Obchodni sladovny, a.s. (Malting Plant Nymburk)

Description of implementation:

For several years, the PROTECO, s.r.o. company from the city of Pardubice has been implementing a new enterprise control system of brewing malt production, energy saving and water works in the Malting Plant Nymburk. Most facility parts in the Malting Plant are controlled by Teco PLCs. Communication between Teco PLCs and the Control Room is provided by the Reliance SCADA/HMI system. The main aim of implementing the new Control System was to control all facility parts in the Malting Plant.

Malting Plant in the city of Nymburk

The new enterprise control system provides:

• Control of receiving and dispatching departments
• Control of storing and conveying the malting barley and malt from the silos
• Control of the rettery, kiln, cooling system and the weighing department
• Control of the cleaning device, degerming machine, cooling basket and the fan exhauster
• Control of the Malting Plant water service
• Waste water treatment plant
• Control of the water preparing plant in the Sadská-Písty remote station
• Control of the main power take-off and its quarter maximum

View of the barley germination in the Saladin trough

Implemented SCADA-based system consists of:

• Seven computers within the main building of the Malting Plant
• Two computers for communication with remote stations (Sadská-Písty water preparing plant, waste treatment plant)
• Eight computers with Reliance Runtime View, installed for monitoring all significant production parts

All computers in the Malting Plant are connected into the local network (LAN) and communicate mutually via TCP/IP protocol. More than one hundred visualization screens were created in the Reliance system to provide reliable control of the Malting Plant. The most of the visualization views display a certain part of prodution technology, the rest of them provide control of the facility parts.

One of the Control Rooms with Reliance system installed on the computers

The SCADA-based system provides:

• Monitoring technology processes
• Controlling technology processes
• Generating alarms
• Logging data
• Creating special reports
• Displaying trends of process variables
• HTML documentation
• Displaying detailed information of the malting barley and malt silos (including monitoring and archiving temperatures of the silos)

The SCADA-based system provides data transfer over:

• RS-485/232 serial link
• TCP/IP protocol
• MEM files
• TCP/IP connection with remote stations over ISDN line

Examples of visualization windows:

Cleaning and conveying the barley

The degerming machine, cooling machine and granulating machine

The malting barley silo

The waste treatment plant - biological treatment part