Background:• Fermentation Science and Technology Program, 1 of 39 nationally • Two state of the art educational breweries for FST students and

local partners Project Goals:

• Oversee the installation of the LSC Brewery• Assist in final construction, design, and automation of the

LSC Brewery

Air Manifold:• Custom designed by students to deliver air to Pentair

Intellitop Valve heads • Multiple iterations, final round two sided design

fabricated by US Engineering• Stress and deformation analysis performed • Quick disconnect fittings for current valves, future

expansion and accessibility

Pentair Intellitop Valves:• Valves trained to know current state under operating

conditions, open/close limits and appropriate indication lights

I/O Check out:• Instrumentation accuracy

verification • Registration testing on valve

head solenoid firing, programrecognition, and PLC registration

Downlink Integration • Gigabyte connection between engineering servers and

breweries • Physical Fiber needed to make connection

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System Automation:• Virtual Machines for Simulation and Production• Human Machine Interface (HMI) Development• Programmable Logic Controller (PLC) Development

System Integration:• Process Descriptions• Functional Design Specifications• Input/Output Checkout

CSU Brewery Design and Automation – LSC BreweryChemical and Biological Engineers – Nathan Reed and Zach Schafer

Computer Engineer – Emily StrackElectrical Engineers – Sam Burns, Thomas Eftink, Anthony Olguin, Layne Rudisille, Nick Wells

Mechanical Engineers – Jason LeJeune, April Rieger and Kellan Sullivan

LSC Brewery and Infrastructure:• Showpiece to illustrate brewing process and collaboration with local

industries • Brewing vessels donated by Molson Coors• Fermenting tanks capable of single or multi-batch• 10 hectoliter (264 gallon) capacity: approx. 2100 pint glasses of beer!• 24 unique instruments that will monitor and control the process

including level, pressure, temperature, flow, and density • 29 Pneumatically actuated valves controlled by a custom designed

Air Manifold

Industry Standard Practices:• Custom designed Piping and Instrumentation Diagram• Standardized caustic/water clean-in-place (CIP) strategies• Fully integrated brewhouse and fermentation system

FST Educational Use:• Articulating lauter tun sparge arm• Fully observable and modifiable processes “We Engineer the Beer!”

● Tony Maciejewski - Project Advisor● Olivera Notaros - Senior Design

Advisor● Jeff Callaway and Brian Emmen-

Fermentation Science and Technology● Dan Malyszko and team - Malisko

Engineering● New Belgium Brewery● Odell Brewery● Rockwell Automation● Brady Carlstrom, Nelson Hollar - CSU

Faculty● Northland Process Piping Inc.● US Engineering ● All Other Donors

The Brewing Process Acknowledgements

Final Work Control System DesignProject Overview

https://goo.gl/tC2mZc

Thank you!

Allen-Bradley PLC

Vessels and Fermenters from Ramskeller Brewery

Instrumentation Verification

Fabricated Air Manifold with FittingsDeformation Analysis

LSC HMI Screen

Background:• Fermentation Science and Technology Program, 1 of 39

nationally• Two state of the art educational breweries for FST students

and local partners Project Goals:• Student designed: vessels, process, instrumentation and

automation• Designed for safety, research ability and consistency in

mind

CSU Brewery Design and Automation – Gifford BreweryChemical and Biological Engineers – Nathan Reed and Zach Schafer

Computer Engineer – Emily StrackElectrical Engineers – Sam Burns, Thomas Eftink, Anthony Olguin, Layne Rudisille, Nick Wells

Mechanical Engineers – Jason LeJeune, April Rieger and Kellan Sullivan

Gifford Brewery:• Value of $800,000+ (USD) including donations• Expected to be operational by end of fall 2018• 2 hectoliter (53 gallon) capacity:

approximately 420 pint glasses of beer!

Process Piping:• Guideline for firm completing the work• Spatial requirements• Instrument requirements• Future additions, rearrangement, and working model along

with P&ID

Process Design and Procedures

Instrumentation

Input/Output (I/O) DesignProject Overview

https://goo.gl/tC2mZc

3D model for process piping

Progression 3: Brewing Process Procedures• Create functional design specifications to conform to PLC topology

Progression 4: PLC Implementation• Use process procedures to create logic in PLC

Progression 1: Brewing Process Descriptions• Highlight process step routes on P&ID and note the purpose

Progression 2: Process Functional Design Specifications• Detailed step-by-step description of the brewing process

I/O Topology and Design Process• Creation of design document

recommendation for I/O. • Power requirements.• Addressing and wiring

specifications.• Industry standard IEC 61131

Module Selection

• Size Constraints• Power Limitations• Number of Inputs• Ethernet Capabilities• Reliability

System Verification• Documentation of Devices• Research of Instrumentation• Consultation of Local

Breweries

• 102 Instruments: flow, temperature, pressure, conductivity• 96 Valves: pneumatically controlled • 12 Motors: 6 variable frequency drives, input/output type,

modulation, variable frequency verification• 7 Vessels System with 6 Fermenter Tanks

Coriolis Flow Meter Temperature Sensor Motor

Construction model of Gifford Brewery

Allen-Bradley Point IO

Gifford Brew Deck and Vessels

Block diagram of feedback controller