Eurotherm by Schneider Electric | Temperature Control, Process

Glass
Leading the way in glass
manufacturing solutions
imagine making the
impossible possible
Invensys Eurotherm glass industry solutions ...
Invensys Eurotherm is a partner who understands your process. We are a global
company taking care of all your process automation and power control solutions; a
partner with the global presence to speak the native language of your local plants’
personnel. We understand your automation problems and can solve them with
you, offering dedicated support that solves your problem always and at any time,
from operations through to technical engineering and on to your purchasing
function. We can and do imagine making the impossible possible for our glass
customers.
Holistic and cost effective
Experience and understanding
Invensys Eurotherm offers the most holistic and costeffective way to optimize your operation’s performance and
overall profitability. We help improve the performance of
your key resources – people, equipment, energy and
materials – in real time, with dramatic, measurable results,
using a collaborative and open approach.
Invensys solutions are globally used in float, container,
fibre, optical and special glass manufacturing companies.
We have been involved with Glass industry automation
projects for more than 45 years doing business with almost
all global glass manufactures as well as with local glass
production facilities.
We are known by our premier brands –
Avantis Eurotherm Foxboro IMServ InFusion
Simsci-Esscor Skelta Triconex Wonderware
Our products are used by more than 40,000 clients in over
200,000 plants and facilities around the world.
The Invensys Operations Management team of dedicated
Glass industry experts is focused on providing high
performance glass applications in a cost-effective manner.
Our full range of solutions are vendor and platform
independent, providing you with an objective and
authoritative view of your operation.
Why Invensys Eurotherm Glass solutions?
• Global expertise and experience in providing solutions
within every major glass manufacturing sector
• Proven track record in rapidly delivering solutions with
optimum return of investment
• More than 45 years of experience in control, data
management and scalable automation solutions
• Cost effective solutions to improve the reliability and
efficiency of your process, and the quality of your
product
• Proven experience in working and integrating with
multiple suppliers and platforms
• Specialist teams, deployed globally, with comprehensive
experience in Glass automation systems
• Local spares supply and service support
• A team to work with your team, a partnership for success
www.eurotherm.com/glass
... reality beyond imagination
Addressing your industry challenges
Maximize Profitability
• Control Excellence - Optimize performance through
production and business control
• Asset Excellence - Balance the effective utilization and
availability of all assets for maximum enterprise
profitability
• Productivity Excellence - Maximize the effectiveness of
people and systems
• Environment & Safety Excellence – Balance your social
responsibility, safety, world-class environmental
sustainably and long-term profitability
Wide ranging application experience
matched with a broad product
portfolio providing a perfect fit for
the glass industry
Confidence in measured value for
your money
The Invensys Eurotherm Glass teams are committed to
developing products and solutions to minimize plant
operating costs, while maximizing productivity and quality.
• Project management planning, management,
implementation and execution
• Training of personnel, management and staff
• Scalable Environmental Monitoring Systems (EMS)
• Wrap & Comply approach to brown field development
and equipment renewal
• Scalable solution from a single control loop to complete
plant automation systems
• Rapid installation during critical hot or cold rebuilds
• Reduced costly energy usage through advanced
monitoring, fuel switch systems, oxygenfuel/gas control
• Reduced labor costs through automation
Invensys Eurotherm provides a broad portfolio of products,
solutions and services for the glass industry including:
• Full lifecycle support and service level agreements to
protect your investment
• Batch house automation and raw material recipe control
and administration
• A complete range of services designed to provide you
with the best value from your system –
• Furnace control and automation
— System development
• Furnace electrical boosting systems
— Installation
• Advanced control systems
— Commissioning
• Sensoring and special thermocouples for glass
applications
— Calibration
• Oxygen sensors and dedicated sensor interfaces and
control strategies
— Spares management
— Technical support
• Drives and motion control
• Electric melting systems
• Bath roof and lehr heating systems
• Bushing control and heating systems
• Utilities and energy management systems
• Plant wide data acquisition, long term secure archiving
and data analysis tools
• Emission calculation, reporting and predictions
www.eurotherm.com/glass
Time-Proven, Modular, Scalable
Process Control Solutions
From the simplest single loop control to full scale information integration and plant wide distributed control systems,
Invensys Eurotherm can provide scalable, modular solutions to match your application and budget. As your requirements
grow, new modules can be easily incorporated into your existing system, integration is a key part of Invensys Eurotherm
offerings. Our products, hardware as well as software, are designed to work on multiple communication platforms with
connectivity at all levels.
However, most cost effective results will be achieved by using the Invensys Operations Management portfolio components
like Foxboro automation products integrated into the Wonderware system platform. They will provide accurate control,
secure data recording and high and redundant system availability.
REMOTE OPERATOR
WORKSTATION
FURNACE
SUPERVISOR NO 1
FURNACE
SUPERVISOR NO 2
nanodac
RECORDER/
CONTROLLER
EYCON 20
VISUAL SUPERVISOR
FOXBORO T2750 PAC
PROGRAMMABLE
AUTOMATION CONTOLLER
BATCH HOUSE
3rd PARTY PLC
ALIN
SERIAL COMMS
2500
CONTROLLER
FURNACE
www.eurotherm.com/glass
T640
INTEGRATED LOOP
PROCESSOR
SERIAL COMMS
BATCH
HOUSE
2704
THREE LOOP
CONTROLLER/
PROGRAMMER
FOREHEARTH
WEB PORTAL AND
ALARM ANNOTATION
QUALITY AND
PRODUCTION REPORT PC
T
RNE
INTE
FACTORY NETWORK
WINDING/CUTTING
WINDING/CUTTING
CONTROL ETHERNET
6100A
PAPERLESS
GRAPHIC
RECORDER
ETHERNET/IP
EYCON 10
VISUAL SUPERVISOR
FOXBORO T2750 PAC
PROGRAMMABLE
AUTOMATION CONTOLLER
3rd PARTY PLC
BUSHING
FOXBORO T2750 PAC
PROGRAMMABLE
AUTOMATION CONTOLLER
WEIGHING
STATION
WINDING
www.eurotherm.com/glass
CUTTING
Strength through vast
application expertise...
Batch Control
Refiner and Distribution Control
• Recipe management
• Split range control
• Raw material ordering
• Gas-air ratio control
• Hopper Sequencing
• Oxy-gas ratio control
• Conveyor belts and mixer control
• Colorants mixing and control
• Batch data recording
• Electrical boosting systems
Furnace Control
• Reversal control
• Furnace pressure control
• Glass level control
• Combustion control
• Excess air control
• Oxy-fuel control
• Advanced control
• Sensoring
• Electrical boosting systems
• Long term secure data archiving
• Long term trending
• Data analysis tools
www.eurotherm.com/glass
... spanning all types of glass
FLOAT GLASS
Building
Windows
Windscreen
Moulding
CONTAINER GLASS
TUBE GLASS
FIBRE GLASS
www.eurotherm.com/glass
Strength through wide-ranging
application expertise
Furnace Control
Electrical Furnace and Forehearth Boosting
Glass melting and fining is a delicate balance between energy efficiency,
glass quality and maximum throughput keeping emissions within
legislative boundaries. The extreme dead times and sometimes frequent
pull rate fluctuation of the furnace makes the control of the furnace
process complex. Stable and smooth control is a must, capable of
keeping all parameters inside their narrow boundaries, as this will have a
positive effect on the furnace lifetime.
To enhance the glass melting process, increase throughput,
improve glass quality and to reduce CO2 emissions
electrical furnace boosting is often used. It also provides a
useful control parameter for advanced glass temperature
control strategies and pull rate fluctuation compensation.
Invensys Eurotherm EPower™ controller based solid state
electrical heating systems provide 100% freedom of control
at optimum efficiency, achieving best power factor with
minimum harmonic distortion. The award winning Predictive
Load Management strategies will eliminate peak power
demand when running in full cycle mode. The Load Tap
Changing capabilities of the EPower controller provide the
highest efficiency when operating in phase angle firing.
Our Foxboro Programmable Automation Controller integrated into the
Wonderware system platform offers a scalable and reliable process
automation environment. Foxboro PAC offers distributed control system
functionality with or without redundancy. The Wonderware Historian
database provides long term archiving and trending, easy data retrieval
and strong data analysis tools. Our process control can be easily
expanded with Advanced Process Control features based on Invensys
SimSci Connoisseur software.
Melter Side Wall
Refiner Side Wall
Melter Crown
Bridge Wall
Forehearth
EPower
Combustion
Air Blower
Feeder
Fibre Glass Bushing Control Solutions
Foxboro PAC
Invensys Eurotherm have a long and successful history of providing
automation and power control solutions into glass fibre applications. Fast
and accurate temperature sensing, complex temperature ramping
strategies together with smooth bushing power control are essential for
maximum yield, minimum bushing downtime and optimum fibre quality.
Bushing
nanodac
An Invensys Eurotherm fibre glass bushing solution provides:
• Increased bushing yield
• Improved overall power efficiency
Modbus
• Increased availability and productivity
EPower
• Setpoint depression and ramping – allowing control of temperature
profile during a production cycle
• Cold bushing protection – preventing the bushing from thermal shock
Winder
• Better than 1°C resolution
• One or two Thermocouples element operation
• Efficient implementation in complex control system
• Pre-programmed start-up sequences
Profibus
• Vertical Integration with Process Control System and Winders
Drives
www.eurotherm.com/glass
Windscreen Forming and Flat Glass Hardening
Over the last decade the use of glass panels in cars has increased rapidly along with the complexity of shape and integration of sensors.
With the automotive industry demanding more and more stringent tolerances and introducing more complex forms and shapes, the
production process of automotive glass panels has become extremely complex. Resulting for example in a Tunnel furnace, having
hundreds of sub zones, requiring precise and complex temperature control running multiple recipes to allow maximum production
flexibility. Resistive elements as well as medium wave infra red heaters have to be controlled to very tight parameters whilst maximising
energy efficiency. Invensys Eurotherm temperature control, power control and supervisory systems for windscreen forming are in
operation around the world providing:
•
•
•
•
•
•
Accurate multi-zone temperature control
Accurate open or closed loop power control
Advanced single cycling for infra-red elements, eliminating DC components
Power control setpoint transfer and monitoring by digital communication, reducing the I/O requirements of the control system
Feed through control
Track and Trace capability
Flat Glass Online and Offline
Coating Systems
Tin Bath Roof and Annealing Lehr Heating Systems for
Float Applications
Many modern glass applications require
additional production or processing such as
coating technologies and coating materials for
advanced building or solar applications. Most
common today are self cleaning, anti reflective,
infra-red reflective and low-emission coatings for
automotive, architectural and PV solar panel
applications.
The bath, being the forming area in a float glass production process requires
precise multiple heating zone temperature and power control. The Silicon-Carbide
heating elements have a far from linear temperature/ resistance curve, an
advanced power control system is therefore critical to control these elements
safely and with maximum efficiency. The annealing lehr needs to avoid any stress
entering the glass during its cooling down from approximately 600°C to room
temperature.
The application of these coatings via complex
on-line chemical vapour deposition and off-line
cathodic sputtering technologies. These
processes require precise control of chemical
flows as well as highly accurate temperature
control as part of the integrated production
process.
Invensys Eurotherm
offers:
• A proven track
record in coating
control systems
• Stand alone as
well as fully
integrated
coating process
control systems
• Highly accurate
temperature
measuring and
control
• Scalable,
redundant DCS
solutions
• Ultra fast and
high precision
power control
Eycon
Precise cooling curve control managed over multiple lehr zones is essential for the
final product’s quality and the maximum float line yield. Precise multiple zone
temperature measurement and control together with sophisticated highly efficient
power control capable of managing non linear heating elements is required.
The EPower controller is specifically designed to control these elements safely
whilst achieving the highest power factor and avoiding any overall system peak
power demands. The Foxboro PAC and Wonderware System Platform are
designed for optimum control of such complex systems.
To SCR/Transformer Power Control Center
HMI
Visualiser
Roof Heating
Elements
From
Furnace
Multiple Zones
To Lehr
Rollers
Molten Tin
T2750 (PAC)
www.eurotherm.com/glass
When all comes together
success is guaranteed
Drives so clever that they are simple
Throughout the glass industry electrical motors and servo
systems are used in raw material transportation, exhaust gas
filters, combustion air supply, refiner and forehearth cooling,
furnace side wall and throat cooling, IS-machine cooling,
annealing lehrs, cutting lines, winders, top roller drives and
many more applications. Invensys Eurotherm variable speed
drives provide precision, compactness and flexibility along side
potential energy savings. We offer a full range of drives; servo,
AC as well as DC including the motors and electrical cabinets.
Invensys Eurotherm combines its outstanding drives expertise
with its overall glass application knowledge integrating drive
technology into the overall glass plant automation.
• Open and closed loop vector control for power ratings up
to 2000kW
• Wind/unwind control
• Speed or torque synchronization
• Top roll control
• Squeezing roll control
• Conveyor control
• Combustion air and
exhaust gas fans
• Annealing lehr cooling
fans and drives
• Energy efficient furnace,
refiner, forehearth and
IS-machine cooling
High performance thermocouples and oxygen sensors
The extremely high temperatures and challenging atmospheric
conditions involved in the glass melting and fining processes,
require the application of special thermocouple technology.
These thermocouples need to be capable of accurate
measurement whilst demonstrating the minimum in temperature
drift over time. This long term stability is a key factor in a glass
manufacturers ability to control and operate processes to the limits of
acceptable glass quality whilst achieving the best in energy
efficiency.
Furthermore if thermocouple technology is applied to measure and
protect critical areas of the furnace, such as the crown, against
overheating it is imperative that these sensors are both reliable and
robust over long periods of time.
Invensys Eurotherm designs, supplies, maintains and services a broad range of
glass customer specified high temperature thermocouples around the globe, in addition to supplying our own market leading high
temperature oxygen probes. Allowing our glass manufacturing customers to significantly improve their fuel efficiency and reduce their NOx
emissions.
Couple these capabilities with our specially designed Foxboro Programmable Automation Controller (PAC) with its ZrO2 interfaces and world
class combustion control algorithms. Then you can be confident you have found a partner in factory automation who know about glass. Our
objective is to bring to the glass industry cost effective high quality, accurate and stable Temperature and Oxygen measurement
www.eurotherm.com/glass
Operations Excellence
Invensys Operations Management division of Invensys was formed
in May 2009 by combining Invensys Process Systems — Avantis®,
Foxboro®, InFusion™, SimSci-Esscor™ and Triconex® — with
Wonderware®, Eurotherm® and IMServ®. The basis for this move
was each of these four traditionally separate and excellent
business units would provide more value for clients working
together to solve difficult business problems that could not be
solved by each unit separately. The Invensys leadership believes
that the combined business would help to define and develop
leadership in an emerging market space referred to as Operations
Management. Invensys Operations Management will focus all of its
resources to help customers drive Operations Excellence into their
businesses.
Attaining Operations Excellence requires that industrial companies
maximize the efficiency and profitability from their operations
through excellent control, drive maximum business value from all
their industrial assets, continually drive and increase productivity
from all operations-focused personnel, all while reducing negative
environmental impact and improving safety. Therefore, Invensys
has defined Operations Excellence along four key themes: Control
Excellence, Asset Excellence, Productivity Excellence and
Environment and Safety Excellence.
Control
Excellence
Asset
Excellence
Operations
Excellence
Productivity
Excellence
These four critical components of Operations Excellence provide
the scope and maturity model for attaining Operations Excellence.
They frame the scope by bringing to light the various aspects of
focus that must be considered when striving for Operations
Excellence. They also explain the maturity model as most industrial
companies progress toward Real-Time Operations Excellence by
starting with Control Excellence, moving to Asset Excellence,
empowering their talent to drive Productivity Excellence and
moving toward a holistic approach by balancing the profitability
improvements possible through effective implementation of the
first three excellence areas with the business constraints imposed
by Environment and Safety Excellence. Although every company
approaches all four areas simultaneously, to some degree, the
formalization of a structured Operations Excellence approach often
matures through these four stages.
The definition of Real-Time Operations Excellence is best
expressed by focusing on both the ongoing aspects as well as the
desired outcomes. The definition of Real-Time Operations
Excellence is continuously improving profitability from industrial
operations in real time. It should be noted that the focus could be
a single asset, an industrial plant, or an entire industrial enterprise.
We know glass, try us.
www.eurotherm.com/glass
Enviroment &
Safety Excellence
Eurotherm is also represented in the
following countries:
Eurotherm:
International sales and service
www.eurotherm.com
AUSTRALIA Melbourne
Invensys Process Systems
Australia Pty. Ltd.
T (+61 0) 8562 9800
F (+61 0) 8562 9801
E info.eurotherm.au@invensys.com
AUSTRIA Vienna
Eurotherm GmbH
T (+43 1) 7987601
F (+43 1) 7987605
E info.eurotherm.at@invensys.com
BELGIUM & LUXEMBOURG
Moha
Eurotherm S.A./N.V.
T (+32) 85 274080
F (+32) 85 274081
E info.eurotherm.be@invensys.com
BRAZIL Campinas-SP
Eurotherm Ltda.
T (+5519) 3707 5333
F (+5519) 3707 5345
E info.eurotherm.br@invensys.com
CHINA
Eurotherm China
T (+86 21) 61451188
F (+86 21) 61452602
E info.eurotherm.cn@invensys.com
INDIA Mumbai
Invensys India Pvt. Ltd.
T (+91 22) 67579800
F (+91 22) 67579999
E info.eurotherm.in@invensys.com
SWITZERLAND Wollerau
Eurotherm Produkte (Schweiz) AG
T (+41 44) 7871040
F (+41 44) 7871044
E info.eurotherm.ch@invensys.com
IRELAND Dublin
Eurotherm Ireland Limited
T (+353 1) 4691800
F (+353 1) 4691300
E info.eurotherm.ie@invensys.com
UNITED KINGDOM Worthing
Eurotherm Limited
T (+44 1903) 268500
F (+44 1903) 265982
E info.eurotherm.uk@invensys.com
ITALY Como
Eurotherm S.r.l
T (+39 031) 975111
F (+39 031) 977512
E info.eurotherm.it@invensys.com
U.S.A. Ashburn VA
Invensys Eurotherm
T (+1 703) 724 7300
F (+1 703) 724 7301
E info.eurotherm.us@invensys.com
ED64
KOREA Seoul
Invensys Operations Management
Korea
T (+82 2) 2090 0900
F (+82 2) 2090 0800
E info.eurotherm.kr@invensys.com
NETHERLANDS Alphen a/d Rijn
Eurotherm B.V.
T (+31 172) 411752
F (+31 172) 417260
E info.eurotherm.nl@invensys.com
Beijing Office
T (+86 10) 5909 5700
F (+86 10) 5909 5709/10
E info.eurotherm.cn@invensys.com
POLAND Katowice
Invensys Eurotherm Sp z o.o.
T (+48 32) 7839500
F (+48 32) 7843608/7843609
E info.eurotherm.pl@invensys.com
FRANCE Lyon
Eurotherm Automation SA
T (+33 478) 664500
F (+33 478) 352490
E info.eurotherm.fr@invensys.com
SPAIN Madrid
Eurotherm España SA
T (+34 91) 6616001
F (+34 91) 6619093
E info.eurotherm.es@invensys.com
GERMANY Limburg
Eurotherm Deutschland GmbH
T (+49 6431) 2980
F (+49 6431) 298119
E info.eurotherm.de@invensys.com
SWEDEN Malmo
Eurotherm AB
T (+46 40) 384500
F (+46 40) 384545
E info.eurotherm.se@invensys.com
Represented by:
© Copyright Eurotherm Limited 2011
Invensys, Eurotherm, the Eurotherm logo, Chessell, EurothermSuite, Mini8, Eycon, Eyris, EPower, nanodac, Foxboro and Wonderware are trademarks
of Invensys plc, its subsidiaries and affiliates. All other brands may be trademarks of their respective owners.
All rights are strictly reserved. No part of this document may be reproduced, modified, or transmitted in any form by any means, nor may it be stored
in a retrieval system other than for the purpose to act as an aid in operating the equipment to which the document relates, without
the prior written permission of Eurotherm Limited.
Eurotherm Limited pursues a policy of continuous development and product improvement. The specifications in this
document may therefore be changed without notice. The information in this document is given in good faith, but is
intended for guidance only.
Eurotherm Limited will accept no responsibility for any losses arising from errors in this document.
Part No. HA028779 Issue 4
Printed in England on recycled paper 08.11
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