Post on 19-Jun-2018
2589-B CMF Automated CIP Skid Project Page 1 of 25
TABLE OF CONTENTS
GENERAL DESCRIPTION ............................................................................................................................................ 2
COMPONENT SPECIFICATIONS ............................................................................................................................... 3
MANUFACTURER'S COMPONENTS .................................................................................................................................... 3 DETAILS CP-0008 ........................................................................................................................................................... 4
Tanks: ......................................................................................................................................................................... 4 CIP Surge Tank Mounted Components: ..................................................................................................................... 5 CIP Supply Components: ........................................................................................................................................... 6 Steam and Condensate Components: ......................................................................................................................... 7 Air Blow Components: ............................................................................................................................................... 8 CIP Return Components: ........................................................................................................................................... 8 Chemical Injection Components: ............................................................................................................................... 9
DETAILS CP-0007 ........................................................................................................................................................... 9 Tanks: ....................................................................................................................................................................... 10 CIP Surge Tank Mounted Components: ................................................................................................................... 11 CIP Supply Components: ......................................................................................................................................... 11 Steam and Condensate Components: ....................................................................................................................... 12 Air Blow Components: ............................................................................................................................................. 13 CIP Return Components: ......................................................................................................................................... 14 Chemical Injection Components: ............................................................................................................................. 15
CONTROLS DESCRIPTION ....................................................................................................................................... 16
SYSTEM CONTROLS ....................................................................................................................................................... 16 MAIN CONTROL PANEL ................................................................................................................................................. 16
Motor Control Equipment: ....................................................................................................................................... 16 Low Voltage Equipment: .......................................................................................................................................... 16 Pneumatic Equipment: ............................................................................................................................................. 17
REMOTE CONTROL PANELS ........................................................................................................................................... 17 Remote Panel for Room 122: ................................................................................................................................... 18 Remote Panel for Room 129: ................................................................................................................................... 18 Remote Panel for Room 263: ................................................................................................................................... 19 Remote E-stop for Room 273: .................................................................................................................................. 19 Remote Panel for Room 274: ................................................................................................................................... 20
SYSTEM ASSEMBLY & FABRICATION ................................................................................................................. 20
ASSEMBLY SPECIFICATIONS .......................................................................................................................................... 20 SANITARY PROCESS PIPING ........................................................................................................................................... 21 SANITARY WELDING ..................................................................................................................................................... 22 STEAM PIPING ............................................................................................................................................................... 23 CONDENSATE PIPING ..................................................................................................................................................... 23 COMPRESSED AIR PIPING............................................................................................................................................... 23 PIPING INSULATION ....................................................................................................................................................... 23 HANGERS AND SUPPORTS .............................................................................................................................................. 24 ELECTRICAL WIRING ..................................................................................................................................................... 24 EXPOSED CONDUIT ........................................................................................................................................................ 24 CONDUIT FITTINGS ........................................................................................................................................................ 24 LIQUID TIGHT FLEXIBLE METAL CONDUIT .................................................................................................................... 24 PNEUMATICS ................................................................................................................................................................. 25 UTILITIES REQUIRED ..................................................................................................................................................... 25
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GENERAL DESCRIPTION
Each CIP system will be single-tank in design with solutions returned via gravity and/or return
pumps installed near/on the equipment being serviced. The IPEC scope of supply for each
system includes the following major components and deliverables:
Water/recirculation tank.
CIP supply pump.
Chemical metering pumps.
CIP supply heat exchanger.
Tank vent filter with heating jacket.
Clean air filter.
Skid framing, hardware and supports.
CIP system control panel.
CP-0007 CIP supply and return valve manifolds
CP-0007 CIP return pump
Remote HMI panels with cutouts for interface terminals and programming.
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COMPONENT SPECIFICATIONS
Manufacturer's Components
The following is a detailed list of manufacturer's components that have been included in this
proposal. The manufactures will be as listed or that of an approved equal manufactures
supply.
Tanks ----------------------------------------------------------------- T&C Stainless
Spray Ball Assemblies ------------------------------------------------------- IPEC
No-Foam Inlet Assemblies -------------------------------------------------- IPEC
Sanitary Centrifugal Pumps ----------------------------------------------- Fristam
Motors ------------------------------------------------------------------------- Baldor
Pumps (metering) --------------------------------------------------------------- LMI
Heat Exchangers --------------------------------------------- Allegheny Bradford
Valves Sample ------------------------------------------------------------------- ITT
Valves/Actuators (diaphragm) ------------------------------------------------ ITT
Valves/Actuators (ball) -------------------------------------------------------- SFV
Valves (gate) ------------------------------------------------------------------- Velan
Valves (globe) ----------------------------------------------------------------- Velan
Valves Control (temperature) ---------------------------------------------- Fisher
Valves Pressure Reducing (clean air) ------------------------------------- Fisher
Valves Pressure Reducing (instrument air) ---------------------------- Fairchild
Valves Pressure Relief (utility) ------------------------------------------- Kunkle
Valves Pressure Relief (clean air) ------------------------------------------ Farris
Valves Check (sanitary) ------------------------------------------------ Check-All
Valves Check (utility) --------------------------------------------------------- Vogt
Vacuum Breakers -------------------------------------------------- Bell & Gossett
Filters/heaters (tank vent) ------------------------------------------------------ Pall
Filters (air blow) ---------------------------------------------------------------- Pall
Strainer (utility) ------------------------------------------------------ Spirax Sarco
Steam Traps ----------------------------------------------------------- Spirax Sarco
Flow meters (mass) ------------------------------------------------- Micro Motion
Flow Switches ---------------------------------------------------- Endress+Hauser
Level Switches (chemical containment) ------------------------------ Lumenite
Level Probes/Transmitters (CIP tank) --------------------------------------- MTS
Level Probes/Transmitters (chemical tank) -------------------------------- MTS
Level probes/Transmitters (guided wave optioned) --------- Endress+Hauser
Rupture Disc/BDI ------------------------------------------------------------ BS&B
Conductivity Elements/Transmitters ----------------------------------- Thornton
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Temperature Elements-------------------------------------------------------- Weed
Temperature Transmitters -------------------------------------------- Rosemount
Pressure Elements/Transmitters ---------------------------------------- Anderson
Pressure Switches (sanitary) -------------------------------------------- Anderson
Pressure Switches (utility) -------------------------------------- Endress+Hauser
Pressure Gauges (sanitary) ---------------------------------------------- Anderson
Pressure Gauges (utility) ------------------------------------------------- Ashcroft
Control Enclosures -------------------------------------------------------- Hoffman
Control Panels ----------------------------------------------------------------- IPEC
Disconnect Switches ------------------------------- Allen-Bradley 1494V Series
Variable Frequency Drives ---------------------- Allen-Bradley PowerFlex 70
Circuit Breakers (single-pole) ------------------------------------------- Square D
Power Transformers ------------------------------------------------------------ Sola
Power Supplies ------------------------------------------------------------------ Sola
Relays ----------------------------------------------------------------- Allen-Bradley
PLC Hardware -------------------------------------- Allen-Bradley ControlLogix
Pushbuttons ---------------------------------------------------------- Allen-Bradley
Air Filters/Regulators-------------------------------------------------------- ASCO
Solenoids (for valve actuation) ------------------------------------------------ Mac
Valves (pneumatic disconnect)----------------------------------------------- SFV
Transfer Panels (optional) --------------------------------------------------- IPEC
Transfer Panel Proximity Switches (optional) -----------------Telemecanique
Bar Code Scanner (optional) ------------------------------- Data Logic Firescan
Details CP-0008
The following is a detailed list of major components that will be provided with the system.
Tanks:
1 – CIP Surge Tank with the following specifications:
Total Capacity: Approximately 540 liters.
Working Capacity: Approximately 500 Liters.
Approximate Dimensions: 30" ID x 36" OD x 43" side sheet.
Materials of Construction: 316L Stainless steel on wetted and 304L stainless
steel on non-wetted surfaces.
Top Head: 10 Gauge, standard ASME dished.
Sidewall: 10 Gauge
Bottom Head: 10 Gauge, standard ASME dished.
Jacket: None
Insulation: 2" Ceramic fiber on sidewall.
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Insulation Sheath: 12 Gauge
Supports: Three (3) pipe legs with raw ends for skid mounting.
Accessories: Grounding and lifting lugs, vortex breaker and clipboard holder.
Finish, Inside: 20Ra-EP with welds polished to the same finish as the parent
metal.
Finish, Outside: 35Ra with welds polished to the same finish as the parent
metal.
Design: 45PSIG/FV @ 150º C ASME code stamped.
Service: Atmospheric.
Ports:
Top Head:
1 – 12" Sanitary hinged and gasketed manway
2 – 3" Sanitary clamp ferrules for WFI supply sprayball assembly
mounting
1 – 3" Sanitary clamp ferrule for PW supply sprayball assembly
mounting
1 – 3" Sanitary clamp ferrule for spare.
1 – 4" Sanitary clamp ferrule for CIP return no-foam assembly
mounting
1 – 2" Sanitary clamp ferrule for level probe mounting
1 – 2" Sanitary clamp ferrule for level switch mounting
1 – 1½" Sanitary clamp ferrule for vent filter mounting
1 – 1½" Sanitary clamp ferrule for rupture disc mounting
Bottom:
1 – 2" Sanitary flush mount tank bottom valve mounting pad.
CIP Surge Tank Mounted Components:
2 – WFI water inlet 316L stainless steel sprayball assemblies each with 2" diameter
ball, 360° x 72/25 spray pattern welded to a 1" down tube with sanitary clamp
connections and a 3" sanitary clamp tank connections. The sprayball assemblies
will be pinned after riboflavin testing.
1 – PW water inlet 316L stainless steel sprayball assembly with 2" diameter ball,
360° x 72/25 spray pattern welded to a 1" down tube with sanitary clamp
connection and a 3" sanitary clamp tank connection. The sprayball assembly will
be pinned after riboflavin testing.
1 – 3" Sanitary clamp cap, gasket and clamp for spare port.
1 – 316L stainless steel CIP return no foam inlet assembly with 2" downtube,
sanitary clamp connection and 4" sanitary clamp tank mounting connection. The
no foam inlet assembly includes a 45 offset inside the tank to direct solution to
the sidewall and designed so it can be easily removed from the tank.
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1 – 2" Sanitary magnetostrictive level probe with 316L stainless steel wetted parts,
sanitary float and sensor pipe, sanitary clamp connection and integral 4-20 mA
transmitter
1 – 2" Sanitary magnetostrictive high-high level probe with 316L stainless steel
wetted parts, sanitary float and sensor pipe, sanitary clamp connection and
integral 4-20 mA transmitter
1 – 1½" Sanitary vent filter assembly with sanitary clamp connections, .2-micron
PVDF element and electric heat jacket with temperature sensor and controls.
1 – 1½" Rupture disc with burst disc alarm strip, 10% manufacturing tolerance, 316L
stainless steel construction and down tube assembly.
1 – 2" Flush bottom tank outlet diaphragm valve with forged 316L stainless steel
body, 20 Ra-EP ID/35 Ra OD finish and sanitary clamp style outlet connection,
coupled to a pneumatic air to open/spring to close actuator with Teflon
faced/EPDM backed diaphragm.
CIP Supply Components:
1 – 1½" Sanitary clamp cap, gasket and clamp for passivation port.
1 – 2½" x 2" Sanitary centrifugal style CIP supply pump sized for 50 GPM @ 57
PSIG. The pump includes 316L stainless steel construction, 20 Ra-EP wetted
surface finish, ¾" case drain, single carbon vs. silicon carbide internal seal and
sanitary clamp connections, close coupled to a 7.5 HP, 3600 RPM, 3 phase, 60
hertz, 230-460 VAC inverter duty motor.
1 – ¾" CIP supply pump casing drain diaphragm valve with forged 316L stainless
steel body, 20 Ra-EP ID/35 Ra OD finish and sanitary clamp connections,
coupled to a pneumatic air to open/spring to close actuator with Teflon
faced/EPDM backed diaphragm.
1 – 1½" Sanitary clamp cap, gasket and clamp for passivation port.
1 – 2" Sanitary pressure transducer with integral 4-20 mA indicating transmitter and
sanitary clamp connection.
1 – ¾" Chemical loop flow orifice. The orifice will be installed in the chemical
slipstream to provide reduced pressure and flow through the chemical loop and
include a low-point hole to ensure complete drainage.
1 – 2" Heat exchanger bypass flow orifice. The orifice will be installed in the heat
exchanger bypass piping with a low-point slot to ensure complete drainage of the
heat exchanger.
1 – Sanitary shell and tube heat exchanger with the following specifications.
Duty: Heat 50 GPM of CIP solutions from 20˚C to 90ºC in multiple passes,
utilizing approximately 100 pounds per hour of saturated steam supplied to
the system at 100 PSIG.
Single shell, 2-pass U-tube, ASME "UM" code stamped design.
316L Stainless steel tube side and 304 stainless steel shell.
2589-B CMF Automated CIP Skid Project Page 7 of 25
Insulation with 304 stainless steel jacket.
20 Ra-EP internal and 35 Ra external finishes.
2" Sanitary clamp tube side connections.
1", 150# RF Flange steam inlet.
1", 150# RF Flange condensate outlet.
¾" FNPT vent connection.
1 – 2" CIP supply conductivity sensor with sanitary clamp connection and remote 4-
20 mA transmitter.
1 – 2" CIP supply temperature probe with sanitary clamp connection and remote 4-20
mA indicating transmitter.
1 – 1½" Sanitary mass flow meter with sanitary clamp connections and integral 4-20
mA indicating transmitter.
1 – 2" x 1" Sterile access CIP supply/air-blow isolation diaphragm valve assembly,
with forged 316L stainless steel body, 20 Ra-EP ID/35 Ra OD finish and butt
weld connections, coupled to a pneumatic air to open/spring to close actuator
with Teflon faced/EPDM backed diaphragms.
1 – Lot of interconnecting 316L stainless steel tubing and fittings.
Steam and Condensate Components:
1 – 1" Manual steam supply isolation gate valve with carbon steel body and NPT
connections.
1 – ½" Drip leg isolation gate valve with carbon steel body and NPT connections.
1 – ½" Drip leg condensate strainer with cast iron body, stainless steel screen and
NPT connections.
1 – ½" Drip leg thermostatic condensate trap with stainless steel construction and
NPT connections.
1 – ½" Drip leg condensate check valve with carbon steel body and NPT
connections.
1 – ½" Manual drip leg isolation gate valve with carbon steel body and NPT
connections.
1 – ½" Steam supply low pressure indicating switch, NPT connection, siphon and
cock.
1 – 1" Steam supply ball valve with carbon steel body, stainless steel ball and trim,
reinforced Teflon seats and seals and NPT connections, coupled to a pneumatic
air to open/spring to close actuator.
1 – 1" Steam supply strainer with cast iron body, stainless steel screen and NPT
connections.
1 – ¾" Steam supply control valve with ductile iron body and NPT connections
coupled to a pneumatic 3-15 PSI actuator with positioner.
1 – ½" x 1" Steam supply pressure relief valve with carbon steel body and NPT
connections.
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1 – ¼" Steam supply pressure gauge with 3½" dial, NPT connection, siphon and
cock.
1 – ¾" Vacuum breaker, bronze body and NPT connections.
1 – ¾" Float and thermostatic trap with cast iron body, stainless steel internals and
NPT connections.
1 – ¾" Condensate return check valve with carbon steel body and NPT connections.
1 – ¾" Manual condensate return isolation gate valve with carbon steel body and
NPT connections.
1 – Lot Schedule 40, carbon steel pipe and fittings for steam supply piping.
1 – Lot Schedule 80, carbon steel pipe and fittings for condensate piping.
Air Blow Components:
1 – ½" Compressed air supply pressure regulator with stainless steel body and
sanitary clamp connections.
1 – 1½" Pressure gauge with 316L stainless steel wetted parts, 3.5" diameter dial, 0-
100 PSI range and sanitary clamp connection.
1 – 1" Compressed air supply pressure relief valve with stainless steel body and
sanitary clamp connections.
1 – 1" Inline air blow filter assembly with sanitary clamp connections, .2-micron
PVDF element
1 – 1" Compressed air supply in-line spring check valve with stainless steel body.
1 – 1" Sanitary low air supply pressure switch with 316L stainless steel body and
sanitary clamp connection.
1 – Lot interconnecting 316L, Schedule 40 stainless steel pipe and fittings for air
piping upstream of the filter.
1 – Lot interconnecting 316L stainless steel tubing and fittings for air piping
downstream of the filter.
CIP Return Components:
1 – 2" CIP return temperature probe with sanitary clamp connection and remote 4-20
mA indicating transmitter.
1 – 2" CIP return flow switch with sanitary clamp connection
1 – 2" CIP return conductivity sensor with sanitary clamp connection and remote 4-
20 mA transmitter.
1 – 2" x ½" Manual zero-static, block body, sample diaphragm valve with forged
316L stainless steel body, 20 Ra-EP ID/35 Ra OD finish and butt weld
connections, coupled to a hand wheel actuator with Teflon faced/EPDM backed
diaphragm.
1 – 2" x 2" Zero-static, block body, CIP return to tank diaphragm valve with forged
316L stainless steel body, 20 Ra-EP ID/35 Ra OD finish and butt weld
2589-B CMF Automated CIP Skid Project Page 9 of 25
connections, coupled to a pneumatic air to open/spring to close actuator with
Teflon faced/EPDM backed diaphragm.
1 – 2" x 2" Sterile access CIP return/drain isolation diaphragm valve assembly, with
forged 316L stainless steel body, 20 Ra-EP ID/35 Ra OD finish and butt weld
connections, coupled to a pneumatic air to open/spring to close actuator with
Teflon faced/EPDM backed diaphragms.
1 – Lot interconnecting 316L stainless steel tubing and fittings for CIP return piping.
Chemical Injection Components:
1 – ¾" x ½" Zero-static, block body, chemical injection diaphragm valve with forged
316L stainless steel body, 20 Ra-EP ID/35 Ra OD finish and butt weld
connections, coupled to a pneumatic air to open/spring to close actuator with
Teflon faced/EPDM backed diaphragms.
3 – ½" Four function back pressure/check valves with PVC construction and NPT
connections.
3 – ½" Metering pumps, ceramic and 316SS wetted parts, 90-1800 SPM, 20 GPH at
up to 50 psig with integral 90 VDC motor.
3 – Metering pump containment pans with 304 stainless steel construction.
3 – ½" Check valves with stainless steel construction and NPT connections.
3 – ½" Manual chemical pump suction isolation needle valves with PVC
construction and NPT connections.
2 – 2" Sanitary magnetostrictive level probe with 316L stainless steel wetted parts,
float and sensor pipe, NPT connection and integral 4-20 mA transmitter
2 – 10 gallon polypropylene chemical drums with cover set in 18" square stainless
steel containment pans.
1 – 304 Stainless steel spare containment pan sized for a 5-gallon pail.
2 – ½" Manual chemical drum drain needle valves with PVC construction and NPT
connections.
2 – 1½" Chemical day tank high-level probes/switches with jacks, 20' cords, and
NPT connections.
2 – ¾" Containment pan level probes/switches with jacks, 20' cords, and NPT
connections.
2 – ½" Chemical supply ball valves with thermoplastic construction and NPT
connections coupled to pneumatic air to open/spring to close actuators.
2 – ½" Manual chemical supply isolation needle valves with PVC construction and
NPT connections.
1 – Lot interconnecting 316L stainless steel tubing and fittings for chemical piping.
Details CP-0007
The following is a detailed list of major components that will be provided with the system.
2589-B CMF Automated CIP Skid Project Page 10 of 25
Tanks:
1 – CIP Surge Tank with the following specifications:
Total Capacity: Approximately 540 liters.
Working Capacity: Approximately 500 Liters.
Approximate Dimensions: 30" ID x 36" OD x 43" side sheet.
Materials of Construction: 316L Stainless steel on wetted and 304L stainless
steel on non-wetted surfaces.
Top Head: 10 Gauge, standard ASME dished.
Sidewall: 10 Gauge
Bottom Head: 10 Gauge, standard ASME dished.
Jacket: None
Insulation: 2" Ceramic fiber on sidewall.
Insulation Sheath: 12 Gauge
Supports: Three (3) pipe legs with raw ends for skid mounting.
Accessories: Grounding and lifting lugs, vortex breaker and clipboard holder.
Finish, Inside: 20Ra-EP with welds polished to the same finish as the parent
metal.
Finish, Outside: 35Ra with welds polished to the same finish as the parent
metal.
Design: 45PSIG/FV @ 150º C ASME code stamped.
Service: Atmospheric.
Ports:
Top Head:
1 – 12" Sanitary hinged and gasketed manway
2 – 3" Sanitary clamp ferrules for WFI supply sprayball assembly
mounting
1 – 3" Sanitary clamp ferrule for PW supply sprayball assembly
mounting
1 – 3" Sanitary clamp ferrule for spare.
1 – 4" Sanitary clamp ferrule for CIP return no-foam assembly
mounting
1 – 2" Sanitary clamp ferrule for level probe mounting
1 – 2" Sanitary clamp ferrule for level switch mounting
1 – 1½" Sanitary clamp ferrule for vent filter mounting
1 – 1½" Sanitary clamp ferrule for rupture disc mounting
Bottom:
1 – 2" Sanitary flush mount tank bottom valve mounting pad.
2589-B CMF Automated CIP Skid Project Page 11 of 25
CIP Surge Tank Mounted Components:
2 – WFI water inlet 316L stainless steel sprayball assemblies each with 2" diameter
ball, 360° x 72/25 spray pattern welded to a 1" down tube with sanitary clamp
connections and a 3" sanitary clamp tank connections. The sprayball assemblies
will be pinned after riboflavin testing.
1 – PW water inlet 316L stainless steel sprayball assembly with 2" diameter ball,
360° x 72/25 spray pattern welded to a 1" down tube with sanitary clamp
connection and a 3" sanitary clamp tank connection. The sprayball assembly will
be pinned after riboflavin testing.
1 – 3" Sanitary clamp cap, gasket and clamp for spare port.
1 – 316L stainless steel CIP return no foam inlet assembly with 2" downtube with
sanitary clamp connection and a 4" sanitary clamp tank mounting connection.
The no foam inlet assembly includes a 45 offset inside the tank to direct solution
to the sidewall and will be designed so it can be easily removed from the tank.
1 – 2" Sanitary magnetostrictive level probe with 316L stainless steel wetted parts,
sanitary float and sensor pipe, sanitary clamp connection and integral 4-20 mA
transmitter
1 – 2" Sanitary magnetostrictive high-high level probe with 316L stainless steel
wetted parts, sanitary float and sensor pipe, sanitary clamp connection and
integral 4-20 mA transmitter
1 – 1½" Sanitary vent filter assembly with sanitary clamp connections, .2-micron
PVDF element and electric heat jacket with temperature sensor and controls.
1 – 1½" Rupture disc with burst disc alarm strip, 10% manufacturing tolerance, 316L
stainless steel construction and down tube assembly.
1 – 2" Flush bottom tank outlet diaphragm valve with forged 316L stainless steel
body, 20 Ra-EP ID/35 Ra OD finish and sanitary clamp style outlet connection,
coupled to a pneumatic air to open/spring to close actuator with Teflon
faced/EPDM backed diaphragm.
CIP Supply Components:
1 – 1½" Sanitary clamp cap, gasket and clamp for passivation port.
1 – 2½" x 2" Sanitary centrifugal style CIP supply pump sized for 50 GPM @ 57
PSIG. The pump includes 316L stainless steel construction, 20 Ra-EP wetted
surface finish, ¾" case drain, single carbon vs. silicon carbide internal seal and
sanitary clamp connections, close coupled to a 7.5 HP, 3600 RPM, 3 phase, 60
hertz, 230-460 VAC inverter duty motor.
1 – ¾" CIP supply pump casing drain diaphragm valve with forged 316L stainless
steel body, 20 Ra-EP ID/35 Ra OD finish and sanitary clamp connections,
coupled to a pneumatic air to open/spring to close actuator with Teflon
faced/EPDM backed diaphragm.
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1 – 1½" Sanitary clamp cap, gasket and clamp for passivation port.
1 – 2" Sanitary pressure transducer with integral 4-20 mA indicating transmitter and
sanitary clamp connection.
1 – ¾" Chemical loop flow orifice. The orifice will be installed in the chemical
slipstream to provide reduced pressure and flow through the chemical loop and
include a low-point hole to ensure complete drainage.
1 – 2" Heat exchanger bypass flow orifice. The orifice will be installed in the heat
exchanger bypass piping with a low-point slot to ensure complete drainage of the
heat exchanger.
1 – Sanitary shell and tube heat exchanger with the following specifications.
Duty: Heat 50 GPM of CIP solutions from 20˚C to 90ºC in multiple passes,
utilizing approximately 100 pounds per hour of saturated steam supplied to
the system at 100 PSIG.
Single shell, 2-pass U-tube, ASME "UM" code stamped design.
316L Stainless steel tube side and 304 stainless steel shell.
Insulation with 304 stainless steel jacket.
20 Ra-EP internal and 35 Ra external finishes.
2" Sanitary clamp tube side connections.
1", 150# RF Flange steam inlet.
1", 150# RF Flange condensate outlet.
¾" FNPT vent connection.
1 – 2" CIP supply conductivity sensor with sanitary clamp connection and remote 4-
20 mA transmitter.
1 – 2" CIP supply temperature probe with sanitary clamp connection and remote 4-20
mA indicating transmitter.
1 – 1½" Sanitary mass flow meter with sanitary clamp connections and integral 4-20
mA indicating transmitter.
1 – 2" x 1" Sterile access CIP supply/air-blow isolation diaphragm valve assembly,
with forged 316L stainless steel body, 20 Ra-EP ID/35 Ra OD finish and butt
weld connections, coupled to a pneumatic air to open/spring to close actuator
with Teflon faced/EPDM backed diaphragms.
3 – 2" x 2" Zero-static, block body, CIP supply routing isolation diaphragm valves
with forged 316L stainless steel bodies, 20 Ra-EP ID/35 Ra OD finish and butt
weld connections, coupled to pneumatic air to open/spring to close actuators with
Teflon faced/EPDM backed diaphragms.
1 – Lot of interconnecting 316L stainless steel tubing and fittings.
Steam and Condensate Components:
1 – 1" Manual steam supply isolation gate valve with carbon steel body and NPT
connections.
1 – ½" Drip leg isolation gate valve with carbon steel body and NPT connections.
2589-B CMF Automated CIP Skid Project Page 13 of 25
1 – ½" Drip leg condensate strainer with carbon steel body, stainless steel screen and
NPT connections.
1 – ½" Drip leg thermodynamic condensate trap with stainless steel construction and
NPT connections.
1 – ½" Drip leg condensate check valve with bronze body and NPT connections.
1 – ½" Manual drip leg isolation gate valve with carbon steel body and NPT
connections.
1 – ½" Steam supply indicating low-pressure switch, NPT connection, siphon and
cock.
1 – 1" Automatic steam supply isolation ball valve with carbon steel body coupled to
an air to open/spring to close actuator and NPT connections.
1 – 1" Steam supply strainer with carbon steel body, stainless steel screen and NPT
connections.
1 – ¾" Steam supply control valve with carbon steel body and NPT connections
coupled to a pneumatic actuator with 3-15 PSIG positioner.
1 – ½" x 1" Steam supply pressure relief valve with carbon steel body and NPT
connections.
1 – ¼" Steam supply pressure gauge with 3½" dial, NPT connection, siphon and
cock.
1 – ¾" Vacuum breaker, bronze body and NPT connections.
1 – ¾" Float and thermostatic trap with carbon steel body, stainless steel internals
and NPT connections.
1 – ¾" Check valve with bronze body and NPT connections.
1 – ¾" Manual condensate return isolation gate valve with carbon steel body and
NPT connections.
1 – Lot Schedule 40, carbon steel pipe and fittings for steam supply piping.
1 – Lot Schedule 80, carbon steel pipe and fittings for condensate piping.
Air Blow Components:
1 – ½" Compressed air supply pressure regulator, stainless steel body with sanitary
clamp connections.
1 – 1½" Pressure gauge, 316L stainless steel wetted parts, 3.5" diameter dial with a
range of 0-100 PSIG.
1 – 1" Compressed air supply pressure relief valve with stainless steel body and
sanitary clamp connections.
1 – 1" Inline filter housing with 316L stainless steel body, 20 Ra-EP ID and 35 Ra
OD finish, sanitary clamp inlet and outlet connection, one (1) 10" Code 7
cartridge.
1 – 1" Compressed air supply in-line spring check valve with stainless steel body.
1 – 1" Sanitary pressure switch and 316L stainless steel tee, 20 Ra-EP ID and 35 Ra
OD finish, sanitary clamp connection.
2589-B CMF Automated CIP Skid Project Page 14 of 25
1 – Lot interconnecting 316L, Schedule 40 stainless steel pipe and fittings for air
piping upstream of the filter.
1 – Lot interconnecting 316L stainless steel tubing and fittings for air piping
downstream of the filter housing.
CIP Return Components:
1 – 2" x 2" Sanitary liquid ring centrifugal style CIP return pump sized for 50 GPM
@ 10 PSIG. The pump includes 316L stainless steel construction, 20 Ra-EP
wetted surface finish, ¾" case drain, single carbon vs. silicon carbide external
seal and sanitary clamp connections, close coupled to a 3 HP, 1750 RPM, 3
phase, 60 hertz, 230-460 VAC motor. The pump will be supplied loose for field
installation by others.
1 – ¾" CIP return pump casing drain diaphragm valve with forged 316L stainless
steel body, 20 Ra-EP ID/35 Ra OD finish and sanitary clamp connections,
coupled to a pneumatic air to open/spring to close actuator with Teflon
faced/EPDM backed diaphragm.
3 – 2" x 2" Zero-static, block body, CIP supply routing isolation diaphragm valves
with forged 316L stainless steel bodies, 20 Ra-EP ID/35 Ra OD finish and butt
weld connections, coupled to pneumatic air to open/spring to close actuators with
Teflon faced/EPDM backed diaphragms.
1 – 2" CIP return temperature probe with sanitary clamp connection and remote 4-20
mA indicating transmitter.
1 – 2" CIP return flow switch with sanitary clamp connection
1 – 2" CIP return conductivity sensor with sanitary clamp connection and remote 4-
20 mA transmitter.
1 –2" x ½" Manual zero-static, block body, sample diaphragm valve with forged
316L stainless steel body, 20 Ra-EP ID/35 Ra OD finish and butt weld
connections, coupled to a hand wheel actuator with Teflon faced/EPDM backed
diaphragm.
1 – 2" x 2" Zero-static, block body, CIP return to tank diaphragm valve with forged
316L stainless steel body, 20 Ra-EP ID/35 Ra OD finish and butt weld
connections, coupled to a pneumatic air to open/spring to close actuator with
Teflon faced/EPDM backed diaphragm.
1 – 2" x 2" Sterile access CIP return/drain isolation diaphragm valve assembly, with
forged 316L stainless steel body, 20 Ra-EP ID/35 Ra OD finish and butt weld
connections, coupled to a pneumatic air to open/spring to close actuator with
Teflon faced/EPDM backed diaphragms.
1 – Lot interconnecting 316L stainless steel tubing and fittings for CIP return piping.
2589-B CMF Automated CIP Skid Project Page 15 of 25
Chemical Injection Components:
3 – ¾" x ½" Zero-static, block body, chemical injection diaphragm valves with
forged 316L stainless steel bodies, 20 Ra-EP ID/35 Ra OD finish and butt weld
connections, coupled to pneumatic air to open/spring to close actuators with
Teflon faced/EPDM backed diaphragms.
3 – ½" Four function back pressure/check valves with PVC construction and NPT
connections.
3 – ½" Metering pumps, ceramic and 316SS wetted parts, 90-1800 SPM, 20 GPH at
up to 50 psig with integral 90 VDC motor.
3 – Metering pump containment pans with 304 stainless steel construction.
3 – ½" Check valves with stainless steel construction and NPT connections.
3 – ½" Manual chemical pump suction isolation needle valves with PVC
construction and NPT connections.
2 – ¾" Containment pan level probes/switches with jacks, 20' cords, and NPT
connections.
1 – Lot interconnecting 316L stainless steel tubing and fittings for chemical piping.
2589-B CMF Automated CIP Skid Project Page 16 of 25
CONTROLS DESCRIPTION
System Controls
A main control panel will be provided and installed on each system. All system-mounted
components will be electrically and pneumatically terminated to the control panels.
Each of the control panels for CP-0007 and CP-0008 will contain low voltage, high voltage
and pneumatic controls for operation of all equipment on the systems. A ControlLogix PLC
and I/O system will interface to all equipment on the skid. High voltage equipment will
include a variable frequency drive (VFD) for the CIP pump, step down control transformer
and appropriate motor protection equipment.
One HMI, provided and installed by others, will be installed in a separate remote panel in
Room 122. This HMI will service both CP-0007 and CP-0008. See remote panels below.
The following is a summary of equipment included with each control panel on CP-0007 and
CP-0008.
Main Control Panel
1 – NEMA 4X stainless enclosure, 60" x 48" x 16" will house the following
components:
Motor Control Equipment:
1 – 30 Amp, 3-phase panel mount fusible and lockable disconnect.
1 – PowerFlex 70 variable frequency drive with human interface module
(HIM).
1 – 3-Pole fuse holder with fuses for VFD protection.
1 – 3-Pole fuse holder with fuses for step down control transformer
protection.
1 – Power distribution block.
1 – Common mode choke for the VFD.
1 – 2KVA, 460/115 VAC step down control transformer.
Low Voltage Equipment:
1 – Emergency stop, illuminated push-pull, on-off switch.
1 – Master control power relay.
1 – Ethernet switch.
1 – Allen-Bradley ControlLogix PLC system to include:
2589-B CMF Automated CIP Skid Project Page 17 of 25
1 – 13-Slot I/O chassis.
2 – Rack mount power supplies.
1 – ControlLogix processor.
1 – Ethernet communication module.
1 – 24 VDC, 16-point discrete input module.
2 – 24 VDC, 16-point discrete output modules.
2 – 4-20 mA, 8-point analog input modules.
1 – 4-20 mA, 8-point analog output module.
1 – Battery backup module.
1 – 24 VDC, 2-amp power supply.
1 – 24 VDC, 10-amp power supply.
1 – Alarm horn.
1 – 8-Port Ethernet switch.
5 – 24 VDC control relays and sockets.
Pneumatic Equipment:
1 – Pneumatic lockable disconnect valve.
1 – Air filter.
2 – Air supply regulators and gauges.
15 – 3-Way manifold mount, 24 VDC air supply solenoids.
1 – I/P transducer for the steam control valve.
1 – Panel mount air pressure switch.
Remote Control Panels
IPEC will provide remote control panels to interface to CIP systems CP-0007 and
CP-0008. The system controls will include the CIP control panels as previously
detailed. A total number of six (6) U.L. labeled control panels and one (1) E-stop
junction box will be provided loose for field installation by others. They are as
follows:
RM-122 HMI
RM-129 HMI high voltage
RM-129 HMI low voltage
RM-263 HMI
RM-273 E-Stop
RM-274 HMI
RM-274 low voltage and pneumatics
All HMI's are provided by others. SCADA or Historian programming and printing
requirements are not included and are assumed provided by others
2589-B CMF Automated CIP Skid Project Page 18 of 25
The remote panels will include the following equipment:
Remote Panel for Room 122:
1 – NEMA 4X stainless steel enclosure, 30" x 24" x 12", containing:
1 – HMI door cut out for customer supplied and installed HMI, dimensions to
be determined.
1 – 4-Port Ethernet switch.
1 – Flex I/O control system, including:
1 – Flex I/O Ethernet adapter module.
1 – 16-Point, 24 VDC input module with terminal base
1 – 16-Point, 24 VDC output module with terminal base.
1 – 4-20 mA, 8-point analog input modules.
1 – 24 VDC, 2-amp power supply.
1 – Panel mount air pressure switch.
1 – Pneumatic lockable disconnect valve.
1 – Air filter.
1 – Air supply regulator and gauge.
10 – Air solenoids.
1 – Emergency stop, illuminated push-pull, on-off switch.
1 – Master control power relay.
1 – 120 VAC, door mount lockable disconnect switch.
Remote Panel for Room 129:
High Voltage Panel:
1 – NEMA 4X stainless steel enclosure, 30" x 24" x 12", containing:
1 – 30 Amp, 3-phase panel mount fusible and lockable disconnect.
2 – 3-Pole fuse holders with fuses for step down control transformer and
motor starter protection.
1 – IEC motor starter with overload protection.
1 – 1KVA, 460/115 VAC step down control transformer.
Low Voltage Panel:
1 – NEMA 4X stainless steel enclosure, 30" x 24" x 12", containing:
1 – HMI door cut out for customer supplied and installed HMI, dimensions to
be determined.
1 – 4-Port Ethernet switch.
1 – Flex I/O control system, including:
2589-B CMF Automated CIP Skid Project Page 19 of 25
1 – Flex I/O Ethernet adapter module.
1 – 16-Point, 24 VDC input module with terminal base
1 – 16-Point, 24 VDC output module with terminal base.
1 – 24 VDC, 2-amp power supply.
1 – Panel mount air pressure switch.
1 – Pneumatic lockable disconnect valve.
1 – Air filter.
1 – Air supply regulator and gauge.
5 – Air solenoids.
1 – Emergency stop, illuminated push-pull, on-off switch.
1 – Master control power relay.
1 – 120 VAC, door mount lockable disconnect switch.
Remote Panel for Room 263:
1 – NEMA 4X stainless steel enclosure, 30" x 24" x 12", containing:
1 – HMI door cut out for customer supplied and installed HMI, dimensions to
be determined.
1 – 4-Port Ethernet switch.
1 – Flex I/O control system, including:
1 – Flex I/O Ethernet adapter module.
1 – 16-Point, 24 VDC input module with terminal base.
1 – 16-Point, 24 VDC output module with terminal base.
1 – 24 VDC, 2-amp power supply.
1 – Panel mount air pressure switch.
1 – Pneumatic lockable disconnect valve.
1 – Air filter.
1 – Air supply regulator and gauge.
4 – Air solenoids.
1 – Emergency stop, illuminated push-pull, on-off switch.
1 – Master control power relay.
1 – 120 VAC, door mount lockable disconnect switch.
Remote E-stop for Room 273:
1 – NEMA 4X stainless steel junction box, 4" x 2" x 4", containing:
1 – Emergency stop, illuminated push-pull, on-off switch.
1 – Master control power relay.
2589-B CMF Automated CIP Skid Project Page 20 of 25
Remote Panel for Room 274:
HMI Panel:
1 – NEMA 4X stainless steel enclosure, 24" x 24" x 12", containing:
1 – HMI door cut out for customer supplied and installed HMI, dimensions to
be determined.
Low Voltage Panel:
1 – NEMA 4X stainless steel enclosure, 30" x 24" x 12", containing:
1 – 4-Port Ethernet switch.
1 – Flex I/O control system, including:
1 – Flex I/O Ethernet adapter module.
1 – 16-Point, 24 VDC input module with terminal base.
2 – 16-Point, 24 VDC output modules with terminal bases.
1 – 24 VDC, 2-amp power supply.
1 – Panel mount air pressure switch.
1 – Pneumatic lockable disconnect valve.
1 – Air filter.
2 – Air supply regulators and gauges.
24 – Air solenoids.
1 – Emergency stop, illuminated push-pull, on-off switch.
1 – Master control power relay.
1 – 120 VAC, door mount lockable disconnect switch.
SYSTEM ASSEMBLY & FABRICATION
Assembly Specifications
Each system will be delivered to the site packaged on a structural frame assembly with all
necessary equipment, piping, instruments, control hardware and electrical devices assembled
to the farthest extent possible and/or practical (unless noted otherwise in this proposal).
Each frame assembly will be designed to support the components under working conditions
in a Seismic Zone 4 designated area and be supplied with adjustable legs for leveling.
Stamping of drawings and calculations by a P.E. licensed in California will be provided for
the systems framing. All framing and support structures will be of 316L stainless steel
structural materials with a 35 Ra or better finish wherever possible and/or practical. Welds
on the frame assembly will be manual TIG type buffed to remove discoloration wherever
possible and/or practical.
2589-B CMF Automated CIP Skid Project Page 21 of 25
The approximate overall assembled dimensions of each assembly are 7' high x 3' wide x 6'
long. The approximate overall weight of the each system will be 1,800 pounds dry and
3,000 pounds operational. (All dimensions and weights are estimates only, actual to be
determined by engineering upon receipt of order.)
Interconnecting process and utility piping within the boundaries of the skidded systems will
be completed prior to shipment, utilizing the materials and procedures as specified in this
proposal. Piping materials and services external to the skidded systems have not been
included in the IPEC scope of supply and are assumed supplied by others.
Interconnecting wiring as defined for the skidded systems will be completed prior to
shipment, utilizing the materials and procedures as specified in this proposal. Wiring
materials and services external to the skidded systems have not been included in the IPEC
scope of supply and are assumed supplied by others.
The CIP systems will satisfy the performance requirements as detailed in this proposal.
Each component for the systems will be capable of performing in accordance with the
requirements of the given application.
Sanitary Process Piping
The tubing and components installed in the CIP piping will be 316L stainless steel with a 20
Ra EP internal finish unless noted otherwise. The sanitary piping and fittings will conform
to applicable sections of ASTM designations.
Alfa Laval, Robert James, and/or Jensen will manufacture all product fittings. Rath Tubing
Company, Janesville Wisconsin, United Industries, Beloit Wisconsin, or Trent Tubing
Division, East Troy Wisconsin will manufacture the stainless steel tubing.
All fittings specified as sanitary clamp or weld will be as follows:
A. All fittings will have the same wall thickness and be of the same material as the
tubing system in which they are installed.
B. All ferrules will be sanitary clamp butt weld type. No expanded joint or soldered
ferrules or fittings will be provided.
C. All butt weld fittings and ferrules will have ends which are circular (minimal
ovalness) and of uniform wall thickness.
D. All sanitary clamps will be 3-segment, heavy-duty style.
E. All sanitary gaskets will be of platinum cured Silicone
When possible, all sanitary product piping, fittings, materials, installation practices and
equipment will conform to the specific applicable 3A and BPE standards and the related
supplements and amendments thereto. Where possible, all pipelines will pitch at a rate of at
2589-B CMF Automated CIP Skid Project Page 22 of 25
least 1/8" inch per foot unless otherwise indicated as level on the drawings. The pitch of all
CIP piping will be continuous from the high point to openings provided for complete system
drainage. Piping will be installed without springing or forcing. Swing elbows will be
installed so that they may be easily connected and disconnected without springing or forcing
the pipe in any manner.
All valves will be installed in such a manner that they are free draining and can be
dismantled for repair of the seat.
Sanitary Welding
The sanitary piping system will be welded and clamp designed. The piping will be of
welded construction to the maximum possible extent. Interconnecting piping will consist of
automatic weld fittings meeting BPE standards wherever possible and/or practical. Joint
design for hygienic tubing and fittings will be square butt type. The tubing and fittings will
have ends prepared by machining or facing to provide a square end that meets the
requirements of BPE. The butt weld joints will be properly cleaned within ½" of the joint
area on the inside and outside surfaces prior to welding. Welding on the tubing will be done
using automatic orbital welding techniques except where size or space will not permit; in
such cases manual welding will be performed.
Tube welding will be performed in an Argon Gas atmosphere with air purged by pressure
from the tubing as far as possible and/or practical. The Argon Gas will be supplied through
a .2-micron filter and Teflon tubing to minimize the amount of impurities in the atmosphere
around the joint to be welded. An oxygen analyzer will be installed on the purge port of the
components to be welded to insure that the oxygen content is 25 parts per million or below
prior to starting the welding process.
Welds will be heli-arc fused, fully penetrated, so as not to present a surface that will
contribute to microbiological growth and contamination of the product. Welds will not have
any discontinuities such as cracks, voids, porosity or joint misalignment that may promote
contamination of the product. All welding procedures will be as defined under the
applicable sections of the BPE standards.
All welds will be videotaped, boroscope inspected and upon acceptance assigned a weld
number and entered into the weld documentation booklet as acceptable. To be accepted the
weld bead will be free of discoloration on the ID with the exception of a light straw or blue
color or hewing that may be present in the heat-affected area. The discoloration level that is
acceptable will be determined by the IPEC inspector assigned to the project in accordance to
the applicable BPE standard. If the weld is found to be unacceptable it will be assigned a
weld number, documented as unacceptable and cut out of the piping system.
2589-B CMF Automated CIP Skid Project Page 23 of 25
Heat numbers of the tubing and/or fittings used for each weld will be documented into the
weld documentation booklet. Weld numbers will be documented on a weld map included
with the turnover package for location reference.
All welds on tubing, fittings and other system components will be color cleaned OD and as
purge welded ID. Polishing of stainless steel weld joints will be done with a scotch brite
wheel or rubber beaded aluminum oxide grinding wheels. Carbon steel tools or those
contaminated with carbon steel particles will not be used on stainless steel joints.
Sanitary piping materials and services external to the skidded systems have not been
included in the IPEC scope of supply and are assumed supplied by others.
Steam Piping
Steam piping will consist of Schedule 40, carbon steel pipe and fittings with socket weld,
flange and/or threaded connections. Steam piping materials and services external to the
skidded systems have not been included in the IPEC scope of supply and are assumed
supplied by others.
Condensate Piping
Condensate piping will consist of Schedule 80, carbon steel pipe and fittings with socket
weld, flange and/or threaded connections. Condensate piping materials and services external
to the skidded systems have not been included in the IPEC scope of supply and are assumed
supplied by others.
Compressed Air Piping
Compressed air piping up and downstream of the filter housing will consist of 316L stainless
steel tube and fittings with sanitary clamp or butt weld connections. Compressed air piping
materials and services external to the skidded systems have not been included in the IPEC
scope of supply and are assumed supplied by others.
Piping Insulation
Insulation of the tanks, heat exchanger and process piping with the exception of IA, CDA
and APW will be insulated for personnel protection. Tanks and heat exchangers will be
covered with stainless steel sheathing and piping with 20 mil. white PVC jacketing.
Insulation materials and services for other piping systems and/or external to the skidded
system have not been included in the IPEC scope of supply and are assumed supplied by
others.
2589-B CMF Automated CIP Skid Project Page 24 of 25
Hangers and Supports
The pipe hanging support systems will be of welded stainless steel construction. Support
members will be of 316 stainless steel structural materials wherever possible and/or
practical. Tubing hanger clamps will be of stainless steel construction, with inserts as
applicable, capable of withstanding temperatures of the application without distortion.
Inserts will be in tight contact to prevent any metal-to-metal contact. All lines and valves
will be hung or supported in a workmanlike manner so that all swing joints make and break
freely. Supports will be close enough to each other, generally not more than 10 feet apart
and at each directional change in the piping systems so that the piping will not sag or settle.
Piping will be so aligned that there is freedom to expand or contract with thermal changes
and not cause undue stress or distortion of the piping systems or equipment. No exposed
threaded rod will be used for sanitary process pipe supports; solid rod will be used for
hanger supports.
Hanging and support materials and services external to the skidded systems have not been
included in the IPEC scope of supply and are assumed supplied by others.
Electrical Wiring
All power, control and pneumatic conduit, wiring and tubing within the skidded system's
boundaries will be complete, wherever possible and/or practical, prior to shipment. The
design of the wiring and pneumatics within the CIP system's boundaries will be such to
minimize the conduits required between the panels and skid-mounted components. Field
conduit, wiring, pneumatic materials, and services external to the CIP systems have not been
included in the IPEC scope of supply and are assumed supplied by others.
Exposed Conduit
Exposed conduit will be rigid galvanized steel (RGS) with PVC coating. Each length shall
have (1) coupling and a thread connector. Minimum conduit size for general use will be ½"
(RGS). Conduit materials and services external to the skidded systems have not been
included in the IPEC scope of supply and are assumed supplied by others.
Conduit Fittings
The conduit fittings will be PVC coated and designed to mate with the specified conduit.
Liquid Tight Flexible Metal Conduit
Flexible conduit will be galvanized steel with extruded gray color PVC jacket. Connectors
will be Appleton type ST series or approved equal.
2589-B CMF Automated CIP Skid Project Page 25 of 25
Pneumatics
Pneumatic filters, regulators and solenoids and I/P transducers will be mounted in the skid
mounted control panel. Pneumatic lines from the control panels will be polyflow plastic,
housed in 316 stainless steel tubing, terminated at stainless steel junction boxes. Final
connections from the junction boxes to the valves will be polyflow plastic tubing and
fittings. Pneumatic materials and services external to the skidded systems have not been
included in the IPEC scope of supply and are assumed supplied by others.
Utilities Required
The following is a list of estimated values for the utilities that will be required to support the
operation of each system. The actual value of each service will be reviewed/confirmed by
IPEC engineering during the design phase of the project.
Compressed Air -------------------------------------- 15-35 SCFM @ 100 PSIG
Plant Steam ------------------------------------------ 100-525 PPH @ 100 PSIG
Condensate --------------------------------------------- 100-525 PPH @ 75 PSIG
Power -------------------------------------------------- 3/60/480 VAC, 30 AMPS
Purified Water ---------------------------------- 25 GPM @ 25 PSIG and 176ºF
Water for Injection ----------------------------- 25 GPM @ 25 PSIG and 176ºF
Waste Drain --------------------------------- 50 GPM @ 10-25 PSIG and 140ºF