Brewing a better future at Heineken Seville using the PI System Infrastructure

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1 Brewing a better future at Heineken Seville using the PI System Infrastructure Presented by Consuelo Carmona Miura Energy Capabilities Project Lead Heineken Western Europe Region Copyr i ght 2014 O SIs oft, LLC.

2 Agenda Heineken Sustainability challenges Solution Results Future Plans Copyr i ght 2014 O SIs oft, LLC. 2

3 Agenda Heineken Sustainability challenges Solution Results Future Plans Copyr i ght 2014 O SIs oft, LLC. 3

4 Copyr i ght 2014 O SIs oft, LLC. 4

5 Copyr i ght 2014 O SIs oft, LLC. 5

6 Spain Seville Copyr i ght 2014 O SIs oft, LLC. 6

7 Copyr i ght 2014 O SIs oft, LLC. 7

8 Copyr i ght 2014 O SIs oft, LLC. 8

9 Agenda Heineken Sustainability challenges Solution Results Future Plans Copyr i ght 2014 O SIs oft, LLC. 9

10 Copyr i ght 2014 O SIs oft, LLC. 10

11 Copyr i ght 2014 O SIs oft, LLC. 11

12 Agenda Heineken Sustainability challenges Solution Results Future Plans Copyr i ght 2014 O SIs oft, LLC. 12

Seville Brewery Water: 3,6 hl/hl Electricity: 7,3 kwh/hl Thermal Energy: 55 MJ/hl Leader in technological innovation & efficiency Capacity: 5 Mill Hls Brewhouse: 2 lines:

13 Seville Brewery Water: 3,6 hl/hl Electricity: 7,3 kwh/hl Thermal Energy: 55 MJ/hl Leader in technological innovation & efficiency Capacity: 5 Mill Hls Brewhouse: 2 lines: hl/day Cellar with 90 tanks (71 FVs + 19 BBTs) Beer Filtration: 2 lines: hl/h Packaging: 2 Keg lines 1 Can line 5 Bottle lines Copyr i ght 2014 O SIs oft, LLC. 13

14 Water and Energy Users Malting Access Control Warehouse Water consumption (hl/hl) Electricity consumption (kwh/hl) Parking Parking Utilities Packaging Compressed air consumption (Nm3/hl) Clinic Offices & Lab Cooling consumption (MJ/hl) BBT cellar Alcohol water (-5 ºC) Canteen Visitors Pavillion Silos Brewhouse Service Block F&M Cellars WWTP Chilled water (3 ºC) Thermal Energy consumption (MJ/hl) (gas natural and biogas) Super heated water (160 ºC 13 bar) Copyr i ght 2014 O SIs oft, LLC. 14

15 Consumption = Demand/Efficiency UTILITY PLANTS DEPARTMENTS Consumption Efficiency Demand Brewing Water Electricity Gas Natural Water treatment plant Cooling plant Super heated water plant Packaging Utilities Others Others Air compressed plant Electrical transformers Copyr i ght 2014 O SIs oft, LLC. 15

16 PI System Architecture PI Interface for OPC DA in HA PI Asset Framework PI Notifications PI Manual Logger PI ProcessBook PI DataLink Heineken Physical Network Windows 7 PLCS7 PI ProcessBook 2012 SP2 PI DataLink 2014 PI Manual Logger 2012 Windows 2008 R2 x64 SP1 Windows 7 Windows 7 PI Data Archive 2012 PI AF Server 2014 PI Notifications 2012 SQL Server 2008 x64 Express Optic Fiber Link PI-OPC DA Warm Failover PI ProcessBook 2012 SP2 PI DataLink 2014 PI Manual Logger 2012 Windows 7 HP EVA PI-OPC DA SAN Disk Cabinet Copyr i ght 2014 O SIs oft, LLC. 16

17 PI Asset Framework Brewery Packaging Brewing Utilities Can line Liter line One way lines Returnable lines KEG lines Brewhouse Fermentation Service Block Cooling Plant Efficiencies SHW Plant Air Compressed Plant Final users Copyr i ght 2014 O SIs oft, LLC. 17

18 PI Asset Framework (Element Structure) 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) Copyr i ght 2014 O SIs oft, LLC. 18

19 PI Asset Framework (Attributes to define a machine) Packaging line pasteurizer machine electricity, water and thermal energy consumption: Real, shift, daily, weekly and monthly consumption Monthly and weekly ratios (ex: kwh/hl beer produced) Copyr i ght 2014 O SIs oft, LLC. 19

20 PI Asset Framework (Attributes to define a process) Cooling (alcohol water) consumers: Real, shift, daily, weekly and monthly cooling demand per user Monthly and weekly ratios (MJ frig/hl beer produced) Target setting Copyr i ght 2014 O SIs oft, LLC. 20

21 PI Asset Framework (Attributes to define an utility plant efficiency) Air compressed plant: Real, daily, weekly and monthly efficiency (Nm3/kw) Copyr i ght 2014 O SIs oft, LLC. 21

by PI AF instead of using PI Performance Equations: Much more intuitive as you do it by using the defined structure

22 PI AF (Analysis Type: Expression) 1. List of attributes: Attributes required for creating the variable 2. Variable definition (PI Point): Expression used for the variable definition Creating complex variables (PI Point) by PI AF instead of using PI Performance Equations: Much more intuitive as you do it by using the defined structure (attributes) You do not need to know/use the names of the PI Tags when building the analysis Copyr i ght 2014 O SIs oft, LLC. 22

maximum, count and median of attributes under the same template (category) Based on search criteria resolved

23 PI AF (Analysis Type: Rollup) 1. List of attributes: Attributes required for creating the variable 2. Variable definition (PI Point): Expression used for the variable definition Calculate sum, average, minimum, maximum, count and median of attributes under the same template (category) Based on search criteria resolved on the fly enabling the return of result sets involving any number of child attributes Copyr i ght 2014 O SIs oft, LLC. 23

PI AF Analysis Advantages All based on PI AF templates to ease deployment and maintenance Create results sets that are stored in the PI Data Archive enabling high performance visualizations on

24 PI AF Analysis Advantages All based on PI AF templates to ease deployment and maintenance Create results sets that are stored in the PI Data Archive enabling high performance visualizations on calculated and aggregated data in real time Create new information previously more difficult to obtain using the more classical tools like PI Performance Equation and PI AF Formula Data Reference This new information is exposed alike any other PI Tags and can be used afterwards to trigger other calculations or PI Notifications Copyr i ght 2014 O SIs oft, LLC. 24

consumption Using staircases to minimize storage and

25 PI Totalizer Subsystem PI Totalizers (PI Point): Storage of shift, daily, weekly and monthly consumption Using staircases to minimize storage and provide comprehensive visualization Copyr i ght 2014 O SIs oft, LLC. 25

26 PI Manual Logger Manual data entries: Beer productions Working hours Used to insert beer production data from SAP of weekly and monthly totals Copyr i ght 2014 O SIs oft, LLC. 26

27 Utility Plant Monitoring (PI ProcessBook) Efficiency data? Ratios data? Historical values as references? Flexible graphs? PI System Compressed air plant Copyr i ght 2014 O SIs oft, LLC. 27

28 Utility Plant Monitoring (PI ProcessBook) Compressed Air PLANT EFFICIENCY (Nm3 / Kwh) = Compressed Air / Power Compressed Air USERS DEMAND (Nm3 / Hl) = Compressed Air / Beer Produced Compressed Air ELECTRICITY CONSUMPTION (Kwh / Hl) = DEMAND / EFFICIENCY Copyr i ght 2014 O SIs oft, LLC. 28

29 Electricity Cooling plant (PI ProcessBook) COP real time = Refrigerating Power / Electrical Power COP references: Daily/weekly/monthly COP Demand real time Demand ratio: Weekly/monthly Demand/Hl produced PLANT EFFICIENCY END USER DEMAND Copyr i ght 2014 O SIs oft, LLC. 29

30 Water and Energy User Monitoring (PI ProcessBook) Beer packed for the line Can packaging line: Shift, daily, weekly and monthly water (softened and chilled water) and energy (electricity and thermal energy) consumption in each machine. Copyr i ght 2014 O SIs oft, LLC. 30

31 Playback past occurrences (PI ProcessBook) Rewind time and accelerated playback to review occurrences in a glance Copyr i ght 2014 O SIs oft, LLC. 31

32 Enable Production Reports in Excel (PI DataLink) Driving System Electricity consumption Monthly follow up Copyr i ght 2014 O SIs oft, LLC. 32

33 Weekly Aggregated Report of Sustainability Goal vs Reality (PI DataLink) Electricity consumption Brewing department Weekly follow up Copyr i ght 2014 O SIs oft, LLC. 33

34 Agenda Heineken Sustainability challenges Solution Results Future Plans Copyr i ght 2014 O SIs oft, LLC. 34

35 Energy & Water KPIs: vision PI System PI System PI System Copyr i ght 2014 O SIs oft, LLC. 35

36 Expected Results PI System Seville Brewery PI System is fundamental to help Heineken Seville realise its Sustainability Strategy Goals by providing insights on highly added value information that was previously not accessible Copyr i ght 2014 O SIs oft, LLC. 36

37 Agenda Heineken Sustainability challenges Solution Results Future Plans Copyr i ght 2014 O SIs oft, LLC. 37

38 Next Steps: PI Event Frames and BI Use of PI Event Frames Compare shift efficiency based on day of the week Compare weekly startup of the plants Report easily on equipment downtime Will enable enhanced rich reporting and faciliate events retrieval via other Reporting tolos like BI Integrate PI System data into Business Intelligence reports PI OData Real targets according to real production and climate conditions calculated by the PI System More PI AF modeling and analysis work Future Data Copyr i ght 2014 O SIs oft, LLC. 38

39 Consuelo Carmona Miura Energy Capabilities Project Lead Heineken Western Europe Region Copyr i ght 2014 O SIs oft, LLC. 39

40 Questions Please wait for the microphone before asking your questions State your name & company Copyr i ght 2014 O SIs oft, LLC. 40

41 Brought to you by Copyr i ght 2014 O SIs oft, LLC.

42 Please don t forget to Complete the online survey for this session eventmobi.com/emeauc14 Share with your friends #UC2014 Copyr i ght 2014 O SIs oft, LLC.