TFL5785 LA County

TFL5785 LA CountyE&I Training

When not logged in, the home screen will display various information for the operator.

Logging in from this screen will allow advanced Maintenance and Engineering Functions to become available for the user of the HMI.

The Login button is on the bottom left.

Pressing on this button will bring up an input window to type the username and password.

When not logged in, the home screen will display various information for the operator.

Logging in from this screen will allow advanced Maintenance and Engineering Functions to become available for the user of the HMI.

The Login button is on the bottom left.

Pressing on this button will bring up an input window to type the username and password.Login Button

For the purposes of this training, I will Login using the Engineer username and password. Your trainer will provide you with the Engineer and Maintenance Usernames and passwords for on-site training.

Having pressed the Login button on the home screen, the keyboard pops up, allowing entry of the username.

Press the Enter key after typing the username.

Enter Key

Typing the password will show a series of #### hashes to mask the password.

Once the correct password is entered, press the enter key again, and the user will be logged in.

Enter Key

The current user code is displayed at the top right hand side of the screen, next to the date and time.

Engineer is currently logged in.

We will begin exploring the HMI through the menu buttons along the bottom of the screen.

The Login button has already been explained, so we will continue with the Startup Sequence.

This screen is where the operator will initiate the start sequence to run the dryer. If all of the drives were in Auto, there would be a visible Start button at the top of this screen.

However, as indicated by the ALL AUTO indication light not being illuminated, the system is not ready to be started due to one of the drives not in automatic mode.

The operator would be required at this point to investigate the other screens to determine which drive is not in auto.

Continuing with the bottom row of buttons, this is the Shutdown Sequence screen.

All of the values listed on this screen are dynamic, and are based on the values in the Auto Control Setpoints screen that is accessible from one of two ways.

The first way is from the Maintenance Menu, which we will discuss shortly. The second way to access the Auto Control Setpoints screen is to press anywhere within the outline box as shown on the next slide.

This area (on both the Startup and Shutdown Sequence Screens) will open the Auto Control Setpoints Screen.

This area of the screen is a hidden goto screen button, which when pressed will allow the operator to change the variables that are shown on this screen.

The Finish Temp, Dryer Off Temp, All TCs < Temp, and the TFH Pump Off Temp, as well as the timers are located on the Auto Control Setpoints Screen.

These values are described in further detail for the Operator Training.

The next screen along the bottom row of menu buttons is the Alarm History Screen.

This screen will display a historical list of the Faults or Warnings that have been active since the last time the HMI was Reset.

This information is not retentive through a Reset.

Faults are displayed in Red with White lettering

Warnings are displayed in Yellow with Black lettering.

*The SPARE Faults have been corrected since the last reset to show actual information.*

The Active Alarms screen will display the currently active Fault or Warning, until the fault or warning has been corrected and the Alarm Reset button has been pressed.

For instance, if the rotor wipe angle is exceeded, the Absolute Wipe Angle Fault #320 will be displayed until the rotors are realigned manually on the encoders screen, placed back in Program control, then the Alarm Reset button is pressed.

Until the fault or warning condition is alleviated, the Alarm cannot be reset.

Finally, the Maintenance Menu.

This is where the manual manipulation of the machine will occur.

From these menus, you will be able to move VFDs, control various functions of the dryer, and see the status of all of the inputs and outputs.

Hopefully you will not need to be in this section very often, but if you do find yourself needing dive deeper into the system, the following slides will describe the information you can find.

For E&I Training, lets being with the top row of menu buttons. These menus allow you to access Inputs& Outputs, the Encoders for the Dual Rotors, and the Remote Feed-In and Remote Discharge System.

I will go into more detail about the first two buttons in this part of the training, and then the Remote Feed-In and Discharge a little later in the training when I describe the information from the home screen in more detail.

On this screen, the analog and digital inputs and outputs are displayed.

When this screenshot was taken, the value for the Oxygen Analyzer Oxygen Level (AIT-15014A) is showing to be in an alarm state.

Pushing on the faceplate for AIT-15014A will display more information.

The faceplate opens to reveal that the High Limit of the Oxygen Analyzer is 9.00 and the High High limit is 13.00 .

When the faceplate was clicked, the value was in the High range, between 9.00 and 12.99, and now that the faceplate is open, we can see that the High High level has been reached.

Clicking on the Alarm reset button will acknowledge this alarm.

As the faceplate values for this alarm are not used specifically throughout the PLC program, these values will not show warning or fault. The oxygen analyzer screen on another page will show more information.

Reset

The next button on the top row of the maintenance screen shows the Encoders screen.

From this screen, an operator can recover from a fault that involves the rotor encoder, such as FAULT #320 ZA-110 Absolute Rotor Wiping Error Too Great.

Faults such as this one will stop the rotors, and the operator will have to manually re-align them to within 10.

Using the Dryer Left Screw / Dryer Right Screw faceplates, the operator can manually jog or run the dryer rotors.

Pressing on the Dryer Left Screw faceplate brings up the left rotor VFD faceplate.

This rotor is in operation and running in Program mode.

On another screen, I will show how to release program mode, enter into operator mode, and run or jog a VFD.

Both of the faceplates can be brought up together on this screen.

This can assist if both rotors need to be jogged.

This is the only screen on the HMI that the faceplate will open in a location other than the top left corner of the screen.

As mentioned earlier, I will go into further detail about the Remote Feed-In and Remote Discharge System screens when I discuss the information on the Home Screen.

At this time, I will discuss the Ancillary Equipment buttons including the Oxygen Sensor, Rock Mode, and Ancillary Alarms.

The Log Sheet button contains information that we record during Commissioning and Performance Testing. This page can be incorporated into your Operations if you would like.

The Oxygen Analyzer screen will allow you to place the oxygen sensor into Maintenance Mode for cleaning operations.

When the oxygen analyzer is placed into Maintenance Mode, the shutdown faults will not be active.

Care MUST be used when operating the dryer with the Oxygen Sensor in maintenance mode, as increased levels of oxygen can lead to material or dust becoming flammable inside of the dryer.

The fault and warning levels are input on the Ancillary Alarms screen, which will be shown shortly.

The Automatic Rock Mode screen provides information as well as settings for the Automatic Rock Mode.

Rock mode, when placed in auto will engage for a number of reasons including:Discharge Screws high average currentLodor Faults involving BOTH LodorsLow Discharge TemperatureSome of these faults will initiate the delay timer, such as the discharge temp. Other faults such as both lodors faulted will immediately initiate the rock mode.

Rock mode can be operator started with the Manual pushbutton.

The ancillary alarms provide inputs for the oxygen analyzer as well as the times for the alarms to engage on the LODORS.

There is VERY little chance that you will need to change any of these values.

If one of Therma-Flite application or process engineers determines that these values need to be changed, we will instruct you as to when and how to change the values.

The log sheet shows various values that we use during our Commissioning and Performance testing.

Many different values are shown on this screen that can be found on the screens throughout the HMI.

If you would like to incorporate these data points into your operator procedures, the operator can find these data points here.

I will not go over all of the Trends pages here.

These are pretty self explanatory.

They are trends for either temperatures or current.

If you believe that you are having an issue with one of the devices, you can watch the trends on these screens to see anomalies.

The Drive Controls section of the Maintenance Menu shows various major components of the dryer system.

This is where these major components can be manipulated.

The Auto Control Setpoints screen is where an operator will input the parameters for startup and shutdown.

These parameters have been set during the commissioning and performance testing of the dryer.

The operator should not need to change these settings unless the incoming material changes significantly.

If a Therma-Flite applications or process engineer determines that these values should be changes, we will provide instructions on when and how to change these values.

From the Auto Control Setpoints screen, or from the Maintenance Menu, the Stepping Startup Settings page can be accessed.

These set points show how the heater will step through various temperatures with various Dwell times in order to allow the thermal fluid heater to heat to the final temperature setpoint correctly.

As the Heater steps through the temperature setpoints, the Dwell timers will count down to the next temperature setting.

Once the final temperature setpoint is reached, the Yokagowa temperature controller will maintain the final temperature through their PID controller.

The Drive Alarm Setpoints screen shows the value of the high and low current faults that are reported by the VFDs. While these values can be changed, doing so can lead to damage of the drive motors.

The VFDs report the Full Load Amperages (FLA) which are then translated into various timed alarms in the PLC.

The Rolling 60-seconds averages show the current of the drives, averaged out for the last minute. If any of these values exceed (20%), the dryer will enter rock mode and all downstream drives will clear out any built up material.

The VFD Faceplates screen allows the operator or maintenance personnel to manually control the various drives. Drives can be placed into operator control, run forward or reverse, or jogged, depending on the situation or the need.

This screen also shows if the VFD is blocked due to an Interlock or Permissive failure. On this screen, the Discharge Conveyor is stopped due to a permissive.

Clicking on the Discharge Conveyor icon, the faceplate opens, showing that the Forward Permissive is preventing the drive from starting.

Clicking on the Forward Permissive icon shows the reason that the drive is being stopped.

The current reason that the Discharge Conveyor is stopped is because the Knife Gate is not opened.

If the Knife Gate were to be opened, then this permissive would be met, and the drive could be operated.

Due to the significant risk of immediate and irreparable damage that can occur from running the discharge conveyor with the knife gate closed, this permissive cannot be bypassed.

The Cooling Conveyor; however, is not being stopped by a permissive or interlock and can be manually operated.

If you need to manually operate this drive, place the drive into Operator Mode by pressing on the Operator Mode icon.

The green highlighted arrow is the run button while the yellow highlighted arrow is the jog button.

Pressing these buttons will move the drive forward either continuously until the stop button is pressed (if run is used) or until the button is released (if jog is used).

Pressing the computer icon places the drive back into Program mode.

Each time a drive is manipulated manually, it SHALL be placed back into program mode after the manual operations are completed.

The Dual Screw Control screen provides a lot of information on how the dryer rotors are performing. This is a valuable troubleshooting tool if you are experiencing faults such as High Current or Rotor Encoder Faults.

As the rotors are operational, the information needed to troubleshoot the drives can be gleaned by observing the values on this screen.

There is a lot of information on this screen, so time should be spent learning how the information is presented to you here.

The Discharge Control Screen allows the operator to control the Discharge Screws in operator or program mode. Typically, this will ALWAYS be set to PROGRAM mode. The only time that this should be changed to Operator control is after a catastrophic un-recoverable error that the operator must completely evacuate the dryer outside of sequential operation.

The Plug Level Tuning can be used if the discharge temperature gets too hot, or if the discharge amperages increase too high.

The Feed Control screen will allow the operator to input the feed setpoint for automatic operations. This screen, like the discharge control screen will mostly remain in PROGRAM mode.

There is not a lot of interaction that an operator will have with this screen on a daily basis.

The pressure control screen on the TFL5785 LA County dryer will also not be used very frequently. As the pressure is controlled through the manual manipulation of the valve between the dryer and the bio-remediation tanks, there will not be much operator interaction with this screen.

If the valve gets changed to an automatically controlled butterfly type valve, this is where the pressure Control Variable (Cv) for the Pressure PID will be input.

The Transfer / Distribution Control screen may be used more by the operators than the other control screens. This screen is the interaction with the LODOR PLC, and provides information on how the LODOR PLC is presenting information to the dryer PLC.

This is also the screen that will allow for the use of the Dust Control Filters, should they be required at a later time.

Pressing on the Indications for the Dust Control will initiate Dust Control Logic in the Dryer PLC.

Pressing the Indicators again will ignore all Dust Control Logic in the Dryer PLC.

If the indications are Red/Green, then the Dust Control Logic in the Dryer PLC is ACTIVE

If the indicators are Yellow, then the Dust Control Logic in the Dryer PLC is INACTIVE.

Pressing the Operator button on the Left side of the screen will open the menus to start and stop the transfer or distribution screws if needed.

This is very similar to the VFD Drives Faceplate screen, just another way to manually manipulate the drives.

Back to the Home screen, there are four other screens that can be accessed for information, manipulation, or data retrieval.

From the Home screen, the Storage and Feed-In screen, the Dry Product Conveyance and Discharge screen, the Bio-Solids Dryer and Condenser screen, and the Thermal Fluid Supply screens can be opened.

Each screen is opened by pressing the appropriately labeled button above the column displaying information about that component of the system. We will start with Storage and Feed System

The only input on this screen is the Hopper Screws Speed Percentage. This input field determines the speed of the live bottom rotors in the hopper as a percentage of the feed pump speed. If the feed pump were pumping at 100% speed, the hopper live bottom rotors would be moving at 35% speed, and so forth.

On this screen, we can see that the Pressure Transducer on the Feed Pump is showing a fault. Touching this faceplate will bring up more information about the fault.

The Feed Pump Pressure Transducer low pressure warning is set to 20 PSI and the Low Low Fault is set to 15 PSI.

As the system is not currently in operation, these alarms are not active.

If the system were in operation, and material was being processed, this fault would register on the HMI Active Alarms screen.

The Discharge System (Dry Product Conveyance and Discharge) screen shows a visual representation of the discharge system. A lot of information can be compiled from this screen. The discharge motor is currently stopped due to a permissive or interlock, the water flow value is in a Low Low state, the Distribution Conveyor motor is stopped due to permissive or interlock, and F-165 Dust Filter is showing to be in a fault. As this programming is ignored, there are no further faults or warnings based on F-165 Fault.

Next, we will see how the interlock and permissives work for the discharge conveyor.

Touching the faceplate for the Knife Gate KGV-162, the operator is able to place this valve in Operator Control, and subsequently manipulate the position of the Knife Gate.

In order to move the discharge screw, the Knife Gate Shall be OPEN.

The Discharge Conveyor is interlocked and permissive upon the Knife Gate open status, as well as a list of other statuses.

When the Knife Gate is OPEN, the permissive is met, and the Discharge Screw can turn on .

The Dryer Screen shows information about the temperatures through the dryer, the water solenoid valves, the nitrogen solenoid valve, the forward and reverse rotation of the dryer rotors, the amperages of the dryer rotors, the compliance and retention times, and the statuses of the Lower and Upper Level Switches.

Opening the LSH-11013 Level Switch High faceplate, you can see how to manually set the value of the switch if needed.

If this switch fails, and the operator is attempting to maintain a product plug in the dryer, this value can be manipulated until the dryer is emptied and maintenance can be performed on the switch.

With the LSH-11013 faceplate opened, the substitute PV button can be pressed, then the desired PV can be pressed to either indicate that the upper level switch is manually active or manually inactive.

An ON value on this faceplate would indicate that material is present at the upper level switch.

The Thermal Fluid Heater screen allows the operator to manually turn on or off the thermal fluid heater, the recirculation pump, the burner, and the modulation enable signals.

The Modulation signal is the temperature at which the Thermal Fluid Heater will release Low Flame and be allowed to modulate the burner to maintain a temperature setpoint.

The TFH Remote Start/Stop, Burner Start/Stop, and Modulate Enable are all MAINTAINED outputs. The Circulation Pump Start and Circulation Pump Stop outputs are MOMENTARY or Pulsed.

For any of the faceplates that expressly say that the output is Pulsed, use the Pulse ON icon within the faceplate:

Otherwise, to turn on the Maintained output, use the ON icon within the faceplate:

If a maintained output is on, and you need to turn it off, use the OFF icon within the faceplate:

Conclusion

The HMI is full of useful information. Knowing where to find the information is key to operating the dryer.

Please feel free to browse through the HMI screens and familiarize yourself with the location of the information.

If you have any questions, please do not hesitate to call! 707-747-5949