Juice Batch Room Three Tank CIP System
Fresh Water CIP Tank (South)
(Refer to Figure 1)
The Fresh water CIP tank is used to supply all the water for the CIP rinse steps. Any time that the CIP system is enabled, water enters this tank via the liquid control valve 3-LCV-133. Two digital level probes control the level in this tank: 3-LSH-133 and 3-LSL-133. When the water level drops below the low level probe 3-LSL-133 the water valve 3-LCV-133 opens allowing the tank to be filled. When the water level reaches the high level probe 3-LSH-133 the water valve 3-LCV-133 is shut.
Wash Recovery CIP Tank (Middle)
(Refer to Figure 1)
The Wash recovery CIP tank is used to supply the wash solution for the CIP wash steps. Any time that the CIP system is enabled, water enters this tank via the liquid control valve 3-LCV-132. Two digital level probes control the level in this tank: 3-LSH-132 and 3-LSL-132. When the solution level drops below the low level probe 3-LSL-132 the water valve 3-LCV-132 opens allowing the tank to be filled. When the solution level reaches the high level probe 3-LSH-132 the water valve 3-LCV-132 is shut.
This tank also has a Conductivity probe, which monitors the Conductivity level of the tank’s solution. During a CIP wash step, the solution is discharged thru the drain valve 3-FV-142 to the CIP pump 3-BPM-15. If the solution’s conductivity is low acid or caustic (depending on the type selected) is pumped into the solution.
After the solution is treated, it is heated, and then sent to whichever system that is to be cleaned. The returning solution’s temperature is monitored by 3-TT-134, and then passes thru 3-FV-123, thru
3-FV-124, then back to the Wash recovery tank.
Rinse Recovery CIP Tank (North)
(Refer to Figure 1)
The Rinse recovery CIP tank is used to supply all the water for the CIP Hot Rinse steps. When a Hot rinse step is enabled the Rinse tank’s discharge valve 3-FV-141 opens. If the tank level is low the Fresh water tank’s discharge valve 3-FV-143 also opens. Water is then pumped thru the CIP pump
3-BPM-15, heated then sent to whichever system that is to be rinsed. The returning water’s temperature is monitored by 3-TT-134, and then passes thru 3-FV-123, back to the Rinse recovery tank.
Two digital level probes control the level in this tank: 3-LSH-131 and 3-LSL-131. When the water level reaches the high level probe 3-LSH-131 the Fresh water tank’s discharge valve 3-FV-143 closes. Anytime the water level drops below the low level probe 3-LSL-131 the Fresh water tank’s discharge valve 3-FV-143 opens allowing the tank to be refilled.
Fresh Water Tank’s Drain Valve (3-FV-143)
(Refer to Figure 1)
The Fresh water CIP tank’s Drain Valve 3-FV-143 will open if the Fresh Water Dump and the Manual Dump selector switches are selected in the CIP Control Panel. It will open Automatically during any cold rinse or post rinse steps, or if the Rinse Recovery Tank is in use and it’s level is low. (See Rinse Tank Recovery Tank on Page A-1)
Wash Recovery Tank’s Drain Valve (3-FV-142)
(Refer to Figure 1)
The Wash Recovery Tank’s Drain Valve 3-FV-142 will open if the Wash Tank Dump and the Manual Dump selector switches are selected in the CIP Control Panel. It will open Automatically only during Step-2 of a 5-Step Acid or Detergent CIP cycle.
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Rinse Recovery Tank’s Drain Valve (3-FV-141)
(Refer to Figure 1)
The Rinse Recovery Tank’s Drain Valve 3-FV-141 will open if the Rinse Tank Dump and the Manual Dump selector switches are selected in the CIP Control Panel. It will open Automatically during any Hot Rinse Step.
Acid Pump Solenoid (3-ASV-137)
(Refer to Figure 1)
If a 5-Step Acid CIP is selected an air solenoid valve 3-ASV-137 is used to activate the Acid Pump. The pump is used to pump acid into the solution during Step-2 (CIP Wash). If the conductivity level measured in the Wash recovery tank is less than 4.4 mS. the Acid pump will be enabled. Two timers in the Batch room’s PLC control the acid pump’s solenoid. These timers cycle the acid pump solenoid ON for 60 seconds then OFF for 120 seconds until the conductivity level in the Wash recovery tank is greater than 4.4 mS.
Caustic Pump Solenoid (3-ASV-136)
(Refer to Figure 1)
If a 5-Step Caustic CIP is selected an air solenoid valve 3-ASV-136 is used to activate the Caustic Pump. The pump is used to pump caustic into the solution during Step-2 (CIP Wash). If the conductivity level measured in the Wash recovery tank is less than 4.0 mS. the caustic pump will be enabled. Two timers in the Batch room’s PLC control the caustic pump’s solenoid. These timers cycle the caustic pump solenoid ON for 60 seconds then OFF for 180 seconds until the conductivity level in the Wash recovery tank is greater than 4.0 mS.
C.I.P. Pump (3-BPM-15)
(Refer to Figure 1)
The CIP pump will run, anytime Hand is selected. It will run in Auto, anytime the CIP system is enabled and any of the three tank’s drain valves (3-FV-141, 3-FV-142, or 3-FV-143) are open. The pump is used to pump the water/solution from the tanks thru the Shell and Tube Heat Exchanger to whatever system is being cleaned.
Shell and Tube Heat Exchanger
(Refer to Figure 1)
The Shell and Tube Heat Exchanger is used to heat the water/solution during certain CIP Steps. The CIP pump 3-BPM-15 pumps the water/solution thru the Heat Exchanger to whichever system is being cleaned. The Steam Flow Valve 3-FV-127 will open if: the CIP Step requires heating, the CIP pump is running, and there isn’t a temperature alarm.
RTD 3-TT-129 controls the Steam Flow Control Valve 3-ASV-129 thru a PID in the Batch room’s PLC. Different setpoints are set in the PID depending on the CIP Step requiring heat.
Temperature Detection
(Refer to Figure 1)
The system has two RTD Temperature Sensors 3-TT-129 and 3-TT-134. The RTD sensor
3-TT-129 senses the temperature of the water/solution leaving the Heat Exchanger. It controls the water/solution’s temperature thru a PID in the Batch room’ PLC. The Taylor recorder’s Red pen in the CIP Control Panel records this temperature.
The RTD sensor 3-TT-134 senses the temperature of the water/solution returning from the system being cleaned. It is used to determine when to start the timing of certain CIP steps. The Taylor recorder’s Green pen in the CIP Control Panel records this temperature.
An alarm bit will be set if the temperature sensed by either RTD sensor is less than 30 F, (This is to sense a broken wire or bad RTD) or greater than 211F. The alarm bit will reset when the temperature is within the proper limits.
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Cold Rinse CIP
Step 1 – Cold Rinse (First Rinse)
(Refer to Figure 1)
When the Flovert piping and all swing elbows are set properly for the system that is to be cleaned the Cold rinse CIP can be started. When the operator selects the Cold Rinse CIP and presses the start pushbutton in the CIP control panel the Batch room’s PLC will start filling the Fresh water tank, if needed. The Cycle timer will be set to 2 minutes and the Cycle timer will start. The steam is left off.
The discharge valves for the Rinse Recovery Tank 3-FV-141 and the Fresh Water Tank 3-FV-143 open, and the water is pumped thru the Heat Exchanger to the selected system to be cleaned.
The returning water flows thru the three 3-way flow control valves 3-FV-123, 3-FV-124 and
3-FV-125 (All denergized) so the water flows to the drain. This cycle will continue until the Cycle timer has timed out. When the Cycle timer has timed out the PLC step counter increments to Step-2.
Step 2 – Cold Rinse (Final Rinse)
(Refer to Figure 1)
The Cycle timer will be set to 15 minutes and the Cycle timer will start. The steam is left off.
The discharge valve for the Rinse Recovery Tank 3-FV-141 open, and the water is pumped thru the Heat Exchanger to the selected system to be cleaned. The Fresh Water Tanks discharge valve 3-FV-143 will open only if the Rinse Recovery Tank’s level is low.
The returning water flows thru the 3-way flow control valve 3-FV-123 back into the Rinse Recovery Tank. This cycle will continue until the Cycle timer has timed out. When the Cycle timer has timed out all valves will denergize and the CIP pump will stop. This concludes the Cold Rinse CIP.
3-Step Hot Rinse CIP
Step 1 – Hot Rinse (First Rinse)
(Refer to Figure 1)
When the Flovert piping and all swing elbows are set properly for the system that is to be cleaned the Hot rinse CIP can be started. When the operator selects the Hot Rinse CIP and presses the start pushbutton in the CIP control panel the Batch room’s PLC will start filling the Fresh water tank, if needed. The Cycle timer will be set to 2 minutes and the Cycle timer will start. The steam is left off.
The discharge valves for the Rinse Recovery Tank 3-FV-141 and the Fresh Water Tank 3-FV-143 open, and the water is pumped thru the Heat Exchanger to the selected system to be cleaned.
The returning water flows thru the three 3-way flow control valves 3-FV-123, 3-FV-124 and
3-FV-125 (All denergized) so the water flows to the drain. When the Cycle timer has timed out the PLC then steps to Step-2.
Step 2 – Hot Rinse
(Refer to Figure 1)
The Cycle timer will be set to 30 minutes but the Cycle timer will not start. The setpoint for the water temperature is set to 195 F.
The discharge valve for the Rinse Recovery Tank 3-FV-141 opens, and the water is pumped thru the Heat Exchanger to the selected system to be cleaned. The Fresh Water Tanks discharge valve 3-FV-143 will open only if the Rinse Recovery Tank’s level is low. Once the CIP pump is running the steam valves will energize. The temperature RTD 3-TT-129 controls the temperature of the water by modulating the steam valve 3-ASV-129 thru a PID in the Batch room’s PLC.
The returning water flows past the RTD 3-TT-134 thru the 3-way flow control valve 3-FV-123 back into the Rinse Recovery Tank. When the water temperature sensed by 3-TT-134 is greater than
184 F the Cycle timer will start. If at any time during this Step the temperature sensed by 3-TT-134 is less than 182 F the Cycle timer will reset to zero. When the Cycle timer has timed out, the steam will be turned off. The PLC then steps to Step-3.
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3-Step Hot Rinse CIP
Step 3 – Hot Rinse (Final Rinse)
(Refer to Figure 1)
The Cycle timer will be set to 2 minutes and the Cycle timer will start. The steam is left off.
The discharge valve for the Rinse Recovery Tank 3-FV-141 opens, and the water is pumped thru the Heat Exchanger to the selected system to being cleaned. The Fresh Water Tanks discharge valve 3-FV-143 will open only if the Rinse Recovery Tank’s level is low.
The returning water flows thru the 3-way flow control valve 3-FV-123 back into the Rinse Recovery Tank. When the Cycle timer has timed out all valves will denergize and the CIP pump will stop. This concludes the Hot Rinse CIP.
5-Step CIP (Acid/Detergent)
The only difference in the two 5-step CIP Processes is the selection of the chemical pumps, and the conductivity levels for the Wash Step. When a 5-Step Acid CIP Process is selected the minimum conductivity level is 4.2 mS. When a 5-Step Detergent (Caustic) CIP Process is selected the minimum conductivity level is 3.8 mS.
5-Step CIP
Step 1 – 5-Step CIP (First Rinse)
(Refer to Figure 1)
When the Flovert piping and all swing elbows are set properly for the system that is to be cleaned the 5-Step CIP can be started. When the operator selects either the 5-Step Acid or the 5-Step Detergent CIP and presses the start pushbutton in the CIP control panel the Batch room’s PLC will start filling the Fresh water tank, and the Wash Recovery Tank, if needed. (See Page A-1) The Cycle timer will be set to 2 minutes and the Cycle timer will start. The steam is left off.
The discharge valves for the Rinse Recovery Tank 3-FV-141 and the Fresh Water Tank 3-FV-143 open, and the water is pumped thru the Heat Exchanger to the selected system to be cleaned.
The returning water flows thru the three 3-way control valves 3-FV-123, 3-FV-124 and
3-FV-125 (All denergized) so the water flows to the drain. When the Cycle timer has timed out the PLC steps to Step-2.
Step 2 – 5-Step CIP (Wash cycle)
(Refer to Figure 1)
The Cycle timer will be set to 30 minutes but the Cycle timer will not start. The setpoint for the water temperature is set to 155 F.
The discharge valve for the Wash Recovery Tank 3-FV-142 opens, and the solution is pumped thru the Heat Exchanger to the selected system to be cleaned. If the conductivity of the solution in the Wash Tank is low the chemical pump will add solution. (See Page A-2) Once the CIP pump is running the steam valves will energize. The temperature RTD 3-TT-129 controls the temperature of the water/solution by modulating the steam valve 3-ASV-129 thru a PID in the Batch room’s PLC.
The returning water/solution flows past the RTD 3-TT-134, thru the denergized 3-way control valve 3-FV-123, thru the energized 3-way valve 3-FV-124 back into the Wash Recovery Tank.
If the conductivity level in the Wash Recovery Tank is greater than the minimum limit, and the water temperature sensed by 3-TT-134 is greater than 144 F the Cycle timer will start. If the conductivity level should fall below it’s minimum limit, the chemical pump will add solution, but the Cycle timer will reset to zero. Any time during this Step the temperature sensed by 3-TT-134 is less than 144 F the Cycle timer will reset to zero.
When the Cycle timer has timed out, the Wash Tank’s discharge valve 3-FV-142, closes. The two
3-way valves 3-FV-123 and 3-FV-124 denergize, the chemical pump is disabled, and the steam is turned off. The PLC then steps to Step-3.
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5-Step CIP
Step 3 – 5-Step CIP (Post Rinse)
(Refer to Figure 1)
The Cycle timer will be set to 2 minutes and the Cycle timer will start. The steam is left off.
The discharge valve for the Rinse Recovery Tank 3-FV-141 opens, and the water is pumped thru the Heat Exchanger to the selected system to being cleaned. The Fresh Water Tanks discharge valve 3-FV-143 will open only if the Rinse Recovery Tank’s level is low.
The returning water flows thru the three 3-way flow control valves 3-FV-123, 3-FV-124 and
3-FV-125 (All denergized) so the water flows to the drain. When the Cycle timer has timed out the PLC then steps to Step-4.
Step 4 – 5-Step CIP (Hot Rinse)
(Refer to Figure 1)
The Cycle timer will be set to 30 minutes but the Cycle timer will not start. The setpoint for the water temperature is set to 195 F.
The discharge valve for the Rinse Recovery Tank 3-FV-141 opens, and the water is pumped thru the Heat Exchanger to the selected system to be cleaned. The Fresh Water Tanks discharge valve 3-FV-143 will open only if the Rinse Recovery Tank’s level is low. Once the CIP pump is running the steam valves will energize. The temperature RTD 3-TT-129 controls the temperature of the water by modulating the steam valve 3-ASV-129 thru a PID in the Batch room’s PLC.
The returning water flows past the RTD 3-TT-134 thru the 3-way flow control valve 3-FV-123 back into the Rinse Recovery Tank. When the water temperature sensed by 3-TT-134 is greater than
184 F the Cycle timer will start. If at any time during this Step the temperature sensed by 3-TT-134 is less than 182 F the Cycle timer will reset to zero. When the Cycle timer has timed out, the steam will be turned off. The PLC then steps to Step-5.
Step 5 – 5-Step CIP (Final Rinse)
(Refer to Figure 1)
The Cycle timer will be set to 2 minutes and the Cycle timer will start. The steam is left off.
The discharge valve for the Rinse Recovery Tank 3-FV-141 opens, and the water is pumped thru the Heat Exchanger to the selected system to being cleaned. The Fresh Water Tanks discharge valve 3-FV-143 will open only if the Rinse Recovery Tank’s level is low.
The returning water flows thru the three 3-way flow control valves 3-FV-123, 3-FV-124 and
3-FV-125 (All denergized) so the water flows to the drain. When the Cycle timer has timed out all valves will denergize and the CIP pump will stop. This concludes the 5-Step CIP.
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