Draught System Operations - California Craft Beer...A Primer on the Design, Installation, Operation and Maintenance of Your Taproom Draught System ... cooler to tower • Glycol-chilled

Draught System Operations:

A Primer on the Design, Installation, Operation and Maintenance of Your Taproom

Draught System

Neil Witte – Master Cicerone, BA Draught Quality Ambassador

Welcome

Today’s Agenda

• Equipment – Short and Long Draw

• Cooling Systems

• Series Kegs

• Carbonation

• Mixed Gas

• System Resistance

• Pouring High-Carbonated Beers

• Troubleshooting

• System Maintenance / Line Cleaning

Short Draw Systems

Gas Supply

CO2

• Extremely high

pressure (800-

1500psi)

• Handle with care

Regulator

Primary regulator

• Makes the high cylinder

pressure usable

Regulated

Pressure

Tank

Pressure

Shutoff

(open)

Primary Regulator

Tubing From the Primary Regulator

• Vinyl - <40psi

• Braided - >40psi

Secondary Regulator

• Transitions from braided to vinyl tubing

• Sets applied pressure to keg

Gas Manifold

Coupler

Beer out

Gas In

Coupler

© Copyright 2017 Cicerone® Certification Program

D Valve/Coupler

11

22

33

1.Bottom seal

2.Probe Seal/

Keg Seal

3.Probe/ Beer

Valve

Coupler Types

Connectors

Beer Nut

Wing Nut

Tailpiece

Washer

• Connects

tubing to parts

in both gas and

beer systems

Stepless Clamp

Keg

Common Keg Sizes

Beer Flow

• Beer Hose (Jumper Line)

• Vinyl/Flexible Tubing

• Should be clear

Shank

Connects the beer tubing to the faucet

Tower

Faucet

Faucet

Long Draw Systems

Gas Supply

CO2

• Cylinder or bulk tank

(dewar)

Gas Supply

Nitrogen

• Cylinder or Nitrogen

generator

Nitrogen and CO2 cylinders

Gas Supply

Gas Blender

• Stand alone

• Nitrogen generator

Gas Supply

Braided tubing

• High pressure >40psi

• Always used before

and after blender

Gas to beer

Jumper Line

• Flexible beer line running from the coupler in the cooler

Wall Bracket

• Fixed transition from jumper to barrier

Beer Pumps

• Alternative to Blended Gas • Very high gas pressures

>38psi

• Brewpub serving from tanks (max pressure of 15 psi)

Foam on Beer Detector (FOB)

• Saves wasted beer from keg change

• Saves pump overuse when keg empties

Gas Supply

Trunk Line

• Carries beer from cooler to tower

• Glycol-chilled bundle

• Individual lines

• Barrier Tubing – more rigid

Draught Tower / Choker Line

• Internal Stainless Steel lines

• 3/16” ID vinyl or flexible tubing

Choker

Plastic inserts3/16” tubing – vinyl/otherStainless

Steel

Cooling Systems

Cooling Systems – Three types

• Direct Draw System

• Blower System

• Glycol System

Cooling System Objectives

1. Keep the beer cold

2. Keep the beer carbonated

Cooling System

• Cooler temp 36-38 °F• For both kegs and lines

Direct Draw System

• Lines are fully contained in the cooler

Shadow Box

Blower System• Lines leave the cooler

• Up to 15 feet

• Cooler air used to keep lines cold

Glycol System

• Lines leave the cooler

• Long distance

• Separate refrigeration for beer lines

Glycol Chiller

Aka Powerpack

• Chills and circulates glycol to keep beer cold in trunk lines.

Pump

Condenser

Compressor

Bath

Beer Line Bundle

Aka Python/Trunk line

• Carries coolant along with beer from cooler to bar

• Two cooling loops with bundles over 8 beer lines

Tower Cooling

• Copper cooling lines

• Sometimes polyvinyl

• Touches backside of faucet shank

Series Kegs

Series Keg Rotation

• Always tap the full keg with the shortest shelf life in the Faucet Keg position.

• Never put a partial upline from a full keg.

• Never tap an empty keg upline from a full or partial keg.

• Never tap more than one partial in the same series.

• To ensure that old beer does not build up in the system, make sure all series systems run dry at least every 7 days.

CO2 and Carbonation

Carbonation

Flavor:

• Acidic• Acrid

Affects other beer aromas/flavors:

• Enhances bitterness, acidity• Carrier for volatile aromas

Purpose of Dispense Gas

1. Maintain the carbonation level of the beer

2. Push the beer from the keg to the faucet

Carbonation

• Measured in volumes per volume or, simply, volumes

• Range in beer varies from 1.0 to 5.0 volumes of CO2

Volumes of CO2

=

2.5 v/v 2.5 v/v

CO2 – Maintaining Carbonation

A balanced keg will maintain the same carbonation throughout the life of the keg.

Two main factors control this:

1. Pressure2. Temperature

2.5 v/v

11 psi @ 38F

Pressure/Temperature Relationship

(Assumes sea-level altitude. Add 1psi for every 2,000ft above sea-level.)

How Does Beer Overcarbonate?

11 psi

2.5 v/v

38 °F

Balanced


• Extra psi forces

more CO2 into

the headspace

of the keg13 psi

2.5 v/v

38 °F

Excess Pressure


• Extra CO2 in the

headspace

absorbs into the

beer13 psi

2.65 v/v

38 °F

Overcarbonated


2.5 v/v

11 psi

38 °F

Balanced


• CO2 is more

soluble in colder

liquid.

• Beer absorbs

more CO2,

causing

overcarbonation2.65 v/v

11 psi

36 °F

Temperature Drop

Overcarbonated

How Does Beer Lose Carbonation?

11 psi

2.5 v/v

38 °F

Balanced


9 psi

2.5 v/v

38 °F • Lower psi

allows less CO2

into headspace

Pressure Too Low


9 psi

2.3 v/v

38 °F• Less headspace

psi allows CO2 to

escape the beer

Undercarbonated


2.5 v/v

38 °F

11 psi

Balanced


2.3 v/v

11 psi

• CO2 is less

soluble in

warmer liquid.

• CO2 escapes,

causing flat

beer.

42 °F

Temperature Increase

Undercarbonated

38F

11 psi = 2.5 v/v 13 psi = 2.65 v/v9 psi = 2.3 v/v

38F38F

Effects of Pressure Changes

11 psi11 psi 11 psi

38 °F= 2.5 v/v 35 °F = 2.65 v/v42 °F = 2.3 v/v

Effects of Temperature Changes

Short Draw

Accomplishes both goals:

1. Keeps beer carbonated

2. Pushes beer to faucet100% CO2

2.5 Volumes

38F

11

psig

Long Draw

11

psig

100% CO2

2.5 Volumes

38F

Accomplishes only one goal:


2. Pushes beer to faucet

Long Draw with Blended Gas

2.5 volumes

38F

70% CO2 /

30% Nitrogen

22

psig

• Nitrogen adds the extra “push”.

• Lower % CO2 at higher pressure

maintains carbonation.

Accomplishes both goals:


2. Pushes beer to faucet

Applied psi for Blended Gas

𝑎 =𝑏 + 14.7

𝑐− 14.7

Where:

𝑎 = Applied psi of blend

𝑏 = Ideal psi with 100% CO2

𝑐 = % of CO2 in blend

OR….

Example:

23 =12 + 14.7

.7− 14.7

EasyBlend App

Nitrogen

• Doesn’t dissolve easily

• ~38psi or greater

• Doesn’t break out easily

• Needs help

Nitro Faucet

Nitro Pour

1.2 volumes

38°

• Creamer faucet has high

resistance to flow

• Nitro beers have low CO2 ~1.2 v/v

• Will absorb 100% CO2 at any

pressure

Nitro Pour

1.2 volumes

38°

25% CO2/75%

Nitrogen

35

psig

• Special Nitrogen-rich blend adds

push but maintains low v/v CO2

• Makes regularly carbonated beers

go flat

Choosing the Correct Gas Blend

Accomplishes both goals

1. Beer stays carbonated

2. Pushes beer to the faucet

Does not accomplish both goals

1. Beer stays carbonated

2. Pushes beer to the faucet

Long Draw

60-70%

Long Draw

25%

CO2-rich blend:

60%-70% CO2

Nitro blend:

25% CO2

System Resistance

Achieving Flow

Balancing two key elements:

1. Applied Pressure (psi)

2. System Resistance (lbs.)

Resistance to flow comes from:

• Gravity

• Tubing, parts

When total system resistance = Applied pressure on the keg, flow will be 1 gallon/minute

Figuring Resistance

Resistance is provided by gravity.

2 ft. = 1 lb. resistance

Measurement is from middle of the keg.

1 foot of vertical rise = .5 lbs. resistance

Figuring Resistance

Resistance is also provided by tubing

Operating Pressure

• Temperature ________

• Volumes CO2

• % CO2

Draught Tower

Gravity

• Vertical Rise - ___ft. x .5 = ____ (Subtract)

• Vertical Fall - ___ft. x .5 = ____ (Add)

Trunk Line

Trunkline ID = ____ID @ ___lbs./ft. x ___ft. = ___lbs.

Jumper ID = ____ID @ ___lbs./ft. x ___ft. = ___lbs.

222.5

38

70%

Glycol Chiller

CO 2 N 2

Example SystemResistance from Gravity

• 12 feet Vertical Rise

• 12 x .5 = 6 lbs. resistance

Operating Pressure


• Volumes CO2

• % CO2

Draught Tower

Gravity



Trunk Line



22

12 6

6

2.5

38

70%

Glycol Chiller

CO 2 N 2

Example SystemResistance from Tubing – Trunk Line (Yellow):

• Barrier tubing - 3/8”, 5/16” or 1/4” ID

• 50 foot system

• 5/16” = .1 lb./ft.

Operating Pressure


• Volumes CO2

• % CO2

Draught Tower

Gravity



Trunk Line



22

12 6

6

5/16” .1 50 5 5

2.5

38

70%

Glycol Chiller

CO 2 N 2

Example SystemResistance from Tubing – Jumper line (Red):

• Vinyl tubing - 3/8”, 5/16” or 1/4” ID

• 5 foot jumper

• 5/16” = .4 lb./ft.

Operating Pressure


• Volumes CO2

• % CO2

Draught Tower

Gravity



Trunk Line



22

12 6

6

5/16” .1 50 5 5

5/16” .4 5 2 2

2.5

38

70%

Glycol Chiller

CO 2 N 2

Example SystemResistance from Tower (Blue):

• 7.5 lbs.

Operating Pressure


• Volumes CO2

• % CO2

Draught Tower

Gravity



Trunk Line



22

12

2.5

6

5/16” .1 50 5 5

5/16” .4 5 2 2

7.5

1.5

38

6

70%

Resistance Chart

Glycol Chiller

CO 2 N 2

Example SystemResistance from Tubing – Choker line (Green):

• Vinyl/flexible tubing – 3/16” ID

• 3 lb./ft.

Operating Pressure


• Volumes CO2

• % CO2

Draught Tower

Gravity



Trunk Line



22

12 6

6

5/16” .1 50 5 5

5/16” .4 5 2 2

7.5

1.5

1.5.5

2.5

38

70%

Glycol Chiller

CO 2 N 2

Example System

Vinyl Alternatives

• New alternative flexible

tubing

• Plastic segment restrictor kits

Glycol Chiller

CO 2 N 2

Over-restricted SystemResistance from Gravity

• 20 feet Vertical Rise

• 20 x .5 = 10 lbs. resistance

Operating Pressure


• Volumes CO2

• % CO2

Draught Tower

Gravity



Trunk Line



22

20 10

10

5/16” .1 50 5 5

5/16” .4 5 2 2

7.5

-1.5

2.5

38

70%

Need to either:

• Increase psi

or

• Decrease resistance

Increasing Pressure

Operating Pressure


• Volumes CO2

• % CO2

Draught Tower

Gravity



Trunk Line



29

20 10

10

5/16” .1 50 5 5

5/16” .4 5 2 2

7.5

4.5

2.5

38

60%

4.51.5

Glycol Chiller

CO 2 N 2

Example System

Operating Pressure


• Volumes CO2

• % CO2

Draught Tower

Gravity



Trunk Line



22

20 10

10

5/16” .1 50 5 5

5/16” .4 5 2 2

7.5

-1.5

2.5

38

70%

Need to either:

• Increase psi

or

• Decrease resistance

Glycol Chiller

CO 2 N 2

Example SystemResistance from Tubing – Trunk Line (Yellow):

• Barrier tubing - 3/8”, 5/16” or 1/4” ID

• 3/8” = .06 lb./ft.

Glycol Chiller

CO 2 N 2

Example SystemResistance from Tubing – Jumper line (Red):

• Vinyl tubing - 3/8”, 5/16” or 1/4” ID

• 3/8” = .2 lb./ft.

Operating Pressure


• Volumes CO2

• % CO2

Draught Tower

Gravity



Trunk Line



22

20 10

10

3/8” .06 50 3 3

3/8” .2 5 1 1

7.5

.5

2.5

38

70%

.5.17

Glycol Chiller

CO 2 N 2

Example System

Now that we’ve talked carbonation and resistance…

Pouring a High-Carbonated Beer


Three methods of adjustment:

• Pressure Adjustment

• Pressure + Restriction Adjustment

• Pressure + Restriction + Gas Blend Adjustment


Pressure Adjustment

PSI Adjustment Requirements

• Dedicated Regulators

PSI Adjustment Requirements

• CO2 content knowledge

• Difficult for retailers

• No definitive list

• General guidelines

• Craft – ~2.5 vol

• Domestic – ~2.7 vol

• Imported Specialty/Wild - ~2.8+

PSI Adjustment

• If you know the CO2 content:1.Look up ideal pressure

2.Keep within 5psi of restriction on system• Minimizes flow rate change

Draught Beer Quality Manual Chart – 100% CO2 McDantim EasyBlend App

PSI Adjustment – Short/100% CO2 System

• If you don’t know the CO2 content:

Flashlight test1. Set regulator low - ~5psi

2. Tap fresh keg – make sure keg is at temp

3. Pour a small amount of beer

4. Look for bubbles in the line coming out of the coupler

5. If bubbles are present – raise pressure by 1 or 2 psi

6. Repeat steps 3-5 until beer no bubbles are present and beer pours clear

• * Keep within 5 psi of restriction on system

PSI Adjustment – Long/Blended Gas System

• Use best estimate of CO2 volumes

• Set psi within 5psi range

PSI Adjustment – Long/Blended Gas System


Pressure Adjustment

+

Restriction Adjustment

Achieving Flow

When System Resistance = Applied Pressure on the keg,

Flow rate will equal 1 gallon/minute

Adding Restriction

Glycol Chiller

CO2

N2

Trunk Line – Set length and

diameter, no adjustment possible

Adding Restriction

Glycol Chiller

CO2

N2

Choker – Permanent installation,

difficult to adjust

Adding Restriction

Glycol Chiller

CO2

N2

Jumper – Some adjustment

possible

Adding Restriction

Tubing Resistance Chart – Draught Beer Quality Manual

Every pound of

restriction equals

about 4 oz/min

flow rate

* This solution

has limitations

with larger

serving vessels

Flow Control Faucets

Maximum flexibility


• Lever allows for manual

control of flow rate

• Bartender training is

imperative


• Tubing restriction should be

set at the low end of target

range

• Target flow rate may be lower

than 1 gal/min

• Very high CO2 volumes may

require an extremely slow

pour

Pouring a High Carbonated Beer

Pressure Adjustment

+

Gas Blend Adjustment

+

Restriction Adjustment

Single Blend

33 3.23

32 3.17

31 3.10

30 3.03

29 2.96

28 2.89

27 2.83

26 2.76

25 2.69

24 2.62

23 2.56

22 2.49

21 2.42

20 2.35

19 2.28

18 2.22

psi 70

%

2.2 – 3.2 vol

• 15 psi range

Multiple Blends

32 2.71 3.17

31 2.66 3.10

30 2.60 3.03

29 2.54 2.96

28 2.48 2.89

27 2.42 2.83

26 2.36 2.76

25 2.31 2.69

24 2.25 2.62

psi 70%60%

2.2 – 3.2 vol

• 8 psi range

Multi-Blend Blenders

Gas Blend/psi/Volumes

psi 60% 80% 100%

30 2.60 3.03 3.46 4.33

29 2.54 2.96 3.39 4.23

28 2.48 2.89 3.31 4.14

27 2.42 2.83 3.23 4.04

26 2.36 2.76 3.15 3.94

25 2.31 2.69 3.08 3.84

24 2.25 2.62 3.00 3.75

23 2.19 2.56 2.92 3.65

22 2.13 2.49 2.84 3.55

21 2.07 2.42 2.77 3.46

20 2.02 2.35 2.69 3.36

30 2.60 3.03 3.46 4.33

29 2.54 2.96 3.39 4.23

28 2.48 2.89 3.31 4.14

27 2.42 2.83 3.23 4.04

26 2.36 2.76 3.15 3.94

25 2.31 2.69 3.08 3.84

24 2.25 2.62 3.00 3.75

23 2.19 2.56 2.92 3.65

22 2.13 2.49 2.84 3.55

21 2.07 2.42 2.77 3.46

20 2.02 2.35 2.69 3.36

Range

• 2.0 – 4.3 vol

• 11 psi

Multiple Blends/Temperatures

Multiple Blends/Temperatures

45F 50F 55F

Gas Blend CO2 % Gas Blend CO2 % Gas Blend CO2 %

100% 80% 60% 100% 80% 60% 100% 80% 60%

1.8 7 12 21 1.8 9 15 23 1.8 11 18 28

1.9 8 14 23 1.9 10 16 27 1.9 13 19 31

2 9 15 25 2 11 18 29 2 14 21 33

2.1 10 17 27 2.1 13 20 31 2.1 15 23 35

2.2 12 18 29 2.2 14 21 33 2.2 17 25 38

2.3 13 20 31 2.3 15 23 35 2.3 18 27

2.4 14 21 33 2.4 17 25 38 2.4 20 28

2.5 15 23 35 2.5 18 26 2.5 21 30

2.6 16 24 37 2.6 19 28 2.6 23 32

2.7 17 25 39 2.7 21 29 2.7 24 34

2.8 19 27 2.8 22 31 2.8 26 36

2.9 20 28 2.9 23 33 2.9 27 37

3 21 30 3 25 34 3 28 39

3.1 22 31 3.1 26 36 3.1 30

3.2 23 33 3.2 27 38 3.2 31

For Beers at

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For Beers at

Be

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CO

2 V

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For Beers at

Be

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Troubleshooting

Troubleshooting

Primary symptoms seen in draft systems

• Foaming beer

• No beer

• Off-flavored beer

Primary areas of focus

• Temperature

• Gas Dispense

• Hardware

Foamy BeerTemperature

• Measure:

• Temperature of beer in glass

• Current temperature of cooler

• Temperature of beer in keg

• Ask about delivery & storage

• Use picnic tap, FOB drain, etc to sample

• Sample other liquids in cooler – bottled

beer, water, etc.

Foamy Beer

Keg Temperature

• Kegs need time to cool down

• During delivery, it only takes 6 hours for keg to warm up to 48 °F

• It takes 24 hours to chill a keg from 48 °F to 38 °F

Foamy Beer

Line CoolingDirect Draw

• In some cases a blower tube will help cooler air get to the faucet

Foamy Beer

Line Cooling

Forced Air

• the blower is working (1)

• the ductwork is sealed properly (2)

• the air is returning. (3)

(1)

(2)(3)

Foamy Beer

Line Cooling

Glycol• Glycol unit is on

(check operation of compressor and recirculation pump)

• The glycol is cold (29-32 °F)

• The condenser fins are free of dust/ debris

Pump

Condenser

Compressor

Bath

Foamy Beer

Dispense Gas

• Gas Tank(s)• Make sure tanks are on,

full, and that all shut-offs are open.

• Primary Regulator(s)• Make sure they are set

high enough to supply the secondary regulators.

Foamy Beer

Dispense Gas

Applied CO2 Pressure

• Above ideal gauge

pressure

• Keg may be

overcarbonated

• Beer may be leaving

faucet too fast

Foamy Beer

Dispense Gas

Applied CO2 Pressure

• Below ideal gauge

pressure

• Bubbles may be

forming in line,

producing foam

Note: Straight CO2 on a forced air or glycol system can

cause foamy beer when the temperature rises from the

cooler to the trunk line

Foamy Beer

Draught Hardware

• Inspect seals for damage

• Coupler

• Keg

Foamy Beer

Faucet

• Make sure faucet vent holes are free of debris

Glasses

• Make sure foaming is not due to use of frosted glasses.

No BeerMake Sure….

Temperature

• The keg or the lines are not frozen

Dispense Gas

• Gas tanks are on, full, and that all shut-offs are open.

Draught Hardware

• The keg is not empty

• The check ball is not stuck

Flat Beer

• 25% CO2 blends used

• Misreporting foamy beer

So what are we up against?

Condition of the Line

Hardware Cleanliness

Installation and Cleanability

What grows in lines?• Organic material – Biofilm

• Yeast• Bacteria• Mold

• Mineral deposits• Calcium Oxalate (beerstone)• Calcium Carbonate

Biological Growth• Perfect environment for microorganisms

• Food• Protein

• Sugar

• Aerobic and anaerobic

• Rough areas• Beerstone

• Splices

• Older generation tubing

• Rapid growth

Biological Growth

Comes from:

• Coupler at tapping

• The brewery

Biological Growth• Pediococcus

• Anaerobic (no oxygen)• Produces diacetyl – butter/butterscotch

• Lactobacillus• Anaerobic (no oxygen)• Produces lactic acid - sour

• Pectinatus• Anaerobic (no oxygen)• Cloudy• Acetic acid – vinegar• Sulfur – rotten eggs

• Acetobacter• Aerobic (oxygen)• Acetic acid - vinegar

Required deep clean and part replacement to remove

Mineral Deposits

• Calcium Oxalate• Beerstone

• Calcium Carbonate• Reaction with caustic and CO2

• Slower development

• Provides foothold for biofilm

In cleaning, the final result

is influenced by 4

interdependent factors,

represented in the Sinner

Circle. If one factor is

reduced, the loss must be

compensated for by

increasing one or more

other factors.

Sinner Circle

Chemical Safety• Adhere to chemical manufacturer

instructions

• MSDS

• Proper Personal Protective Equipment (PPE)

• Eye protection• Gloves

• pH test rinse water

• Never rinse chemical with beer

Time• Cleaning every two

weeks

• 15 minutes of recirculation

• Faucets cleaned every time

• Couplers cleaned every time

• FOBs/couplers detailed semi-annually

Temperature• Temperature

• Hot is more effective BUT:

• Safety hazard

• Can warm up other lines in bundle

• Hot but not too hot• Hot tub temperature

• 80-110

Chemicals

• Caustic• High pH

• Removes organic material

• Every two weeks

• Acid• Low pH

• Removes inorganic/mineral

• Quarterly

Chemicals

• Caustic Solution• 2% - 3%

• 2% for regular use

• 3% for older or problematic lines

• Only use chemical which provides explicit directions

Acid Solution• Follow

manufacturer’s

instructions

Mechanical Action

Circulation Pump:

• High Pressure up to 1 ½

times flow rate

• Mechanical force assists

in removal of build-up

• More Time Efficient

• 15 minutes contact time

Mechanical Action

Mechanical Action

Cleaning Canister:

• Pressure restricted to the

regulator setting

• Stagnant (no flow)

• Time Consuming

• Development of Carbonic

Acid

• 20 minutes contact time

Surfaces to be cleaned

• Coupler

• Faucet

• Tubing, fittings

• Draught Tower

• Drain Pan

• Cooler wall

SummaryEvery two weeks

• Caustic chemical solution at 80-110F• 2% solution, 3% for old or problem lines• Recirculate with an electric cleaning pump 15 minutes• Disassemble and clean faucet at every cleaning• Scrub Coupler at every cleaning

Quarterly• Acid line cleaner – descaling

Semi-Annually• Disassemble and detail FOBs• Disassemble and detail couplers

Always pre-rinse and post-rinse with fresh waterAlways use proper PPE

Industry-Wide Draught Quality Standards

Questions

Documents

Draught System Operations - California Craft Beer...A Primer on the Design, Installation, Operation and Maintenance of Your Taproom Draught System ... cooler to tower • Glycol-chilled