cip cleaning in place - predict cip losses and costs we must know the cip circuit volume. this has...

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  • JohnsonDiversey

    CIP Cleaning in place

    The circulation of non foaming cleaners without dismantling

    the equipment.

    An automatic and systematic cleaning of the inner

    surfaces of tanks, heat exchangers, pumps, valves

    and pipes.

  • JohnsonDiversey

    CIP properties

    Strong and hot solutions can be used. The heat, the chemistry and the mechanics can be sustained long.

    The solutions can be reused.

    Can be automated and reproducibility is good.

    Investment in equipment is high.

    The mechanics are not always sufficient

  • JohnsonDiversey

  • JohnsonDiversey

    Flow Rate vs. Flow Velocity

    =

    ..3600

    .4

    2d

    Qv

    Where,v = flow velocity meters per secondQ = flow rate m3 per hour = pi (3.1415,) dimensionlessd = inside pipe diameter meters

    second 1secondper volume

    diameter inside

  • JohnsonDiversey

    Velocity vs flow

    1.5 m/s velocity 2.0 m/s velocityPipe size ID mm

    Litres / sec Litres / sec

    DN 50 47 2.6 3.5

    DN 80 77 6.9 9.3

    DN 100 97 11.1 14.8

    DN150 147 25.5 33.9

  • JohnsonDiversey

    Vertical vessel flow requirements - sprayballs

    Vertical vessels

    For most vessels, the sprayball delivers a uniform

    quantity of solution to the upper circumference of the

    vessel

    Based on soil level, deliver a given quantity of solution

    to a unit length of circumference - called liquid loading:

    Dont forget about flow OUT of vessels

  • JohnsonDiversey

    Sprayball Placement

    +=2

    -180tan D Height Dome Sprayball ofDepth

    Where, = angle of coverage, degreesD = diameter of vessel, metersDome height meters

    NOTE: This is valid for simplevessels without obstructions.Additional sprayballs may berequired.

    Depth of Sprayball

    Dome WeldSprayball

    Dome Height

    140

  • JohnsonDiversey

    example

    15

    100 gpm

    6 dia.

  • JohnsonDiversey

    Sprayball pressure

    Sprayball pressure is critical

    Generally in the range (1.0) 1.5 - 2.5 (3.0) bar

    Too little pressure and the vessel walls are not reached

    Too much and the spray atomises reducing mechanical

    action

    Larger sprayballs with larger hole diameters can operate

    at higher pressures without atomising.

    All sprayballs have specified flow / pressure curves

  • JohnsonDiversey

  • JohnsonDiversey

    Vertical vessel flow requirements - sprayballs

    Flow as a function of diameter and soil

    QR = required flow rate liters per minute

    DT = vessel diameter meters

    p = pi (3.1415,) dimensionless

    FS = soil factor liters/(meter-minute)

    FS = 27 for light soil conditions

    FS = 30 for medium soil conditions

    FS = 32 for heavy soil conditions

    SFTDRQ =

  • JohnsonDiversey

  • JohnsonDiversey

  • JohnsonDiversey

    High pressure rotary sprayheads

    Add impingement to the mechanical action

    Generally consume a little less water

    Have specific times to wet surfaces and impinge on them dependent

    on pressure and gearing

    Not very effective on larger vessels under 5 bar pressure

    Use similar data to specify as sprayballs

    Use manufacturers recommendations

    Toftejorg have a computer simulation

    program called TRAX - use it

  • JohnsonDiversey

    CIP Optimizing

    CIP optimizing is the process of minimizing the cost inputs of CIP

    cleaning

    water

    effluent

    energy

    chemical

    electrical

    heat CO2 production time

  • JohnsonDiversey

    Optimizing drivers

    CIP system design

    clean circuits - no dead legs, no flow splits

    accurate and non competing instrumentation - conductivity

    monitoring

    no leaks

    CIP program

    correct CIP program philosophy

    CIP preparation sequence - correct conductivity starting point

    tidy CIP fluids interface management - always in lines never in

    tanks

    correct valve sequencing on monitor signals

    defined terminators each CIP step

  • JohnsonDiversey

    CIP optimizing - circuit volume

    To predict CIP losses and costs we must know the CIP circuit volume.

    This has nothing to do with the size of the CIP tanks.

    It is the amount of liquid held up in the CIP headers and the vessel or line being

    cleaned.

    To calculate the circuit volume for a line clean we need to know the diameters of

    the lines and the length of each line size.

    To calculate the circuit volume of a vessel clean we need to know the line

    information and the dimensions of the vessel being cleaned.

    If there is other processing plant in the CIP circuit, we need to know its volume

    too.

  • JohnsonDiversey

    Vessel Hold-up Volume

    Assume a 2 millimeter film thickness

    (0.002 m)

    Assume a completely wetted surface

    Determine internal surface area

    Dome

    Cylinder

    Cone

    Dome

    Cylinder

    Cone

  • JohnsonDiversey

    Vessel Hold-up Volume

    Area of Dome:

    Area of Cylinder:

    Area of Coneh2

    h1

    D

    2DomeArea r=

    2CylinderArea hD=

    ( )212124ConeArea hDD +=

    Dr2

    1:NOTE =

  • JohnsonDiversey

    CIP optimizing - chemical loss management

    Liquid loss for an efficient vessel CIP system is about 10% of circuit volume.

    Line cleans can be run more efficiently than vessel cleans - as low as 5% loss.

    Effective loss management depends on:

    Effective Flow meter or conductivity interface detection.

    Managing liquid interfaces into pipes not vessels.

    When managing liquid changes in vessels the program must be stepped.

    New liquid to sprayball chasing old liquid into vessel.

    Over scavenge old liquid from vessel into return line.

    New liquid into vessel chasing old along return line to interface

    detector.

    First step should be volumetric and set for each vessel.

  • JohnsonDiversey

    CIP optimizing - chemical loss management

    measured as % of concentrate detergent lost compared to the concentrate

    detergent in the CIP circuit volume

    concentrate detergent lost is calculated by CIP tank, volume and

    concentration, before and after CIP

    concentrate detergent in circuit volume calculated as the volume of solution

    held in the CIP circuit excluding the CIP tank at the starting concentration

  • JohnsonDiversey

    The CIP flow is best circulated bypassing the CIP tanks with theheating and chemical dosing in line

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