glass service erik muijsenberg thierry barriant - glassman events · 2019-09-23 · model example 2...
TRANSCRIPT
![Page 1: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/1.jpg)
Combining high resolution NIR furnace vision with Expert System III model based furnace control
GLASS SERVICEErik MuijsenbergThierry Barriant
Glassman Conference 2019Lyon, France
![Page 2: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/2.jpg)
GS GROUP2
gsl.czfic-uk.comflammatec.comasens.hr
Process SimulationDefect analysisExpert System controlSpecialized EngineeringRaw materialsBurnersBoostingNIR Furnace Camera’s
![Page 3: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/3.jpg)
Augmented Reality, IoT
Volvo AutopilotUsing cameras, radars andSoftware
Self flying TaxisVertical takeoffNot possible to fly yourself
![Page 4: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/4.jpg)
4
Additional PC computer with OPC/DDE communication is only necessary HW addition to run ESIII. Original control equipment is used:
ES IIITM INTRODUCTION
SiemensHoneywellABBAllen BradlyYokogawaRosemount FisherEurotherm
![Page 5: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/5.jpg)
• ESIII finds correlations between multiple input and output variables, incl. disturbance variables.
• GS ESIII state of the Art with about 5% of glass furnaces worldwide installed
• Final Goal is automatic glass quality control (melting seeds)
Models are in most cases created automaticaly from Historic data and used for Full Automatic Furnace control 95% of time
MPC Models
Historical data
Courtessy of Cortex
Internal customers: - Temperature for IS machines- Energy for all
![Page 6: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/6.jpg)
Model example 2
Gas Boosting Cullet Ratio Pull
MPC PROCESS MODELS EXAMPLES
PID MPC
![Page 7: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/7.jpg)
Model example 2
Gas Boosting
MPC PROCESS MODELS EXAMPLES
PID MPC
![Page 8: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/8.jpg)
8
ESIIITM ADVANCED CONTROLLERS TOOLBOX
ESIIITM Advanced Controllers
MIMO process control
MPCModel-based Predictive Control
FLCFuzzy Logic Control
RLCRule-based Logic Control
SLCSetpoint-based Logic Control
![Page 9: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/9.jpg)
9
ESIIITM NAVIGATION WITH PROCESS PREDICTION
![Page 10: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/10.jpg)
10
Evaluation period: 05.09.2007 – 09.10.2007 and 18.10.2007 – 31.10.2007
(ESIII pretest and missing data periods excluded)
Total 43 days
Evaluation period: 02.02.2008 – 16.03.2008
Total 43 days
Changes in furnace glass pull (‘Glastrek’)Most frequent pulls 144 tpd (line D closed) and 204 tpd (max. pull)
Operator Control ESIIITM Control
Data from Fibre furnace control
glass temperature
gas
glass pull
![Page 11: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/11.jpg)
11
Data sampling 5 minutes
TB3 tolerance Operator ESIIITM (old furnace) ESIIITM (new furnace)± 2 °C 19.6% 64.8% 74.4%± 4 °C 44.5% 91.6% 97.4%
Percentage of time TB3 is within tolerances ± 2 °C and ± 4 °C during entire process control, including pull changes
Data sample 2 months
ESIIITM was in control for 96% of the time
ESIIITM seoint zone± 1°C for TB3 control
Temperature stability
![Page 12: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/12.jpg)
12
Data sampling 5 minutes
TB3 tolerance Operator ESIIITM (old furnace) ESIIITM (new furnace)± 2 °C 19.6% 64.8% 74.4%± 4 °C 44.5% 91.6% 97.4%
Percentage of time TB3 is within tolerances ± 2 °C and ± 4 °C during entire process control, including pull changes
Data sample 2 months
From 1.4.2010-1.6.2010ESIIITM was in control
for 96% of the time
ESIIITM setpoint zone± 1°C for TB3 control
To safe additional energy SP can be lowered
![Page 13: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/13.jpg)
13
How to Save Energy with ESIIITM Process Control?
Glass temperature stabilization can be used to save energyby reduction of production temperature setpoint
Operate furnace at lower temperature,but keep above critical limit to prevent glass defects
1390
1380
1370
1360
13501350
![Page 14: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/14.jpg)
Example adding E boosting with MPCBottom Temperature control
Manual Control ESIII Control
![Page 15: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/15.jpg)
15
Combustion Controller
ESIIITM Extended Combustion Control Design for Melter
Gas SP’s
Gas Profile Crown Temperatures
BTU
CV’s CV’s
DV
MV
Batch Charger
O2
Air/Gas Ratio
DV
MV
(O2, CO on-line sensors in port, regenerator or stack)
CV’s
DVMin
Max
Min
Max
Air/Gas Ideal
Gas Chromatograph
GasComposition
Ambient Temp.
DV
CV SP: NOx/CO,O2 Stack or Port
![Page 16: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/16.jpg)
ESIIITM NOx and CO minimizer, one stack sensor, 2 furnaces
![Page 17: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/17.jpg)
• GS IP HD Visual & Near Infrared Camera with 1.300.000 virtual TC’s
GS ASENS Near Infrared Camera
Picture: GS New Furnace Camera System
![Page 18: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/18.jpg)
• Monitoring• Input to the ES III
Camera info is forwarded into ES4/ESIII Computer for digital image analysis
ES IV level
Operator level
PLC level
Process instrumentationlevel
Picture: Camera(s) in furnace process control
![Page 19: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/19.jpg)
ES IIITM CAMERA – Overview for Float furnace
Projection
Measured data, statistics, analysis
+
![Page 20: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/20.jpg)
Image Grabbing and Batch Identification
Batch Identification and Monitoring Container Glass
A furnace camera image isgrabbed and analyzed every minute.
Special batch identificationsoftware is able to recognize the islands of batch(yellow) floating on top of theglass (blue). Potential builduparound the camera opening(red) is excluded from theanalysis.
In a calibrated top viewthe batch can becharacterized in termsof distribution of batchcoverage [m2] andmaximum batch length[m].
Bat
ch le
ngth
[m]
![Page 21: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/21.jpg)
Batch cover relation with crown temperaturesExample
Batch coverage in front of furnace above 1.5 m2 has been related toAffect the number of glass defects.
Trend of batch coverage [m2] in front of furnace.
Critical area in front of furnace.
![Page 22: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/22.jpg)
Batch cover correlation with crown temperature
Variation in batch coverage has direct impact on furnace temperatures: crown temperature dropswhen batch moves to front offurnace.
Measured batch coverage area isused as additional input in ESIIIfurnace temperature control.
Next step: ESIII control of batchcoverage by automatic adjustmentof batch charging directions.
Crown temperature
Batch front area [m2]
![Page 23: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/23.jpg)
GS A-Sens new camera solution With 2 video streams, one visual one Infrared
Removed large animations
![Page 24: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/24.jpg)
GS A-Sens NIR cameraWith Multiple Virtual TC’s
![Page 25: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/25.jpg)
Glass quality in relation to batch cover & temperature monitoring (example)
1 day
Batch front (bad) Batch short (good) Batch front (bad)N
see
ds /
100
gr
Virtual NIR Temperature info correlates well with crown temperature
![Page 26: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/26.jpg)
Batch image, history and trend IP Browser
Picture:: Browser
![Page 27: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/27.jpg)
27
Batch image, history and trend IP Browser
![Page 28: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/28.jpg)
28
Batch correction example with automatic burner control
![Page 29: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/29.jpg)
ESIII Integration into DCS
29
![Page 30: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/30.jpg)
30
![Page 31: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/31.jpg)
Complete melting process overview for advanced control, 2 melters and forehearths
31
Additional control can be added depending on available data.
![Page 32: GLASS SERVICE Erik Muijsenberg Thierry Barriant - Glassman Events · 2019-09-23 · Model example 2 Gas Boosting. MPC PROCESS MODELS EXAMPLES. PID. MPC. 8 ESIII TM ADVANCED CONTROLLERS](https://reader033.vdocuments.site/reader033/viewer/2022050403/5f80dd2c5232b57b377b438f/html5/thumbnails/32.jpg)
GLASS SERVICE, a.s.Rokytnice 60, 755 01 VsetínCzech RepublicT: +420 571 498 511F: +420 571 498 599
[email protected]@glass-service.euwww.gsl.cz
Thank you for your attention
CO2 price: 22.4 €/ton