Client : SABMiller - Rosslyn Brewery
Duration : 12 Months
Budget : R35,000,000
CSS CSS Ltd. was selected for the design, supply and commissioning of the overall Control and Automation of several new PLC and SCADA systems for the new 1500 Hl Brewhouse that consisted of; new Lauter-Tun, Syrup dosing plant, four new Mills, new Filter line, ten new fermentation vessels, two new CIP stations and Chlorine dioxide generation/dosing.
In addition to this, alterations were required to existing plant consisting of four CIP stations, conversion of five fermentation vessels to storage vessels, raw materials handling, syrup dosing, Lauter-Tun 2, and lastly modifications to the Tanker bay for transporting beer to and from other SAB breweries.
CSS were also the project managers for the electrical portion of the project that included the design, installation and commissioning of several MCC's and all other electrical work on the project.
The electrical portion of the project involved modifying the existing power reticulation to allow for nine new intelligent motor control centres. The individual motor cubicles consisting of Allen Bradley direct on line starters and soft starters and Danfoss variable speed drives were networked using DeviceNet and connected to existing and new ControlLogix PLCs with ControlNet.
The control system upgrade required in the Brewhouse involved introducing one new L63 ControlLogix PLC networked with ControlNet to seventeen field control panels containing Flex I/O modules, which were integrated into the existing Allen Bradley PLC networks at Level 1. The Filtration and Cellars control system upgrade required the introduction of four new ControlLogix PLCs where the field devices were connected via Profibus to twenty-one IFM dual AS-i controllers that were connected to the field instrumentation at Level 0 by several AS-i networks. Two ArchestrA Application Servers, one RSBatch batch server utilising Top Server I/O drivers for PLC and Server communications were utilised at Level 2.
