Namibia Breweries Limited

The company has a 1MW roof-mounted solar plant with more than 4,000 panels, 66 inverters and four cluster controllers.

Namibia Breweries Limited

AVEVA's Process Historian plays a central role in utilities management at Namibia Breweries.

Goals

  • Record critical production information from the solar, NH3 cooling, boilers, and CO2 plants, as well as from the water and power meters.
  • Transfer production information to the existing DCS.
  • Develop a dashboard system for management to view consumption-related information linked to production volumes and KPIs.

Challenges

  • Getting the buy-in from all stakeholders
  • Time synchronization between the old Historian and the OPC server

Results

  • CO2 sales targets are met by optimising sales versus storage capacity and usage.
  • Help with meeting water savings regulations as required by the city of Windhoek and NamWater.
  • Electricity savings with maximum demand implementation.
  • Improved solar plant operational effectiveness.
  • Improved fault-finding with Historian Client and video playback functionality on the central DCS.
  • Improved decision making regarding plant requirements (historical thermal energy data allowed NBL to reduce their new BioMass boiler requirement from 8MW to 5MW).
  • Better loss control by being able to view consumption data in conjunction with production information.
  • Historian Client is critical to NBL’s business and is used to verify the KPIs of new plant and equipment.
  • More accurate calculation and reconciliation of project KPIs and ROIs.

Windhoek, Namibia – Optimal utilities management contributes to a greener environment and a healthier bottom line at Namibia Breweries Limited (NBL) where the AVEVA Process Historian helps to generate daily, weekly and monthly consumption reports for water, electricity, chemicals, thermal energy, solar generation, carbon dioxide, and air, then compare these results with KPI targets. Linking Historian tags to the company’s production system has also led to faster and more accurate problem detection.

Background

With regard to renewable energy, NBL has put into practice what others only talk about. The company has a 1MW roof-mounted solar plant with more than 4,000 panels, 66 inverters and four cluster controllers. The whole system is connected to three of the company’s generator sections. When it was installed in 2013, it was the largest hybrid system in the world and it also made NBL completely self-sufficient regarding electrical power.

But this was only the start. Electricity, though a major component, is only one factor in the complex world of utilities which, today, are highly significant contributors to product costs, competitiveness and profitability. There’s also more to effective utilities management than simply watching the meter.

A Manufacturing Operations Management Survey conducted by LNS Research showed that the top two operational challenges for meeting strategic manufacturing objectives were that companies had to deal with disparate systems and the lack of cooperation across their different departments.

“In our case, we have the brewing, packaging, and distribution departments,” said André Engelbrecht, Manager, Industrial Control Systems, NBL. “Each of them focuses on doing their job to the best of their ability, but without necessarily much concern for the common denominator that makes it all possible – utilities.”

NBL decided to unify its various departments into a cohesive entity that could make real-time business decisions with regard to utility usage based on a single version of the facts.

The scope of the implementation would include access to the CO2 plant, NH3 Ammonia cooling, boiler house, water treatment plant, sterile air plant, and power meters.

namibia-breweries-ltd-diagram-900x400

Implementation

The project was started in February 2015 and changeover to the new system was done after a two-week parallel operation during January and February 2016. But according to Engelbrecht, this is not the end as it is a “living” system designed to grow and supply the company’s information needs well into the future.

NBL has a central DCS which controls the beer-making process from start to finish, but achieving NBL’s goals of accurate decision support based on reality and real-time production information, there was a need for more data collection and collation resources.


AVEVA Software's Agnosticism and Third-Party Integration

“It was vitally important that we got the buy-in from all stakeholders regarding the value of doing this, after which we decided to use the power of Historian and the scripting capabilities of Historian Client,” says Engelbrecht. “We also installed Software Toolbox’s TOP Server to retrieve data from our utility plants and systems and used the DCS to build a SCADA system. We then developed a web-reporting system for production personnel and a dashboard system for management. Most of our physical servers are now hosted in a virtual environment and this has made things a lot easier, such as time synchronization between the old Historian and the OPC server.”

namibia-breweries-ltd-nbl-900x460

100 PLCs and More

NBL configured a virtual enterprise consisting of two TOP Servers (to balance the load of more than 100 PLCs and systems), one DataHub Server, Historian, the main historian data warehouse and a web server. A secure https dashboard server enables management to view daily and monthly sales, as well as operational KPIs from anywhere. Weekly real-time stock volumes are sent to NBL’s advanced planning system using Historian Client queries, and SAP files are imported daily regarding sales, production, logistics, and depot information.

The system lets qualified personnel view various utility consumption and production information at the same time wherever they may be. They’re also able to view daily, weekly, and monthly consumption information on the same platform. In the future, NBL will be able to switch off non-critical plant equipment to ensure that their maximum demand remains below target.


AVEVA Scalability and Extensibility

“It is great to see what can be done with technology and data when you use the right tools such as the AVEVA products we implemented in this project. It was also a great learning experience to combine the products we chose to enable us to make our end results and user experience better and more effective,” said Annemarie Kruger, MES/MIS Specialist, NBL.

“In my opinion, some of the most outstanding features of the system include its open standards, the wide range of drivers available, scalability to go as big as we want to go, as well as its ease of use, customisation, and integration with other initiatives,” added Engelbrecht

namibia-breweries-ltd-energyprod-900x400(1)

Results

  • CO2 sales targets are met by optimising sales vs. storage capacity and usage.
  • Help with meeting water savings regulations as required by the city of Windhoek and NamWater.
  • Electricity savings with maximum demand implementation.
  • Improved solar plant operational effectiveness.
  • Improved fault-finding with Historian Client and video playback functionality on the central DCS.
  • Improved decision making regarding plant requirements including the availability of historical thermal energy data, which allowed NBL to reduce their new BioMass boiler requirement from 8MW to 5MW.
  • Better loss control by being able to view consumption data in conjunction with production information.
  • Historian Client is critical to NBL’s business and is used to verify the KPIs of new plant and equipment.
  • More accurate calculation and reconciliation of project KPIs and ROIs.

Related Success Stories

Oil and Gas
Apply Sørco

Apply Sørco, a Norwegian engineering company based in Starvanger, embraced new technologies to win contracts with big clients demanding lower costs.

Oil and Gas
Sakhalin Energy Investment Company Ltd.

Sakhalin Energy operates the world’s largest oil and gas development and used AVEVA to streamline its contract management process.

Oil and Gas
Yamal LNG

Yamal LNG is the most northern liquefied natural gas project in the world, and used AVEVA to enhance collaborations in this joint venture.

Oil and Gas
TekSolv

With AVEVA, TekSolv improves oil/gas and water/wastewater site management processes, and reduces project deployment time to only minutes or hours instead of ...

Monitor and Control
Azbil

The largest AVEVA VAR/OEM customer depends on the software to provide powerful capabilities and versatility to support worldwide growth

Asset Performance
Chevron

Using IntelaTrac Mobile Operator Rounds to accelerate and sustain process improvements, Chevron has reduced maintenance costs, improved availability and ...

Oil and Gas
Kuwait Oil Company

Kuwait Oil Company (KOC) captures the inherent value in the knowledge base of its workforce, and integrates it into a comprehensive training program through ...

Asset Performance
Western Refining

AVEVA Enterprise Asset Management software helps Western Refining manage maintenance activities, track materials, maintenance employees, contract labor, and ...

Operate and Optimise
Infineum

The AVEVA Mobile Operator Rounds solution at Infineum has allowed the operational procedures for visual inspections of equipment to be optimized and ...

Oil and Gas
Chevron Oronite Company LLC

System Platform and MES/Equipment Operations Module at Chevron Oronite makes it easy to connect to the ERP application while monitoring the production of ...

Oil and Gas
Bluewater

Bluewater and its customer can now monitor the control and safety systems, both on and offshore, in real time with AVEVA software automation.

previous next

Sign up for our newsletter and get all the latest information straight from the source.