The Clean Design Guidebook A Discussion of Clean Design

A Discussion of Clean Design

DEFINITION OF CLEAN DESIGN

Clean design details are those features of design that control dirt and dust, make a
machine or facility easy to clean, and promote, in the operating people, a desire to keep a
machine or facility clean. Because of this latter aspect, clean design should also denote
“pleasing to the eye, orderly, and uncluttered.”

The term clean design is not synonymous with sanitary design. Sanitary design is
required where the potential for bacterial growth is present and it must be held in check.
A small crevice which might be acceptable in clean design would be unacceptable in
sanitary design because it would provide a harborage for bacterial growth. Sanitary
design requires considerable caulking and concern for access for washing and cleaning.
Clean design is intended to promote normal machine and facility cleaning, but not regular
washing or elimination of all harborages.

THE DESIGN PROBLEM

Clean design is a part of the total design package. When a machine or facility is to be
designed, the usual objectives are minimum initial cost, minimum operating cost,
operability, maintainability, access, strength, life, etc. Clean design is one more objective
that must be conscientiously pursued.

Clean design features must be worked into the total design from the beginning. If clean
design features can be made a part of the design from the beginning they will not, in most
cases, increase the cost of the machine or facility.

Often, as the design is developed, two desirable features such as minimum initial cost and
high strength design are not in accord. An “optimum” compromise must be reached
between these two objectives. This will be the case many times with clean design
objectives.

RESPONSIBIL ITI ES

The DESIGNER has a major responsibility for clean design because it is generally the
details of design that contribute to or detract from the ease of clean-up. Therefore, the
designer must be constantly aware of those design features that promote clean design.

The TECH ENGINEER must accept and support the same clean design objectives that
guide the designer so that in developing the basic concept of a machine or facility, he
does not hinder or prevent the incorporation of clean design features. When reviewing the
designs he should motivate and support the designer’s clean design activities.

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RESPONSIBILITIES (Cont’d)
Because a design cannot be developed in such detail that no decisions have to be made in
the field, the CONSTRUCTION FORCES must be well aware of clean design objectives
and apply the principles of clean design to field decisions.

PLANT PERSONNEL must also encourage clean design by feeding back knowledge of
problem areas or potential problem-areas that can be eliminated in the design. They must
maintain a high level of regard for clean design so that plant-executed modifications and
additions do not destroy the clean design features built into the original facility.

BASIC PRINCIPLES OF CLEAN DESIGN

There are seven basic principles to be considered in clean design:

1. ELIMINATE OR CONTROL DIRT SO THAT IT DOES NOT SPREAD

THROUGHOUT THE AREA.

If dirt or dust is eliminated or controlled at its source, it will not become a clean-up
problem in other areas. Control all normally produced dirt or dust. This would include
paper trim, dust from filling a container, steam water and dirt from an automatic dumping
steam trap or filter, and lubricating oil and grease drippage. Isolate and enclose lubricated
machine drive parts. Include provisions for abnormal situations like overflow of a tank or
the opening of a clean-out door. Control the dirt, dust, or debris to ease the clean-up job
before it even begins.

2. DESIGN WITH OPENNESS, EASY ACCESS AND SMOOTH CONTOURS SO

THAT AREAS SUBJECT TO DIRT CAN BE CLEANED EASILY.
Here is where design detail is most vital. Use piping or tubing for frames or support
instead of channels and “I” beams. When channels or angles are used, turn the legs down
so that dirt will not accumulate in the corners. Use surfaces that are smooth and free of
projections. Where there is an electrical unit, conduit, piping, etc., try to locate it inside
the main housing to reduce the number of items that have to be cleaned around. Reduce
(minimize) the amount of horizontal surface area that is exposed to dirt. Consider the
machine or facility in total from the beginning. The practice of hanging pipe, conduit or
controls on a piece of equipment as an afterthought is a prime cause of unclean design.
Do not place drive mechanisms; control boxes, etc., under the product flow where spilled
product can fall on them and make clean-up difficult.

The proper use of materials is an important consideration. Do not use a porous,

absorbent, rough surface material in an area where it is likely to get dirty and would need
to be cleaned off quickly and easily.

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BASIC PRINCIPLES OF CLEAN DESIGN (Cont’d)

3. WHERE OPENNESS AND EASY ACCESS ARE IMPOSSIBLE, FILL IN OR

SEAL THE AREA TO PREVENT DIRT FROM ACCUMULATING.
This principle deals with those areas that are impossible to reach. These areas should be
sealed shut so that dirt cannot get into them; e.g., seal tube ends, grout machine bases to
the floor and consider boxing in structural supports to prevent dust from accumulating on
hard-to-reach horizontal surfaces.

It is poor practice to simply put a shroud or cover over a dirty area. This practice simply
removes it from view and does not solve the problem. The intent of this principle is a true
sealing-out of dirt.

4. HAVE A WELL THOUGHT OUT, CONVENIENT LOCATION FOR

EVERYTHING THAT IS USED IN THE AREA.
“A place for everything and everything in its place” is the essence of this principle. This
includes raw materials, tools, cleaning equipment, changeover parts, protective clothing,
etc. It is also important that the storage areas be convenient so that the operating
personnel are encouraged to use them. Storage areas, like everything else, should be
designed with clean design principles in mind. Hang equipment rather than stand it on the
floor; avoid ledges and hard-to-clean corners; call for smooth contours and use hard, non-
porous materials.

5. AVOID CLUTTER.
Every installation has a number of auxiliary devices, motor starters, controls, vacuum
pumps, air compressors, etc., that do not have to be located in the prime area. When
possible, install these items in a remote location to avoid additional clean-up problems in
the most likely area for spills. Many times a drive motor can be located beneath the floor
or a vacuum pump can be located in the next room. Piping and conduit can often be
located beneath the floor and be brought into the prime area at the point of usage. Some
of these items can be put in common enclosures. The best example of this principle is the
advantage of a motor control center over individually mounted starters or a rack of
starters.

The Floor

The floor is of particular importance for two reasons:

- Because it is normally the dirtiest part of a facility, the floor sets the
tone or standard for the rest of the area.

- Since the floor is the usual place for dust, dirt, and debris to fall,
special emphasis is needed to make it accessible for easy cleaning.

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BASIC PRINCIPLES OF CLEAN DESIGN (Cont’d)

The Floor (Cont’d)

Concern for the floor leads to two additional principles of clean design:

6. KEEP THINGS OFF THE FLOOR

Where possible, support things from above or combine supports so that instead of two or
three supports on the floor there will only be one. Consolidate (gang) pipe and conduit or
other penetrations through the floor in a common opening with a single sleeve around
them. This will reduce the task of cleaning around many individual pipes.

7. THINGS ON THE FLOOR SHOULD BE SEALED.

Items that do touch the floor should be sealed to the floor, and be smooth and rounded. Use
pedestal bases without projections, grout around machine bases, and cove bases and walls.

ASPECTS OF MACHINE DESIGN -- FACILITIES DESIGN

There are two aspects to the clean design problem; the design of a specific machine and
the design for the complete plant facility. Both aspects require the same concern for clean
design objectives and application of clean design principles, but the approach to the
problem might be slightly different.

• Machine Design
In designing a machine, the total machine must be considered as a
complete system from concept to the final design stages. This system
includes the machine, controls, piping, wiring, auxiliary equipment,
dust control system, instrumentation, etc. All of these items must be
considered in the design and be coordinated into one clean, uncluttered
frame. Very specific details are important, such as choice of nuts, bolts
and other fasteners, structural shapes, access, drip pans, etc. Strength is
a consideration. A horizontal surface that an operator might stand on
must be strong enough to hold him, for it could be bent out of shape
and become difficult to clean. Guards that can be bent out of shape and
become hard to reinstall won’t be used.

Most of our machines are purchased from others, many of whom,

unfortunately, do not apply clean design principles to their designs.
These machines should be inspected prior to purchase with the intent
of determining how to clean design” the machine without incurring
exorbitant add-on charges. Consider such features as:

- can the electrical controls be put in a common control cabinet?

- can auxiliary equipment be removed and located elsewhere?
- can pedestal bases be substituted for machine feet?

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ASPECTS OF MACHINE DESIGN -- FACILITIES DESIGN (Cont’d)

- can the machine be raised to give enough clearance to clean

underneath it?
- can the base be filled with grout to make it easier to clean?
- can dust control or drip pans be added?
- can tube ends or other voids be sealed?
- can better fabrication techniques be used (i.e., grinding, welds, etc)?
- can difficult corners be filleted with caulking compound? etc.

• Facilities Design

Facilities design is totally our responsibility. There must be a

commitment to clean design from the start of the project. Because each
project is different, the design team, including the plant, and if possible
the construction forces, should meet at the start of a project and
analyze the dirt generating potentials and the level of cleanliness
desired and/or required and then develop clean design guidelines for
that specific project. Everyone must be committed to those guidelines
and follow through on them.

Use a design presentation technique that will give the reviewers full
comprehension of the facilities. Design reviews must be held with the
plant to examine the cleanability of the facilities. The full intent of that
design has to be transmitted to the field so that the construction forces
can understand the objectives and make their field decisions
accordingly. Consider every aspect of the facility from major
equipment to clean-up equipment, including all piping, conduit and
tubing.

Site clearance of existing piping, equipment and building structures

should be done to eliminate any unnecessary cleaning problems.
Consider reworking existing facilities that are to remain to achieve a
more easily cleaned area.

Proper lighting levels, attractively painted and color coordinated walls

and equipment, and attention to the overall appearance of the facility
will build pride in the operating personnel and encourage them to keep
the area clean.

Finally, not to be forgotten, the exterior areas, yard, roadways, etc. ,

should be designed with clean design principles in mind also.

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