Filtration and Clarification (CL-101)

The objective of filtration is to get rid of visible foreign matter. The milk is preheated to about
35-40°C using plate or tubular heater for efficient filtration and clarification. Preheating
becomes essential, if the incoming milk is cold. As the temperature of the milk increases, the
viscosity of milk decreases resulting in more efficient filtration and clarification. Simple
filtration could take away suspended particles by straining method whereas clarification
removes the identical by centrifugal sedimentation. Filters typically contain textile or pad of
delineated pore size, that retain smaller particles, whereas clarification removes sediments or
slime way more efficiently than filtration .Clarifiers take away even finer particles that escape
filters. The plant had installed clarifier tank for filtration and clarification process. The new
installed equipment need to undergo precomissioning, commissioning and start up process to
make sure that the equipment achieved stable and reliable operating conditions while meeting
product specifications.

Pre-commissioning of Clarifier (CL101)

Figure 2 shows clarifier tank

The first thing in the precommissioning activities are drawing check. The pre-commissioning
activity involve the activity of ensuring all the part in the equipment are well fitted according
to the drawing provided. It is important to refer the drawing to prevent wrong setting of the
part in the equipment shown in figure 2. Part and component of the clarifier also need to be
checked as it had been mentioned in the drawing. Then, the team need to do the inspection on
the part and component whether it had been installed properly. Wrong set of component or
loosen bolt at the equipment can damage the tank. As to make the precommissioning run
smoothly, a set of checklist need to be prepared. The following item need to be done in the pre
commissioning of clarifier:
 1. Air and stream blowing
2. Flushing, chemical and mechanical cleaning
3. Electrical system verification
4. Instrumentation verification

Commissioning of Clarifier (CL101)

Commissioning is a verification process used to confirm that a facility has been designed,
procured, fabricated, installed, tested, and prepared for operation in accordance with design
drawings and specifications. There are several item need to be checked in the commissioning
of clarifier:

1. Operational Tightness Testing

2. Run in of rotating equipment
3. Drying Out and inerting
4. Instrument and electrical function testing
5. Function testing of safety systems

First activities in commissioning for clarifier tank are hydro testing. Before that, ensure power
supply is available for all the pumps, instruments & equipments in the plant. The clarifier are
filled with water to check if any water leak found in the tank. Then, the mechanism of the
clarifier tank need to be check whether it suitable for the operation. The impeller must installed
tightly to prevent the damaged of the tank. The speed of mechanism are being set according to
recommendations. Check the suction and delivery valve of raw water pump. Start the raw water
transfer pump and set the flow by adjusting its delivery valve. Start the flash mixer agitator and
impeller in clarifier mechanism once the level get filled up to agitator.

Start up of CL-101
Before running the tank, inspect the tank and mechanism path for any obstructions. Start the
unit while the tank is still empty and watch carefully for correct rotation and possible
interferences. Then, all the problem listed in the punchlist need to be settled. After that, the raw
milk is being introduced in the tank. Then, start the mechanism and associated equipment, and
begin the operation. The impeller in the bottom of the tank will begin to rotate, and result in
sedimentation of visible foreign matter. The raking mechanism at the tank bottom collects the
solids as they settle. The rake blades push solids to the sludge trough for removal. The speed
of the raking mechanism has been set for the particular machine. The product of the claifier
tank will then be tested in the next process, which is standardization. The product from start-
up procedure are used for testing only with no intention on commercialization.
Rotary screw compressor

Rotary screw compressor is a new equipment in the modified plant of condensed milk.
Apparently, condensed milk are well known with it thick, sticky and semi-fluid consistency.
Generally, a screw compressor consist of two screw like rotating elements, a casing, an air
filter, rubber seals, suction valve and delivery valve mainly.

Figure 3 shows the illustration of rotary screw compressor

The mechanism of rotary screw air compressor in producing high volume of pressured air are
by trapping air between two meshed rotors and reducing the volume of that trapped air as it
moves down through the rotors. In this case, the compressor can be used to force the sticky
condensed milk against the internal surface of the vessel and pipeline, thus maximum
condensed milk can be transfer to the next vessel.

PRECOMMISSIONING OF ROTARY SCREW COMPRESSOR

New or modified plant need to undergo pre-commissioning before being used for
commercialization. This process will determine the efficiency and stability of the operation.
Pre-commissioning are always about the drawing’s checking. The first activities of pre-
commissioning for rotary screw compressor are checking the component of mechanism based
on drawing. The rotating screw of the compressor need to be inspect by the team to see if it
fitted for the equipment. Then, the equipment must undergo cleaning and flashing process to
remove the visible foreign matter like dirt resulted from the installation of the equipment. Then,
the equipment must be blown by hot steam to avoid contaminant that will affect the production
of condensed milk. After that, the operator need to brief about the equipment with the latest
Standard Operating Procedure and provide the manual on maintenance and operation. After
that, electrical system and instrumentation of the equipment will be verified to avoid the short
circuit if the machine are run. As the precommissioning item mentioned above had been
applied, the commissioning activities can be start.

COMMISSIONING OF ROTARY SCREW COMPRESSOR

Commissioning activities are activities that determine the equipment are functioning according
to the specific requirement of the equipment. Hydro testing is common in commissioning as
the testing objective is to determine the strength of the equipment and to see the probability of
leaking. After completion of the hydro testing, the compressor will be kept running for a
minimum of four hours after running conditions have stabilized, while the mechanical
performance is checked. The pressure ratio will be as near to the normal operating conditions
as possible whenever the discharge temperature limitation permits. As for the heat run, the
suction and discharge pressures shall be so adjusted that the discharge temperature will meet
the specified value. During the mechanical run and the performance check, the suction may be
throttled to obtain as near as the specified pressure ratio. Heat run temperature must be in
specified value with specific tolerance. During the mechanical run, the discharge temperature
should be within the limitation. During the test, the shaft seal portions except seal gas supply
nozzles of the compressor will be open to atmosphere. If there are any problem occur in the
testing, list the problem in the punch list before running the start up activities.

START UP OF ROTARY SCREW COMPRESSOR

The following checks should be made when the compressor is started for the first time. First,
make sure that the compressor does not make an unusually high pitched noise at initial startup
and that the oil pressure builds as the compressor operates. Lack of oil can result in a loud
pitched noise from the compressor and if heard the compressor should be shut off immediately
and the source of the noise investigated. Then, if at any point the compressor suction pulls into
a deep vacuum, it should be shut off immediately. The compressor should never operate with
lower suction pressure. Operation in a deep vacuum will cause the rotors to quickly overheat.
This can lead to contact between the rotors and rotor housing resulting in damage to or failure
of the compressor. After that, ensure that the motor cooling valve is energized and feeds when
called by the module. Ensure that the de-superheating valve feeds when the discharge
temperature is high. The temperature inputs should be examined to make sure that both the
motor and discharge temperatures rise when the compressors starts. This will confirm that the
sensors are installed and are operating correctly. Ensure that the following solenoids turn off
when the compressor shuts down which are oil solenoid valve, economizer solenoid valve and
de-superheating solenoid valve.