PI System at Heineken Seville Brewery: a base for our

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© Copyr i gh t 2013 OSIso f t , LLC.

PI System at

Heineken Seville

Brewery: a base for

our Sustainability

Goals

Consuelo Carmona


Agenda

• Heineken

• Sustainability challenges

• Solution

• Results

• Future Plans

2


Agenda

• Heineken


• Solution

• Results

• Future Plans

3

© Copyr i gh t 2013 OSIso f t , LLC. 4


Seville

Spain



Agenda

• Heineken


• Solution

• Results

• Future Plans

7



Agenda

• Heineken


• Solution

• Results

• Future Plans

9


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


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


DEPARTMENTS

Brewing

Packaging

Utilities

Others

12

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


PI System

• PI AF

• PI Manual Logger

• PI ProcessBook

• PI DataLink

• PI Notifications

13


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)


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


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


Utility plant monitoring (PI ProcessBook)

Efficiency data?

Ratios data?

Historical values as references?

Flexible graphs?

PI System Compressed air plant


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


Video mode


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


Thermal Energy - Super heated water plant (boilers)

PLANT EFFICIENCY END USER DEMAND

Boilers Efficiency

Gas/biogas

consumption

Demand real time:

thermal power


Water and Energy user monitoring (PI ProcessBook)

Daily Softened and Chilled Water consumption

Pasteurizador 1100 (Packaging line) – Water Consumption


Water and Energy maps (PI ProcessBook)

Brewery Water Map



Reports (PI DataLink)

Compressed Air Deployment


Reports (PI DataLink)

Electricity consumption – Brewing department – Weekly follow up


Driving System – Energy and Water KPIs


Agenda

• Heineken


• Solution

• Results

• Future Plans

28


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


Agenda

• Heineken


• Solution

• OSIsoft Products and PI System Architecture

• Results

• Future Plans

30


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

31


• 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.

32

Seville Brewery


Consuelo Carmona

[email protected]

Western EU Electricity project lead

Heineken

33


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34

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PI System at Heineken Seville Brewery: a base for our