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Auto Code Generation and Rapid Brewery/Distillery Automation

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This presentation details how the Siemens Brewing template, a TIA Portal based auto code generation tool created developed in partnership by DMC and Siemens, can be used to create complete automation in rapid brewing and distillery.

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Auto Code Generation and Rapid Brewery/Distillery Automation

  1. 1. Auto Code Generation and Rapid Brewery/Distillery Automation Ryan Landwehr Project Director, DMC, Inc. usa.siemens.com/summitUnrestricted © Siemens 2019
  2. 2. 2019 Automation Summit • Title: Rapid Brewery/Distillery Automation and Success Stories • Track: PE • Presenter: Ryan Landwehr • Company: DMC, Inc. • Session # (for your survey): 1.2
  3. 3. DMC Overview Established in 1996, offices in Chicago, Boston, & Denver and customers throughout the world Established in 1996, DMC serves customers worldwide from offices in Chicago, Boston, Dallas, Denver, Houston, New York, Seattle, and St. Louis employees & growing 170+
  4. 4. DMC has the highest number of S7 certified engineers in the US. Siemens Expertise 35+
  5. 5. DMC Customers
  6. 6. Industries Served Energy & Utilities Printing Automotive Food & Beverage Semiconductor Chemical Oil & Gas Engineering Specialty Machinery Consumer Goods Packaging Machinery Programming Telecommunications Defense Contracting Pharmaceutical Test & Measurement
  7. 7. Ryan Landwehr Project Director, DMC Dallas • BS Electrical Engineering • Rose-Hulman Institute of Technology • With DMC since 2014 • Siemens Certified Professional (4 years) • PLC/HMI/SCADA, Motion, Failsafe Systems • Dedicated Craft Brewery/Distillery Consumer Presenter Info
  8. 8. • Who likes craft beer? • Craft spirits? • Anybody tried brewing their own beer? • Distilling their own spirits? Audience Info
  9. 9. Siemens Brewing Template: Rapid Brewery/Distillery Automation
  10. 10. 1. Siemens Brewing Template Intro 2. Project Layout 3. Creating a Project 4. Case Study: Witherspoon Distillery 5. Other Brewing Template Successes 6. Live Demo!
  11. 11. 1. Siemens Brewing Template Intro 2. Project Layout 3. Creating a Project 4. Case Study: Witherspoon Distillery 5. Other Brewing Template Successes 6. Live Demo!
  12. 12. • A robust and modular brewing template geared towards craft brewers and distillers. • Controls System Components (recommended): • TIA Portal • WinCC Professional What is the Siemens Brewing Template?
  13. 13. • Open Source – Customize it to meet your application needs Software Overview
  14. 14. • Based on known Craft Brewery designs and 35+ years of Brewing Industry Experience Software Overview
  15. 15. • PLC Compatibility • S7-1200 (Ladder Logic) • S7-1500/ET200SP (S7-Graph) Software Overview
  16. 16. • HMI Compatibility • WinCC Comfort, WinCC Professional, WinCC 7.4 • Basic? Yes…but no Software Overview
  17. 17. • 4 Vessel Brewhouse with Fermentation Vessels • Mill, Mash Tun, Lauter Tun, Wort Kettle, Whirlpool • Add/Remove/Customize modules as needed Default Setup
  18. 18. • Control Modules developed using Siemens Open Library Uses Standard Library
  19. 19. • Fully test your system before installing Built-In Simulation
  20. 20. • Event Driven Reporting built-in Built-In Reporting
  21. 21. • Enter, save, and modify recipe library using WinCC Recipes Built-In Recipe Management
  22. 22. • OpenNess – Customize program your CMs using MS Excel • SiVArc – Customize program HMI using MS Excel Rapid Customization
  23. 23. Open Library Drag-And-Drop (PLC)
  24. 24. Open Library Drag-And-Drop (HMI)
  25. 25. • (Almost) Anyone! • Not just limited to breweries, distilleries can be supported Who can use Brewing Template?
  26. 26. • Built-in support for Grain Handling, Brewhouse, and Fermentation Vessels, but can easily be adapted to control: • Filtration Systems • Clean-In-Place (CIP) Systems • Utilities (Boiler, Cooling Towers, Chillers) • Bottling/Packaging Where else can you expand to?
  27. 27. • Easy to use, scale, and customize both hardware and software • Fully Tested Demo – based on 35+ years of brewing market experience • Standard Programming Library – Siemens Open Library • Support: Siemens, Siemens Partners, and System Integrators • Training Courses provided regularly by SiTrain Why use it?
  28. 28. 1. Siemens Brewing Template Intro 2. Project Layout 3. Creating a Project 4. Case Study: Witherspoon Distillery 5. Other Brewing Template Successes 6. Live Demo!
  29. 29. Brewhouse Overview
  30. 30. Mill Subsystem
  31. 31. Mill Subsystem Recipe
  32. 32. Mill Subsystem Running
  33. 33. Mash Cooker Subsystem Running
  34. 34. Lauter Tun Subsystem Running
  35. 35. Wort Kettle Subsystem Running
  36. 36. Whirlpool Subsystem Running
  37. 37. Fermentation Overview
  38. 38. Recipe Manager
  39. 39. Recipe Status
  40. 40. Sequence Logic (S7-Graph)
  41. 41. 1. Siemens Brewing Template Intro 2. Project Layout 3. Creating a Project 4. Case Study: Witherspoon Distillery 5. Other Brewing Template Successes 6. Live Demo!
  42. 42. Openness Setup • Device List Generated using included MS Excel Sheet Unit UnitName Tag Name Description Style Network Comment IO Field 1 1Mill M-801 Malt Mill Motor Motor Horizontal M801 1Mill M-802 Silo to Mill Auger Motor VFD Horizontal M802 1Mill M-803 Specialty Malt to Mill Auger Motor Motor Horizontal M803 1Mill M-804 Mill to Grist Case Chain and Disk Motor Motor Horizontal M804 1Mill M-805 Grist Case to Mash-in Chain and Disk Motor Motor Horizontal M805 1Mill AV-801 Grain Inlet Valve Valve Vertical AV801 1Mill AV-802 Bulk Bag #1 Bottom Valve Valve Vertical AV802 1Mill AV-803 Bulk Bag #2 Bottom Valve Valve Vertical AV803 1Mill WT-801 Malt Silo Weight AnalogInput Horizontal WT801 1Mill WT-802 Grist Case Weight AnalogInput Horizontal WT802 1Mill WT-803 Bulk Bag #1 Weight AnalogInput Horizontal WT803 1Mill WT-804 Bulk Bag #2 Weight AnalogInput Horizontal WT804 2MashCooker M-101 Mash Pump Motor Motor Horizontal M101 2MashCooker M-102 Mash Mixer Motor Motor Vertical M102 Subsystem Index Subsystem Name Device Name Device Description Device Type Used for SiVArc Used for Tag Declaration
  43. 43. Run the Openness Tool1. Open Portal with Openness API 2. Open Template Shell Project
  44. 44. Run the Openness Tool3. Load Excel File 4. Generate Project
  45. 45. Results! Unit UnitName Tag Name Description 1Mill M-801 Malt Mill Motor 1Mill M-802 Silo to Mill Auger Motor 1Mill M-803 Specialty Malt to Mill Auger Motor 1Mill M-804 Mill to Grist Case Chain and Disk Motor 1Mill M-805 Grist Case to Mash-in Chain and Disk Motor 1Mill AV-801 Grain Inlet Valve 1Mill AV-802 Bulk Bag #1 Bottom Valve 1Mill AV-803 Bulk Bag #2 Bottom Valve 1Mill WT-801 Malt Silo Weight 1Mill WT-802 Grist Case Weight 1Mill WT-803 Bulk Bag #1 Weight 1Mill WT-804 Bulk Bag #2 Weight 2MashCooker M-101 Mash Pump Motor 2MashCooker M-102 Mash Mixer Motor
  46. 46. Closer Look IO Integrated Simulation Integrated Built-In HMI Control Built-In Error Handling
  47. 47. What’s next? • Base Project: • All Device FBs and Global/Instance DBs have been created • Subsystem FBs have been created • What’s left? • Add Sequencing Logic • Add OB’s • Run SiVArc to generate base HMI project
  48. 48. Screen Name Device Mill Valve Horizontal Mill Valve Vertical Mill Analog Input Mill Analog Valve Mill PID Mill Flow Totalizer Mill Flow Indicator Mill Motor Horizontal Mill Motor Vertical Mill Motor Pump Horizontal Mill Motor Pump Vertical Mill VFD Motor Horizontal Mill VFD Motor Vertical Mill VFD Pump Horizontal Mill VFD Pump Vertical Mash Cooker Valve Horizontal Mash Cooker Valve Vertical Mash Cooker Analog Input Mash Cooker Analog Valve Mash Cooker PID Mash Cooker Flow Totalizer Mash Cooker Flow Indicator Mash Cooker Motor Horizontal Mash Cooker Motor Vertical Mash Cooker Motor Pump Horizontal Mash Cooker Motor Pump Vertical SiVArc Setup • SiVArc Rules generated using included MS Excel Sheet HMI Object Type Screen Name
  49. 49. Screen Name Device Mill Valve Horizontal Mill Valve Vertical Mill Analog Input Mill Analog Valve Mill PID Mill Flow Totalizer Mill Flow Indicator Mill Motor Horizontal Mill Motor Vertical Mill Motor Pump Horizontal Mill Motor Pump Vertical Mill VFD Motor Horizontal Mill VFD Motor Vertical Mill VFD Pump Horizontal Mill VFD Pump Vertical Mash Cooker Valve Horizontal Mash Cooker Valve Vertical Mash Cooker Analog Input Mash Cooker Analog Valve Mash Cooker PID Mash Cooker Flow Totalizer Mash Cooker Flow Indicator Mash Cooker Motor Horizontal Mash Cooker Motor Vertical Mash Cooker Motor Pump Horizontal Mash Cooker Motor Pump Vertical SiVArc Setup • Create Blank Master Copies in Portal Project
  50. 50. SiVArc Setup • Import SiVArc Rules, resolve any discrepancies
  51. 51. SiVArc Setup • Generate the visualization
  52. 52. SiVArc Tips • Before running SiVArc, PLC project must already be generated and compiled • Create HMI screens in project before dragging to Master Copies • Reuse Brewing Template screens (after deleting devices) to maintain formatting • Template is based on Siemens Open Library, must have this downloaded and pulled into Project Library
  53. 53. What did we just create? • By running Openness and SiVArc, we’ve just generated HMI manual control of all of our devices in the entire brewery! • All that is left is to generate automated sequence logic • Start with default layout from Brewing Template Project and adapt to your needs
  54. 54. 1. Siemens Brewing Template Intro 2. Project Layout 3. Creating a Project 4. Case Study: Witherspoon Distillery 5. Other Brewing Template Successes 6. Live Demo!
  55. 55. Witherspoon Distillery • Founded in 2011 in Lewisville, TX • All US raw materials • Mash, fermentation, distillation, aging, bottling, and packaging • Primarily whiskey, but distills all spirits for Tasting Hall cocktails
  56. 56. Previous Automation • Automation Direct PLC/HMI • Some automated control, but primarily manual process • No recipes, no reporting • No utilities
  57. 57. Witherspoon Goals • Increase capacity • Improve consistency • Integrate utilities • Integrate new Still • Have a solution that can be expanded when they are ready to expand again
  58. 58. Solution • Customize Siemens Brewing Template • S7-1500 PLC, WinCC Professional HMI • Integrate Utilities • Boiler, Chiller, Cooling Tower • Add new Still • 68BBL, previous were both 10BBL • Add new grain delivery system, sour mash pump
  59. 59. Solution Team • Functional Specification • Controls Programming • Drawing/Instrumentation review • Commissioning • Instrumentation Selection • Panel Design & Build • Commissioning • Specification Input/Approval • Mechanical Installation • Field Wiring • Commissioning
  60. 60. Results • Currently fermenting first batches using the automated system!
  61. 61. Lessons Learned • Solution Partner/Distributor Relationship is Great! • WinCC Pro V15 and V15.1 – one or the other, not both • Load Cells • Remove installation hardware • WebUX • Not compatible with faceplates
  62. 62. 1. Siemens Brewing Template Intro 2. Project Layout 3. Creating a Project 4. Case Study: Witherspoon Distillery 5. Other Brewing Template Successes 6. Live Demo!
  63. 63. Founders Brewery • Brewpub automation – small scale, R&D brewing • Required mostly manual control, quickly implemented with Siemens Brewing Template
  64. 64. Founders Brewery
  65. 65. Craft Brewing OEM • Full brewhouse and cellar automation • General Product Line with standard customizable options • Support for further customization as needed
  66. 66. East Coast Microbrewery • Utilized a system from Craft Brewing OEM • Very similar to standard Brewing Template Project (4 vessel brewing and fermentation)
  67. 67. Siemens Brewing Template Recap • Open Source • Built on standard libraries, easy to scale • Built in Reporting, Simulation • Fully Customizable
  68. 68. 1. Siemens Brewing Template Intro 2. Project Layout 3. Creating a Project 4. Case Study: Witherspoon Distillery 5. Other Brewing Template Successes 6. Live Demo!
  69. 69. Live Demo
  70. 70. Rapid Brewery/Distillery Automation Name: Ryan Landwehr Company: DMC, Inc. Email: Ryan.Landwehr@dmcinfo.com Phone: (972)-432-5536 Session # (for your survey): 1.2

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