Process control board - GLASS SERVICE

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

Solution 2 example

redundancy CPU
+
redundancy HMI

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

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.