STANDARD OPERATING PROCEDURE Jet Cooker Model: SC2-3 Manufacturer: Pick Heaters, Inc. Location: Wet Processing Pilot Plant, 1091 Food Sciences Building Publication Date: 07/23/2014 Iowa State University does not discriminate on the basis of race, color, age, ethnicity, religion, national origin, pregnancy, sexual orientation, gender identity, genetic information, sex, marital status, disability, or status as a U.S. veteran. Inquiries regarding non-discrimination policies may be directed to Office of Equal Opportunity, 3350 Beardshear Hall, 515 Morrill Road, Ames, Iowa 50011, Tel. 515 294-7612, email eooffice@iastate.edu.
Description and Uses The SC2-3 pilot-scale heater was designed to heat a variety of slurries at a low product flow rate through a high temperature rise with little or no product degradation. As the slurry is pumped through the jet cooker, the helical flights within the mixing chamber create some turbulent action of the liquid flow, exposing more of the slurry surface to the injector. This ensures proper mixing of the steam from the injector with the product while in the mixing chamber. The unique multiple orifice design allows the steam to pass into the slurry in the form of tiny multiple streams that are easily and quickly absorbed by the liquid stream, thereby elevating the temperature of the liquid stream quickly and effectively within the mixing chamber. Once the produce has been heated to the desired set point, the slurry exits the mixing chamber, flows past the back-pressure control with its low-shear diaphragm and into the flash chamber where it discharges out of the 3-inch bottom port. It is this higher liquid pressure that allows the operator to cook at higher temperatures within the mixing chamber of the SC-cooker without flashing. Since steam is injected directly into the product, only culinary steam should be used, as house steam contains inedible boiler additives. Power Specifications Motor: Model 32-24588S Power: 5 HP Voltage/Amperage: 220V/20A Air Pressure: Regulator Supply 20 psi (not to exceed 35 psi or 2.4 bar); Regulator Output 3-15 psi Steam Pressure: 40 psig for culinary steam; 100 psig for unfiltered steam Maximum Temperature: 255ºF Product Flow Rate: 1-2 gal/min Potential Hazards and Safety Precautions Electric Shock/High Voltage (220-V) Make certain to use the correct outlet that is specifically designed to fit the electrical cord plug. Make sure the area around the outlet, floor and your hands are completely dry when plugging or unplugging the electrical cord to/from the outlet. Moving Parts and Pinch Points/Possible Entanglement of Extremities, Hair, Jewelry or Clothing The jet cooker operates with moving parts that can create possible pinch points. Keep extremities (especially hands), hair, jewelry and clothing clear of all moving parts while the cooker is in operation. Make sure to secure long hair and any loose clothing or jewelry before operating the jet cooker. 2
Flying Debris/Potential Eye Damage Always use proper personal protective equipment at all times while operating the jet cooker. Very High Temperatures and Hot Surfaces/Possible Burns to Skin and/or Extremities The jet cooker uses steam and operates at very high temperatures. Keep hands and extremities away from steam and heated tubes while the jet cooker is in operation. Heat-resistant gloves and smock should always be worn to avoid potential burns or injury. High Pressure/Possible Explosion The jet cooker operates under high-pressure using steam that is derived from a boiler. Any boiler malfunction can possibly lead to an explosion. As a result, never operate the boiler and/or jet cooker without direct supervision and training from the pilot plant manager. Required Personal Protective Equipment Safety Goggles Protective Footwear (No Open-toed Shoes) Lab Coat Hair Net (Tie Back Long Hair) Heat-resistant Gloves Long Pants and Long Sleeves Heat-resistant Smock No Loose Fitting Clothing Training Required Training *Denotes courses offered online Fire Safety & Extinguisher Training* Laboratory Safety: Core Concepts* Machine & Site-Specific Training Recommended Training for Frequent Users *Denotes courses offered online Electrical Safety & Lockout/Tagout Laboratory Safety: Spill Procedures Shop Safety Fundamentals: Basic Procedures & Policies* 3
Operation Operation: For Heating Below 210 F 1. Safely plug in and turn ON the Powers 545 Controller (Figure 1). Loop 1 Temperature operates at the desired variable set point. 2. Engage the manual button. Once engaged, the RED light for manual settings will be in the ON position. 3. Tap the display button until the word OUT is displayed in the second display line. Push the DOWN arrow to have the value next to the word OUT read zero 0 or a Figure 1 minus value. The steam control valve is now completely closed and will remain so, unless you go to the automatic mode or push the UP arrow while in the manual mode and display OUT has an input value that is above zero. 4. With the steam valve closed, slightly open your steam supply to the upstream from the steam-block ball valve. Once the steam has relieved itself of any excess condensate, open the steam-block valve. The steam pressure gauge should now read 40-psig (for culinary steam) or 100-psig (for unfiltered steam). With the steam valve closed and the block valve open, the system is ready to run. 5. Push the display button on the controller until SP is displayed. This sets the desired variable set point for your process. To set: move the UP or DOWN arrow to the desired cooking temperature. Once this is done, the system is now ready to heat your slurry. 6. Start the liquid-slurry pump. Once flow has been initiated and the temperature probe indicates that the liquid has been sensed at the probe (the process temperature will change at the large display), you may choose to switch the controller to automatic or continue to operate the system manually. 7. To switch the process into the Automatic mode, simply depress the lighted RED manual button. Once the light goes off, the system is operating in the Automatic mode, the steam control valve will open, and the controller will attempt to control the process at your desired set-point temperature. To continue to operate the system in manual, do not depress the RED manual button. Instead, push the display button until it reads OUT and zero (0). Then, move the UP arrow to increase the OUT value from zero to a positive value, thereby opening the steam-control valve. Once your set-point temperature has been reached in the manual mode, stop opening the steam-control valve. Note: Pressing the UP arrow and FAST button will cause the steam valve to quickly open when you are in the OUTPUT display. Holding the DOWN arrow and FAST button will cause the steam control valve to quickly vent itself and close. 8. Once you have completed your test, always turn the steam off first, but never let the process run unheated nor let the slurry tank go empty, as you will cause steam to flash downstream. To prevent this, have water ready to chase into the slurry tank after the final bit of product has been pumped through the cooker. Then, you can turn the steam control valve OFF in the manual mode by holding down the FAST button and DOWN arrow while in the OUT display mode; or you can set the process variable to zero 0 while in the automatic mode. Both options will force the steam valve to close. 4
Operation: For Heating Above 210 F 1. If the slurry needs to be heated above 210 F, it will require the assistance of the back-pressure control valve loop. Control of the sanitary back-pressure control valve is accomplished on Loop 2, the Pressure circuit of the Powers 545 Controller (please refer to Figure 1 on a previous page). To engage or display Loop 2 Pressure, depress the DISPLAY/FAST button on the controller. 2. The word Pressure should now be displayed along with the standard display features. Once in this mode, depress the display button once. 3. When the display button is pressed while in the pressure mode, the word OUT will appear on the display. Moving the UP or DOWN arrow while OUT is displayed will cause the back-pressure control valve to open or close. A 0 value in the OUT display indicates the back-pressure valve is fully open. A 100 value indicated in the OUT display indicates the back-pressure valve is fully closed. Note: Never permit the valve to go fully closed, as this may cause damage to the pump or jet cooker. 4. Any time you heat a slurry above 210 F, you must remember to set your set-point variable in the Temperature Loop to the higher temperature. Depressing the DISPLAY/FAST button will scroll you from the Pressure mode to the Temperature mode, i.e. DISPLAY/FAST moves you back and forth between the two loops. Operation: Shutdown Procedure 1. Always turn OFF the steam first. Note: Never have the liquid lines empty and the steam still on, as there is a strong possibility that one could accidentally open the steam-control valve and have steam flash down the empty lines when there is no water or product flowing. 2. Open the back-pressure valve if it has been used. Put the Pressure Control Loop at zero and remove the air from the valves. The steam-control valve should now be completely open after the air has been removed. 3. Turn OFF the product pump and begin to flush hot water into the lines. Once the water runs clear and there appears to be no other debris in the system, disconnect the pump. 4. Make sure the controller is in the manual mode and that all Outputs are at zero. Then, turn OFF the controller. 5. Disconnect the air supply from the I-P transducers. The steam- control valve should now be completely closed and the back-pressure control valve completely open. 6. Engage the manual steam-block valve. Then, close the line. There may be a slight buildup of pressure that will remain in the line. Once you have isolated the system from your steam pressure, it should be possible to relief that slight pressure by burping the block valve. 7. Disconnect all electrical cords to the controller and pumps. Note: Make sure the area around the outlet, floor, and your hands are completely dry when plugging or unplugging the electrical cord to/ from the outlet. 8. Initiate clean-up procedures. 5
Clean-up Procedures 1. After completing the shutdown procedure, begin a more thorough cleaning. It is best not to spray water into the flash chamber, but rather remove the unit from the frame, disassemble as needed, and hand wash and rinse all parts with hot water to remove any excess debris. Disassembly will also allow a thorough cleaning of the heating unit. 2. Place the clean parts on a drying rack and allow them to dry. 3. Clean and mop the surrounding work area. 4. Once the parts are dry, reassemble the unit onto the frame under the supervision of the pilot plant manager. 5. Have the cleaned machine and work area inspected and approved by the pilot plant manager. 6. Initiate check-out procedures. Machine Care and Maintenance Inspect the machine after every use for any leakage or broken parts. Note: All final inspections are performed by the pilot plant manager. Report any operational difficulties, leaks or broken parts to the pilot plant manager before leaving the work area. For detailed maintenance procedures, please refer to the equipment manual, located in the file cabinet in the pilot plant office, 1955 Food Sciences Building. Accessories None 6