Ensuring On-Time Delivery
Mahou-San Miguel needed to modernize the control system it used for reliable operation of its largest factory to face the challenges of Industry 4.0. The brewery, the second largest in Europe, was essential to the delivery of the top-quality beers customers had come to expect from Mahou-San Miguel for the last 125 years.
Prior to the control system change, Mahou-San Miguel had to invent various complicated methods to share data, making it difficult to trace maintenance issues throughout the software and to monitor and solve production issues quickly. The organization wanted a control system that would be open for the easy exchange of data with other systems.
Though Mahou-San Miguel knew it needed a change, the company could not afford an extended outage that would disappoint loyal customers. Over the entire three-phase, 5-year project, the organization would have only a single shutdown window of one week. All other programmed shutdowns would occur in phases during weekends.
Make it Simple
Mahou-San Miguel selected Emerson after an in-depth study of the state-of-the-art in automation technologies. Emerson’s expert knowledge and DeltaV™ distributed control system (DCS) with Electronic Marshalling and CHARMs technology, would allow the company to plan a complicated control system migration, and deliver it without extended production upset.
Implementing DeltaV and wireless communication allowed MahouSan Miguel to introduce flexibility into the installation of the brewery’s control system. Electronic marshalling simplified the configuration of I/O enclosures and prevented I/O problems from causing delays and extending the planned shutdown window of the plant.
Emerson wireless technologies enabled the commissioning and start-up of valve nodes in the field, rather than in the control room, saving significant commissioning time, and allowing MahouSan Miguel to maintain its short downtime window.
Quality Results
Because Mahou-San Miguel couldn’t afford to extend its shutdown or project deadlines, the plant’s upgrade project had to be done right the first time. A great deal of effort and resources were devoted to FAT testing, resulting in success.
By creating a detailed and personalized FAT procedure focused on critical functions, and working with Emerson control systems specialists and Mahou-San Miguel process specialists, the organization completed its migration project within its short shutdown window, in three different phases, without changes in the budget or schedule.
A satisfied project schedule and no risk of product shortage ensured that there would be only satisfied customers drinking Mahou-San Miguel in Spain and across the globe.
