Media Prep Skid
Typical Filter Housing CIP Applications
CIP of Filter Housing Carts
The first application of Filter Housing CIP was for a project already nearing the end of construction. The (1) Filter Housing Carts had been fabricated to the original design, (2) and included only hand-operated valves, and (3) were intended to be manually cleaned in the traditional manner. The owner did not want to drastically modify the carts to incorporate all air-operated valves. An analylis of what was available, and what was needed, suggested that Retrofit of Filter Housing CIP to existing Filter Carts was an available alternative. The photos at the left and right illustrate two of the many carts converted to be included in fully automated CIP circuits.
The schematic drawing below illustrates how the Media Filtration Carts were modified. The housings had 1″ vent ports on the inlet nozzles and were already piped with manual valves and 1/2″ COND piping. They were adapted for automated CIP cleaning via the replacement of actuators on only two (2) air-operated valves, thence controlled for process and CIP via use of air hoses with quick-disconnects at the CIP location, which was also the use location. These carts were cleaned in a 1-1/2″ Media Transfer line from three Media Prep Tanks by means of a supply hose connection from a through the wall end of the transfer line. The discharge hose became the CIPS hose via relocation from the destination Media Tank port on a Transfer Panel to a CIPS port added to this panel. The CIP flow was in reverse through the filter at equipment and piping. SIP was accomplished by steam from the Media Tank passing backwards through the filters and piping, with COND discharge via a trap to drain.
The provision of a swing elbow to drain and relocatable to the outlet port of valve (2) made it possible to apply automated CIP to several filter carts essentially similar to those shown in the included photos. The Tube Spray was selected to permit the inlet nozzle tee branch containbing the gage to be cleaned by reverse flow through the VENT/COND lines the low-level COND header.
The CIP Procedure included the following steps.
- Remove cartridges, wipe housing joints, and reassemble housings.
- Relocate discharge end of outlet hose from Media Tank port to the CIPS port on the Media Transfer Panel. The Media port was capped.
- Install CIPS Hose from AV2 to DRAIN Elbow rotated Up.
- All Hand Valves were fully opened.
CIP Program Control included Device Sequencing software to control:
- Filter Housings were sprayed with solution and entrained air for approximately 20 seconds of each minute. The CIP line was supplied via a valve off of the CIPS supply path to the Media Prep tank sprays at either 60 or 80 Gpm. Spray back presure profided the motive force to supply thie path at well over 25 Gpm and the supplow flow to the sprays merely dropped for the 20 second period.
- Outlet valve AV1 was closed and “pulsed” open 5 seconds of each minute to clean inlet connection to the first (right-hand) housing in reverse flow.
- AV2 valve to the COND/VENT header was “pulsed” open 5 seconds of each minute to clean COND/VENT piping.
- The flush, wash and rinse solutions from AV1 and AV2 joined the full time flow through the sprays and passed onwards to the second (left-hand) housing and all flows then continued through the Media Transfer Line to the Media Supply Transfer Panel, to join the flow from the Media Tank being washed at the same time.
For SIP, the drain connection elbow was moved to direct COND (trapped) from the header to drain.
Other Options for Inclusion of Filter Housings in Product Transfer Line CIP Circuits
There are numerous means of incorporating Filter Housings in Process Piping CIP Circuits. Three incorporated in the schematic diagram below are described by the narrative below the diagram.
The above diagram created for explabatory purposes, and not a ral case example, shows an ESC SURA CIP Skid connected to two filter trains and a vessel with a filter housing in its supply line. No valve are shown The three circuits include:
(1) Purple – Three Filter Housings in series, being cleaned in parallel; i.e., the flush, wash and rinse solutions leaving the first pass through the next two. This approach would require each Filter Housing spray (or disc) to pass the quantity of water required for 5 FPS in the asociated piping. The manual filter outlet valves and spray supply valves would be open full time, providing full flow through the housing sprays . The Filter Inlet valves (2) would be opened for a couple of seconds of each minute to permit spray back pressure to cause nearly full flow through the inlet port.
(2) Orange – Three Filter Housings in series, being cleaned in series; i.e., the flush, wash and rinse solutions being divided into three approximately equal streams. The three flows combine in the outlet header. Inlet vlave V1 would be pulsed a few seconds of each minute for flow through the first filters inlet port. This approach would require the Filter Housing spray (or disc) to pass only 1/3 rd the quantity of water required for 5 FPS in the asociated piping. The manual filter outlet valves and spray supply valve V1 wouled be open full time. V1 could be a manual valve. V2 must be air-operated and automaed.
(3) Green – The incorporation of the Filter Housing in a vessel fill line used also for CIPS requires a Filter Housing spray capable of passing the vessel spray CIPS flow, for examole perhaps 80 Gpm for a 10,000L vessel. A Tube Spray or Disc Distributor might be sized to pass 80 Gpm at only 5 PSi. The flush, wash and rinse solutions and entrained air would pass through the Filter Housing and contiue to the vessel sprays. Air dis-engagement would occur in the vessel providinf air-free CIPR back to the CIP skid.
All of these concepts have been working soemplace sincr the early 2000s.
Air Injection Requires Air Disengagement – Whereas the introduction of air to the CIP Flush, wash and rinse solutions substantially reduces water, chemical and time requirements, it imposes some design and operating constraints. The CIP return flow from any line circuits containing Filter Housings must be to a CIP Skid which allows air disengagement before the return flow enters the CIP Supply pump. The ESC SUEA (Single-Use Educator-Assisted) CIP skid has handled return flow from such circuits in a highly effective manner. Conventional low speed (1750 Rpm) return pumps may be used if a vented process vessel is downstream of the Filter Housing. A means of disengaging all air from the return stream is essential, either prior to or as part of the CIP Skid. The by-pass type CIP System requires air disengagement capability upstream of the CIP skid in a process vessel.