Brewery Re-Automation

Brewery Re-Automation

The Client was running the only remaining UK example of a particular obsolete integrated visualisation/controller package (SCADA/PLC) process control system in the Brewhouse. This represented a serious business risk. In addition there was a mix of isolated automation "islands" and manual control elsewhere in the Brewery. The ideal scenario would have been for the Brewery would be to combine re-automation of the Brewhouse with integration elsewhere. However a number of studies had produced costs varying from high to extremely high and the Brewery had resigned itself to only tackling the business risk represented by the Brewhouse.
When I was asked to produce a request for tender document there was a realisation that a great deal more was possible within this budget than just a like-for-like replacement. This arose from the following observations: - Only the Brewhouse PLC and SCADA needed replacing - the plant input/output hardware (IO) was sustainable in to the foreseeable future with new build equipment available. - The "preferred" upgrade path was very expensive and despite an apparent lineage with the obsolete system, this offered no engineering shortcuts, i.e. the new system would be 100% new. Given this there were far more cost-effective alternatives using more traditional Brewery-orientated PLC/SCADA systems. - Similar opportunities existed in the non-Brewhouse areas. There was much IO and automated equipment that could be re-used. - Within the non-Brewhouse areas there were current manual areas that could be retained without negating the benefits of integrating automation elsewhere. In other words an "80%" solution could be delivered for "20%" of the cost. This enables the culture of a Brewery-wide control system to be established and then refined/extended in the coming years. - Separating the Functional Design Specification (FDS - how the system was to work) from the main contract would give the Brewery far longer to transfer the existing knowledge and methods into a form that could be reviewed. This was something that would greatly reduce the risk and allow far more input from the current operating staff.

Shown are the 3 areas of process in transition from "islands" into a single fully automatic system - largely re-using existing equipment.

The Client had limited manpower resources and it was recognised after the Brewhouse changeover that despite its success, there was a lot of catching up in terms of training and familiarisation to do. As a result, the second phase (non-Brewery Automation) was delayed for nearly 6 months to allow this to take place.
Phase 2 commissioning took place from late December 2016 to April 2017 and comprised the following major areas: - Yeast Room Re-automation (12 tanks and associated manifolds). Automatic yeast pitching added. - CIP Sets (8 single-use Sets, over 200 routes). Where automated, cleans were called from a single programme, not CIP Set and Cleaning Route as previously. - Fermentation Profile. Previous control had been via stand-alone 3-term controllers requiring manually operated profiles. This was transferred to PLC to allow automatic recipe-driven profiles. - Fermentation Tank Manifolds. Automation of manual manifolds and incorporation into automatic filling from Brewhouse. - Conditioning Tank Manifolds. Automation of manual manifolds and incorporation into automatic filling from FVs via Centrifuge. - Pre-Filter Manifold. Automation of manual manifolds and incorporation into automatic filtration and blending from CTs to Bright Beer Tanks. - Automatic Barm Yeast Collection Pre-Filter, storage and sterilisation by flash pasteuriser.

It was interesting to note how during this project the automation forced a complete review of brewing AND engineering practises. Management for the first time was faced with the degree to which the process had been adapted to the failings of the existing equipment. The benefits of this project went far beyond the expected risk saving and ensuring repeatability.