glass machinery plants & accessories 3/2017 1

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Forehearth solutions

Glass serviceglass forehearth full

redundancy control board

When Bormioli Luigi had to rebuild the control system board for

a forehearth and distributor for the new furnace in Parma, they

contacted Glass Service, a company that provides complete

solutions for the glass industry.

From batch plants to forming robots, from heat recuperators to

turnkey projects for all types of glass

Bormioli luigi's reBuild

Glass Service's customer Bormioli Luigi had to rebuild the control system board for a fore-hearth and distributor for its new furnace in Parma.

The main specifications of the board required were the follow-ing:• Controlledareas

- one distributor- five forehearths- 34 controlled temperature

zone - five controlled cooling zone - four coupled fans (one

stand-by) controlled in pressure loop by electronic inverter

• Full redundancy includingI/O,CPUs,powersupply

• SIL2forsafetyissues• sevenlocaltouchscreeninter-

face • oneSCADAEthernetconnec-

tion to the local iFIXSCADAsoftware

The conTrol sysTemThe control system is made

up of four different logic control boards:1.Control section A, managing

the complete plant tempera-ture control and function logic

2.Switching board, managingthe switch from control board AandB

3.ControlsectionB,thesameof

configuration of control board A

4.SIL2 safety board, managingthe safety plant device (back fire, flame injection, etc.)Control section A and B are

a complete redundancy control system with redundancy of power supply,CPUs,I/Oboard.

Control sectionA andB bothinclude the following HC900controller configuration:• threeI/Orackswith12slots• threepowersupplies• oneCPU70• 128analogueinputs,4-20mA,

thermocouple• 32analogueoutputs,4-20mA• 160digitaloutputs• 64digitalinputs

This configuration is installed in each controller section A andB, so that the total value of con-troller HC900 installed is twicethe above reported list.

The sil2 safeTy BoardTheSIL2safetyboardincludes

the following HC900 controllerconfiguration:• oneI/Orackwith12slots• onepowersupply• oneCPU50SIL2• 64analogueinputs• 64digitaloutputs• 64digitalinputs

Control section A and B aresupplied with complete redun-dancy I/O included and the operatorcanswitchfromAtoBaccording to plant conditions.

Allparameter settingssuchasSP, loop configuration, alarm threshold, OP are aligned in the boot controller section.

comBusTion sysTem servomoTors

The local combustion sys-tem servomotors are Honeywell Herculine 2000, with three-stepcontrollers and back-forward configuration by means of dou-ble0-1000Ohmpotentiometers.

Each potentiometer is con-nected to one controller section

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Forehearth solutions

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AandBforfullredundancy.The management of the end

stroke and servomotor position is carried out by special HC900software tools independent for each controller section.

PlanT safeTyPlant safety is managed from

thededicatedSIL2safetyboard.SIL2 configuration guaranteesplant safety and conformity to the EuropeanstandardEN746/2.

The control system and safety is able to manage:• 34 temperature controlled

zones• fivecoolingzones• fourcoupled fans(onestand-

by), including eight fan invert-ers, eight reversal fan valves, 16fanreversalvalveswitches,four pressure fan transmitters. The fans are managed in con-trolled pressure loop

• 34 burner manifolds pressuretransmitters

• 34 anti explosion valves inSIL2mode

• 34backfire thermocouples inSIL2mode

• Severalsafetypressureswitch-esinSIL2mode

• 39 safety gas valves in SIL2mode

• Alarmsystemmanagement• Black out and restart proce-

dureEachfanhasalocalkeyboard

installed to manage the fan man-ual switches and fan maintenance mode.

The first level of the HMI (Human Machine Interface) is made up of seven local 10”Honeywell touchscreen control station panels. Each panel soft-ware can be dedicated to the single forehearth or section by password managed software.

Several screen displays can be selected by the local operator for single forehearth temperature management and alarm system information.

The second level of the HMI

is the SCADA iFIX softwareincluding a local sever integrated in a factory network for remote control.

conclusionThe control boards provide

complete redundancy manage-ment of the forehearth and dis-tributor plant, including redun-dancy I/O according to the cus-tomer's request.

The plant started operations in November 2016 with completesuccess. �

Via Cascina Lari56028 San Miniato (PI) - Italy

Tel.: +39 - 0571 - 4442Fax: +39 - 0571 - 417051

E-mail: glass-service@glassservice.it

www.glassservice.it

glass service srl