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CIP Troubleshooting
Failures & Possible Solutions
Problem #1

CIP supply pump fails to reach target GPM or PSI

Solution?
Solution #1

Cause or failure mode

Pump seal leaking on pump

No water or low water supply to pump

Impeller and/or pump head plugged with foreign material

Excessive foam in CIP solution tank

CIP supply pump not running

Solution Tank Outlet Valve (TOV) not open

Filter/Strainer housing plugged

Sprayball missing

Routing valve open
Problem #2

CIP return pump fails to evacuate the vessels

Solution?
Solution #2
Cause or failure mode

Gaskets leaking or not used on inlet to return pump

TOV pulsing is too long, resulting in stall of return solution and poor evacuation
of tank

Restrictor orifice in CIP supply line removed or distorted, resulting in hydraulic
unbalance of system

Program drain times too short or pre-rinse times too long

Foreign material in CIP return pump impeller or in CIP return circuit

Return line filter full of materials

Leaking CIP return pump seal, resulting in air incorporation and cavitation

CIP return hose or jumper leaking or crushed

Return pump air eliminator fouled
Problem #3

Improper detergent or sanitizer concentration

Solution?
Solution #3
Cause or failure mode

Conductivity cell or sensor soiled or fouled

CIP operator overriding detergent feed system by manually adding detergent
to circuit

Electronic controller set-point changed

Control wire from sensor or probe to electronic controller off or loose

Chemical feed pump malfunction

Conductivity cell exposed to air by water level in tank dropping below probe

Empty detergent dispenser or barrel

Detergent time feed – timer setting changed, time malfunction

Plant water pressure increased, adding more water volume to circuit

Detergent injection check valve or anti-siphon valve malfunction
Problem #4

Low chlorine concentration

Solution?
Solution #4

Cause or failure mode

Chlorine may be old or gassed off

Chlorine pump malfunction

High organic load in CIP solution
Problem #5

CIP solution returning back into fresh water tank

Solution?
Solution #5

Cause or failure mode

Return or outlet valves malfunctioning

Air actuator not closing valve

No air actuator

Check supply air pressure

Check return line fittings above tank
Problem #6

CIP valve failure (air operated valves)

Solution?
Solution #6

Cause or failure mode

Actuator fails to operate valve stem

Piston sticking in actuator

Valve stem disconnected from actuator

Insufficient air pressure to actuator, causing no movement in valve stem
Problem #7

CIP system steam valve fails to reach target temperature or

has extended delay to temperature

Solution?
Solution #7

Cause or failure mode

CIP discharge pressure or flow rate is low, causing interruption of
steam supply to heat exchanger or CIP system

Steam valve fails to open

Steam valve air actuator sticking

Insufficient steam supply to CIP

Refrigeration left on vessel

Heat exchanger water logged

CIP supply discharge strainer plugged
Problem #8

CIP fresh water tank overflows

Solution?
Solution #8

Cause or failure mode

Liquid Level Control (LLC) board failure or improper analog scale for
level transmitters

Inadequate connection to probes or transmitter

Water valve leaking

CIP balance problem, water additions forced due to poor hydraulics
Problem #9

CIP system goes into over temperature alarm

Solution?
Solution #9

Cause or failure mode

Steam valve malfunction or leaking

RTD/Temperature switch malfunction

Low CIP flow through shell and tube heat exchanger
Problem # 10

Alkalinity noted in post rinse or acidified/sanitize rinse

Solution?
Solution #10

Cause or failure mode

Detergent check valve or anti-siphon valve malfunction

Alkaline pump improperly programmed

Inadequate post-rinse and/or drain times
Problem #11

Temperature fluctuation when cleaning a line circuit after

solution has reached preset temperature

Solution?
Solution #11

Cause or failure mode

Excessive leaks in line circuit, resulting in water additions during wash
cycle, causing temperature decrease

Improper valve pulsing routine
Problem #12

Tank/Vessel cleaning - areas within vessel/tank not being

cleaned

Solution?
Solution #12

Cause or failure mode

Plugged spray device (foreign material in spray device)

Incorrect detergent concentration

Spray device missing

Improper flow or pressure to sprayball

Inadequate return pump performance
Cleaning Failures

Air valve on processing tank not clean

Failure to pulse

Improper pulse routine

If valve cannot be pulsed during wash cycle, valve was not manually
cleaned
Cleaning Failures

Improper CIP preparation

Sample valve and tank door gasket should be removed for manual
cleaning

Check the door gasket for cracks or holes and replace as necessary

Manually clean with chlorinated, general cleaner solution at 115-
125°F

Brush-clean the front and back of the door, the port for the sample
valve and the area inside of the tank just beneath the doorway

Rinse all parts thoroughly

As the tank door is being re-assembled, make sure that all parts are
either dipped in sanitizer solution or sanitized with the central
sanitizer system hose
 Cleaning Failures

Unclean sections of pipe

Failure to include the pipe in the CIP circuit

Inadequate velocity (5 ft./sec. minimum)

Inadequate cleaning solution strength

Inadequate cleaning wash temperature

Inadequate cleaning cycle time

Processing valves washed within the circuit not operating properly
or not programmed to pulse
Cleaning Failures

Unclean portions of tank surface

Spray device plugged with debris

Distribution holes incorrectly spaced/located

Spray device position too high or too low from top of vessel

Inadequate flow rate to spray device

Inadequate detergent concentration

Inadequate wash temperature

Inadequate wash cycle time

Product allowed to dry on surface before CIP cycle is run

Pressure of cleaning solution through spray device too high,
causing solution to atomize
Cleaning Failures

Ring of soil in lower part of the tank/vessel

Return pump capacity not sufficient to correctly evacuate or return
solution to CIP system

Return pump air bound

Inadequate detergent concentration or improper temperature

Constant rinse allowing soil to float

Inadequate rinse times
Cleaning Failures

Blue Metal

Protein film - improper chemical

Temperature shock - hot water on cold tank or water temperature
too high

Water softener needs recharging

Magnesium deposits in water (12 ppm)
Cleaning Failures

Corrosion and pitting

Delays in rinsing when emptied

Excessive use and concentration of cleaning chemicals and
sanitizers

Surface not cool when sanitizing

Chlorine or Iodophor sanitizer too warm

Prolonged contact with chlorine

Inadequate rinse after cleaning

Stainless steel not passivated
Cleaning Failures

Build-up of white (soft) film

Cleaning solution low in active alkalinity

Failure to rinse properly and thoroughly after wash step

Build-up of white (hard) film

Hard water used at high temperature 145°F

Cleaner allowed to dry on surface before rinsing

Cleaner used at too high temperature
Cleaning Failures

Bronze/Brown metal

Iodine based sanitizer concentration elevated

Post-rinse temperature too high

Improper rinse

High iron content in water (3 ppm) or more

Iron fittings used somewhere in the CIP circuit or system

Elevated temperatures during base caustic wash
Cleaning Failures

Deterioration of gaskets

Excessive cleaner strength

Excessive cleaning temperature

Sanitizing with chlorine solution too long in advance of equipment
being used

Failure to follow cleaning with adequate rinsing