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Automation Article PDF
Automation Article PDF
The BREWER & DISTILLER INTERNATIONAL • Volume 3 • Issue 8 • August 2007 • www.ibd.org.uk
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AUTOMATION
The BREWER & DISTILLER INTERNATIONAL • Volume 3 • Issue 8 • August 2007 • www.ibd.org.uk
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over 100% since 1987, the relative always used to its full effect. The 10°C for temperature and 0 – 10 Figure 5 below: A
costs have reduced and the quality control plant suppliers offer any ppm for oxygen, when the target is modern Tuchenhagen
and reliability of the valve have number of parameters to trend, but likely to be 0°C for temperature and valve matrix on a tank
increased substantially. Control these are not always configured on less than 0.10 ppm (100 ppb) for farm.
equipment – e.g. PLCs, field relevant pages and their scaling is oxygen. I challenge people to go into
instrumentation and programming often outside the useful range for their breweries and see whether their Figure 6 bottom: An
have all reduced considerably in quick and meaningful diagnostics. SCADA (Supervisory Control and automated filter plant at
price since the early days. An example of this might be Data Acquisition) trend graphs are SABMiller’s plant at
trending of dissolved oxygen and optimally configured, I would only Poznan in Poland.
A few tips for reducing temperature on a filtration plant. expect a handful of positive replies.
automation costs How often is a scaling seen as 0-
In my time I have become an expert
in getting automation installed on
plant where project engineers have
been keen to keep overall costs to a
minimum. Remember:
• When planning a project, take
account of any future projects and
install as large a PLC as it is
reasonable to justify; this will
reduce future automation and
control costs. If this is not
possible, make sure what is
installed is easily adaptable and
expanded.
• When looking at automation
projects, take a really close look at
how much plant is required. For
example, how many tanks are
required? Do we need three of
these, can we work with two? The
efficiencies afforded by
automation very often reduce the
requirement for extra plant; this
cost saving can often be used to
offset the cost of automation,
especially when projects are
engineered to a budget.
• Automation gives the opportunity
to build in flexibility, but how
much of this flexibility will
actually be used and how often?
Over-engineering is often the
cause of projects being too
expensive.
Trends
The improvement in process control
instrumentation, plant schematics
(Fig 7) and trending of parameters
provides useful information for plant
operators. In my experience,
trending data has always been part of
the requirement of any plant control
system, but the information is not
The BREWER & DISTILLER INTERNATIONAL • Volume 3 • Issue 8 • August 2007 • www.ibd.org.uk
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AUTOMATION
The BREWER & DISTILLER INTERNATIONAL • Volume 3 • Issue 8 • August 2007 • www.ibd.org.uk
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will always be there, and are twice Figure 9: Schematic of
as awkward and costly to address on modern brewery IT
site, so my advice is to leave as little architecture showing
as possible till the last minute. ERP, MES linking in
with SCADA and brewer
The Top End ERP and MES PLCs.
Automation and reporting has been
around for a long time using
SCADA, but there was always
difficulty bridging the information
gap between what happened on the
plant and what information (and its
accuracy) reached the planners and
executive management. Inputting
data by hand that is readily available
electronically in SCADA and
numerous other systems was, to
those who had to do it, a real ‘pain’.
In the last few years systems have and process comparisons to be breweries. The ‘lights out’ “There will therefore
been developed and improved so made. Many breweries have ERP philosophy will only exacerbate this be increased
that manual double entry is being systems like SAP which are separate and may not be totally desirable. investment in MES
replaced by electronic transfer in from production, There will Questions I often ask people if they systems which will
what are called ERP and MES therefore be increased investment in have problems in a brewery are: enable electronic
systems. ERP (Enterprise Resource MES systems which will enable what does it look like?, what does it transfer of data
Planning) systems are the top layer, electronic transfer of data across the taste like ?, have you felt the pipe to across the whole
and handle ordering, planning, whole operation. see if it’s hot? (there is a health and
operation. This will
finance and HR while MES This will improve overall safety issue here if it’s too hot, but
(Manufacturing Execution Systems) improve overall
efficiency and cost by reducing order then HSE is a whole new ball
provides the electronic bridge to efficiency and cost
time fulfilment, reducing game!).
SCADA and the process itself (Fig manufacturing cycle times from ‘Lights out’ operation may be less by reducing order
9). MES systems basically gather ordering materials to shipment of of a target to some brewery CEOs, time fulfilment,
data and analyse it for management order, improving inventory control, but hectolitres per man will remain a reducing
control and decision making. It can reducing rework from improved key comparator for high level manufacturing cycle
be said to have three main functions: quality management. Breweries company assessment. In reality I times from ordering
1) To provide an electronic which have invested in ERP and think money is more likely to be materials to
paperless system and data flow. MES will require and implement invested in reducing the high areas shipment of order,
2) Enables key performance higher levels of automation with of costs – namely energy, water and improving inventory
indicators (KPIs) to be more rigid standards in order to waste, and in ERP and MES systems control, reducing
established and monitored maximise benefits from these which will improve cost and rework from
within a brewery, and in large systems; this in turn will lead to a efficiency, and vital data flow over improved quality
groups, if the data collection continued reduction of staff, who the whole operation. management.”
systems are comparable, will be more highly trained. The ‘Lights out’ is not ideal, maybe
between plants. traditional departmental structure of keeping a light on in the corner so
3) Recipe management in a brewhouse, fermentation, processing that the new vigilant operators can
controlled environment. and packaging will probably give still ‘walk the plant’ and experience
way to a simple brewing and and see a bit of what is going on is
One effect of a properly packaging control structure, preferable. In any case who’s going
implemented MES is to force the although packaging would remain to feed the brewery cat – or maybe
brewery into rethinking its work more labour intensive due to the even that can be outsourced? ■
processes. Running processes in need for more manual intervention.
‘manual’ leads in inaccurate
reporting, which has an adverse Those mouse-click
‘knock on’ effect over the whole Brewmasters
system. I was talking to a German
Brewmaster the other day about
The future ‘mouse-click’ brewmasters – that is
I asked Paul Bunyan and Tony brewers who work in automated
Goodman of FMA about their view plant relying on PLC feed back for
of the future trends in IT and all their information. We were in
automation in breweries. Their view ‘grumpy old men mode’ and agreed
was that large breweries are that this new breed of brewer was
collecting their ‘islands of technologically very competent, but ● Acknowledgements
automation’ into plant wide systems, in the real world were not exposed to My thanks go to Andrew Ball
with an emphasis on standards the sounds, smell and vision of the (Tuchenhagen), Frank Ainsworth (CAL
Systems Ltd), Paul Bunyan and Tony
which will ease maintenance and process, and therefore missed out on Goodman ( FMA Process Engineering
bring consistency to information, having a true feel and understanding Ltd) and Robin Cooper for their help in
which would allow realistic plant of what was happening in their writing this article
The BREWER & DISTILLER INTERNATIONAL • Volume 3 • Issue 8 • August 2007 • www.ibd.org.uk
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