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Module 3 > Week 2 > Flashcards

Week 2 Flashcards

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1
Q

Examples of quarter-turn valves

A

Butterfly and ball

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2
Q

An example of a single seat valve and why you would use one

A

Divert valves:
Fully CIP’able, faster response time, more hygienic, automation

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3
Q

Why might you use Mix Proof valves?

A

-Can fully automate 24/7
-Can run cleaner through one and product through the other side at same time

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4
Q

4 goals of sanitary design (in valves)

A

Cleanable - can you run CIP through it?

Self- draining - product or liquid doesn’t remain in the valve after usage

Made of compatible materials - FDA/USDA compliant elastomers - can be digested if pieces come off in product
Construction materials must be full compatible with product, environment, cleaning materials and methods used and be inert, nonporus and nonabsorbent

Smooth and accessible surfaces - free of pits, cracks, corrosion, gaps, bolts, rivets, dead ends. Easily disassembled for inspection and cleaning

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5
Q

Cool things about Electropolish?

A

Can fill any cracks caused by hydropressing or cold pressing

Good wettability
Sluff off pollutions more easily
Easier to spot corrosion

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6
Q

Three functions of valves, regardless of design

A

Shut-off

Divert

Modulating (or throttling) control

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7
Q

What is a converging valve?

A

A divert valve that allows flow into one outlet from two different inlets (at a time)

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8
Q

Why would a reverse acting shut off valve be beneficial?

A

For dynamic closures

Reduces hydronic shock

Free-draining top-to-bottom flow

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9
Q

Benefits of running a matrix of valves?

A

Can run concurrent processes with separation

Run multiple, dissimilar products flow through each valve and require separation (concurrent filling, emptying and CIP cleaning ex)

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10
Q

What is an atmospheric gap in a valve?

A

Prevents cross contamination by venting liquid out if a seal fails
Bonus, it gives you a visual indicator of a failed seal by leaking

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11
Q

Advantages of a matrix over a flow panel?

A

Adv matrix:
PLC control
Probability of occurrence low
Product safety is not jeopardized
Record of activity

Neg of flow panel:
Uncertainty to “what” could happen
Probability of occurrence high
Consequences could be severe to product safety
No record of activity

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12
Q

What application might a constant pressure valve be utilized for?

A

A filler - to provide a steady flow and constant pressure

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13
Q

Name the 3 heat transfer mechanisms

A

Conduction
Convection
Radiation

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14
Q

What factors affect heat conduction through a surface?

A

Material type, thickness of wall, surface area and distance

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15
Q

Which are more effective at transferring heat: co-current or countercurrent in heat exchangers?
Why?

A

Countercurrent

Liquids come into “contact” at the most extreme differences in temp

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16
Q

What must be taken into consideration when using direct steam injection?

A

Do you have the capacity to handle extra product, concentration…(look this up)

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17
Q

Give 3 uses for heat exchangers in breweries

A

Cool wort
Mashing w/ heating jackets
Collandria
Tunnel pasteurization
HLT
Steam boiler

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18
Q

Why are plate heat exchangers so efficient?

A

Turbulent flow, plates close together, big surface area, capable of countercurrent flow, thin plates

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19
Q

What happens to aluminum in contact with caustic?

A

Forms Hydrogen gas (explosive!)

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20
Q

Define the term “wetting” in terms of a material’s surface

A

You want material to have well wetted properties which allows a surface to accept a cleaning solution and not “ball up” and only contact in a small patch

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21
Q

What are the two most common SS used in modern breweries?

A

304L and 316L

L are “low carbon” versions that have better resistance to corrosion

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22
Q

What is galvanic corrosion

A

Dissimilar materials in a conductive medium (like water)

Example wrench left onto the top of a fermenter (moisture in the air can act as the conductive medium)

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23
Q

What is general uniform corrosion?

A

Rust

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24
Q

Examples of erosion corrosion?

A

Abrasion (grain, etc), cavitation

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25
What is intergranular corrosion?
Corrosion caused by repeated heating and cooling cycles - weld decay, heat affected
26
What causes pitting?
Loss of passivation on SS - damage of that thin protective layer (more) Chlorine is one of the biggest causes, exasterbated by heat
27
What is contact corrosion?
Similar to galvanic, it’s a combination of multiple factors
28
Name the 9 types of corrosions
General uniform Galvanic Erosion Intergranular - not common in breweries Pitting Crevice - between two joints, bad welds Contact - sum of galvanic, pitting, and crevice Microbiological induced Stress corrosion cracking
29
What happens during passivation?
Removes “free iron” contamination left from the fabrication process and promotes the protective Chromium Oxide layer Starts w/ caustic cleaning of oils & dirt Then Acid wash (nitric or (better/safer) citric acid @ 4%) 45min (20-120min) @ 100F (60-160F) @ 4% citric acid solution (20-50% Nitric acid by volume)
30
Three types of welding? And what is the most common in brewery construction?
Stick MIG* TIG
31
Name some locations of important elastomers in the brewhouse
Valve seats (internal seals) Manway gaskets Pump seals Inter-fitting gaskets Hose linings Bottle line O-rings Keg Fittings Filter gaskets
32
What are some elastomer types and where they might be beneficial in the brewhouse
Buna / BunaN - widely used in food, dairy, beverage and sanitary. Limited use due to temp and chemical concerns <80C, good oil and solvent resistance. 2% caustic 0.5% acid, moderate resistance to aromatics. EPDM - very resistant to steam, good resistance to mild acids, alkalis and alcohols, very abrasion resistant, good tensile strength - widely used in Europe , most likely best choice in brewery use Neoprene - not common, has a smell that can be picked up Silicone - rarely used, ok for cold applications if not running high % caustics or acids Teflon - steam applications, if held flat, will deform otherwise. Good for valve stem seats, but poor ability to crest seal Viton - good for 320-350F, but not for steam. Very acid resistant - in valve seats primarily
33
Why do we insulate? 6 things
Conserve energy by reducing heat loss or gain Control surface temps for personal protection Facilitate temp control of a process Prevent water condensation in cold surfaces Increase operating efficiency of HVAC and other systems Prevent or reduce damage to equipment - also a bit of physical protection from accidents
34
What’s “R value”?
The thermal resistance “R”: the overall resistance of a system to the flow of heat. How well the insulation creates a barrier to the heat
35
Types of insulations (5)?
Fiberglass Armaflex (used to cover glycol piping). Both of these will suck up water unless protected Closed cell polyethylene Styrofoam Trimer
36
Name 7 materials used in brewing vessels
SS, copper, brass, aluminum, glass/epoxy lined, steel, wood
37
List 5 material properties that must be considered in brewing vessels and equipment
Temp resistance Chemical resistance Corrosion resistance Ductable density - formability Heat capacity Heat transmission Finish Hardness Clean ability (wettability)
38
What causes contact corrosion in SS?
Contact with a dissimilar metal (particularly anodic or least noble) in an electrically conductive liquid
39
Name 6 materials that may be transferred by piping in a brewery
Beer, steam, water, glycol, CO2, compressed air, refrigerant gas/non glycol
40
Why is it important to inspect gaskets on a routine basis?
For micro bacterial contamination, physical condition (broken, leaking, deformation)
41
Name two advantages and two disadvantages of Buna-N as a gasket seal material
2 adv: cheap, resistant to organic (oils, solvents), resistant to tearing and abrasion 2 diss: less resistant to PAA sanitizers, limited temp resistance
42
What are the three types of compressors?
Piston, worm (“screw”), turbo
43
What type of refrigeration is most commonly used in a brewery?
Compression chillers
44
List the components of a basic single-level compression refrigeration system?
Compressor Evaporator Condenser Expansion valve (throttle)
45
What is the function of the compressor in a basic refrigeration system?
Increases pressure, increases temperature and acts as a flow mechanism
46
List the critical factors important for the efficient operation of a compression refrigeration system
Want evaporation temp to be high and condensation temp to be low. The delta Temp between them to be as close as possible for efficiency
47
What is the definition of a primary refrigerant?
It is the refrigerant that is circulating and doing the cooling. By changing its state, heat will be absorbed (evaporation) or released (condensation).
48
Why are secondary refrigeration systems often used in breweries?
People safety, food safety - don’t want to cross contaminate
49
List 3 secondary refrigerants
Glycol, water, brine
50
Why is ammonia a commonly used primary refrigerant?
It’s effective, thermodynamics are excellent, pretty cheap, phase change is close, has a smell and it’s been around and used for a very long time - it’s well known 1874
51
List 3 general classes of refrigeration compressors
Piston, worm (“screw”), turbo
52
List 4 advantages of centralized refrigeration plants
Common condensers, common equipment, spare parts (lower inventory, training), you can have a cooling reserve, energy demands spread across the entire brewery. You can take out a single condenser for maintenance and the system still can work. If you are using ammonia, it’s not spread out everywhere
53
List 4 disadvantages of de-centralized refrigeration plants
Spare parts, need a back up for every system in case it goes down, more expensive, electrical demand Advantages: shorter lines, temp control more precise
54
Instead of a compressor, what is the driving mechanism for an adsorption refrigeration plant?
It’s thermal drive - done through chemical nature vs mechanical means
55
Select objectives when selecting valves (4)
Low cost Good longevity Desired service characteristics Compatibility w/ controlled fluids
56
What is a Cv value?
Cv is the flow coefficient. It’s defined as the flow rate through a valve as a ratio of the corresponding pressure drop across it Higher Cv = lower pressure drops
57
What is the Cv value used for?
It’s used to define the flow characteristics of a valve throughout its range, from fully open to full closed. The engineer must match the value to an actuator and the fluid system requirements
58
Define the term controller
The device which establishes set point and differentiates set point value from feedback value to produce a control response
59
What is a gas compressor?
A mechanical device that increases the pressure of a gas by reducing its volume
60
Why must compressed gas (air) be dried?
Because it will release moisture once pressure is released otherwise. This moisture can cause corrosion at pneumatic actuating drives
61
List 4 uses of CO2 related to brewing
Carbonation of beverages High pressure extraction Inert gas packaging - fillers Neutralization if alkaline effluents
62
What are the tasks of a CO2 recovery plant?
Eliminate undesirable ingredients from the fermentation CO2 (cleaning) Storage of the cleaned, compressed CO2 gas
63
What substances are commonly contained in recovered CO2 from a fermenter?
Ethyl alcohol Hydrogen sulfide Dimethyl sulfide Acetone Oxygen
64
List steps in CO2 recovery and storage in a brewery
Foam trap - removed any foam Gas re-direction station - to outside Gas balloon - acts as buffer Gas washer - w/ O2 free water CO2 compressor - CO2 pre-filter - CO2 dryer CO2 active carbon filter CO2 trap filter CO2 condenser CO2 stripper CO2 storage as liquid
65
What’s bad about oversized steam pipes? What’s bad about undersizing steam pipes?
Neg Over: greater cost Greater heat loss Great volume of condensate formed Neg Under: Lower pressure to steam users, or Not enough volume of steam Water hammer and erosiom
66
Name 3 types of pressure reducing valves
Direct acting pressure reducing valve Pilot operated reducing valve Pneumatic or electric pressure reducing valve
67
Name 3 basic types of steam traps
Mechanical/density Thermostatic Kinetic Energy
68
Name 3 main phases of a brewery construction project
Feasibility and pre-study Pre- project Engineering
69
How much water is used to wash a bottle in a bottle washer?
Min 150-200ml/bottle regardless of size

Module 3 (2 decks)

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