Aggregates Manager Digital Magazine
Issue link: http://read.dmtmag.com/i/718149
Preparing for Winter OPERATIONS Winter P reparing a plant to shut down for the winter really falls under the larger um- brella of "winterizing" — whether for shutdown or to operate through the winter season. "Our shutdowns in the northern regions might be only for a few weeks, and many of our plants operate year- round," says Trent Carney, Rogers Group Inc.'s area production man- ager for Indiana. "For those plants that we do shut down, we want to make sure our winterization leaves open the possibility to produce if we need to." That said, Carney explains that preparations for winter begin as early as August or September, when the company looks at long-term weather forecasts, production needs, and inventory. "We look at what kind of winter is expected. Will we need snow removal? Is it expected to be wet and rainy? We talk on a regular basis, planning a shutdown date and working toward that. From a cost standpoint, we want to make sure we produce each day that we have planned to produce." Wade Lippert, fi eld service repre- sentative for Kolberg-Pioneer, Inc., says the primary villain every plant battles in the winter is moisture. "Freezing liquid is freezing liquid — and it all is bad for a plant. And moisture in components will create rust over time, which can damage everything from bolts and fasteners to gear teeth, bearings, shafts, and other parts — leading to malfunction or failure, as well as safety issues," he says. What is the answer? Lubrication is a producer's best friend, notes Patrick McGuire, service manager for Johnson Crushers International, Inc. Bearings must be purged and cleaned, then fully greased to keep moisture out. Screens require lubri- cation of the wheel case to make sure there is no moisture. "In short, grease everything you can grease, " he says. Both McGuire and Lippert em- phasize the importance of using the correct, factory-recommended lubricants. "Our engineering depart- ment spends a lot of time research- ing oils and grease so that we can recommend for specifi c pieces of equipment and specifi c applications," Lippert says. "Our operating manuals provide all of the information you will need as to what lubricants are recommended." For washing equipment, the key is to completely drain everything. "Make sure there is no standing wa- ter in lines or pipes or it will freeze and they'll break, creating downtime and lost revenue later," McGuire says. "Blow out lines and pipes with dry air and then fi ll with antifreeze, if applicable. And clean everything. Properly cleaning the plant will remove buildup that can harbor moisture, leading to rust." AGGREGATES MANAGER Water — when it freezes — can break steel; ruin hy- draulic, air, and water lines; and damage fuel. For wet processing equipment, most care revolves around com- pletely draining what is possible to drain. It is import- ant that the ability to drain the equipment is designed from the start to be convenient, so that it will be done. Automatic pressurized drains are a benefi t. Prepare for winter by injecting air and antifreeze into lines and pipes to reduce condensation and resist freezing. With more operations choosing to produce through during the winter months than in the past, traditional, months-long winter shutdowns are not as prevalent as they once were. That said, producers in northern states and providences still may choose to shut down for a matter of several weeks. The down period provides opportunity for them to handle scheduled maintenance on equipment. Planning begins in August or September. Shutdown considerations Wet processing plan 1 4