Colorado State University

Brews Up Modern DCS for Students

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Rockwell Automation TechED 2017 @ROKTechED #ROKTechED Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 2
FERMENTATION SCIENCE & TECHNOLOGY

Colorado State University Brews up

Modern DCS for Students

BRIANA CHAMBERLAIN COLORADO STATE UNIVERSIT Y

JEFF CALLAWAY COLORADO STATE UNIVERSIT Y
DAN MALYSZKO MALISKO ENGINEERING, INC.
FERMENTATION SCIENCE & TECHNOLOGY

AGENDA
Introductions
FST Background
STEM / Collaboration
On-Campus Breweries
Industry Involvement
Engineering Senior Design
Automation Vision and Technology Solutions
The Future
INTRODUCTIONS

Briana Chamberlain Jeff Callaway Dan Malyszko

Colorado State University Colorado State University Malisko Engineering, Inc.
B.S.Ch.E 2017 Associate Director of Director of Operations - Denver
Brewing Automation Intern Fermentation Science and Colorado State B.S.E.E.
Brewery Automation Senior Design Technology (FST) Commercial Brewing Background
MALISKO ENGINEERING, INC.
Specialists in Manufacturing Automation and Validation

Founded in 1994

St. Louis, MO Denver, CO Eau Claire, WI.

Emphasis in Food & Beverage, Pharmaceutical, Brewing, Life Sciences, Dairy, Specialty Chemicals

Partnerships, Certifications, Associations, Recognition:

Control | Process | Information

Industrial IT | PQ&EM
COLORADO STATE UNIVERSITY
Founded in 1870 as Land Grant University
Made up of 8 Colleges
College of Health and Human Sciences (6 departments and 2 schools)
Department of Food Science and Human Nutrition (3 programs)

> 33,000 students

> $300 million/year spent on research
FERMENTATION SCIENCE & TECHNOLOGY

FST BACKGROUND
HISTORY
Brewing Science and Technology Course
2005
Creation of a B.S. degree program
2010-2013
Fermentation Science and Technology (FST)
August 2013
Broader than brewing
CURRICULUM

Scientifically rigorous
Industry involvement
Application of education to industrial
situation
Fermentation SCIENCE & TECHNOLOGY
FERMENTATION SCIENCE & TECHNOLOGY

STEM & COLLABORATION

STEM

From Field to Foam

Entire supply chain

Science
Chemistry, Organic Chemistry, Biochemistry,
Microbiology, Physics

Technology
Instrumentation/automation/software,
compressed air, piping, milling, pumps,
valves, heat exchange, etc.

Engineering and Math

Expanded curriculum and collaboration with
College of Engineering
COLLABORATION

Industry
Breweries
Raw materials
Equipment
Consulting

Education
College of Business
College of Agriculture
College of Liberal Arts
College of Engineering
FERMENTATION SCIENCE & TECHNOLOGY

ON-CAMPUS BREWERIES
TWO BREWERIES?

Gifford Building
Academic
Education
Research
Professional Development
Large scale commercial
TWO BREWERIES?
Lory Student Center
Experiential
Public showcase
Brewpub/small craft brewery
FERMENTATION SCIENCE & TECHNOLOGY

INDUSTRY INVOLVEMENT
INDUSTRY DONOR PARTNERS
FERMENTATION SCIENCE & TECHNOLOGY

ENGINEERING SENIOR DESIGN

Project Goals:
Design, Construct, and Automate the Gifford Brewery
Assist in Construction and Automation of the LSC Brewery
Project Breakdown:
System Design
Process and Vessel
Electrical
Automation Design
TEAM INTRODUCTION

Multidisciplinary Team
CBE
Briana Chamberlain
Keaton Sloan

ME
Julia Tucker
Andrew Ross

ECE
Dustin Tauxe
Nick Wells
Tyler Myers
Phil Sefcovic
SYSTEM SIZING

Introduced students to the PlantPAx

DCS via training materials and hands-
on demonstration

PlantPAx System Estimator Provides a

starting point for:
Supervisory Ethernet network with all servers, operator
and engineering workstations, and controller chassis
List of required catalog numbers
Ethernet network for each controller including I/O
requirements
PROCESS DESIGN

Unlike the Student Center

brewery, Gifford did not have a
P&ID nor a device list

Worked with industry partner

New Belgium Brewery designing
several iterations of P&ID and
device lists

Worked with Malisko Engineering

on preliminary I/O requirements
as well as E+H instrument
specification
PROCESS DESIGN

Small System (2hL), but

needed to represent large-
scale commercial brewery
Had to consider both process
and CIP piping/devices
Base vessel dimensions
completed by others prior
Senior design team
responsible for finalizing
vessel design including
process and instrumentation
connections
VESSEL DESIGN
ELECTRICAL AND POWER SYSTEMS

Gifford
N.E.C. Available Fault
Current for panels
Assist in Panel Design
Instrumentation
Requirements
Lory Student Center
Mapping of electrical /
Datacom pathways
3D mapping
Electrical/mechanical
support
AUTOMATION DESIGN PROCESS

Rockwell Automation
FactoryTalk, Studio 5000,
PlantPAx Distributed Control
System
Development environment
Engineering Workstation (EWS)
Process Automation System
Server (PASS) VM

Process Automation Tasks

Process Descriptions and FDS
Human Machine Interface Design
PLC AOI Device Configuration
Library of Process Objects
Simulation
Systems Integration Gifford Brewery HMI Screen
FERMENTATION SCIENCE & TECHNOLOGY

AUTOMATION VISION
& TECHNOLOGY SOLUTIONS
THE VISION & FUNCTIONAL REQUIREMENTS

1. Automation must support many functions:

Academic
Education
Research
Professional Development
2. Software must be flexible and supportable locally
3. Automation system features must include:
Recipe Formulation Creation and Editing
Built-in Trending and Reporting
Integration with Quality Assurance Systems
Flexible Procedure Creation and Editing
Easily Upgradeable
4. Commonality between the two breweries
5. Provide a platform for Industry to showcase latest hardware and software technologies
THE INDUSTRIAL AUTOMATION SOLUTION

Standardized on ISA-88 Batch Control

Rockwell Automation PlantPAx DCS
Brewing-specific libraries, operations, and procedures
Modern UI/UX
Scalable architecture
Integration into common virtualized IT environments
WHAT IS ?
The Foundational System is the Rockwell Automation PlantPAx DCS
Selection Guide proces-sg001_-en-p
Reference Manual proces-rm001_-en-p
Application Configuration User Manual proces-um003_-en-p
Library of Process Objects Reference Manual proces-rm002_-en-p
Infrastructure Configuration User Manual proces-um001_-en-p
Virtualization User Manual 9528-um001_-en-p
HARDWARE
ControlLogix L75
I/O:
1756 ControlLogix
1734 Point
Spectrum Controls 1734 Point I/O HART Analog
Instrumentation:
E+H Promag Electromagnetic Flowmeter EtherNet/IP
E+H Promass Coriolis Flowmeter EtherNet/IP
E+H Temperature, Hydrostatic Level, Differential Pressure, Conductivity
Variable Frequency Drives:
PowerFlex 525 EtherNet/IP
Connectivity:
Panduit Watershed Zone Enclosure with Stratix 5700
DLR for I/O
Star for Instrumentation
SOFTWARE

Directory
Security
Activation
Audit
Live Data
Alarms & Events
BATCH APPLICATION TOOLKIT

Provides a framework for

PlantPAx Batch Deployments
HMI Objects consistent with
Rockwell Automation Library of
Process Objects
BATCH VIEW MOBILITY + ENHANCED UX/UI

Graphics are capable of

adapting to any mobile
device, such as iPhone
and Android
Can be leveraged on
FactoryTalk Batch
workstations as the HMI
visualization interface to
the batch
Intuitive workflows
Access real-time
information, interact with
processes and secure
approvals from anywhere
in a plant
USER EXPERIENCE CONSIDERATIONS

Rockwell Automation Mobile UI design integrated into BatchBrew for common look and feel
Modern, mobile-savvy users are becoming more accustomed to mobile interfaces
BatchBrew HMI DESIGN
CONTROL RECIPE STRUCTURE

This document consists of information which is confidential and proprietary to Malisko Engineering, Inc. This information is furnished in confidence, and with the understanding that it
may not be disclosed to third parties, reproduced or used, in whole or in part, for any purpose without the explicit written consent of Malisko Engineering, Inc.
FORMULATION MANAGER
Formulation Parameter Sets for each Product Code / Brand is bound to a Batch Control Recipe
Dozens of User-Defined Parameters per Unit
Ability to Modify Formulation Parameter Set and Save to New for new brands

This document consists of information which is confidential and proprietary to Malisko Engineering, Inc. This information is furnished in confidence, and with the understanding that it
may not be disclosed to third parties, reproduced or used, in whole or in part, for any purpose without the explicit written consent of Malisko Engineering, Inc.
UNIT PARAMETERS

This document consists of information which is confidential and proprietary to Malisko Engineering, Inc. This information is furnished in confidence, and with the understanding that it
may not be disclosed to third parties, reproduced or used, in whole or in part, for any purpose without the explicit written consent of Malisko Engineering, Inc.
BREW INFO

This document consists of information which is confidential and proprietary to Malisko Engineering, Inc. This information is furnished in confidence, and with the understanding that it
may not be disclosed to third parties, reproduced or used, in whole or in part, for any purpose without the explicit written consent of Malisko Engineering, Inc.
KETTLE ADDITION SCHEDULE
Addition Type, Quantity, and EUs fed in from Formulation Manager
Utilizing P_Prompt to notify
Acknowledgements tracked in Batch Reporting

This document consists of information which is confidential and proprietary to Malisko Engineering, Inc. This information is furnished in confidence, and with the understanding that it
may not be disclosed to third parties, reproduced or used, in whole or in part, for any purpose without the explicit written consent of Malisko Engineering, Inc.
LAB DATA ENTRY
Configurable In-Process Check
Logged to SQL and reported in Batch
Reports

This document consists of information which is confidential and proprietary to Malisko Engineering, Inc. This information is furnished in confidence, and with the understanding that it
may not be disclosed to third parties, reproduced or used, in whole or in part, for any purpose without the explicit written consent of Malisko Engineering, Inc.
BREWHOUSE AND FERMENTING REPORTING

This document consists of information which is confidential and proprietary to Malisko Engineering, Inc. This information is furnished in confidence, and with the understanding that it
may not be disclosed to third parties, reproduced or used, in whole or in part, for any purpose without the explicit written consent of Malisko Engineering, Inc.
FERMENTATION SCIENCE & TECHNOLOGY

THE FUTURE
WHERE DO WE GO FROM HERE

Phase 1
Current, almost finished
Implement degree and physical buildout
Phase 2
Expand Curriculum
Nationally and internationally recognized program
Faculty, Graduate degree, Research
Phase 3
Institute
Annual conference
Academia and industry relationships
Career development
R&D
COLLEGE OF HEALTH & HUMAN SCIENCES

THANK YOU!

BRIANA CHAMBERLAIN COLORADO STATE UNIVERSIT Y

JEFF CALLAWAY COLORADO STATE UNIVERSIT Y
DAN MALYSZKO MALISKO ENGINEERING, INC.
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