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.

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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

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Flow Rate vs. Flow Velocity

volume per second

1 second

inside diameter

v=
Where,

4.Q 3600.d .
meters per second m3 per hour dimensionless meters
2

v = flow velocity Q = flow rate = pi (3.1415,) d = inside pipe diameter

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Velocity vs flow

1.5 m/s velocity Pipe size ID mm Litres / sec DN 50 47 2.6

2.0 m/s velocity Litres / sec 3.5

DN 80

77

6.9

9.3

DN 100

97

11.1

14.8

DN150
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147

25.5

33.9

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

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Sprayball Placement

180 - Depth of Sprayball = Dome Height + D tan 2

Depth of Sprayball
140

Dome Height
Where, = angle of coverage, D = diameter of vessel, Dome height degrees meters meters

Sprayball

Dome Weld
NOTE: This is valid for simple vessels without obstructions. Additional sprayballs may be required.

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example

100 gpm

15

6 dia.
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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

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Vertical vessel flow requirements - sprayballs

Flow as a function of diameter and soil

QR = required flow rate DT = vessel diameter p = pi (3.1415,) FS = soil factor

liters per minute meters dimensionless liters/(meter-minute)

FS = 27 for light soil conditions FS = 30 for medium soil conditions FS = 32 for heavy soil conditions
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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

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

water effluent energy

chemical electrical heat

CO2 production time

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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
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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.

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processing plant in the CIP circuit, we need to know its volume

too.

Vessel Hold-up Volume

Assume a 2 millimeter film thickness (0.002 m)

Dome
Assume a completely wetted surface

Determine internal surface area

Dome Cylinder Cone

Cylinder

Cone

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Vessel Hold-up Volume

Area of Dome:

Area of Cylinder:

Area Dome = r

Area Cylinder = D h2

h2 h1

Area of Cone

1 2 2 Area Cone = D D + h1 2 4

NOTE :

r =

1 D 2

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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

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

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