SOP on Sanitization of Purified Water Generation System and Distribution System

Purpose
To describe the procedure for Sanitization of Purified Water Generation System and Distribution System.

Sanitization or cleaning of Purified Water Generation System RO – 1^st Procedure:

• Sanitization of RO-1^st shall be done with H₂O₂ in case the bioburden load get increases and done with Citric Acid, NaOH if DP increase or flow decrease beyond the set value.
• Before start the Sanitization of Purified Water Generation System, inform to the concern department.
• Ensure that compressed air available 4-6 kg/cm².
• Fill purified water in CIP tank approx. 250ltr.
• Close the valve of RO-2 feed line.
• Connect the CIP circulation line for RO-1^st.
• Open the CIP valve for RO-1^st.
• Add 3.5 Ltrs. of H₂O₂ in CIP tank and close the lid of CIP Tank.
• Start the CIP pump and run the solution in RO-1st loop up to 45 minutes.
• After circulation Open the drain valve of CIP Tank to drain the complete water of CIP tank.
• Fill water in CIP tank again and run the system on rinsing for 20 to 30 minutes and then drain the complete water from line.
• Check the conductivity of water and , conductivity should be 10 to 20µS/Cm
• To ensure the residual of H₂O₂ in RO water, take the water sample and send to QC lab for analysis.
• If the residual of Hydrogen peroxide is present in water, then again rinse the whole system till residual of Hydrogen peroxide are totally removed from the water, also check the conductivity after sanitization it should be 10 to 20 µs/cm.
• Frequency of chemical Sanitization of RO plant: Quarterly (± 7 Days) or whenever Bioburden exceed beyond the limit.

Sanitization of RO-2.

• Ensure that compressed air available between 4-6 kg/cm2.
• Fill purified water in CIP tank approx. 250ltr.
• Connect the sanitization line for RO-2nd, open the valve for feed of RO-2nd and close the valve of RO-1^st.
• Start heating electrode on to maintain the temperature 85±5 °C.
• As temperature reached to 85°C start the CIP pump and circulate hot water in RO-2^nd loop for 2 hours.
• Note down the time of temperature achieve 85 °C in return loop of tank and circulate the hot water for 2 hours in loop. During this period maintain the temperature of water automatically through electrode.
• After completion of process drain complete water by opening drain valve, check the conductivity after sanitization it should be 05 to 10 µs/cm.
• Frequency of Sanitization of RO-II (Fortnightly ± 2 Days).

Sanitization of Mother Purified Water Loop and Distribution System 1 ,2 &System 3.

• Ensure that compressed air available between 4-6 kg/cm2.
• Ensure that purified water on Mother Purified Water Storage Tank, System 1&2 storage tank, System-3 storage tank should be fill more than 50 %.
• Ensure that steam Boiler should be in running condition before start the activity.
• Open manually steam inlet valve of Mother Purified Water Loop, System-1&2, and System-3 purified water storage tank.
• Open the HMI screen for Mother Purified Water Storage Tank and Loop, System-1&2, System-3 control and press Sanitization mode –ON.
• Start the distribution pump for circulation, steam inlet valve opens automatically for temperature maintaining, when temperature of return line loop reached 85 ⁰C steam inlet valve get close and when temperature get down to 80⁰C steam inlet valve reopen for temperature maintaining. This process repeats continuously for two hours for maintaining the temperature 85±5°C.
• At the same time HMI shall display indication for start of Sanitization of Vent filter. This Sanitization will continue for two hours.  
• Now circulate the hot water for 2 hours in loop. During this period maintain the temperature of water.
• After Sanitization is completed Open the drain valve of Purified Water Storage Tank and drain the tank up to ½ level.
• Now gradually add purified water to the storage tank while recirculating water through the system till the temperature of recirculating water reaches up to 35-40 °C.
• Drain all user points by opening the diaphragm valve in respective areas, check the conductivity after sanitization it should be NMT 1.3 µs/cm.
• Standby pump shall be replaced with used pump to ensure sanitization and proper working of standby pump. Similarly, this process shall be repeated every time before sanitization.
• Inlet / outlet pump connections of used pump shall be made Dummy. open the suction / discharge valve of the pump to make stand by pump operational.
• Frequency of Cleaning and Sanitization of Mother Tank, Distribution System  (Fortnightly ± 2 Days).

CIP of Ultra Filtration unit.

• Drain the water from Potable water storage tank-1, fill the Purified Water Approx. 250 Ltrs.
• Add Citric Acid (Approx. 5 Kg) and make solution for 1% to 3% Concentration.
• Circulate the Solution for 1 to 3 Hrs. with soaking time 10 to 15 minutes.
• Drain the water and flush the UF membrane for 10 to 15 Minutes
• Now refill purified water in Potable water storage tank Approx. 250 Ltrs
• Prepare Naocl Solution of 3000 PPM (Approx. 750 Ml in 250 Liter of water).
• Now circulate the Solution for 1 to 3 Hrs. with soaking time 10 to 15 Minutes.
• Drain the water and flush the UF membrane for 10 to 15 Minutes

CIP and Regeneration of FEDI

• Add 200 Liter purified water in CIP tank, prepare solution of 1-2% (Approx. 7.5 Ltrs.) by adding HCL (LR/AR Grade).
• Disconnect the DC supply.
• Connect the line or loop to FEDI feed /Concentrate/Rinse and start the CIP pump 
• Circulation time 30 to 45 Minutes and Soaking time shall be 15-20 Minutes.
• Drain the chemical water.
• Flush the FEDI with RO permeate water till pH reaches 6 to 7.
• Now fill the purified water again in CIP tank 
• Add sodium chloride 5% (Approx. 10 Kg) and Sodium Hydroxide 01 to 02 %- (Approx-3.5 kg) after proper dissolving and prepare 200 Liter volume in CIP tank with purified water.
• Start CIP Pump and circulate chemical solution in FEDI unit  feed flow
• Soak the FEDI after circulation 15-20 minutes and flush properly with RO permeate water till conductivity of FEDI outlet reach 50 µs/Cm.
• After flushing and cleaning the FEDI should be regenerated as per flowing procedure,
• Start generation system with FEDI and set the previous cleaning flow and switch on the DC supply and set current 4.5 to 5.5 Amp and regenerate the FEDI till the conductivity reach under predefined limit. Regeneration will take approximately 5 to 8 Hours.