Musk Engineering Welcomes IBD & BFBi
Presentation To:IBD & BFBi
Initial Design By Owen Core Design Brief URS & P&ID Automation Mechanical Design Electrical Design Commissioning
Initial Design By Owen Core HIGHEST EXTRACT EFFICIENCY FASTEST CYCLE TIME TARGETS MUST BE ACHIEVABLE AND BALANCED BEST WORT QUALITY
Wort Copper EWB Whirlpool Underback CIP Plant HLT Lauter Tun MCV
By John Coates Design Brief URS & P&ID Automation Mechanical Design Electrical Design Commissioning
By John Coates Grist Case Mash Vessel Lauter Tun Kettle Whirlpool Wort Cooling
By John Coates Leading on from the URS & P&ID 1. Functional Design Considerations 2. Functional Design Specification (FDS) 3. Software Development 4. Internal Testing 5. Client Testing 6. Factory Acceptance Testing 7. Software Installation Leading onto Commissioning
Functional Design Considerations Taking into account the Brewhouse User Requirement Specification (URS) & P&ID we need to produce a Functional Design Specification (FDS) which will enable the software to be written. Before we can do that we need to analyse the URS and P&ID. Expanded step sequence Easy to maintain and fault find Design pitfalls Split the plant into zones Look for any parallel operations and tasks Flexible design
This image cannot currently be displayed. Functional Design Considerations Single Step Sequence Method Single Brewhouse Sequence MCV Pre Warm MCV Foundation Liquor Salts Add Filling Additions Mash Conversion LT Pre Warm
This image cannot currently be displayed. Functional Design Considerations Single Step Sequence Method LT Foundation Liquor LT Filling MCV Emptying MCV Rinse MCV Chase MCV Drain Main MCV Vessel Rinse MCV Drain Vessel LT Recirculation LT Run Off Deep Bed LT K
This image cannot currently be displayed. Functional Design Considerations Single Step Sequence Method LT Sparge KettleFilling LT Rake LT Bed Drain LT Grains Removal LT Drain Vessel Under Plate Flush LT Sparge LT Drain Vessel Pumped Recirculation Pre Boil
This image cannot currently be displayed. Functional Design Considerations Single Step Sequence Method Pre Boil Early Sugar Raise Hop Boil Hop Boil Hop Boil Late Sugar Ad Boil to Boil Add Add Add d C Add
This image cannot currently be displayed. Functional Design Considerations Single Step Sequence Method Late Sugar Ad d Boil Casting Rinse Chase Drain Main Vessel Rinse Drain Vessel Add
This image cannot currently be displayed. Functional Design Considerations Pitfalls Rigid design No flexibility Poor utilisation of the plant
Malt Handling Grist Available Grist Available Grist Available Mash Vessel Salts Add Additions Salts Add Additions Pre Warm Foundation Liquor Filling Mash Conversion Emptying Rinse Chase Drain Vessel Drain Main Rinse Vessel Foundation Liquor Filling Mash Conversion Emptying Rinse Chase Drain Vessel Drain Main Rinse Vessel Filling Sparge Filling Sparge Lauter Tun Pre Warm Foundation Liquor Recirculation Run Off Bed Drain Grains Removal Drain Vessel Foundation Liquor Recirculation Run Off Bed Drain Grains Removal Drain Vessel Deep Bed Rake Rake Down Under Sparge Plate Wash Flush Deep Bed Rake Down Under Sparge Plate Wash Flush Bed Raking Bed Raking Early Sugar Late Sugar Early Sugar Late Sugar Kettle Filling Filling Pre Boil Raise to Boil Pre Boil Boil Boil Vessel Drain Rinse Vessel Pre Boil Raise to Boil Boil Boil Vessel Drain Rinse Vessel Pumped Recirculation Thermosyphon Pumped Thermosyphon Boil Main Casting Rinse Chase Drain Recirculation Thermosyphon A dd Pumped Recirculation Thermosyphon Pumped Thermosyphon Main Casting Rinse Chase Drain Recirculation A dd Hop Add Hop Add Hop Add Hop Add Hop Add Hop Add Whirlpool Zinc Add Filling Standing Emptying Trub Vessel Drain Removal Rinse Vessel Zinc Add Filling Standing Emptying Trub Vessel Drain Removal Rinse Vessel Chillier Chillier SDown Chillier Chillier SDown Wort Cooling Purge Main Wort Transfer Dilution Chase Chase to Drain Purge Main Wort Transfer Dilution Chase Chase to Drain Wort Oxygenation Wort Oxygenation Yeast Pitching Yeast Pitching Additions Additions
This image cannot currently be displayed. Functional Design Considerations MASTER LAUTERING PROFILE DIAGRAM. Start of continuous Sparging Sparge flow = Wort flow when volumes equal F3 Spargeflood Ramping Rate R Sparge finishes. Rake-down starts F1 F Wort Firstworts Secondworts Lastworts Recirculation DP 1000mmwg DP 1500mmwg DP 1000mmwg Deep-Bed-Rake at maximum DP V0 V1 V2 (when required). V3 V4 V5 Finish Wort Collection Start Wort Collection Target Total Wort Collection Period F2 Sparge Volume Total
Functional Design Considerations Recipe control of the plant Batch history Trending Brew scheduling HMI Full SCADA Full MES MIS (Human Machine Interface) (Supervisory Control and Data Acquisition) (Management Execution System) (Management Information System) Push buttons and indicators PLC (Programmable Logic Controller)
This image cannot currently be displayed. Functional Design Considerations MES Server Op Term Op Term Op Term Op Term Malt PLC Brewhouse PLC Malt Plant MCV Plant Lauter Tun Plant Kettle Plant Whirlpool Plant Wort Cooling Plant
Functional Design Considerations Feed Forward and Back Trigger Points Calculate the optimum time to start the next brew depending on the progress of the current brew. Feed forward the Start Request to the Lauter Tun so that it is ready and waiting with its Foundation Liquor to receive the Mash from the MCV without delays. Plus other trigger points.
Functional Design Considerations Feed Forward the Actual Data to Recalculate Setpoints Calculate required Liquor Volume depending on the actual Malt Charge and the Liquor Grist Ratio. Calculate the required Boil Steam Volume from the actual volume plus the sugar addition and required evaporation %
This image cannot currently be displayed. Functional Design Specification (FDS) Taking into account the above points an FDS can be developed for each individual sequence Mash Conversion Vessel Main Sequence Additions 1 Sub Sequence Additions 2 Sub Sequence
This image cannot currently be displayed. Functional Design Specification (FDS) Lauter Tun Main Sequence Filling Sub Sequence Sparge Sub Sequence Deep Bed Rake Sub Sequence Raking Sub Sequence Under Let Under Plate Flushing Sparge Washing Under Plate Jetting
This image cannot currently be displayed. Functional Design Specification (FDS) When compiling the FDS it is best to produce an individual FDS for each sequence. The FDS contains a revision history at the front of the document and a signed Approval Box at the end. This may seem over the top but if the FDS for one sequence requires modification, the revision numbers for the other parts don t need to be changed. The FDS contains a Tested / Checked column for each individual sequence step description, which is used on simulation to check the completed software code against the FDS.
This image cannot currently be displayed. Software Development When the FDS has been approved by our Client (this may be Owen in some circumstances), the software can be developed. The PLC Software will be developed with a file structure in line with the FDS sections. On completion of the software coding we would then test the completed system using a Simulator to behave as the Brewhouse Plant.
This image cannot currently be displayed. Simulation MES Server Op Term Op Term Op Term Op Term Malt PLC Brewhouse PLC Plant Simulator (Simulation Computer)
This image cannot currently be displayed. Software Simulation There are several varieties of simulation software available. We use PIC s Simulation Software, which we configure to mimic the Brewhouse Plant and Devices. Algorithms can be set up in the Simulator, simulating Vessel Levels when filling and emptying. We can also model rising or falling temperatures when a vessel or main is being heated or cooled. Once the simulation software is complete the Simulation Computer will be connected to the Control System to behave as if it is the Plant. This enables the automation software to be thoroughly tested before leaving the offices.
This image cannot currently be displayed. Software Simulation Phases Initially the completed software will be tested in-house to make sure that it meets the FDS and the sequences hang together correctly. Once this is OK the Client will be invited to run the simulation. This usually involves the Operators who operate the original plant. After this we move on to Factory Acceptance Testing (FAT). This simulation is usually conducted by the client s responsible person. The FAT should be carried without software intervention, with the aim of making sure the system is robust enough for site installation. At the end of the FAT the system will be signed off by the Client as fit for installation on site.
This image cannot currently be displayed. Software Simulation Completion Once the FAT is successfully completed the software will be released for installation on site. Simulation is one of the most important steps during the lifecycle of the project. It allows the Operators to see for the first time how the new plant will operate. Good simulation can / will highlight any shortcomings in the design. Simulation drastically reduces commissioning time and some fairly major software changes can be accomplished without having long shutdown periods.
Software Simulation Completion Once released the software is installed on site. Usually the receiving Control Panels are already being installed on site electrical team, whilst he software development / simulation phases are carried out. Once the Mechanical, Electrical, MES System and Control System software installation is complete we can move onto commissioning.
Lauter Tun & MCV Combined Process Schematic AV1203 HL 85 C CIP+ Ø50 HL 85 C CL 13 C AV1103 MI1104 AV1110 CV1111 MIXER Ø76 AV1210 CV1211 Ø25 CL 13 C TRUB RETURN 188 HL/HR CV1105 FM1106 TTx 1112 FM MAG FLO FTx FQ Ø38 AV1114 AV1113 MI1204 MIXER TTx 1212 CIP Ø65 AV1213 MV1967 403 HL/HR Ø80 AV1127 Ø40 RS MV1961 MV1960 Ø38 MV1963 MV1962 CV1205 FM MAG FLO FTx FM1206 FQ Ø50 MV1966 SG1235 2 1/2" NB STEAM 329KG/HR @3 BARG CV1101 TTx 1117 AV1128 1½" AV1102 1½" T1131 AV1107 Ø25 AV1108 Ø76 HLP 1116 STR1130 MV1129 AV1109 MCV 1100 LLP 1118 VSD M1122 7.5kw SS1115 AV1125 AV1124 P1126 Ø150 Ø50 DRAIN 150 HL/HR UPJ Ø50 Ø150 Ø50 150M³/HR AV1123 Ø50 MV1965 MV1964 AV1207 HLP 1216 AV1202 Ø200 PN16 AV1201 Ø51 Ø51 AV1208 LAUTER TUN Ø76 AV1240 WORT OP1209 SS1215 M1304 18M³/Hr WATER DRAIN 4" Ø65 Ø25 RECIRC LTx 1217 LTx 1218 AV1301 HP1302 LP1303 MV1319 AV1229 3/4" AIR Ø25 MV1969 MV1968 DP/PLC FQ FTx AV1318 1" NB Ø25 Ø25 LLS1234 P1231 Ø50 FM 1230 20M³/HR @2.0Barg AV1232 AV1317 Ø80 AV1316 DRAIN Ø50 AV1233 Ø50 AV1241 Ø50 DRAIN MV1971 MV1970 CV1237 AV1238 AV1239 P1954 Ø50 CIP SCAVENGE SP1236 Ø50 DRAIN WORT CIP SCAV SPENT GRAINS
MCV & Lauter Tun Based 4 Vessel Brewhouse Cycle Time LAUTER TUN BREWHOUSE Hour/Minutes 10 20 30 40 50 1hr 2hrs 3hrs 4hrs 5hrs 6hrs 7hrs 8hrs 9hrs 10hrs 10 10 10 10 10 10 10 10 10 20 30 40 50 20 30 40 50 20 30 40 50 20 30 40 50 20 30 40 50 20 30 40 50 20 30 40 50 20 30 40 50 10 20 30 40 50 20 30 40 50 180 360 11hr 12hrs 13hrs 10 10 20 30 40 50 20 30 40 50 MCV 1 11 50 10 5 1 1 11 50 10 5 1 1 11 50 10 5 1 Lauter Tun 72 5 72 5 5 3 5 1 10 131 10 15 5 3 5 1 10 131 10 15 5 3 5 1 10 131 10 15 5 Copper 88 131 5 45 10 10 10 60 5 45 10 10 60 5 45 10 Whirlpool 259 10 30 60 5 10 3 10 30 60 5 10 3 10 30 60 5 10 3 10 10 10 20 30 40 50 10 20 30 40 50 10 20 30 40 50 10 20 30 40 50 10 20 30 40 50 10 20 30 40 50 10 20 30 40 50 10 20 30 40 50 10 20 30 40 50 20 30 40 50 20 30 40 50 10 20 30 40 50 10 20 30 40 50 1hr 2hrs 3hrs 4hrs 5hrs 6hrs 7hrs 8hrs 9hrs 10hrs 11hr 12hrs 13hrs MCV Foundation 1 min. Mash In 11 min. Stand/Raise 50 min. Stand 10 min. Mash Transfer 5 min. Rinse 1 min. 78 mins. LAUTER TUN Flood Plates 3 min. Mash Transfer 5 min. Dwell 1 min. Recirc. 10 min. Run Off 131 min. Trub (during Sparging) (5 min). Drain 10 min. Grains Out 15 min. UPJ 5 min. 180 mins It can be seen that the turn-around time is approx 3 hrs. (Mash Tun Cycle Time = 4 Hr 40 Mins)
By John Coates Any Questions End of Part One THANK YOU
Brewhouse Optimisation & Affect of Raw Ingredient Changes Brewhouse Recipe Analysis A professional brewhouse designer will optimise the brewhouse design specifically for a customer s desired recipe range. The design will optimise extract performance, wort quality and throughput around the most common and core product recipes. For a new brewhouse design, the results of the brew analysis will be used to determine the ideal plant parameters, for instance, optimum Lauter Tun diameter, etc. and these factors all feed forward to optimised cycle time, wort extract contribution, and wort quality. Musk are one of the only companies in Europe who always provide customised Lauter Tun diameters. If our recipe analysis suggests a 4.32m diameter Lauter Tun is optimum, we build it at 4.32m diameter. Almost all other brewhouse manufacturers have standard 0.5m diameter step increments, (e.g. only 4.0m & 4.5m diameters are available).
Choice of Brewhouse Based upon Prices of Cereals The Mash Tun relies on well-modified malt, which is relatively expensive, compared to less modified, un-modified malts and cereals, which are commonly used in MCV / Lauter tun brewhouses. The availability of supply of well modified malt, is assured for the immediate future, and has been confirmed by major recent investments in Mash Tun brewhouses. Good quality fermentable extract is available in a wide array of other lower cost cereals, which can be used in conjunction with well-modifed malts in a MCV / Lauter Tun brewhouse. If beer styles are excluded, there is a financial consideration of payback of : Capital plant Vs A life-time of lower cost raw material costs High volume breweries can take advantage of the lower cost raw materials, as the initial investment in process plant has a realistic payback. Increased capital costs are not limited to the brewhouse, and significant downstream investment is also required in beer processing.
Mash Conversion Vessels The MCV is required in conjunction with a Lauter Tun to process less modified malts and other cereals used in brewing throughout the world. The decision to use this style of brew plant may be based upon: The style of beers being brewed. The availability of well modified malt for climatic reasons. Financial considerations (the cost of well modified Malt vs other cereals). The basic function of the MCV is to convert the starches in the milled cereals to their maximum fermentable extract and is essentially a low temperature cooking vessel. Cereals are mashed into the MCV using a pre-masher, usually a sleeve-type vortex masher, which provides consistent levels of hydration, and mash start temperature. Put simply, the mash is subjected to a fixed recipe driven increasing temperature profile, with temperature rest periods, using steam heating, over a set period.
Mash Conversion Vessels The MCV will raise the temperature of the mash according to the profile in a recipe driven automatic system, providing both consistency and quality, and is rarely manual. There is additional equipment compared to a Mash Tun, such as the agitator, steam jackets, steam & temperature control, and this equipment demands complex automation systems for consistent reliable results.
Mash Conversion Vessel Process Schematic HL 85 C CL 13 C CIP+ AV1103 AV1110 CV1111 MI1104 MIXER Ø76 CV1105 FM1106 TTx 1112 FM MAG FLO FTx FQ Ø38 AV1114 AV1113 403 HL/HR Ø80 AV1127 Ø40 RS MV1961 Ø38 MV1963 MV1960 MV1962 2 1/2" NB AV1107 Ø25 AV1108 Ø76 AV1109 SS1115 STEAM 329KG/HR @3 BARG HLP 1116 MCV CV1101 TTx 1117 AV1128 1½" MASH 1100 AV1102 1½" LLP 1118 VSD M1122 7.5kw AV1125 AV1124 P1126 Ø150 150M³/HR AV1123 Ø50 MV1965 MV1964 T1131 STR1130 MV1129 Ø25 DRAIN P1954 CIP SCAVENGE CIP SCAV
Brehouse Automation Mash Conversion Vessel General Arrangement
Lauter Tuns The Lauter Tun is required in conjunction to the MCV to process less modified malts and other cereals used in brewing, and is used to filter the sweet wort from the cereal solids, and to rinse the available extract from the grains. An MCV & Lauter Tun brewhouse utilises a different milling spectrum to a Mash Tun, with typically 50% less husk, and 300-400% higher flour constituents, It results in a much less permeabable mash than a Mash Tun, that easily blinds. As a consequence, the Lauter Tun operates with a much lower bed depth than a Mash Tun, and is fitted with Lautering knives, (rake gear) which occasionally cut into & open-up the mash bed to aid permeability. The rake gear is complex, and has the requirement to lift and position the knives accurately within the mash bed. The Lauter tun is filled quickly from the bottom, to reduce oxygenation, and the fill point is offset from the Lauter tun pedestal to prevent undue spashing.
Lauter Tuns The wort run-off from a Lauter tun is carefully controlled with a variable flow profile and is recirculated during the lautering process, both at the beginning of run-off, to establish the filter bed, and following deep bed raking, and alternates between recirculation, and forward flow to the wort copper. The Lauter Tun mash bed is fitted with differential pressure transmitters, which measure the permeability of the mash bed, and are used to determine when the rake gear is employed for shallow or deep bed raking, according to a flexible pre-stored profile. A sparging system is used, similarly to a Mash Tun, to wash fermentable extract from the grains. The Lauter Tun process is usually fully automatic and has additional process equipment required in addition to the Mash Tun, recirculation flow control, hydraulic power pack for rake gear operation etc.
Lauter Tuns Changes in raw material properties will affect the lautering, particularly in the filter bed thickness & permeability, but the control system is designed to be flexible and operates according to both actual instrumentation, and the pre-determined brew recipe. If the raw material changes are slight, the Lauter tun will cope easilly. The Lauter Tun is an expensive piece of equipment, and is often a challenge to install, with very large diameter vessels for large brew-lengths requiring to be cut in half and re-built on site following delivery by road.
Lauter Tun Process Schematic AV1203 HL 85 C AV1210 Ø25 CL 13 C TRUB RETURN 188 HL/HR Ø50 CV1211 MI1204 MIXER CIP Ø65 AV1213 TTx 1212 MV1967 150 HL/HR UPJ Ø50 P1126 Ø150 Ø50 CV1205 FM MAG FLO FM1206 AV1207 HLP 1216 AV1202 Ø200 PN16 AV1201 Ø51 Ø51 AV1208 LAUTER TUN Ø76 AV1240 WORT MV1966 OP1209 SS1215 M1304 18M³/Hr WATER DRAIN 4" Ø25 RECIRC LTx 1217 LTx 1218 AV1301 HP1302 LP1303 MV1319 AV1229 AIR Ø25 MV1969 MV1968 3/4" DP/PLC FQ FTx AV1318 FM 1230 Ø25 Ø25 LLS1234 P1231 Ø50 20M³/HR @2.0Barg AV1232 AV1317 Ø80 AV1316 DRAIN Ø50 AV1233 AV1241 DRAIN MV1971 MV1970 SG1235 CV1237 AV1238 AV1239 P1954 Ø50 CIP SCAVENGE SP1236 Ø50 DRAIN WORT CIP SCAV SPENT GRAINS
Lauter Tun General Arrangement
Advantages to a change from Mash Tun to MCV / Lauter Tun Brewhouse Available beer styles are very diverse, almost nothing is impossible. Productivity increases massively. Brew period of 3 hrs compared to 4 hrs 45 mins. Up to 8 brews per day is possible, compared to 5. Quality and consistency increases, because the automation required to operate the plant, it is also used for quality and consistency purposes. Lower cost raw ingredients become more widely available to use. Supplier competition has reduced the cost of complex brewhouse plant.
Mash Filters Mash Filters have not been discussed on grounds of time constraints. Mash filters are used when specific ingredients are used with very fine milling profiles, where LT filter beds would otherwise blind with the recipes used. Mash filters are better producing high gravity beers, and can generate more extract as the milling spectrum is further still towards the flour end. Usually where an MCV Lauter tun brewhouse will recycle weak worts to aid extract performance, a mash filter brewhouse does not need to. Mash filters are quicker still than an MCV / Lauter tun brewhouse.