EUROTHERM FLEXIBLE SOLUTIONS

Heat Treatment
LEADING THE WAY IN RELIABLE SOLUTIONS

Eurotherm - The Heat Treatment solutions provider

WHY EUROTHERM?
Eurotherm has been providing engineered solutions to the Heat Treatment and Metals industries for more than 40 years. We have metallurgists and engineers dedicated to these markets, proving leading edge control and visualisation solutions to multi-national clients. With a knowledge base of Heat Treatment applications second to none, over 3000 customers turn to Eurotherm to provide: Cost reductions Capacity increases Productivity gains Increased quality Secure data management Accredited services With experience in stringent regulatory demands, Eurotherm specialised teams deliver scalable solutions that can be applied to individual furnaces or an entire plant.
Start small, grow big Right solution for the application Modular

Connectivity at every level

Plant wide solution

Accurate control

Secure data

Nadcap and TS16949

3rd party integration

Profibus Ethernet Modbus

www.eurotherm.com/heat-treatment

Confidence in Control
Eurotherm understand the technical nature of the heat treatment processes and use this knowledge to bring wideranging benefits with their solutions. Global installed base across all industry sectors World-renowned control and performance From simple discrete to applied automation solutions Flexible yet secure, Heat Treatment specific process recipes Guaranteed profile compliance with Heat Treatment specific control features Process and Process Plant diagnostics Energy control and efficiency solutions

Secure, remote viewing Plant wide visualisation

Diligence in Data Management

Secure process data management, recording, reporting and batch management Long term archiving and retrieval of data built into the design Authorised and audited levels of access control
Process automation

Batch

Proactive response to the continuing demands of changing regulation Built in regulatory features for Nadcap and other industry standards

Data recording

Single loop control

Confidence in measuring value for your money

Eurotherm are committed to developing products and services specifically for the Heat Treatment industry, continually minimising cost while maximising your productivity.

DCS

Standard function blocks

Consultation and projecting services to ensure you get exactly what you need Reusable engineering Solution upgrade paths Commercial and technical alliance partnership for customers seeking control system consistency across their whole business Complete life cycle support and range of life time services System design and build

Efficient electrical power control

Life time services OPC DeviceNet

Installation Commissioning and plant optimisation Accredited calibration Thermal Uniformity Surveys (TUS) Spares management training and technical support

www.eurotherm.com/heat-treatment

Improved performance delivers quality

How does Eurotherm help to deliver quality?
Eurotherm provides engineered solutions for Heat Treatment applications right around the world and have been working in the industry for more than 40 years. Many of our employees have a background in this market and we use our knowledge to continually improve our customers processes. Application knowledge and customer feedback has created designs and solutions that maximise efficiency, productivity and ultimately your return on investment.

Some of the benefits you receive from a Eurotherm solution:

Secure recipes with profiles, designed to meet metallurgical process requirements World-renowned algorithms providing automatic control stability Special control optimisation techniques to allow equipment to be used over the widest of temperature ranges with highest variability of work piece loading Cut back control features to ensure overshoot elimination for step changes

Work-piece thermocouple control routines for mixed and variable load sizes Direct interface with industry standard sensors for carbon potential, dew-point and oxygen control and monitoring

Special ramp-dwell transition filtering to ensure overshoot elimination on thermal profiles Embedded atmosphere control algorithms for surface chemistry processes and reducing atmosphere applications Specialist function blocks for many heat treatment applications including Vacuum furnaces Sealed Quench and other atmosphere controlled, batch and continuous furnaces Specialist retort furnaces Multi-loop applications Creep test furnaces Laboratory applications Nitriding furnaces Override control algorithm for simple thermal head applications Cascade control for deep-shallow temperature control on retorts and complex furnace loadings Direct interface with vacuum sensors and other non linear gauges with scientific notation and logarithmic displays Power or energy density control routines Load sharing and load shedding techniques for electrical installations Energy monitoring Remote and low cost supervisory control solutions Heat Treatment specific displays with secure audited access for Operators, Engineers, Laboratory Personnel and Management

www.eurotherm.com/heat-treatment

How does Eurotherm help you show you are delivering quality?
With ever-changing regulatory requirements in much of the Heat Treatment market it is our vision and direction to help customers meet the demands of their audited processes. Standards, such as AMS2750D, define the operation of many Heat Treatment plants. Conformance to regulations, along with proof of compliance is essential to Heat Treaters. The subject forms a strategic part of Eurotherm business and is integrated into every part of our day-to-day work; bringing benefits to our customers at every part of their process and business life cycle.

All Products are manufactured and tested to ISO 9001:2000 and TickIT Guide Issue 5 Data management products, which meet industry regulatory specifications Secure Data storage Tamperproof files Networked and local file management Secure and automatic routines for file data transfer Calibration accuracy and resolution to AMS2750D Remote viewing facility Batch data entry Routines to support long term archiving and retrieval of digital data including review software for encrypted files Export of data to common applications for replay in human readable format while still preserving core proof data Supply of calibration certified products and solutions to National Standards and the requirements of Nadcap On site calibration services to National Standards for System Accuracy Tests On site Thermal Uniformity Surveying of thermal processing equipment On-site service for improved furnace performance and optimisation Customer reports

Control System Security

Audit trail and individual password protection giving defined level of secure control system access Guaranteed recipe revision control Client material test data embedded in stored data reports Selected recipe embedded in stored data file

www.eurotherm.com/heat-treatment

Modular, scalable Heat Treatment solutions - plant wide integration

DATA HISTORIAN BRIDGE & REVIEW

BUSINESS SYSTEMS

OPERATIONS VIEWER

ETHERNET

OPERATIONS SERVER

CLIENT ACCESS INFORMATION MANAGER QUALITY CONTROL MATERIAL TEST

C O N T R O L C O M M U N I C AT I O N S - E T H E R N E T

DIN RAIL MOUNTING PROGRAMMABLE AUTOMATION CONTROLLERS EYCON VISUAL SUPERVISOR

3RD PARTY PRODUCT INTEGRATION

DISCRETE FURNACE CONTROLLERS DIN RAIL MOUNTING DATA MANAGEMENT EPOWER CONTROLLER

MODULAR FURNACE I/O CONTROL GRAPHIC RECORDERS

www.eurotherm.com/heat-treatment

MANUFACTURING SYSTEMS

WORK PLANNING

BATCH PLANNING

FISCAL MONITORING

DATA ARCHIVING

LOCAL CLIENT ACCESS

BATCH SCHEDULING

RECIPE MANAGEMENT

QUALITY SYSTEMS

MATERIALS TESTING

I/O COMMUNICATIONS - MODBUS TCP/IP (ETHERNET), MODBUS RTU, PROFIBUS, DEVICENET

PRODUCTION LINE HEAT TREATMENT

SPECIALIST HEAT TREATMENT PROCESS

HEAT TREATMENT IN IRON AND STEEL PROCESS

LABORATORY AND MATERIAL TESTING

www.eurotherm.com/heat-treatment

Audited regulations for Heat Treatment

The Heat Treatment and Metals industries are subject to multiple standards, dependant on the final markets being served. The ability to meet the standards and to prove compliance at audit is central to the success of a Heat Treatment business.

Eurotherm has a range of products and services designed to meet the audit regulations for heat treatment. Regulations fall into two main categories and Eurotherm provide solutions to meet both requirements. Prescriptive quality systems such as the Aerospace Industry standard Nadcap Company quality manual processes such as the Automotive Industry Standard QS9000 and TS16949

Electronic Records
Secure process values and setpoints (including audit trail for alarms, events, operator actions, recorded logins, operator notes and electronic signatures) Protection of data through binary compressed and check summed records Batch entry details embedded in process data records Accurate time stamps against automatic Time

Nadcap
The defining regulations for the Aerospace industry are laid out in the National Aerospace and Defence Contractors Accreditation Programme (Nadcap). For Heat Treatment, Nadcap has specific audit requirements covered in AS7102 and the audit criteria AC7102. Eurotherm are committed to helping customers achieve the demands of this specification and the associated Thermal processing specification AMS2750 Rev D. Incorporation of Nadcap requirements into product design for Control Instrumentation and Data Management equipment to aid compliance Incorporation of user routines into Control Instrumentation and Data Management products to aid systems accuracy test (SAT) compliance World renowned control algorithms to aid accurate performance against defined thermal profiles Special routines to eliminate thermal overshoot and achieve guaranteed thermal soak times Soft-wired control solutions to accommodate workload thermocouples monitoring The provision of equipment and services to aid temperature uniformity surveys (TUS) to nationally accredited standards Secure local and remote data recording at every level, local and plant-wide Routines for recipe revision control and recording of selected recipe profile against actual furnace performance Special routines and input types to support accurate control of furnace vacuum and atmospheres

Synchronised clock source Secure data archiving with automatic file backup and transfer to aid long term data archiving routines Provision for electronically copying data for archive Export facility allowing viewing of secure records in human readable format Remote channel access to record loaded recipe, setpoint profiles, and furnace atmosphere

www.eurotherm.com/heat-treatment

Electronic Signatures
Control and Data Management equipment protected by secure password routines All actions can be configured to require password entry or operator sign in Audit trail and password features are available to log actions and prevent unauthorised control system use Support for electronic signatures

ISO9000 and ISO/TS16949

For many years the Automotive industry has worked in an environment of continuous process improvement. The quality standard ISO/TS16949 is used by the worlds major Automotive companies. Confidence in the performance of thermal processing equipment, and sure knowledge of the security of process records, leads suppliers to define clear procedures into their quality manuals and improvement systems. Eurotherm builds accuracy, performance and consistency into their systems, to ensure that customers can have complete confidence in their heat treatment equipment.

www.eurotherm.com/heat-treatment

Strength through wide-ranging application experience

Our range of application experience has enabled many customers to increase productivity and lower costs. All of our solutions into the Heat Treatment industry are flexible and scalable to match your process requirements.

Example applications
Gas Carburising of Steel
Surface hardening of steels by the chemical diffusion of carbon into the surface layer of a component requires the precise control of temperature, furnace atmosphere and time. By varying the composition of the gas to include Carbon and or Nitrogen, various surface finishes can be achieved. Precise loop control for temperature and carbon Furnace sequence control Case depth diffusion control or direct carbon potential control Robust atmosphere probe Secure recipe management Setpoint profiling Secure data management Integral quench programmes Endothermic gas generator controllers Quench oil control and integral quench cycle control

Dual Hearth Retort Diffusion Furnace

Aluminised surface finish of turbine components.

PILOT

PILOT

02

ATMOS

PILOT

Hearth transfer and furnace sequence control 3 zone cascade temperature programming and gas mass flow control Gas safety monitoring
PILOT

Guaranteed work-stack soak dwell times Atmosphere and temperature data management Electrical power control
Three Gas IR

HEATING COOLING

Furnace Sequencing Product Transfer Temperature Programming & Control Furnace Diagnostics Recipe Management Carbon Potential & Diffusion Control Power/Gas Control

Atmosphere Probes & Gas Sequencing Data Management Endo Generator Control Quench Sequence Control Quench Recipes Quench Oil Control

Energy monitoring and consumption control Recipe control and recipe revision control Accredited control systems

Vacuum Furnace Heat Treatment

Vacuum sequence control Temperature programming and control Gauge switch over Tracking over-temperature protection Pump down timers and leak rate detection Work piece thermocouple control routines Partial pressure control Electrical heater control Quench sequencing and control Vacuum heater interlocks Back-fill control Programme time/temperature events Direct interface with vacuum gauges Guaranteed work piece temperature profiling
HEARTH 2 HEARTH 1

www.eurotherm.com/heat-treatment

Energy Management Solutions

Load management for electrical and gas fired furnaces Specialist algorithms to control rising energy costs Load shedding and load sharing solutions Steady state control

AMS2750D Scheduling TUS, SAT and Calibration

Calculates TUS, SAT and Calibration due dates All classes of furnace and instrument types Calculates reduced periodic TUS frequency Calculates max allowable SAT interval Life monitoring for local thermocouples

Specialist combustion control Solutions Standard application function block Multi-fuel change over Accurate fuel air ratio Lead lag cross over control Excess air feedback control

Case Depth Diffusion Control

Diffusion control allows the user to accurately set the effective desired carbon depth profile in the component. A typical case depth profile is shown in the diagram opposite.

Materials Testing - Multi-Zone Tensile Creep Test Furnace

Materials testing in the Automotive and Aerospace Industry requires precise, long term fatigue and performance analysis of test samples. Eurotherm have automated this process to remove variation and manual intervention in the test set up and procedure. Configurations for single or multiple sample thermocouples Optional cascade control from work piece thermocouple Digital communications for supervisory control and process diagnostics Specialist power and temperature algorithms to give precise temperature uniformity across the work piece High stability flat zone temperature control Automatic sensor failure and load break abort routines Integrated load and strain monitoring Cascade control Power failure recovery routines Multi-zone thermal profiling

Furnace Atmosphere Control

Specialist atmosphere probes Probe impedance monitoring Calculations for oxygen, carbon potential & dewpoint Reference air supply with failure alarms Mass flow control blocks Furnace pressure control Reducing atmosphere control

Setpoint Programming
Multiple profiles and programmes Optional program synchronisation routines Free format program size Hold-back for ramps and dwells Ramp/Dwell Transition overshoot inhibition Guaranteed soak time Power fail routines Time/temperature events Wait input or wait for load sensors Fast run and skip segment Call program routines Embedded quench routines

www.eurotherm.com/heat-treatment

Eurotherm Leading Products and Solutions for Heat Treatment

Return on Investment (ROI) is a critical financial measure in industry. Eurotherm has delivered cost savings to customers along with improvements in plant capacity and productivity. Eurotherm solutions deliver a high ROI and a financial advantage to our customers. Eurotherm have a wide range of solutions for Heat Treatment covering simple, discrete applications through to complete shop floor and plant wide automation.

Standard Control Solutions

Sealed Quench Furnaces with Atmosphere Control Vacuum Furnaces Pit Furnaces Specialist Retort Furnaces Gas Retort Annealing Furnaces Creep Test Furnaces Continuous Mesh Belt Furnaces Bell or Top Hat Furnaces/Rotary Hearth Furnaces Diffusion and Diffusion Bonding Furnaces Nitriding Furnaces

Special Functions
Eurotherm have wide experience in building application specific function blocks. Our soft-wired products give complete flexibility to build and integrate customer specific benefits into both simple and complex solutions. Case Depth Diffusion Control Carbon Potential Combustion Control Oxygen and Dewpoint Control Vacuum Sequencing Dissociate Ammonia Control Load Management Power Steady State Control Algorithms Work Thermocouple Optimisation Routines Report Generation Automatic Tuning and Furnace Control Optimisation Routines Nitriding Potential Control

www.eurotherm.com/heat-treatment

Solution Attributes
Shop floor automation Furnace mimics and screen navigation Temperature programming and control Atmosphere programming and control Quench programming and control Batch management Furnace sequence control Recipe control and recipe management Programme management Data management Reporting Power control and energy management Furnace diagnostics Time synchronisation Mathematical functions Scientific notation Optional redundancy

Communication and Digital Access

Modbus master and slave devices DeviceNet network Profibus network master and slave devices Range of Ethernet protocols Support for USB components Peer-to-peer architectures Support for bar code readers and printers Support for remote furnace diagnostics Support for Email/SMS alarm and event notification Automatic backup and retrieval routines Client/Server architectures

www.eurotherm.com/heat-treatment

Eurotherm Leading Products for Heat Treatment

Discrete Solutions
Temperature controllers Multi loop controllers Process controllers Programmers Over-temperature protection devices Alarm units Paperless, graphic recorders Paper chart recorders Signal conditioning units

Energy Solutions
Power Thyristors 1,2 & 3 Phase 15Amps 4000 Amps Resistive loads Silicon carbide heaters Complex Heater Materials: MoSi2 Graphite Molybdenum Tungsten Transformer coupled heater loads Shortwave and medium-wave infrared heaters True power control devices

Specialist Probes
Carbon Potential, Oxygen and Dewpoint Applications

Energy Monitoring products Energy scheduling and load shedding solutions

Systems Products
Distributed Process Automation Control (PAC) Eycon Visual Supervisors Machine Controllers Remote I/O Operator Panels DCS Operational Viewer Information Manager DCS Controller Range

www.eurotherm.com/heat-treatment

Eurotherm Heat Treatment Our Satisfied Customers...

Eurotherm Heat Treatment solutions deliver quantifiable benefits to plants world wide. With a global customer base Eurotherm has been proud to serve leading Heat Treatment and Metals companies such as: AIMT Airbus Alcan Alcoa Aubert & Duval Bodycote Chromalloy Corus Dassault Aviation EADS Finmeccanica Federal-Mogul Goodrich GKN Lisi Aerospace Lockheed Martin Lufthansa Mettis Aerospace Northrop Grumman Novelis Outokumpu PCC Group QinetiQ Renault Robert Bosch Rolls Royce Sandvik SKF Snecma SSAB Stork Fokker Timet Volkswagen

Eurotherm products and solutions are also the choice of many furnace OEMs. Our products can be found in many leading brands, including: AFC-Holcroft AGA Linde Aichelin ATI Furnace BMI ECM Cieffe Forni Ipsen Seco/Warwick Solar Manufacturing Stein Heurtey Wellman Furnaces

www.eurotherm.com/heat-treatment

Eurotherm: International sales and service

Understanding and providing local support is a key part of Eurotherm business. Complementing worldwide Eurotherm offices are a whole range of partners and a comprehensive technical support team, to ensure you get a service you will want to go back to.

AUSTRALIA Sydney Eurotherm Pty. Ltd. T (+61 2) 9838 0099 F (+61 2) 9838 9288 E info.au@eurotherm.com AUSTRIA Vienna Eurotherm GmbH T (+43 1) 7987601 F (+43 1) 7987605 E info.at@eurotherm.com BELGIUM & LUXEMBOURG Moha Eurotherm S.A/N.V. T (+32) 85 274080 F (+32) 85 274081 E info.be@eurotherm.com BRAZIL Campinas-SP Eurotherm Ltda. T (+5519) 3707 5333 F (+5519) 3707 5345 E info.br@eurotherm.com DENMARK Copenhagen Eurotherm Danmark AS T (+45 70) 234670 F (+45 70) 234660 E info.dk@eurotherm.com FINLAND Abo Eurotherm Finland T (+358) 22506030 F (+358) 22503201 E info.fi@eurotherm.com FRANCE Lyon Eurotherm Automation SA T (+33 478) 664500 F (+33 478) 352490 E info.fr@eurotherm.com GERMANY Limburg Eurotherm Deutschland GmbH T (+49 6431) 2980 F (+49 6431) 298119 E info.de@eurotherm.com HONG KONG & CHINA Eurotherm Limited North Point T (+85 2) 28733826 F (+85 2) 28700148 E info.hk@eurotherm.com

Guangzhou Office T (+86 20) 8755 5099 F (+86 20) 8755 5831 E info.cn@eurotherm.com Beijing Office T (+86 10) 6567 8506 F (+86 10) 6567 8509 E info.cn@eurotherm.com Shanghai Office T (+86 21) 6145 1188 F (+86 21) 6145 1187 E info.cn@eurotherm.com INDIA Chennai Eurotherm India Limited T (+91 44) 24961129 F (+91 44) 24961831 E info.in@eurotherm.com IRELAND Dublin Eurotherm Ireland Limited T (+353 1) 4691800 F (+353 1) 4691300 E info.ie@eurotherm.com ITALY Como Eurotherm S.r.l T (+39 031) 975111 F (+39 031) 977512 E info.it@eurotherm.com KOREA Seoul Eurotherm Korea Limited T (+82 31) 2738507 F (+82 31) 2738508 E info.kr@eurotherm.com NETHERLANDS Alphen a/d Rijn Eurotherm B.V. T (+31 172) 411752 F (+31 172) 417260 E info.nl@eurotherm.com NORWAY Oslo Eurotherm A/S T (+47 67) 592170 F (+47 67) 118301 E info.no@eurotherm.com POLAND Katowice Invensys Eurotherm Sp z o.o. T (+48 32) 2185100 F (+48 32) 2177171 E info.pl@eurotherm.com

SPAIN Madrid Eurotherm Espaa SA T (+34 91) 6616001 F (+34 91) 6619093 E info.es@eurotherm.com SWEDEN Malmo Eurotherm AB T (+46 40) 384500 F (+46 40) 384545 E info.se@eurotherm.com SWITZERLAND Wollerau Eurotherm Produkte (Schweiz) AG T (+41 44) 7871040 F (+41 44) 7871044 E info.ch@eurotherm.com UNITED KINGDOM Worthing Eurotherm Limited T (+44 1903) 268500 F (+44 1903) 265982 E info.uk@eurotherm.com
www.eurotherm.co.uk

Eurotherm is also represented in the following countries:

Algeria Azerbaijan Bahrain Bangladesh Benin Bosnia and Herzegovina Bulgaria Burkina Faso Cameroon Canada Czech Republic Egypt Georgia Greece Guinea-Conakry Hungary Indonesia Iran Iraq Israel Ivory Coast Japan Jordan Kazakhstan Kenya Kuwait Latvia Lithuania Malaysia Mali Mexico New Zealand Niger Nigeria Oman Pakistan Philippines Puerto Rico Qatar Romania Russia Saudi Arabia Serbia and Montenegro Singapore Slovak Republic Slovenia South Africa Sri Lanka Thailand Togo Tunisia Turkey Turkmenistan UAE Ukraine Uzbekistan

U.S.A. Leesburg VA Eurotherm Inc. T (+1 703) 443 0000 F (+1 703) 669 1300 E info.us@eurotherm.com
www.eurotherm.com

ED55

Represented by:

Copyright Eurotherm Limited 2007

Invensys, Eurotherm, the Eurotherm logo, Chessell, EurothermSuite, Mini8, Eycon, Eyris, EPower and Wonderware are trademarks of Invensys plc, its subsidiaries and affiliates. All other brands may be trademarks of their respective owners. All rights are strictly reserved. No part of this document may be reproduced, modified, or transmitted in any form by any means, nor may it be stored in a retrieval system other than for the purpose to act as an aid in operating the equipment to which the document relates, without the prior written permission of Eurotherm limited. Eurotherm Limited pursues a policy of continuous development and product improvement. The specifications in this document may therefore be changed without notice. The information in this document is given in good faith, but is intended for guidance only. Eurotherm Limited will accept no responsibility for any losses arising from errors in this document.

Part No. HA028265 Issue 4

Printed on recycled paper in England 11.07