sGlassFocus

We love Glass

ideas for the glass industry

8

11

12

In this issue

Do-it-yourselfmodernizationMigration from Teleperm M to

Simatic PCS 7 at BSN glass pack

Brilliantly clear picturesTotally Integrated Automation

at LG.Philips Displays

Together we are strongPartners of Siemens

GlassFocus 2002

2

A cost efficient production process in the glass in-

dustry is based on concepts for using energy more

efficiently, the ability to react quickly to changing

market demands and locking up less capital. The

Siemens motto “We love glass” is not only demon-

strating the close cooperation that has been exist-

ing between the Siemens GlassTeam and the glass

industry for many years will be continued and in-

tensified. It is also synonymous with the Siemens

commitment to support both glass industry and

glass machining and to use Siemens competencies

to help its customers to be successful in today’s

and tomorrow’s markets.

Content FocusGlass Industry

Solutions

4 Optimum useEnergy solutions for the glass industryfrom Siemens

Totally integratedExpert in glass production: Simatic PCS 7

5 Eyes and ears in productionField devices from Siemens monitor all parameters

Everything under controlAdvanced Process Control optimizes glass production

6 Glass from Northern IrelandSimatic PCS 7 controls UK’s newest glass factory

7 Central Control Room SolutionSimatic PCS 7 automates glass tube production at Osram

8 Do-it-yourself modernizationMigration from Teleperm M to Simatic PCS 7 at BSN glass pack

9 A crystal-clear decisionModernization with PCS 7 in ongoing operation

10 Take-off in ChinaTotally Integrated Automation and Simatic PCS7 at Arc International

Designing with light and glass

11 Brilliantly clear picturesTotally Integrated Automation at LG.Philips Displays

Excellent viewSimatic PCS7 in glass production for LC displays

12–15 • Nikolaus Sorg GmbH & Co KG

• AAC GmbH

• Zippe Industrieanlagen GmbH

• Siemens Industrial Solutions and Services

• STG GmbH

• SiliTec

• Schlemmer Prozess Systeme GmbH

• AEG SVS Power Supply Systems

• ASE-Industry Services AG

• IWG Glasofenbau

16 The Siemens GlassTeam:Think global – act local

Successful Sequel at Kaveh Float Glass

Expertise convinces Sisecam

Saint-Gobain Isover is readyfor new opportunities

Case Studies

Partners

From around the world

GlassFocus 2002

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T he glass industry performs refine-ment in its most literal sense. Eventhe manufacturing process im-

presses the observer with its physicalpresence of heat and noise. But for all itspassion, the glass industry is also gettingsmaller and more competitive. Marketsare merging, global presence and sup-port presence are more important thanever. Important decisions have to bemade in a real time.

Partners for success

The glass manufacturer cannot meet thechallenges of increasing productivitywhile retaining quality and flexibility,and at the same time reducing costs, en-ergy consumption and emissions suc-cessfully on his own. He needs partnerswho share his fascination for glass andwho apply globally recognized and openstandards, use integrated systems anddevelop innovative technologies andconcepts worldwide, to aid and assistglass producers to achieve their strategic

and operational business goals. Linkingall facets in the production chain togeth-er, best satisfies growing consumerneeds and demands. Responsibilitiesand interactions have to be well defined,and being open is important not onlywith respect to technical standards.

Intelligent solutions for greaterproductivity and transparency

The main job of a glass factory is to pro-duce just what the market needs in onetank cycle as quickly as possible and to tieup less capital in raw materials, equip-ment and finished glass.

The Siemens glass competencies rangefrom supplying single products to com-plete electrical solutions, and include theintegration of production and manage-ment level into one coherent system – fromglass production through glass process-ing to shipment of the finished product.

Together with customers, machinebuilders and glass specialists as theirpartners, Siemens develops intelligent

solutions that help to operate glassplants more flexibly and more efficiently.Solutions for integration between theprocess, production and management al-low the glass manufacturers to plan,manufacture and evaluate productionmore effectively. This allows manage-ment teams to communicate and makethose competitive decisions on a realtime basis using real time informationfrom around the world.

In addition to innovative technology,Siemens offers international project sup-port and realization. The people who co-ordinate this variety of solutions for theglass industry and regularly share expe-rience have now become the SiemensGlassTeam – a close-knit team with acommon vision, to become the world’snumber one supplier of Automation andEnergy systems for the Global glass mar-ketplace by using their expertise to fur-ther the glass industry’s success.

Christian Dittrich, Karlsruhe

Optimum useEnergy solutions for the glass industryfrom Siemens

In theory, it takes about 2.2 millionBTUs to melt a ton of glass, but inreality it takes twice that much energybecause of inefficiencies and losses intoday’s process designs. This ratioshows that energy efficiency offers anenormous potential for savings.

Measures for saving energy arevery important in the glass in-dustry and not just for environ-

mental reasons. Energy is an importantcost factor in the long run. To reduce itsenergy consumption, the glass industryrelies on the one hand on the develop-ment of more efficient methods of glassproduction. Parallel to this it aims to re-duce energy consumption by developingmore efficient heating technologies andimproving existing systems.

For an effective energy management,the glass industry relies on having part-ners who are familiar with the glassprocess with all its characteristics. Thesepartners should take into account not on-ly isolated systems and individual prod-ucts but also the entire process and whonot only have the necessary energy butalso automation and industry know-how.

All from one source

For its customers in the glass industry,Siemens offers an extensive package of

services and solutions to analyze andoptimize energy consumption of aplant. Experienced specialists examinethe production lines for weak points,develop suitable countermeasuresand, where necessary, also supply theappropriate financing concepts. Inmany cases, simply improving the ex-ploitation of existing equipment willresult in considerable savings. Togeth-er with its partners, Siemens also of-fers services that will achieve project-ed ongoing energy savings of three to

five percent per year over the next fiveto six years.

Siemens can call on the combinedknowledge of being one of the world’smost renowned companies in the fieldof automation, drive and energy supplyand distribution technology – knowl-edge that helps the glass industry tomake better use of their resources and toachieve an optimum return on invest-ment.

Bob Newell, Spring House

GlassFocus 2002

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Totally integratedExpert in glass production: Simatic PCS 7

The Totally Integrated Automation concept is the foundation for the effectivehorizontal and vertical integration of information, automation, field and drivetechnology. The Simatic PCS 7 process control system is an integral part of thisconcept.

S ince it was launched in 1996,Simatic PCS 7 has been and is beingused in many production plants in

the glass industry because of its func-tionality and openness. Simatic PCS 7 hassince undergone further development toimprove its user friendliness and reduceengineering expense.

Glass technology add-ons for enhanc-ing energy efficiency, monitoring quali-ty, improving control accuracy, minimiz-ing emissions in flue gases and reducingconsumption of resources have been de-veloped in cooperation with glass spe-cialists and can be integrated easily inSimatic PCS 7.

Bernd Lehmann, Karlsruhe

Solutions

GlassFocus 2002

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T he bottom and crown tempera-tures in glass melting furnaces canbe controlled optimally with the

MeltingExpert software. As a result, thechannel temperature in the transitionbetween the furnace and the conditionercan be stabilized and then reduced by6 °C for instance.

ProfileExpert makes sure that the tem-perature distribution of the glass at thefeeder output is stabilized and set specif-ically to predetermined values. This al-lows direct influencing of the viscosity ofthe glass before further processing.

TubingExpert is a software package forautomatic control of the wall thicknessand diameter in glass tube manufacture.With TubingExpert the wall thicknessand diameter are controlled not onlyduring straight running but also duringchangeovers. This minimizes waste andconsiderably shortens conversion times.

Siemens has also developed suitablesolutions for additional glass applica-tions such as temperature control in thefloat bath and for glass bulb manufac-ture.

Stefan Bergold, Karlsruhe

From analysis of process gases toreliable recording of filling levels evenunder the most difficult of conditions,there is (almost) no task that Siemensfield and analysis devices cannothandle. Plus, these devices come withan extra advantage: they can beintegrated quickly and withoutcomplications into the masterautomation system.

In glass production, a great number ofparameters has to be monitored reli-ably. Yet the requirements could not be

more different: In the batch house, largequantities of sand, cullet and additiveshave to be dosed accurately and continu-ously. Level monitoring in the batch siloshas to cope with high dust levels and ad-hesive materials and in the melting fur-nace the bottom and crown temperaturesmust be kept within strict limits.

The Siemens field devices are built toresist even the toughest conditions.Field-proven devices like the highly accu-rate Siemens-Milltronics belt scales forcontinuous weighing and dosing of bulkmaterials, and with Pointek point levelswitches or Echomax ultrasonic transduc-ers, precise level monitoring is possibleeven under difficult conditions. TheSitrans LR radar technology devices pro-vide reliable level measurement even inextremely dusty environments.

Siwarex weighing systems are usedfor steady-state weighing applicationslike silos or bunkers. The pressure, tem-perature and flow monitoring devices ofthe Sitrans P, T and F families of trans-mitters are available in many differentvarieties that cover a wide range of ap-plications. The Sipart DR process con-trollers were developed for both smalland medium-sized plants and back-up

control tasks, and the Sirec processrecorder series provide continuous doc-umentation of important process pa-rameters.

Important components such as oxy-gen or nitrogen monoxide in gases orthe pH value of sewage water can bemeasured reliably and accurately withgas analyzers of the Oxymat and Ultra-mat series and Sipan liquid analyzersfrom Siemens. Siemens can also providecomprehensive analytic solutions rightup to turnkey analysis containers.

Siemens also offers a brand new solu-tion for in situ analysis of exhaust gases:the Laser Diode Spectrometer LDS 3000was especially designed for high temper-ature processes such as DeNOx plants.

Helmut Schneider, Karlsruhe

Eyes and ears in productionField devices from Siemensmonitor all parameters

Everything under controlAdvanced Process Control optimizes glass productionAdvanced Process Control (APC) software from Siemens makes sure that thesystem is always “on track”. For the glass industry that means: more stableprocesses and a better product quality. Investment in APC pays off quickly –usually within 9 to 15 months.

Q uinn Glass operates the mostmodern center for glass manu-facture in Great Britain and Ire-

land. After a construction period of just18 months, the plant came on line inCounty Fermanagh, Northern Ireland.300 employees are now responsible forthe daily production of up to 600 tons ofbottle glass on eight production lines.

First-class reliability

The manufacture and processing ofglass poses a major challenge for au-tomation and process control technolo-gy. If only one melting end is in opera-tion, any disruption can result in hugecosts or lead to irreparable damage.That’s why Diarmuid O’Donovan, re-sponsible for electrical equipment andinstrumentation at Quinn, didn’t enter-tain any thoughts of compromise whenit came to control technology: “Themelting ends are in continual operationfor around eight years until they are ex-changed. We expect a lifetime of at least20 years for a process control systemand a high degree of reliability duringthis time.”

Siemens and the Simatic PCS 7 processcontrol system were selected from ninepotential suppliers. “In addition to itsbroad knowledge of the sector, the sup-port offered by Siemens played a majorpart in our decision,” explained O’Dono-van. The system now installed witharound 3,500 I/O points is operated byfive operator stations. An OP25 OperatorPanel is also available for the on-site op-eration of the cooling furnace. ProfibusDP is used for communication in theplant and Industrial Ethernet at the oper-ator stations. Integration into QuinnGlass Management Information System(MIS) is also planned.

Turnkey solution

The tasks of the process control systemare in the so-called hot area and also inthe upstream and downstream process-es. This involves glass batch preparation,insertion of the glass batch, meltingends, feeders and cooling furnaces.

Glass from Northern IrelandSimatic PCS 7 controls UK’s newest glass factory

Operating a modern glass factory requires a high degree of automation, distributed intelligence and anefficient process control system. Quinn Glass of Northern Ireland made the right choice when it selectedthe Simatic PCS 7 and Totally Integrated Automation.

Case Studies6Blow Glass

GlassFocus 2002

GlassFocus 2002

7Case StudiesGlass Bulbs

Central Control Room SolutionSimatic PCS 7 automates glass tube production at Osram

Glass tube production at Osram in Augsburg was automated fairly early withcontrol technology. The due repair of melting end C gave Osram theopportunity to rethink its current operating philosophy and to modernize itscontrol technology.

T he operation in Augs-burg employs around2000 staff and compris-

es the glass factory, the lampfactory and the machinery de-livery center. The glass factoryproduces the glass tubes usedin the lamp factory to manu-facture fluorescent lights.

Innovative from the verybeginning

As part of a melting end re-pair in 1980, the central con-trol technology was equippedwith the Teleperm M AS220automation system – some-thing new for the glass indus-try at the time. When the newmelting end B opened in1987, it was equipped withthe same technology. Lastyear as part of the repair workon melting end C, the existingcontrol technology islandswere replaced by a central so-lution, which also integratedthe glass batch preparationand the tube pulling (Velloprocess).

In the spring of 1999, Siemens wasawarded the contract to automate thenew control room with the SimaticPCS 7 process control system. In addi-tion to proven expertise in the sector,local presence and good long-term co-operation, also crucial to awarding ofthe contract was the migration solu-tion offered which allows the existingTeleperm M system to be integrated in-to the new automation concept. As theI/O periphery could also be taken overwithout changes, no new peripherytest was required. This resulted in re-duced costs and shortened repairtimes. In order to guarantee continu-ity, the inventory was networked viaProfibus to the Simatic S5 115U con-trollers and the existing Sipart DR22controller. Two redundant serverslinked the system bus with the termi-nal bus. The system is operated via five

operating stations, one of which is be-ing also used as an engineering sta-tion.

Scheduled implementation

In a period of around five months, a con-siderable amount of engineering workhad to be completed. According to HeinzMüller, Osram Chief Project Engineer,the fact that it was possible to keep to theSeptember 1999 start time for the melt-ing end could be attributed to the excel-lent cooperation within the project teamand the short decision-making paths. DrKarl Zirkelbach, factory manager, wasable to present the new plant to an inter-ested audience at the DGG meeting inUlm in May 2000.

Johann Fendt, Augsburg

The control of the melting end is par-ticularly critical as temperature between1580 °C and 1590 °C must always be main-tained. Quinn uses regenerative endsand the heating is switched over every 20minutes. With Simatic PCS 7, the end pa-rameters, the influence on the glass con-sistency and the energy consumptioncan be constantly optimized.

Normally, each end has its own chim-ney, but at Quinn it was decided to have acommon outlet, as the problems which

may arise as the result ofpressure fluctuations in ashared system can be easilyovercome with Simatic PCS 7.

Flexibility leads to progress

As with many plants of thissize, the project engineeringfor the control technologydid not go completely accord-ing to plan. In the originalplanning, an independentcontrol system was plannedfor the exhaust gas purifica-tion plant. However, it soonbecame clear that the inte-gration of this part of theplant into the control systemwould provide better controlover the entire process. In thecourse of the project, it wasalso decided to integrate thecontrols for the auxiliary sys-tems into the control system.The same applies to the batchcontrol, which was only in-corporated at a relatively latestage. This demonstrated thestrength of the Simatic PCS 7.While other products can on-ly talk about flexibility, withPCS 7 demands could be metwhich would be difficult toimplement with convention-al systems.

The number of I/O pointswas also a point in its favor.Conventional systems willhave already reached theirlimits at 3,500 points; whilefor PCS 7 this application isan example of a medium-sized installation. SimaticPCS 7 is primarily a symbol ofmodularity and scalability –properties that give the plantdesigner the highest degreeof flexibility.

Mark Chung, Manchester

Five Operator Stations monitorthe new system.

Case Studies8Blow Glass

Do-it-yourself modernizationMigration from Teleperm M to Simatic PCS 7 at BSN glass pack

When BSN glass pack in Leerdam in Holland decided to replace the Teleperm Msystem with the Simatic PCS 7 process control system, the company chose aninnovative solution: BSN did the migration themselves – with the technicalsupport of the Siemens system experts. In this project PCS 7 proves once againthat it makes no compromises when it comes to simple handling and userfriendliness.

T he BSN glass pack Company withsubsidiaries in four countries isone of the leading manufacturers

of glass bottles, glasses and food jars.With about 45 glass furnaces at a total of21 sites, BSN produces about 3.8 millionstons of glass annually in 144 productionlines – or 13 billion single glass items.One of the subsidiaries is BSN Nether-lands with three sites in Schiedam, Maas-tricht and Leerdam.

The migration from Teleperm M toSimatic PCS 7 is the third project whichBSN glass pack has implemented in Eu-rope with Simatic PCS 7 and Siemens. Atthe beginning of 2000 BSN glass packhad already decided to automate thetransport systems for the glass raw ma-terials and the process control of a fur-nace in two projects with PCS 7 at theSchiedam site. The positive experiencegathered with the new process controlsystem was also the decisive argument infavor of choosing PCS 7 for the modern-ization of the control system for the glassfurnace in the Leerdam factory.

Migration made easy

“What was much more important to us,however, was the fact that Siemens wasable to offer us a highly sophisticated mi-gration strategy from Teleperm M to thenew system. This put us in a position to

continue using about 60 percent of theexisting hardware – an enormous costadvantage”, states René Meuleman, Pro-ject Manager at BSN glass pack Nether-lands. “In addition, PCS 7 has a look-and-feel that is similar to Teleperm M, so thatour production staff could continueworking in a familiar environment.”

Since Simatic PCS 7 had alreadyproved in Schiedam how easy it is to han-dle, BSN decided to do the necessary mi-gration themselves after appropriatetraining at Siemens and only consultSiemens specialists for the fine-tuning ofthe system. A courageous and not alto-gether everyday step as René Meulemanconfesses. “This decision was aimed pri-marily at reducing both the runningcosts and the costs for maintenance andservice of the system. Although wesigned a service contract with Siemens,our on-site technician still has to makethe right decision within minutes shoulda serious fault occur – and that is why wehave to know the system inside out.” Inaddition, BSN glass pack is planning toinstall PCS 7 in other plants as well,therefor a build-up of know-how is alsoimportant in this respect.

Exact process control is crucial

The temperature of the molten glassmust be kept within narrow and exactly

defined limits to avoid a loss in quality ofthe finished product. With the TelepermM system BSN had already developedstrategies that were able to achieve thishigh accuracy. PCS 7 continues usingthese strategies and is expanding them.Advanced Process Control systems,which Siemens has developed in cooper-ation with the IPCOS Technology special-ists in Boxtel in Holland, will not only en-able a more accurate process control infuture but will also ensure that the plantswork more energy-efficient.

Easy commissioning

Since the three glass lines in Leerdam op-erate continuously, the furnace conver-sion had to be completed during the rou-tine cold repair. The project teambenefited from the experience with theSchiedam project. For example, tem-plates for system installation and parts ofthe system software were simply copied.

The good cooperation between BSNglass pack and Siemens will continue. Atthe moment a furnace control with PCS 7is being implemented at the Maastrichtsite.

René Meuleman, BSN glass pack, Maastricht

A sophisticated migration strategyreduces refitting costs

GlassFocus 2002

GlassFocus 2002

9

From Teleperm M to Simatic PCS 7

Both melting furnaces were automatedwith Teleperm M AS 230 during a cold re-pair in the 1980s. Since then the systemhas been operating reliably and withouta single failure – operation of the controlsystem was only interrupted during thescheduled routine annual maintenance.The discontinuation notice for theTeleperm M AS 230 systems triggered thedecision to modernize the furnaces withthe Simatic PCS 7 process control system.

Two-stage implementation

Each of the two melting furnaces wasequipped with its own AS 416 automa-tion system that communicates with a re-dundant PCS 7 Operator Station via In-dustrial Ethernet. The I/O level andimportant control circuits with SipartDR-24 positioners, thyristor actuators,variable speed drives and the pellet-weighing unit with Siwarex M are net-worked directly via the Profibus DP.

The whole conversion was executed intwo stages. The most important require-ment that Schuller made: The glass pro-

duction was not to be interrupted orstopped during the entire moderniza-tion. When the contract had been award-ed to Siemens, the project of convertingthe furnace number 2 was set on coursein the spring of 2001. Existing low volt-age switchgear and parts of the existingcontrol room were integrated in thehardware planning. Based on the re-quirements specification previously ne-gotiated with the Schuller GmbH, a teamof glass experts at Siemens in Colognetook over the PCS 7 engineering. The cus-tomer conducted the software accept-ance test in Cologne, and the actual mi-gration began immediately after thehardware plans were submitted.

Thanks to the excellent cooperationbetween the project teams of Siemensand Schuller, the peripheral signals wereconverted quickly to the new systemwithout affecting the continuous glassproduction. “Furnace 2” has been inoperation using PCS 7 since April 2002.PCS 7 offers greatly extended operatingand monitoring features compared toTeleperm M while controlling the samequantity structure that have been opti-mally implemented in the software andhave led to a high acceptance with thepersonnel in production.

The changeover of “Furnace 3” toPCS 7 began in May 2002 and will becompleted by the fall of this year.

Jürgen Herbach, Thilo Behringer-Stephan,Schuller GmbH, Wertheim

A crystal-clear decisionModernization with PCS 7 in ongoing operation

The Schuller GmbH – a subsidiary of the internationally active Johns ManvilleCompany since 1971 – is one of the top companies in textile glass production.After years of good experience with the Teleperm M process control system, thecompany management decided to modernize the Wertheim production withSimatic PCS 7, the Siemens control system succeeding Teleperm M.

Case StudiesFiberglass

The new PCS 7 control room

I n 1936, Werner Schuller reached animportant milestone in the history ofthe Schuller GmbH with the develop-

ment of glass fibers that were fit for spin-ning. Today, almost 70 years later, thecompany is the world’s leading manu-facturer of glass fiber products and thelargest glass fiber mat producer in Eu-rope. The recipe for the company’s suc-cess is based on a skilful combination oftechnical creativity, decade-long expert-ise in innovative customer-oriented so-lutions and clearly defined productioncriteria. What counts is a production atthe highest technical level – fast, flexi-ble, just in time – and the finest qualityproducts.

In the factory’s own glassworks at theWertheim site, C-glass pellets are manu-factured as a base material for the subse-quent fiber production. The batch housefeeds the raw materials for productioninto two electrically heated melting fur-naces. The resulting liquid raw glass getsthe proper shape on the pellet machines.After cooling, the pellets are transferredto the roving or hank fiber production.

Arc International inArques in France havebecome the world leaderin glasses and tableglassware with suchtrade names as Cristald’Arques, Luminarc orArcopal. The companyis now preparing toconquer one of the

world’s most importantmarkets: China. Arc is

building a new produc-tion plant in Nanjing, 200

kilometers from Shanghai.Siemens is supplying the automationand drives for this project.

T he Central Engineering depart-ment at Arc International was re-sponsible for the development

and design of the oven and the ma-chines. For local support to the team,Arc was looking for a partner for the au-tomation and drives part of the project

who not only had the necessary industryknow-how but could also offer a strongglobal presence. With its Totally Inte-grated Automation concept, its interna-tional GlassTeam and the excellent localsupport in both France and China,Siemens were able to meet Arc’s re-quirements.

The feeders and the glass furnacewere automated with the Simatic PCS 7process control system. Masterdrives,1FT6 motors and other components be-longing to the Totally Integrated Au-tomation family make sure the produc-tion runs without a hitch. Siemens alsosupplied the Siwarex weighing systemsfor the Nanjing site.

Locally, Siemens Industrial Automa-tion Shanghai (SIAS) also helped the cus-tomer in recruiting and training automa-tion and drives technicians and were alsoresponsible for the erection of the con-trol cabinets.

Olivier Vincent, Caluire-et-Cuire

Take-off in ChinaTotally Integrated Automation andSimatic PCS 7 at Arc International

GlassFocus 2002

Case Studies10

Glass blocks have establishedthemselves as an indispensablebuilding element in modern day

architecture owing to their interestinglight conducting effects and the effec-tive symbiosis of functionality and de-sign.

The Building Glass Division of theSaint-Gobain Oberland AG with itsheadquarters in Wirges near Koblenzis the leading European glass blockmanufacturer. The wide range of prod-ucts is exported to more than 70 coun-tries worldwide.

Together with Siemens, Saint-GobainOberland AG has already completed sever-al successful products. For example, a newfurnace for bottle production was auto-mated with PCS 7 in Spring 1999 in Wirgesand the furnace for glass blocks in Decem-ber of the same year.

At glasstec 2002, visitors were able toadmire the “offspring” of this cooperation.A wall of glass blocks from Saint-GobainOberland carrying the fair motto “We loveGlass” caught everybody’s attention.

Cornelia Dürrfeld, Karlsruhe

Designing with light and glass

Table Glass Glass Blocks

GlassFocus 2002

11Case Studies

Brilliantly clear picturesTotally Integrated Automation at LG.Philips DisplaysCathode ray tubes will continue to dictate the market for TV and computermonitor tubes in future owing to their low costs and excellent picture quality.But the demands on picture tubes are increasing: Flatter screens with a higherresolution at a low price are what the customer wants. The market leaderLG.Philips Displays is reacting to these demands by building a new CRT glassfactory in Zhengzhou in China that is automated with components from TotallyIntegrated Automation (T.I.A.).

O ne in four color screens for theworld’s TV sets and computersare made in one of the 32

LG.Philips Displays factories. This makesthe joint venture between the Korean LGElectronics and Philips Electronics of theNetherlands the world’s largest providerof cathode ray tubes for TV and computerscreens.

LG.Philips Displays was looking for aprocess control system which allows ex-tremely complex and flexible solutionsand at the same time guarantees maxi-mum precision and consistent quality –requirements that are essential in manu-facturing these glass tubes. For instance,the required quantities of glass must be

exactly proportioned and the aperturemask has to be applied to the screen withan accuracy of a thousandth of a millime-ter. In a new glass factory in Zhengzhouin China, LG.Philips Displays chose anautomation solution based on theSiemens T.I.A. concept for the first time.

This project is called ANFEI and is be-ing installed on new premises. In the firstphase of the project, two furnaces withtwo production lines each are being im-plemented. The ANFEI project is basedon a partnership with a Chinese compa-ny and is a real international coopera-tion: Siemens Netherlands produced theswitching cabinets for the glass presswhich were installed and successfully

tested together with the whole press inthe USA by the press manufacturersLynch. Then they were transported toChina and installed on site.

Siemens also provided the entire au-tomation technology, including theSimatic Controller, distributed SimaticET 200S I/O devices, Masterdrives, servomotors and the switching technologyand process analysis systems. Profibusand Ethernet networks handle the com-munication between the individual com-ponents.

Martin Stofregen, The Hague

between 0.3 and 1.1 millimeters thick;the size of the finished glass panes forthe displays is 355 x 406 millimeters forthe STN-LCDs and 680 x 880 millimetersfor the TFT-LCDs.

The entire plant, from the mixing sec-tion right through to packing of the fin-ished products, has been automatedwith Totally Integrated Automation(TIA) components. A total of 20 Simaticcontrollers control the processes andthe 12 Operator Stations of the Simatic

PCS 7 process control system ensurethat the personnel always has an eye onall the important information. AEG SVSsupplied the systems for the furnaceheating which are also integrated intothe TIA concept.

Siemens Limited Taiwan was responsi-ble for implementing the entire networktechnology for COTC and integrated theproduction utilities into the PCS 7 system.

Ludo Goethals, Karlsruhe

Excellent viewSimatic PCS 7 in glass production for LC displays

Cell phones, computer monitors, field devices or handheldorganizers – Liquid Crystal Displays (LCD) can be found almosteverywhere. The possibilities of this technology have by no meansbeen exhausted as the rapid progress of the TFT-LCD proves. Themicroscopically small structures of the displays are manufacturedin a process that is similar to semiconductor production – exceptthat the carrier is not silicon but a very thin, flat panes of glass.This motherglass is produced by COTC in Taiwan using the SimaticPCS 7 process control system.

A n ever-increasing number of de-vices are now equipped with anLCD– and the end to the boom is

not in sight. The basis of LCD productionis the so-called motherglass that mustmeet exact quality specifications.

The new production line of the COTCChina Optoelectronics Technology Cor-poration produces motherglass for Su-per Twisted Nematic LCDs (STN-LCD) andThin Film Transistor LCDs (TFT-LCD) intwo melting furnaces. The motherglass is

Case StudiesMonitors

GlassFocus 2002

12

No system breachesIntegrated automation from thebatch house to the working endSiemens components and the experience of theproject team of the Nikolaus Sorg GmbH & Co KGwere a guarantee that the expansion and renovationof an existing glass melting furnace would be a totalsuccess. With this project, the melting furnacespecialist from Lohr am Main was once more able toprove its great expertise.

T he order also included the controlequipment for the melting furnaceand the forehearths as well as the

partial renovation and expansion of thebatch house and the corresponding elec-trical equipment from the EME Maschi-nenfabrik Clasen GmbH, a subsidiary ofthe Sorg group.

For automation of the system, Sorg re-lied on the Totally Integrated Automation(TIA) concept which, thanks to the highdegree of integration of hardware andsoftware, minimizes spare parts stocks,reduces wiring due to consistent use offield bus technology and reduces thespace demand in the wiring ducts.

The ten scales of the glass batch plantare automated with Simatic S7 400 con-

trollers and Siwarex U weighing systems.The automatic sand moisture correctionfrom EME guarantees an exactly definedSiO2 percentage in the batch. The cullethandling is coupled to the automationvia Profibus and, like the batch plant, canbe operated from all four WinCC opera-tor panels.

An S7-400 controller is responsiblefor the furnace, the working ends andthe forehearths including the Sorg cas-cade heating system and the Sorg stepcontrol for the cooling systems. Thesubordinate Simatic S7 300 controllertakes over regenerative reversal of theheating and transfers the relevantprocess data via Profibus DP to the S7400 controller.

All functions of the plant can be moni-tored and controlled continuously by theSimatic WinCC visualization system.WinCC also allows access to other plantparts such as filter plant and coolinglehrs, which are linked to the system viaProfibus.

contact: Richard Sims

e-mail: sims@sorg.de

web: www.sorg.de

Know-how from AAC is much askedfor all over the world: COTC Tai-wan, for instance, chose a PCS 7-

based control system to optimize au-tomation in the batch house. Well-knowncustomers such as Saint-Gobain GlassFrance also rely on the German companyboth for equipping new plants and mi-gration projects from Teleperm M sys-tems to PCS 7.

The solutions from AAC optimize ef-fectiveness, flexibility and quality inglass production. The recipe manage-ment with connected SQL database forexample takes care of time-controlled pa-rameter changes to the feeder con-trollers, thus simplifying and accelerat-ing product changeovers.

An IS machine cooling solution wasdeveloped in cooperation with Siemensand Silitec to measure the baffle temper-ature without contact and to control itconstantly. This guarantees the consis-tent quality of glass packs.

At Saint-Gobain Desjonqueres inFrance, setup times for product changescould be reduced considerably by usingan AAC fuzzy controller for the feedercontrol and a greater temperature con-stancy was achieved.

contact: Andreas Ade

e-mail: andreas.ade@aac-st.de

web: www.aac-s7.de

Partners

The AAC Ade Automation ConsultingGmbH has an excellent reputationwhere complete process engineeringsolutions for hollow and flat glassproduction are concerned. The company develops andimplements process-specific add-onsthat extend the scope of functions of Simatic PCS 7 in close cooperationwith Siemens.

Processengineeringknow-howThe AAC GmbH – a global partner to the glass industry

GlassFocus 2002

13

Under contract to the Saint-GobainGlass Deutschland GmbH, the ZippeIndustrieanlagen GmbH built a newturnkey batch house in Cologne-Porz.The innovative plant has been runningsuccessfully since June 2001 –controlled by two Simatic S7-400 andS7-300 controllers.

Since its foundation in 1920, theZippe Company has been focusedon supporting the international

glass industry. Zippe develops and im-plements solutions for handling raw ma-terials in glass production – from theplanning and basic engineering throughplant design, to building and commis-sioning.

With two mixers and fourteen con-tainer scales the batch house in Cologne-Porz handles the equivalent of 800 tonsof molten glass in 16 hours. The ratedload of the scales ranges from 200 gramsto 3,500 kilograms, and each is equippedwith its own weighing and proportion-ing computer. The compressor systemand the cullet process are each con-trolled by a dedicated Simatic S7-300controller. The raw materials registra-tion is monitored by a barcode readersystem with a large display. This systemsends the delivery data to the central S7-400 controller that also controls theentire batch house. All components arenetworked via Profibus DP. The recorded

data can be used for raw material ac-counting and distribution.

An optical glass fiber network con-nects the automation system with the op-erator stations in the furnace controlroom and in the batch house. A comfort-

High-precision mixingZippe builds a new plant for Saint-Gobain

T he STG GmbH Cottbus offers inno-vative technological solutions forindustrial furnaces, especially glass

melting furnaces. STG works in close co-operation with Siemens in the field ofprocess automation in the glass industry.Comprehensive solutions using PCS 7systems have been implemented forSaint-Gobain Glass Mannheim and Stol-berg. Siemens technology was also usedfor the Guardian float plant in Poland.

Glaverbel, the Schott group, Isover, Sam-sung Corning, Philips, BSN glass packand Saint-Gobain Oberland also rely ontechnological solutions developed by thecompany from Cottbus, Germany.

One of the developments of STG arelong-life zircon dioxide oxygen sensorsfor high temperature applications thatare used as a basis for lambda-controlled

combustion air supply. Energy savingand low-emission solutions for gas- andoil-fired burners, dynamic air buffles foroptimum control of combustion air dis-tribution or video image evaluation ofthe furnace room for online analysis ofthe melting behavior, are also part of theproduct portfolio. The combination ofintelligent automation and innovativetechnology leads to energy savings of upto 10 % – and this at NOx emissions of400 to 800 mg/Nm3 depending on thefurnace type. The return on investmentcan be within the year.

contact: Dr. Peter Hemmann

e-mail:stg_cottbus@t-online.de

web: www.stg-cottbus.de

Intelligent and efficientTechnological solutionsfor the glass industryfrom STG

Glass ExpertsSiemens IndustrialSolutions and Services

N o matter whether it comes toblow glass, float lines or glassfiber production: More than fif-

teen experienced technicians and engi-neers plan electrical equipment for alltypes and stages of glass production atSiemens Industrial Solutions and Ser-vices. The team from Bayreuth, Germanynot only implements energy supply anddistribution solutions using type-testedswitchgear but also provides efficientdrives and controls engineering. Theportfolio covers every stage of produc-

tion from the batch house through fur-nace, float bath and annealing lehr up tothe cross cutters and packaging units.

The performance catalog includes ex-tensive know-how in hardware and soft-ware configuration, visualization, controltechnology, switch cabinet construction,on-site installation and commissioning.This guarantees reliable equipment forthe whole life cycle of the machinery.

At the moment, the successful team isfitting out a new Guardian float systemwith drive technology. Contracts in theSaint-Gobain and Pilkington factorieshave been completed within the narrowtime schedules of cold repairs.

contact: Reinhold Selz, Bayreuth

e-mail: reinhold.selz@siemens.com

Partners

able SPC module with an XRS chartand various trend displays for plantmonitoring and optimization is an in-tegral part of the system. A displaypanel with manual control featuresand four control cameras are also in-tegrated in the control system.

The maintenance and service mod-ule checks all the important functions,provides maintenance at the right timeand provides the necessary manuals.The plant is in contact with the ZippeService Center via modem. This centerprovides support and can access thecontrols and control system directly.

contact: Franz Rhein

e-mail: info@zippe.de

web: www.zippe.de

GlassFocus 2002

14

W hen it comes to stabilizing andoptimizing glass productionprocesses, the SiliTec employ-

ees know best.The company from Freiberg, Saxony,

implements accurate process diagnosissystems and develops products for theprocess stabilization by automatic con-trol engineering for glass manufactur-ers. Based on automation systems fromSiemens and supported by the process-technical know-how of a whole networkof specialized companies, SiliTec offers awide range of innovative solutions.

One example for these solutions isthe modular control system CMCS forstabilizing the mould temperatures onIS machines and cycles. This system wasimplemented for the Hermann HeyeGlas company in Germersheim usingthe following configuration: Cooling airand mould temperatures are monitoredby measuring instruments and con-trolled by a Simatic C7 controller and athrottle valve or alternatively by a fre-quency inverter. The system is linked toa separate PC for process control and toSimatic WinCC for continuous docu-mentation. SiliTec also implemented ateleservice concept for remote servicingof the system.

Another component for process stabi-lization is the VisControl; a solution forviscosity-dependent glass conditioningin the feeder which ensures that everychange in viscosity is measured precise-ly. Here too, the dedicated control con-cept DeltaControl can be connected toevery process control system fromSiemens without any problems.

contact: Harald Zimmermann

e-mail: info@silitec.de

web: www.silitec.de

T he Schlemmer Prozess SystemeGmbH in Deggendorf developsfaceplates for the Simatic PCS 7

process control system that are adaptedexactly to customer requirements andbased on internationally recognizedstandards. Schlemmer provides cus-tomer support throughout the produc-tion life cycle from planning throughcommissioning right down to day to day

production. For the Heinz Glas GmbH inOberfranken SPS has equipped threemelting furnaces complete with numer-ous sub-plants with the PCS 7 controlsystem within the last three years. ForHeinz and other SPS customers, factory-wide process automation has long sincebecome one of the prerequisites for a fu-ture-safe quality assurance and increasein production.

The economical advantages of theseuniform hardware and software compo-nents are obvious. The modular struc-ture ensures that extensions to parts ofthe plant can be implemented quicklyand at low cost. It simplifies spare partsstocking and reduces personnel trainingto a minimum. The common user inter-face not only makes it easier for produc-tion staff to handle the different parts ofthe plant on site but also considerably re-duces outage times and production fail-ures. The cabling and installation costsare also reduced by the distributed struc-ture of the control system including theoperator stations.

contact: Heribert Schlemmer

e-mail:SpS@SpS-gmbh.de

web: www.sps-gmbh.de

SettingstandardsNew automationstandard with SimaticPCS 7 faceplates

Partners

ControlledcoolingSiliTec exploitsoptimization potentialin glass production

Getting theretogetherAEG SVS and Siemens:a winning team

GlassFocus 2002

15

The exact control of the electricalpower supply is a tricky business notjust for the glass industry. But herethe particularly high demands onprecision and efficiency make powersupply one of the “hot spots” ofapplication engineering.

S iemens therefore placed greatemphasis on consistent opti-mization of the power control

from the start and found the ideal so-lution in the partnership with AEG SVSPower Supply Systems, the leadingprovider of thyristor power actuators.With these devices, the electrical ener-gy supply can be controlled not onlyloss-free and precise regardless of themethod used – phase gate principle orclock principle – but also monitoreddown to the finest detail. AEG SVS hasconsistently integrated interfaces toProfibus and the Siemens world of au-tomation in all digital devices. And thecooperation pays off: Short plant com-missioning times, high operationalreliability, lower costs and increasedefficiency – plus points which the cus-tomers require.

For example at Saint-Gobain: In thefloat plant in Thourotte, the Frenchcompany had 33 heating zonesequipped with the communication ca-pable power actuators Thyro-P fromAEG SVS. These were linked to themaster PCS 7 process control systemfrom Siemens via Profibus DP. Thisfirst installation of Thryo-P, Profibusand PCS 7 in a combination worldwidehas drastically reduced the conversiontime and eliminated many problemsthat Saint-Gobain had with other solu-tions in the past.

A large number of customers allover the world put their faith in the in-tegrated solution – for example infloat glass lines, directly heated melt-ing or motherglass plants for TFT dis-play production.

contact: Harro Liese

michael-harro.liese@aegsaft.alcatel.de

web: www.aegsvs.de

I ntranet and Internet and modern dig-ital video technology open up new di-mensions in the monitoring and con-

trol of processes and procedures. TheASE-INDUSTRY Services AG in Bruchsalwas able to prove this claim successfullyin several projects. ASE works in close co-operation with Siemens, developing fu-ture-proof digital video solutions for di-verse applications in the manufacturingand process industries.

Event-triggered image data are re-corded by on-site cameras and – adaptedto the respective customer – stored cen-trally on the Visor video server devel-oped by ASE. Here they can be accessedany time so that a detailed, up-to-dateprocess database can be easily createdand maintained. Faults and failure times

are therefore minimized, productioncosts are reduced and the whole operat-ing process is optimized.

The modular structure simplifiesmaking individual adaptations and lateradd-ons. That way the system can bemodified to fit to all company and plantsizes. The ASE video surveillance sys-tems can also be equipped with compo-nents for networking as well as controland interface software.

Kontakt: Eric Steck

e-mail: eric.steck@ase-industry.com

web: www.ase-industry.com

Video surveillance saves costsDigital image data recording opens up new possibilities

Successfulin Russia –as wellIntelligent processautomation with TIA

Together with their partners, thespecialists of the IWGGlasofenbau company in Zwieselhave successfully equipped acontinuously operating glassmelting furnace with a capacityof six tons in the city of GusKhrustalny, 250 km east ofMoscow, with Totally IntegratedAutomation (TIA) componentsfrom Siemens. This project isanother success story in thecooperation between therenowned furnace manufacturerand Siemens.

T he heart of the automation is a Simatic S7-Controllerfrom Siemens. Moreover, the

Siemens control system handlesthe plant HMI (Human MachineInterface). Forty-eight customizedprocess images and menu-guidedoperation make operation of thesystem easy. The training expenseshave been reduced considerably asa result.

For example, all the process da-ta can be called from the Control-ling and Preparation units at anytime via the Ethernet and pro-cessed as desired. Remote mainte-nance by IWG is no problem eitherbecause all texts are convertiblefrom Russian to German at a clickof a mouse.

contact: Markus Schreder

e-mail:info@iwg-online.com

Partners

16

Successful Sequel atKaveh Float GlassKaveh Float Glass had already beenworking with Siemens when theyequipped the line 1 of their float glassproduction. In that project, Siemens hadmade such a good impression thatKaveh opted for a sequel to this coopera-tion when they decided to build a secondline with a capacity of 600 tons per day inSaveh southwest of Teheran, Iran.

For the new project, which is sched-uled to start at the second quarter of2003, Siemens are also supplying notonly the Simatic PCS 7 process controlsystem, but also heating transformersand thyristor cabinets. Additionally,Siemens are also responsible for the en-gineering and commissioning. The fac-tory acceptance test was conducted suc-cessfully at the end of July and right nowthe system is on its way to Iran.

Thorsten Reichenecker, Karlsruhe

Saint-Gobain Isover is ready for newopportunitiesThe new Saint-Gobain Isover productionfor glass wool in Yegorievsk, Russia willhelp to strengthen Isover’s position inthis important market. Since Siemenshad already made an excellent impres-sion in the automation project for an-other Isover production in Poland,Siemens will also supply the processcontrol system Simatic PCS 7 plus in-strumentation and be responsible forthe installation, engineering and com-missioning of the systems.

Tuomas Tuomela, Ulvila

Expertise convincesSisecamWhen Sisecam was looking for a newprocess automation system for their sec-ond float glass furnace in Luleburgaz,Turkey, Siemens was able to secure thecontract against a strong competitionowing once more to industry know-how,a comprehensive product portfolio andthe impressive advantages of Totally In-tegrated Automation (TIA).

The Siemens scope of supply consistsof process automation with SimaticPCS 7, low and middle voltage switch-gear, drives, controllers and the WinCCprocess visualization system from theTIA systems family. Engineering, imple-mentation and commissioning of theautomation systems and switchgear ispresently underway and by December2002, the entire project will be com-pleted.

Hakan Ersin, Istanbul

From around the World

Siemens has built a network of specialistswith the necessary industry know-howwho offer services including testing,training and after-sales service andmade-to-measure solutions rangingfrom planning and concept developmentright through to implementation on thebasis of Totally Integrated Automation.Throughout the entire project, the ex-perts will cooperate closely with all par-ties involved, thus guaranteeing that theimportant deadline for furnace firing upis met and ensuring cost-saving and fastimplementation of the project.

The regional project support for theUSA comes from Spring House (Philadel-phia), for Europe from Germany, for

GlassFocus

PublisherSiemens Aktiengesellschaft, Automation and DrivesDivision, Erlangen

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PhotosKoerber (2, 3, 5, 6), W. Geyer (4), Quinn Glass (6), Osram(7), BSN glass pack (8), Werner Schuller GmbH (9), Arcinternational (10), Philips (11), Nikolaus Sorg GmbH & CoKG (12), STG GmbH (13), SiliTec (14), SPS (14), AEG (14)

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© 2002 by Siemens Aktiengesellschaft Berlin und München.All rights reserved by the publisher.

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For more info visit our website: www.siemens.com/glass-industry

Southeast Asia from Singapore and forChina from Shanghai.

A regular exchange of information be-tween the experts guarantees that theSiemens industry know-how is availableall over the world.

“Think global – act local” also meansthat the responsible Siemens project

team is always right where the project is,whether in the planning phase, the im-plementation or commissioning. In thisway the customer can be sure of alwayshaving a competent partner from theSiemens GlassTeam at his side.

Bernhard Saftig, Karlsruhe

The Siemens GlassTeam:Think global – act local