MechChem Africa

January 2017

•

MechChem Africa

⎪

Automation, process control and instrumentation

⎪

byE+Htobe the fastest reacting sensors in themarket.

The sensors come with a welded hygienic process

connection. In the standardpackage (Figure2) theyare

installed in three tanks –water, caustic and acid– after

the heat exchanger and in the backflow. The tempera-

ture control within the process gains speed because

the tanks can be heated up internally before the CIP

process is started. It is the same for the concentration

of caustic and acid. Including a CLS54D conductivity

sensor in each of the tanks will determine the concen-

tration, evenwhen theCIPplant is not in operation, so

the media are always properly prepared.

The conductivity sensor is equipped with an

internal temperature sensor to compensate for the

influence of changing temperatures. Connected to a

central CM44x transmitter, the signals of both can be

converted into a concentration value. The transmitter

(also available for DIN rail installation) can host up to

eight sensors. This allows the phase shift meter in the

backflow to be either a compact CLD18 or a CLS54D.

Instead of a flow switch, the electromagnetic

Promag 10H flow meter is used. This hygienic sensor

supplies the information more accurately than the

flowphant by using the flowrate signal. The Liquipoint

limit switches are replaced by liquiphant vibration

point level switches. They are installed in the three

tanks and positioned in front of the supply pump and

the return pump. Liquiphant level switches are easier

to commission and work with all liquid media, even if

not conductive and are the standard sensors in this

application. The RSG35 still has the capacity to show

and report all relevant data.

There are sensor options to choose from that im-

prove theCIPcontrol system. They supply information

more accurately and faster, helping to save water, en-

ergy, cleaning agents and time. The higher investment

costs often be recouped in a very short time thanks to

reducedoperational costs. Hygienic design adds some

cost to a project, but the savings in every phase shift,

during production or cleaning support short return on

investment periods.

In the advanced system (Figure 3), velocity is

measured with a Promag H 100. Based on the same

hygienic sensor, this unit is equipped with a more

sophisticated transmitter than thePromag 10H. After

each cleaning, the Heartbeat™ Verification tool veri-

fies the sensor is working within its specification. The

Promag H 100 features empty pipe detection that

Figure 1:

The CIP

starter package for

Endress+Hauser enables

simple automation of CIP

processes.

Figure 2:

CIP standard

package includes options

that supply information

more accurately and faster,

helping to save water, en-

ergy, cleaning agents and

time.

Figure 3:

In the advanced

automation package,

velocity is measured with

a Promag H 100, which

is equipped with a more

sophisticated transmitter.

recognises when the return pipe is completely filled,

even when installed horizontally. Flow can still be

measured when the pipe is not full, however, an alarm

signal is then given to suggest the system may not be

cleaned completely.

TwoSmartecCLD134compactdevicesareinstalled

in the two agent tanks when a local display is needed.

Two CLS54D sensors connected to the CM44P

transmitter can be used to measure conductivity and

directly calculate concentration. The same contact

device is used in the return line. It detects variation

in the concentration of the returning cleaning liquid

as fast as possible.

TheTM401QuickSensisusedtomeasuretempera-

ture and control themake-up in the tanks. The TM411

QuickNeck is installed in the backflow, after the heat

exchanger. These temperature measurements are

important tomaintain consistent quality, and frequent

sensor calibrationprovides the required level of safety.

The QuickNeck is installed with a specific fixed bayo-

net thermo-well so the entire loop can be calibrated

without opening the process or cable connection. The

spring-loaded Pt 100 element is still in close contact

with theprocess and thereforehas a fast T90 response

time. The limit switches are replaced with a hygienic

sensor that uses a combination of capacitance and

conductivity technologies.

Supplying the same easy, flexible operation as the

Liquiphant, the Liquipoint FTW33 can be installed

flush-mounted. This is the next step inhygienic design.

The Liquipoint’s function can be easily tested with

a service magnet, without opening the process. The

central unit is changed to a RSG35 data recording

and displaying system in order to properly display this

complex system and record more values.

The differentiator in this high end system is the

OUSAF11absorptionsensor.Thissensor,connectedto

the same CM44P as the conductivity sensors, quickly

detects when the majority of the product remains are

flushed out of the system, enabling demand-driven

(instead of time-controlled) flushing. This saveswater

andprotects the caustic frombeing loadedmore often

thannecessary. Nevertheless, thefirst caustic pumped

through the system takes the majority of impurities

with it. It makes sense to drain this caustic rather than

to recycle it into thebuffer tank, where it contaminates

theothercaustic.Thisresultsinabetteruseofcaustics,

which leads to lower costs.

Figure 2

Figure 3