Intrinsically Safe Chemical Cleaning in Place

CLEANING OF PROCESS EQUIPMENT MADE EASIER THAN EVER BEFORE WE NOW CAN CHEMICALLY CLEAN YOUR STATIC EQUIPMENT IN SITU

Depending on your requirement, you can either dry hire the skid or opt for our complete solution including chemicals and trained technicians

INTRODUCING OUR NEW CIP SKID

WHAT BENEFITS WILL IT BRING TO YOU

CIP (Cleaning in place) skid has enabled us to clean the interior surface of your closed systems.

1) Reduce your downtime as the equipment is not needed to be removed from the site for cleaning.

Cleaning is accomplished by circulating a chemical fluid through the unit. The combination of turbulent flow and chemical action dissolves and loosens deposits from the process equipment which are then filtered out.

2) Save you the disassembly cost, as we can now clean your equipment without disassembling it.

CIP can be used for a wide variety of process equipment including but not limited to pressure vessels, condensers, shell and tube heat exchangers, small tanks etc.

3) Reduced chances of environmental contamination 4) Pressure gauges to monitor the cleaning effectiveness

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KEY FEATURES OF OUR CIP SKID Below are the key features of CIP skid 1) Stainless steel used throughout; enabling us to use a large variety of chemicals to clean your equipment.

2) 100% intrinsically safe.

3) 2 x 2" double diaphragm pumps 50% duty each. The unit can operate with 1 pump or 2 depending on the volumetric flowrate required for cleaning.

4) 500-litre chemical holding capacity.

5) Temperature gauge to monitor any reactional changes resulting in a rise of fluid temperature.

6) Discharge & suction pressure gauges to measure before and after differential pressure to determine clean effectiveness.

7) Fully itemized valve matrix (figure 1) makes it easy to understand and operate.

8) The entire process can be performed with connection /disconnection required only at commencement and completion of the clean, Fig. 1 :Valve matrix to control chemical flow minimizing spillage.

9) Stainless steel strainer to withhold particles as small as 400 microns.

CHEMICALS USED FOR CLEANING Our expert will select the best chemical suited for your equipment based on the nature of scaling/fouling. Below is the list of some of the chemicals we may use.

1) Sulphamic Acid / JosRed 2) Phosphoric Acid / JosBlue 3) Sodium Hydroxide 4) Citric Acid

CIP SKID TECHNICAL SPECS PUMPS Circulating Pumps Maximum Fluid Working Pressure Air pressure operating range Maximum air consumption* Air consumption at 70 psi/60 gpm* Maximum free-flow delivery* Maximum operating temperature Construction Ball & Diaphragm

2 x 2" Air-Operated Diaphragm Pumps 120 psi / 0.8 Mpa / 8 bar 20 - 120 psi/ 0.14 - 0.8 Mpa / 1.4 - 8 bar 175 scfm 60 scfm 150 gpm (568 l/min) 65.5°C 316 stainless steel PTFE

* These numbers are per pump. If both pumps are operated simultaneously then free-flow delivery as well as air consumption will be doubled.

TANK, PIPING, VALVES & HOSES Tank Volume Construction Piping and Valves Hoses

500 liters Fully welded, 316 stainless steel 316 stainless steel 2" /3" UHMW Polyethylene

SKID FRAME & STRUCTURE Fully welded, 304 stainless steel Fig 2: Stainless steel diaphragm pump Heavy Duty, Biaxial and Lockable Yes Certificate No.: AEC2018-054-L1358 Rev 0 Onshore and On-Platform Lifts Lifting Frame Applicable Codes and Std. AISC. AWS D1.6, ASTM A 240, AS3990 , AS4991 Construction Caster Wheels Forklift Slots Lifting Frame Design Verification

OVERALL WEIGHTS AND DIMENSIONS Width x Length x Height CIP Pumping Skid Weight (Empty) CIP Pumping Skid Weight (with water) CIP Pumping Skid Weight (with H3PO4) Total Hoses Weight (qty 4)

1320 x 1900 X 1550 mm 600 kg 1350 kg (600+750) 1942 kg** (600 + 1.69 * 750) 130 kg

** This calculation is with phosphoric acid at (85% conc.). The actual filled in weight of skid will vary from case to case depending on the type and concentration of chemical

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PERFORMANCE CURVES OF PUMPS The performance curve below (figure 3) provides information on how 1 pump will perform at various air pressures. The left axis indicates fluid outlet pressure while the right axis indicates air consumption. The horizontal axis shows the fluid flow.

The fluid flow is determined by system back pressure or whatever the restrictions are downstream of the pump.

The four solid lines and four dashed lines (A, B, C & D) correspond to supply air pressures being 8.4, 7.0, 4.8 and 2.8 bar respectively. These air pressure lines serve as reference points from which any other air pressure within the system’s operational range can be interpolated.

HOW TO READ THE PUMP PERFORMANCE CHART Determine Fluid Outlet Pressure.

Desired fluid flow rate 303 lpm.

Available 7.0 bar operating air pressure.

1) Locate fluid flow rate 303 lpm along the bottom of the chart.

2) Follow the vertical line up to solid line B which is the fluid outlet pressure curve that corresponds to 7.0 bar air pressure.

3) Follow left to fluid outlet pressure approx. 3.0 bar

Determine Pump Air Consumption.

Desired fluid flow rate 303 lpm.

Available 7.0 bar operating air pressure.

1) Locate fluid flow rate 303 lpm along bottom of chart.

2) Follow vertical line up to dashed line B which is the air consumption curve that corresponds to 7.0 bar air pressure.

3) Follow right to air consumption approx. 2.5 m3/min.

Fig. 3: Performance curve of 1 out of 2 pumps Example: System design information indicates a heat exchanger operates with 190 lpm fluid flow and requires 2.8 bar fluid pressure to overcome pressure loss and meet application needs. Ideally, cleaning at 1.5 times the system flowrate gives optimum results. So cleaning flow rate = 285 lpm and with the assumption that 4.1 fluid outlet pressure is sufficient to overcome the higher pressure losses associated with the higher flow rate. Determine the air pressure required and air consumption (refer yellow lines in figure 3).

Determine Air Pressure required.

Desired fluid flow rate 285 lpm.

Required fluid outlet pressure 4.1 bar.

1) Locate fluid flow rate 285 lpm along the bottom of the chart.

2) Follow the vertical line up to a horizontal dashed line which corresponds to 4.1 bar fluid outlet pressure.

3) Interpolate between A (8.4 bar) and B (7.0 bar) fluid pressure lines to solve for the air pressure estimates 7.9 bar

Determine Air Consumption.

Desired fluid flow rate 285 lpm.

Required fluid outlet pressure 4.1 bar.

1) Locate fluid flow rate 285 lpm along the bottom of the chart.

2) Follow the vertical line up to a 7.9 interpolation value between the dashed air consumption lines and read across to the corresponding value of 2.6 m3/min on the right axis.

In case the flowrate required for cleaning cannot be achieved from 1 pump, the second pump can be engaged, with the flowrates equally distributed among the 2 pumps. Assume you want to achieve a flowrate of 570 lpm. Divide the required flowrate by 2 i.e. 570/2 = 285 lpm to get flowrate per pump. And then calculate the air pressure and air consumption for each pump separately as delineated in the above example. www.heatexchangers.com.au

LIMITATIONS OF CIP FOR PLATE EXCHANGER 1) The PHE inlet pipes must have appropriate connections for chemical inlet and outlet points.

2) The isolation valves must be completely effective in order to prevent chemical contamination of the plant down or upstream.

3) If appropriate connections for CIP are not available pipework will need to be removed. Steel bolts or studs on the flanges are susceptible to corrosion and may be difficult to undo. Breakage of a bolt or stud will add substantially to the cost and time taken to complete the cleaning process.

4) If the heat exchanger is partially or fully blocked the chemicals will flow through the clear path (figure 4) and will clean the exposed surface. If the chemicals cannot come into contact with the contaminant CIP will not be effective.

5) Cannot guarantee the plate has been completely cleaned as it cannot be inspected visually.

6) The plates cannot be integrity tested for fluid crosscontamination via UV crack testing.

7) The cleaning chemicals must be specifically designed for the contaminant that has formed upon the plates.

8) Compatibility of the chemicals with the heat exchanger plate pack, processing, and piping materials must be assessed in terms of potential corrosion risks.

9) Noxious by-products may be generated by the cleaning process.

Unanticipated compounds may form inside a heat exchanger through variations in process conditions or feed material.

Fig. 4: Formation of flow channels during chemical cleaning of plate type heat exchanger

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