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Beer Release to Finished Beer Line Modification

Approximately six existing process PLCs and two clean in place (CIP) tenor drums were modified on line. Two existing Allen Bradley Advisor CRTs also were modified to allow graphic Operator selection of the new bottle line from about 30 sources. New Tuchenhagen valves were added to the beer release header to allow this selection and to provide for the new sections of pipe to be cleaned in place. The new process was integrated into the existing finishing cellar operation without interruption of production.

The printouts of the existing programs were marked up during the PLC programming phase at Emerson Process Management for subsequent use during on line programming. There was coordination with Factory Link GUI programing which was done by others. The components could not be set up for simulation before checkout / start up as most were existing and in operation.

Marked up PLC program printouts were used during on line programming of approximately 6 existing PLCs. The modified Advisor programs were downloaded into the existing GUI computers on site. Extensive coordination was required between plant maintenance, plant operations, plant engineering, Factory Link programmers, corporate engineers installing the new bottle line, two installation contractors and the bottle line turnkey equipment vendor. All programs were backed up on line before and after modification.

The bottle line started up ahead of schedule requiring that the beer release be complete ahead of schedule. This was accomplished without inadvertent shutdowns and the plant was extremely happy with the outcome.

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Problem:

To modify the existing upstream process to allow all brands of beer from multiple headers to be supplied to a new bottle line. The project had high visibility because the bottle line
was the first to be installed as turnkey from the equipment vendor.

The beer absolutely had to be there when the bottle line was ready to run.


Solution:

The customer chose Emerson Process Management because of its prior brewery and on-line programming experience, including capabilities in GUIs and PLCs.

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