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CIP Coordinator EM Class/Type Configuration

Welcome to S88 Builder CIP EM Configuration

At the heart of a CIP system is a CIP Coordinator and is the interface by which batch controls the CIP process.  The CIP coordinator must be configured precisely as shown here because it has special CIP logic that manages all the CIP functions and expects certain parameters in certain locations.

Class Coordinator – CIP System is a Coordinator class EM
Name CIPSys – Name is not important but this is a well-recognized name.
Value Class unique – This value must be a non-zero unique value within the class.
Options Set these options to yes if the return path is used to regulate the specified process variable.

Some CIP systems monitor the supply and return variables but only one can be used by the logic to determine if the CIP is within limits.

  • Temp. applies to return (yes/no)
  • Cond. applies to return (yes/no)
  • Flow applies to return (yes/no)

Is CIP = Yes – Causes coordinator to execute the Coordinator CIP logic.

Hold Children on Hold = Yes (Hold child EMs if coordinator is held or suspend if suspended)

Coordinator Hold on Suspend = No (Don’t suspend coordinator if child Holds)

Coordinator Suspend on Fault = No (Don’t suspend coordinator if child faults)

Coordinator Hold on Hold (if Child Holds) = No (Don’t hold coordinator if child Holds)

Custom Run Routine ID = 1 (obsolete)

Max Acquired = 2 (Coordinator EM must be acquired by both the CIP System and CIP Unit phase)

Messages Add these messages which are used by Custom Procedural #2 Abnormal Condition

1: Flow Rate Too Low (raised if min > 0 source flow < min or dest flow < min and source or destination is selected and depending on flow applies to return option)

2: Temperature Too Low (raised if SP > min > 0 and destination > none and supply temp < min or return temp < min depending on temperature applies to return option)

3: Conductivity Too Low (raised if source is conductive and min > 0 and supply conductivity < min or return conductivity < min depending on conductivity applies to return option)

4: Waiting for MPV Clean Cycles to Complete

5: Conductivity is not as Expected (raised if source is conductive and destination conductivity < min. or if source is not conductive but destination conductivity > Transition conductivity > 0)

6: Acquiring Sanitizer

7: Turbidity Too High, Sending to Drain (raised if source is rinse and destination turbidity > max and CIP duration > duration SP)

Child EMs Add these children (sanitizer EM is optional)

A CIP coordinator links together at least 4 EMs and possibly a sanitizer EM.  At this time the CIP Source, Destination and Sanitizer EMs are set in the CIP System instance but the Supply and Return are left open to be found at run time.  The source/destination CP # points to the CP that represents the Unit ID.  The coordinator needs to know this to select the child EMs based on the EMs source or destination unit.  For the supply EM this would be its destination.  For the return EM it would be its source.  Auto is left unchecked because custom logic determines how these EMs are started.  Required is checked because all EMs must be available before starting any.  Parallel is irrelevant because auto is unchecked.

Later once the CIP EM types have been configured you can map the child parameters to coordinator parameters:  Child CPs are mapped from the coordinator parameters because the phases only interact with the coordinator.  Update Continues means the child parameter is updated every scan while in auto so it cannot be changed.  Reverse update indicates the coordinator is updated by the child on change.  Inherit indicates the coordinator will 1-time inherit the child parameter but then the coordinator will update the child unless reverse update is true.

 

Control

Parameters

Source: (CIP_System) Selected source vessel.  This enum includes all the sources found in the 1st EM child’s sources.

Unit: (CIP_Unit) Selected CIP unit which is initially mapped from the CIP System phase but then updated by CIP Unit phase which allows multiple units to be cleaned by the same CIP sequence.  This enum will list all the units found in all the possible children that could be mapped to this coordinator.

Sply Comp: (CIP_Unit) Selected unit supply component.  This enum is replaced with the selected supply child EM’s component enumeration.

Rtn Comp: (CIP_Unit) Selected unit return component.  This enum is replaced with the selected return child EM’s component enumeration.

Destination: (CIP_System) Selected destination vessel. This enum includes all the destinations found in the 4th EM child destinations.

Flow Rate: (CIP_Unit) Minimum flow rate allowed for cleaning.

Temp: (CIP_System) Temperature Setpoint.

Cond: (CIP_System) Minimum conductivity allowed for cleaning.

Duration: (CIP_Unit) Duration to CIP for current component in seconds.  If set then the CIP Unit phase will complete when duration has been met. The duration will only be accumulated when the flow rate, temperature and conductivity are above minimum levels. Also includes sanitizer if it is specified.

Amount/Turb: (CIP_Unit) Amount to CIP for current component set by the CIP unit phase.  CIP unit phase will complete when the amount is reached.  The amount will only increase when duration is also incrementing.  This parameter may also be changed to minimum Turbidity if a turbidity sensor exists and amount isn’t needed.

CleanMPV: (CIP_System) Clean MPV is an enumeration with the values No, Yes w/o Confirm and Yes which determines if MPV will be cleaned and if the phase can complete before the MPV cleaning has been confirmed.  Use w/o confirm if the MPV may be cleaned over multiple component CIP Unit phases.  Otherwise the MPV must each be cleaned the specified number of cycles before the phase will complete even if the duration has been met.

Sanitize: Not sure what this parameter is for.

AdvMode: Yes/No enumeration that when yes will enable the advance push button to advance the CIP Unit phase in the recipe.

MinTemp: Minimum Clean Temperature as specified in the source child EM.

TransCond: Transition Conductivity level when the returning flow should switch from caustic to rinse water and back.  This value is inherited from the destination child EM

Complete: (CIP_Unit) Set by CIP Unit phase when CIP is complete and the unit is clean.

Report

Parameters

Src(Source)/Dest(Destination) report parameters are mapped to their respective instruments for each CIP Coordinator instance.

SrcFlow/Temp/Cond: Source flow, temperature and conductivity.

DestFlow: (CIP_System) Destination flow state; yes or no, flowing or not flowing.

Temp/Cond/Turbidity: Destination temperature, conduvtivity and turbidity.

ReclState: (CIP_System) Reclaim State enum as Above/Below/Unknown/NoValue as compared to Destination CP2

Duration: (CIP_Unit) CIP Duration for the current CIP Unit parameters.

Amount: (CIP_Unit) CIP Amount for the current CIP Unit parameters.

System:  CIP System acquired for this coordinator (not currently used)

CondState: (CIP_System) Destination Conductivity State as Above/Below/Unknown/NoValue as compared to Cond RP8.

StepAdv: (CIP_Unit) Step Advance = Yes/No when in Step Advance Mode and Step button is pressed to advance the recipe.

TurbState: (CIP_System) Turbidity state enum as Above/Below/Unknown/NoValue as compared to Turb limit (or CP10)

 

EM Layout

 

Child EM Selection 

The CIP coordinator EM can have its child EMs mapped to specific EM instances or it can find those instances by searching for matching EMs that meet certain criteria at run time.  While the coordinator EM is running the child EMs are locked in until the EM is idle again.

In this example the CIP Source, Destination and Sanitize EM are mapped at design time (not shown).   However, the CIP Supply and Return EMs are selected at run time based on the CIP Unit selection.  Here is how the coordinator selects these child EMs.

To select the child EM two things must be known about the children which are provided by the configuration above.

Child EMs Class/Type 

Only EMs that are of this class and type will be considered as valid children.  In this case the children for the supply and return EMs must be of class CIP and of type Supply or Return.

Child EMs Source/Destination 

When searching through the EMs of the correct class and type it will choose the first one that comes from the specified source and go to the specified destination.  The above configuration specifies where the source and/or destination unit can be found in the coordinators control parameters (see Source CP# and Dest CP#).  In this case it is looking for a Supply EM that goes to the destination found in CP2 which is the unit to be CIP’d and a Return EM that comes from the same unit in CP2.  Notice only the source or destination is defined; when no source or destination is provided it will default to the coordinators source or destination for the missing piece.  In the case of the CIP coordinator this is the CIP System itself.

 

In conclusion the CIP Coordinator will select a child Supply EM that has a class/type of CIP/Supply that comes from the coordinators CIP System and goes to the unit specified in CP2 of the coordinator.  Likewise it will select a child Return EM that has a class/type of CIP/Return and comes from the unit specified in CP2 and returns to the coordinators CIP System.

 

In the following find which child EMs K4 CIP System 1 coordinator (EM 300) will choose for MT402:

 

  1. First find the EMs of class CIP/Supply and CIP/Return circled with green below.
  2. Identify the supply that come from K4 CIP Sys 1 of EM 300 and return to K4 CIP Sys 1 circled with red.
  3. Find the Supply that goes to MT402 and the Return that comes from MT402 circled in blue.

 

The Supply and Return EM that meets all 3 criteria are circled in black which would be the child EMs the K4 CIP System 1 coordinator would choose when the selected unit in CP2 is MT402.

Coordinator/Child Parameter Mapping 

The CIP System and CIP Unit phases only interface with the coordinator but the child EMs do much of the work so the parameters provided to the coordinator must be mapped to the child EMs and in some cases the child parameters are mapped back to the coordinator for the coordinator to manage.  Note:  The parameters shown here only include the standard CIP parameters configured in the CIP Type.  Each CIP EM instance may include addition parameters required by that instance.

CIP Skid Source EM 

The source EM selects a CIP tank and pumps the CIP fluid to the Unit Supply EM typically through a heater and various instruments.   So the source EM needs to know from what vessel (CP1: Source), at what temperature (CP14: MinTemp and CP7: Temp) and at what rate (CP6: FlowRate).  Notice that the MinTemp (CP14) is reverse update that is because the parameter originates in the Source EM but the coordinator needs to know this value so it knows when to accumulate clean duration and amount.  Also notice that FlowRate and Temp (CP6 & 7) are not updated continuously.  This means that the operator could go to the Source EM and change the flow rate or temperature and return to auto with those new values.  However, the values will be re-updated from the coordinator if they are changed at the coordinator or the associated phase goes through a transition of control.  Other parameters used by the Source EM but not mapped are (these will be covered in detail later):

  • Caustic Conductivity Setpoint
  • Maximum Conductivity
  • Push MPV Seats
  • Lift MPV Seats
  • Pump Speed
  • Pump Bump Speed

CIP Skid Destination EM 

The destination EM selects a destination CIP tank and monitors various instruments.  So the destination EM needs to know to what vessel (CP5: Destination).  The coordinator needs to know what conductivity it should transition from the chemical tank to rinse recovery (CP15: TransCond).  There are many transition decisions made on the destination but that is all handled by the coordinator.  The destination EM simply opens the CMs to the specified destination.  Other parameters not mapped are:

  • Reclaim Caustic Conductivity
  • Transition Turbidity
  • Frac Tank Pump Speed

CIP Unit Supply EM 

The supply EM opens a route or task to the selected unit (CP2: Unit) from the selected source (CP1: Source) via the selected component (CP3: Comp).  It also is told if MPV should be cleaned along the way (CP11: CleanMPV).   In the above example there was only one possible source, or CIP System, so the source parameter wasn’t necessary.  Other parameters not mapped are:

  • Minimum MPV Cycles
  • Maximum MPV Cycles
  • MPV Seat Clean Time (s)
  • Pump Speed (read only)
  • Pump Bump Speed (read only)
  • Water Hammer Ack. Delay Time (s)
  • Water Hammer Ack. Dwell Time (s)
  • Water Hammer Bump Speed Dwell Time (s)

CIP Unit Return EM 

The return EM opens a route or task back to the CIP System from the selected unit (CP2: Unit) through the selected return component (CP4: Rtn Comp) cleaning MPV along the way (CP11: CleanMPV).   It also has these other standard unmapped control parameters:

  • Pump Speed
  • Minimum MPV Cycles
  • Maximum MPV Cycles
  • MPV Seat Clean Time (s)
  • Water Hammer Bump Speed
  • Water Hammer Ack. Delay Time (s)
  • Water Hammer Ack. Dwell Time (s)
  • Water Hammer Bump Speed Dwell Time (s)

Sanitizer EM 

The sanitizer EM is a unique CIP source because it requires its own EM that must be shared with all CIP systems.  It meters in sanitizer with rinse water for the final step.  The only parameter it needs is the CIP System it is servicing.  This is pushed to the EM directly in the CIP Coordinator logic when it is needed (I’m not sure why this isn’t just mapped like the other child EMs).  Notice this child EM is not marked as required so it is acquired just in time instead of when the coordinator is acquired.

Coordinator Responsibilities 

The coordinator manages the child EMs and carries out the responsibilities of the CIP logic.  Here are its main tasks:

  1. Find and acquire child EMs
  2. Map Control Parameters
  3. Links Child EMs to work as one large EM.  The CIP Source EM is linked with the CIP Unit Supply EM and the CIP Unit Return EM is linked with the CIP Destination EM.  Linking EMs make them act as a single EM so that the start/stop and hold/resume in the correct order.  This prevents dead heading pumps or pumping material to the wrong location.  The CIP Unit Supply may also be linked with the CIP Unit Return EM if the coordinator determines that the CIP route is just a loop or that there isn’t a buffer, such as a vessel, between the two.  The coordinator determines if the CIP route is a loop by checking if any of the following are true:
    1. The Supply Component enumeration exists and ends in a 0 such as 0, 10, 20, …
    2. No CIP Unit is specified
    3. The CIP Unit vessel is configured as a section of pipe.
  4. Start and Stop all child EMs as required based on the selected source and destination.  Also suspend child EMs if the coordinator is in Step Advance mode.
  5. Hold/Suspend Child EMs if coordinator holds or suspends and one-shot trip the Source/Supply EM if the Return/Destination EM trips so the CIP unit doesn’t fill with chemical.
  6. Acquires and starts the Sanitizer EM if selected as the CIP source (note: the sanitizer will be suspended if the process conditions are not as expected, i.e. when the duration and amount tracking is suspended)
  7. Determines if the CIP material is conductive, rinse water, air or sanitizer.  To make this determination the CIP material must be configured with the following options:
    1. CIP chemical material must be configured with the Is Conductive option.
      Required to know if conductivity is as expected and if vessel has chemical in it.
    2. Rinse water material must be configured with the Is Rinse option.
      Required to know if vessel CIP is complete.
    3. Air material must be configured with the Is Air option.
      Required to know to ignore process variables such as flow rate, temperature and conductivity.
    4. Sanitizer must be configured as a source with an enumeration of 4 in the CIP Source EM sources.
      Required to know when to acquire and start the sanitizer EM and to mark the vessel as being CIP’d.
  8. Switches to alternate destination if one is configured and the current destination is Full or Overflowing.  Will switch back if the original destination is no longer full for at least 8 seconds.
  9. Shares other information behind the scenes between child EMs using their Tag values.
  10. Monitors CIP Duration and Amount
    1. Resets both when selected source, destination, component or CIP unit changes.
    2. Suspends tracking when the temperature, flow or conductivity is low.
  11. Monitor and raise condition if any process variable is not as expected.
    1. Low Flow
    2. Low Temp
    3. Low Conductivity
    4. MPV cleaning not complete
    5. Conductivity not as expected
    6. Sanitizer unavailable
  12. Enables supply MPV cleaning when the clean duration exceeds 20s and return MPV cleaning when destination flow exists.
  13. One shot complete the CIP_Unit phase when the end condition is met (Actual Duration or Amount > Setpoint).
  14. Marks the CIP Unit vessel as being CIP’d and clears the Unit Product Code once the Rinse or Sanitizer phase is completed or when the Complete control parameter is set from the phase interface.
  15. Manages the Transition Conductivity, Turbidity and Reclaim Conductivity State enumeration report parameter as Unknown, Above, Below or No Value.
  16. Manages Step Advance Mode and Advance Push Button report feedback.

 

Updated on December 19, 2018

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