寶潔日化培訓(xùn)課件3-8-005 Welding Do-Don't rv 9-16-2011

Author:DennisMcCulloughCleanDesignPrinciples‘Do/Don’ts’forWeldingMicro/CleanDesignDo-Don’tsareprimarilyreferencetrainingmaterials;forP&Gprojectexecution,alwaysrefertotheCleanDesignStandards.MINIMALRISK(=standardfornewequipment)MODERATERISKHIGHRISKMaterialrecommendedbyP&GMaterialsEngr.ForrequiredproductserviceNon”L”gradefor304and316stainlesssteelCarbonsteelFRPRa=0.8microm(Ra=32microin.)MAXIMUMHigherRaMuchhigherRaInternalweldsgroundsmoothandpolished(tanksandPressureVesselsonly)pipingweldstoconformtoASMEBPEtableMJ-3orFig.MJ-1InternalweldsgroundsmoothwithlittleregardforsurfacefinishInternalweldsnotgroundfortanksandpressurevesselsCheckyourMOCcompatibilitywithyourproduct&sanitizingagentwithCETL!Welding:MaterialsofConstructionMicro/CleanDesignPrinciplesMoredetails:SeeP&GCleanDesignStandardsoncGMPsiteCleanDesignSpecsforWeldingonpipingDesign:Machinewelded(Orbitalwelding)–tobeused100%unlessapprovedbyP&GengineeringinadvanceWeldspolishedandgoodqualitymustconformtoallacceptancerequirementsinASMEBPEtableSF-1AllunpolishedweldstoconformtoASMEBPEtableMJ-1andfig.MJ-1perP&G15371and15375Allinsidesurfacescleanable;e.g.,CIP/SIPcapableNoimpactstoequipmentdrainabilityProtectedagainstcontaminationfromoutsideenvironmentWeldsonpipingthatconformtoP&G15371(forregulated)or15375(forunregulated)donotrequireadditionalfinishingpriortopassivationMicro/CleanDesignPrinciplesMicro/CleanDesignPrinciplesP&GWeldingGuidelines:RegulatedProductsSpecificationforSanitaryTubingandPiping(15371,Rev.1):ClickHere

Non-RegulatedProductsSpecificationforSanitaryTubingandPiping(15375,Rev.0):ClickHereAllRFQsandPurchaseOrdersforweldedequipmentneedtoincludeCBAWE05:ClickHereP&GCorporateWeldingSiteReferences: ReferenceCorporateWeldingStandardsandSpecificationssite: ClickHereKeyWeldingPoints:Allpipingjointsareapotentialsourceformicrobialcontamination.ThenumberofmanualweldsinanysanitarydesignpipingsystemshouldbeminimalandmustbeapprovedinadvancebyP&Gengineering.Forallweldsonsanitarypipinguse:OrbitalGasTungstenArcWelding(GTAW)process(1stchoice)ManualGasTungstenArcWelding(GTAW)(alsoknownasTIGwelding)proceduresadheringtoP&GspecificationsareacceptableforanyStainlesssteelweldingapplicationbutarenotoptimum(2ndchoice)Micro/CleanDesignPrinciplesKeyWeldingPoints(cont.):ManualGTAWweldswillrequireplantmicrobiologistand/orsectorQAapproval.Allweldsmustbecontinuouscompletepenetrationweldsmadewithbuttjoints.Nosocketorothertypeweldsthatleadtodeadspaceorpocketsallowed.Allweldsrequirepassivationpriortocommissioningofthepipe.Allweldsneedtobesmoothwithpipeinternals,meetingallrequirementsofASMEBPEtableMJ-3andfig.MJ-1specifications.Thismaybeverifiedbyinternalfiberoptic(Borescope)inspection.AnyWeldingProceduresotherthanMachineWeldingtoconnecthighpuritywaterpipingmustconsultwiththeGlobalWaterSystemsOwnerandWeldingEngineeringGroupMicro/CleanDesignPrinciplesWeldQuality&Inspection(cont.):Ifdoubtorquestions,callyourQC.Firstlineofdefense,resource.OribitalweldsrequireinspectionsamplingperASMEBPE.Manualweldsrequire100%visualinspectionontheoutsideandINSIDE.Weldstandardswillbeperthecodeofconstruction.WeldcolorwillbecomparedtocalibratedvisualstandardAWSD18.2.

"Thebacksideof--stainlessorhigheralloyweldsshallbesilvertolightgold--sugaring(darkcolor)isprohibited.WeldcoloracceptancecriteriaisperP&GDesign&ConstructionSpecification15371forregulatedproductand15375forunregulatedproduct.Micro/CleanDesignPrinciplesNote:AWSD18.2isacopyrightedvisualstandardandcannotbeduplicated.Copiesmaybepurchasedatwww.AWS.org)Micro/CleanDesignPrinciplesImageaboveiscolorchartfromAWSD18.2

WeldColorQualitySampleNumber12345678910PPMO21025501002005001000500012,50025,000Loweroxygenlevelsproducecleanerweldswithlessheattint.Note:AWSD18.2isacopyrightedvisualstandardandcannotbeduplicated.Copiesmaybepurchasedatwww.AWS.org)“Don’t”4–10havehighcorrosionrisk“Do”1–2for15371;1–2-3for15375situationsMicro/CleanDesignPrinciplesWeldingPrinciples“Do”“Don’t”Example:WeldQualityMicro/CleanDesignPrinciplesSpecialWeldingRequirements:ChecktheWeldingProceduresanddrawingsforanyspecialrequirementsforyourweldingjob?StainlessSteeltubingMUSTbeblockedandpurgedwithArgon(oranotherapprovedgas)untiltheoxygencontentislessthan25ppmpriortowelding.MakesurefilletweldsmeetrequiredsizesandlengthsMakesureallmetaliscleanedwithalcoholanddryforatleast1"fromtheweldareaDonotweldoverpaint,rust,galvanizing,moisture,etcIfyoucansmellburnedpaint,itisn'tcleanedfarenoughSpecialWeldingRequirements(cont.):AllfinishedweldsmustbepassivatedonproductcontactingsurfacesWeldsontheinsideofpipingdonotrequireadditionalprocessingpriortopassivationiftheymeettherequirementsof15371forregulatedproductsor15375forunregulatedproductsStainlessweldsthataregroundflushandpolishedmustmeetASMEBPEtableSF-1requirementsfortheproductcontactsurfacesoftanksandpressurevesselsMicro/CleanDesignPrinciplesSpecialWeldingRequirements(cont.):Provideproperpipeclearancesfororbitalwelding(minimum8”pipecenterspacing)forfieldweldingexecutionsMicro/CleanDesignPrinciplesWeldingPrinciples“Do”“Don’t”Example:PrepallWeldsproperly.Micro/CleanDesignPrinciplesWeldingPrinciples“Do”Insistthattheinsideweldsonstainlesstubingbenicelycontouredwithlittleornoheattint“Don’t”Allowtheinsideofweldedstainlesstubingtobedarkor“sugared”InspecttheINSIDEoftubingweldsforheattintfromweldingMicro/CleanDesignPrinciplesWeldingPrinciples“Do”“Don’t”EnsurepipesspacedproperlyfororbitalweldingexecutionMicro/CleanDesignPrinciples“Do”“Don’t”Example:EnsureweldingspatterisminimizedMicro/CleanDesignPrinciplesWeldingPrinciples“Do”“Don’t”P(pán)oorweldquality–ChippingHammerDamageoncarbonsteelweldMicro/CleanDesignPrinciplesWeldingPrinciples“Do”“Don’t”Example:ProperlycontaingrindingparticlesfromfinishedsurfacesMicro/CleanDesignPrinciplesAlwaysusestainlesssteelgrindingdiscsandwirebrushesonstainlessapplicationsonly.Toolsshouldbemarked“stainlessuseonly”.Neverusecommongrindingdiscsandbrusheswithdifferentmetalapplications.Donotgrindcarbonsteelnexttostainlessmaterialwithoutpropercontainmentorprotectingstainlessmaterial.Alwaysisolatestainlessmaterialfromcarbonsteelcontaminantswhileinstorageonpiperacksorwithinthetoolholder.WeldingPrinciplesMicro/CleanDesignPrinciples“Do”“Don’t”Example:WeldQualityWeldingPrinciplesMicro/CleanDesignPrinciples“Do”“Don’t”Example:WeldQualityandsubsequentimpacttomicrobialcontaminationWeldingPrinciplesExcessiveconvexityormisalignment“Do”“Don’t”P(pán)oorweldquality-Corrosionatweldandheataffectedzone–productaccumulation,potentialenvironmentalcontaminationduetoleakMicro/CleanDesignPrinciplesWeldingPrinciples“Don’t”P(pán)oorweldquality-Corrosionatweldandheataffectedzone–productaccumulation,potentialenvironmentalcontaminationduetoleakMicro/CleanDesignPrinciples“Do”WeldingPrinciplesWeldingPrinciples“Do”P(pán)oorweldquality–intermittentweldsdonotprovidecompletemicroprotectioninprocessapplicationsMicro/CleanDesignPrinciples“Don’t”“Do”“Don’t”P(pán)oorweldquality–Manualweldment(“Don’t”)vs.machineweldment(“Do”)Micro/CleanDesignPrinciplesWeldingPrinciples“Do”“Don’t”Micro/CleanDesignPrinciplesWeldingPrinciplesPoorweldquality–Manualweldment(“Don’t”)vs.machineweldment(“Do”)“Do”“Don’t”P(pán)oorweldquality-Weldedpartsmisaligned,promotesproductaccumulationandisinviolationwithacceptancecriteriaMicro/CleanDesignPrinciplesWeldingPrinciplesAlsoincludescarbonsteelcontaminationMicro/CleanDesignPrinciples