System Construction, Installation, Inspection and Repair
Zuuk understands certain clients demand impeccable design and construction of clean, corrosion-resistant systems. Our teams are highly skilled, certified tradesman capable of completing projects governed by the strictest codes and standards. Zuuk holds the “S”, “U”, “PP”, “NB” and “R” stamp certifications issued by the American Society of Mechanical Engineers (ASME) and the National Board of Boiler Inspectors (NBBI), which allows it to perform fabrication and installation of systems in accordance with the most quality-critical requirements.
Industries that employ high-purity/critical-needs autogenous orbital welding typically join stainless or corrosion resistant high-alloy and non-ferrous metals. These industries include:
• Food and Beverage
• Specialty Chemicals
• Research and Development
Orbital welding gives the welding operator the ability to make consistent, repeatable, high-integrity welds at speeds impossible to achieve by manual processes. Zuuk specializes in an orbital welding process which operates by establishing an arc between a non-consumable tungsten electrode and the base metal being welded. The process is conceptually simple: tubes/pipes are held in place while an orbital weld head rotates an electrode, creating a welding arc around the weld joint. This application is used when the integrity of the weld joint has the highest quality requirements.
There are many reasons to use orbital welding over other processes, including:
• Weld Integrity – Orbital welding systems outperform the best skilled welder.
• Productivity – An orbital welding system can drastically outperform the speed of manual welders.
• Consistency – Eliminates normal variability, inconsistencies, errors and defects of manual welding.
• Safety – the need for radiographic inspections are reduced or eliminated.
• Application – Orbital welding systems are capable of joining both piping and tubing
Welding alters the chrome/iron ratio (measure of corrosion resistance). In order to return this ratio to its original state, the weld surface and tangible boundary must be returned to a passive state. This is accomplished by removing free iron (anodic contaminants) from the surface of the corrosion-resistant specimen, resulting in chromium and iron oxides as the primary metal components.
Zuuk Inspection, a division of Zuuk International, provides a third-party inspection service (and subsequent record keeping) for industries such as aerospace, bio-pharma, semi-conductor and food/beverage.
Almost 100% of tube welding conducted in the construction of biopharmaceutical facilities is high-purity, autogenous orbital gas tungsten arc welding (GTAW). These welds must be validated before governing agencies will approve the commencement of manufacturing. Moreover, if a facility is constructed in accordance with the ASME BPE2002, 100% of the weld is subject to visual examination of its outside diameter (OD) and inner diameter (ID). All welds and materials are documented and recorded.
While some defects may be obvious from the outside, more critical defects can only be seen from the inside. The most common ID inspection for this type of construction is remote visual inspection (RVI) by means of a boroscope. This form of VT inspection will ensure that all welds are completed having the same integrity throughout, having no visible impurities.