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Sanitary Welding Procedure

How Weld Inspection can affect Beer Quality by Wright Gibb and Tim Casper Coors Brewing Company www.coors.com MBAA-RMD Presentation at A-B, Fort Collins May 9, 2007. Sanitary Welding Procedure. Weld test Autogenous weld Orbital welding Sensitization of a weld and it’s heat affected zone.

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Sanitary Welding Procedure

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  1. How Weld Inspection can affectBeer Qualityby Wright Gibb and Tim CasperCoors Brewing Companywww.coors.comMBAA-RMD Presentation at A-B, Fort CollinsMay 9, 2007

  2. Sanitary Welding Procedure • Weld test • Autogenous weld • Orbital welding • Sensitization of a weld and it’s heat affected zone. • Filler metal 304L or 316L

  3. Roughness Average • Pipe RA • Vessel plate • EP removes up to 30% • Prepping ID of pipe joint.

  4. Magnified surface with stylus

  5. Machined Surface Rolled Sheet Surface Cast Surface

  6. A.W.S. D18.1 • Means of visual examination. • Bore scope • Flash light and mirror • Radiograph

  7. A.W.S. D18.1 • Visual examination acceptance criteria • Welds shall be full penetration.

  8. Sanitary Weld Specifications AWS D18.1 Maximum Allowable Discontinuities Non-Product Contact Surface -Maximum Concavity

  9. Sanitary Weld Specifications AWS D18.1 Maximum Allowable Discontinuities Non-Product Contact Surface -Maximum Convexity

  10. Sanitary Weld Specifications AWS D18.1 Maximum Allowable Discontinuities Product Contact Surface -Maximum Convexity

  11. Sanitary Weld Specifications AWS D18.1 Maximum Allowable Discontinuities Product Contact Surface -Maximum Concavity

  12. Sanitary Weld Specifications AWS D18.1 Proper looking weld

  13. Sanitary Weld Specifications AWS D18.1 IP: Incomplete Penetration • Travel speed is to fast • Inadequate heat

  14. Sanitary Weld Specifications AWS D18.1 IP: Incomplete Penetration • Travel speed is to fast • Inadequate heat

  15. Sanitary Weld Specifications AWS D18.1 IP: Incomplete Penetration • Travel speed is to fast • Inadequate heat

  16. Sanitary Weld Specifications AWS D18.1 Sugar • Oxidation during weld process • Inadequate or no purge of pipe interior with inert gas, such as argon.

  17. Sanitary Weld Specifications AWS D18.1 Sugar • Oxidation during weld process • Inadequate or no purge of pipe interior with inert gas like argon.

  18. Sanitary Weld Specifications AWS D18.1 Concavity (Suck Back) • Excessive heat • Excessive purge gas pressure into pipe

  19. Sanitary Weld Specifications AWS D18.1 Convexity – Product Contact • To much filler wire being used • Rough surface can trap Bio • Caustic cleaning has trouble getting to all pits and cracks

  20. Sanitary Weld Specifications AWS D18.1 Welds shall not contain cracks, undercut, crevices, pits or embedded or protruding material. • To much weld wire being pushed through weld and burning off inside the pipe

  21. Why do we need to follow Sanitary Weld Specification AWS D18.1? The primary reason welds need to be free from defects is to reduce places that Beer Spoiling Organisms can grow. Beer Spoiling Organisms come in various sizes and shapes but generally they are tiny. In an area the size of a dot from a pencil, there could be as many as 40 organisms.

  22. Why do we need to follow Sanitary Weld Specification AWS D18.1? Some of the organisms are 0.7 to 0.8 um in diameter and 2.0 to 9.0 um in length. 0.7um equals .0000276”! Another comparison could be to an average human hair: the size of fine hair is 25 um which is 36 times larger in diameter than some of the organisms!!

  23. Why do we need to follow Sanitary Weld Specification AWS D18.1? Beer Spoiling organisms reproduce exponentially. This rapid rate can cause a population explosion down the system from the initial source.

  24. Consequences of Bad Welds Following are some illustrations of how organisms can take root in poor welds

  25. Results of Mismatched Pipe Slow flow Fast flow PipeWall Slow flow Weld Beer spoiling Organisms PipeWall

  26. Results of IP Cleaning solution Cleaning solution Pipe Wall Pipe Wall Concentrated organisms Weld

  27. Result of Sugared Welds Cleaning solution Cleaning solution Sugared Weld Weld Pipe Wall Pipe Wall

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