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April 16, 2015 2015 Craft Brewers Conference Stainless Steel 201 Considerations about an important ingredient of the brewery plant Ashton Lewis Brewery Product Manager Paul Mueller Company Springfield, MO

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Page 1: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Stainless Steel 201Considerations about an important ingredient of the brewery plant

Ashton LewisBrewery Product ManagerPaul Mueller CompanySpringfield, MO

Page 2: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

A Good Fit for the Duty

Why is Stainless Steel Used?

Mechanical Properties• Malleable

• Strong

• Easily welded

• Easy to polish

• Durable

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April 16, 2015 2015 Craft Brewers Conference

Allows heads to be dished …

Malleability

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April 16, 2015 2015 Craft Brewers Conference

Allows heads to be dished …

Malleability

… and Flanged

Page 5: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Allows heads to be dished …

Malleability

… and Flanged

Tubing can be drawn

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April 16, 2015 2015 Craft Brewers Conference

Requirements Duty Dependent

Surface Finishes

Finish Types

• 2B / Cold Rolled

• Mechanically Polished

• Hot Rolled, Annealed and Pickled (HRAP)

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April 16, 2015 2015 Craft Brewers Conference

To a Point!

Durable …

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April 16, 2015 2015 Craft Brewers Conference

“Stainless” is not Absolute

Chloride Pitting

Stress Corrosion Cracking

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April 16, 2015 2015 Craft Brewers Conference

Picking the proper tool for the job

Steel Type

Type 304• Most common austenitic stainless type

used in food and beverage processing

• Commonly referred to as 18-8

• Most brewing equipment is fabricated from Type 304 stainless

• Relative cost = 1.00

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April 16, 2015 2015 Craft Brewers Conference

Steel Type

Type 316• Similar to Type 304, except for the inclusion of

2% molybdenum

• “Moly” adds improved resistance to chlorides and helps ward off pitting corrosion

• Type 316 is the most common type of stainless steel used in pharmaceutical equipment

• Also commonly used for surgical instruments

• Relative cost ~ 1.30

Picking the proper tool for the job

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April 16, 2015 2015 Craft Brewers Conference

Big Salt Piles Contribute to Great Diving!

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April 16, 2015 2015 Craft Brewers Conference

Picking the proper tool for the job

Steel Type

2205• Duplex steel

• Magnetic

• Does not readily succumb to SCC

• Readily available

• More difficult to form than Types 304 and 316

• Difficult to apply heating surfaces

• Relative cost ~ 2.00

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April 16, 2015 2015 Craft Brewers Conference

Picking the proper tool for the job

Steel Type

AL6XN• Austenitic

• Does not readily succumb to SCC

• Readily available

• Has similar forming and fabrication qualities to Types 304 & 316

• Expensive

• Relative cost ~ 4.50

Page 14: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Summary of Alloy Compositions

Steel Type

Alloy Cr Ni Mo Cu N C

304L 18-20% 8-12% - - 0.10% max

0.03% max

316L 16-18% 10-14% 2-3% - 0.10% 0.03% max

2205 22%Avg

5%Avg

3%Avg - 0.14%

Avg0.03% max

AL6XN 20-22% 23-25% 6-7% 0.75% max

0.22% Avg

0.03% max

Page 15: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Summary of Alloy Compositions

Steel Type

Alloy Cr Ni Mo Cu N C

304L 18-20% 8-12% - - 0.10% max

0.03% max

316L 16-18% 10-14% 2-3% - 0.10% 0.03% max

2205 22%Avg

5%Avg

3%Avg - 0.14%

Avg0.03% max

AL6XN 20-22% 23-25% 6-7% 0.75% max

0.22% Avg

0.03% max

Material selection is typically the buyer’s responsibility

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April 16, 2015 2015 Craft Brewers Conference

Different Alloy …Visually Indistinguishable

Buyer’s Protection• Material specifications

• Material certifications

• X-Ray Fluorescence (XRF) guns are used for nondestructive testing and separate alloys by elemental composition

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April 16, 2015 2015 Craft Brewers Conference

CHAPTER II

PROTECTING YOUR INVESTMENT

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April 16, 2015 2015 Craft Brewers Conference

Readying New Equipment for Use

What?Used for lubrication is polishing and machining operations

How?✓ Degreasers and other solvents

✓ Detergents

✓ Elbow grease

Removal of Atypical Soils …➢ Manufacturing oils

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April 16, 2015 2015 Craft Brewers Conference

Readying New Equipment for UseRemoval of Atypical Soils …

➢ Manufacturing oils

➢ Adhesive residues

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What?Used to secure protective films to stainless steel during manufacturing

How?✓ Degreasers and other solvents

✓ Detergents

✓ Elbow grease

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April 16, 2015 2015 Craft Brewers Conference

Readying New Equipment for UseRemoval of Atypical Soils …

➢ Manufacturing oils

➢ Adhesive residues

➢ Road grime

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What?➢ Brake dust (rich in iron)

➢ Oils

➢ Salt

➢ Dirt

How?➢ Degreasers and other solvents

➢ Detergents

➢ Salt binding compounds

➢ Iron chelating compounds

Page 21: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Readying New Equipment for UseRemoval of Atypical Soils …

➢ Manufacturing oils

➢ Adhesive residues

➢ Road grime

➢ Free Iron

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What?➢ Iron that is not part of the crystalline matrix

of stainless steel

➢ Can come from tools, carbon steel dust and contaminated grinding abrasives

How?➢ Iron chelating compounds

➢ Passivating acids, such as nitric and citric acid

Page 22: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Readying New Equipment for UseRemoval of Atypical Soils …

➢ Manufacturing oils

➢ Adhesive residues

➢ Road grime

➢ Free Iron

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4

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April 16, 2015 2015 Craft Brewers Conference

The Invisible Force1

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Page 24: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

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April 16, 2015 2015 Craft Brewers Conference

The Invisible Force is Real! 1

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April 16, 2015 2015 Craft Brewers Conference

The Invisible Force is Real! 1

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Page 27: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Vacuum Defined

External pressure > Internal Pressure

Page 28: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Vacuum Defined

External pressure > Internal Pressure

This Sucks!

Page 29: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Common Causes of Vacuum

Pumping out of an unvented vessel or accidentally draining an unvented vessel

Page 30: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Common Causes of Vacuum

Pumping out of an unvented vessel or accidentally draining an unvented vessel

Note that vessel vents can become obstructed!

Page 31: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Common Causes of Vacuum

Pumping out of an unvented vessel or accidentally draining an unvented vessel

Page 32: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Common Causes of Vacuum

Pumping out of an unvented vessel or accidentally draining an unvented vessel

Overfilling a vessel without a siphon breaker … really?

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April 16, 2015 2015 Craft Brewers Conference

Tank OverfillingQuestion:

While filling a tank, beer begins overflowing from the vent line. What do you do?

Page 34: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Tank OverfillingPossible Actions:

❑ Shut the inlet valve

Page 35: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Tank OverfillingPossible Actions:

❑ Shut the inlet valve

❑ Turn off the supply pump

Page 36: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Tank OverfillingPossible Actions:

❑ Shut the inlet valve

❑ Turn off the supply pump

❑ Shut the overflow/vent line valve

Page 37: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Tank OverfillingPossible Actions:

❑ Shut the inlet valve

❑ Turn off the supply pump

❑ Shut the overflow/vent line valve

❑ Close all valves and turn off supply pump

Page 38: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Tank OverfillingPossible Actions:

❑ Shut the inlet valve

❑ Turn off the supply pump

❑ Shut the overflow/vent line valve

❑ Close all valves and turn off supply pump

❑ Grab a pitcher to prevent beer loss

Page 39: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Page 40: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Tank Overfilling

Possible Actions:

❑ Shut the inlet valve

❑ Turn off the supply pump

❑ Shut the overflow/vent line valve

❑ Close all valves and turn off supply pump

These actions can all lead to a siphon if not performed properly

Page 41: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Tank Overfilling

This is what happens if you simply stop liquid supply…

Page 42: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Tank Overfilling

This is what happens if you simply stop liquid supply…

Page 43: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Tank Overfilling

This is what happens if you simply stop liquid supply…

Page 44: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Tank Overfilling

This is what happens if you simply stop liquid supply…

Page 45: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Common Causes of Vacuum

Pumping out of an unvented vessel or accidentally draining an unvented vessel

Overfilling a vessel without a siphon breaker … really?

Spraying caustic into a CO2 atmosphere

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April 16, 2015 2015 Craft Brewers Conference

Caustic & Carbon Dioxide

CO2(g) + NaOH(l) NaHCO3(s)

CO2(g) NaOH(l)

Page 47: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Caustic & Carbon Dioxide

CO2(g) + NaOH(l) NaHCO3(s)

Page 48: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Caustic & Carbon Dioxide

CO2(g) + NaOH(l) NaHCO3(s)

Page 49: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Common Causes of Vacuum

Pumping out of an unvented vessel or accidentally draining an unvented vessel

Overfilling a vessel without a siphon breaker … really?

Spraying caustic into a CO2 atmosphere

Hot CIP followed by cold rinse

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April 16, 2015 2015 Craft Brewers Conference

When Hot Meets Cold

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April 16, 2015 2015 Craft Brewers Conference

When Hot Meets Cold

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April 16, 2015 2015 Craft Brewers Conference

Real-World Examples

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April 16, 2015 2015 Craft Brewers Conference

Real-World Examples

Page 54: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Real-World Examples

Page 55: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Preventing Vacuum-Related Failure

1. Installation of properly sized vacuum relief valves. Attention must be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered.

❖ Free-draining is often considered to be the worst case for sizing purposes

❖ Hot cleaning followed by ambient/cold rinse typically is more extreme than free-

draining

❖ KNOW YOUR PROCESS!

Page 56: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Vacuum Relief Valve Types

What?➢ Spring type valve

➢ Combination pressure and vacuum relief or vacuum-only designs

Notes➢ May have relatively high vacuum relief

pressure with respect to tank design, especially for larger tanks

➢ Limited gas flow due to size, and most useful for smaller vessels

➢ Cleaning actuators not available

Page 57: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Vacuum Relief Valve Types

What?➢ Rupture Disk

➢ Combination pressure and vacuum relief (dual acting) or vacuum-only designs

Notes➢ When these devices act they vent the

vessel to atmosphere and do not re-seat

➢ Burst disk indicators flag alarms about the condition

Page 58: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Vacuum Relief Valve Types

What?➢ Weight-loaded vacuum relief valve

Notes➢ Available with varying and quite low

vacuum pressures (easy to open)

➢ Available in a range of sizes up to 400 mm (~16”)

➢ Cleaning actuators available

➢ Heating inserts available

➢ Can equip with proximity sensors to flag alarms

Page 59: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Preventing Vacuum-Related Failure

1. Installation of properly sized vacuum relief valves. Attention must be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered.

2. Maintaining and inspecting vacuum relief valves, vents and overflows.

Vent line with heat tracing on milk silo

Page 60: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Preventing Vacuum-Related Failure

1. Installation of properly sized vacuum relief valves. Attention must be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered.

2. Maintaining and inspecting vacuum relief valves, vents and overflows.

Vent line with heat tracing on milk silo

CautionConvenient location can cause problems when rapid vacuum

occurs!

Page 61: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Preventing Vacuum-Related Failure

1. Installation of properly sized vacuum relief valves. Attention must be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered.

2. Maintaining and inspecting vacuum relief valves, vents and overflows.

3. Proper training to correctly respond to atypical events, such as tank over-filling.

Page 62: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Preventing Vacuum-Related Failure

1. Installation of properly sized vacuum relief valves. Attention must be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered.

2. Maintaining and inspecting vacuum relief valves, vents and overflows.

3. Proper training to correctly respond to atypical events, such as tank over-filling.

4. Implementation of procedures consistent with process.

Page 63: Considerations about an important ingredient of the ......be paid to the worst-case scenario when selecting relief valves and all possibilities need to be considered. Free-draining

April 16, 2015 2015 Craft Brewers Conference

Take Home Messages1. Select stainless steel material type with the same care used when choosing your brewing materials.

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April 16, 2015 2015 Craft Brewers Conference

Take Home Messages2. Prepare new equipment for use by removing atypical soils.

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April 16, 2015 2015 Craft Brewers Conference

Take Home Messages3. Recognize and respect the invisible force!

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Thank You forthe Opportunity!

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Contact InformationAshton LewisBrewery Product ManagerPaul Mueller CompanySpringfield, MO

[email protected](417) 830-2337