Furnace equipments products

Process Control
Board

The Glass Service process control board should manage the glass production process and relative equipment as well batch plant, melting furnace, Distributor and Forehearth.

The control process board developed by Glass Service places particular emphasis on the safety of the managed devices in accordance with current regulations, as well as providing an easy interface for the operator.

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Design

Glass Service process control board design uses the best advanced technologies and software. Expert designers are involved, in the first-class component selection (Siemens, Schneider, ABB) and sizing. The process control procedures and software analysis as well the risk analysis are evaluated in Glass Service team involving software engineer, electrical engineer, combustion engineer, process production expert.

Glass Service design of process control board includes:

Process control analysis

Electrical diagram and electrical sizing

DCS-PLC sizing

DCS-PLC software design

HMI/SCADA software design

Process control board cold test inside and on field, start up

Main Performances

The main performances of Glass Service process control board are:

1. High reliability
2. Safety according the current regulation
3. Full automatic process control
4. Easy interface with the operator and easy manage
5. Full process information and variable available in real time or historical data base and time trend
6. Alarm manage and alarm historical data base
7. Automatic troubleshooting
8. Remote control

Loops

The loops controlled by the board are:

  • Temperature (input from thermocouple or pyrometer)
  • Gas/air ratio
  • Oil/air ratio
  • Gas/oxy ratio
  • Furnace pressure
  • Combustion air temperature

Alarms

The alarms are displayed on the touch screen and recorded in the memory, the main allarm groups are:

  • High/low temperature
  • Device fault (fans – motor)
  • Incorrect ratio Gas/air, Oil/air, Gas/oxy
  • Water cooling fault (es. For the batch charger)

Trends

The trends are reported on the HMI SCADA PC and on touch screen displays.

The trends are recorded in internal memory.

DCS and PLC controller

Glass Service installs the Honeywell DCS HC900 or the Siemens PLC series 1500 and S7-400 as the standard controller.
All controllers can be configured with single or dual CPUs and various redundancy strategies.

DCS HC900 EDGE Honeywell

The ControlEdge HC900, belonging to the ControlEdge 900 Platform, is an advanced process and logic controller with a modular, scalable design that is built to work with a wide range of process equipment in a cost-effective way. It comes with a touchscreen operator interface that makes it very easy to operate.

The process and safety controller pos sesses a flexible architecture that can accommodate the most demanding application.

With its advanced features and versatile connectivity, it is capable of customized pinpoint control. The ControlEdge HC900 also simplifies the documentation process and eliminates filing errors.

HC900 most important performance

  • Hot Software upgrade, software can be modified with furnace in operation with continuity of control supervision
  • Hot swap, I/O board can be changed in hot condition with furnace in operation with continuity of control supervision
  • SIL2 version available
  • Remote control I/O connected by Ethernet TPC/IP standard
  • Touch screen directly connected to the CPU by Modbus RS485 communication
  • CPU redundancy available, single CPU or double CPU rack
  • Power supply redundancy available for CPU and/or I/O rack
  • I/O health monitor for Thermosensors

PLC Simatic S7-1500 Siemens

Using the SIMATIC S7-1500 controller gives you top performance and built-in viability into the future.

You can turn the most sophisticated machine designs into reality thanks to the modular structure of the controller, which provides reliable assistance as you work your way through the digital transformation.

Siemens S7-1500 most important performance

  •  SIL2-SIL3 version available
  • Remote control I/O connected by Profinet standard
  • Touch screen directly connected to the CPU by independent communication
  • CPU redundancy available, single CPU or double CPU rack
  • Power supply redundancy available for CPU and/or I/O rack

The simplest control architecture proposed as standard by Glass Service includes a system based on
a PLC/DCS with one CPU + various I/O boards and an HMI touch screen user interface.
With the same controls, more complex control architectures can be designed using remote I/O units.

Redundancy strategy

On the 24h/7d equipment redundancy strategy is very important for control continuity. The redundancy strategy should be managed with several solution.
Glass Service developed several redundancy strategy, some sample are reported in the table. Some customized strategy can be applied.

Solution 1 example

single loop controller
+
redundancy PLC

  • one single loop controller manages each control PID loop
  • electromechanical redundancy manages the ON/OFF of the electrical device (fans, Shutt off valves, etc.)
  • simple PLC manages the complex equipment (batch charger, oxy-gas combustion skids, glass level controller)

Solution 2 example

redundancy CPU
+
redundancy HMI

  • the PLC install a redundancy CPU + redundancy CPU power supplier
  • HMI SCADA PC has a touch screen (one or more) as redundancy
  • network communication from CPU and I/O is double and redundant
  • redundancy PC SCADA Server

By the design of a redundant control system, Glass Service is able to ensure complete service continuity both in the event of failures of individual units and during routine maintenance, such as software controller modifications.

Safety integration level process control board SIL2-SIL3

According current regulation EN746/2 (EU) and ANSI/NFPA86 (USA) the combustion process controller must be in compliance with the correct safety integrity level.
Glass Service approached the SIL methodology by the LOPA risk management technique.

Glass Service can certify the process control board SIL2-SIL3 capable.

SIL2-SIL3 capability is request for in European Community as well USA for:

Melting combustion

  • Distributor and Forehearth combustion
  • Electrical power booster safety
  • Dangerous device
Activity Description LOPA methodology in charge to Solution

1. Process Design
Good process design provides a system that is robust and can prevent or tolerate deviations in operating conditions.
Glass Service design office
Glass Service proven design knowledge

2. Basic Process Control System (sometimes denoted as the process control system PCS)

BPCS is the control system used during normal operation. Input signals from the process and/or from the operator are generated into output which make the process operate in a desired manner. If the system discovers that the process is out of control (e.g. high pressure) it may initiate actions to stabilize the process.
- Glass Service process control board
- Glass Service software design
- Glass Servicerisk analysis
- Glass Service SIL process control design
- SIL certified DCS/PLC
- Glass Service SIL certified process control board
- Glass Service SIL certified software

3. Alarms and Operator Intervention
Alarms monitoring certain parameters (e.g. pressure and temperature) are considered another protection layer. When the alarm is tripped, the operator may intervene to stop the hazardous event.
Glass Service process control board
- Glass Service SIL process control design
- Glass Service SIL DCS/PLC simple and reliability HMI

4. Safety Instrumented System SIS
Implements the wanted safety function SIF (Safety Instrumented Function) to bring the process to a safe state. In LOPA, SIFs are considered as critical protection layers.
Glass Service process control board
- Glass Service SIL process control design
- SIL certified DCS/PLC

5. Physical Protection (Relief Devices)
Physical protection includes equipment like pressure relief devices. E.g. in a separator this may be a blow off valve which blows-off if the pressure is too high protecting the underlying equipment.
Glass Service combustion skids
Glass Service combustion skids

6. Physical Containment (Bunds)
Post release protection is physical containment such as disks, blast walls etc. These have their function after the release or explosion has occurred to prevent spread of damage.
Customer

7. Emergency Response Layer
Plant and community emergency response, are considered the final protection layer. If an accident occurs, procedures, evacuation plans, equipment and medical treatment help the exposed personnel to escape, or to mitigate damage/injury.
Customer

HMI Human Machine Interface

HMI is an important section of the process control board. In Glass Service design approach HMI must have the main features:

Easy to manage and understand by operator

Stable and reliable

Collect all data for historical analysis

Able to manage alarm and historical data alarm

HMI/SCADA software design

Glass Service developed the HMI in 2 main family:

PC SCADA

TOUCH SCREEN

PC SCADA

PC SCADA HMI is mainly based on WIN software and PC based hardware.

The SCADA software application running on WIN used by Glass Service could be according the customer request, main software used are WIN-CC Simens; CITEC Schneider, IGNITION.

Problem

High reliability of PC hardware

Solution

  • Use only industrial PC hardware
  • Fan less PC preferred

Clear HMI interface

  • Large screen used standard is N.2 curved 32” monitor each PC
  • Clear and simple graphic software
  • N.2 PC can be installed by server/Client architecture

24h/7d continuity service

  • Redundancy PC, N.2 PC server used
  • Redundancy data base

Data analysis

  • Data base storage of all furnace variable
  • Data analysis software tools, as well trend view of historical data

Software assistance

  • Remote control by Glass Service software electronic office

Data protection

  • Independent Ethernet network for SCADA PC
  • Firewall software installed
  • VPN use only for remote control connection

TOUCH SCREEN HMI

Touch screen can be used as redundancy HMI or as main HMI for low cost process control board. The main touch screen used by Glass Service are:

  • Siemens HMI panel machine size 12.1” to 21.5“
  • Honeywell Control station size 10.4” to 15”
  • ASEM size 12” to 24”

Standard software uses on Touch screen is:

  • Siemens WinCC
  • Honeywell station designer
  • ASEM

Problem

High reliability of hardware/software communication

Solution

  • Directly connection to controller CPU
  • Connection property communication protocol

Clear HMI interface

  • Large screen used standard from 10.4 to 22” colour display
  • Clear and simple graphic software

24h/7d continuity service

  • First quality hardware

Software assistance

  • Remote control by Glass Service software electronic office

Data protection

  • Directly connection to controller CPU
  • Connection property communication protocol
  • No window-based software used
  • VPN use only for remote control connection

Remote Control

Glass Service remote control design developed the features of:

Remote software assistance and upgrade

Trouble shooting of furnace or DH&FH manage

Data safety and intrusion protection by the use of EWON VPN Talk2m industrial cloud connection

High data speed connection worldwide by cloud connection