Integrating CIP Units and Routing with Process Vessels in BRAUMAT and SIMATIC PCS 7

In brewing and liquid food processing plants automated with SIMATIC BRAUMAT / SISTAR (V7.5 or higher) or PCS 7, integrating Cleaning-in-Place (CIP) plants with process vessels (such as Mash Tuns, Lauter Tuns, and Wort Coppers) is implemented using Unit Streaming and Cross-Streaming recipe architectures. In BRAUMAT, process vessels and CIP lines are modeled as distinct Units (UNIT_BLOCK). When a vessel triggers a cleaning phase, the recipe initiates a Cross-Stream that requests a CIP Supply and Return route through a shared valve matrix. For PCS 7 environments, Siemens provides the standardized PCS 7 Unit Template 'CIP - Cleaning in Place' (SIOS Entry ID 78463886), which utilizes APL and SIMATIC BATCH to coordinate cleaning cycles, chemical dosing, and conductivity-based rinse cutoffs.

Executive Summary

In brewery automation, sanitary process integrity mandates that brewing vessels (brewhouse mash tuns, lauter tuns, whirlpools, fermenters, and bright beer tanks) are cleaned thoroughly between production batches using automated Cleaning-in-Place (CIP) systems. Engineers developing projects with SIMATIC BRAUMAT / SISTAR V7.5 (utilizing S7-1500 or S7-400 controllers) frequently struggle to integrate central CIP preparation units with distributed brewing vessels. This technical reference clarifies the unit allocation and recipe streaming mechanics defined in Chapter 7 of the BRAUMAT manual, compares them with the standardized SIMATIC PCS 7 CIP Unit Template, and provides the step-by-step methodology to coordinate multi-tank cleaning routes.

Architecture and Fundamental Mechanics

BRAUMAT / SISTAR Recipe Streaming and Cross-Streaming Architecture

+-------------------------------------------------------------------------+
|                   CENTRAL CIP PLANT (SUPPLY & RETURN UNITS)             |
|                                                                         |
|   - Caustic Tank (NaOH)       - Acid Tank (HNO3)                        |
|   - Fresh Water Tank          - Recovery Water Tank                     |
|   - CIP Supply Pump & Heat Exchanger                                    |
+-----------------------------------|-------------------------------------+
                                    |
                                    v CIP Supply Stream (Stream 1)
+-------------------------------------------------------------------------+
|                     SHARED VALVE MATRIX / SWING BEND PANEL              |
|                     (Route Allocation: LINE_BLOCK / ROUTE_BLOCK)        |
+-----------------------------------|-------------------------------------+
                                    |
         +--------------------------+--------------------------+
         | Cross-Stream Request                                | Cross-Stream Request
         v                                                     v
+------------------------------------+           +------------------------+
| BREWHOUSE UNIT: Mash Tun           |           | BREWHOUSE UNIT:        |
| - Unit Instance: UNIT_BLOCK (UT01) |           | Lauter Tun (UT02)      |
| - CIP Recipe Phase Active          |           | - Standby / Brewing    |
| - Spray Ball Return Pump           |           +------------------------+
+------------------------------------+                                     
                                    |
                                    v CIP Return Stream (Stream 2)
+-------------------------------------------------------------------------+
|                     CONDUCTIVITY & FLOW MONITORING                      |
|                                                                         |
|   - Conductivity Sensor evaluates chemical return concentration         |
|   - Diverts return: Recovery Tank (if reusable) or Drain (if rinse water)|
+-------------------------------------------------------------------------+

The Mechanics of Recipe Streaming

Unit Separation: In BRAUMAT and PCS 7, the CIP preparation station is an independent equipment unit with its own control sequences (heating caustic, controlling dosing pumps). The vessel being cleaned is a separate equipment unit.
Cross-Streaming (Braumat Chapter 7.3): A cleaning recipe running on a brewing vessel (e.g., Lauter Tun) requests access to the CIP unit via a Cross-Stream. The Braumat recipe manager evaluates route availability, reserves the required valves, and synchronizes the vessel's spray ball return pump with the CIP supply pump.
Conductivity-Based Transition: Transitions between recipe phases (Prerinse -> Caustic Wash -> Intermediate Rinse -> Acid Wash -> Final Rinse) are governed by in-line conductivity and turbidity sensors, ensuring chemicals are recovered and rinse water is purged.

Step-by-Step Implementation Procedure

Step 1: Model Vessels and CIP Lines as Separate Units

In BRAUMAT Engineering (or SIMATIC Manager Plant Hierarchy for PCS 7):
Create independent Unit instances for each vessel:
- Unit_MashTun (UNIT_BLOCK 1)
- Unit_LauterTun (UNIT_BLOCK 2)
- Unit_WortCopper (UNIT_BLOCK 3)
Create dedicated Unit instances for the CIP plant:
- Unit_CIP_Line1 (UNIT_BLOCK 10 - Supply & Return Line 1)
- Unit_CIP_Line2 (UNIT_BLOCK 11 - Supply & Return Line 2)

Step 2: Configure Route and Line Blocks for Valve Matrix Routing

Insert ROUTE_BLOCK and LINE_BLOCK instances to model the pipe network between the CIP supply manifold and the vessel inlet spray balls.
Configure mutual exclusion: Ensure that when a CIP route is assigned to Unit_MashTun, all product transfer routes into the Mash Tun are mechanically interlocked to prevent chemical cross-contamination.

Step 3: Configure Recipe Cross-Streaming in BRAUMAT Recipe Editor

In BRAUMAT Recipe Editor, open the Master Recipe for vessel cleaning.
In the Recipe Header, define Streaming parameters:
- Set Stream 1 to command the CIP Supply Unit.
- Set Stream 2 to command the Vessel Spray Ball and Return Scavenge Pump.
Configure phase synchronization points: Ensure the CIP supply pump cannot start until the vessel return valve confirms open status.

Step 4: Implement the Standard PCS 7 Unit Template (Alternative PCS 7 Approach)

If operating on pure SIMATIC PCS 7 with SIMATIC BATCH:
Download the official application package: PCS 7 Unit Template 'CIP - Cleaning in Place' (SIOS Entry ID 78463886).
Import the pre-configured CMTs, SFC Types, and BATCH equipment phases into your Master Data Library.
Map analog conductivity transmitters (Pcs7AnIn) to the phase transition triggers.
Compile CFC charts and OS.

Verification

Route Reservation Test: In BRAUMAT / PCS 7 OS Runtime, initiate a CIP test sequence on the Mash Tun. Verify that the valve matrix reserves the correct CIP supply path and locks out product valves.
Pump Interlock Check: Force a fault on the vessel return scavenge pump. Verify that the CIP supply pump interlocks and stops within 1 second, preventing vessel overfill.
Phase Advancement Verification: Inject a conductivity test value. Confirm that the sequence automatically advances from Prerinse to Caustic circulation when conductivity exceeds the target threshold (e.g., 45 mS/cm).

Limitations and Operational Precautions

Cross-Contamination Safeguards: Never rely solely on software interlocks for CIP safety; critical food, beverage, and pharma applications require physical mix-proof double-seat valves (VlvDsL) or mechanical swing-bend proximity switches.
Licensing: SIMATIC BRAUMAT requires dedicated SISTAR/BRAUMAT runtime and recipe licenses in ALM; PCS 7 implementations require SIMATIC BATCH and AS/OS RT PO licenses. Validate packages with an authorized Siemens distributor or the Siemens Industry Mall.

Engineer FAQ

Where is recipe streaming explained in the BRAUMAT manual?

In Chapter 7 (Section 7.3: Streaming and Cross-Streaming) of the SIMATIC BRAUMAT/SISTAR V7.5 Manual.

What is a Cross-Stream in BRAUMAT?

A recipe mechanism that synchronizes two independent equipment units (such as a CIP kitchen and a brewing vessel) within a single coordinated recipe.

What is the official Siemens PCS 7 CIP application template?

The PCS 7 Unit Template 'CIP - Cleaning in Place' published under SIOS Entry ID 78463886.

Can BRAUMAT run on S7-1500 controllers?

Yes, BRAUMAT V7.5 and V8.0 support SIMATIC S7-1500 controllers (e.g., CPU 1518-4 PN/DP) as well as classic S7-400 controllers.

How are CIP phases typically triggered?

By elapsed time, reached temperature, and inline chemical concentration measured via conductivity sensors.

How do I prevent cleaning chemicals from entering product lines?

By implementing mutual routing exclusions in LINE_BLOCK/ROUTE_BLOCK and utilizing mix-proof double-seat valves (VlvDsL).

Can multiple vessels be cleaned simultaneously?

Yes, if the CIP plant features multiple independent supply and return lines (e.g., CIP Line 1 and Line 2).

What block models equipment units in BRAUMAT?

The UNIT_BLOCK (FB100 series in BRAUMAT) models vessels and operational units.

Does the PCS 7 CIP template use SIMATIC BATCH?

Yes, the PCS 7 Unit Template is structured around SIMATIC BATCH recipes and SFC Types.

Where can I find Braumat technical documentation?

On Siemens Industry Online Support under Entry ID 109758240.

Technical References

Related Tags

BRAUMAT
CIP
SISTAR
Cleaning in Place
S7-1518
Unit Template
Brewery Automation

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Integrating CIP Units and Routing with Process Vessels in BRAUMAT and SIMATIC PCS 7