model predictive control (mpc) in glass furnaces is ... · that includes its proprietary model...
TRANSCRIPT
GLASS SERVICE
Glassman Sao Paulo , May 2019
Model Predictive Control (MPC) in glass
furnaces is becoming a standard control
tool.
Agenda for presentation
1. Brief Description Of GS furnace control expert system
that Includes its proprietary model predictive control
software .
2. Who is using GS MPC software ( ESIII)
3. Example of typical improvement and Benefits
4. Next generation of Cameras that will allow us to jump
to next generation of control software ESIV
Stand B2
GS GROUP (GS, FT, FIC, ASENS)
Furnace modeling
Model studies
(Regen. & FH)
GFM SW License
Furnace Control
ESIII MPC
Batch Monitoring
Industry 4.0
control by ES 4.0
Lab. Services
Glass Defects
R&D Projects
Lab Equipment
Rapidox
HTO
Applied Modeling Engineering Services
Physical Modeling
Forming Modeling
Other Forming
specialized
Simulations
Eg. Tin Bath
Pot Furnaces
Specialized
Glass Tanks
Equipment for
Hand Production
Burners and
Combustion
Equipment
FLAMMATEC
Electric Boosting
Electric Furnaces
FIC
Glass Service Inc. (headquarter) Czech Republic (total approx. 100 people)
Other Divisions of Glass Service Inc. :
• Furnace data analysis & Inspections
• Raw Materials Deliveries
• GS Offices in USA, UK, NL, FR, D, SK,
Russia, China, Japan
• 800 Customers Worldwide
FT Germany FIC Germany
Additional PC computer with OPC/DDE communication is only necessary
HW addition to run ESIII. Original control equipment is used:
ES IIITM INTRODUCTION
Siemens
Honeywell
ABB
Allen Bradly
Yokogawa
Rosemount Fisher
Eurotherm
4.0 Industrial revolution Based on cyber-physical-
systems
• Standard PID control loops are used for fast processes with single input/output variables
(SISO) that almost controls entire glass production line.
• Strong correlations between multiple input and output variables (MIMO) , incl. disturbance
variables.
Glass Service expert system furnace control
MPC Models
Historic data
Model example 2
Gas Boosting Cullet Ratio Pull Bubbling
MPC PROCESS MODELS EXAMPLES
PID MPC
Models are in most cases created Models are in large percentage created
from Historic data and MPC is used for
Full Automatic Furnace control 90% of
time
0
20
40
60
80
100
120
140
Europe America Asia Africa Australia
GS Installations by continents
0
20
40
60
80
100
GS Installations by type of Glass Products
float
fiber
container
other ( tableware, jewlery, lighting , tubing, TV)
7
Total of GS Advance Control Systems: 225
GLASS SERVICE ADVANCED CONTROL INSTALLATIONS
WORLDWIDE: 1996 - 2019
Main Objectives to use MPC
Major ES III™benefits and objectives:
1. Increased stability of the glass production unit : More
stable unit operations improve the product yield and
quality.
2. Fuel consumption optimization (energy savings).
3. Automatic full control, limited operator interventions
4. Operation consistency – 24 hours per day, 7 days per
week
5. Independent of operators knowledge and experience.
6. Environmental issues, reduction of NOx,
Why GS ESIII ?
1. GS Experienced team of installation engineers how to configure and tune ESIII on glass melting furnace
2. Psychological experience to convince production plant team to accept, understand and use ESIII 3. ESIII can make automatic identification of the process and so make automatic models 4. Our MPC can handle a larger Matrix solution and include and combine Rule Base & Fuzzy logic control
and other control techniques 5. Our Visualization with predictive trends is highly intuitive 6. ESIII High Temperature Furnace Camera (with Infrared option) incl. Furnace Batch monitoring and
coupling into ESIII is a unique solution for glass industry 7. We also have some partial solution for Tin bath logic (control) and spread and edge monitoring
(control). See attached recent update presentation.
1. GS Experienced team of installation engineers know how to
configure and tune each installation using MPC .
2. GS Proprietary Software ESIII that can make automatic
identification of the process and make automatic models.
3. GS MPC can handle a larger Matrix Solution with MPC and if
needed it combine Rules Base & Fuzzy Logic Controls
4. Partnership with furnace operational and plant personnel to
work together to obtain successful results, to accept, understand
and use ESIII.
Stand B2
Float furnace control agenda – recent example 2018
CONTROL AGENDA -
BATCH CHARGING
MELTER CROWN TEMPERATURE
CONTROL
CANAL TEMPERATURE CONTROL
GLASS LEVEL
CONTROL
O2 CONTROL
BTU COMPENSATION
PULL CHANGE
GAS CONSUMPTION
…
1
FURNACE TEMPERATURE CONT, Recent
ROLreee
Operator Control: April 2018
ES III Control: November 2018
MELTER TEMPERATURE CONTROL Recent installation
MELTER TEMPERATURE CONTROL
Operator Control ES III Control
MELTER TEMPERATURE CONTROL
FURNACE TEMPERATURE CONTROL
0
1000
2000
3000
4000
5000
6000
7000
8000
1550 1555 1560 1565 1570 1575 1580
Fre
qu
en
cy
Crown control Histogram
Operator
ES III Nov
Melter Crown Temperature Control Evaluation
Operator ES III November
Standard Deviation 2.21 1.2
Improvement [%] 45.7%
MELTER TEMPERATURE CONTROL
CANAL TEMPERATURE CONTROL
PID Control ES III Control
CANAL TEMPERATURE CONTROL
0
2000
4000
6000
8000
10000
12000
14000
16000
3 2 1 0 -1 -2 -3
Fre
qu
en
cy
Canal Error Histogram
PID
ES III
Canal Temperature Control Evaluation
Operator
ES
III
Standard Error Deviation 0.92 0.32
Improvement [%] 65.2 %
CANAL TEMPERATURE CONTROL
GLASS LEVEL CONTROL
Operator Control: April 2018
ES III Control: October 2018
GLASS LEVEL CONTROL
GLASS LEVEL CONTROL
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
-3.0 -2.0 -1.0 0.0 1.0 2.0 3.0
Fre
qu
en
cy
Glass Level Error Histogram
PID
ES III Oct
Glass Level Control Evaluation
Operator ES III October
Standard Error Deviation 0.65 0. 37
Improvement [%] 43%
GLASS LEVEL CONTROL
“ … good improvement in furnace stability and even better canal and glass level control that helped us to reduce edge losses.”
Mr. F.F., project coordinator for corporation
STANDARD APPROACH:
1. TEMPERATURES PROFILE SETTING IS HIGHER A BIT
– TO BE ‘SAFE’
2. OPERATORS LIKE TEMPERATURES MORE HOT THAN
NECESSARY, THE ACTUAL VALUE ABOVE ITS SET
POINT IS CONSIDERED AS IDEAL SITUATION
3. AIR/GAS RATIO ADJUSTMENT FOR OPTIMAL
COMBUSTION IS NOT CONSIDERED AS IMPORTANT
4. BATCH LINE POSITION IS TYPICALLY SHORTER THAN
NECESSARY
GAS CONSUMPTION ASSISTANT
ES IIITM APPROACH:
1. LOWERING THE TEMPERATURES VARIATION BY MPC
CONTROLLER THE SET POINTS CAN BE DECREASED
2. MPC CONTROLLER KEEPS THE VALUES AS CLOSE AS
POSSIBLE TO THEIR SET POINTS AND USES THE ENERGY
EFFECTIVELY
3. AIR/GAS RATIO ADJUSTMENT FOR OPTIMAL COMBUSTION IS
DONE BY BTU COMPENSATION RULES OR WITHIN O2 CONTROL
4. BATCH LINE CAN BE OPTIMIZED BY BATCH MONITORING
AND MODIFYING THE SET POINTS ACCORDINGLY
SET-POINT
TEMPERATURE
GAS
OPERATOR’S CONTROL ES IIITM CONTROL
TEMP. STABILIZATION ES IIITM CONTROL
ENERGY SAVINGS
{ GAS
SAVINGS
STEP 1 ESIII
ESIII DECREASED ERROR
STEP 2 ESIII
FUEL SAVING DUE TO
THE CONTROL NEXT TO THE
LOWER LIMIT
1
ESIIITM Specific Energy Cost Calculation
The Expert System Department devised procedures for
calculating specific energy cost within automated task.
NOx
550 mg/Nm3
NOx
850 mg/Nm3
Air/Gas ratio left
Air/Gas ratio right
Air/Gas ratio fix
ESIIITM NOx and CO minimizer
ES IIITM CAMERA - OVERVIEW
Projection
Measured data, statistics, analysis
+
• To help operator we need
visual/ thermal information
• To work with control software
need very high visual
resolution and temperature
information.
• Camera info is forwarded into ES4/ESIII
Computer for digital image analysis
Image Grabbing and Batch Identification
Batch Identification and Monitoring
A furnace camera image is
grabbed and analyzed
every minute.
Special batch identification
software is able to
recognize the islands of batch
(yellow) floating on top of the
glass (blue).
In a calibrated top view
the batch can be
characterized in terms
of distribution of batch
coverage [m2] and
maximum batch length
[m].
Batc
h le
ng
th [
m]
Batch cover relation
Batch coverage in front of furnace above 1.5 m2 has been related to
increase number of glass defects.
Trend of batch coverage [m2] in front of furnace.
Critical area in front of furnace.
Variation in batch coverage has
direct impact on furnace
temperatures:
crown temperature drops
when batch moves to front of
furnace.
Measured batch coverage area is
used as additional input in ESIII
furnace temperature control.
Next step: ESIII control of batch
coverage by automatic adjustment
of batch charging directions.
Crown temperature
Batch front area [m2]
Batch cover relation with crown temperatures
Batch Coverage vs glass quality
• The Glass Service Expert System is not the replacement of the glass technical
personnel but fast becoming a very important tool where their experience and
knowledge are adapted inside the control software strategy to make daily
operational decisions much easier and uniform.
• GS MPC is a tool that can operate furnaces in a more steady and reliable
way thus allowing furnaces save energy , with possible quality and yield
increase.
• Using MPC allows for companies to dictate an uniform furnace operation
strategy across different plants and furnaces.
• As any useful tool that is used in the industry by early adapters later on
becomes standard and used by most as for example Cameras to view
furnaces , glass contact thermo couples etc.