CIP Training Series CIP Chemical Control Chemical Dispensing

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CIP Training Series CIP Chemical Control Chemical Dispensing and Control Equipment For Clean-In-Place Systems

CIP Training Series CIP Chemical Control Chemical Dispensing and Control Equipment For Clean-In-Place Systems Used by the Food Processing Industry Training For Sanitation Consultants and Plant Personnel

CIP System Audit For Chemical Control Dispensing Equipment Design z From this training module

CIP System Audit For Chemical Control Dispensing Equipment Design z From this training module you will learn the basics behind engineering/selecting the appropriate CIP detergent and sanitizing dispensing equipment. z Optimal control of the CIP system chemical program

CIP System Audit For Chemical Control Dispensing Equipment Design Goals via the plant audit

CIP System Audit For Chemical Control Dispensing Equipment Design Goals via the plant audit z Collect the necessary information to configure the dispensing equipment that best fits the food facilities needs. z Collect the necessary information to consistently control the concentrations in the proper ranges. z Design/Build dispensing and control equipment specifically for each application (CIP system).

CIP System Audit For Chemical Control Dispensing Equipment Design Goals z We want to

CIP System Audit For Chemical Control Dispensing Equipment Design Goals z We want to avoid poorly engineered and operated CIP systems. This is an example of a neglected CIP unit

CIP Tanks Volume Measurement General CIP Tank Data z Re-use or single-use system? z

CIP Tanks Volume Measurement General CIP Tank Data z Re-use or single-use system? z Number and identify of all CIP tanks. y Chemical/wash CIP tanks y Rinse, recovery (rinse reclaim), etc. z Determine volume capacity and actual fill volumes (measure in inches) y d = diameter, h = height: y Cylindrical: (Within ~2% error) x Vgal. = 0. 5 x (d/12)2 x h x Measure/calculate for hcapacity and h. CIP Solution fill x [Input in inches, volume output in gallons] y Square: x Vgal. = (l x w x h)/231 x Calculate for hcapacity and h. CIP Solution fill x [Input in inches, volume output in gallons]

CIP Tanks Volume Measurement When the CIP tank volumes and the concentrations required are

CIP Tanks Volume Measurement When the CIP tank volumes and the concentrations required are known: z Determine the volume of chemical required to charge the tanks at the set point concentration. z For large CIP tanks (V ≥ 500 gal. ): initial charge via panel push button may be needed even though tank may be probed (optional).

CIP Chemical Products Number of chemical products z What are the total number of

CIP Chemical Products Number of chemical products z What are the total number of products dispensed to a CIP unit? z Include CIP detergents, additives (chlorine, chelants, defoamers), and sanitizers. z Feed point of chemical products? z If replacing the current dispensing and control equipment, can improvements be made in product choice and chemical control?

Type of Controlled By Conductivity? z CIP detergents that contribute significant electrical conductivity can

Type of Controlled By Conductivity? z CIP detergents that contribute significant electrical conductivity can be probed. y Alkali (chelated caustic) y Chlorinated alkaline cleaner (CAC) y Acid products z Cleaning additives are not probed y Defoamers y Chelates or other water conditioners

Chemical Control CIP Detergents & Additives How will each cleaning chemical be controlled? z

Chemical Control CIP Detergents & Additives How will each cleaning chemical be controlled? z Time-based or conductivity or both? z Anderson Chemical panels may have: y Conductivity: Delay timer and relay y Time-based: Run timer and delay timer y Latest equipment installs: Smart Relays z CIP Detergent (Caustic, CAC, Acid) y Can be conductivity or time y Enzyme detergent program-timed only z Additives (Chlorine, Defoamers, Chelants) y Timed feed only y Chlorine - may be desirable to have cycle timer dispense at timed intervals during CIP cycle. (More fine-tuned control, especially for soiled circuits. )

Chemical Control Sanitizer Who controls sanitizer dosing? z Controlled by food facility CIP system

Chemical Control Sanitizer Who controls sanitizer dosing? z Controlled by food facility CIP system PLC (programmable logic controller)? z Controlled by sanitation company equipment (via “Antrol panel”)? z If sanitizer inject times programmed into customers PLC, do preset times vary by equipment cleaned and lines? y Obtain sanitizer inject times for each circuit on the CIP system. Often PLC is programmed with preset times for each sanitize step and time of dosing. y If CIP PLC can’t control times, Antrol panel must be designed with the capability z What is sanitizer control based on? y Flow rate and once-through with air blow? y Once-through but no air-blow? y Recirculated based on CIP volume? y Timed feed in-line inject typical

Control Panel Basic Setup z Equipment department configures the panel (layout, buttons, wiring, etc.

Control Panel Basic Setup z Equipment department configures the panel (layout, buttons, wiring, etc. ) based on collected information. z Does the customers CIP system microprocessor control all pumps, times, and conductivity? y Full control—then sanitation company provides only the pumps. y If not, equipment we design/build will need to provide the control. No matter the chemical control design, Safety features, such as an emergency “Stop”, are often built into the control panel

Control Panel Basic Setup Panel Buttons z How are the solutions to be charged

Control Panel Basic Setup Panel Buttons z How are the solutions to be charged and boosted? Determine for each chemical. z Simplest control is a stand alone system, no probes. Charge and boost buttons only, timers in panel. z Boost buttons (panel timers) for additives (chlorine), or, can be done automatically (Anderson’s Antrol panel timer energized by customer’s PLC signal in CIP mode). z Typically the Antrol panel has charge buttons on the panel front—for initial chemical charge of the CIP tank(s) (due to periodic draining of dirty solutions and a fresh water recharge). y Probes can bring concentration to set point. y If probe energized in CIP mode—then it may be best to use a button for large CIP tanks due to time lag of probed addition. z Probed control is best (in-line) - this will be covered in further slides

Control Panel Dispensing Equipment Chemical Control and Safety z Any variation of equipment design

Control Panel Dispensing Equipment Chemical Control and Safety z Any variation of equipment design for CIP systems can be built for product control and dispensing z Design safety into control panel y Color coded buttons match product safety classification and product label color codes z Panel faces with color coded control buttons: y y Blue-Alkali Red-Acid Yellow-Chlorinated Green-p. H neutral

Control Panel Equipment Examples Chemical Control - 3 Examples z z z PLC controls

Control Panel Equipment Examples Chemical Control - 3 Examples z z z PLC controls concentrations (food facility PLC controls conductivity) Stand alone panel using push buttons and timers (no probes) Panel with its own conductivity control (sanitation supplier controls) PLC of CIP system controls chemical concentrations. Push buttons charge chemical after CIP tanks are refilled with fresh makeup water Push button control for CIP chemical dispensing. Stand alone panel—no CIP system PLC interface Chemical panel controls conductivity, charges to all freshly refilled CIP tanks and chemical boosts. Panel is energized from PLC of CIP unit during CIP mode

Control Panel Equipment Examples Continued Chemical Control - CIP system has all conductivity control

Control Panel Equipment Examples Continued Chemical Control - CIP system has all conductivity control functions z The sanitation supplier does not provide any of the controls z The sanitation supplier only installs the air pumps for the cleaning products and sanitizer z The caustic and acid wash solution conductivities are setpoints that are inputted into a CIP screen. In-line and tank conductivity probes signal if chemical is needed during CIP washes y Probes must be calibrated to read the proper conductivity (u. S or m. S) y Proper concentrations validated/verified during CIP using appropriate chemical concentration test kits z The CIP system PLC controls all chemical pumps. Preset times for sanitizer times, etc. are set by operator interface with the PLC touch screen.

Type of Control Signaling/Probes Control Design New installs use Idec “Smart Relays” y No

Type of Control Signaling/Probes Control Design New installs use Idec “Smart Relays” y No longer use timers or PLC’s, Smart Relay handles these functions y Each Smart Relay can handle 6 inputs and 4 outputs for single-stroke pump y Double-stroke pumps require 2 Smart Relays (2 outputs used per pump) Smart relay wired to front Panel face buttons controlling Chemicals by timer. Inside Antrol CIP chemical dispensing and control panel showing Smart Relay, air regulator & air solenoids for control of multiple air/diaphragm dispensing pumps.

Type of Control Conductivity Design-Probes z In-the-tank probes y Drop in probe (top) y

Type of Control Conductivity Design-Probes z In-the-tank probes y Drop in probe (top) y Bayonet probe (side-wall) y Locate bayonet in tank side-wall close to bottom y Consider hydraulic balance during CIP—large CIP volume tanks with bottom probes may cause overfeed due to delay in read of probe y Potential overfeed if contact energized continually (not only during CIP mode)—little mixing occurs of dispensed chemical at top of tank (unless circulation or in-tank steam on). y Generally 2 probes max. —alkaline cleaner (or chlorinated alkaline cleaner—CAC), and acid

Type of Control Conductivity Design-Probes z In-line probes y Button probe (if cap fitting

Type of Control Conductivity Design-Probes z In-line probes y Button probe (if cap fitting on pipeline) y Bayonet probe (if customer supplied long tee on pipeline) - these are an improvement over button probes y Locate on CIP return line near CIP system tanks (validation of return conductivity) y Locate on CIP supply pump discharge-side y Mount on vertical section of pipe or flooded zone of horizontal pipe (flooded for properation) Button type Bayonet types

Type of Control Signaling/Probes Designing conductivity control z For in-tank probes avoid overfeed situation.

Type of Control Signaling/Probes Designing conductivity control z For in-tank probes avoid overfeed situation. y If probe out of solution, it can not signal the conductivity. y Option is too have a low level alarm that shuts down the CIP. y Install probe below level of low level alarm. y Should have proper CIP system design, allowing control/operation that provides proper volume balance in CIP tanks, avoiding too low volume (below probe). Level control probes or DP control should prevent too low tank levels. z Option of panel manual selector switch (alkali-acid, high-low alkalinity examples). y y One in-line probe can be used. Generally prefer no selector switch as it is one more thing that can lead to manual error.

Type of Control Signaling/Probes Designing conductivity control Continued… z Does the Antrol panel require

Type of Control Signaling/Probes Designing conductivity control Continued… z Does the Antrol panel require conductivity probes and transmitters or does the customer have their microprocessor control conductivity? z If the panel control is supplied by the food facility (i. e. , CIP system supplier), does the sanitation supplier install a probe or does the CIP system come equipped with a probe? z Plant CIP unit may be equipped with an in-line conductivity meter. y May have an output that could allow sanitation company to control conductivity by its panel. (versus food facilities control—via their CIP PLC or microprocessor) x Allows simple access to concentration control/adjustment.

Type of Control Optimal CIP System Design For Both Conductivity Control and CIP Validation

Type of Control Optimal CIP System Design For Both Conductivity Control and CIP Validation z Wash solution probes are often located on the supplyside piping (after the CIP system CIP supply pump). z Do not control CIP solutions for long line circuits on the return piping. The long delay time will lead to chemical overfeed (excessive delay time until the probe “sees” the solution). z Mount the control probe on the CIP supply piping. z A return probe is used to validate CIP concentrations (to a PC terminal, for example). z Alternatively, a return probe can be used to control the solution concentration if a time delay is programmed after the start of the wash step; the probe then controls the solution after it “sees” the chemical solution (this setup may not be preferred). z Most preferred - Have both supply and return in-line conductivity probes. The CIP supply probe is the default reading/control probe; the CIP return probe is the CIP validation probe. z Also preferred - Have a return in-line conductivity probe (validation) together with an in-tank probe (control). [Various working options are possible—The programmer could set up default control to the return probe too, once the CIP flow has circulated for a required period of time. ]

Type of Control Signaling/Probes Control Design z Single CIP wash tank (alkaline or CAC)

Type of Control Signaling/Probes Control Design z Single CIP wash tank (alkaline or CAC) y y Typical conductivity control of CIP detergent May have automatic timer control of chlorine Boost button for chlorine as needed Probe must be in-line, as CIP solution may bypass the CIP tank during vessel CIP (not lines CIP) z Two CIP wash tanks y Alkaline (or CAC) and acid conductivity control is most preferred y May prefer automatic timed additions per circuit wash y Typical automatic timer control of chlorine y Boost buttons could be done, but often neglected and poor control may result

Conductivity Control of Cleaning Chemicals Electronics Typical method to control alkaline or acid CIP

Conductivity Control of Cleaning Chemicals Electronics Typical method to control alkaline or acid CIP products (i. e. , probe control) - when supplied by Anderson Chemical Co. ü Conductivity control from transmitters z y Signet 8850 controller Model 8850 -2 (conductivity/resistivity transmitter) Digital readout— x x Conductivity display in u. S or m. S and temperature compensation 316 stainless steel probes

Conductivity Control of Cleaning Chemicals Transmitter Electronics z Signet 8850 controller y y Two

Conductivity Control of Cleaning Chemicals Transmitter Electronics z Signet 8850 controller y y Two controllers in one—can set 2 concentration set points, 2 relays, 2 probes (if want separate probes), and 2 outputs Can use just one probe for both caustic (or CAC) and acid control (in-line applications) Can be used for in-tank probes (each CIP tank has a controller) Use with Signet probes x Various control ranges cover 1 up to 400, 000 u. S (typically use 100 -200, 000 u. S probe)

Conductivity Control of Cleaning Chemicals Transmitter Electronics z Signet 8860 controller y This controller

Conductivity Control of Cleaning Chemicals Transmitter Electronics z Signet 8860 controller y This controller may be used for in-tank conductivity control or for both CIP supply and CIP return conductivity having two separate relay setups (4 programmable displays). x x x y Input the setpoint for acid conductivity Set the other relay for control of alkalinity conductivity The CIP system PLC “tells” the controller which wash step the CIP program is in (alkaline or acid) and which relay setting to use. Capabilities x x x 2 -Channel input and simultaneous display (u. S or m. S) Three 4 - 20 m. A outputs and 4 programmable displays, a selector switch activates two open collector outputs in place of two of the relays for output versatility Time delay relay function

Dispensing Pumps Chemical feed (pumps) required z Air pumps (air-operated diaphragm) z Single or

Dispensing Pumps Chemical feed (pumps) required z Air pumps (air-operated diaphragm) z Single or double-stroke air pumps z PP or Kynar y Hypochlorite (10 -12. 5% neat) requires Kynar y Peracetic acid (~6% and higher) requires Kynar y CAC and other chemicals use PP (polypropylene), but prefer Kynar y May be advisable to use all Kynar pumps for chlor alkali, nitric-based acids, chlorine and peracetic acid, since it’s easier to stock just one plastic type and Kynar outperforms PP y Graco pumps available in Kynar-1/4” or 1/2” y Double-stroking are accurate for timed applications (and are used for conductivity too) z For New Installations y Anderson Chemical uses the Husky 205 doublediaphragm pump for CIP systems y [Note: Peristaltic (old technology for CIP)]

Dispensing Pumps Technical Specifications z Graco Husky 205 air pump is reliable and accurate

Dispensing Pumps Technical Specifications z Graco Husky 205 air pump is reliable and accurate y CIP Cleaners y CIP Sanitizers

Dispensing Pumps Performance Curve z Graco Husky 205 air pump performance curve

Dispensing Pumps Performance Curve z Graco Husky 205 air pump performance curve

Physical Layout Equipment Location of panels, pumps, piping, etc. z Where can the panel

Physical Layout Equipment Location of panels, pumps, piping, etc. z Where can the panel be mounted for easy access? y On a wall or structural support? y Block wall, stainless, other? Affects type of fasteners used. z Best location of chemicals is in a dedicated CIP room with ample space for chemicals, control panels, and pumps. z Is there a nearby chemical storage room with proper utilities (electrical, air). Configure chemical lines/piping to location of CIP system. z May locate chemical barrels/pumps near CIP system in production area as final alternative. Try to avoid water/chemical spray! z Discuss equipment options and needs with food facility managers and personnel (prior to final install!). They may have preferences. z Discuss equipment location, mounting. z Available utilities (air, electricity) at proposed location? If not, what would this require?

Engineering Details Tubing Piping (tubing, fittings, checks, etc. ) z What is the distance

Engineering Details Tubing Piping (tubing, fittings, checks, etc. ) z What is the distance from the chemical pumps to the CIP system? z What is dispensing tubing/piping material. y y PP polytubes, nylabraid, PVC, CPVC? 1/2” dia. polytube standard Long distances use 5/8” polytube or 3/4” hard pipe Stainless may be required for certain products for long-term safety (or, run polytube lines in stainless conduit for safety and professional appearance) z Do the solutions dispense to the CIP tank or in-line? PP (polypropylene) tubes and PP fittings

Engineering Details Point of Injection Check Valves Product check Valves y Prevents siphoning into

Engineering Details Point of Injection Check Valves Product check Valves y Prevents siphoning into CIP tanks or CIP line at point of injection. y CIP tank chemicals: Use simple ball or diaphragm checks at line termination. In some cases, positive shutoff (air-to-open spring-to-close checks may be needed at chemical line termination at CIP tank).

Engineering Details Sanitizer Checks z Diaphragm checks, air-operated diaphragm checks, and ball checks often

Engineering Details Sanitizer Checks z Diaphragm checks, air-operated diaphragm checks, and ball checks often used (and others). z For sanitizers air checks provide best control (air-to-open, spring-to-close) at in-line feed point y Other check valves (such as ball checks) can leak and siphon acid sanitizers; leakage into circulating chlorinated alkaline cleaning solutions during the alkaline wash CIP mode can cause corrosive and toxic chlorine gas. Acid sanitizer injected into suction-side of CIP pump piping Example of check without air operation

Engineering Details Sanitizer Checks z Ball checks can leak and are not recommended. y

Engineering Details Sanitizer Checks z Ball checks can leak and are not recommended. y Require proper mounting for gravity to pull ball to the seat (flow direction up). y Pressure is required to seat ball exactly to the seat —require some reverse flow and pressure. z Diaphragm checks seal in any mounting position or flow condition; normally-closed. z Air-operated diaphragm checks are used by Anderson Chemical for a tight consistent seal. (Use stainless nipples to avoid check cracks) Plast-O-Matic air check on suction-side of CIP supply pump

Engineering Details Sanitizer Throttling/Control z Needle valves are often used to fine tune the

Engineering Details Sanitizer Throttling/Control z Needle valves are often used to fine tune the sanitizer concentration y Locate on the outlet port or discharge-side of the sanitizer air-operated dispensing pump. This is the preferred location. y Also can locate above the air-operated check valve mounted on the nipple fitting on the suction-side of the CIP supply pump piping. Needle valves on outlet ports

Engineering Details Piping, Fittings, Supports z Sanitizer feed points, may have more than one

Engineering Details Piping, Fittings, Supports z Sanitizer feed points, may have more than one CIP supply pump, requires additional set of checks, etc. z Anti-siphon fittings for drum pickup tubes. z Check valves for air pump outlet lines. y Prevent draining of chemical feed lines during pump maintenance or replacement. Or, can rely on check at CIP tank. z New installs: Control panel and pumps mounted on same PP mounting board. y Depends on space available. y No PP board if panel separated from pumps. z Need feed line supports from pumps to the CIP tanks? No sagging lines! y Do not attach to steam lines! y Always prefer stainless conduit (with more than enough diameter—to ensure it can accommodate plastic chemical lines for long run lengths and for any elbows/bends, etc. ).

Engineering Details Tubing, Piping Tubing and Supports z Run 1/2” polytubing to the CIP

Engineering Details Tubing, Piping Tubing and Supports z Run 1/2” polytubing to the CIP tanks. Longer distances require the 1/2” diameter tubing (braided tubing can also be used for additional durability and elimination of potential kinking). z Attach (tie wrap) the tubing to permanent fixtures. Be careful not to kink the polytubing. z Do not attach tubing to hot pipes. z May be desirable to run tubing inside of PVC (or even stainless) piping for safety and improve appearance of installation y 4 -6” diameter (or as needed) for polytube in ss conduit y Avoid ss elbows in some cases for installation ease Polytube outlet from air-op pumps Polytube inlet to air-op pumps Air line to panel air solenoids

Engineering Details Additional System Setup System Prime, Setup, and Calibration z Mount the solenoid

Engineering Details Additional System Setup System Prime, Setup, and Calibration z Mount the solenoid panel (if used) and pumps in the vicinity of the chemical drums. The system may or may not have an additional solenoid panel. z Mount the Antrol control panel in the vicinity of the CIP system. Connect 1/4” air lines from the control panel to the solenoid panel. Connect 1/4” air lines from the solenoid panel to the air pumps. z Run 1/2” tubing from the air pumps to the PVC drum pickup tubes. (Note: the polytubing inserted into the drum pickup piping has check valves to hold solution when changing out chemical drums). [Other options: Colder Products Co. Drum. Quick® Pro] z Run tubing from the discharge side of the air pumps to the CIP tank locations. At the discharge of the polytubing insert a check valve. This is done at the point of injection to eliminate the potential for product draining out of the lines. z Run the tubing from the sanitizer pump to the suction side of the CIP supply pump. Install a check valve and/or air solenoid valve as needed. A needle valve can also be installed for additional control.

Engineering Details Additional System Setup System Prime, Setup, and Calibration z Calibrate the output

Engineering Details Additional System Setup System Prime, Setup, and Calibration z Calibrate the output of the sanitizer air pump (speed and stroke) and/or needle valve, based on the output required to achieve the sanitizing concentration. The volume output and time of dispensing may depend on each circuit (tank and/or pipeline) and the CIP controller inputs (such as flow rate). z Note: The water flow rate (gpm) may vary per circuit. As a starting point use 100 gpm flow. The dispensing volumes depend also on the method of sanitizing— either once-through and air blow, “chase rinse” method of CIP operation, or recirculation of the sanitizing solution. z Prime all product pumps to fill the polytubing. Turn on the Antrol control panel and follow the proper priming procedure. z The initial tank charges and recharges (chemical maintenance), if based on time instead of conductivity, will need to be calibrated for each pump. Collect the pump discharge from the end of the polytubing at the CIP tanks. Adjust the pump output timing in this manner until the volumes are correct.

Startup and Testing Quick Performance Checklist New Equipment Installations ü ü Be on site

Startup and Testing Quick Performance Checklist New Equipment Installations ü ü Be on site for startup. Check for properation and control. Are pumps coming on? Any leaks? Test solution concentrations during CIP mode. Adjust settings. ü Fine tune as required. ü Check CIP system programming for improvements. ü Example: Rinse times too long or too short. ü Check CIP system for mechanical problems. ü Valves not working? ü Poor hydraulic balancing? ü Etc.

CIP Training Thank you for your time! Questions?

CIP Training Thank you for your time! Questions?