Evaluation of Costly & Common CIP System Problems
We, as customers, believe that when a CIP system is installed, and line and tank circuits are set up to be cleaned, everything is balanced for optimum efficiency. However, considering the many components that go into a modern CIP system, numerous factors need to be evaluated on each circuit to insure that it operates as efficiently and cost effectively as possible. Over time, plants grow and changes are made to lines and equipment which can negatively affect the operational efficiency of CIP systems.
Some common examples of negative effects on CIP systems:
o Reduced cleaning effectiveness
o Waste of expensive chemicals
o Increased energy demand
o Unnecessary water usage
o Loss of production due to extended cleaning time
These changes normally occur gradually, allowing them to go unnoticed, while significantly impacting the bottom line. Dividends returned on higher efficiency are not only financial, but environmentally sound as well. Water conservation saves money and conserves limited resources while reducing effluent volume. Smaller discharge volume results in lower disposal costs and less strain on the sewage infrastructure. Reduced energy consumption not only saves money it produces a smaller carbon footprint.
In order to locate these negative changes or problems and regain lost efficiency, each circuit must be observed and evaluated independently. Plant personnel rarely have the necessary training, resources or experience to perform these evaluations.
Following is a partial list of common problems inherent to CIP systems resulting from plant operation and expansion.
CIP Tanks:
o Level controls drift out of calibration and wash tank does not re-fill before sending solution to drain resulting in wasted wash solution on each circuit.
o Chemical feed sensors develop a scale coating or drift out of calibration resulting in wash concentration being either too high or too low
o Time feed systems become damaged resulting in chemical concentration below set point.
o Steam traps stick open on heat exchangers resulting in increased steam usage, wasting energy and extending circuit time.
o Steam traps fail to open totally resulting in delayed attainment of temperature set point and extended circuit time.
CIP Supply Pumps:
o Pump seals leak causing cavitation, reducing flow rate resulting in less than turbulent flow through lines and insufficient flow to spray balls.
o Incorrect impeller replacement lowers capacity resulting in less than turbulent flow through lines and insufficient flow to spray balls.
o Flow meters drift out of calibration resulting in less than turbulent flow through lines and insufficient flow to spray balls.
Line Circuits:
o New sections of larger diameter pipe are added to existing line circuits resulting in less than turbulent flow in new section.
o Lines are added to existing circuits creating higher head loss resulting in diminished flow rate and loss of turbulent flow.
o Lines are added to existing circuits and sanitizer feed time is not extended resulting in sections of line not receiving adequate sanitizer.
Tank Circuits:
o Spray balls are installed incorrectly, or incorrect spray balls are installed resulting in shadowing and dead spots in tanks.
o Flow rate is set too high resulting in spray atomizing and loss of mechanical action.
o Flow rate is set too low resulting in umbrella spray not impacting walls of tank correctly.
o No filter on supply line resulting in plugged spray devices causing dead spots on tank walls, agitators or baffles.
Return Pumps:
o Incorrect impeller replacement lowers capacity resulting in return flow reduction causing solution to build up in vessel and extending circuit time.
o Air eliminator gaskets wear allowing return pump to cavitate resulting in reduction in return flow, causing solution to build up in vessel and extending circuit time.
o Length is added to return lines causing higher head loss resulting in reduction in return flow, causing solution to build up in vessel and extending circuit time.
o New tanks with higher flow demands are added to existing return pump resulting in a miss-match between supply and return flow on existing tanks.
CIP system evaluation and optimization is a specialty at J White Enterprises. We look forward to working with you on retuning your systems to optimum efficiency.
