mongoose33:
More than once, I've read "buy once, cry once" on this site, and I'm in full agreement.
I do intend to test some of my ideas, but I'm going to test them on some major parts that conform to how I discover the system should be built. We are in agreement.
It's 3 kettles up front, I'm certain. I'll forego the controller and software initially and manually use a digital thermometer, timer, etc to brew a few batches just to see what the process is like as you suggest. I just believe automation can only improve the outcome given a sequence of steps that the automation can control better than I can. Further, brewing isn't rocket science. I'm a reasonably intelligent guy and by educating myself and eventually trying different things with equipment in hand, I'm confident I can produce good beer as I've never failed at anything I set my mind to. It's the beer I'm after ultimately.
At some point, I intend to write up my design and ask people, experienced people, to shoot holes in it before I purchase anything. I don't know how well that will be received or if the effort will be worth it, so at the present I'm asking questions to try to guide some of my thoughts.
For example, I've decided to put the majority of the ports through the bottom of the kettles. Only the heating element is on the sidewall according to my thinking. I got that idea from BrunDog on this site and that one idea seriously changed my design. It opened up new possibilities and, of course, challenges even at the contemplation stage.
Ports in the bottom led me to remove the HERMS coil and just use a heat exchanger instead. The lack of side wall ports allows me to put removable insulation around the kettles easily to better control temperature. One thing leads to another. Should a show stopper come up, I'll have to back track.
Sounds like a sound plan.
While brewing isn't rocket science, there are a lot of moving parts, so to speak. Making beer is simple, making great beer not quite so much. I don't doubt you can get there, my suggestion was just to help accelerate the process.
I've done 30 batches now, 27 have been all-grain. I remember what it was like to be a newbie, but I'm also producing pretty good, very good, quite good beer. I think. People keep drinking it. I like it.
But I remember. Lotsa new terminology, like racking, sparging, wort, vorlauf, grant, HERMS, etc. etc. I think sometimes that was the hardest part, making those myriad new terms part of my working vocabulary.
Being able to buy high quality equipment at the outset can be a joy. I started with fairly good stuff, then over Christmas I upgraded the Kettle, Chiller, Burner, and Thermometer (Thermapen MK4). It might have made sense to do that at the beginning but truth be told, I didn't know enough to make that choice properly. It took nearly a year of brewing to get to the point where I
knew what I wanted. I'd have gone electric but don't have good access to 220 power where I brew, and we may be moving in a year or so, thus I didn't want to sink money into something I couldn't take along.
One thing I didn't see mentioned was a fermentation chamber. It is said, and I believe it, that the single biggest improvement new brewers can make is fermentation temperature control. The fanciest brew rig in the world (and yours sounds like it will be) can't overcome lack of fermentation temperature control resulting in a too-warm fermentation. Since your tap water is 90 degrees it seems unlikely you have a cool basement, so having a way to control the temperature of the fermenting wort is crucial. I use a refrigerator, many do, some a freezer, a few make their own.
The other consideration is whether you want to bottle or keg. Don't know if you've given that much thought or not. I bottled my first three batches, then said "screw this" and went to kegs. Built a keezer and now, if I want, I can bottle off the taps.
Anyway, I hope you can take some pics and post them as you do this. Should be fun!