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Clean In Place Made Simple

Written By: John Robert Parraga

Global Process Technical Consultant

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2 | Clean In Place Made Simple

Abstract

Clean in Place (CIP) Automation is typically a complex part o the automation process. In manyinstances it is more complex to automate the cleaning process than to make the product since the

nal CIP automation sequence is oten dened ater the process equipment is built and cleaning

tests are perormed.

There are many requirements or cleaning equipment as well as many cleaning types. Some process

equipment is cleaned with only water while other equipment is cleaned using detergents such as

acids or caustic solutions. Some plants have taken to recovering the water used or a nal rinse and

use it as the initial rinse o the next CIP sequence in order to reduce the overall cost o production.

Although there are many approaches to implementing a CIP solution, each approach has limitations

and/or allows or signicant improvement. The ollowing paper discusses an approach that makes

CIP automation a straight orward task and provides ample modularity and exibility through the

use and application o ANSI/ISA-88 (S-88) concepts.

Fig. 1 Sample CIP Process Overview

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Clean In Place Made Simple | 3

Creating control code or the typical major steps o CIP including preliminary ush with water,

caustic cleaning, hot water ush, acid ush, and nal rinse

Establishing the conditions that dene when a step has completed, such as waiting or a

conductivity value ollowing the preliminary ush beore moving on to the next step.

Complex routing

Creating control code to perorm the CIP procedures as dened during automation design

Physical actors, biological actors, chemistry o detergents, concentration, temperature, exposure

time, ow rate, etc.

Coordination between the CIP skid and the destination to be cleaned

Equipment arbitration

By applying the S-88 concepts, we are able to separate the Equipment Model (EM) rom the

Procedural Model (PM). This approach allows or the creation o procedures (recipes) ater the

process has been automated without requiring changes to the overall control system. This

modularity allows or rapid recipe creation, as well as optimization o the CIP procedures, typically

resulting in an overall cost reduction and CIP duration.

What Makes CIP aComplex Problem?

Fig. 2 ANSI/ISA-88 Fundamental Concept

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Focusing in the Equipment Model (EM) or What

can the equipment do? the ollowing describes

the essence o a typical CIP process.

By using a single EM, we can expose all

parameters required on the CIP skid side as well

as the parameters required at the destination.

The key to the simplication o the CIP process

is to set up the equipment using a single EM.

This allows or the denition o all the possible equipment congurations in a simple modular

manner, and then by using the Procedural Model o S-88, we can speciy the sequence required

to perorm the required procedures.

In order to describe the automation

approach, we will independentlyocus on what can be done on

the CIP skid side then move to

the destination side. First we will

look at a sample CIP station. By

gaining an understanding o this

automation approach, we will

see how this solution would be

applicable to diferent CIP skid

types.

Fig. 3 - CIP Basic Overview

Fig. 4 CIP EM Basic Overview - Operator Interface

Fig. 5 - Sample CIP Skid Detail

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What Can the CIP skid Do?

Deliver a material rom a SOURCE

Detergent A, Detergent B, wash water, rinse water, return solution, air, in-line detergent

Control the FLOW RATE

Control the TEMPERATURE

Receive material and RETURN to

Detergent A, Detergent B, wash water, rinse water, return solution, drain

Monitor Supply and Return conditions

Supply temperature, ow rate, conductivity; return temperature, ow rate, conductivity

The destination may include tanks, transer lines, etc. Each destination may have multiple options

or a supply inlet path as well as return path. For simplicity, only two destination tanks will be

used in this example. This methodology is applicable to one or many destinations and paths.

Fig. 6 - CIP Sample Destination

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What Can the Destination Equipment Do?

Deliver a material to a destination

Tank_1

Tank_2

I the destination is Tank 1 then the cleaning solution can enter via two paths

Spray ball, side o tank, or these can be used in conjunction

I the destination is Tank 2 then there are no options to select rom

Spray balls is the only option

For the return path o each o these tanks, no options are possible

Adding more detail to the CIP EM o Fig. 4, the ollowing parameters can be specied.

Fig. 7 - CIP EM Overview

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Additional parameters (not shown in diagram) that can be used by the EM include:

Duration o step, how much time should this step setting last

Amount (weight or volume) o uid, or the step

Looking at the destination equipment, we are able to select which tank to CIP and, in the case o

Tank 1, we are able to speciy which tank inlet to use.

The code implementation required to build the EM is straight orward, while the EM is running each

o the actions required to meet the parameters specied are enorced. No procedural sequence

resides in the EM, as EM actions are very basic and typically include:

Open paths

Control ow rate

Control temperature

Additionally, the EM monitors i the required ow rate and temperature are met and, only i these

conditions are within tolerance, will the timer and amount be enabled.

The duration has been met

The required amount has been met

Via the EM aceplate, we can see that any destination can be cleaned using any source o cleaning

material, at a specied ow rate, and at a specied temperature. This can run or a time interval or

or a designated amount.

Continuing with the equipment denition, the destinations to be cleaned are considered units, sincea procedure or recipe needs to be used to speciy how to clean the equipment. In this example,

Tank 1 and 2 are units. The CIP skid equipment is not considered a unit unless a procedure needs to

be specied or that equipment; typically the unctionality required around the CIP skid is made up

o EMs, which can be responsible or controlling temperature, agitation, etc.

Each o these units will contain one (1) Equipment Phase to perorm the CIP process. In our example

these phases belong to diferent classes because they can speciy diferent parameters sets.

The phase parameters expose what the equipment is capable o to the recipe editor.

Fig. 8 Destinations to be Cleaned are Units Fig. 9 Phase Instances of Each Unit

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Fig. 11- Parameter Values for Class 1 Phase

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The phase reports when the desired conditions are met. These then can be used in a recipe

transition in order to move orward with the operation.

The actors that can be used to make decisions in the recipe are exposed to the recipe by

dening Unit Tags. These can be used to build simple or complex Transitions Expressions.

Once the Equipment Phase (EP) is dened it can be used to construct the recipes or procedures.

Fig. 12- Reported Information

Fig. 13 Unit Tags

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What Do We Want to do With the Equipment?

Using the recipe editor, diferent, reusable, operations can be built to perorm major tasks. The

ollowing are traditionally associated with the cleaning procedures:

Set up equipment

Preliminary ush with water

Caustic cleaning

Hot water ush

Acid ush

Final rinse

Fig. 14 Equipment and Procedural Models

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During recipe execution, a CIP phase instance will contain the required parameters or a specic

step. These parameters are downloaded rom the recipe phase to the equipment phase then to

the EM. Note that all parameters related to the equipment to be cleaned, as well as the CIP skid, are

specied in the recipe phase.

The sample operation contained in Fig. 16 is set to perorm the ollowing tasks:

Check that all equipment is ready (all in Auto, none ailed, etc.) and, i not,1.

prompt operator to check.

Prompt operator to make required equipment setup, transer panel connections,2.

close tank hatch, etc.

Download operating parameters to CIP EM and evaluate the transition3.

conditions beore proceeding.

Fig. 15 Equipment and Procedural Models

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In Fig. 16, transition T4 is dened to move rom the rst instance o the CIP phase

(CIP_CLS_1:1) to the second instance (CIP_CLS_1:2) once the specied amount has been met.

During this transer (transer o control), the new specied parameters get downloadedto the EM without stopping the CIP process. The timer and amount are reset and the new

operating parameters are evaluated in the ollowing transition conditions T5.

Fig. 16 Sample Operation

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In some processes, a single destination equipment can be cleaned using one o multiple CIP

stations, but each CIP station is used on a rst come rst served basis. For example: Destination

TK_1 can be cleaned by CIP A or CIP B. I all CIP stations are being used by other destinations, thenthe recipe or cleaning TK_1 will wait until any CIP station gets released and becomes available to be

acquired by TK_1.

The ollowing is an approach used to allow the multiple CIP stations to be allocated and arbitrated.

Fig. 17 Skid with Two CIP Circuits

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A CIP_AQUIRE equipment phase is added

to each unit and a recipe phase is added in

parallel in the CIP recipe Operation.

The CIP_ACQUIRE phase logic determines

i any o the CIP stations are available

then makes the request to reserve the

appropriate CIP station. -(CIP_A or CIP B).

Once a CIP station has been allocated to the

phase, the phase reports that the CIP station

is available. This report is used in the recipe

transition to start running the cleaning

process. Once the destination equipment

cleaning is complete, the CIP_ACQUIRE

phase releases the CIP station used, making

it available or other destination equipmentto use.

Fig. 16 Sample Operation

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Conclusion

By applying S-88 concepts, we have provided a modular and exible CIP process withsignicant advantages:

The automation team is not required to know how to CIP the equipment

It provides a modular, straight orward design and implementation approach

There is no need to change the code to create or change the CIP procedure

Create reusable operations to meet standard CIP operating procedures

This straight-orward methodology results in reduced costs in both engineering and

implementation time, as well as a exible solution that can be implemented across a acility with

limited re-work o code.

Author

Rockwell Automation

John Robert Parraga

Global Process Technical Consultant

15458 North 24th Dr, Suit B

Phoenix, Arizona 85053

(+1) 623 225 [email protected]

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