Gas cabinets and panels for heat treatment plants

Since 1996, AVION Europe’s field of activity has expanded enormously and, in addition to spare parts and services, increasingly includes complex tasks such as the design of gas mixing batteries, modernization of control systems (e.g. S 5 to S 7), control cabinet construction and the creation of complete SCADA systems according to individual customer requirements.

In the following, we explain our delivery options in these areas in bullet form. Prerequisite for all respective systems: Intensive consultation by our specialists with many years of experience in the heat treatment industry.

• Automatic control of carbon potential and atmospheric generation (nitrogen and methanol).
• Analog or digital flow meters for perfect measurement and control of gas consumption
• Custom design and build on customer preferred high quality components
• According to the current safety and industry standards
• Gas leak detection system with alarm
• Gas supply with:
  • Propane or natural gas
  • Nitrogen
  • Air
  • Endoatmosphere
  • Methanol
  • Ammonia
  • other

Modernization or complete new construction of gas mixing and control stations or even measurement of atmospheric composition from a single source. As stationary systems with clocked measurements of several individual furnace systems or as a mobile solution for individual control measurements. The gas analysis devices of Supersystems Europe (SSI) are distributed in German-speaking countries exclusively by AVION Europe – service included.

• Automatic 3 or 4 gas analyzers of the latest technology with single zone or multi-zone technology, integrated with control systems and gas flow regulation panels.
• Multi-zone analyzers for measuring up to 8 zones or separate furnaces one after the other, save money on investment and ensure very good measurement quality
• 3 Gas analyzers for measurement
  CO, CO², CH4
• 4 Gas analyzers for measuring
  CO, CO², CH4 and H²
• Easy integration with existing PLC software to control, monitor and record carbon potential,
• Integrated systems ensure best product quality and process repeatability
• Complies with CQI-9 and AMS2750

• Complete control cabinets and control systems for industrial furnaces, heat treatment lines and auxiliary equipment
• Designed and built based on the latest proven components available on the market (Siemens, Eaton, AEG, Rittal …).
• Modern PLC controls and software based on many years of experience in the heat treatment industry
• Carbon potential, temperature and many other process control parameters integrated in Siemens PLC software (no additional controllers required)

• SCADA system based on Siemens WinCC for individual furnaces or complete hardening shops
• Full integration with PLC software
• Available communication and information exchange option with other systems (warehouse, quality, gas consumption,…)
• Custom interface and graphics
• Easy identification of faults, alarms, integrated with electrical schematics and PLC alarms.

• Single Station – one computer with one WinCC V7 application

  • Operation from a single PC

  • Cost-effective

  • Not recommended for 24/7 production mode

The SCADA system

The construction of individual SCADA (Super-visory Control and Data Acquisition) systems is the new flagship of AVION Europe’s service portfolio. Our customers use SCADA systems to control their plants across sites, and to collect and record data about their operations.

AVION Europe’s SCADA systems, which are individually tailored to our customers, usually include a combination of software and hardware elements, such as programmable logic controllers (PLCs) and remote control terminals (RTUs). Data collection begins with the production equipment at the plant level, which communicates with the manufacturing equipment via sensors.

The data collected in this way is then transmitted to the next level, such as a control station, where operators can monitor the PLC and RTU controls using human-machine interfaces (HMI). AVION Europe SCADA systems allow operators and higher-level interfaces (QA, production management…) to control processes either locally or remotely, as well as to interact directly or centrally with all components such as motors, pumps and sensors.

In addition, AVION Europa SCADA systems enable our customers to monitor, document and archive their processes using real-time data.

Trends:

• Actual SP, PV values
• User-defined filters (e.g. hardening, tempering)
• History up to 5 years
• Print as .pdf
• Export data in CSV format

Safety Integraion:

• Up to 128 user groups (e.g. administrators, maintenance, technical, operators)
• Each component permission in the application can be defined
• Create, modify and delete users during the entire period of use
• Domain authorization option

Parameters & PID:

• PID parameter
• Correction parameters
• Authorization for technology group
• Input parameters with constraints (min / max)

Compatible with CQI-9

Graphic system:

• Analog process values
• SP Program
• Displays alarms, warnings
• Events in the process status overview window (complete line)
• Each part of the system (e.g. hardening, tempering, oil, water) has its own window for displaying the respective status
• Menu system for operation
• More than one display language for the operation

Process programs

• Create:
  1,000 programs can be created in SCADA
• Extinguish:
  Operator can delete old programs
• To edit:
  Operator can open and change programs
• Send:
  The operator can transfer the program to the PLC
• To print:
  Operator can print programs as .pdf file

Features and benefits:

• no flaring (1:5): Reduction of operating costs
• Significant reduction in CO² emissions
• minimizes maintenance
• Endogas is available immediately after heating up to operating temperature:
  • no “running in” of the generator necessary
  • Minimizes setup and startup time
• constant control of the gas/air ratio
• Constant regulation of the dew point: less soot formation
• clear display on a color touchscreen

Included in the system

• colored touch screen
• Integrated dew point measurement and control
• integrated temperature measurement and control
• permanent ratio control gas/air mixture
• integrated, digital chart recorder (data storage for 5 years and more)
• electronic air mass meter
• digital quantity display air / natural gas or propane / endogas
• safety route
• air inlet filter
• Frequency converter for stepless control of the blower motor