Innovative Ex-Remote I/O solution ensures economical and efficient production of a cult beverage

How to make whisky today

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ANTARES REMOTE - I/O - Solutions

Antares RemoteI/O solutions

Global spirit producers rely on BARTEC’s Ex-Remote I/O to upgrade their distilleries. The innovative system provides a decentralized part of the control system for the reliable in- and output of process control data in the distillation process to make sure that the famous malts can be produced competitively.

Rail control unit:• Power supply and communication module• Connection chambers for power supply

and bus interface

The word “whisky” derives from the Scottish Gaelic uisge beatha and means “water of life”. The English later anglicised the term to today’s whisky. Aquavi was first documented in 1494, mentioned in the Scottish tax records when the Benedictine monk John Cor from a monastery in County Fife buys just under 500 kilograms, which is about 400 bottles. The ordering client was allegedly King James IV. Over time, more and more private distilleries were founded because every Scottish Clan claimed to be producing its own water of life. Today whisky is a cult. A good single malt matures for at least 12 years before being sold. Only storage in different oak, bourbon and sherry casks gives it its unmistak-able taste.

COMPLEX EX-SOLUTION SIMPLY AND FLEXIBLY IMPLEMENTED

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Worthwhile investmentFor years, small independent distilleries, no longer competitive on their own, have been bought and modernized. Topics such as cost-effectiveness, energy efficiency, heat recovery and environmental protection play an important role for the new owners. Many of these distilleries no longer rely on conventional point to point Ex-isolators but instead on the BARTEC ANTARES remote I/O system. This allows them to make produc-tion much more economical and efficient and generate significant savings in cabling and isolators.

The company became aware of ANTARES at a trade show. The system features impressed the project team members and shortly after BARTEC was granted an order for the ANTARES I/O system. The first systems have been working reliably and without problems in one of the distilleries since spring 2013.

The first project was so successful that multiple cus-tomers have placed a number of follow up orders.

For example, the system of Ex-specialists from BARTEC, Bad Mergentheim, is used in a small but fine traditional distillery in the Scottish Highlands. This is where the innovative remote I/O system controls and monitors a variety of analogue control valves in Ex Zone 1 at the stills. These I/O systems are responsible for ensuring that an alcohol content of approx. 67% is always guar-anteed. Also important in a distillation and especially with single malts, is temperature monitoring. Scotch whisky is distilled three times, Irish twice and Bourbon once in copper stills. Decisive for the taste is not least the intensity of heating. Excessive heating causes too many flavours to volatilize; heating too slowly makes the whisky too “soft” on the tongue. The art of the Master Distiller is thus to choose the right temperature and speed for the heating process. The temperature monitoring integrated in the Ex remote I/O system ANTARES helps the Master Distiller with this task.

ANTARES collects the signals from the valves and temperature measuring devices and forwards them to a process control system, which controls the entire system.

The biggest challenge was to integrate the previously manually operated valves in a controlled process and so generate an efficient, fully automatic process.

EX-REMOTE I/O SYSTEM SECURES THE RIGHT TASTE

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ANTARES REMOTE - I/O - Solutions

assembly of these conventional systems had to be certified. Once the defined system structure is changed or exchanged, the Ex approval is void and recertification is mandatory. This costs time and money. The ANTARES remote I/O system has a system approval - a revolutionary approach. For the first time, BARTEC’s innovative solution allows engineers to plan their system freely and to change and expand it as required. The innovative Ex-Remote I/O ANTARES controls and monitors a large number of analogue control valves at the six stills in the distillation process.

The innovative Ex-Remote I/O ANTARES controls and monitors a large number of analogue control valves at the six stills in the distillation process.

In addition, the Ex-I/O system ANTARES can be easily integrated in existing industrial Ethernet standard communication networks.

The customers chose ANTARES because the inno-vative system ensures easy management, planning, commissioning and maintenance.

And: It ensures high availability with simple means. The unique system certification and easy extension have impressed customers. Previously, I/O systems in hazardous areas needed to be mounted in explo-sion-protected enclosures. Moreover, the complete

The first of its kindCommunication takes place via an Ethernet based protocol. In the distillery, multiple Ex-Remote I/O systems are used on the various stills in the distillation process. Two systems are housed together in a stainless-steel cabinet. As point-to-point Ex-isolators are not used, separate and expensive pressurized enclosure are no longer required. By mounting the remote I/O system directly in the field, the majority of cable routes and cable ducts are eliminated during planning which lowers the installation costs.

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ANTARES REMOTE - I/O - Solutions

Another powerful argument for the BARTEC system was the compact form of the system for the control and automation team. The problem of all operators of old systems: the number of signals grows almost daily, but the space in the auxiliary room remains the same. The remote I/O system installed in the field requires no additional footprint in the auxiliary rooms and can cover large amounts of I/O on small footprint in the field. Finally, yet importantly, signifi-cant savings can be achieved on cabling.

The signal state of each I/O channel is easily checked by on-board diagnostics via LED indica-tions. So you can always see at the system itself,

not only the status of each I/O channel but also the status of all the system modules, an important feature for the maintenance and service team. The modules can be replaced very quickly and easily. Every single module can be replaced separately. A hot-swap feature ensures high availability of the system.

Since all configuration data is stored on an SD card at the system itself, no reprogramming is necessary when replacing any hardware - a real advantage in terms of maintenance and service. Long and costly production interruptions and downtime finally become a thing of the past.

Plenty of benefitsThis new approach offers many advantages over other systems. The specially developed designer software and its intuitive operation make it possible to design and configure with just a few mouse clicks. The program monitors system limits during creation, for example, distances, power management and the maximum cable length, are maintained. The ANTARES Designer calculates required in- and outputs including reserves for the most cost-effective, optimal system, and gives the user the opportunity to see exactly how much power capacity is left. Besides this, the ANTARES provides online diagnostics and generates Ex-Documentation from the as built system configuration.

Success all the wayThe system of Ex-specialists has passed the prac-tical test in the distillery with flying colours and fully convinced the responsible persons. With all its advantages, the system was able to do so especially with its unique flexible system certification and the

very compact design score points. There will soon be quite a few distilleries who have one thing in common; the Ex-Remote I/O system ANTARES from BARTEC, which make production more economical, efficient and more safe.

bartec.de

For more information, please contact:Adem Saricioglu

Strategic Marketing Manager Electrical Safety Systems

BARTEC GmbH

Max-Eyth-Str. 16

97980 Bad Mergentheim

Germany

Phone: +49 7931 597 263

Mobile: +49 163 6597 017

E-Mail: adem.saricioglu@bartec.de

The technology in detail

� Profinet and ethernet IP for the EX area

� No ex-approval for housing required

� No external safety isolators or barriers necessary

� Same bus topology as in non-EX area

� Integrated ethernet switch enables you to build ringtopologies

� Powerful power supply supplies up to 32 I/O modules

� Real system redundancy at profibus-dp

� Designer sofware with intuitive user interface