99.04.07.202 E and I Design Guidelines PDF

E&IDESIGNGUIDELINE
ForProductionInstallations
CONTENTS:
1.
REVISION HISTORY
2.
INTRODUCTION
2.1 PURPOSE OF DOCUMENT

2.2 GENERAL
3.
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3
STANDARDS
3.1 BREWERY REQUIREMENTS

3.2 CONFORMIT EUROPENNE (CE)
4.
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3.2.1 Supplies in Europe

3.2.2 Supplies outside Europe
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ELECTRICAL GUIDELINES
4.1 ELECTRICAL ENGINEERING
4.1.1 Electrical components

4.1.2 Voltages
4.1.3 Requirements for electrical motors
4.1.4 Protective Earthing (PE)
4.1.5 Bonding system
4.1.6 Emergency stop and process stop
4.1.7 Maintenance Switch for motors and consumers
4.1.8 Auxiliary power
4.1.9 Overvoltage protection.
4.1.10 Constant Voltage transformer
4.1.11 24 V DC supply
4.1.12 Protections
4.1.13 Frequency converters and servo controllers
4.1.14 Soft Starters
4.1.15 Cabling and wiring
4.1.16 Cable ladders & trays
4.1.17 Cable protection conduit
4.1.18 Cable screen connection
4.1.19 Fixing of field components
4.1.20 Tie-raps
4.1.21 Cable glands
4.1.22 Cable coding
4.1.23 Un-interruptable Power Supply (UPS)
4.2 ENGINEERING MEASURES FOR AREAS WITH INCREASED RISK FOR DUST EXPLOSION
4.2.1 Cable ladders
4.2.2 Malt lorry bonding system
4.2.3 Spark detection
4.2.4 Explosion detection
4.2.5 Electrical components
4.2.6 Fail safe components
4.2.7 Socket outlets
4.2.8 Bonding
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4.3 CONTROL PANELS
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4.3.1 General specifications control panels

4.3.2 Central panel room control panels
4.3.3 Field control panels
4.3.4 Field remote I/O panels, operator panels and terminal boxes
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4.3.5 Air coolers
4.3.6 Anti condensation heating
4.3.7 Minimum cross section of wiring
4.3.8 Wiring colours
4.3.9 Terminals
4.3.10 Colours operation appliances
4.3.11 Signal lighting
4.3.12 Push buttons
5.
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INSTRUMENTATION GUIDELINES
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5.1 GENERAL
5.2 INSTALLATION
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5.2.1 Housing
5.2.2 Process Connections
5.2.3 Instrument air tubing and distribution
5.2.4 Sunshade
5.2.5 Local indicators
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5.3 MEASUREMENTS OVERVIEW & GUIDELINES
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5.3.1 Flow Measurements

5.3.2 Level
5.3.3 Pressure Measurements
5.3.4 Quality
5.3.5 Solenoids
5.3.6 Temperature measurements
5.3.7 Valves
5.3.8 Weight
5.3.9 Other
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5.4 RANGES AND ACCURACIES
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5.4.1 Ranges
5.4.2 Accuracies
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5.5 COMMUNICATION
5.6 INSTRUMENT CALIBRATION
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DRAWING GUIDELINES
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6.1 STANDARD SUPPLIERS CONTROL DIAGRAMS

6.2 HEINEKEN HOUSE STYLE DIAGRAMS
6.3 GENERAL GUIDELINES FOR THE ELECTRICAL DIAGRAMS AND INSTRUMENT LISTS
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7.
MANUFACTURING INSPECTION
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8.
TRAINING
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8.1 GENERAL
8.2 ELECTRICAL TRAINING
8.3 INSTRUMENTATION TRAINING
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COMMISSIONING, START-UP AND HAND-OVER
10. DOCUMENTATION
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1. REVISION HISTORY
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Change description
Revised and updated according new
structure at Heineken
Technical specifications updated
Emergency stop clarified
Maintenance stop clarified
HMESC code assigned
Requirements renamed to
Specifications
The following section are updated:
4.2.8, 4.2.11, 4.2.12 4.2.13.4, 4.3,
4.4, 6.3, 6.4, 7.1.8
Protection class frequency convertors
minimal IP2X
EM stop button: key release removed
Status
Author
Date
Final
L. van Hugten
28/03/2006
Final
W. Vergunst
15/06/2006
Final
A.C. Bakker,
L. van Hugten
16/12/2007
Final
L. Van Hugten
04/01/2008
Final
J.Boer
08/02/2010
Specification renamed to guideline.

General and Electrical paragraphs
rewritten and combined.
Included part of process connection
Final
document, and small adaptations
throughout instrumentation update
Items summarized in logical engineering
subparagraphs
HMESC number in footer updated
Sections 5.1 and 5.3.6. updated
Final
Section 7 replaced by reference to
purchasing procedure
H.H.J. Bloemen,
31/05/2011
L. van Hugten
G. Barnhoorn
HHJ Bloemen
11/07/2011
2. INTRODUCTION
2.1 PURPOSE OF DOCUMENT
This E&I Design Guideline advises the best practices for Electrical Engineering and Instrumentation, further called: E&I
Design Guidelines.
2.2 GENERAL
Requirements for Process Automation, and Process Information systems, have been described in the PASS
(Production Automation System Set-up).
This guideline can be a part of an inquiry, or an order, for all types of brewery electrical or instrument installations.
Part of this guideline can be used as specification if this is indicated in the relevant electrical and instrument
datasheets.
3. STANDARDS
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Legal standard and regulations shall always be followed. The electrical installation shall comply with the national and
/or local authorities of the country in which the installation will be installed and is not limited to:
Local applicable Standards and Regulations
IEC
ISO
ATEX
3.1 BREWERY REQUIREMENTS
It can be possible that the brewery has their own requirements. Brewery requirements are always mandatory above
this document.
The E&I Design Guideline can be read with other engineering documents for brewery installations. Other engineering
documents can be:
1.
2.
Basic E&I brewery specification.

E&I components Guideline.
3.2 CONFORMIT EUROPENNE (CE)

3.2.1 SUPPLIES IN EUROPE
Installations, which will be installed and operational in the European Community, shall be in compliance with the
Machinery Directive and must be delivered including CE declaration of conformity.
A CE declaration of conformity has to be issued over the total installation including all subcontracted/supplied
installation parts as well
3.2.2 SUPPLIES OUTSIDE EUROPE

Installations, supplied outside the European Community, shall comply with the Machinery Directive as stated in the
order specification.
For this purpose, the specifications are pointed on use of CE approved components and CE approved safety measures
for installations as supplied.
In case as requested by the brewery, the supplier shall issue next stated information:
The electrical and control system boundaries of the suppliers scope of supply.
The safety measures with regards to safety for operators and maintenance people
Which components have been included to accomplish the necessary safety measures
All documentation, lists, reports and diagrams shall be in the language as indicated (normally English or French). If CE
Standards so dictates (for the European Community), documentation, operator instructions etc. must be made
available in the applicable country language.
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4. ELECTRICAL GUIDELINES
4.1 ELECTRICAL ENGINEERING
4.1.1 ELECTRICAL COMPONENTS
Electrical materials to be used, are advised in the E&I component guideline.
Electrical components with similar functionality can be advised in close consultation with the brewery engineer in
charge. It is strongly advised that the amount of brands is limited to one or two per type.
4.1.2 VOLTAGES
Power supply voltages, motor voltages, etc, are specified in the Basic E&I Brewery specifications
PLC power supply
24VDC*
I/O
24VDC
Control interfaces/converters
24VDC
Operator displays
24VDC / 230VAC
Text displays
24VDC
Contactors
24VDC
Auxiliary relays
24VDC
Solenoid valves
24VDC
Signal lamps and push buttons
24VDC
2-wire transmitters
24VDC
Instruments with separate power supply
24 VDC
Lighting fitting(s) and socket outlet(s)
230VAC
Air/air cooler unit(s)
230VAC or 400VAC
Note: Deviation from above stated voltages only in consultation with the brewery representative.
*If 230VAC is used, the voltage stall be stabilized via a 230VAC UPS
Non Fused terminals, with build-in separator, shall be used for field mounted passive instruments (2-wire type) if
powered from the PLC which is short circuit proof. In all other cases the instrument power supply requires a fuse
terminal.
For field mounted active instruments (4-wire type) the instrument power supply requires a fuse terminal.
4.1.3 REQUIREMENTS FOR ELECTRICAL MOTORS
Norms
Insulation class
Enclosure (housing)
Thermistor protection for frequency
converter controlled motors
Thermistor protection for all motors
Thermistor protection for all motors in malt
intake/storage/treatment installation
Frequency controlled motors
Efficiency class
Voltage & Frequency
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In accordance with IEC standards

B or F
IP55
7,5kW
55kW
For all sizes
Motor construction must be suitable for
this application.
IE2
3 phase Delta connection is accordance
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with Basic E&I brewery specification
For all motors
For conveyors > 0.55kW
Condense drain plugs

Permanent Magnet Motors
4.1.4 PROTECTIVE EARTHING (PE)

All Protective Earthing (PE) shall be designed on maximum man protection, and lowest impedance, in accordance with
the local and IEC regulations.
The control panel shall be equipped with a copper PE distribution bar.
From this PE bar, all earthing connections shall be made.
All non-live metal parts, which can carry a potential in case of a fault, shall be securely earthed.
For earthing of screened cables, bracket clips shall be used (spring type or screw type).
These bracket clips can be mounted direct on an earthed mounting plate, or on an earth bar.
4.1.5 BONDING SYSTEM
4.1.5.1 GENERAL
Aim of bonding is to equalize all potentials, which can appear on structures of installations, also to have a low
impedance path for all equalizing currents in control installations.
The bonding system shall consist of:
Main bonding bar in each low voltage room.

Interconnecting cables to connect all main bonding bars.
Bonding cables to:
o All control installations.
o Protective earth in MSB.
o Lightning protection.
o Metal building structures.
o All in coming/outgoing pipe work in buildings.
o Cable ladders and trays
4.1.5.2 BONDING CABLES TO CONTROL INSTALLATIONS

All control panels to be connected to the main bonding bar by means of insulated 70sqmm CU cables.
Main field installation equipment (e.g.: Vessels, valve matrices, etc.) must be bonded, from the control panel
concerned, sufficiently by means of insulated 50sqmm CU cables. See for typical bonding set-up drawing: 629301.
4.1.6 EMERGENCY STOP AND PROCESS STOP

The implementation and design of emergency stop(s) in brewery installations is suppliers responsibility and shall be a
result of applicable standards and risk analysis.
In all emergency stop zones the highest installation risk category, as determined for all used installations in these
zones, shall be applied.
The Emergency stops for Packaging installations shall be in accordance with the Heineken Loto specifications.
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4.1.6.1 RISK ANALYSES
To ensure that safety measures and circuits will be applied according international standards, the supplier is
responsible for the selection of the risk category.
4.1.6.2 EMERGENCY STOP
Emergency stops shall be executed in accordance with the IEC and local regulations. Below a summary of the used as
a guideline:
Actions, and type of emergency circuit execution, depending on selected risk category.
It is strongly advised to use an emergency stop relay (E.g.: make: Pilz, type: PNOZ).
Every installation (eg. brew house, bottle line, cooling plant, steam plant, etc) shall have its own
emergency stop.
The execution and number of emergency stops shall be advised by the supplier based on a risk analyse
of the supplier and reviewed and/or adappted by the BREWERY representative.
Minimum numbers of push buttons can be advised by the specialist of the BREWERY).
The emergency stop (relay) shall not react during a power failure that takes less than one hour (UPS
power shall be separated). Reset of the emergency circuit shall not be necessary in this situation. It shall
be possible to make a distinction between power failure and emergency stop.
The emergency switch push-button shall be two-pole (mushroom type)
Emergency stops shall be based on the fail-safe principle.
Emergency stops shall be installed on a logical location that will be passed during an escape from the
calamity source (escape route). Locations shall be clearly indicated.
The emergency stop push button shall be of the same release type (either push-pull or push turn).
Each individual emergency stop push button within a brew house, service block or cellars shall be
indicated when activated on the HMI (eg. location on a process screen, operation panel, etc.). I/O cards
for the emergency stop circuits also behind a UPS.
The emergency stop shall have an individual reset per installation. Automatic restart after release of the
emergency stop push button is not allowed.
Each emergency stop shall have a text plate indicating the consequences of pushing the emergency stop
in the language of the country. The text plate shall looks like:
o
o
o
Colour plate: Red; colour text: White.

Size plate: 80x25mm.
Size text : 10mm.
Activating an emergency stop shall mean that a complete part of the installation will be swicthed to safe
mode (only for brewing department) unless the machine or part of the installation is visual separated.
Activating an emergency stop on the panel within the engine room shall mean that only the involved
machine will be will be switched to a safe mode. Activating the emergency stop on a central place shall
mean that the compete installation shall be switched to a safe mode.
Example of emergency stop actions are
o
o
Cut-off of power to motors by means of central contactor(s) or by means of contactor (s) per motor
group (including frequency converters) and servo controllers)..
Cut-off of power to control equipment by means of switching off the power supply to output cards.
4.1.6.2.1 EMERGENCY STOP RELAYS AND I/O CARDS

The emergency stop relays and related I/O cards should also be powered by a UPS, because of the following reasons:
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to prevent the emergency stop system from being activated by a power failure,
to be able to detect which emergency stop is pressed and to reset in case the main power supply is
triggered by the emergency stop,
and to be able to distinct between a power failure and an emergency stop.
See also chapter Emergency stop for further details.

4.1.6.3 PROCESS STOP
A process stop shall be specified in close consultation with the process and automations engineer
The functionality of a Process stop is to block all controls, and power supply to motors, of a pre-determined part of the
installation (e.g.: wort copper in brewhouse).
The rest of the installation is not blocked and can be in normal operation.
Use of Process stop concerns mostly brewhouse vessels, which should be equipped with a process stop per vessel.
A process stop ensures that persons can execute safe internal cleaning and maintenance of the particular vessel.
Requirements for process stop execution:
Actions, and type of process stop circuit execution, depend on selected risk category.
All process stop components is normally based on an emergency circuit component.
Is is strongle advised to use an emergency stop relay (e.g.: Pilz, type: PNOZ).
Process stop operating push button shall be a key blocked two-pole emergency stop push button of
mushroom type, release by turning.
Process stop operating push button to be equipped with auxiliary contact, which shall be connected to a
PLC input.
Each process stop operating push button shall be executed together with a reset push button.
Each process stop operating push button shall be equipped with a text plate. Requirements for text plate:
o
o
o
Colour plate: Red; colour text: White.

Size plate: 80x25mm.
Size text : 10mm.
Text indicates vessel (e.g.: wort copper), which will be blocked.

Example of actions per Process stop:
o
o
o
Cut-off of power to motors

Cut-off of power to control equipment and valves
Pumps, for general use of, e.g. caustic soda, hot water, etc., must be blocked as well.
For packaging a short stop is equivalent to a process stop, additional requirements can be read in the Loto
specification
4.1.7 MAINTENANCE SWITCH FOR MOTORS AND CONSUMERS
A safety switch per motor is advised for maintenance in order to lock the motor against unforeseen starting. (note that
some countries has this as local requirements).In case of locking the whole system or part of the system (eg. central
maintenance switch), the supplier shall guarantee unforeseen starting by means of a risk analyses.
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Motor on the washing machine and pasteurizer must be equipped with a maintenance switch.
For elevators, a separate maintenance switches must be installed at the bottumand at the top of the elevator.
Maintenance switches must be foreseen with a stainless steel protection cover. The maintenance switches shall be
installed near the motor. In case of a screened cable, the screen must be fixed in the EMC cable gland. The EMC
cable glands in the polycarbonate housing of a maintenance switch must be connected to each other by means of a
metal strip.
Maintenance stops are advised to have a feedback to the automation system.
4.1.8 AUXILIARY POWER
At the terminal strip of auxiliary power supply entry, which will not be switched off by the main switch, a warning
indication plate must be mounted indicating Warning, this power supply remains live when main switch is in off
position..
4.1.9 OVERVOLTAGE PROTECTION.
Each control panel should be equipped with an overvoltage protection as per NEN-EN-IEC60204.
A contact of the overvoltage protection shall be connected to the control system for signalisation. Thecross section of
the earth wire shall be as large as possible to ensure low impedance.
4.1.10 CONSTANT VOLTAGE TRANSFORMER
In case, the Basic E&I Brewery Specification indicates a voltage fluctuation of more than +/10%, a
constant voltage transformer must be used to protect electronic equipment.
Each control voltage transformer must be of the separated primary/secondary coil type. Primary tappings
2,5% and 5%.
4.1.11 24 V DC SUPPLY
The max. load of 24V DC supply voltage units may not exceed 80% of its nominal capacity.
The maximum allowable ripple for 24V DC voltage circuits should be less than 0,5%.
4.1.12 PROTECTIONS
Motor groups to be protected by means of motor protection switches.

The use of fuses must be strictly limited
Direct current (DC solenoids, motor contactors and relays should be provided with suppressing diodes).
4.1.13 FREQUENCY CONVERTERS AND SERVO CONTROLLERS

For frequency converters the next points are applicable
Installation instructions should be strictly executed.

In case of application of a maintenance switch, cable screen should be linked according instructions of
Frequency Converter supplier.
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4.1.14 SOFT STARTERS
Soft starters shall be by-passed after starting by contactor for motors above 7.5kW
4.1.15 CABLING AND WIRING
General
All cables shall be installed in one length without joints.

All cables should exit the cable ladder via the bottom or sidewall of the cable ladder
To avoid shortage of cables, an additional cable length of approximately 300 mm is advised. This
additional length shall be installed in the cable ladder at cable conduit connecting point.
Pigtails/loopa at field components are not allowed.
All cables, in cable trays and ladder, shall run parallel and shall be tied in groups of maximum 20 cables.
The following cables shall be used in the follow situation

Unless noted otherwise
Cables shall be non armoured/screened and fire retardant and in accordance with the local law
For frequency controlled motors/consumers
Cables shall be screened as per suppliers installation instructions. Note that also auxiliary cables for frequencycontrolled motors shall be screened
For cables in raw materials areas
All cables are advised as screened cables in particular cases, this to ensure protection against rodents.
For instrumentation
4-20mA signal cables shall be executed as shielded cable.
Underground cables
Underground cables shall be multi-core and armoured.
Underground cables shall be installed in according with the local rules and regulations.
4.1.16 CABLE LADDERS & TRAYS

If not mentioned otherwise, the following cable ladder and trays shall be used in the following situation. Deviations in
consultation with the Heineken representative.
Hot dipped galvanised cable trays and ladder:
In general (indoor and outdoor)

Main cable routes on pipe bridges.
Engine rooms
Silo buildings
Areas without risk for hygiene
Dry areas in Packaging lines (in consultation with brewery representative)
Stainless steel cable ladder:
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Brewhouse & service block

Packaging hall (wet areas)
All other wet areas
All other areas with risk for hygiene
The following cable trays and ladders shall be covered
Vertical cable ladders and trays

Cable ladders and trays outside buildings (sun protection)
Cable ladder and trays, on locations from where cables can be seen in the cable ladder under three
meters
Cable trays in machines
Data cable shall be always installed in a cable duct executed with a cover. This cable duct can be installed into the
signal part of the cable ladder.
Motor cables, control and signal/data cables are allowed to be installed in one and the same cable tray (duct) by using
a metal partition between the motor and control/signal/data cables.
Dimensioning of cable ladders shall include:
Main cable ladders: 50% spare after first installation.

Sub cable ladders: 20% spare after first installation.
Cable ladders shall be mounted onto the installation support construction. Use of process piping, etc, for support of
cable ladders is not allowed.
Cable ladder connection between galvanized and stainless steel is only acceptable if isolation is installed
between the two materials.
In case of use of cable basket, supports shall be used every 60 centimeter in order to avoid bending, Baskets to be
executed with covers.
4.1.17 CABLE PROTECTION CONDUIT

Only stainless steel protection conduit till a maximum diameter of DN65 can be used in case the number of cables is
limited.
The cable protection conduit shall run up to 300mm from the concerning field component.
In case the cable conduit will be larger than size DN65, cable ladder in a stainless steel execution should be used.
Stainless steel cable protection conduit must be fixed with stainless steel clamps, fasteners etc. onto the installation
support construction.
Ends, holes, of cable protection conduits shall be finished in that way that cables cannot be damaged.
Cables, running in vertical cable conduits, shall be supported to avoid that weight of cables will damaged the cables in
top of cable conduit.
Dimensioning of cable conduits shall include 20% spare after first installation.
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4.1.18 CABLE SCREEN CONNECTION
Cable screens shall be connected to protective earth on both cable ends unless otherwise indicated by the component
manufacturer.
4.1.19 FIXING OF FIELD COMPONENTS
For fixing, stainless steel fixing materials have to be used
All instruments and electrical components have to be fixed properly with the suitable fasteners or anchor bolts for the
specific purpose.
The location and fixing position of the instruments and electrical components shall be in consultation with the
installation manager or his representative.
All equipment shall be installed in such a way that they are easy accessible for maintenance, troubleshooting and
checks.
4.1.20 TIE-RAPS
All used tie-raps shall be UV-resistant. (Black colour) with a minimal width: 4.8 mm.
4.1.21 CABLE GLANDS
All cable entrances in electrical components (eg. motors, junction boxes, switches, instruments, etc) shall be with cable
glands. Plastic cable glands, of good quality can be used in general.
Cable glands must be suitable for the used cable diameter.
Use of additional filling materials is not allowed.
In case of EMC specifications screened signal cables and frequency controlled motor cable, appropriate metal EMC
glands shall be used. The EMC gland shall be connected galvaniclly, by means of a metal plate in the maintenance
switch.
4.1.22 CABLE CODING

All cables shall be coded according Heineken cable coding system.
All field control equipment shall be coded with the Tag. number as indicated on the electrical and or engineering
diagrams of the installation concerned.
The cable coding shall be fixed on both cable ends.
Execution of Tag number shall be as indicated on drawing: 607966.
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4.1.23 UN-INTERRUPTABLE POWER SUPPLY (UPS)
4.1.23.1 PLC & PROCESS VISUALISATION SYSTEM SUPPLY VOLTAGES
The supply voltage for PLC & Process visualisation systems shall be in accordance with the specifications of the
manufacturer of these control systems.
An Un-interruptible Power Supply must be applied for:
All systems with a central server function,
At least one of the visualisation workstations
Process visualisation systems Servers, Application processors, Workstations, etc.)
Central PLC racks for processors.
Process control data network communication modules (e.g.: Ethernet hubs, switches, routers, etc.)
4.1.23.2 OTHER UPS SUPPLIED EQUIPMENT
Equipment, which can lose relevant information, or has vital functions for human safety, has to be connected to an
UPS.
Examples
Empty bottle inspectors

Full bottle inspectors
Inkjet coding equipment
PE control in pasteurisers
Off-line flow Kieselguhr filter
Blender information
CO2 room-detection
Ammonia leakage detection.
Alcohol leakage detection
Smoke detection systems
Paging systems.
In countries, where the voltage fluctuation or power dips are more than +/- 10%, a central UPS should be installed per
bottle line to feed the CPUs and operation panels.
4.1.23.3 PLC SYSTEM AND FIELD INTERFACE DESIGN SPECIFICATIONS
Make and type, of control system in, co-ordination with the Heineken representative.
Type of field interface components, according the E&I components guideline.
Interfacing between the different installations to be carried out via data link communication between PLCs. In
consultation with Heineken, IO/IO-communication can be used.
Requirements for I/O set-up:
Field bus type in consultation with the BREWERY representative.

All IO shall be of the galvanic isolated type.
All outputs shall be short circuit proof, minimal 0.5A output current.
All analogue input cards shall be of the isolated type. (Isolation between input channels)
All not used slots to be closed/covered with blind front plates
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IO-rack shall be coded with control diagram code.

Each IO-point shall be coded with the Tag number, or if no Tag number available, the control diagram
code of the component connected to the IO.
4.2 ENGINEERING MEASURES FOR AREAS WITH INCREASED RISK FOR DUST EXPLOSION
Malt & adjuncts storage and handling installations are considered as areas with increased risk for dust explosion. All
engineering measures as indicated in this paragraph are additional engineering measures to the normal engineering
specifications.
Note that for this type of installation, the applicable regulations and standards with regards to dust explosion (ATEX)
must be strictly followed
4.2.1 CABLE LADDERS
All cable ladders shall be mounted in a vertical position. (All cables shall be tightened by means of Tie-raps).
All cable ladders shall be foreseen with covers.
All cable ladders passages, through floors and walls, shall be sealed off by means of fire retardant sealant.
4.2.2 MALT LORRY BONDING SYSTEM
At the malt intake a Malt lorry bonding system shall be foreseen. This system shall give a signal to the control system
when the truck is properly bonded. The function of this static discharge equipment must be based on resistive and
capacitive measurement principle.
4.2.3 SPARK DETECTION
In case spark detection equipment must be applied, signal for each spark detection point should generate and alarm.
During this alarm, measures should be taken to prevent the spreading of the spark. Detection unit mall functioning
should be visible on the control system.
4.2.4 EXPLOSION DETECTION
Explosion detection must switch off the total installation by means of the emergency stop circuits.
The explosion detection components, inside control panels (wiring; wire duct; terminals; etc) and in the installation,
shall be executed with a blue colour.
By means of a common signal, explosion detection shall be signalised to the control system.
4.2.5 ELECTRICAL COMPONENTS

All electrical components and equipment shall have a protection class in accordance with the applicable ATEX zone.
4.2.6 FAIL SAFE COMPONENTS
Alignment sensors, stow switches, etc. must be executed as fail-safe circuits.
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On the PLC input, in normal operation conditions, a logical 1 shall be present.
4.2.7 SOCKET OUTLETS
All socket outlets, in the malt storage, and malt treatment, shall be foreseen with a switch. The plug can be plugged in /
removed only when the switch is in off position.
4.2.8 BONDING
All metal parts and all interconnection pieces of the mechanical installation shall be bonded with braided copper strips
(size minimal 20x150mm) to ensure lowest impedance to avoid static electrical discharges and equalisation currents
(M8 treated rods shall be welded onto metal parts for the bonding connections)
All main malt handling equipment shall be connected to the bonding system.
All cable ladders shall be connected to the bonding system.
4.3 CONTROL PANELS
Next guideline is advised to implement for the mounting plate set-up of control panels:
Power supply entry: preferable at left section of control panel.

Power supplies, including protections: at left section of control panel.
Motor groups/frequency converters: in middle section(s) of control panel.
PLC rack(s) including Inputs/Outputs, measuring converters, etc: at right section(s) of control panel.
EMC rules shall be taken into consideration.
Cable entry, including all terminals, at bottom side of the control panel.
4.3.1 GENERAL SPECIFICATIONS CONTROL PANELS

Control panels must be designed to cope with the local circumstances and environmental conditions.
General specifications for all control panels:
Control panel housing shall be metal

A control panel shall consist of two sections.
Power section at one side of control panel section at the other side of control panel.
Practical spare space on mounting plate is 10-15%.
All components shall be coded on the components and on the mounting plate above the components. The
coding shall be the Tag number. When no Tag number applicable, then drawing component code shall be
used.
Accessibility of components shall be easy for maintenance and must be possible without removing other
parts. (No double layers of components)
Connection of power supply cable to main switch always direct without terminals.
No connections inside wire ducts.
All power distribution to components from bus bar systems.
No multi power distribution bars for motor protection switches and circuit breakers shall be used.
Panel coding plate at right panel top of all panels as supplied. Text black on white plate.
Dimensions of plate and text:
o Plate
: 80x40 mm
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o Text installation
: 10 mm
o Text panel code
: 10 mm
o Text drawing number : 3mm
Drawing holder in each control panel. To be mounted in the main power section of control panel.
4.3.2 CENTRAL PANEL ROOM CONTROL PANELS

If the control panels will be located in a central panel room, the hereafter listed specifications is applicable:
See all items in chapter 4.4.

Panel make: Rittal, type: TS. (PS in special cases).
Panels, in principle, without doors with a red fall-in safety bar for each panel section.
Protection class IP2X.
Panel dimensions:
o Width :
800mm or 1200mm (per section).
o Height :
1800mm (without plinth).
o Depth :
500 mm (600/800 in special cases).
Panel(s) executed in mild steel, colour RAL 7035 (Rittal standard).
100mm mild steel plinth.
Cable entry: bottom.
Cables pull relief to be integrated.
4.3.3 FIELD CONTROL PANELS

For freestanding field control panels, the hereafter listed specifications are applicable:
See all items in chapter 4.4.

Panel make: Rittal, type: TS. (PS in special cases)
Protection class IP55.
Panel dimensions:
o Width :
800mm or 1200mm (per section)
o Height :
1800mm (without plinth)
o Depth :
500 mm (600/800 in special cases)
Dry area panel(s) executed in mild steel, colour RAL 7035 (Rittal standard).
Wet Area panel(s) executed in stainless steel.
All panel(s) executed with a 200mm stainless steel plinth on stainless steel panel feet height : 100mm
Hygienic design roof when located in process of packaging lines
Cable entry: bottom via plinth.
Cable support in plinth: by means of Rittal standard cable support plates.
Cable entry in control panel: Rittal standard rubber grommet plates in control panel bottom.
Drawing support table to be mounted inside one of the control panel doors.
Internal lighting switched on/off by door-switches (or infrared switch), the socket outlet(s) not switched.
Door handles standard Rittal suitable for cylinder key and executed as pop out handle. (Stainless steel
door handles to be used for stainless steel panels)
Each field panel door to be foreseen with a key-lock, with standard key number 3524. (or different if
specified by the brewery)
4.3.4 FIELD REMOTE I/O PANELS, OPERATOR PANELS AND TERMINAL BOXES
For field remote IO panels, operator panels, terminal boxes, the hereafter listed specifications and accessories are
applicable:
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See all items in chapter 4.4..

Panel make: preferable Rittal.
Protection class IP55.
Panel dimensions: depending on application.
Dry area panel(s) executed in mild steel, colour RAL 7035 (Rittal standard).
Dry area panel(s) executed with a stainless steel support made of rectangular conduit.
Wet Area panel(s) executed in stainless steel.
Wet Area panel(s) executed with a stainless steel support made of rectangular conduit.
Cable entry bottom by means of cable glands.
Internal lighting switched on/off by door-switches (or infrared switch), the socket outlet(s) not switched.
Each field panel door to be foreseen with a key-lock, with standard key number 3524. (or different if
specified separately)
Handgrip to be used for all door locks.
4.3.5 AIR COOLERS

Air coolers shall be used for field panels if local circumstances require and if conditions are deviating from NENEN-IEC60204. Use of fan units is not allowed on field panels. The specification of the air cooler:
To avoid condensation inside control panels necessary measures have to be made to keep temperature
7,5C above dew point.
To be supplied from separate 230VAC air cooler power supply group. If 400VAC air coolers shall be used,
because of large required cooling capacity, power supply direct from control panel power supply via circuit
breaker protection.
Air cooler with environmentally friendly gas to be used only.
To be controlled by thermostat.
Over temperature alarm and failure to be connected to the PLC for indication
Mounting on one sidewall of control panel. Panel top mounted air coolers not allowed.
Air coolers, integrated in control panel doors, are permitted when sidewall installation cannot be executed
or when more air coolers are required on one control panel.
When a panel door is open, the air cooler shall be shut off by means of door contact.
On mild steel panels, mild steel/stainless steel air coolers to be used.
On stainless steel panels, stainless steel air coolers to be used only.
4.3.6 ANTI CONDENSATION HEATING

Anti condensation heating specifications is required if the environmental conditions do not met the requirements as
per NEN-EN-IEC60204:
To be supplied from separate 230VAC power supply. (Together with internal panel lighting/socket outlets)
Control by means of hygrostat.
4.3.7 MINIMUM CROSS SECTION OF WIRING

Application
Minimum cross section
Wiring general
PLC
0,75 mm
0,5 mm
< 0,5 mm in consultation with the Heineken
representative
>=1,5 mm
Power
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Pt 100
1,5 mm
4.3.8 WIRING COLOURS

Based on colours as indicated in the Machine Directive IEC/EN60204-1 with the following deviations
Power circuits
Phase colours
labelled from power distribution bar at the main

switch:
L1 - L2 - L3
Control and signal voltage (after a control voltage transformer)

Voltage
24VDC
Line wire
Blue (+)
24VDC
Switching wire
Grey
Neutral wire
Blue/White (-)
Blue(+)
+
Emergency
stopcontacts
Grey
PLC
24VDC
Blue/White()
General wiring
External voltages / potential free contacts
Auxiliary power
Analogue instrument signals (4-20mA)
Pt-100 element signals (without
converter)
Other internal voltages/signals
White
White
White/black (striped)
Transparent
Purple
Wiring for panel auxiliaries such as panel lighting, air coolers etc. to be considered as external voltages, thus white
coloured wires to be used.
If standard Rittal appliances, including cables and connectors will be used, the standard Rittal cable colour may be
used.
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** All 24VAC control wiring shall be coded to avoid mistakes with the other control voltages. Wire code to be used:
24VAC on both ends of each wire.
4.3.9 TERMINALS
All wiring for connections to field equipment shall be terminated on terminal strips.
The terminal strips are located at the bottom side of the panel.
If there is insufficient space available to fit all terminals horizontally, vertically mounted terminal shall be applied
The maximum number of wires that may be connected to one screw connection is 2.
Each outgoing motor and power cable shall be executed with a PE-terminal.
Each terminal strip shall provide 10% spare terminals with a minimum of 5 terminals.
The cable connection terminal lists shall be coded as follows:
X0
X1
X2
X3
X4
X5
X6
X7
X8
X9
X10
X13
X14
X15
X16
X17
400V AC
230V AC
24V DC
External voltage, potential free contacts
230V AC for panel lighting, socket outlets and panel
air-coolers system (with warning plate
Speed monitoring
24V AC
Brake contacts
Down time registration
24V AC (vessel lighting)
Internal not defined other voltages
Analogue signals (4-20mA / 1 - 5 V eso)
Other signals
Pt100 signals
Pneumatic signals
Different signals (NOT 230V) in one connection cable
to field instrument (standard instrument connection
cable)
4.3.10 COLOURS OPERATION APPLIANCES

4.3.11 SIGNAL LIGHTING
Based on colours as indicated in the IEC/EN60204-1
Signal lights shall be of the LED type.
4.3.12 PUSH BUTTONS
Based on colours as indicated in the IEC/EN60204-1
5. INSTRUMENTATION GUIDELINES
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5.1 GENERAL
All instruments (incl. connections and housing) shall comply with
the area zone classifications for explosion proof (ATEX),
hygienic (EHEDG), for contact with product in the cold part of the production process
Commission Regulation (EU) No 10/2011 of 14 January 2011 on plastic materials and articles intended to
come into contact with food (for contact with product).
all other standards mentioned in the project documentation (classification for the installation or unit).
all other applicable standards

For hygienic design a reference is made to the Hygienic Design Manual (HMESC 99.04.04.100). In hygienic area's Ra
< 0,8m is required for roughness of any instrument in contact to medium. Instruments have to be suited for pressures
and temperatures that are applicable to the respective process unit.
Hook up design and instrument selection shall suit manufacturer specifications for all environmental and process
conditions (e.g. vibration, maximum temperature for electronics, etc).
5.2 INSTALLATION
All installation work shall be carried out in a good manner with workmanship and sound engineering practices.
Installation and usage of instruments has to be executed conform the manufacturers instructions. Copies of the
installation instructions of the instrument supplier have to be available on site.
The location of instruments shall be selected to suit the process but also be maintainable. Instruments shall be
accessible for maintenance by means of platforms for heights or other means according applicable SHE guidelines.
All measuring and control instruments shall be reliable coded according the numbering shown on the engineering
diagrams.
Mounting of instrumentation must be such that dust accumulation is avoided.
Welding in process areas is not allowed when instrumentation is already installed.
5.2.1 HOUSING
IP class shall be IP65 as a minimum. If additional provisions are needed to comply, please consult GSC.
Housing of instruments from Wortcooler up to and including Filler made of stainless steel. Housing of instruments in
packaging wet-area made of stainless steel. Housing of instruments in CIP area's made of stainless steel.
5.2.2 PROCESS CONNECTIONS
Based on hygienic aspects, availability, flexibility, standardisation, 99.04.04.100 Hygienic Design Manual and
operational (maintenance) aspects the following process connections for instruments are recommended:
5.2.2.1 VARIVENT FOR ALL ON-LINE INSTRUMENTS IN SS PIPES FOR HYGIENIC APPLICATIONS:
Pressure transmitters,
Conductivity transmitters
pH Transmitters
OG Analysers
Oxygen and Carbon Dioxide Analysers
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Empty pipe detectors

Temp sensors,
Pressure Transmitters
Pressure Switches
Flow switches
Level switches
Empty pipe switches
Level Transmitters
Insertion Flow meters
5.2.2.2 VARIVENT FOR ALL INSTRUMENTS IN SS TANKS FOR HYGIENIC APPLICATIONS.
Pressure transmitters,
Level Transmitters
Level Switches
Foam electrodes
Level electrodes
5.2.2.3 DIN 2501 FLANGE FOR IN-LINE INSTRUMENTS FOR HYGIENIC APPLICATIONS
All hygienic control valves >DN 150
All not hygienic control valves
Hygienic flow meters >DN 100
Only recommended by Heineken for Flow transmitters < DN 100 and control valves > DN150
5.2.2.4 FOR NON-HYGIENIC APPLICATIONS
Manufacturerstandardispreferred,ifnotavailableinchNPT
5.2.3 INSTRUMENT AIR TUBING AND DISTRIBUTION
Instrument air tubing shall be metric 6mm x 1mm or 8mm x 1mm. For valves the supplier has to consider 8mm x
1mm tubing.
Suggested materials for instrument air tubing is polypropylene or polyethylene, depending on the application.
Instrument air tubing has to have a high resistance against high temperatures and ultraviolet light. Tubing outside
should be black, while in building the colours black or blue can be used.
Fittings shall be preferable brass and of the quick fit type. Brass fittings are not allowed in aggressive areas.
All pneumatic equipment should be supplied via air headers.
An air header shall be executed as follows:
Stainless steel supply pipe from the main air supply line stop valve.
Stainless steel air header
Filter/drain (reducer) device
Ball valve to be used for each air hose connection.
Number of connections limited to approx. 10. To be calculated by the contractor.

Inside control panels, pneumatic equipment has to be mounted separated (by walls) from the electrical equipment
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5.2.4 SUNSHADE
Field instruments installed in open air shall be equipped with sunshades to protect the instrument electronics against
overheating and deterioration.
5.2.5 LOCAL INDICATORS
Field instruments have to be equipped with local indicators, except for temperature transmitters.
In case transmitters are installed on locations that are out of normal sight limits, a separate remote transmitter has to
be used. Local indicators shall be visible at all times.
5.3 MEASUREMENTS OVERVIEW & GUIDELINES
5.3.1 FLOW MEASUREMENTS
Flow calculation shall be made to calculate minimum and maximum flow with corresponding accuracies.
Flowmeter have to be provided with an empty detection and zero cut-off (MV<2% of adjusted range). Standard
damping factor is 1 second, except for dosing and filling.
Compact flow meters can only be applied if installed below 2.5 m from floor and good attainable for maintenance
purposes. All flow meters should be connected with analogue (mA) and an active pulse output, connected to the I/O of
the control system (pulse width 250 ms /max. 2 pulses/second / 10 pulses per hl).
Magnetic flow meters shall be installed at a minimum distance of 100 mm from any steel structure.
The mechanical process design must be in such a way that the magnetic flow meter is always filled with process liquid.
Description
Flow counter
FQ
Flow switch
Flow meter product,
beer, wort, water, CIP,
dosings
FS
FT
x
x
x
x
Flow meter steam,

superheated water
FT
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Units field equipment /

Remarks
Utilities
Packaging
Production
Fucntion Code
Measuring principle
Thermal
Electro-magnetic, induction
Vortex, incl. PT
compensation
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Product in hl
Dosings in l
Yeast in kg or l
Utilities in 0.1 m3
Digital signal (Bistate)
Product in hl/h, l/h,
Dosings in l/h (designed
for pulsating flows when
applicable)
Utilities in m3/h, l/h
kg/h (mass) or m3/h (volflow), or MJ/h (energy)
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Flow meter yeast
FT
Flow meter gas (air,

oxygen, CO2)
Flow meter hop (liquid)
FT
FT
Massflow coriolis
Magnetic in combination
with yeast monitor (for
dosing)
Massflow, thermal or
coriolis
Massflow coriolis
l/h or kg/h
kg/h, g/h (or g/hl)
5.3.2 LEVEL
Description
Fucntion Code
Production
Packaging
Utilities
Measuring principle
LS
LS
x
x
x
x
X
X
Vibrating fork
Vibrating fork, or capacitive
LS
Capacitive
LS
LS
LT
x
x
x
x

Remarks
Level
Level switch general
Empty/full/medium
detection dry solids
Empty/medium
detection wet solids,
trub
Level detection
(empty/full) tanks and
lines and pump guard
Leakage detection
Level transmitter
product vessels/tanks,
water, CIP tanks, sugar
syrup
X
x
Vibrating fork
Conductivity
General: hydrostatic
pressure
Sensor: strain gauge or
capacitive bridge/ceramic
or metallic diaphragm
Ultrasonic, radar, and
others in consultation.

Mbar(g), 0100 %, hl
5.3.3 PRESSURE MEASUREMENTS

Size of dials shall be 80mm as a minimum. Dials shall be well readable from the normal path. Damping shall be used
where applicable. Remote transmitters shall be used where the process connection is not accessible.
Pressure transmitters in product lines, with alternating hot and cold conditions and pressures => 10 bars have to be of
the absolute type, and to be calibrated in the same way as relative transmitters. The local indicator should indicate
gauge pressure. On steam-pipes a manual block-valve and pigtail has to be used always.
In wet area's the manometers must be stainless steel also for air components.
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Measuring principle
Production
Packaging
Utilities
Fucntion Code
Description
Pressure switch/guard,
Electronic switch
PS
PIS
Differential pressure
switch (dust filters)
Stow switch solids
PdS
PS
PT
Pressure transmitter
(absolute or relative)

Remarks


Inductive sensor in
combination with
mechanical part, Capacitive
sensor
bar, mbar
5.3.4 QUALITY
Description
QT (turb)
Turbidity bright beer
QT (turb)
Consistency (derived
from density)
Density in line
Original gravity
Oxygen in beer
Apparent extract
pH measurement
QT (cons)
Gas guarding system

rooms (closed areas)
QT (dens)
QT (OG)
QT (O2)
QT (AE)
QE/QT
(pH)
QT (CO2
)

Remarks
Utilities
Production
Turbidity brewhouse
Packaging
Fucntion Code
Measuring principle
Light scattering, 11-12

angle
Light scattering, 90 and
25 angle.
Coriolis
0-100 EBC, sapphire

window
0-2 EBC, sapphire
window
%
kg/m3
0-20.0 Plato
ppm, ppb
Coriolis
Sound speed
Electro-chemical, or optical
Density
Glass electrode, mV
NDIR
0-2.0 vol%
pH
5.3.5 SOLENOIDS
DC solenoids must be provided with suppressing diodes.
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No solenoids in field installation / to be mounted in panels
5.3.6 TEMPERATURE MEASUREMENTS
Following scaling shall be used for temperature measurements.
Application
Scaling
Product lines / cooling systems

Product tanks cold
General
Boiling applications
Cooling media, cold side
-10C + 100C
-10C + 40C
0C + 100C
0C + 120C
-25C + 25C
Size of dials shall be 80mm as a minimum. Dials shall be well readable from the normal path.
Temperature transmitters shall be provided with active failsafe function for lead wire breakage.
Temperature probes to be installed with matching thermowells. Design of these shall be in such way that minimum lag
will occur between measured value and actual PV and that the insert can be removed easily for maintenance
purposes.The insert is of the same model as applied for other temperature applications.
Description
Temperature switch
Temperature transmitter
TS
TT

Remarks
Utilities
Packaging
Production
Fucntion Code
Measuring principle
Resistance, Pt100
Resistance, Pt100

C
5.3.7 VALVES
Control valves shall be calculated by the supplier, among others based on process data. Calculation shall be made
available to GSC. The close off pressure has to be 1.5 times the maximum pressure at the input of the valves
Control valves have to be forced to their closed position if the control signal (mA) becomes smaller than 2 %, by
blocking the pneumatic signal to the valve motor (venting). This is a parameter in the valve positioner. If this parameter
is not available in the positioner, an extra solenoid and software could be applied to achieve the same result.
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Production
Packaging
Utilities
Control valve product /

non-product
Control valve gas
Measuring principle
Fucntion Code
Open/close valves and

control valves should
close in such a way that
water hammer is
avoided at all times,
except emergency
cases.Description
*V
*V

Remarks
0-100.0 % or 4-20 mA
Leakage class class IV
0-100.0 % or 4-20 mA
Leackage class class VI
5.3.8 WEIGHT
Description
Fucntion Code
Production
Packaging
Utilities
Weight element / sensor

/ transmitter
Measuring principle
WE

Remarks
Strain gauge, pizo

sensors
kg
5.3.9 OTHER
Description
Fucntion Code
Production
Packaging
Utilities
Measuring principle
Current detection, load

switch
EE/ES
Electrical coil/transformer
Current transmitter, load

monitor
EE/ET
Electrical coil/transformer
Conductivity
CE/CT
Elevator belt out of line

sensor
Off bellt detection
Manhole detection /
door switch / proximity
switch / swing bend
GE
GS
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Remarks
Inductive coil
Inductive, failsafe
Inductive PNP 3-wire,

magnetic/reed
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Digital signal (Bistate).

Element/transformer in
mA/A
A.
Element/transformer in
mA/A
CIP: 0-200 mS/cm,
Product: 0-4000 S/cm
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Maintenance switch
motors/pumps
Maintenance switch
installations (Process
stop)
Rotation (sensor / guard
/ transmitter / counter)
Pump speed control
(SX, FX, PX, LX)
Overvoltage protection
Electrical
contact/mechanical
Key switch (supplier
standard),
Key not removable in
position operation
Inductive sensor

Output: electrical contact
HS
NE/NS/N
T/NQ
SX
XA
Electrical contact
XA
Electro-magnetic
Thermal alarm
(circuitbreakers panel,
pumps/motors)
Leackage detection
hose pump
Vibration measurement
3-Phase alarm
XE/XS
Conductieve, capacitive,
vibration fork
XE/XT
XS
Explosion detection
XS
Electro-magnetic
(differential relay)
Breakage plate supplier
standard
Spark detection
Overboil detection
(wortcopper)
Foam detection product
tank (HH)
Earthing clip Truck
XS
XS/XE
x
x
XS/XE
XZ
YN
Signal lamp, LED /

Control(led) signal
Digital signal (Bistate),

rpm
0-100.0 % or 4-20 mA

mm/sec
Conductivity

Vibrating fork, Conductivity
Electrical contact
Not applicable

Safety item, execution
supplier standard
5.4 RANGES AND ACCURACIES

5.4.1 RANGES
All instruments ranges shall be selected in such way that nominal Process Value (PV) will be 60% - 80%. Maximum PV
shall be 85% - 90%. Unless stated otherwise.
5.4.2 ACCURACIES
The mentioned figures are defined as the maximum possible deviation related to the Full scale of the complete
particular measurement loop (sensor, transmitter, and indicator or control system input) or in engineering units,
including installation effects.
Following accuracies should also be used in utility installations in case measuring signals are used for the UMS
system.
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5.4.2.1 RAW MATERIALS / BREWHOUSE / WORT COOLING
Application
Accuracy
Weight (malt bins)

Temperature measurements general
Temperature measurements wort cooler
Pressure measurement
Level measurement general
Level measurement & pressure difference lautertun
Flow measurement product
Flow measurement hop dosing
Air flow measurement wort aeration
Quality measurements OG
Turbidity measurement
Weighing systems solids
pH measurements sparging water
Conductivity measurements
0,2%
0.5C
0.4C
1%
0,5%
3 cm WC
0,5%
2%
2%
0.15 Plato
2%
0,2%
0,1 pH
2%
5.4.2.2 CELLARS
Application
Accuracy
Temperature measurements tanks

Level measurement general (not pressurised) tanks
Tank volume pressurised product tanks
Flow measurement
Flow measurement yeast dosing
Weighing systems (Yeast)
0.4C
1%
1%
1%
0,5%
2%
0,5%
2%
5.4.2.3 SERVICE BLOCK / BEER FILTRATION

Application
Accuracy
Temperature measurements tanks

Level measurement general (not pressurised) tanks
Tank volume pressurised product tanks
Flow measurement product
Flow measurement additives
Flow measurement isohop dosing
OG measurements
CO2 content in beer measurement
0.4C
1%
1%
1%
0,5%
1%
3%
0,05Plato
0,015% by Weight
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Weighing systems
O2 measurement
1%
0,01 ppm
2%
5.4.2.4 BOTTLING HALL

Application
Accuracy
Bright beer interface detection (conductivity

measurement)
Beer pressure to filler
Vacuum pressure filler
CO2 pressure to filler
Keg weigher before and after keg filler
Pressure rinsing water bottle washer
Caustic concentration cleaning bath bottle washer
Temperature pasteurization zones bottle pasteurizer
Beer flow flash pasteurizer
Temperature flash pasteurizer
5% (concentration)
3%
0,1 bar
3%
20 gr
3%
2%
0,5C
1%
0,5C
5.4.2.5 CIP INSTALLATIONS / GENERAL

Application
Accuracy
Temperature measurements general

Level measurement
Flow measurement liquids
1C
1%
1%
2%
2%
5.4.2.6 UTILITIES
Application
Accuracy
H2S concentration in CO2 before treatment plant

Sulphur detection in CO2 after treatment plant
H2S concentration in CO2 after treatment
Dew point CO2
Oxygen concentration in CO2 after treatment plant
Dew point compressed air
5%
5%
5%
4 C
1 ppm
4 C
5.4.2.7 WWTP INSTALLATIONS

Application
Accuracy
Temperature measurements
1C
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Level measurement
1%
1%
Flow measurement liquids

pH measurements
Dissolved oxygen measurements
In-line COD measurement influent
2%
2%
0,2 pH
0,1 ppm
10%
5.5 COMMUNICATION
Analogue signals shall be 4-20mA with a HART protocol. In case specific instruments do not utilize the HART protocol,
this shall be clearly indicated in the quotation.
When a bus system is applied the condition monitoring data of field instruments shall be made available to the
workshop workstation.Malfunction of an instrument must be automatically detected and indicated on the HMI as an
alarm.
Instrument switched outputs must always be fail-safe (TRM, Production Automation System Set-up [HMESC
01.20.20.001], section 16 Requirements for In- and Output signals.)
5.6 INSTRUMENT CALIBRATION

The calibration and configuration of the instrumentation shall be included in the scope and has to be in accordance
with the application and their related operating conditions.
The accuracies mentioned in the chapter Accuracies are based on measurement loops, including installation effects.
The supplier has to ensure that these accuracies are reached under process conditions and the supplier has to
eliminate installation and/or process effects.
The calibration and settings of all instruments, which have the possibility of zero, span and range calibration, shall be
checked before installation on site to ensure correct operation and calibration settings of the instruments.
The range of instruments has to be adjusted close to the possible range in the applicable process-part.
Calibration of instruments has to be done with traceable calibration equipment. Calibration with non-traceable
equipment will be rejected.
Flowmeters, which influence the efficiency of the installation or flowmeters required for bookkeeping must be easily
accessible for frequent calibration. Calibration provisions shall be installed for temporary connection of a master flow
meter for wet calibration of these flowmeters. Typical is an installation of two pieces Tuchenhagen Varivent valvehousings and one butterfly valve. At the calibration provision for flowmeters for bookkeeping a Harting connector to be
installed. (female part for a HAN 6 E)
Relevant flowmeters in the production area should be wet calibrated on site to ensure the accuracy. The applicable
flowmeters have to be determined in consultation with Heineken. The determination of flowmeters for bookkeeping
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purposes is done by Heineken. In case calibration provisions are not or not all mentioned on the P&ID a list of
flowmeters for bookkeeping purposes should be requested by the supplier.
The supplier has to check with Heineken whether the calibration unit of the applicable brewery can be used for this
purpose, otherwise the supplier has to provide a calibration unit according the Heineken standard.
Whenever Allen Bradley PLCs are used, the accuracy of the Analogue I/O has to be checked at commissioning. This
can be done using a spot check method of 10% of the I/O amount, and discussing the result with Heineken.
In order for Heineken engineers to be able to check the calibration and setting activities following paper documents
have to be ready and used:
Checklist documentation and installation instructions available on site.

List of calibration reports from the instrument supplier
Filled-in parameter- and setting-list for all kinds of instrumentation
List of traceable calibration equipment
Empty calibration reports for all kinds of instrumentation
Checklist for calibration progress with all instruments and activities
During commissioning the documents should be kept up-to-the-minute.

The documents should be ready for use two weeks before commissioning, and should be accepted for use by
Heineken..After the commissioning the documents have to be handed over to Heineken.
In case of electronic instruments a parameter list should be made, which has to be submitted together with the
intermediate "as built" diagrams and information.
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6. DRAWING GUIDELINES
6.1 STANDARD SUPPLIERS CONTROL DIAGRAMS
To ensure that standard suppliers E&I control diagrams are accepted by the brewery, the Specifications Electrical
Drawings (99.04.07.201) shall be followed.
6.2 HEINEKEN HOUSE STYLE DIAGRAMS
When the control diagrams should be made according the Heineken house style , an Eplan Heineken Context is
available on request and consists of:
Set-up for Heineken project

A manual with drawing specifications and settings.
Heineken standard sheets.
6.3 GENERAL GUIDELINES FOR THE ELECTRICAL DIAGRAMS AND INSTRUMENT LISTS
Drawing numbers, panel codes and administration codes are exclusively issued by Heineken Supply
Chain.
One complete set of all electrical diagrams shall be issued for review , before panel fabrication starts
A complete set of instrument lists shall be submitted for comments before the supplier orders the
instruments.
One copy of each control diagram and instrument list when the panels will be transported to site.
During the erection on site the supplier shall indicate all the changes in the drawing as soon as they have
been made.
The supplier shall hand over during start-up, one complete set of as-built control diagrams (dated and
marked as-built. This to bridge the time the final control diagrams are not yet available.
Final diagram maximum one month after commissioning of the complete installation.
All final drawings shall be issued electronically in CAD format.
CD-Rom of each AutoCAD diagram and instrument lists with file names as per Heineken specification.
7. MANUFACTURING INSPECTION
See MI Procedure Heineken Supply Chain BV 20101214.docx
8. TRAINING
8.1 GENERAL
A detailed training program and schedule to familiarise the brewery staff with the new equipment shall be a part of
suppliers scope.
This training, as meant in this document, applies for electrical and instrumentation personnel.
The complete training shall consist of a class room training and Hands-on training in the field.
Trainings manual shall be discussed between the supplier and the brewery representative to ensure the correct
training performance. If possible, the training can be finalized with a test.
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8.2 ELECTRICAL TRAINING
For Electrical training, the following points should be considered:
Operation and functional principles the electrical system and components

Maintenance of the electric system and components
Troubleshooting.
Documentation review and easy references where to find
8.3 INSTRUMENTATION TRAINING

For instrumentation training the following points should be considered:
Operation and functional principles applied instruments

Maintenance applied instruments
Troubleshooting applied instruments.
Detailed instrumentation application training.
9. COMMISSIONING, START-UP AND HAND-OVER

After completion of the installation, the complete installation shall be commissioned.
The E & I commissioning is part of the overall commissioning of the complete installation.
During this commissioning, all necessary tests shall be executed by the supplier and can be witnessed by Heineken or
his representative. The supplier is responsible to record the tests (including test results)
During the installation, commissioning and start-up, failures, mismatches or other items can be observed by the
brewery representative. These outstanding items will be added in the LOI which is same LOI as started during the
manufacturing inspection. The LOI is a live document that will be frozen four weeks before the site acceptance test
(SAT). At the start of the SAT, all items on the LOI shall be closed.
The hand-over procedure (including electrical and instrumentation) are normally indicated in the commercial contract.
10. DOCUMENTATION
To ensure that maintenance and troubleshooting can be executed efficiently, documentation and manuals shall be
delivered. In principle, all documentation as per NEN-EN-IEC 60204 1 shall be part of the scope for the supplier
Installation manuals of all used components shall already be available during installation and commissioning of the
installation.
All documentation such as, instruction manuals, lists, equipment documentation, certificates, reports and spare parts
list shall be also available on CD-Rom.
If not indicated elsewhere, 2 hardcopies and 2 CDROMs (copy of the hardcopy) shall be issued by the supplier.
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E&IDESIGNGUIDELINE

2.1 PURPOSE OF DOCUMENT

3.1 BREWERY REQUIREMENTS

3.2.1 Supplies in Europe

4.1 ELECTRICAL ENGINEERING

4.1.1 Electrical components

4.3 CONTROL PANELS

4.3.1 General specifications control panels

5.3 MEASUREMENTS OVERVIEW & GUIDELINES

5.3.1 Flow Measurements

5.4 RANGES AND ACCURACIES

6.1 STANDARD SUPPLIERS CONTROL DIAGRAMS

COMMISSIONING, START-UP AND HAND-OVER

Specification renamed to guideline.

Basic E&I brewery specification.

3.2 CONFORMIT EUROPENNE (CE)

3.2.2 SUPPLIES OUTSIDE EUROPE

In accordance with IEC standards

Condense drain plugs

4.1.4 PROTECTIVE EARTHING (PE)

Main bonding bar in each low voltage room.

4.1.5.2 BONDING CABLES TO CONTROL INSTALLATIONS

4.1.6 EMERGENCY STOP AND PROCESS STOP

Colour plate: Red; colour text: White.

4.1.6.2.1 EMERGENCY STOP RELAYS AND I/O CARDS

See also chapter Emergency stop for further details.

Colour plate: Red; colour text: White.

Text indicates vessel (e.g.: wort copper), which will be blocked.

Cut-off of power to motors

Motor groups to be protected by means of motor protection switches.

4.1.13 FREQUENCY CONVERTERS AND SERVO CONTROLLERS

Installation instructions should be strictly executed.

All cables shall be installed in one length without joints.

The following cables shall be used in the follow situation

4.1.16 CABLE LADDERS & TRAYS

Hot dipped galvanised cable trays and ladder:

In general (indoor and outdoor)

Stainless steel cable ladder:

Brewhouse & service block

The following cable trays and ladders shall be covered

Vertical cable ladders and trays

Main cable ladders: 50% spare after first installation.

4.1.17 CABLE PROTECTION CONDUIT

4.1.22 CABLE CODING

All systems with a central server function,

At least one of the visualisation workstations

Process visualisation systems Servers, Application processors, Workstations, etc.)

Central PLC racks for processors.

Empty bottle inspectors

Field bus type in consultation with the BREWERY representative.

IO-rack shall be coded with control diagram code.

4.2.5 ELECTRICAL COMPONENTS

Power supply entry: preferable at left section of control panel.

4.3.1 GENERAL SPECIFICATIONS CONTROL PANELS

General specifications for all control panels:

Control panel housing shall be metal

4.3.2 CENTRAL PANEL ROOM CONTROL PANELS

See all items in chapter 4.4.

4.3.3 FIELD CONTROL PANELS

See all items in chapter 4.4.

See all items in chapter 4.4..

4.3.5 AIR COOLERS

4.3.6 ANTI CONDENSATION HEATING