple rack-and-pinion gate design provides easy height adjustments to accommodate a variety of material gradations. The variable-speed drive system assures precise material flow at varying production rates and is monitored by dual flow indicators.
Towering, 20'-tall bulkheads have 1/4" steel walls supported by heavy steel channel and I-beam construction. Wing walls, 12' long, attach to the bulkhead and support the guardrail for ramp construction. Ample access around the bins and feeders facilitates cleaning and maintenance.
additional Features & Benefits:• Heavy-dutylegsupportsandsteellegsprovideunmatcheddurability
• Massivelybuilt,hingedgrizzlieswith6"X6"openingsscalpforeignmaterialfromtheaggregate
• A simplepinadjustmentvariesthescalpingangle
• A large,36"-widetroughedfeederbeltwithadjustabletensionreducesspillageandeliminatestheneedforrubberskirting
• A 10-hp,variable-frequencydrivemotorandtorque-arm,shaft-mountedspeedreducerprovideprecisecontrol ofthefeederbelt
PRODUCT INNOVATIONS
high-volUMe, high-prodUction Feed SySteM
SuPer-Sized MegabiNS
gencorinnovationS
at work
28
Portable Five-Bin Cold Feeder
Gencor’s cold feed systems are ruggedly built for years of use under the harshest conditions. The innovative
bin design provides steep-sided, tapered walls and a self-relieving throat to virtually eliminate bridging and material flow problems. A rugged rack-and-pinion gate design provides easy material height adjustment to suit a variety of material gradations.
The innovative five-bin portable feed system has tandem axles on 49" spacing. A set of individually operated landing gear is mounted at each end and between each bin for easy leveling. Bins are 10' x 14' with 12" fold-down dividers, and 5'-4" reversible bulkheads are mounted to pivoting arms that fold down against bin legs for travel. Collector extensions also fold over for travel.
additional Features & Benefits:• Rugged,steep-sidedtaperedbins
• Feedersaredrivenby7.5-hpvariable-frequencydrivemotorswithdual-flowindicators
• Tail-shafttachometershelpsetandholdconsistentflowratestomatchproductionrequirements
• Quick-disconnectwiringspeedssetupandteardown
PRODUCT INNOVATIONS
the hoteSt SetUp in cold FeedSPOrtabLe FiVe-biN cOLd Feed
Cold Feedergencor
innovationSat work
29
Ultraflo 182 BaghouseThe innovative Ultraflo baghouse system is the ultimate
alternative to pulse-jet baghouses. Developed to increase efficiency and reduce size and weight for improved transportability, the Ultraflo is the most compact design with the greatest cleaning efficiency. In addition to improved mobility, the low-profile Ultraflo 182 provides longer bag life and fewer moving parts than conventional pulse-jet baghouses.
Durability is provided by 3/16" unitized wall construction. The entire structure is fully insulated to reduce heat loss and condensation. A Corten steel top prevents oxidation and promotes a cleaner stack. A wedge-type top and encapsulated gasket system provide tightly sealed doors that prevent secondary air leaks. There are no hinges to rust or break. The bottom line: You’ll find the Ultraflo 182 longer lasting, more efficient, and easier to maintain than any other baghouse.
additional Features & Benefits:• Ellipticalbagsprovidethreetimesmoreclotharea
• Largervolumehouseslowsvelocityandprovidesevenflowdistributiontobags;built-inbafflesalsohelpmaintainevenairflow
• A largeaccessdoorandlatchprovideeasyentrywithnobolts
• A sequentialcleaningdistributoreliminatestheneedforsolenoidsandanaircompressor,keepingyourmaintenanceandoperatingcostslow
• Sensorsmonitorincomingtemperaturestoprotectbags(thefirstsettingbringstheburnertolowfire,thesecondsettingshutsburneroff)
• Anautomaticstart-stopsequencepreventsexcessivecleaning,andwearandtearonbags
• Consistentairflowoverawiderangeofoperatingconditionsandpressuresismaintainedbyahigh-efficiency,backward-slopedexhaustfan
PRODUCT INNOVATIONS
low-proFile, high-eFFiciencyuLtraFLO 182 baghOuSe
gencorinnovationS
at work
gencorinnovationS
at work
30
PRODUCT INNOVATIONS
Only Gencor builds MegaPlants that use less energy and produce more tonnage faster than any other manufacturer. When you want real performance, think fast, think big, think Gencor.
Call 407.290.6000 or visit www.gencor.com for more information.
Gencor MeGaplantsBigger, cleaner, faster
121842_GEN_MegaPlantAd_Rev.indd 1 5/22/12 12:42 PM
Equi
nox®
Equi
nox®
Equi
nox
Vec
tor B
urne
r 135
®
Vec
tor B
urne
r 135
®
Equi
nox
The Equinox® combustion system from Gencor is so advanced, it challenges the imagination with
its simplicity and ease of operation. Environmentally conscientious Contractors from New Jersey to California rely on the industry’s most innovative combustion technology to help their hot mix plants comply with ever-tougher regulations.
The Equinox combustion system is designed to eliminate or reduce the need for Flue Gas Recirculation (FGR) through a patented two-stage process. The unique design of Equinox incorporates a sophisticated pre-mix accumulator that prepares the gas/air mixture prior to combustion, ensuring a lower peak flame temperature in the combustion zone. By way of a patented injection system, the second stage further cools the flame by introducing water and directing it only to the areas of the flame that are at peak temperature. The result is more stable combustion through the use of latent heat evaporation, with little to no effect on the exhaust system of the plant or production.
Low-NOx emissions, reduced noise, and more efficient combustion of gaseous fuels are benefits you, your neighbors and governmental officials will appreciate. The Equinox combustion system has proven to be a significant breakthrough for the HMA industry.
additional Features & Benefits:• TheEquinoxiscompletelyassembledonaunitized,steelframe
forinstallationease
• Totalcontrolovertheair,fuelandoperatingrange
• Stablecombustionflameaddsconsistencyandhigherproductivitytotheheatingprocess
• Thermalefficiencyandusableplantexhaustcapacityareincreasedbyasmuchas20%elsewhere
• Reduceddrumgasvelocitiesandfinescarry-outhelpprotecttheexhaustsystemandextendthelifeofplantcomponents
system of the plant or production.
Low-NOx emissions, reduced noise, and more efficient combustion of gaseous fuels are benefits you, your neighbors and governmental officials will appreciate. The Equinox combustion system has proven to be a significant breakthrough for the HMA industry.
PRODUCT INNOVATIONS
MoSt-advanced, low-nox technologythe equiNOx® 135 burNer
gencorinnovationS
at work
The Equinox combustion system is designed to significantly reduce, or perhaps even eliminate, the need for FGr through a patented two-step process.
32
Ultr
a II™
Ser
ies
High
-Effi
cien
cy B
urne
r™
Ser
ies
High
-Effi
cien
cy B
urne
r™
Ultra II™ high-efficiency burners can be used in any rotary drying process that requires heat release of 25 million to 150 million BTU/
hour. The low NOx emissions and total air system reduce noise and provide complete, efficient combustion of conventional fuels including oil, gas, LP and coal.
With no refractory or combustion port requirement, you achieve faster heat-up and cool-down, lower maintenance costs, and reduced heat loss. The innovations in this compact package provide the perfect solution where size and/or weight are critical.
Nothing can compare to the fuel efficiency of the proven Ultra II burner. Unbelievable power, unshakable reliability and faster response make it the most dependable burner available.
additional Features & Benefits:• UltraIIcomescompletelyassembledonasturdyunitizedframefor
easyinstallation
• Advancedprocesscontrolsprovidetheperfectcombinationofformandfunction
• Youcanevenburnmultiplefuelssimultaneously
• Highpressure,turbulentairflowhelpscreateidealflameshapingandclean,efficientburning
• Controloftheair,fuelandoperatingrangeisatyourfingertips
PRODUCT INNOVATIONS
the greeneSt BUrner on the planetuLtra ii™ SerieS high-eFFicieNcy burNer
gencorinnovationS
at work
33
EquinoxEquinox ® Vector Vector® Vector®
Burner Control
The Vector is the latest evolution in process automation that programs and controls the character of the plant draft and fuel over the entire operating
range for optimum fuel-to-air ratios.
The environmentally advanced Vector™ burner control is a fully automatic digital control system that minimizes fuel usage and gaseous emissions, while maximizing production capacity. It is designed to control the start-up sequence, firing rate, and safe operation of industrial burners.
A large 10" LCD display with a touch-screen, controls the burner functions. A visual display indicates the burner status and alarm conditions via the HMI and audible alarm.
Digital actuators improve burner performance providing highly accurate and independent control of air, oil, and gas valves. Physical minimum and maximum positions for each servo are programmable, allowing for up to 10 program points for optimal air-to-fuel characterizations.
additional Features & Benefits:• On-screen,helpdisplayandremoteinternetdiagnostics
• Visualdisplayandannunciation,indicatesthecurrentburnerfunction,status,andalarmconditionsviatheHMIwithaudiblealarm
• Digitalservoactuatorsimproveperformancewithindependentcontrolofairandfuel
• 10userprogrammablepointstocreateair/fuelcharacterizationsets
• Advancetemperaturedetectionforearlydetectionofmoistureorloadchange
• DigitalexhaustfandamperpositionmeterfordamperorVFDfan
• Canberetrofittedforexistinginstallationsorsuppliedaspartofanintegratedcontrolsystem
PRODUCT INNOVATIONS
MoSt environMentally advancedVectOr burNer cONtrOL
gencorinnovationS
at work
34
Ultr
alog
iks™
Pla
nt C
ontr
ol S
yste
m™
Pla
nt C
ontr
ol S
yste
m™
The Gencor Ultralogiks™ Plant Control System is a totally integrated automation package that manages and monitors all
plant control functions within a Windows-based environmental and graphical user interface. The hardware is an advanced PLC control platform that performs all plant operating functions, including blending and loadout.
The graphical user interface is PC based using a high-speed IBM compatible computer with large-capacity hard drive. A backup computer and redundant hard drive assure the operator of complete data and operating system security in the event of a PC or PLC failure.
The innovative Gencor Ultralogiks Plant Control System’s main operating screens provide a logical and complete presentation of operating data through the use of segregated screen sections. The upper section displays items at the point of liquid asphalt injection; the center section offers selectable views of Motors, Maintenance, or Event Log Information, as well as configuration settings and calibration screens. Detailed user screens for each equipment component are displayed by simply clicking on the equipment image.
additional Features & Benefits:• Unlimitedmixformulamemory
• A “mixtonsto-go”featurewithautomaticshut-down
• ACno-flowandmaterialno-flowindications
• Unlimitedstorageofjob,customer,product,andtruckfiles
• AutomatictrucktareandGVWtopreventoverloading
• Dailyreportsavailablefortrucks,jobs,andcustomers
• Graphicallydisplayedinventoryforeachsilo
PRODUCT INNOVATIONS
gencorinnovationS
at work
integrated, aUtoMated proceSS control
uLtraLOgiKS™ PLaNt cONtrOL SySteM
35
Ultrafoam®Ultrafoam®Ultrafoam GX® GX®
2 GX2 GXW iththearrivaloftheGreenMachineUltrafoamGX2 System, warm mix
technologyhasneverworkedsowell.TheinnovativeUltrafoamGX2 achieves consistent foaming at varying production rates without the use of a powered mixing device.
Basedonitspatenteddesign,theUltrafoamGX2 provides variable orifices for both AC and water and a means to keep the two flows in intimate contact, so that the available mixing energy is used effectively. The perfect AC-water ratio is maintained at all production rates. By creating smaller, evenly sized, more-stable bubbles, the industry’s most consistent asphalt foaming process has established a new best practice.
Warm mix can lower emissions, improve quality, and lower costs in four major areas:
1. Reduce emissions of volatile hydrocarbons
2. Eliminate objectionable odors
3. Increase the compaction time on the mat
4. Reduce fuel consumption
additional Features & Benefits:• ACandwateraremixedtogetherinaproportionate,continuousprocess
• Nolossofpressuredropandmixingenergy
• Improvesworkabilityofthemix
• Allofthemixingenergyisprovidedbythepumpingsystem
• Theprocessissimple,reliable,repeatable
PRODUCT INNOVATIONS
the green MachineuLtrFOaM® gx2
gencorinnovationS
at work
36
Turbocoil HY
The Turbocoil HY is an economical, thermal-fluid heater that incorporates a high-thermal-efficiency, closely wound,
helical-coil design. With temperatures to 400ºF and a duty range of one million to two million BTU/hr, the Turbocoil HY provides many innovative design features included with much larger Gencor heating systems.
The unique coil design results in skin and stack temperatures being much cooler than competitive units, minus the maintenance problems typically associated with internal-blanket or castable, refractory insulation. Lighter thermal fluids with low flash points can be safely and effectively utilized, because the helical design provides higher velocity flow through the coil.
Packaged and skid-mounted for easy installation, Turbocoil HY heaters are the perfect combination of economy, reliability and efficiency.
additional Features & Benefits:• Suitableforindoorandoutdoorinstallations
• Removablecoilandfrontheadplateforeasyaccess
• Largecombustionzoneforevenheattransferandlongerthermalfluidlife
• Safe,low-pressureoperation
• Quiet,drip-freemechanicalsealedpump
• HighGPMcentrifugalpump
• Automaticaireliminationsystem
• Factoryfiretested,andsystemsafetiesandinterlocksincluded
PRODUCT INNOVATIONS
gencorinnovationS
at work
Bring More heat, More eFFiciently
turbOcOiL hy
37
CuSTOMEr STOrY
40% recycling ability helps Asphalte Drummond maintain customer commitments
KEEPING
IN CHECKRiSinG coSTS
38
Francois Guilbeault found himself in a situation faced by too many asphalt manufacturers.
“The cost of aggregate continued going up,” said Guilbeault who, with his brother, owns Asphalte Drummond, based in Drumondville, Quebec, Canada. “It was having an impact on our business.”
In theory some of the cost could be passed to customers, though that is not a business approach Asphalte Drummond likes to take. Customers don’t appreciate rising prices, and Guilbeault doesn’t want them searching for lower-cost alternatives.
Yet surrendering profit margin is not a healthy business approach, either. “We had to find a way to control the costs, while not hurting our business,” Guilbeault said. He believes others in the industry face similar challenges.
“Aggregate prices are going up,” said Guilbeault. “That is the case everywhere, and it is happening in Quebec, too.”
taking actionA little more than a year ago Asphalte Drummond Inc. began a comprehensive financial review. It included a close look at its current costs, as well as future expectations.
Guilbeault saw aggregate costs as a key obstacle. And he saw a solution, too: Using more recycled material. “The material costs less,” he said. “I can keep my prices to customers lower. With recycled asphalt, I can stay in the game. It will make me more competitive.”
The existing plant did not have the capability to process enough recycled material to make a significant change to the cost of mix. Guilbeault turned to the experts at Gencor, to spec a batch plant that would allow flexibility to his customers while increasing recycle into his operations. Asphlalte Drummond has since increased their RAP use significantly and eventually will take full advantage of the plants 40% RAP capability.
As a result, Guilbeault has a renewed commitment to recycling and an updated state-of-the-art plant that provides other environmental benefits, too.
CuSTOMEr STOrY
Continued on page 40
3939
CuSTOMEr STOrY
the plantAsphalte Drummond produces about 280 tons per hour with the new batch plant, though it could produce more. The 280 tons is a large increase from the approximately 60 tons per hour produced by the previous plant.
The new plant has a special drying drum that pre-heats the RAP as it enters.. A special bin on the batch tower then enables RAP to be metered into the pugmill at a 40% rate.
The plant’s ability to integrate recycled asphalt will help keep costs in line for current customers, while the increased tonnage will enable Asphalte Drummond to serve more customers. Asphalte Drummond has a healthy business, including many local municipalities who use patching, as well as laydown and overlay mixes.
Guilbeault also is hoping for increased efficiencies beyond the use of recycled materials. The new plant runs on natural gas, which is expected to help reduce fuel costs.
The Gencor team helped install the plant, and Guilbeault liked their thorough approach, as well as the training they provided.
The Gencor team erected and commissioned the plant, and Guilbeault took full advantage of the exceptional training they provided. In addition, Gencor provided guidance on improving operations to maximize overall plant efficiency.
“There are many reasons to buy the new batch plant,” Guilbeault said. “Noise is not a worry with this plant, neither is dust. “We have a new operation, and we are confident it can help our business grow and make our future more secure.”
20 FactorsThat Gencor Will Help You Consider1. Complete evaluation of your current plant
2. Areas for improved efficiencies of your currrent plant
3. Current production capacity and anticipated future needs
4. Surveying your needs and potential for growth
5. The competitive environment in which you operate
6. Permitting and approval process
7. Plant innovations and technology upgrades
8. Ability to utilize RAP and RAS
9. Potential fuel savings, use of natural gas
10. Improving your environmental footprint
11. Safety improvements
12. Number of plant installations / every customer a reference
13. Plant specing / ordering process, delivery timing
14. Erection assistance: turnkey to support your team
15. Training and startup assistance
16. Ongoing access to operations and maintenance experts
17. Parts availability, distribution and service support
18. Plant financing options and assistance
19. reductions in your cost per ton
20. Impact on your bottom line / payback timing
40
Are you thinking about upgrading to a new batch plant that can help you introduce more recycled asphalt into your operation? Here are the specs from the Asphalte Drummond plant to help you contemplate what your new plant could look like.
• Six bin, 10'-by-14' stationary cold feed system
• 5'-by-10' stationary vibrating screen with 7.5-hp drive
• 30"-by-75' stationary aggregate scale conveyor with 15-hp drive and emergency pull cord
• 103", 320 TPH stationary insulated dryer with four 30-hp drives
• Ultra II™-100 oil/gas-fired burner
• RAP pre-heat inlet collar
• Model # RA-80 Batch Tower with five insulated bin compartments with a 120-ton capacity
• Hot bucket elevator with 50-hp drive
• UHS-3516-D screen with 25-hp drive
• Model SM-156 mixer with 150-hp drive
• 3" AC pump with 15-hp drive
• Remote controlled flop chute with five-position feed gate
• Primary collector
• Model CFS-151, 74,029 CFM stationary baghouse – 15,059 sq. ft. of cloth with a 4.92:1 air-to-cloth ratio
• Model 490-BCS exhaust fan with 200-hp motor
• 500 BBL mineral dust silo with weigh pod
• 12-ft.-by-40-ft. skidded operator’s control center
• Batching process control, FC-250 Feeder Control, Gen 3D™ Burner Control
• Internet modem
• Cable trays
• 8'-by-14' stationary Series IV Recycle System, with 36"-by-12' feeder and 5-hp Eddy current drive
• 36" collector conveyor with 7.5-hp drive
• 4'-by-8' stationary vibrating screen with 5-hp drive
• 24"-by-75' stationary scale conveyor with 10-hp drive
• 30,000-gallon indirect-fired vertical AC tank
conSidering a new Batch plant?
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GENCOR_ServiveAd_AC_Rev1.indd 1 2/28/14 5:11 PM
GENCOR_ServiveAd_AC_Rev1.indd 1 2/28/14 5:11 PM
Uh-oh, Heater not Lighting!
One of the worst problems you can face is a thermal fluid oil heater that won’t light. Without a doubt, it’s a serious situation. Instead
of hot mix (and money) flowing, you have idle crews—not to mention a cold pump and asphalt cement lines.
But the tools for self-diagnosis have come a long way. Gencor has made it easy for you to pinpoint the cause of the problem—and resolve it quickly. The key is understanding the safety interlock logic of the Hy-Way™ panel, and taking advantage of the aid that can be provided with Fireye flame controller diagnostics.
Identifying the CauseHow can you pinpoint the cause? A trouble-shooting flowchart on pages 44 and 45 provides guidance. But understanding the normal operational sequence is the best place to start.
First, the two control panels: Powerflame panel mounted on the burner, and the Hy-Way control panel mounted on the right side of the heater. (While versions of each can provide different power configurations, the Hy-Way control panel normally is powered by 480 vac 3 ph, or Canadian 575 vac 3 ph.)
At this point, the circulating thermal fluid pump is running in either “manual” or “auto.” (The Hy-Way control panel has a transformer that provides the 120 vac for the burner control power and safety interlocks.) At power-up, (with the circulating pump running) all interlocks are electrically closed. The status of other elements includes:
1. The “expansion tank low-level limit” switch (mounted on the expansion tank float) is closed when the fluid is at normal level.
2. The “flow” switch is closed, indicating sufficient oil flow to light the burner.
3. The “stack high temperature limit” is closed when the temperature is below the stack limit of 800ºF.
4. The “circulating oil limit” is closed when below the limit of 400ºF.
Temperature ControllerAt this point, the “limit” light should be on. Next, the temperature controller senses whether the thermal fluid temperature is below the set point. When the temperature is at an appropriate level, the controller closes and sends 120 vac to the Powerflame control panel. (This is done via the R1 relay mounted in the Hy-Way panel).
The signal to the Powerflame panel goes through the off/on switch, and the fuel selector switch then energizes the Fireye controller. At this point, the Fireye controller “op ctrl” light will be on. The Fireye controller immediately starts the blower motor, and the “intlk” (or “airflow”) light will be on. The Fireye initiates “PTFI” (pilot trial for ignition) after the purge time is complete.
With the pilot ignited, the main fuel will be energized and PTFI will be off. And, presto—the main fuel will light.
But you’re not done yet. You also should understand that the burner will continue to fire until the high set point is met, at which time the Fireye will shut off the burner and engage a post-purge circuit for 15 seconds. On Hy-Way 200 heaters, the burner will shut down to “low fire” at the set point. It will continue to operate until the “high fire” set point is met—or the temperature drops and the “high fire” is re-engaged.
Normal Operation of the BurnerNow that the heater is lit, let’s look at how the burner should operate.
Diesel Fired – A diesel burner will ignite the fuel through direct ignition using a 10,000-vac transformer connected to Jacobs ladder ignition electrodes. The fuel pressure on “PTFI” will be 100 psi on the Hy-Way 200 heater and 300 psi on the Hy-Way 100 heater. The Hy-Way 200 heater will go to “high fire” within five seconds of igniting the pilot/low-fire flame. The pressure at “high fire” will be 300 psi.
Gas Fired – Gas pressure to the heater must be 8 ounces and remain at that level when the burner lights and goes to “high fire.” The gas regulator for the heater must be within 10' of the burner. The burner pilot pressure is approximately 3.0" of water column (in. w.c.) pressure. Pressure at the main fire test port is approximately 2.9" w.c. pressure when the burner is at “high fire.” The pressures for vaporized propane will be higher—4" to 5" w.c. pressure—however restrictors are used.
As you can see on pages 44 and 45, you should take a series of steps if your heater doesn’t light. But the key to understanding what might be wrong is to first grasp how the system should work.
System Understanding Key to Diagnosis
See pages 44 and 45 for a troubleshooting flowchart detailing a series of steps to take when your heater won’t light.
John Price Service ManagerGeneral Combustion Corp.
PRODUCT SUPPORT
PRODUCT SUPPORT
therMo FlUid heater troUBle-Shooting Flowchart
The Hy-Way Control Panel is powered - normally 480VAC 3 phase, .120VAC TERM 1 & Term 5 The HY-Way control panel has a transformerthat provides the 120VAC for the Hy-Way control panel safety interlocks and the PowerFlame control panel (the only exception is 575VACCanadian where PowerFlame has a separate power supply.)
No Power “On”Light
Limit Light“Off”
When the TEMPERATURE CONTROL senses that the thermal �uid temperature is belowthe set point, the control will close and send 120VAC to the Power�ame control panel viathe R1 relay that is mounted in the Hy-Way panel. 120VAC TERM 3 and J-1 HEATDEMAND light “on” if not temperature control or relay R1 defective
Limit Light“On”
No HeatDemand
Light
Fireye NotIn Lockout
BurnerFails to
Ignite onStart Up
Fireye In Lockout
Refer to LockoutMessage Code
Heat Demand Light“On” Burner DoesNot Try to Ignite(No PTFI On Fireye)
The 120VAC signal from term3 in the Hy-Way panel goes tothe PowerFlame panel, throughthe OFF/ON switch and throughthe fuel selector switch to energize120VAC to term 7 base of Fireye(also to term TERM 4 & 4G onHY200)
“Op Cntl” led light “on” blower motor will start interlock light “on” andremain running until PURGE is complete. The PTFI led will light.Trial for ignition commences.
If no “PTFI”, fuse in Fireye is blown on Meuv Fireye. Fuse is located on Fireyechassis.
Fireye terminals in back plate of Fireye are tarnished and need to be cleaned
Fireye programmer or chassis is defective, on/off switch is defective
Check for power at Term 4 Fireye base, if not Fireye is defective, open wiring
If power, 120VAC at Fireye base term 4 then 120VAC then FUEL CONVERSIONswitch is defective
No power 120VAC on OIGPFP* when PTFI led is “on”
Oil �red 120VAC on termOIG PFP* from the sightglass at the burner you normallycan see the spark
OIL FIREDPTFI led light “on”but no pilot �ame
Codes ContinuePage 2
FlameFailPTFI
GAS FIREDContinued Page 2
Expansion Tank low level limit switch mounted on the expansion tank �oat, Closed , Red light off.120VAC TERM 6Fill tank to above low level cut off
The Flow Switch is closed indicating suf�cient oil �ow, , Red light off; red light on means diff120VAC to TERM 8pressure too low or too high, consult operations manual for min/max pressures
The circulating pump running the auxiliary mtr interlocks closed. 120VAC on TERM 10 when limit closed
The Stack High Temperature Limit is closed, temperature is below the stack limit of 800F. when120VAC TERM 11limit closed reset limit if in alarm & monitor temperature
The Circulating Oil Limit is below the limit of 400F, when limit closed - reset limit if in alarm120VAC TERM 12and monitor temperature
Check 10,000 volt ignition xfmr - 1/2 in spark to gnd is 10,000 volts
Broken spark plug wire
Check setting of ignition electrodes; refer to PowerFlame C manual
NoSpark
No fuel, tank empty or line �lter plugged
Loose �ttings on fuel lines
No fuel pressure (300 psi HY 100 & 100 psi HY 200) fuel pump defective
Fuel pump drive coupling defective
Nozzle strainers obstructed; replace nozzle
Pilot solenoid valve inoperative, open wiring
Blower air insuf�cient, check for correct rotation of blower
Blower air damper open too much or closed too much, normally 1/2 in to 1 in gapon each damper
Ignition electrodes and diffuser not adjusted properly, refer to non-pressurizedcombustion chamber pilot setting in PowerFlame C manual
Sparkand fuelbut will
not ignite
Spark but nofuel sprayfrom the
nozzle
Thermo Fluid Heater Trouble Shooting Flowchart
Lockout Message Code Table
LOCKOUT MESSAGEOP
CONTROLINTERLOCK PTFI FLAME
Line Frequency Noise
Flame Fail - PTFI
Fault Unknown
Amplifier Count Fail
Flame Fail MTFI
False Flame Idle
Interlock Open
Interlock Closed
Chassis Opto
Flame Fail - Auto
Check Chassis
Check Programmer
Check Amplifier
Amplifier Auto Check
Check Blown Fuse
Check Scanner
* PFP- PowerFlame panel terminal**Terminals listed are Hy-Way panel terminals unless otherwise noted.
LockoutMessage
Code
Fireye LED light “on”
Fireye LED light “off”
44
GAS FIREDPTFI light “on”but no pilot �ame
No power 120VAC onGIG & PV PFP* whenPTFI led is “on”.
Check for power, Fireye base,120VAC at Term 4if not, Fireye is defective
If power, 120VAC at Fireye base term 4 then FUEL CONVERSIONswitch is defective or set to off or oil
Viewed from the rear sightglass you can see the �ame ofthe gas pilot at 10 o’clock ifno pilot:
No Spark
Spark butno Gas
Check 6,000VAC ignition transformer
Check ignition electrode setting
Flame fail MTFI
Open
Close
Interlock orAir Flow
Flame fail PTFIContinued from Pg 1
Lockout CodesContinued from
Page 1
False Flame
False Flame Auto
Line FrequencyNoise
Cleveland air pressure, switch (blower air pressure) is open Term A1 to A2 - Pneumatic tubeobstructed with dirt-defective pressure switch
Cleveland air pressure, switch (blower air pressure) is closed when burner blower is offTerm A1 to A2 closed - Defective pressure switch
Flame present - fuel valves not closed
No �ame, scanner or ampli�er defective- False �ame
Loss of �ame when the burner modulates to high �re (5 sec.) on the HY 200 LO-HI-LO heater. Low manifoldgas pressure; low fuel oil pressure, low oil pressure
AC supply line voltage erratic or line spikes
Fault Unknown Fault was lost due to loss of voltage or line noise; fault is held for 15 seconds
AC supply line voltage erratic or line spikesAmpli�er CountFail
Chassis Opto Circuits that monitor faults in the Fireye are defective; replace chassis
Flame Fail AutoLoss of �ame when the burner modulates to high �re (5 sec) on the HY 200 lo-hi-lo heater. (Gas) low fuelpressure, or low main �ame pressure. (Oil) fuel pressure low or air damper opening slow.
Check Chassis Voltage on term 3 & 4 at improper time; watch dog relay bad on chassis; replace chassis
Check Programmer Programmer on Fireye; chassis on programmer defective; voltage term 5 at improper time - check fuel valvewing; replace program/ chassis
Check Ampli�er Ampli�er module in Fireye inoperative - voltage to S1 & S2 should be 570vac; replace ampli�er
Ampli�er AutoCheck
Flame signal too high (use ori�ce to reduce �ame signal) or internal ampli�er diagnostic failure. Used onself checking scanners to detect self existing scanners.
Check BlownFuse
Circuits for terminals 3, 4 & 5 are protected by a fuse on the Fireye chassis; fuel valves, on ignitiontransformer over current
Check ScannerDetected �ame signal during the shutter closed period of the 45UV5 - 1009 scanner - faulty tube orshutter; replace scanner
Check for 8 ounces (or 13.7 inches W.C.) gaspressure to burner manifold. If pressureis incorrect, adjust supply regulator
Check for 3 inches W.C. pressure at pilot test port.If no pressure, pilot gas regulator is bad orpilot solenoid is defective
Check �ame signal at main �ame. Does it rise slowly or quickly as the burner lights? A slow signal strength mayindicate that the �ame scanner port is partially obstructed. Observe �ame as burner goes to main �ame. The �ameshape may be distorted or too small for the scanner to see. Pressure at main �re test port ~2.9 in W.C. (GAS) or300 PSI fuel oil at gauge.
PRODUCT SUPPORT
45
Training investmentYields Huge returns
Gencor University Training center
TrAINING
46
Year after year, customers tell us that Gencor University provides the best course curriculum and hands-on training program, bar none.
The same course materials used to train our own service technicians are also shared with your plant operators and superintendents. At our Orlando headquarters, your team members will benefit from the industry’s most advanced training facility, including the largest assemblage of real equipment that creates the optimum learning experience. Ask anyone in the industry who has attended; nothing even comes close.
You‘ll see how investing a little in Gencor University training saves a lot for years to come. You can expect improvements in plant efficiency, production, availability, technology application, diagnostic capabilities and maintenance practices. As a direct result, you’ll also experience decreases in maintenance, repair and parts costs, and production-robbing emergency shutdowns and unscheduled downtime for repairs.
training philosophyYears ago, Gencor adopted the philosophy that providing “self-help” through training is the most efficient way to address plant-downs. Quite simply, experience has taught us that well-trained plant personnel can respond more quickly and efficiently, even if a Gencor service technician is located nearby. In the process, we also learned that in-depth training made better, more confident operators who are much less dependent on the expensive service calls that some competitors seem to prefer.
on-call help 24/7You can always count on Gencor’s 24/7 telephone help-desk to provide technical support for both electrical and mechanical problems. All calls are routed to a qualified expert who will handle your particular problem. Most diagnostics, programming and software changes can be made remotely via Internet connection with our exclusive Ultralogiks network. If you need a field service technician, one will be dispatched immediately. Simply call 407-290-6000.
proven curriculumDuring an intensive 5-day, hands-on training program, Gencor experts systematically take students through all the areas of the plant that assure optimal efficiency and proper operation. Your team will learn important tips related to HMA and WMA production and the potential
for increased utilization of RAP and RAS. It’s your opportunity to listen and learn from the experts through the use of control simulators and live equipment demonstrations with hands-on student participation. All classes are held at the Gencor University Training Center. Class sizes are limited to assure maximum interaction with instructors and provide one-on-one discussion time related to each student’s experience level and responsibilities. Courses include:
• PlantOperation&Maintenance
• PlantControls
• CombustionTesting&Training
• Thermal-Fluid-SystemsTraining
• Exhaust-SystemOperation
• ElectricalSchematics
• LoadCells
• Variable-SpeedDrives
• TroubleshootingTechniques
Customized Workshops – 2-day and 3-day custom training courses are also available on your site at any time. Our professional trainers will conduct a training workshop tailored to your priorities including:
• DryerOperation&Maintenance
• PlantControls
• CombustionTesting&Training
• Thermal-Fluid-SystemsTraining
• Exhaust-SystemOperation
• Variable-SpeedDrives
training classesAchieve your production goals, reduce your costs and maximize your ROI by making sure key members of your team are well trained. Gencor University basic and advanced classes are scheduled each year during January and February in Orlando. Check Gencor.com for the latest schedules or call 407-290-6000 to discuss the best approach to meeting your particular on-site training needs. Based on the advanced knowledge and expertise your team will gain in the science and technology of hot mix asphalt production, you’ll be ready to conquer any challenge!
Training investment
TrAINING
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5201 North Orange Blossom TrailOrlando, Florida 32810
(407) 290-6000gencor.com
