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imagine making the

impossible possible
Leading the way in glass
manufacturing solutions
Glass
Holistic and cost effective
Invensys Eurotherm offers the most holistic and cost-
effective way to optimize your operations 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.
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.
Experience and understanding
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.
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
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.
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
Invensys Eurotherm provides a broad portfolio of products,
solutions and services for the glass industry including:
Batch house automation and raw material recipe control
and administration
Furnace control and automation
Furnace electrical boosting systems
Advanced control systems
Sensoring and special thermocouples for glass
applications
Oxygen sensors and dedicated sensor interfaces and
control strategies
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
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
Full lifecycle support and service level agreements to
protect your investment
A complete range of services designed to provide you
with the best value from your system
System development
Installation
Commissioning
Calibration
Spares management
Technical support
Time-Proven, Modular, Scalable
Process Control Solutions
REMOTE OPERATOR
WORKSTATION
FURNACE
SUPERVISOR NO 1
FURNACE
SUPERVISOR NO 2
BATCH
HOUSE
3rd PARTY PLC
BATCH HOUSE
FURNACE
FOREHEARTH
EYCON 20
VISUAL SUPERVISOR
2704
THREE LOOP
CONTROLLER/
PROGRAMMER
FOXBORO T2750 PAC
PROGRAMMABLE
AUTOMATION CONTOLLER
2500
CONTROLLER
T640
INTEGRATED LOOP
PROCESSOR
nanodac
RECORDER/
CONTROLLER
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.
www.eurotherm.com/glass
SERIAL COMMS
S
E
R
I
A
L

C
O
M
M
S
A
L
I
N
QUALITY AND
PRODUCTION REPORT PC
WINDING/CUTTING WINDING/CUTTING
BUSHING
WINDING
CUTTING
WEIGHING
STATION
6100A
PAPERLESS
GRAPHIC
RECORDER
EYCON 10
VISUAL SUPERVISOR
3rd PARTY PLC
FOXBORO T2750 PAC
PROGRAMMABLE
AUTOMATION CONTOLLER
www.eurotherm.com/glass
WEB PORTAL AND
ALARM ANNOTATION
FOXBORO T2750 PAC
PROGRAMMABLE
AUTOMATION CONTOLLER
FACTORY NETWORK
CONTROL ETHERNET
E
T
H
E
R
N
E
T
/
I
P
IN
T
E
R
N
E
T
Batch Control
Recipe management
Raw material ordering
Hopper Sequencing
Conveyor belts and mixer control
Batch data recording
Strength through vast
application expertise...
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
Refiner and Distribution Control
Split range control
Gas-air ratio control
Oxy-gas ratio control
Colorants mixing and control
Electrical boosting systems
Batch Control Refiner and Distribution Control
Furnace Control
www.eurotherm.com/glass
FLOAT GLASS
CONTAINER GLASS
... spanning all types of glass
TUBE GLASS
FIBRE GLASS
Building
Windows
Windscreen
Moulding
www.eurotherm.com/glass
Furnace Control
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.
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.
Electrical Furnace and Forehearth Boosting
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.
An Invensys Eurotherm fibre glass bushing solution provides:
Increased bushing yield
Improved overall power efficiency
Increased availability and productivity
Setpoint depression and ramping allowing control of temperature
profile during a production cycle
Cold bushing protection preventing the bushing from thermal shock
Better than 1C resolution
One or two Thermocouples element operation
Efficient implementation in complex control system
Pre-programmed start-up sequences
Vertical Integration with Process Control System and Winders
Fibre Glass Bushing Control Solutions
To enhance the glass melting process, increase throughput,
improve glass quality and to reduce CO
2
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.
Melter Side Wall
Melter Crown
Refiner Side Wall
Bridge Wall
Forehearth
Combustion
Air Blower
Feeder
EPower
Foxboro PAC
Bushing
nanodac
EPower
Winder
Drives
Modbus
Profibus
www.eurotherm.com/glass
Strength through wide-ranging
application expertise
www.eurotherm.com/glass
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 600C to room
temperature.
Precise cooling curve control managed over multiple lehr zones is essential for the
final products 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.
Tin Bath Roof and Annealing Lehr Heating Systems for
Float Applications
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
Windscreen Forming and Flat Glass Hardening
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 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
Flat Glass Online and Offline
Coating Systems
Multiple Zones
Roof Heating
Elements
From
Furnace
To Lehr
Rollers
Molten Tin
To SCR/Transformer Power Control Center
HMI
Visualiser
Eycon
T2750 (PAC)
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
Drives so clever that they are simple
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 ZrO
2
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
High performance thermocouples and oxygen sensors
www.eurotherm.com/glass
When all comes together
success is guaranteed
Operations
Excellence
Control
Excellence
Asset
Excellence
Productivity
Excellence
Enviroment &
Safety Excellence
www.eurotherm.com/glass
We know glass , try us.
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.
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.
Operations Excellence
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
Represented by:
Eurotherm is also represented in the
following countries:
Eurotherm:
International sales and service
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AUSTRALIA Melbourne
Invensys Process Systems
Australia Pty. Ltd.
T (+61 0) 8562 9800
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E info.eurotherm.au@invensys.com
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Eurotherm GmbH
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E info.eurotherm.at@invensys.com
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Moha
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E info.eurotherm.be@invensys.com
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