Cross Services Engineering Ltd - Cross Services brings Pilkington furnace back in to action

Cross Services Engineering Limited (CSEL) has taken a central role in the £10m electrical and mechanical shutdown and rebuild of an important glass furnace control system for leading manufacturer Pilkington Group Limited. The multi-discipline engineer was part of a consortium of experienced specialists which carried out the far reaching project for the world renowned glass manufacturer.
Pilkington Group Limited, which pioneered the float glass process for commercial manufacture in the late 1950’s, was looking to upgrade and enhance the electrical and mechanical control systems which operate as the ‘nerve centre’ of its Cowley Hill float glass furnace in St. Helens. For this ‘operation critical’ project Pilkington turned to CSEL, contracting it to deliver all electrical and instrumentation engineering on the furnace infrastructure, according to Pilkington’s design.
To enable this installation, CSEL stripped the existing PLC control systems, before the on-site build and fitting of 20 new control panels. These vital panels allow the operation of the thermocouple controls, which are used to adjust the temperatures at various stages of the ‘bath’ of molten tin on which float glass is manufactured.
CSEL’s project manager David Howie comments “The electrical engineering phase was central to the overall success of this project. Cross has worked with Pilkington and its consortium to deliver a powerful, sophisticated and reliable system. Built to specification and successfully integrated with the furnace’s existing computer controls, it helps maintain Pilkington’s productivity at the site.”
The next major part of the project involved the repair or replacement of actuated valves, which feed the gas into the furnace system. The gas is then used to heat the giant furnace producing the molten glass that flows across the tin bath.
CSEL installed and brought into operation over 1,600 pre-calibrated and calibrated instruments during the course of this project, including actuated air valves and pressure differential valves, which are crucial to the safe management of the furnace’s gas control system.
The completion of this shutdown, achieved in just 12 weeks, allows Pilkington to resume full use of the furnace, with the new systems safeguarding the existing furnace infrastructure. CSEL is also providing full on-site technical support to ensure a continued smooth transition to full furnace operation.
David Howie concludes “Here at CSEL we welcome involvement in these large scale industrial projects as we have a proven track record in completing major work for blue chip companies. We relish taking on work in the important industrial sector as it allows us to work at the peak of our abilities.
“The Pilkington float glass furnace refurbishment is a case in point, where we have taken a demanding brief and produced a number of new systems and maintenance measures that will enable Pilkington to benefit from continued use of the Cowley Hill furnace.”

Email: Anthony.walker@nativemarketing.com