ETIQUETA
Enviado por Jenny • 6 de Septiembre de 2015 • Tareas • 1.828 Palabras (8 Páginas) • 158 Visitas
Functional Design Specification for
Winterization of Refined Oil
(18/12 or Omega 30 %)
System PWR
TABLE OF CONTENT
1 INTRODUCTION
2 PROCESS AND OPERATIONAL DESCRIPTION
3 DESIGN SPECIFICATION – MAIN EQUIPMENT
3.2 Other Equipment
3.3 Operability
3.4 Cleaning
3.5 Design codes and standards
4 MATERIAL AND CONSTRUCTION
5 INTERFACE AND UTILITIES
6 SAFETY AND ENVIRONMENT
7 DOCUMENTATION AND TESTING
8 MAINTENANCE AND TRAINING
9 REFERENCES
INTRODUCTION
This document is the FDS (Functional Design Specification) for Winterization for Refined Oil (18/12 or Omega 30 %).
The purpose of this FDS is to specify design, operational and functional aspects of the system according to the requirements given in the URS-PWR.
SCOPE
The scope of this FDS is defined by the URS-PWR.
The Winterization system consists of feed tanks, crystallizers, centrifuge, olein tank and stearine tank.
The design of the Winterization for Refined Oil system is defined by the P&ID: CSL-123200-313-SC-PI-001 Rev. R1.
VALIDATION
The system will be located within a GMP compliant facility; however, it shall not be used for API production, and will have IQ (Installation Qualitification) and OQ (Operational Qualitifcation) completed. The system shall meet the requirements for food standards and hygienic design. The documentation shall comply with the principles described in the ISPE GAMP 5 guideline.
Change control shall become operative for this system when this FDS is approved and signed out by TASA Omega.
RESPONSIBILITY
Everybody involved in the project shall act in accordance with the scope, specifications and requirements of this document.
PROCESS AND OPERATIONAL DESCRIPTION
The oil shall be heated to 50 – 55 °C, and kept at elevated temperature until all solids are melted, prior to entering the crystallizer and cooled down according to a cooling curve dependent of the oil quality. Food grade propylene glycol is recirculated to cool the batch and make crystals. When the crystallization is finished the slurry shall be separated on a centrifuge. The centrifuge shall be primed with a melted stearine fraction and as soon as the feeding is started from the crystallizer the stearine feed shall stop.
Stearine will be separated and collected in a stearine melting vessel and pumped to the stearine tank. The olein phase is collected in a separate tank for approval prior to further processing.
DESIGN SPECIFICATION – MAIN EQUIPMENT
Crystallizers (Tag No. : PWR-EQ-01; PWR-EQ-02; PWR-EQ-03) | ||||
Function / Design | Specification | Description | Ref.: URS-PWR | |
3.1.1 | Batch Size | Max. 15,2 t/batch | The winterization process is a batch wise process | 5.2.2 |
3.1.2 | Capacity | > 40 t/d | The plant is designed to process 45 t/d, 355 per year | 4.1.1 |
3.1.3 | Feed | Protein < 0 Phospholipids <10 ppm Water < 0,1 % Soaps <50 ppm AV < 10 FFA < 0,1 % POV < 5 | Fish Oil is neutralized, bleached and stripped before entering to winterization system | 4.5.1 |
3.1.4 | Product | Refined Fish Oil (18/12 or Omega 30 %) | Specification of product to be obtained is:
| 4.1.2 4.5.2 |
3.1.5 | Yield | > 50 % | Expected yield of olein from normal 18/12 or Omega 30 % fish oil is 50 % - 75 % | 4.1.3 |
3.1.6 | Feed Temperature | > 15 °C | During the crystallizer filling stage the oil is preheated in the economizer and then further heated to the temperature > 15 °C above the apparent melting point, and minimum to 50 °C, to ensure complete melting of all present crystals. Right after is cooled down in a crystallization pre-cooler to a temperature of about 35 °C | 4.3.2 4.3.3 |
3.1.7 | End temperature for crystallization | Approx. 0 °C | ------ | 4.3.4 |
3.1.8 | Agitator | 5.5 kW Speed (max): 42 rpm | Crystallizers provided with slow running agitators with speed control to avoid mixing in gas Agitator flanged on top of crystallizers | 4.3.6 4.3.7 5.2.5 |
3.1.9 | Dimensions | Total height: 4856 Diameter: 2200 | The height includes only body tank without legs and agitator | ----- |
3.1.10 | Feed inlet | From bottom of crystallizer | To avoid mixing in gas | 4.3.7 |
Other Equipment
Function / Design | Specification | Description | Ref.: URS-PWR | |
3.2.1 | Oil Feed pump Tag No.PWR-BO-01 | Gear lobe pump | 22 m3/h x 6 barg Capacity range: sufficient to fill Crystallizer in < 45 min | 4.3.1 |
3.2.2 | Oil Economizer Tag. No.PWR-IC-01 | Plate heat exchanger Flow rate: 20 t/h | For energy economizing For economizing cold feed oil with heated oil in flow filling line. Reduces heat duty from 20 kWh/t to 10 kWh/t (at feed inlet 20 °C and final heat temperature 60 °C) | 5.2.4 |
3.2.3 | Pre-heater module Tag No. PWR-IC-02 | Plate heat exchanger Flow rate: 20 t/h Steam: 120 °C | For pre-heating oil feed to crystallizer from 30 °C to 65 °C by steam water | 4.3.3 |
3.2.4 | Pre-cooler module Tag No. PWR-IC-03 | Plate heat exchanger Flow rate: 20 t/h Coolant (water): 30°C | Designed for cooling oil by cooling water | --- |
3.2.5 | Nozzle Separator (Centrifuge) Tag No. PWR-EQ-04 | Bowl volume : 21 L Bowl speed : 6600 rpm Wetted parts : AISI 316 Temp. °C : Design : 0 °C – 100 °C Operation : 5 °C | Centrifuge:Separation stearin/olein separation | --- |
3.2.6 | Separator Feed Pump Tag No. PWR-BO-05 | Progressive cavity pump Capacity: 30 t/h | The oil/crystals suspension is transferred by a pump rotating at low speed in order to ensure that crystals are not broken during the passage through the pump | 5.2.6 |
3.2.7 | Turbidity Control Loop Tag No. PWR-QE-051 | Adjustable turbidity range (0 – 500 ppm) to enhance sensitivity | For monitoring of the separation efficiency | --- |
3.2.8 | Olein Discharge Pump Tag No.PWR-BO-06 | Centrifugal type Capacity: 20 t/h | ----- | --- |
3.2.9 | Stearin Discharge Pump Tag No. PWR-BO-07 | Progressive cavity type Capacity: 6 t/h | ----- | --- |
3.2.10 | Feed Tanks (PWR-TQ-01/02) | Acc. to IN-S31 | ----- | 5.2.1 |
3.2.11 | Stearin Tank (PWR-TQ-04) | Acc.to IN-S36 | ----- | 5.2.1 |
3.2.12 | Olein Tank (PWR-TQ-03) | Acc.to IN-S32 | ----- | 5.2.1 |
Operability
Function/Design | Specification | Description | Ref.: URS-PWR | |
3.3.1 | Automation | Automatic | The plant is automated for charging the crystallizer, cooling profile (cooling profile has to be set manually for each kind of oil), start, separation and stop of separation | 4.2.1 |
3.3.2 | Operation | 1 operator | The system is automated to enable operation by one operator partly | 4.2.2 |
3.3.3 | Nitrogen blanketing | To avoid atmospheric oxygen | Atmospheric crystallizer, olein tank and stearine tank with nitrogen blanketing and breather valve | 4.3.8 4.3.9 4.3.10 5.2.3 |
Cleaning
Function/Design | Specification | Description | Ref.: URS-PWR | |
3.4.1 | General | Hygienic design-fully drainable | The winterization system is designed according to hygienic design criteria and is fully drainable. The cleaning of the winterization system is in place (CIP), and all piping and equipment shall be arranged for washing with CIP-liquid Control of the cleaning is performed by visual inspection/swab test, preferably not having to dismantle major parts of the equipment for testing. Cleaning manual is provided by supplier | 4.4.4 5.1.1 4.4.1 4.4.3 6.2.11 |
3.4.2 | Automation | Semi automatic CIP | Automation of the system is controlled through the process automation system but only a small amount of controls are required for this system | 4.4.2 |
3.4.3 | CIP solution | Light distillates or NaOH (2 % to 5 %) solutions | Normally with light distillates | 4.4.5 |
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