New greenfield Brewery for Heineken Spain in Sevilla Automation meeting - José Mª Moreno C.
←
→
Page content transcription
If your browser does not render page correctly, please read the page content below
New greenfield Brewery
for Heineken Spain in Sevilla
Automation meeting
José Mª Moreno C.
08-09-2011
New Brewery
for HESA in Sevilla
1. Introduction: Heineken Spain & Sevilla Brewery
2. Business Case
3. Brewery Design
4. Brewery Layout and Equipment
5. Key issues
6. General Automation
7. PCS-MES
8. LGV´s
08-09-2011
Old Sevilla brewery:
A Centenary Brewery
• Built in 1904 in the field.
• Initial production 30.000 hl per year.
• Today is in the centre of the town
• 2006 production was 3.500.000 hl per year (grew 100 times)
08-09-2011
The Business Case: justification
• Layout, as a consequence, is suboptimal
• Severe space limitations for capacity extension
• Restrictions for trucks circulation
• Low potential productivity (production costs)
• High investments for replacement required
• Major Replacement programm in an operative brewery is
very complex to manage
• New EU legislation on Environment and Safety would
make its continuity not feasible .. / ..
08-09-2011
The Business Case: justification
• High value of current land (rezoned to urbanistic use)
• Avoidance of further investments on capacity extension
in other breweries in Spain
• Capacity extension close to the market, reducing
logistics costs
• Regional government subside to enable attractive Early
Retirement Programme, to fit the required reduction of
personnel
• Warehouse operations could be contracted out to a
Logistics Service Provider.
08-09-2011
Sevilla New Brewery
Location
The new brewery is being built within Sevilla municipality
in a new industrial area at the outskirts of the city
for an initial sales capacity of 4 mln hl
designed to be extended easily
08-09-2011
Brewery Design
• Sales capacity: 4,0 extendable to 5,0 mill. hl, based on future
domestic market
• Productivity: 15.000 hl/man (Warehousing operations excluded)
• Latest but proven technology, guarantying same product
quality/profile (taste). Existing recipes.
• Environmentaly friendly brewery, efficient in energy/water
usage. Responsible waste management.
• Automation & IT: Latest, but proven technology. Standard
solutions
• Industrial safesty operation. Lowest ammonia .. / ..
08-09-2011
Brewery Design
• Product Integrity and T&T: Full compliance with European
legislation and Heineken standards
• Practical design, easy to clean, accessible. High standard on
Hygiene. Modular layout, easy to extend
• Design the brewery for the desired productivity and production
costs, at the targeted budget
• Warehouse operations to be outsorced. On site, Wall to Wall.
Full logistics on site incl. ret. empties sorting activities,
maintenance kegs and spears
• Automation connection between Packaging area and Logistics.
• Reasonable flexibility in brewing, High flexibility in packaging,
leaving enough space in the layout.
08-09-2011
Brewery Design
First layout
08-09-2011
08-09-2011
First brew
08-09-201108-09-2011
Sevilla new brewery
Main instalations and suppliers
• Brewhouse: 2 lines: 20.000 hl/day • HUPPMANN
• GEA TUCHENHAGEN
• Cellar with 90 tanks
LANDALUCE
• Beer Filtration: 2 lines: 1.200 hl/hr
• FILTROX
• Packaging:
• 2 Kegging lines, • COMAC
• 1 Canning line and 5 Bottling lines • KRONES
• Automation • PROLEIT
• BA System
• LGV and automatic warehouse
08-09-2011Sevilla new brewery
Main capacities in utilities
3 Boilers of 16 Mw of SHW (160 ºC & 12 bars).
Cooling: 2 circuits: ethanol (-5ºC) and production water (2ºC): total
capacidad of 12.400 KW.
Electricity input: 2 lines of 132 KV with 2 trafos of 15 MVA.
CO2 recovery: 2 lines of 2.100 Kg/h (3Kg/100 L of beer)
Tratement plant of raw water and WWTP
Energy savings: 20% electricity, 35% water and 20% gas.
08-09-2011Empties & finished products
management
08-09-2011Secondary materials & waste
management
08-09-2011Key issues: Construction design
• Standarization of equipment to facilitate its operation,
maintenance and spare parts.
• Systems management (screens/reports) standardized to
facilitate the training and flexibility of operators.
• Line management, quality cheks by operators, etc., through
MES system .
• Materials management from the machinery screens.
• Lines mirrored to optimized the synergy of operators.
08-09-2011Generalidades de automatización
1. Gestión de la instrumentación para asegurar la máxima
integridad del producto y disponibilidad de la instalación al
menor coste.
2. Mejora continua de la disponibilidad de las instalaciones,
procesos de producción y resultados.
08-09-2011Generalidades de automatización
• Red única de datos ethernet
– 6 anillos redundantes de F.O. CAT 6 Gigabit
– Cableado estructurado con paneles y latiguillos
– Switchtes estandares :CISCO con POE y N+1
– Varias Vlan´s: IT, seguridad (cámaras y control de acceso),
LGV´s (WiFi), Proceso, envasado, telefonía, etc.
– Pequeño CPD para todos los servidores de control de
proceso, etc. compartiendo CORE y unidad de discos
redundantes (EVA de HP)
08-09-2011Generalidades de automatización
• Gestión de Activos
– Total Instrumentación planta : 2240 en PA con DTM
– Redes de comunicación :Ethernet - Profibus DP/PA - AS-I
– PLC’s : 189
– Pc industriales 100
– Paneles Tactiles 25
– Pc control SCADA 15
– Más de 3.000 válvulas automáticas con cabezal AS-I
08-09-2011Generalidades de automatización
Elección del Software (2007) + Training (Fieldcare de Endress+Hauser)
Definición del Proyecto junto con E+ H (2008) 3 Proyectos
independientes
Implementación en Cerveceria (11 pasarelas Fieldgate) 2008
Implementación en Envasado y Energias (31 pasarelas Fieldgate) 2009
La aplicación esta montada en la Estacion de Ingenieria en sala de control
De Cerveceria .
Esta es accecible desde cualquiel lugar del mundo por medio de
08-09-2011Arquitectura de control en cervecería
08-09-2011Ejemplo PLC cervecería
08-09-2011Arquitectura de control en envasado
08-09-2011Generalidades de automatización
• Características de nuestras aplicaciones :
TOTAL : 2.240 dispositivos con DTM
– Zona Producción : 1.393 Dispositivos
– Zona Envasado : 607 Dispositivos
– Zona Utilities : 240 Dispositivos
• Por tipo de dispositivos :
Marcas : Endress+Hauser, Samson ,ABB, Flowserve
Foxboro , Yokogawa,
Caudal 13% - Nivel Continuo 6% - Presion 16%
Valvulas 15% Analisis 4% Nivel 21% Temp. 24%
08-09-2011Integración buses de campo en la red
Ethernet de fabrica
08-09-2011Sala de control con tecnología FDT
Desde la sala de control se puede
acceder a cualquier instrumento
instalado en planta compatible con
esta tecnología.
Permite realizar un primer análisis de
la incidencia sin desplazar al técnico.
BENEFICIOS:
• Acceso remoto a la instrumentación de
campo
• Copias de seguridad de las
configuraciones
• Ajuste de equipos remoto
• Rápida sustitución de equipos
08-09-2011Algunas fotos
08-09-2011Algunas fotos
08-09-2011Sala de control con tecnología FDT
08-09-2011The result of such a
team effort
Questions ?
08-09-2011You can also read
