GENERAL DESCRIPTION 2 COMPONENT SPECIFICATIONS 3 · general description..... 2 component...

2589-B CMF Automated CIP Skid Project 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


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.


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


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.


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.


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,




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


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.


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


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


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


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



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


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




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.


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.


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.


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.


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,



CIP Supply Components:


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






1 – 2" Sanitary pressure transducer with integral 4-20 mA indicating transmitter and


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


1 – 1½" Sanitary mass flow meter with sanitary clamp connections and integral 4-20


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


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 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


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.


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




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


1 – 2" CIP return temperature probe with sanitary clamp connection and remote 4-20


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


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



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



1 – Lot interconnecting 316L stainless steel tubing and fittings for CIP return piping.


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


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.


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:


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 – 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


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 – 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 – Air filter.

1 – Air supply regulator and gauge.

10 – Air solenoids.



1 – 120 VAC, door mount lockable disconnect switch.


High Voltage Panel:


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:



be determined.





1 – 16-Point, 24 VDC input module with terminal base





1 – Air filter.









be determined.




1 – 16-Point, 24 VDC input module with terminal base.





1 – Air filter.






Remote E-stop for Room 273:

1 – NEMA 4X stainless steel junction box, 4" x 2" x 4", containing:





HMI Panel:



be determined.

Low Voltage Panel:





1 – 16-Point, 24 VDC input module with terminal base.

2 – 16-Point, 24 VDC output modules with terminal bases.




1 – Air filter.

2 – Air supply regulators and gauges.





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.


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


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.


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


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.


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


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


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


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.


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


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

GENERAL DESCRIPTION 2 COMPONENT SPECIFICATIONS 3 · general description..... 2 component...

Documents

Transcript of GENERAL DESCRIPTION 2 COMPONENT SPECIFICATIONS 3 · general description..... 2 component...