Sand Drying Plant: Instruction Manual

Sand drying plant
YPF
Instruction manual
Year of construction: 2014
As at: 03/2016
Version: 02
Processed by: Th. Zanner
ALLGAIER
Process Technology GmbH
Adolf-Safft-Strasse 10
D-73037 Göppingen
Tel. +49 (0) 71 61 / 3 01-1 01
Fax: +49 (0) 71 61 / 3 01-50 35
YPF
Drying plant for sand
Table of Contents
1 NOTICE TO THE USER 4
2 NOTES ON SAFETY 5
2.1 FUNDAMENTAL SAFETY INSTRUCTIONS 6
3 OPERATING THE MACHINE 8
3.1 SWITCHING ON THE PLANT 8

3.2 MAIN MENU 9
3.2.1 Password levels .................................................................................................... 10
4 MENU STRUCTURES 11
4.1 MENU STRUCTURE “CONTROL SYSTEM” 11

4.2 MENU STRUCTURE “PARAMETER” 12
5 OPERATION MODES 13
5.1 CONTROL ON/OFF 14

5.2 MAINTENANCE MODE 14
5.3 PLANT OPERATION MODES 15
5.3.1 Manual / automatic ............................................................................................... 16
5.3.2 Automatic start/stop ............................................................................................. 16
5.3.3 Remote control ..................................................................................................... 17
5.3.4 Bypass burner ....................................................................................................... 17
5.3.5 Material way selection .......................................................................................... 17
5.4 GENERAL FUNCTIONS 18
5.5 PLANT STATUS 19
5.6 CHOICE OF OPERATION MODES 20
5.6.1 Manual operation.................................................................................................. 20
5.6.2 Automatic operation of the plant .......................................................................... 21
5.6.3 On site operation .................................................................................................. 21
5.6.4 S-BE-602 Auxiliary drive .................................................................................... 21
6 PARAMETER 22
6.1 PARAMETER 1 - GENERAL 23

6.2 PARAMETER 2 - LIMITS 24
6.3 PARAMETER 3 - TURN ON AND TURN OFF TIME 25
6.4 PARAMETER 3 - STANDARDISATION MEASUREMENT SIGNALS 26
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7 CONTROL SYSTEMS 27
7.1 CONTROL SYSTEM PIC101 27

7.1.1 Controller parameter............................................................................................. 29
7.2 CONTROL SYSTEM TICA+301 30
7.3 CONTROL SYSTEM D-FC-510 / D-FC-520 32
7.3.2 Operating method D-FC-5x0................................................................................ 34
7.3.3 Regulation set point wet material supply ............................................................. 34
8 OPERATING HOURS 35
9 PID 36
10 PASSWORD MANAGEMENT 37
11 FAULT DISPLAY AND TROUBLESHOOTING 38
11.1 ACTUAL FAULTS 38

11.2 ARCHIVE – FAULTS 39
11.3 ARCHIVE – WARNINGS 40
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1 Notice to the user
This instruction manual contains important information on how to operate the drying plant safely and
professionally.
Proper operation and maintenance prevents problems and enables efficient use of the plant.
Every person who is involved in setting up, starting up, operating, maintaining or repairing the machine
must be appropriately qualified and must comply with the instructions in this manual.
In addition to this instruction manual itself, recognised rules and country-specific regulations about
working safely and professionally as well as handling machinery must also be observed.
General and basic control elements are described in the main section. Customer-specific operation,
equipment, parameter values and an overview of the location of sub-elements are presented in the
corresponding chapters.
Despite the great care with which this instruction manual was compiled, errors cannot be entirely ruled
out.
We would like to thank you in advance for any suggestions you may have to improve this manual.
Allgaier Process Technology GmbH
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2 Notes on safety
The drying plant is fitted with various safety devices and has undergone extensive safety tests and
acceptance inspections.
Despite all precautions, however, operating mistakes, misuse, unprofessional handling or inattentiveness
may result in a risk to life and limb for the operator or other people, and may also cause damage to the
plant or other property.
To highlight particular sources of danger the following symbols are used in this manual:
Danger!
Information and alerts regarding particular sources of danger to prevent injury or serious damage to
property
Caution!
Information and alerts regarding a potentially dangerous situation that might result in injury or damage to
property
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2.1 Fundamental safety instructions
Maintenance and repair work

As a general rule, skilled and instructed staff must be present during maintenance and repair work. These
persons must, in particular, ensure the following:
the emergency stop button must be activated (emergency stop circuit interrupted)
the main switch on the switch cabinet must be set to “0”
the main switch must be padlocked to secure it against being

unintentionally switched on again. The key must be carried by the
servicing staff.
Caution!
Some parts in the switch cabinet remain live even when the main switch has been turned off. Information
on this can be obtained from the circuit diagram and from labels in the switch cabinet.
Approved operating personnel

Only authorised persons are permitted to stand next to the drying plant and work on it. The operator is
responsible for the safety of third persons in his/her working area.
The operating personnel must have read the instruction manual and must observe the safety instructions
before starting work.
The responsibilities for the different activities involving the machine must be defined clearly and upheld.
Unclear competences are a safety risk!
Changes and conversions

Unauthorised changes to the plant and components, as well as to software, may jeopardise the function
and safety of the plant. The declaration of conformity will lapse if unauthorised changes are made.
Caution!
Access routes in, under and next to the plant must not be blocked and must be kept free of bulky and
slippery substances.
The operator must ensure that the area surrounding the plant is clean and organised at all times.
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Workstations on the machine
All workstations on the machine must be outside the protection zone. The machine is operated using the
individual terminals. Details of the location of these terminals, as well as fitted controls, can be found in
the installation drawing.
Safety equipment
Safety devices on the machine must not be modified or removed without authorisation. They must not be
climbed over or covered.
Unprotected areas that are not normally accessible on account of their location must not be made
accessible with the help of ladders, platforms or other structural changes.
Behaviour in an emergency
In an emergency, the plant must be stopped immediately using the emergency stop and, if necessary,
medical help must be sought in line with existing company instructions.
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3 Operating the machine

The plant is operated using the Siemens MP277 operator terminal or the PC station. Manual operation, automatic
operation, display of operational statuses and measured values, issue of fault messages and input of operating
parameters are all executed via the operator terminal or the PC station.
3.1 Switching on the plant
After switching on the plant, the start screen appears on the display. It is possible to jump from here to the main
menu.
The languages can also be selected in this mask. This screen and all other screens will then be displayed in this
language. The languages available are German, English and Spanish.
Exit Runtime
Language switching Link to main menu

German / English / Spanish
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3.2 Main menu
From the main menu, the required function screen is called by pressing the corresponding buttons on the display.
To prevent unauthorised access, screens are partly protected with passwords of different levels.
Passwort level 1
Operator
Passwort level 2
Administrator
Passwort level 2
Administrator
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3.2.1 Password levels
Once a field of set points / parameters or a branch image button is pressed with password protection, the
following login window will appear.
Here you must enter a user name and a password. The entries must be subsequently confirmed with the "OK"
button. A successfully login releases the entry fields and buttons.
Level 1 – Operator
This level gives permission to change normal production set points of the plant.
At this password level it is not possible to adjust parameters or operate system functions.
Level 2 – Administrator
In addition to the functions of level 1, all the parameters of the plant (limit values, times, controller parameters,
recipe data etc.) can be adjusted and system functions executed at level 2.
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4 Menu structures
4.1 Menu structure “Control System”
Menu
Control System
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4.2 Menu structure “Parameter”
Menu
Parameter
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Operating
Mode
5 Operation modes
Operating elements and possible status displays on this “operation mode” screen are described below.
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5.1 Control on/off

The control system is switched on and off using the two buttons depicted below. All the other functions of the
plant are only released for operation if the control system is switched on.
Control on button Control off button
If the plant's control system has been switched on or off, this will be displayed via the colour of the name box.
control on locked
The plant’s control system cannot be switched on. This may be because the main switch is off, the control circuit
fuse (24V=/230V~) has blown or the emergency stop button has been activated.
control off
The plant’s control system is switched off, but can be switched on by pressing the button.
control on
The plant’s control system is switched on, but can be switched off by pressing the button.
The plant is ready for operation and can be controlled in both manual and automatic mode.
5.2 Maintenance mode

Press the button “SERVICE MODE” to switch to “maintenance mode” (only with password – level 1).
In maintenance mode, it is possible to operate individual components without observing the relevant interlocks
for switching on and off.
This function should only be operated by trained personnel because unprofessional operation may result in
damage to the plant.
The operation mode is indicated by a corresponding colour status of the name box.
control off
The plant’s control system is switched off. The plant cannot be operated in maintenance mode.
maintenance mode off

The plant is in “manual mode”.
To switch to “maintenance mode”, press the „SERVICE MODE“ button and enter the relevant password.
maintenance mode locked

The plant is in “automatic mode”.
It is not possible to switch to maintenance mode.
maintenance mode on
The plant is in “maintenance mode” and can be operated without any interlocks.
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5.3 Plant operation modes
Material way
Selection
Operating elements and possible status displays on this “operation mode” screen are described below.
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5.3.1 Manual / automatic

Press the Button „Operating mode“ (manual/automatic) button to switch to the mode required.
In manual mode, it is possible to switch the components on in their correct starting sequence. The interlocks for
switching the plant on and off must be observed. It is, therefore, possible to run the plant up in manual mode and
also switch it off again without the control loops becoming active.
In automatic mode, the plant waits for a start command (automatic start) from the operator.
The operation modes are indicated by corresponding status displays.
control off
The plant’s control system is switched off. The plant cannot be operated in manual or automatic mode.
manual mode
The plant is in “manual mode”. The plant’s individual drives can be controlled manually on the corresponding
screens of the operator terminal. (see later in this manual)
manual – automatic locked

The plant is in “maintenance mode”. It is not possible to switch to automatic mode.
automatic mode
The plant is in “automatic mode”, but has not been started yet.
5.3.2 Automatic start/stop

Press the Button „Automatic“ (automatic start/stop) button to start or stop the plant in automatic mode.
This is indicated by a corresponding status display.
control off
autom. stop – start locked

The plant is in “manual mode”.
It cannot be started.
autom. stop – start released

The plant is in “automatic mode”.
It can be started by pressing the Automatic button
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autom. stop – automatic start locked

The plant is in “automatic mode”. It is not possible to start the automatic.
automatic startet
The plant is in “automatic mode” and has been started.
5.3.3 Remote control

With the Button „remote control“ you can choose, if the scada-system has the permission to operate the drying
plant or not (only with password – level 1).
5.3.4 Bypass burner

For testing the drying plant with dry sand you have the possibility to bypass the burner. In this case you can use
the whole plant in automatic mode without any start signal for the burner (only with password – level 2)..
5.3.5 Material way selection
In this part of the screen you select the way of the material through the classification plant.
Here it’s possible to select the filling of the bunker S-FH-610 / S-FH-620 as well as the working way of each
material flap after the screening machines.
Furthermore the classification plant is divided in 7 product lines of each screening machine.
Over the selection buttons you can choose with which and with how many screening machines you want to
produce.
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5.4 General functions
Selection of Material way
turn drives on/off in manual mode
turn drives on/off in manual mode with setpoint
Link buttons
Previous page / Next page / Jump back one menu level
Reset faults using “fault reset”
Call interrupt list

Press this button to jump to the “faults” screen. If there is a fault message, the button displayed here changes
colour from green to orange or red.
Reset horn using “horn reset”
Plant overview (PID)
User log off
Display field – no input possible !!!
Input field
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5.5 Plant status
control off
manual mode activ

The plant is in manual mode. The drives can be switched on and off manually in line with the interlocks. Used in
conjunction with “maintenance mode”, the plant’s interlocks are largely cancelled.
Caution: unprofessional operation may cause damage to the plant!!!
automatic – start locked

The plant is in automatic mode. However, it cannot be started because not all the start conditions have been met.
Start conditions: no plant faults !!!
automatic – start released

The plant is in automatic mode and can be started. All the start conditions have been met.
automatic – start-up phase

The plant was started in automatic mode – the drives are switched on in their correct sequence.
automatic – heat-up phase

The burner has started. The plant is heated up over a present period of time. Once this time has expired, the start
of the dryer is released.
automatic – start product supply

All the plant’s drives are running.
The product supply must be activated manually once, while running up the plant, by pressing the button product
start/stop at automatic mode”.
Should any faults occur and the product feed fails, this procedure will not be needed again. The product feed will
restart automatically once the fault has been remedied.
automatic – product supply selected

The plant is in automatic mode – the product supply has been released but is not yet in operation.
automatic – product supply run

The plant is in automatic mode – all drives including the product supply and the conveyor belt hopper are
running. The plant is in production.
automatic stop – plant shut down

The plant was stopped; the drives are disconnected in their correct stopping sequence.
accumulation fault
There is at least one fault. Further information on fault messages to be dealt with can be found in the interrupt
list.
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5.6 Choice of operation modes

The operator has the following operation modes at his/her disposal for the plant: manual, automatic and
maintenance. The manual and automatic modes have been released if this is indicated in the right corner of the
screen (operation modes) by the corresponding plant status.
The manual mode enables manual operation of the plant.

In automatic mode, the plant is started according to the start-up programme. If automatic mode is stopped, the
plant is “run down” according to the shutdown programme.
Switching back from automatic to manual or maintenance mode triggers the immediate disconnection of all
components.
If an emergency stop button is activated, or the control system is switched off, all drives currently in operation
are disconnected immediately.
5.6.1 Manual operation

The manual mode makes it possible to set components running in their correct starting sequence. The interlocks
for switching on and off must be observed. You can open the manual mode buttons by clicking on each symbol in
the “overview” screen. The drives are switched on and off by pressing the corresponding button in the menu of
the drive. The operational status of the individual drives is displayed in the colour of the symbol of each part.
The maintenance mode makes it possible to switch components on irrespective of their interlock in relation to
one another. Major interlocks, such as the operation of inlet and exhaust air fans when starting the burner are also
active in maintenance mode.
Manual operation over each

individual symbol
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5.6.2 Automatic operation of the plant

In automatic mode, press the “AUTOMATIC” button (automatic start/stop) to start the plant up in the correct
starting sequence and in line with the delay times. If the button is pressed again, automatic operation stops and
the plant is shut down in the correct stopping sequence and in line with the delay times.
5.6.3 On site operation

For the drives S-SC-610, S-SC-611, S-SC612, S-SC-613, S-SC-620, S-SC-621, S-SC-622 and S-BE-602 you
have the possibility to operate each drive over 2 buttons on site.
Drive start / stop in local
Remote
Off
Local
With the selection button you can decide, if each individual drive can be operated over the HDMI (position
remote), stays off (position off) or can be operated on site over the start/stop button (position local).
The operation over the start / stop button is only possible in manual or maintenance mode.
To run the individual drive in automatic mode, the selection button must be in remote position.
The Positon of the selection button is also shown in the PID of the HDMI
Position selection
button
5.6.4 S-BE-602 Auxiliary drive

For maintenance purposes the bucket elevator is equipped with an auxiliary drive. To run the elevator with this
drive you need to activate it at the PID-screen.
If the auxiliary drive is active, you can operate it over the normal icon operation of the symbol from the auxiliary
drive. Also the on-site operation of the S-BE-602 is switched to the auxiliary drive if it is active.
The activation of the auxiliary drive is only possible in maintenance mode.
Auxiliary drive on / off
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6 Parameter
Links to the individual parameter

screens
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6.1 Parameter 1 - general
On this page you can adjust the power of each drive with fixed speed, the delay times for switching off the
automatic according to special faults and the delay times for the skew controls.
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6.2 Parameter 2 - limits
On this page you can adjust all limit values for temperatures, pressures, levels measuring and digital
measurements with the associated delays.
Limit explanation:
If the measuring signal falls below the set min limit value, a warning is issued.
If the measuring signal falls below the set min/min limit value, a fault message is issued, and the shutdowns occur
after the lock list.
If the measuring signal exceeds the set max limit value, a warning is issued.
If the measuring signal exceeds the set max/max limit value, a fault message is issued, and the shutdowns occur
after the lock list.
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6.3 Parameter 3 - Turn on and turn off time
On this page you can adjust the time delays from the automatic start and stop sequence of each individual drive.
The start delays become effective when starting up the plant in automatic, while the stop delays take effect when
shutting down the plant in automatic.
Also the pulse time and pause time of the individual vibration drive can be specified.
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6.4 Parameter 3 - Standardisation Measurement Signals
The measuring sensors at the drying plant deliver a standard signal of 4..20mA. This indicates what physical size
(e.g. mbar) corresponds to the value of 4 or 20mA.
For example:
If the plant has a built-in pressure sensor with a measuring range of
-50.0mbar to +50.0mbar, this corresponds to the following allocation
Lower limit 4mA -50.0mbar
Upper limit 20mA +50.0mbar
Furthermore you have the possibility to deactivate a broken sensor and set a replace value for the measurement
signal.
Also each rotary control sensor of every drive can be individually deactivated.
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7 Control Systems
7.1 Control System PIC101
Controller PIC101 / TICA+301
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The “pressure in the dryer PIC101” screen provides the complete regulation of the exhaust air fan D-FA-310.
In plant’s manual operating mode the single controller can be switched to automatic mode. The result is that the
controller regulates the set point. If the plant and the controller are in manual mode the set point „man.“ is used.
In plant’s automatic mode the controller is set to automatic mode, too. Manual controller mode is not available in
plant’s automatic mode.
The actual value and the min./max. control range is only for information on the main part of the screen. Changes
to the min. / max. control range and to the controller parameters can be made in the controller parameters
window.
Passwort level 1
Operator
Controller Actual value

Parameters
Change operating
mode
Manual operation
Exhaust fan
Actual control
value
Actual set point

Set point Exhaust
fan manual mode
Controller
Parameters
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7.1.1 Controller parameter
PID-Controller
Parameters
Release Auto:
When the plant goes in automatic,
Maximum you can decide if this controller
Set point goes also in automatic or works
with the manual set point
Minimum
Set point
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7.2 Control System TICA+301
Passwort level 1
Operator
Ramp
Parameters
ON / OFF
RAMP
Manual operation
Burner
Actual control
value
Ramp
Actual set point Parameters
For a better temperature regulation of the burner during the start-up phase it’s possible to activate a ramp
function for the set point of the temperature TICA+301.
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In the controller parameter of the ramp function you can adjust at which temperature the ramp starts and after
which time the ramp increases the set point to which value.
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7.3 Control System D-FC-510 / D-FC-520
Controller D-FC-510 / D-FC-520
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Passwort level 1
Operator
Ramp
Parameters
ON / OFF
RAMP
Manual operation
Exhaust fan
Actual control
value
Ramp
Actual set point Parameters
For a better regulation of the plant it’s possible to activate a ramp function for the two belt conveyors of the wet
material supply.
In the controller parameter of the ramp function you can adjust at which set point the ramp starts and after which
time the ramp increases the set point to which value.
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7.3.2 Operating method D-FC-5x0

In the control screen D-FC-510 / D-FC-520 it is possible to adjust, which belts in the bunker of the wet material
supply are active for the production.
Passwort level 1
Operator
7.3.3 Regulation set point wet material supply

For the amount of wet material supply through the dryer there is a function integrated, which calculates the set
point depending of the number of channels in operation (number of product lines).
Set point calculated = Set point total

Number channels in operation
Passwort level 1
Operator
Function
On / Off
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8 Operating hours
Passwort level 1
Operator
On this page it’s possible to control and reset the operating hours of each individual drive.
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9 PID
The PID-screen gives an overview of all important aggregates and values.

In manual mode it is possible to start each aggregate by pressing the corresponding symbol.
The colour of the frame around the symbol shows you the actual status of the aggregate.
Over the “Info-Button” you will get a description of the color legend.
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10 Password Management
This page gives the possibility to control the actual password and change the logoff time (only with password –
level 2).
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11 Fault display and troubleshooting
11.1 Actual Faults
Faults in the operating sequence are displayed in the faults list. Faults that have already been remedied are
deleted by pressing the (fault reset) button.
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11.2 Archive – Faults
This screen shows all alarms that occurred in the past (Export / Delete only with password – level 2).
Export list Delete list
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11.3 Archive – Warnings
This screen shows all warnings that occurred in the past (Export / Delete only with password – level 2).
Export list Delete list
Seite 40

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Sand drying plant

Year of construction: 2014

Processed by: Th. Zanner

1 NOTICE TO THE USER 4

2.1 FUNDAMENTAL SAFETY INSTRUCTIONS 6

3 OPERATING THE MACHINE 8

3.1 SWITCHING ON THE PLANT 8

4.1 MENU STRUCTURE “CONTROL SYSTEM” 11

5.1 CONTROL ON/OFF 14

6.1 PARAMETER 1 - GENERAL 23

7.1 CONTROL SYSTEM PIC101 27

11 FAULT DISPLAY AND TROUBLESHOOTING 38

11.1 ACTUAL FAULTS 38

1 Notice to the user

Allgaier Process Technology GmbH

2.1 Fundamental safety instructions

Maintenance and repair work

the main switch on the switch cabinet must be set to “0”

the main switch must be padlocked to secure it against being

Approved operating personnel

Changes and conversions

Workstations on the machine

3 Operating the machine

3.1 Switching on the plant

Language switching Link to main menu

3.2 Main menu

3.2.1 Password levels

4.1 Menu structure “Control System”

4.2 Menu structure “Parameter”

5.1 Control on/off

Control on button Control off button

5.2 Maintenance mode

maintenance mode off

maintenance mode locked

5.3 Plant operation modes

5.3.1 Manual / automatic

The operation modes are indicated by corresponding status displays.

manual – automatic locked

5.3.2 Automatic start/stop

This is indicated by a corresponding status display.

autom. stop – start locked

autom. stop – start released

autom. stop – automatic start locked

5.3.3 Remote control

5.3.4 Bypass burner

5.3.5 Material way selection

5.4 General functions

Selection of Material way

turn drives on/off in manual mode

turn drives on/off in manual mode with setpoint

Previous page / Next page / Jump back one menu level

Reset faults using “fault reset”

Call interrupt list

Reset horn using “horn reset”

Plant overview (PID)

User log off

Display field – no input possible !!!

5.5 Plant status

manual mode activ

automatic – start locked

automatic – start released

automatic – start-up phase

automatic – heat-up phase