MECHANICS BUILDING KITCHEN CIP CLOGGED DRAIN

L | C | LOGISTICS PLANT MANUFACTURING AND BUILDING FACILITIES EQUIPMENT

Engineering-Book

ENGINEERING FUNDAMENTALS AND HOW IT WORKS

September 2014

Expertise in Process Engineering Optimization Solutions & Industrial Engineering Projects Management 

Supply Chain Manufacturing & DC Facilities Logistics Operations Planning Management

Freezer ComponentsHow it Works

A freezer works by drawing the heat out of the freezer compartmentTo start the process, the refrigerant in gas form goes into the compressor where the compression process causes it to get very hotThe hot gas moves through more coils and starts to cool off. This causes the gas to turn into a liquid. Gas is forced into an expansion valve while in the liquid formThis valve has a very small opening which--when the refrigerant is forced through it--turns into a very cold mist

As the mist goes through the coils under the freezer compartment, it starts to evaporate and turn back into a gasThe temperature of the mist is around -27 degrees at this point, and it takes the heat from the freezer compartment with it

The refrigerant starts to warm up again as it draws out the heat, and it is sent back to the compressor to start the process over againEach time the refrigerant goes through it cycle, it takes more heat from the freezer compartment until there is none leftThis is what leaves you with frozen food

Freezer ComponentsThermostats and Refrigerants

The thermostat detects the temperature inside the freezer compartment and tells the compressor when to come on

This is why you will sometimes hear the freezer cycle on and off. This is also one of the most common repairs needed on a freezer

If the thermostat doesn't work, the freezer will either keep running or not come on at all

The freezer system is sealed, and you should never see refrigerant. Freon and pure ammonia are highly toxic and should not be handled by anyone who is not certified to do so

A refrigerator maintains a temperature a few degrees above the freezing point of waterOptimum temperature range for perishable food storage is 3 to 5 °C (37 to 41 °F)A similar device that maintains a temperature below the freezing point of water is called a freezer

Freezer ComponentsA vapor compression cycle is used in most household refrigerators, refrigerator–freezers and freezers. In this cycle, a circulating refrigerant such as R134a enters a compressor as low-pressure vapor at or slightly above the temperature of the refrigerator interior

The vapor is compressed and exits the compressor as high-pressure superheated vapor. The superheated vapor travels under pressure through coils or tubes that make up the condenser; the coils or tubes are passively cooled by exposure to air in the room

The condenser cools the vapor, which liquefies. As the refrigerant leaves the condenser, it is still under pressure but is now only slightly above room temperature

This liquid refrigerant is forced through a metering or throttling device, also known as an expansion valve (essentially a pin-hole sized constriction in the tubing) to an area of much lower pressure

Freezer ComponentsThe sudden decrease in pressure results in explosive-like flash evaporation of a portion (typically about half) of the liquid

The latent heat absorbed by this flash evaporation is drawn mostly from adjacent still-liquid refrigerant, a phenomenon known as auto-refrigeration

This cold and partially vaporized refrigerant continues through the coils or tubes of the evaporator unit

A fan blows air from the refrigerator or freezer compartment ("box air") across these coils or tubes and the refrigerant completely vaporizes, drawing further latent heat from the box air

This cooled air is returned to the refrigerator or freezer compartment, and so keeps the box air cold

Freezer Components

Freezer Components

Freezer Components

Freezer Components

Freezer Components

Freezer Components

Freezer Components

Freezer Components

Freezer Components−18 °C (0 °F) (freezer)0 °C (32 °F) (meat zone)5 °C (41 °F) (cooling zone)10 °C (50 °F) (crisper) [ ] : min temperature = −6 °C (21 °F). Maximum storage time for (pre-frozen) food is 1 week∗[ ] : min temperature = −12 °C (10 °F). Maximum storage time for (pre-frozen) food is 1 month∗∗[ ] : min temperature = −18 °C (0 °F). Maximum storage time for (pre-frozen) food is between 3 ∗∗∗and 12 months depending on type (meat, vegetables, fish, etc.)[∗ ] : min temperature = −18 °C (0 °F). Maximum storage time for pre-frozen or frozen-from-fresh ∗∗∗food is between 3 and 12 months

Many modern refrigerator/freezers have the freezer on top and the refrigerator on the bottomMost refrigerator-freezers—except for manual defrost models or cheaper units—use what appears to be two thermostats. Only the refrigerator compartment is properly temperature controlled

When the refrigerator gets too warm, the thermostat starts the cooling process and a fan circulates the air around the freezer. During this time, the refrigerator also gets colder

Freezer ComponentsThe freezer control knob only controls the amount of air that flows into the refrigerator via a damper system Changing the refrigerator temperature will inadvertently change the freezer temperature in the opposite direction. Changing the freezer temperature will have no effect on the refrigerator temperature

The freezer control may also be adjusted to compensate for any refrigerator adjustment. This means the refrigerator may become too warm

However, because only enough air is diverted to the refrigerator compartment, the freezer usually re-acquires the set temperature quickly, unless the door is opened

When a door is opened, either in the refrigerator or the freezer, the fan in some units stops immediately to prevent excessive frost build up on the freezer's evaporator coil, because this coil is cooling two areas

Freezer ComponentsWhen the freezer reaches temperature, the unit cycles off, no matter what the refrigerator temperature is. Modern computerized refrigerators do not use the damper system. The computer manages fan speed for both compartments, although air is still blown from the freezer

A few manufacturers offer dual compressor models. These models have separate freezer and refrigerator compartments that operate independently of each other, sometimes mounted within a single cabinet

Each has its own separate compressor, condenser and evaporator coils, insulation, thermostat, and door. Typically, the compressors and condenser coils are mounted at the top of the cabinet, with a single fan to cool them both

This design, where no air passes between the two compartments, provides for more appropriate humidity levels and much tighter temperature control in each compartment. It also requires much less energy to operate, since each compressor & coolant system can be optimized for a specific temperature range. Further, opening the door of one compartment does not affect the temperature of the air or humidity level in the other compartment

COLD ROOM

COLD ROOM

COLD ROOM

CIP ProcedureCIP (Cleaning In Place) is usually accomplished through the action of chemicals by spraying or pressure re-circulating the flushing, washing, and rinsing solutions under the controlled conditions of time, temperature and chemical concentration

The flushing solution is the first one to clear out the contents of the equipment to be CIP. At the end of flushing, chemical treatment starts. Usually an alkali (Sodium Hydroxide – NaOH) and a dilute acid (Hydrochloric Acid – HCL) form the chemical wash

The rinsing solution varies from soft water to Water For Injection (WFI). In a CIP system, the conductivity of the final rinse solution is checked to determine the cleanliness of the equipment subjected to CIP

Reaction Tanks & others can be effectively cleaned by distributing flush, wash and rinse solutions on the uppers surfaces at pumping rates equivalent to 7.5-10 LPM (Liter per Minute) per square feet of circumferential area (Internal) for vertical vessels and at 0.75 – 1 LPM per square feet of the internal surface for horizontal and rectangular tanks and other equipment such as mixers, bins, dryers, cyclones and centrifuges

CIP Procedure The CIP solution is either generated internally in the tanks subjected to CIP or mixed and circulated from a centralized CIP system. The solution after entering the equipment is re-circulated using a local pump which is normally called as Mobile CIP pump

After achieving the required cleanliness after each cycle, the solution is drained

The CIP solution is normally heated up to 70ºC for better clean ability. Detergent wash is also carried out according the requirement

The time taken for cleaning has to be validated and fixed according to each process

CIP ProcedurePiping Systems can be effectively cleaned via recirculation of flush, wash, and rinse solutions at a velocity of 1.5 meters per second or more in the largest diameter piping in the CIP circuit

This velocity is necessary to assure continuous movement of the air entrained in long horizontal runs

The time taken for cleaning has to be validated and fixed according to each process

The Piping system includes Filter Housings, Valves in the lines, pumps and the components like Heat Exchanger, Condensers and others. Filter cartridges are normally removed before the CIP of the Housings

CIP ProcedureThe control of in-place cleaning is a two part operation

The first involves managing the process itself to ensure that every part of the cleaning cycle is performed optimally. This does not normally involve any microbiological procedures; it consists of monitoring such things as time, temperature, detergent concentration, flow rates etc

The second part involves assessing whether the procedures have been effective and this is where microbiological controls are often used

By using data obtained in this way it is possible to ensure that the procedures used will be effective for cleaning and sterilizing the plant

For instance, measurements of time, temperature and causticity of a detergent can be used to ensure that the appropriate biocidal "dose" has been given to a piece of equipment

CIP ProcedureIn order to be able to control the process it is necessary to obtain information in real time such as:

cycle timessolution temperaturesflow ratespressures

Additionally, a wide range of chemical analyses can be used including:

detergent concentration (using conductivity)alkalinity (either in-line or off-line)specific chemical activities (e.g. sequestrant concentration)pHsoil load of detergent solution (this can be determined by measuring colour, suspended solids, tendency to foam etc.) causticity

CIP ProcedureMethods for Assessing Cleanliness of Plant

1.Visual Inspection. The only tools which are required are a small lens and a torch to help with the inspection

2. Final Rinse Sampling. Either a pressure spray is used to rinse a vessel and the liquid draining out collected and analyzed or, more usually, a sample of the final rinse from the CIP sequence is collected

Additionally the liquor used for the final rinse must itself be sterile or the test will be worthless. There are a number of ways of sterilizing this liquor, both physical (ultraviolet light, heat, filtration) or chemical (silver, ozone, chlorine dioxide, per acetic acid)

Where terminal sterilants are added it is vitally important that these are neutralized before any tests are carried out since the sterilant will continue acting in the test medium and give a false negative result

Final rinse samples can, of course, be assessed for the presence of product, chemical contamination or microbes but in all cases the contaminant materials must be either soluble or physically removed by the rinse if they are detected

CIP Procedure

Flow rate and flow velocity. The cleaning solution should be turbulent and not laminar flow in order to create that mechanical action

When you are cleaning vessels or tanks then we only need to consider flow rate and pressure.

CIP ProcedureChemical - This refers to the chemical energy, or oftentimes also referred to the concentration of the cleaning solution. The choice of the most appropriate detergent is determined by the following requirements: • - Rapid and complete solubility in water • - Rapid swelling and dissolving of specific soil components • - High sequestrate • - Good risibility • - Foam free or possibility to reduce foreign foam • - Good compatibility with the wetted parts of the equipment being cleaned - Corrosion safe! • - Biodegradable according to legislative requirements, with minimal effluent impact

Temperature - This refers to the thermal energy. The choice of temperature for cleaning will depend on: o - Heating facilities o - Difficulty of removing the soil o - Chemical formula of detergent o - The materials of construction of the plant / equipment being cleaned •10oC temperature increase doubles the detergent rate of reaction.

CIP ProcedureCoverage - cleaning without COVERAGE, is one very important element. Without good coverage then you can't even achieve good complete clean

Pressure - is defined as force per unit area. The SI unit of pressure is the Pascal (Pa), which is a very small unit, So for convenience, the bar is often used, where 1 bar = 1,000,000 Pa. One bar is approximately equal to 1 atmosphere. Also used are kilopascals (kPa) and mega Pascal (MPa), whereas the Imperial units are pounds per square inch (psi)

Temperature - is a very important property, because it will affect viscosity and alter reaction rates, which is important for chemical detergents. Temperature can simple be defined as the degree of hotness, it determines the direction of heat transfer: energy is transferred from high to a low temperature, and the rate of heat transfer (J/sec or W) is proportional to the temperature difference

Temperature control is important, and hotter is not always better. In this context , accurate temperature measurement and periodic calibration of thermometers are important. Energy is required in cleaning operations to bring detergents to the required temperature

CIP ProcedureVolumetric Flow rate - is defined as unit volume per time. the SI unit of volumetric flow rate is cubic meter per sec (m3/sec) and this will play a major role in the cleaning process. Not enough volumetric flow rate for a particular pipe line or vessel would mean insufficient cleaning.

where: v = velocity, m/sec Q = volumetric flow rate, m3/hr d = inside pipe diameter pi = 3.1416 (dimensionless) 3600 sec = 1 hour

CIP ProcedureLaminar and Turbulent Flow - When a fluid flows through a pipe, the flow is one of two possible types: Laminar (streamline) flow or turbulent flow. For cleaning operations and efficient heat transfer, turbulent flow is usually required. The type of flow can be distinguished by a dimensionless group known as the Reynolds number (Re): this represents the ratio of the internal forces to the viscous forces acting upon the liquid. When inertial forces predominate, the flow is turbulent, and when viscous forces predominate, the flow is streamline (laminar). If the Reynolds number is less than 2000, the flow is laminar; if it is greater than 4100, the flow is turbulent.

Fluid flow velocity - is defined as the distance traveled per time, (m/sec, feet/sec) this can be calculated using this equation:

Pipe CIP: Sub-laminar layer. The fluid velocity varies across the pipe diameter, high in the middle of the pipe, lower at the pipe wall due to friction, this is called the velocity profile

The fluid velocity at the surface of the pipe is always "zero" this liquid layer is called the sub-laminar layer or the non-slip condition

As the fluid velocity increases, the sub-laminar becomes thinner and soil on the pipe surface can be subjected to Mechanical Action, while the minimum required fluid velocity is 1.50m/sec for cleaning, inorder to satisfy the minimum required flow velocity at the sub-laminar layer of at least>0.30m/sec an ideal flow velocity of 1.80m/sec is highly recommended to compensate for flow velocity variations during the cleaning cycle

CIP Procedure

With this phenomenon, It is therefore wise to increase the fluid flow velocity to at least 1.80m/sec to ensure effective cleaning every time anytime

Of course this should be going along with the four other cleaning parameters, (time, chemical, temperature and coverage)

Many of the cleaning problems encountered in the factory are fluid dynamic issues, however, since the quickest parameter to change are temperature and detergent concentration

Without the required flow it will always follow in time that microbiological problems will occur. Potential bio-film formation may happen in the production lines and will certainly lead to product quality issues and a risk to food safety standards.

CIP ProcedureTurbulence in the cleaning solution would probably be around 75% of the CIP regime while 25% would be attributed to the chemistry behind the cleaning detergent

Mechanical energy (turbulence) is generated by a pump. This energy in the form of pressure energy is dissipated in the form of friction and turbulence inside the pipe to be cleaned

For CIP, the mechanical energy required is less than for the manual cleaning. Actions of manual cleaning, including scratching and brushing, require more energy than pumping

The mechanical energy is also more constant since CIP is not subjected to human intervention.

It is essential that the length of the dead ends do not exceed the equivalent of 2 times the pipe diameter when measured from the centre line of the pipe. If measuring from the outside of the pipe then a rule of 1.5 times the diameter should be used

CIP ProcedureUltrasonic sensor flow meter is installed at the floor of a channel or pipe; it sends out pulses or ultrasonic beams through the water and then back again. The beams travel through the water at a consistent rate, and then how speedily it comes back up to the sensor (taking into consideration the speed of sound in water) will be the measurement of how deep the water level is. An installation of a down-looking sensor can be done in the case of turbulent waters

An ultrasonic flow meter is a type of flow meter that measures the velocity of a fluid with ultrasound to calculate volume flow. Using ultrasonic transducers, the flow meter can measure the average velocity along the path of an emitted beam of ultrasound, by averaging the difference in measured transit time between the pulses of ultrasound propagating into and against the direction of the flow or by measuring the frequency shift from the Doppler effect

Ultrasonic flow meters are affected by the acoustic properties of the fluid and can be impacted by temperature, density, viscosity and suspended particulates depending on the exact flow meter. They vary greatly in purchase price but are often inexpensive to use and maintain because they do not use moving parts, unlike mechanical flow meters

CIP ProcedureUltrasonic flow meters measure the difference of the transit time of ultrasonic pulses propagating in and against flow direction. This time difference is a measure for the average velocity of the fluid along the path of the ultrasonic beam

By using the absolute transit times both the averaged fluid velocity and the speed of sound can be calculated

Using the two transit times and , and the distance between receiving and transmitting transducers and the inclination angle one can write the equations:

where is the average velocity of the fluid along the sound path and is the speed of sound

CIP Procedure

CIP Procedure

Clogged Drain RemovalPlungerSmear a layer of petroleum jelly around the edge of your plunger. This will help the plunger stick to the surface of the sink or toilet. Place the plunger over the opening in the clogged toilet or sink. If you have a second sink near the clogged sink, you will need to plug it up before you start plunging. Press down hard and quickly lift back up. Do this several times. If the water goes down, you have dislodged the clog. If the water remains, plunge a few more times. Move on to another method of clog removal if the plunging isn't successful

Baking Soda and VinegarUtilize an all-natural approach to removing clogged drains. Pour one-half cup of baking soda down the clogged drain. Next, pour one-half cup of vinegar down the drain. The baking soda and vinegar will react to each other and begin eating away the clog. Wait 15 minutes for the baking soda and vinegar to do their job and then pour a kettle full of boiling water down the drain. This will flush the area and get it clean again

Sewer SnakeSome stubborn clogs that are deep in the pipes can be removed by using a sewer snake. Take out any traps and slowly push your sewer snake down until it reaches the clog. Twist the snake clockwise to wrap the clog around the snake. Pull the snake back out to remove the material that clogged the drain, and toss the material in to the trash. Replace the traps you removed

Clogged Drain RemovalStore Bought ChemicalsChemical drain cleaners are sold in department and hardware stores. They contain such chemicals as sulfuric acid or lye. These chemicals quickly eat away at the material clogging up the drain. Pour the designated amount of drain cleaner as instructed on the product label down your drain. Wait the prescribed amount of time and flush clean with a kettle of boiling water

Pipe Disassembly ToolsIn some cases, there may be no alternative but to remove the toilet or disassemble the P-trap on a sink drain and manually remove the obstruction. You only need one tool to disassemble most drains or remove a toilet, and that is a set of slip-lock pliers. It serves the function of a wrench for unscrewing bolts and P-trap nuts and is also useful for gripping pipes to pull them apart. Besides the pliers, have a large slot screwdriver on hand to pry debris from inside the trap or toilet, and a flashlight so you can see what you're doing

Kitchen CleaningDaily Kitchen Chores

Clean up dishes, pots and pans after every meal (by either putting in dishwasher, or hand washingRun dishwasher as needed (and empty when clean, as needed)Wipe down kitchen counters, table, and stove top (you will also need to disinfect spills or food leakages)Empty trash canSweep kitchen floorChange out your kitchen towelsWipe up spills as they occur

Weekly Kitchen Chores

Clean out the refrigerator and freezer of older foodMop the kitchen floorCheck cleaning supplies, and restock as necessaryFlush kitchen drain with boiling water (helps keep drain clear and unclogged)Thoroughly disinfect kitchen counters and other food work surfacesTake out recycling

Kitchen CleaningMonthly Kitchen Chores

Clean coffee makerClean dishwasher, inside and outClean oven (may need to do less often, depending on the amount of use)Make sure pest control methods are working and properly suppliedClean kitchen sink drain with vinegar, baking soda and boiling waterClean inside refrigeratorWipe outside of kitchen appliancesUpdate pantry/freezer inventoriesWash kitchen rugsClean microwaveStraighten cabinets and drawersDust light fixturesWipe down areas that accumulate cooking grease with a degreaserClean garbage can

Kitchen CleaningClean coffee maker

•One of the many uses of vinegar is to clean up mineral deposits.•The mineral deposits in water can clog a drip coffee maker, and therefore the brewing mechanism of the coffee maker should be cleaned regularly, approximately once a month.•You may want to clean your machine more often if you use it all the time or if the water in your area is especially hard

Instructions

•Step 1: Fill the coffee carafe with equal parts white vinegar and water.•Step 2: Pour the mixture into the reservoir, put a fresh paper filter in the basket, and turn on your machine.•Step 3: After several cups have run through the machine (but before all of the cups of liquid have been made) turn it off, and let it sit for an hour or so.•Step 4: Turn the coffee maker back on, and let the cycle complete.•Step 5: Throw away the vinegar and water that is in the carafe.•Step 6: Run the coffee maker 1-2 more times through with plain water to completely remove all traces of the vinegar

Kitchen CleaningCleaning The Outside Of The DishwasherTo clean the exterior of your dishwasher use a clean, damp sponge with a mild detergent. After washing, make sure to rinse with a clean sponge to remove any soap residueWhen cleaning the outside of your dishwasher make sure you do not use too much water, or spray a cleaner directly on the controls, because you could wet down the controls or electronic portions of the machine causing damage

Using Vinegar To Clean The Inside Of Your DishwasherTypically, what needs to be cleaned inside a dishwasher is the residue of hardwater which builds up with extended useThe easiest way to do this is to use white vinegar. Vinegar is acidic in nature, and will naturally break down alkaline hard water depositsWith an empty dishwasher, place a bowl or cup filled with vinegar in the top rack and run it empty, WITHOUT detergentIf you do this every couple of months you will keep hard water deposits from building up in your dishwasher

Removing Detergent Stains From The Inside Door Of Your DishwasherIf you get a stain on the inside door of your dishwasher, looking like it is dripping down from your detergent dispenser, this is a sure sign that you are using too much dishwasher detergent each time you run your dishwasherTo avoid this problem in the future cut back on the amount of detergent used. You really don't need to fill the dispenser all the way to the top. Experiment with what works best for your dishwasher, but 1/2 to 3/4 full should be sufficientTo get the detergent stain out now, if the vinegar does not work, try rubbing the area with a sponge sprinkled with the same automatic dishwasher detergent causing the stain, and it should come out

Kitchen CleaningUses For All Purpose CleanersAll purpose cleaners are used to remove dirt and grease, and are generally mildThey are versatile because they can be used on so many types of surfaces However, they are not disinfectants

Homemade Disinfectant RecipeIngredients:•3/4 cup of chlorine bleach•1 gallon warm water•1 tablespoon powdered laundry detergent

Directions:Mix the ingredients listed above into a solution in a cleaning bucket.If you want to put your disinfectant cleaner in a labeled spray bottle you can then pour a portion of the solution into it, or reduce the amount of solution made proportionately, so it all can fit in the spray bottle.Make sure you use warm water because it will help completely dissolve the powdered detergent in the water and chlorine bleach solution

Kitchen CleaningAll Purpose Cleaner Recipe With AmmoniaIngredients:•1 tablespoon ammonia•1 tablespoon liquid laundry detergent (or dishwashing liquid)•1 pint waterAll Purpose Cleaner Recipe With Washing SodaIngredients:1/2 cup washing soda1 gallon warm waterAll Purpose Cleaner With Rubbing AlcoholIngredients:1 1/2 pints water1/3 cup rubbing alcohol (also known as isopropyl alcohol)1 tsp household ammonia (non-sudsing)1 tsp mild dishwashing liquid1/2 tsp lemon juiceVery Gentle All Purpose CleanerIngredients:2 cups water2 tablespoons dishwashing liquidDirections:Mix the solution into a spray bottle.This gentle cleaner can be used on hard surfaces to remove dirt and grease.For all four homemade cleaning recipes listed above rinse thoroughly after using them to cleanWarning: do not use this cleaner on fiberglass or aluminum

Thank You

L | C | LOGISTICS PLANT MANUFACTURING AND BUILDING FACILITIES EQUIPMENT

Engineering-Book

ENGINEERING FUNDAMENTALS AND HOW IT WORKS

MECHANICS BUILDING KITCHEN CIP CLOGGED DRAIN