LG

Phase 1: Basic Component Replacement (0 Production Stoppage)
Deploy the PT1000 sensor and EEV valve body overnight → Connect a temporary controller to verify accuracy
Install the capacitor filter and pressure switch over the weekend
Phase 2: Core System Integration (1-day production stoppage)
1. Cutting Area: Oil Cooler Circulation 2 (Cutting Fluid Cooling) + Double-Wall Piping
2. Entire Workshop: Waste Heat Recovery Piping Installation
3. Rest Area: Absorption Chiller Installation
Phase 3: Intelligent Operations and Maintenance
Cloud-based monitoring platform: Real-time tracking of component health (e.g., coil impedance/capacitor capacity).
Predictive maintenance: Early warning of contact aging based on relay actuation frequency.

Electronic Expansion Valves (EEV) & Coils:
Model: Danfoss ETS 2.0 (stepper motor drive, regulation accuracy ±0.1°C)
Function:
Dynamic adjustment of opening (range 0-100%) based on superheat, saving 18% energy compared to thermal expansion valves.
Coil temperature resistance up to 150°C (Class H insulation), preventing motor burnout.
Application: Fermentation tank cooling circuit (independent EEV control for each tank)
VFD Motors & Contactors:
Motor: Siemens 1LE8 series (IE5 energy efficiency, 5% efficiency increase vs. IE3).
Contactor: ABB A series (1 million cycles mechanical life, surge current resistance).
Control Logic:
Compressor speed is linked to the fermentation stage (e.g., 100% during main fermentation → 40% during ripening).
Soft start function (adjustable ramp-down time 0.5-30 seconds) reduces mechanical shock.

(DCS):
Architecture:
A main PLC (Siemens S7-1200) coordinates all EEVs/variable frequency motors/sensors.
Redundant relays (Omron G7L) ensure seamless failover in the event of a fault.
Algorithm:
Fuzzy PID control of fermentation temperature (to prevent heat shock to yeast metabolism).
Automatically adjusts the cooling curve based on the hop addition phase (e.g., dry hop phase → -1°C quench).
Energy recovery module:
Components: Transformer (380V → 24V DC) powers sensors/EEVs.
Heat Recovery:
Compressor waste heat is used to preheat saccharification water (60°C → 78°C) via plate heat exchangers.
Annual gas savings: $8,500 (based on eight batches per day).

Component Redundancy and Failure Protection:
Relay Redundancy: Dual relays in parallel for critical circuits (one active, one backup).
Dual Pressure Switch: Dual high/low pressure switches prevent false triggering (±0.3 bar tolerance).
Capacitor Backup: Controller capacitor bank with a 2-hour battery life (to mitigate grid outages).