寶潔日化培訓課件3-8-016 Pigging Do-Don't rv 9-16-2011

Author:DennisMcCulloughCleanDesignPrinciples‘Do/Don’ts’forPiggingDesignMicro/CleanDesignDo-Don’tsareprimarilyreferencetrainingmaterials;forP&Gprojectexecution,alwaysrefertotheCleanDesignStandards.Micro/CleanDesignPrinciplesCleanDesignSpecsforPiggingDefinitionsPrinciplesMaterialsofConstruction(MOC)Design:PigPiggingsystemRadiusrequirementsLaunch/RetrievalStation3-wayvalvesPigcontrolCIP/SIPDesignforcleaningefficiencyOtherDesignConsiderationsNewImprovements:IcePiggingMicro/CleanDesignPrinciplesPiggingDesignOverviewComponentsofaPiggingSystemMicro/CleanDesignPrinciplesPiggingDesignPiggingDefinition(s)Pigging

meaning(s):

(n)

domesticswine(n)

acoarseobnoxiousperson(n)

apersonregardedasgreedyandpig-like(n)

uncomplimentarytermsforapoliceman(n)

moldconsistingofabedofsandinwhichpigironiscast(n)

acrudeblockofmetal(leadoriron)pouredfromasmeltingfurnace(v)

livelikeapig,insqualor(v)

eatgreedilyA“Pig”isadevicethat,propelledbyfluidflow,travelthroughpipelinesinordertoremovedeposits,displaceproduct,andinspectormaintaintheline.Micro/CleanDesignPrinciples“Don’t”PiggingDefinition(s)PiggingDesignMicro/CleanDesignPrinciplesPiggingDesignPrinciplesManagementofMicroforoursystemsrequirescleaningandsanitization.Piggingsystemsareaneffectivewayofcleaning,eliminatingusagelossesandreducedwashwater.However,currentpiggingtechnologiesrequirespecialpipingdesign,whichaffectstheeconomicattractivenessofpiggingsystems.PiggingDesignMicro/CleanDesignPrinciplesIsthepipingIDsconsistentthroughoutthepiggablepathorwillpipeneedtobereplaced?Doexistingpipingsystemshaveelbowswithradiisufficienttopassthepig?Dotheexistingsystemshavevalvingorcomponentsthatwillrequirereplacementorreconfigurationinordertoallowthepigtotraveltheentirepath?Willmultiplepigsberequiredtoachievethedesiredresults?CannotputbutterflyvalvesinapiggablesystemPiggingDesignPiggingDesignPrinciplesMINIMALRISK(=standardfornewequipment)MODERATERISKHIGHRISKPiggingSystem:Designincorporates"captivesmartpig",thepigis"trackable"viaelectronicmeansandis(bi-directionalpigdesign.Pipelineitselfisneveropenedupduringprocessoperation.Theinternalcoreofthepigcontainsflexiblemagnetizedsiliconethatallowsittobedetectedinthepipenon-intrusively,usingaspecificallydesignedPigDetector.Designdoesnotallowreceiptofpigsatthelauncher,asblockagesinthepipelinemayrequirethepigstobepushedbacktothelauncher.PipeDesign:316LSS.AllinternalsurfacesorbitallyweldedandgroundsmoothandpolishedtoRa<0.8μm(32μinch).withnovisibleroughness,pitting,corrosionordamagedareas.Constantborediameter.316SS.Allinternalweldsgroundsmooth.StandardmillfinishofRa0.8-1.0μm(32-42μinch)oninternalpipewallsSomeroughnessevident,butnopittingorcorrosionevident.Not316or316LSS.Weldsandinternalfinishesnottreated,corrosionandpittingpresentinanypartofthesystem.Clamps/gaskets/sealsprotrudeinteriorofthepiperestrictingpigflowpath.Pig:FDA/Medical&FoodGradeapprovedmaterial.Compatiblewithprocessmaterialwithnodegradationofthepig.InternalweldsgroundsmoothCompatibilityissuewithpigandproduct.CheckyourMOCcompatibilitywithyourproduct&sanitizingagentwithCETL!Micro/CleanDesignPrinciplesPigging:MaterialsofConstruction/DesignMoredetails:SeeP&GCleanDesignStandardsoncGMPsiteMicro/CleanDesignPrinciples“Don’t”“Do”PigwithClawsRegularPig1LiterBottle(sizecomparison)PigDesign(CascadeCoolerExamples)PiggingDesignMicro/CleanDesignPrinciplesPiggingDesign“Do”PigDesignExample(CourtesyofLIAG)Micro/CleanDesignPrinciplesPiggingDesignPigLaunchStation:Example“Do”“Don’t”“Do”PiggingDesignMicro/CleanDesignPrinciplesPipeCleaningLaunchStation:Ensureallpartsofthelaunchandretrievalstationsarefullycleanableanddrainableconnectionsaredrainable;nobutterflyvalvesNote:Mustcleanandsanitizethroughlaunchandretrievalstationsradius=3D=12”r=12”r=12”4”diameterpipeDefinox(piggingvendor)recommendsthatthebendradiusbe3Xthepipediameter.Micro/CleanDesignPrinciplesPiggingDesign“Do”Note:Thereare“special”pigDesigns;e.g.,LiagthatcanmeetStandardpipebendradii(1.5D)Micro/CleanDesignPrinciples“Don’t”PiggingDesign3-wayValveDesign:EnsureMicrobiologyreviewspiggingdesigns:AvoidcrevicesthatdonotallowfullcleaningShowPBM3-wayvalveascomparisonPiggingsystemthree-wayvalveThree-wayvalvesealsbrokenandleakingMicro/CleanDesignPrinciples“Don’t”PiggingDesignMariscala3-wayPiggingValveDesign:EnsurewecheckwithMicrobiologyonproposeddesignsOneshouldconsiderthedifferentoperationsthatthepig/pipingsystemwillneedtoperform:

BackfillLine(followingpigwithproducttoavoidaeration)ProductRecovery(avoidproductlossbypushinglinefillsintostorage)ProductFilling/Recovery(controlpressureatfillerwithpigwhilerecoveringproductinfillingsystem)Micro/CleanDesignPrinciplesPiggingDesignMicro/CleanDesignPrinciplesPiggingDesignLevelofControl:Willitbenecessarytoremovethepigswhileprocesslineisinoperation?Note:thisdoesnotprovideoptimum“Minimal”microrisk.Thiswillrequireasystemtoincludepiggablevalves.Somemanufacturershavefeaturessuchasmilledareasontheballtodirectfluidflowthroughthecavityofthevalvebody.Cleaningsequencesshouldbeverifiedthatthebodycavitiesarebeingsufficientlycleaned.Sudmo,Defonix,PBMandothermanufacturemakevalvesdesignedtopasspigsaswell.Donotusebutterflyvalves—thepigwillnotpass.Willitbenecessarytostopthepigsatpointsintheline?Thiswilldetermineifthedesignneedstoincludeequipment(e.g.,liketheintermediateactuatorfromDefinox).Willitbenecessarytoknowthewhenapigreachesapointintheline.Mostpigsareequippedwithalinedetectionsystem.Thiscandeterminethepig’sposition.Doesthesystem/operationswishtowashandsanitizethesystemwithpigsinoroutofthecatch?Somesystems(catches)donothaveproperclearancestowashandsanitize.Thesesystemsrequireremovalofthepigsandsanitizingofthepigbyseparatemeans(i.e.hotboxoralcoholbath)PigControlRequirementsMicro/CleanDesignPrinciplesAutomaticPressureControlTomoreaccuratelydeterminethestoppingpointsofpigs,wecandecreasethepressurewhenthepigisnearthecatcher.Thiswillhelptoreducetheforceoftheimpact.PiggingDesign“Do”PigControlRequirementsPumpMMTankBottomMillNewSimplifiedDesignToHXMicro/CleanDesignPrinciplesPumpMMTankBottomMillToHX“Do”“Don’t”O(jiān)riginalDesignCIP/SIPdesignpipingtopromotedrainabilityforequipmentPiggingDesignPumpFMTankBottomMicro/CleanDesignPrinciplesPumpFMTankBottom“Do”“Don’t”CIP/SIPdesignpipingtopromotedrainabilityforequipmentNewSimplifiedDesignOriginalDesignPiggingDesignA“Pig”isadevicethat,propelledbyfluidflow,travelthroughpipelinesinordertoremovedeposits,displaceproduct,andinspectormaintaintheline.Anice“Pig”consistsofcrushediceinwaterwithafreezingpointdepressant.Anice-waterslurrycontainingafreezingpointdepressant,behaveslikeapigataniceconcentrationofabout40%.Below30%andslurrybehaveslikewater,whileabove70%icetheslurryistoosolidtomove.Slurriescanprovideincreasingmechanicalscouringatthewallwithouthavingtoincreasetheflowrateandsoenhancecleaning.The“effectiveviscosity”ofafluidcontainingparticulatematterishigherthanfluid.Micro/CleanDesignPrinciplesIcePigging(InDevelopment)Micro/CleanDesignPrinciplesInconstantdiameterpipe,theiceslurryicepresentsa‘solid’piston-likeprofileTheicepigcannegotiatepumps,valves,staticmixers,heatexchangersandpipelinesthatcannotcarryconventionalpigsCommonly,saltmaybeusedasthefreezingpointdepressantbutothersubstancescanbeusedsuchasglycerol,sorbitol,ethanol,glycol,oraceticacid.Infact,itmaybepossibletousetheproductitself(orasol