pi system at heineken seville brewery: a base for our...
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Presented by
© Copyr i gh t 2013 OSIso f t , LLC.
PI System at
Heineken Seville
Brewery: a base for
our Sustainability
Goals
Consuelo Carmona
© Copyr i gh t 2013 OSIso f t , LLC.
Agenda
• Heineken
• Sustainability challenges
• Solution
• Results
• Future Plans
2
© Copyr i gh t 2013 OSIso f t , LLC.
Agenda
• Heineken
• Sustainability challenges
• Solution
• Results
• Future Plans
3
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Seville
Spain
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© Copyr i gh t 2013 OSIso f t , LLC.
Agenda
• Heineken
• Sustainability challenges
• Solution
• Results
• Future Plans
7
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Agenda
• Heineken
• Sustainability challenges
• Solution
• Results
• Future Plans
9
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Leader in technological
innovation & efficiency
Capacity: 5 Mill Hls
Brewhouse: 2 lines: 20.000
hl/day
Cellar with 90 tanks (71 FVs
+ 19 BBTs)
Beer Filtration: 2 lines: 1.200
hl/h
Packaging:
2 Keg lines
1 Can line
5 Bottle lines
Seville Brewery
Water: 3,6 hl/hl
Electricity: 7,3 kwh/hl
Thermal Energy: 57 MJ/hl
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Parking Parking
Malting Access Control
Warehouse
Utilities
Packaging
Offices & Lab
BBT cellar
F&M Cellars
WWTP Brewhouse Service Block
Silos
Visitors
Pavillion
Clinic
Canteen
Water consumption (hl/hl)
Electricity consumption (kwh/hl)
Compressed air consumption
(Nm3/hl)
Cooling consumption (MJ/hl)
Alcohol water (-5 ºC)
Chilled water (3 ºC)
Thermal Energy consumption
(MJ/hl) (gas natural and biogas)
Super heated water
(160 ºC – 13 bar)
Water and Energy users
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DEPARTMENTS
Brewing
Packaging
Utilities
Others
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Consumption = Demand/Efficiency
UTILITY PLANTS
Efficiency
Water treatment plant
Cooling plant
Super heated water plant
Air compressed plant
Electrical transformers
Water
Electricity
Gas Natural
Others
Consumption Demand
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PI System
• PI AF
• PI Manual Logger
• PI ProcessBook
• PI DataLink
• PI Notifications
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PI AF (PI Asset Framework)
Flexible asset models that allows us to
organize and structure PI System data and
other data according to:
Water, electricity or thermal energy
Departments, areas and equipment
(hierarchical models)
To model more than one element based on the
same Attributes Element Templates (Set of
base Attributes)
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1. Performance Equations (Calculated Point): Refrigerating Power (Kw frig)
Calculated trough PI points: Flow,
density, inlet and outlet temperatures,
medium specific heat
COP = Refrigerating Power / Electrical Power
3. PI AF (Attribute by equation): COP (Cooling Plant Efficiency) (Kw frig / kw)
2. PI AF (Attribute): Electrical Power (kw) (PI point)
Cooling Plant Efficiency by PI System
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PI Manual Logger Manual data entries:
Beer productions
Working hours
PI System calculates daily/weekly/monthly
water and energy consumption per hl
produced or working hour
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Utility plant monitoring (PI ProcessBook)
Efficiency data?
Ratios data?
Historical values as references?
Flexible graphs?
PI System Compressed air plant
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Utility plant monitoring (PI ProcessBook)
Compressed Air
USERS DEMAND
(Nm3 / Hl) =
Compressed Air /
Beer Produced
Compressed Air
PLANT EFFICIENCY
(Nm3 / Kwh) =
Compressed Air /
Power
Compressed Air
ELECTRICITY
CONSUMPTION (Kwh / Hl) =
DEMAND / EFFICIENCY
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Video mode
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Electricity – Cooling plant
PLANT EFFICIENCY END USER DEMAND
COP real time =
Refrigerating Power /
Electrical Power
COP references:
Daily/weekly/monthly
COP
Demand real time
Demand ratio:
Weekly/monthly
Demand/Hl produced
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Thermal Energy - Super heated water plant (boilers)
PLANT EFFICIENCY END USER DEMAND
Boilers Efficiency
Gas/biogas
consumption
Demand real time:
thermal power
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Water and Energy user monitoring (PI ProcessBook)
Daily Softened and Chilled Water consumption
Pasteurizador 1100 (Packaging line) – Water Consumption
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Water and Energy maps (PI ProcessBook)
Brewery Water Map
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Reports (PI DataLink)
Compressed Air Deployment
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Reports (PI DataLink)
Electricity consumption – Brewing department – Weekly follow up
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Driving System – Energy and Water KPIs
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Agenda
• Heineken
• Sustainability challenges
• Solution
• Results
• Future Plans
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Seville Brewery
PI System a fundamental base to helps
Heineken Seville realise its Sustainability
Strategy to reach World Class Excellence
and become the Industry Benchmark for
Supply Chain
Results
World Class Excellence
PI System
© Copyr i gh t 2013 OSIso f t , LLC.
Agenda
• Heineken
• Sustainability challenges
• Solution
• OSIsoft Products and PI System Architecture
• Results
• Future Plans
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© Copyr i gh t 2013 OSIso f t , LLC.
Next steps
• Use of PI Event Frames – Compare shift efficiency
– Compare weekly startup of the plants and downtimes
– Ease the creation of BI cubes
• Use of upcoming Abacus – Alleviate the visualization of calculated AF attribute
• Connection with MES/SAP to remove manual data entries
• Real targets according to real production and climate conditions calculated by PI System
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• Quick answer against energy
and water consumption
deviation
• Anticipate efficiency losses
• Cost savings and reduction in
CO2 emissions
Solution Results and Benefits
PI System: A base for our Sustainability Goals
Business Challenge
• Continued progress water
and energy efficiency of our
brewery
• Achieve World Class
Excellence
• Become the Benchmark
• Implemented The PI
System as Energy&Water
Monitoring and Reporting
System
• Energy & Water
Management
Part of our Sustainibility program “Brewing a Better Future”
is to reduce water and energy consumption in our
breweries. The “Energy&Water Monitoring and Reporting
System” will enable brewery to put in place an effective
system to address energy and water losses and improve
efficiency.
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Seville Brewery
© Copyr i gh t 2013 OSIso f t , LLC.
Consuelo Carmona
Western EU Electricity project lead
Heineken
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