Introducing automation Getting started FV control By Sara ... · share your experiences today #BevExpo2016 Introducing automation Getting started FV control By Sara Nichols

share your experiences today #BevExpo2016

Introducing automationGetting started FV control

By Sara Nichols


AgendaSiemens – Brewing HistoryAutomation – Is it only for Large Brewery’sTypes of ManufacturingControlling / Automating the Brewing process

HardwiredAutomation PLC / SCADADedicated Brewing Solutions

Staring SmallFV AutomationMeasurement / FlowOther consideration

Dedicated Brewing solutionsConcluding considerations


Siemens - Brewing Industry Pedigree


SIEMENS - Partner of Brewing industry for more than 100 years

• 1897 • Brewery F. Oettler Weissenfels a.d. Saale installs as one of the first of its kind decentralized electrical

motors from Siemens• 1901• Electrification of Brauhaus Nuremberg by Siemens• 1973• Simatic Industry controller from Siemens are used in breweries• 1977• Braumat: The first controller based recipe controlled automation system for breweries occurred in the

market• 1993:• Braumat uses the first time Windows PCs as basis of he human machine interface• 1997• Implementation of graphical recipe system• 2003 • Introduction of area overlapping control• 2012• For the first time Chinese as operator language is implemented

Simply, Siemens has been associatedwith Brewing for a long time


Automation – “Is it only for Large Breweries”?


Of course It's not ... Has Brewing Changed over the last 300 years?

Not reallyHas technology changed?

Yes and the rate of change is speeding upHas consumer behaviour, demands & expectations changed?

Yes and a lot of this change is fuelled by technology

So where does automation fit and what are the challenges? Is it smoke and mirrors?


Types of Manufacturing- Discrete / Process

Discrete Manufacturing vs Process Manufacturing

• Discrete / Digital Factory• Is it present? Yes / No• How many, how often• Has a complex BoM• Typically assembles Products• Has conveyers

• Process / Variable• How much• How long• How Hot / cold• Works to a recipe• Typically move liquid, powder, fluids ...• Is often a batch driven process

Automation requirements for Discrete & Process Control ...

FIELD DEVICES

FIELD DEVICES


Process Instrumentation ...

If you can’t measure it, you can’t control it!


Controlling / Automating the Brewing ‘Process’


Brewing is a Process – Automation OptionsSo we’ve establish that the Brew House is a Process – So what are the control options?

Hardwired - Relays, Timers, dedicated control devices, push buttons, lamps

Programmable Logic Controllers PLC / Human Machine Interface HMI / Supervisory Control And Data Acquisition SCADA

Dedicated Brewing Solutions - Recipe, Batch & Routing management

Automation - Temperature Control Brew House Fermentation

For this explanation we will focus on the control of fermentation attemperation


Hard wired - What does this look like?


‘Real’ examples?


Inside the control Panel?

What ‘Hard’ wired panels can look like


Hard wired – Vessel side – ActuatorsGlycol cooling


Discrete Control Pro’s / Con’sPro’s

It’s simpleYou don’t need to be an engineer to fitLow cost?You can easily see & change the set point

Con’sIt’s based in the Brew House so can only be viewed in the Brew HouseIt can’t be viewed or managed remotely Trending and storing values is an additional investment, an add onCost, expensive to maintain?Fermentation profiles ..?


AutomationPLC HMI / SCADA Control

Automation - Temperature Control Brew House Fermentation

Where to start?We think Fermentation / AttemperationWhy?Feedback from UK BrewersIt happens over several daysYou can’t be there all the time to tweak the chillingThis part of the process can affect your marriage!Yeast likes stability not oscillation


PLC, HMI, SCADA – What the hardware looks like

Current examples


FV Automation Pro’s / Con’sCon’s

It needs programmingCost ..?It has to be installed ..?

Pro’sIt’s can be viewed from anywhereIt’s can be control from anywhere (with the obvious safety considerations)It can store variables (200) to an SD Card that can be down loaded to a PCCost?Fermentation profiles ..?iOS / Android app support


Common Question – Controlling from SG ReadingCan it be done? Yes

Technology typesTuning Fork - E&HOptical - SigristIn tank submersible transmitters

Is it viable for small brewing companies? Probably notWhy? What are the challenges

Cost , set up, calibration, cleaning & maintenanceThe science coupled with product variability makes this a difficult nut to crack, plus

The instrument The hole in the tankAdditional CIP considerationsTechnical know how to maintain accuracy


Plan B


Other considerationBe clear about the problem you are solving & the constraintsPrograms can now be developed into function block – I’ll explainInstallation is no different to a stand alone control unitIt can be supported remotelyIt can be developed / grown to cover HLT temperature, liquor measurements, flow, CIP ...If you grow even further you retain the investment as it can build into bigger systemsYou can grow your investment in bite size chunksYou can use the system to start to record some manual entries e.g. SG sample valuesBut most importantly ......


Product qualityConsistent repeatable quality across the fermentation process & seasonPrioritisation of FV’sStable temperature control for your yeastEasy storage and management of fermentation values for:

HMRCYour own use

You can build your automation slowly


Dedicated Brewing Solutions

Temperature Control – Dedicated Brewing Solution

Brew House Fermentation

Dedicated Brewing Solution - What the hardware looks like

Temperature Control – Dedicated Brewery Solution

Route C

ontrol

Are a comprehensive process control system for brewing industryHave objects and libraries embedded for all control & process requirements Provides easy to use; administration, engineering, visualization and recipe design can be conducted by one engineer with limited training effortsDelivers powerful recipe control as well as an efficient route controlAllows for software modifications during production with extremely short turnaround timesEmbeds event management and process history

Process

Control

Trendin

g

Test


Concluding considerations


The Eternal Brewing TriangleExtract Efficiency

Wort QualityCycle Time

Process Instrumentation ...

Will probably be the same or very similar whatever the control methodology


Control Process Options pros and consHardwired

An electrician can fault findProcess is typically manualCan start very small and make it up as you goOften considered the cheapest optionThe process is typically dependent on human input management and over-seeing totally on peopleAny process data capture would need to be manual

PLC / HMI / SCADA (Purity, Thornbridge, Camden Town ...) Should be based on a well developed user & functional scope / understandingIncludes many of the library objects found in batch applicationsCan easily incorporate alarms and historyPotentially needs to be modified with recipe changesCan be used to collect necessary process information to satisfy for regulatory complianceRequires support from a skilled person


Control Process Options pros and consDedicated Brewing Solutions - Recipe, Batch & Routing

Larger Breweries typically use a dedicated Batch application for Brewing e.g. Heineken, BrewDog, Hall & Woodhouse, Adnams ...Primary control is PC / Server basedThe solution supports all user & business interface in respect to the processes Allows for recipe development within the solution (no coding changes)Has alarm and history functions built inGives agility & flexibility to the Brewhouse / New Product Introductions / Seasonal variations Provides robust process control to deliver repeatability and optimised use of raw materialsRequires a more specialist skill set to deliver solutionCaptures data for tracking & tracing, optimizing and regulatory complianceCaptures data to support quantity control and associated laboratory requirementsIs programmed in function block

Retro-fitting a Batch solution means starting again


Commercial realitiesEngineering resource is becoming harder to find?How to support and maintain?Remote access and visibility?Art or science?Increasing record keeping requirements from ‘off trade’Automation comes at a cost?Implementing the right automation delivers value

- YES

End User

Automation Supplier

Solution Provider

Consultant

it’s not magic Or is it?


Questions?


Thank you for your attention!

siemens.com/breweries

Sara Nichols – Account Development ManagerSiemens plcDigital Factory & Process Industries and DrivesFactory Automation Sir William Siemens HousePrincess RoadManchester M20 2UR

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Introducing automation Getting started FV control By Sara ... · share your experiences today #BevExpo2016 Introducing automation Getting started FV control By Sara Nichols