Alfalaval CIP 200L Operation instructions

Operating & Maintenance Manual
Cleaning In Place Unit
XX
Model : CIP 200L & 400L
Valid for : CIP 200L & 400L
Manufacturing numbers : 969951-00, 969951-01, 969951-10,
969951-11, 969952-00, 969952-01
Document No: 130021 R08
Original Manual - English
Alfa Laval Support Services Pvt Ltd
<

www.alfalaval.com
The instructions given in this manual are intended as a general
instruction to Alfa Laval CIP units
Alfa Laval reserves the right to make changes at any time without prior notice.
Any comments regarding possible errors and omissions or suggestions for improvement of this
publication would be gratefully appreciated. Please forward this information to the address below.
If further clarification regarding this manual is required, please contact your local Alfa Laval
representative.
Copies of this publication can be ordered from your local Alfa Laval Company.
Published by: Alfa Laval Support Services Pvt Ltd, India
Engineering & Supply
© Copyright Alfa Laval Support Services Pvt Ltd
This manual and its content must not be copied, reproduced, transmitted or disclosed to any third
party without consent of Alfa Laval Support Services Pvt Ltd

Subject
Page
FIELD OF APPLICATION
3of 38
www.alfalaval.com
Table of Contents
1.0.0 INTRODUCTION......................................................................................................................................... 4
2.0.0 FIELD OF APPLICATION.......................................................................................................................... 5
3.0.0 SAFETY INSTRUCTIONS AND WARNING ............................................................................................ 6
3.1.0 General Safety Regulations..................................................................................................................... 7
3.2.0 Safety Regulations during Installation.................................................................................................... 8
3.3.0 Safety Regulations during Operation and Maintenance...................................................................... 8
3.4.0 Noise Emission.......................................................................................................................................... 9
3.5.0 Modifications and Reconstruction........................................................................................................... 9
4.0.0 INSTALLATION AND COMMISSIONING GUIDELINES.......................................................................10
4.1.0 Unpacking................................................................................................................................................. 10
4.2.0 Lifting Instructions.................................................................................................................................... 11
4.3.0 Electrical Installation ............................................................................................................................... 13
4.4.0 Commissioning Instruction..................................................................................................................... 13
4.4.1. Commissioning preparation work.......................................................................................................... 14
5.0.0 STORAGE GUIDELINES..........................................................................................................................16
6.0.0 GENERAL TECHNICAL DATA................................................................................................................17
6.1.0 Technical specification:........................................................................................................................... 17
6.2.0 Equipment list:.......................................................................................................................................... 17
6.3.0 Valve list:................................................................................................................................................... 17
7.0.0 OPERATING INSTRUCTIONS.................................................................................................................18
7.1.0 Operating precautions: ........................................................................................................................... 18
7.2.0 Operating Principle.................................................................................................................................. 18
7.2.1 Start-up preparation:............................................................................................................................... 20
7.2.2 General Operating procedure:............................................................................................................... 22
7.3.0 Operating procedures ............................................................................................................................. 24
7.3.1 Start-up, mixing and pre-heating of cleaning liquids .......................................................................... 24
7.3.2 CIP-cleaning of the heat exchanger ..................................................................................................... 25
7.3.3 Reverse flow............................................................................................................................................. 26
7.3.4 Neutralization ........................................................................................................................................... 27
7.3.5 Use of pump for emptying HE back to CIP tank ................................................................................. 28
7.3.6 Draining of PHE externally through Pump........................................................................................... 29
7.3.7 Self draining.............................................................................................................................................. 30
7.3.8 Self draining of the heat exchanger only.............................................................................................. 30
7.4.0 Disconnecting the CIP-unit..................................................................................................................... 31
8.0.0 MAINTENANCE.........................................................................................................................................32
8.1.0 Introduction............................................................................................................................................... 32
8.2.0 Control Panel............................................................................................................................................ 32
8.3.0 Maintenance Interval............................................................................................................................... 32
9.0.0 TROUBLE SHOOTING.............................................................................................................................34
10.0.0 SPARE PARTS..........................................................................................................................................36
10.1.0 Ordering Spare Parts.............................................................................................................................. 36
10.2.0 Alfa Laval Service.................................................................................................................................... 36
11.0.0 REVISION HISTORY.................................................................................................................................37
APPENDIX 1: EC DECLARATION OF CONFORMITY....................................................................................................... 38

Subject
Page
FIELD OF APPLICATION
4of 38
www.alfalaval.com
1.0.0 Introduction
Alfa Laval Cleaning - In - Place unit has been designed as a portable cleaning unit specifically,
for use in confined areas of service around a Plate Heat Exchanger.
The unit is thus equipped with a tank for mixing and storage of liquids during the Cleaning in
place of Plate Heat Exchangers. The unit is further equipped with internal heating system,
pump for circulation of cleaning liquid and valves to support and facilitate running different
programs of cleaning in place.
The unit can be started and operated from a built-in electrical control panel.
The unit is provided with different built-in safety arrangements and devices for safe operation.
These are never to be put out of function
These instructions give safety precautions and requirements which are to be followed in order
to avoid any harm to persons or damage to the unit itself.

Subject
Page
FIELD OF APPLICATION
5of 38
www.alfalaval.com
2.0.0 Field of Application
The Cleaning-In-Place is designed for cleaning compact heat exchangers like Gasketed,
Welded & Brazed plate heat exchangers. It can also be used for cleaning Spiral heat
exchangers and Compact tubular heat exchanger but with alteration some details in the
instructions in below sections. Please contact MU for further information.
Cleaning-In-Place unit has been designed as -
-An easy & convenient transportable cleaning unit.
-Remove scaling without damaging the plates or gaskets.
-Increase the lifetime of heat exchanger.

Subject
Page
SAFETY INSTRUCTIONS AND WARNING
6of 38
www.alfalaval.com
3.0.0 Safety Instructions and Warning
The following symbols in this manual point out safety precautions. It means your
attention is needed and your safety is involved.
WARNING
This symbol is used to indicate the presence of a hazard, which can or will cause
severe personal injury, if the warning is ignored.
CAUTION
Certain passages of the text will be marked with a caution mark. This mark
indicates the presence of hazard, which will or can cause property damage if the
instructions are not observed.
NOTE
This type of instruction indicates a situation, which, if not avoided, could result in
damage to the equipment.
Equipment is delivered with following signs:
Requirements signs
Warning signs
Always use protective foot
wear
General warning
Always use eye protection.
Dangerous electrical voltage
Always use protective
handwear.
Caustic agents
Hot surface
In case sign (s) is not found on the equipment or sign(s) is damaged new ones must
be ordered.

Subject
Page
SAFETY INSTRUCTIONS AND WARNING
7of 38
www.alfalaval.com
3.1.0 General Safety Regulations
The following general safety rules must be followed on every occasion:
The installation and operating manual contains vital information that must be
considered during all handling of the CIP unit. All personnel who are in contact
with the equipment must read the operating and installation manual. The operating
manual should be kept available near the equipment.
If the safety regulations are not followed, there is a risk of injuries as well as
damage to the machinery and the surrounding environment. If these safety
regulations have not been followed, Alfa Laval cannot be claimed responsible.
WARNING
Emergency stop must be installed on control panel as per local regulations.
WARNING!
The CIP unit must never be used when there is a risk for poisonous or lethal
fumes or vapors to be released from the fouled equipment during CIP cleaning.
When connected to the equipment to be cleaned, the CIP unit is being part of an
open system why any fumes or vapors being released will be released out into
the atmosphere through mainly the tank.
When any risk of dangerous vapor or gas in the CIP cleaning system, gas detector
and protective breathing equipment must be worn.
Noise hazards
Use ear protection in noisy environments.
Crush hazards
Do not work under hanging load.
Wear head protection during installation and maintenance of the equipment.
Cut hazards
Wear gloves when handling machined parts.

Subject
Page
SAFETY INSTRUCTIONS AND WARNING
8of 38
www.alfalaval.com
3.2.0 Safety Regulations during Installation
Read and follow the Operator’s manual before attempting to install or operate the
modules and supporting equipment.
Do not operate the system before installation is complete.
Install all equipment in accordance with requirements of the Local Electrical
Authority.
Ensure power is OFF before installation, inspection, assembling and
disassembling.
Ensure all pipe lines, Hoses and PHE are de-pressurized and emptied before
installation, inspection, assembling and disassembling.
The safety functions of the premises must be checked before the first start.
Only authorized and qualified personnel should carry out the installation.
All work on the machinery must be performed when it is not in operation and the
main power supply is switched off.
All local regulations regarding transport and lifting must be followed at all times.
3.3.0 Safety Regulations during Operation and Maintenance
Never put hands, other parts of your body or foreign objects into the machinery
without making sure the main supply has been switched off.
Do not attempt to do any kind of maintenance work on the unit itself until the
system has come to complete stop and check that the main power is SHUT OFF.
For inspection and maintenance of any component: Strictly follow the
corresponding technical documentation.
In case of any emegency puch E-STOP avilable on heater and pump panel.
High temperature
Parts of some equipment coming in contact with hot process liquid can
cause burns if touched.
Be careful when working near pipes, valves and equipment
Hot machine parts occur during operation of the plant, and then the user
must ensure that these cannot be touched by accident.
Chemicals
Safety precautions for use of chemicals: use eye protection and
gloves. Avoid skin contact, eye contact and contact with clothes.
Clean empty chemicals containers before disposal.
Chemicals are hazardous; Material Safety Data Sheets should be
read carefully before handling chemicals.
Make sure to locate eye shower and emergency shower before
start of handling corrosive chemicals!

Subject
Page
SAFETY INSTRUCTIONS AND WARNING
9of 38
www.alfalaval.com
Control system
NEVER neglect a red signal/alarm. Find out what caused the alarm and
remedy it by skilled person and reset the alarm.
3.4.0 Noise Emission
Noise emission corresponds to the values for the pump mounted.
The mean sound pressures levels (Lp) measured at as Curve A (ISO 1680
standard).
The noise values were measured with 50 Hz motor running idle with a tolerance of
3 dB(A).
LpA<70 dBA
3.5.0 Modifications and Reconstruction
Please note that the machinery must not be altered or modified in any way if not
directly approved of by Alfa Laval.
Use of original spare parts and accessories guarantee a safe operation. Use of parts
from other manufacturers can lead to premature failure of the machinery, cause
damage to the machine and surrounding area and jeopardize the warranty.
Module is designed for safe area installation. It should not be used for any hazardous
or ATEX classified area.

Subject
Page
INSTALLATION GUIDELINES
10 of 38
www.alfalaval.com
4.0.0 Installation and Commissioning Guidelines
For details on Dimensions, Connections, Service area, etc.: See the order specific
dimension drawing.
The CIP unit is delivered as complete machine ready to bring into service.
Check and assemble the hoses carefully between CIP-unit and heat exchanger.
Please make sure the CIP module is in horizontal direction.
All electrical installations must be done in accordance with local regulations. A
certified electrician should carry out this job.
During working on the electrical installations, the main power supply must be shut off
at all times.
WARNING
Before start up please connect supply cable from customer to the socket located
on pump and heater trolley.
4.1.0 Unpacking
When unpacking, take care not to damage the CIP unit.
Check the delivery. Make sure that the CIP-unit with accessories is complete
according to packing list and orders.
Check the tank. The inlets and the outlets must be free from possible packing
materials.
Verify all electrical connections are intact.
Make sure that the CIP unit has not been damaged during the transport.
If transport damages are found, please contact local Alfa Laval agent.
Alfa Laval cannot be responsible for incorrect unpacking & handling of CIP unit.

Subject
Page
INSTALLATION GUIDELINES
11 of 38
www.alfalaval.com
4.2.0 Lifting Instructions
CAUTION
Always use approved equipment for the lifting.
Refer to dimensional drawing for the specific CIP unit for the weight of the
equipment.
When lifting a CIP unit, use certified and approved slings and makes sure that
the CIP unit is prevented from tilting or rotating.
CIP unit must be completely empty during lifting or transportation in order to
avoid unstable lifts and damage to CIP unit.
Follow local safety precautions/guidelines while lifting CIP units.
The CIP unit should only be lifted by using lifting slings fitted according to the following
illustrations.
CIP 200L and 400L
1) Place lifting slings around
tank as shown in the
drawing carefully, see how
the tank, Pump trolley
balances. If the trolleys do
not balance move lifting
slings closer to tank and
pump respectively and lift
carefully.
2) Repeat procedure until the
trolleys gets balance.
To lift Tank trolley place
lifting slings through the
tank frame close to heater.
Cross check that slings are
not touching the heater.
Place second sling through
frame handle close to tank
make sure that it is close
towards tank to provide
Locking system.
To lift Pump Trolley place
slings through frame close
to pump and place second
sling close to valve cluster.

Subject
Page
INSTALLATION GUIDELINES
12 of 38
www.alfalaval.com
WARNING
Always use lifting slings of appropriate strength and dimension to handle the
weight of the CIP unit.
Always lift the CIP unit by the lifting points, as shown above.
Operators should avoid lifting of heavy components.

Subject
Page
INSTALLATION GUIDELINES
13 of 38
www.alfalaval.com
4.3.0 Electrical Installation
All electrical installations must be done in accordance with local regulations. A
professional electrician should carry out this job.
Apart from the fact that the electrical installation must be effected in a safe, proper
and approved way, the different methods of how to regulate the equipment should be
considered.
Please refer to ‘Start-up preparation’ in the below sections and decide how to adapt
the electrical installation to the means of operating the machinery.
During working on the electrical installations, the main power supply must be shut off
at all times.
The power supply is in accordance with the technical data for the unit. (see the
type tag on the motor and heater)
That electrical hooks-up are connected correctly
WARNING
Failure to comply with electrical regulations can cause risk of death by touching
electrified parts
4.4.0 Commissioning Instruction
1
The system must be commissioned before putting into operation.
It is the responsibility of customer or of by the customer appointed
responsible for the commissioning, to ensure that any person involved with
the commissioning and operation of this system is sufficiently skilled, has the
appropriate experience or has received adequate training.
Operators must read and understand the “Commissioning Instructions”,
“System Operating Instructions”, and the Operating Instructions of the
respective equipment before start-up of the system.
Before start up please connect supply cable from customer to the socket
located on pump and heater trolley.

Subject
Page
INSTALLATION GUIDELINES
14 of 38
www.alfalaval.com
4.4.1. Commissioning preparation work
Before commissioning or start-up of the system can be initiated, the following
conditions should be fulfilled:
1) Mechanical completion
Mechanical Completion is the checking and testing of equipment and
construction to confirm that the installation is in accordance with drawings
and specifications and ready for commissioning in a safe manner and in
compliance with project requirements.
Connect hoses to in and out of CIP module and respective PHE
connections.
Check hoses are not lying on any sharp edge and no obstacles are in
between.
Fill up CIP tank with CIP fluid at volume of 200L in each tank.Without filled
liquid never start heating element.
Dry run of heater will damage heater and may be injuries to operator.
2) Electrical connections
Before start up please connect supply cable from customer to the socket
located on pump and heater trolley.
Connect electrical socket to supply port. (Refer below image)
Whenever leaving from module make sure that electric supply is OFF to
module.
Heater Panel
Pump Panel
24S3- Start
24S3.1- Stop
24H1- Phase control OK
23S6- ESTOP
CN1-Main supply
(Customer scope)
30S2- Start
30S2.1 Stop
30H1- Phase control OK
29S6- ESTOP
CN1-Main supply
(Customer scope)

Subject
Page
INSTALLATION GUIDELINES
15 of 38
www.alfalaval.com
3) Pre-commissioning
Pre-commissioning is the phase where a system or unit is prepared for the
commissioning. The purpose of the pre-commissioning is to verify and
check if all parameters necessary for the operation are in accordance with
the specifications.

Subject
Page
STORAGE GUIDELINES
16 of 38
www.alfalaval.com
5.0.0 Storage Guidelines
Unless otherwise agreed, Alfa Laval delivers the equipment ready to be put in service
upon arrival and after installation.
If it is necessary to store equipment for a longer period, certain precautions should be
made in order to protect and prevent unnecessary wear of the equipment.
Often the best solution is to leave the equipment in the packing until installation will
occur. In this case Alfa Laval should be informed and proper type of packing should
be ordered.
Do not store the liquid more than a week in CIP tank. Drain and rinse all other
equipment after finished CIP cleaning.
Store hoses and other accessories in dry area protected from physical damage
after disconnecting it from CIP-unit.
NOTE
There should not be any ozone producing equipment in the storage room, like
operating electric motors or arc welding. Ozone destroys many rubber
materials.
Do not store organic solvents or acids in the storage room.
Do not store the module in wet area.
Avoid heat and ultraviolet radiation.
Outdoor storage should be avoided. The precautions mentioned above should be taken as
far as possible. The need for protection against the climate is more important in this case.

Subject
Page
GENERAL TECHNICAL DATA
17 of 38
www.alfalaval.com
6.0.0 General Technical Data
6.1.0 Technical specification:
Refer the General technical data in Technical documentation.
6.2.0 Equipment list:
Refer the General technical data in Technical documentation.
6.3.0 Valve list:
Refer the General technical data in Technical documentation.

Subject
Page
OPERATING INSTRUCTIONS
18 of 38
www.alfalaval.com
7.0.0 Operating Instructions
7.1.0 Operating precautions:
Operator should take the following precautions before the operating unit –
Check the power supply is in accordance with the technical data and make sure
that electrical hooks-up are connected correctly.
Pump should rotate as indicated with the arrow on the housing of the pump.
Never start the pump or heater without liquids in the tank.
The cleaning liquid to be used is in accordance with the cleaning procedure to be
carried out. (Refer section “Cleaning liquids procedure and ordering”)
Check the temperature during the operation. It should not exceed 85°C.
To set the desire temperature, open the heater cover & adjust the temperature
accordingly. (Make sure power supply is off during this procedure)
Check that all valves are in correct position when starting the unit and the drain
valve V11 and V06 (and V14 for CIP 400L) on the unit should be closed.
The heat exchanger should not be under pressure when starting the process.
The heat exchanger should be isolated from the normal system.
7.2.0 Operating Principle
Alfa Laval CIP units includes following operations mainly -
Shut off and drain the heat exchange to be cleaned.
Connect the CIP unit to the heat exchanger.
It is essential that
Lower heat exchanger port is connected to hose S03
Upper heat exchanger port to hose S02
Refer to P&I diagram in technical dossier, section 3.
Fill tank/tanks with water: 90 % of total cleaning volume, calculated as per
section 7.2.2.2, step 2.
CAUTION! To avoid risk of overflow, tank B02 shall not be engaged in circulation.
When in operation, the main volume of the liquid is to be in the Heat Exchanger
and a minor part of it in the main tank B01 for heating and circulation.
Pump the water volume into the Heat Exchanger - if CIP unit is 400 litre version,
start emptying tank B02 and then B01. Recirculate/clean only using tank B01,
inlet and outlet valves for B02 shall be closed.
To avoid accidents, circulate with water only to check for leakages to begin with.

Subject
Page
OPERATING INSTRUCTIONS
19 of 38
www.alfalaval.com
Mix the cleaning agent with water in the tank and heat it up to specified
temperature.
Circulates the cleaning solution for specified time.
Drain the cleaning solution as per any of the options 7.3.5 –7.3.8 and rinse the
system with clean water.
Disconnect the CIP unit.
CIP equipment must never be left unattended. In case of unexpected pump stop, like for
example power failure, valves V03, V04 and V08 must be closed to avoid uncontrolled
backflow from the heat exchanger and valves V05, V02 and V12 should be opened to
allow ventilation to the top of the heat exchanger to avoid pressure build up. This is
especially important when a CIP 400L is in operation since a power failure and free
draining to a single tank causes a major risk of overflow.

Subject
Page
OPERATING INSTRUCTIONS
20 of 38
www.alfalaval.com
7.2.1 Start-up preparation:
Heater
Make sure the heater is in Off-position before connecting the power.
Check that the thermostat is in the correct position. The most effective cleaning
interval is between 50 to 70oC. Check the temperature during the operation. Use the
positioner to set the require temperature. It must never exceed 85 °C.
Make sure the main switch of the heater panel is in 0-position before connecting the
power. Put the hand auto switch to 0, to stop the heating. Putting the switch to auto,
starts the heating with temperature control, setting it to hand, starts the heating
without temperature control.
The thermostat incorporated in the heater regulates itself. The safety thermostat (in
the heater) will switch off the heater, in case of over temperature.