welding journal | june 2016 - amazon s3 · 60 welding austenitic smo 254 stainless steel for the...

PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDINGAND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING

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60 Welding Austenitic SMO 254 Stainless Steel for the Desalination Industry More is being learned about welding corrosion- resistant alloys as the push for desalination plants increases — M. Sternisha

66 Sip on This: Welded Tanks Support Beer Production A small shop finds its niche in fabricating stainless steel brewing systems — K. Campbell

72 Welding Pipe in Extreme Weather Conditions Weather conditions are a factor when welding on energy projects in Alaska — W. C. LAPlante

78 Fixtures for Tube Welding Tight fitup and repeatability are achievable with modern modular fixturing tables — P. Farley

82 FABTECH Canada Continues to Grow A review of happenings at FABTECH Canada M. R. Johnsen

JUNE 2016 / WELDING JOURNAL 3

CONTENTS

185s Effects of Ultrasonic Power on the Hardness of Aluminum 3003H18 Alloy The relationship between power and hardness is studied in ultrasonic additive manufacturing K. Sojiphan et al.

194s CurrentIndependent Metal Transfer by Using Pulsed Laser Irradiation Part 2: Affecting Factors One droplet per laser pulse is achievable with the application of high power to irradiate the droplet neck J. Xiao et al.

202s Visual Sensing of the Physical Process during Underwater Wet FCAW An image capture system was developed to monitor bubble, droplet, and arc behavior activity C. B. Jia et al.

210s Investigating Friction Stir Welding on Thick Nylon 6 Plates Controlling rotational speed proved an important factor in friction stir welding of polymeric materials — A. Zafar et al.

219s Measurement and Application of Arc Separability in Plasma Arc A novel system based on a split anode was developed to better understand the ability to adjust heat and arc pressure distribution without a change in current — S. J. Chen et al.

WELDING RESEARCH SUPPLEMENT

June 2016 • Volume 95 • Number 6

FEATURES 60

78

72

82

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6 Editorial8 Press Time News

10 Washington Watchword12 International Update14 News of the Industry20 Business Briefs22 Aluminum Q&A26 Brazing Q&A30 Product & Print Spotlight36 AWS Financial Report

86 Coming Events90 Certification Schedule94 Welding Workbook97 Society News98 Tech Topics

101 Section News117 Guide to AWS Services118 Personnel129 Classifieds132 Advertiser Index

OFFICERSPresident David L. McQuaidD. L. McQuaid and Associates, Inc.

Vice President John R. BrayAffiliated Machinery, Inc.

Vice President Dale FloodTri Tool, Inc.

Vice President Thomas J. LienertLos Alamos National Laboratory

Treasurer Carey ChenCincinnati, Inc.

Executive Director Ray W. ShookAmerican Welding Society

DIRECTORST. Anderson (At Large), ITW Welding North AmericaU. Aschemeier (Dist. 7), Subsea Global SolutionsD. J. Burgess (Dist. 8), Alstom PowerD. A. Desrochers (Dist. 1), Old Colony RVTHSD. L. Doench (At Large), Hobart Bros. Co.D. K. Eck (At Large), Praxair Distribution, Inc.K. Fogleman (Dist. 16), ConsultantP. H. Gorman (Dist. 20), Sandia National LaboratoriesS. A. Harris (Dist. 4), Altec IndustriesJ. Knapp (Dist. 17), ConsultantM. Krupnicki (Dist. 6), Mahany Welding SupplyD. J. Landon (Past President), Vermeer Mfg. Co.S. Lindsey (Dist. 21), City of San DiegoD. E. Lynnes (Dist. 15), Lynnes Welding TrainingC. Matricardi (Dist. 5), Welding Solutions, Inc.S. M. McDaniel (Dist. 19), Big Bend Community CollegeW. R. Polanin (At Large), Illinois Central CollegeR. L. Richwine (Dist. 14), Ivy Tech State CollegeD. J. Roland (Dist. 12), Airgas USA, LLC,

NorthCentral RegionR. W. Roth (At Large), RoMan ManufacturingM. Sebergandio (Dist. 3), CNH AmericaK. E. Shatell (Dist. 22), Pacific Gas & Electric Co.M. Sherman (Dist. 10), SW&E, LLC

M. Skiles (Dist. 9), ConsultantW. J. Sperko (At Large), Sperko Engineering ServicesJ. Stoll (Dist. 18), The Bohler Welding Group U.S.H. W. Thompson (Dist. 2), UL, Inc.R. P. Wilcox (Dist. 11), ConsultantJ. A. Willard (Dist. 13), Kankakee Community CollegeD. R. Wilson (Past President), Wilson and Associates

WELDING JOURNALPublisher — Andrew CullisonEditorialEditorial Director Andrew CullisonEditor Mary Ruth JohnsenFeatures Editor Kristin CampbellAssistant Editor Melissa GomezAssistant Editor Annik BabinskiPeer Review Coord. Sonia AlemanPublisher Emeritus Jeff Weber

Design and ProductionProduction Manager Zaida ChavezSr. Production Coordinator Brenda FloresManager of International Periodicals andElectronic Media Carlos Guzman

AdvertisingSr. Advertising Sales Exec. Sandra JorgensenSr. Advertising Sales Exec. Annette DelagrangeManager of Sales Operations Lea PanecaSr. Advertising Production Manager Frank Wilson

SubscriptionsSubscriptions Representative Evelyn [email protected]

MARKETING ADVISORY COUNCIL(MAC)D. L. Doench, Chair, Hobart Brothers Co.S. Bartholomew, Vice Chair, ESAB Welding

& Cutting Prod.Lorena Cora, Secretary, American Welding SocietyD. Brown, Weiler BrushC. Coffey, Lincoln ElectricD. DeCorte, RoMan ManufacturingS. Fyffe, Astaras, Inc.D. Levin, AirgasR. Madden, Hypertherm

D. Marquard, IBEDA SuperflashJ. F. Saenger Jr., ConsultantS. Smith, WeldAid ProductsD. Wilson, Wilson and AssociatesJ. N. DuPont, Ex Off., Lehigh UniversityL. G. Kvidahl, Ex Off., Northrop Grumman

Ship SystemsD. J. Landon, Ex Off., Vermeer Mfg.S. P. Moran, Ex Off., Weir American HydroE. Norman, Ex Off., Southwest Area Career CenterR. G. Pali, Ex Off., J. P. Nissen Co.N. Scotchmer, Ex Off., Huys IndustriesR. W. Shook, Ex Off., American Welding Society

American Welding Society8669 NW 36 St., # 130, Miami, FL 331666672(305) 4439353 or (800) 4439353

On the cover: A welder performs aGTAW root pass on 36in.diameterpipe at the Carlsbad desalination plant.(Photo by Logan Kucerak, Kiewit SheaDesalination.)

Welding Journal (ISSN 00432296) is published monthly bythe American Welding Society for $120.00 per year in the UnitedStates and possessions, $160 per year in foreign countries: $7.50per single issue for domestic AWS members and $10.00 per singleissue for nonmembers and $14.00 single issue for international.American Welding Society is located at 8669 NW 36th St., # 130,Miami, FL 331666672; telephone (305) 4439353. Periodicalspostage paid in Miami, Fla., and additional mailing offices. POSTMASTER: Send address changes to Welding Journal, 8669 NW36th St., # 130, Miami, FL 331666672. Canada Post: PublicationsMail Agreement #40612608 Canada Returns to be sent toBleuchip International, P.O. Box 25542, London, ON N6C 6B2,Canada.

Readers of Welding Journal may make copies of articles forpersonal, archival, educational or research purposes, and whichare not for sale or resale. Permission is granted to quote from articles, provided customary acknowledgment of authors and sourcesis made. Starred (*) items excluded from copyright.

Copyright © 2016 by American Welding Society in bothprinted and electronic formats. The Society is not responsible forany statement made or opinion expressed herein. Data and information developed by the authors of specific articles are for informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.

DEPARTMENTS

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One of my favorite quotes is from poet T. S. Eliot (Four Quartets, Section V), “We shall not cease from exploration, andthe end of all our exploring will be to arrivewhere we started and know the place for thefirst time.” At the start of every year, all operatingand financial goals are completely reset withnew challenges and higher bars to achievefor the new year. The American Welding So-ciety (AWS) posted record-setting results in2014 with even higher aspirations for 2015. Before getting into details of the 2015 fi-nancial results, I would first like to extendmy gratitude to Robert Pali for his service asAWS treasurer and Finance Committeechair over two terms, from 2010 to 2015. Without further delay, I am pleased toannounce another record-breaking year forAWS in 2015. Financial highlights include • Revenues for 2015 were $40.7 million,which represents an increase of 12.9% over2014 results. The surplus for 2015 was$11.8 million, 20% greater than 2014. Boththe revenues and surplus have establishednew financial records for AWS once more. • Strong performance in the revenuesand surplus over the annual operating planwas due in large part to the acquisition ofWorld Engineering Xchange (WEX) in 2015.WEX added $1.7 million in additional royal-ties and contributed $1.2 million to the sur-plus. Considering the purchase price forWEX of $1.9 million, we feel the acquisitionwas a solid investment. • The reserve fund on December 31,2015, was $29 million, representing an in-crease of $4.9 million or 20.3% greater thanthe December 31, 2014, balance. The twolargest drivers in this increase were a trans-fer from operations of $9 million and anoutgoing transfer to the AWS Foundation of$4 million. The aforementioned results were realizedthrough the steadfast efforts of all of theAWS operating teams and the amazing workof all of the volunteer committees. Severalspecific arenas of strategic activity drovegrowth and surplus in 2015, including • AWS Foundation. The AWS Founda-tion’s assets on December 31, 2015, grew to$49.3 million, up 6.6% over the December31, 2014, balance. The major factor in theincrease was the aforementioned transfer of$4 million from AWS Operations. As a newmilestone, 2015 was the first year that the

AWS Foundation independently funded itsown operating expenses. • Certification. The Certification teamsigned a contract with Prometric, which willfacilitate computer-based exams. In addi-tion, capabilities and personnel in Asia(specifically China) were enhanced. Finally,questions for the Certified Welding Inspec-tor exam have been greatly expanded andimproved. • Information Technology. This team ledseveral efforts to modernize AWS’s plat-forms, which involved implementing newsoftware and collaborating effectively withother AWS teams. Examples of successfulimplementations include the following:Moodle (learning management system),Customer Relationship Management, Share-Point (collaboration tool), and Great Plains(accounting system). • Learning/Education. In April 2015, thelearning/education team launched the firstphase of WeldLink, an online career plan-ning and management system specificallydesigned to bring together individuals, busi-nesses, and schools in the welding industry. • Membership/Publications. New mem-bership increased by 9.7% in 2015, withnondues revenue increasing by 6.6%. Theteam also signed an agreement with HigherLogic to provide a cloud-based platform forsharing digital content with members andSections. Also, the Welding Journal en Es-pañol became the first publication in LatinAmerica to publish peer-reviewed weldingresearch. Last, professional customer serv-ice training was provided for all AWS staffmembers. • Sales/Marketing. Above-budget revenuegrowth was achieved both on a domesticand international basis. The team grew itsinternal resources through well-earned promotions and key strategic hires. An ex-clusive global sponsorship agreement wassigned with WorldSkills International, andthe 43rd WorldSkills Competition tookplace in São Paulo, Brazil. As the incoming treasurer for 2016 to2018, the financial condition and futuregrowth prospects appear quite robust forAWS. Congratulations to everyone in our in-dustry for their part in making 2015 an out-standing year. Also, thanks in advance foryour continued support for AWS in 2016(where we reset the bars once again) andstrive for even better results.

EDITORIAL

AWS Revenues, Surplus EstablishNew Financial Records


Carey ChenAWS Treasurer

“As the incomingtreasurer for 2016 to2018, the financialcondition and futuregrowth prospectsappear quite robustfor AWS.”

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“Sometimes you want to go where everybody knows your name.And they’re always glad you came.” These classic theme song words, from the TV sitcom Cheers,still ring true for how regular bar patrons feel about visiting theirlocal establishments. Only now, their horizons have expanded tohometown breweries that offer one-of-a-kind light and dark beerblends. Long before that ice-cold liquid is ready for consumption, weld-ing plays an important role in creating the place where its ingredi-ents (primarily a mix of flavored hops, malt, yeast, and water) areprocessed. Here’s the tale of one fabricator’s techniques.


Sip on This: Welded Tanks SupportBeer Production

Follow the journey of how these in-demand,stainless steel vessels aredesigned, constructed,inspected, and installed

BY KRISTIN CAMPBELL

Fig. 1 — This custom brewhouse, fabricated by MCF Craft Brewing Systems for Bale Breaker Brewing Co., Yakima, Wash., features(from left) a 20-bbl hop back, 30-bbl whirlpool (11 ft tall), 30-bbl steam jacketed kettle, and 30-bbl mash lauter tun with an abovegrist case. It also contains piping that connects the vessels and a platform with ladders, plus designed control panel systems.(Photo courtesy of MCF.)

CORRECTED CAMPBELL JUNE 2016.qxp_Layout 1 5/12/16 4:09 PM Page 66


The Need for Tanks

When Charlie Frye first built astainless steel tank for a brewery sev-eral years ago in his 125-sq-ft garage,he never imagined making this andspecialty items, including a draft beertower, would turn into a full-timebusiness, or that it would flourishenough to serve more than 130 brew-eries worldwide, including 30 statesand Norway. That’s only the stuff ofdreams, right? But this did happen, forwhich the artistic son of a steel workeris grateful every day. Metalcraft Fabrication was formednearly 10 years ago after Frye recog-nized the demand for his tanks andthe brewing industry’s popularity. Heacknowledged Cofounder JenniferBaque for her work during that time,including product customization. “Idon’t deserve all the credit,” he said. Located in the heart of Portland,Ore., the company is now known as MCF Craft Brewing Systems (mcfpdx.com) — Figs. 1, 2. What started as a one-man shophas expanded to nearly 50 employees,20 of whom weld — Fig. 3. A majorityof the talented staff members areyounger, which has led to an energeticenvironment. “A big part of building the companyhas been finding the best way to dothings, listening to others, a willing-ness to try, and treating everybodywith respect,” Frye said.

Fig. 2 — Matt Cartwright is not scared of heights. In MCF’s shop, with lift assistance,he gas tungsten arc welds a 12-gauge shell at the top of a 12-ft-tall, 30-bbl fermenter.

Fig. 3 — MCF staff members, shown here in a group shot, value teamwork. Behind the banner (first row, center) are Sales and Marketing Director Liz Shearer and President/Founder Charlie Frye.



In late 2014, MCF moved to a30,000-sq-ft facility and office space. Focusing on customer satisfaction,not rushing projects or overcommit-ting, and providing high-quality tankshave earned the company a goodword-of-mouth reputation. Last year, MCF made around 185tanks and earned more than $6 mil-lion in gross revenue. This year, it ex-pects to fabricate 210 tanks and hasmore aggressive projections. “Two-thousand new breweries willbe opening in the United States in thenext three years,” Frye said. “Thegrowth is staggering, exciting, andbrings more work.”

Fabrication Features

The company creates complete,functional brewhouses from 10 to 40barrels (bbl). These often include sev-eral tanks, over a small footprint,serving different purposes in beer pro-duction with piping to connect them.Adding platforms with ladders allowsowners to easily reach tank openings.The company also designs control pan-el systems (see Fig. 1 for the setup atBale Breaker Brewing Co., Yakima,Wash.). Cellar vessels are constructed aswell. These consist of fermenters withinterior mixing apparatuses, andbright beer tanks, from 10 to 400 bbl.The fermenters are actually built up-side down, with their legs in the airand tank down below, so getting inside

of them to work is much easier. “Many craft breweries will occupy abuilding not designed for that, so wemake custom tanks to fit in differentspaces,” Frye added. Grain-handling equipment and oth-er products are fabricated, too. “On average, it takes 150 to 300hours to make each tank,” Frye said.Most don’t exceed 3 tons. Every tank serves a distinct pur-pose. As two examples, a fermenter isused for fermenting beer while abright beer vessel is used for storageand conditioning. Shapes are deter-mined by function. The height of the tanks also varydepending on required specifications.A shorter tank could stand 7 ft while ataller one might be 30 ft; a large fer-menter’s conical bottom alone couldbe 9 ft. The tanks can be made of severalparts, including inner/outer shells,layers of insulation, large rings fordouble-walled vessels to bridge open-ings with the shell and outer tank (act-ing as a structural rib), tubing, brac-ing, extra legs for support, and circulardoors imported from Italy. “Common tanks range from$17,000 to $45,000 each,” Frye said.

Sculpting Stainless Steel

Type 304 stainless steel is used in amajority of the fabrication because it’sknown as the industry standard andhas sanitary properties.

“Oftentimes, it’s ready to weld,clean, and requires minimal prepara-tion,” Frye said. Sheets and tubes come from NorthAmerican mills, when possible, andbars and pipes are delivered. Ship-ments arrive several times a week.

Design Developments

When Frye first started construct-ing tanks, he wanted to develop astriking design. Therefore, he chose touse square legs, not to add brass orcopper to the exterior (as that metalwould require upkeep), and finishedthe exterior welds so the tanks ap-peared seamless. Lompoc Brewery Owner JerryFechter was one of Frye’s first cus-tomers. A 12-ft-tall tank Frye made isstill in use at its closeby N. WilliamsAve. location in Portland. Getting thetall structure inside the facility requiredrolling in, then tipping up the product. “Here, it’s almost a way of life,”Fechter said about having breweries. As MCF grew and more complexsystems were requested, the Engineer-ing Department led by Tom Sage tookover developing designs to supportparticular beer styles, a range of brew-ing/fermentation techniques, andworkspace preferences. Tank drawings are done using Solid-Works software. Individual sketchesare sent for customer approval beforeconstruction; feedback is welcomed.

Floor Supervision

In MCF’s shop, there are three con-nected bays offering workstations,cranes, machines/tools, and a smallparts division. Production Manager Jon Lien andOperations Manager William Dallshare floor managing responsibilities. “We move 20 tons of steel permonth,” Lien said. The former CoastGuard serviceman also noted tankbuilding is seen as a personal projectwhere each craftsman is relied on tocomplete the job. “The guys on the floor are whywe’re successful. They constantly de-liver for us,” Lien acknowledged. Dall, a former general contractor,stays calm in stressful situations. “It’s metalcraft Tetris,” Dall joked ofmanaging the workflow. “There’s al-ways something to do with gettingtanks ready to ship. I enjoy problemsolving.”

Fig. 4 — Jacob Duvall details the inside of a large flanged and dished head with a90-deg pneumatic tool.



Cutting Capabilities, Forming

Craftsmen use plate shears, cut-offwheels, CNC, and plasma cutting ma-chines. Laser and waterjet services areoutsourced. A majority of forming takes placein-house thanks to plate roll and barforming machines. For flanged and dished heads (basi-cally domes), there are two steps:stamping the overall radius and usingvendors to hydroform the heads. Jacob Duvall, a newcomer to MCF,has spent time detailing them — Fig.4. “I really like stainless steel becauseit’s clean and uniform,” Duvall said.

Welding Work

Gas tungsten arc welding (GTAW)and gas metal arc welding (GMAW) areperformed when fabricating the tanks. For GTAW, 1⁄16-, 1⁄8-, and 3⁄32-in. rodsare used with argon gas blends, whilefor GMAW, 0.045-in. wires are usedwith trimix gas blends. A majority of material thickness is10 or 12 gauge. Challenges working onthis include achieving a balance ofpenetration without superheating thematerial or causing porosity. In addition, small tanks can be hardto work on because of accessibility.Large tanks can be difficult becausegood fitup is required when puttingtop/bottom halves together, pluswelders need lifts for welding up high. Many welds are made to not only

provide structural strength but alsolook ideal cosmetically. These consistof butt and lap joints, fillet welding,and sanitary tube purging. “It really is an art,” Frye empha-sized about welding on stainless steel,especially to the level needed for meet-ing sanitary purposes.

Staying Safe, Scheduling

Beside the welders wearing person-al protective equipment, these safetymeasures are followed: guards ongrinding tools, forklift/fall protection,lockout/tagout OSHA protocols, Ore-gon state rules, and annual hearingtests. Dave Sage is in charge of human re-sources and safety. Welders work 8-hshifts Monday through Friday andchoose their starting times. Overtimeis as needed. “There’s a lot of flexibility withyour workweek of 40 hours,” Sage said.“We have low turnover and don’t haveto work hard to fill roles. People likeworking here, it’s a livable place, andthe proof is in the retention.”

Personal Perspectives

Harry Stringer hasn’t been withMCF that long but brings three yearsof professional welding experience and is getting used to its tank-buildingmethods as he works on his first fermenter.

“There’s a lot of independence. Youget set on your own project and aretrusted with your work until it’s done,”Stringer said. Several welders have been workingat the company four or five years, in-cluding the gentlemen listed next. In recently making a large manway,for an extension piece to go on a fer-menter, Trevor Keith took two piecesof metal rolled in-house, welded themtogether, and assembled that to fit in front of the tank’s skin — Fig. 5. He can quickly adapt to blueprintmodifications. Matt Voss has built stainless steelitems for 20 years and likes creativelyturning flat metal into something. “I’ve got probably the most diversebackground of anyone in the shop,” hesaid about his metals experience. Voss further feels everything can bechallenging, yet “accepting that turnsroadblocks into milestones, you turnadversity into a functional way of do-ing something. It’s a matter of findingways you can grow from or figure ashortcut around.” Matt Cartwright doesn’t mindwelding many feet off of the ground(see Fig. 2). He described GTAW as a“zen-like feel.” He has welded morethan 20 years and enjoys this aboutthe job: “Metal fabrication and the lotsof talented people here. I’ve learned alot.” Jorge Gamez is comfortable weld-ing stainless steel pieces much tallerthan he, likes starting new projectsand thinking differently — Fig. 6. “You have the opportunity here tomove up,” Gamez added. “When youare happy and you are motivated, youenjoy work.” Jose Reyes Ochoa handles a little ofeverything, from cutting various partsto installing insulation. He likes keep-ing everything in order for colleaguesto do their jobs. His son shares thesame name and is also an employee. “It’s almost like a dream to workalongside your father,” Jr. said. He pol-ishes and housekeeps, but aspires tobe a welder.

Resistance Welding Addition

Recently, MCF purchased a resist-ance welding machine. Representingan investment of more than $200,000,it will soon be used to spot and lapseam weld the cooling jackets on fer-menters (the “dimpled” sheet layer),

Fig. 5 — Trevor Keith uses GTAW on a manway more than 22 in. tall and 17 in. wide fora fermenter that will stand 12 ft and hold 30 bbl when finished.


which is where the coolant (glycol) cir-culates. Previously assembled by handusing GMAW, this automated methodwill mean fewer openings to seal, en-able reliable repeatability, and savetime.

Inspection Importance

Supervisor Casey Antonick is incharge of quality control and alsotrains new welders. “What’s inside the tank representslots of money for customers, so con-tamination can’t happen,” Antonickexplained. He described the in-house inspec-tion process as vigorous. A quality con-trol checkpoint management tool isused to ensure what’s built meets com-pany standards. There are differentcriteria on a tank’s inside and outside,for instance, that must be acceptable. Several assessments take place dur-ing the construction process. “Thoseare mostly visual,” Antonick added. Currently, MCF is in the process ofachieving ASME Boiler and PressureVessel certification. “We look for pit-free welds andhave rigorous inspections for pinholes,pits, cracks, and inclusions, as theylead to bacterial contamination,” Fryecontinued. Procedures include penetrant andultraviolet porosity tests, visual in-spections, and making sure edgesaren’t sharp. Mechanical stress andload limit tests take place on structur-al parts in the weldment stage. On cooling jackets, air and hydro-static tests are made at different pres-sure capabilities for several hours. Thesame goes for testing shells, wheretanks are filled with water and pres-surized to ensure there are no leaks.

Finishing Front

In the beverage industry, ultrafinefinishes are of the utmost importanceon a tank’s interior, because that’swhere beer ingredients and liquid are held before consumption. Ultra-smooth blending and deburring mustoccur so there are no metal shavings,which could result in bacterial contamination. “All welds need to be free of porosi-ty to be finished to a sanitary level,”Frye added. Fitup and preparation arecritical factors in GTA welds, which getground to 150-grit or more.

It’s also preferred for the outwardappearances to look just as good andseamless. “Extra time is taken to applyan aesthetic finish to the outside oftanks. The polishing is all by hand,”Frye said.

Providing ProjectManagement, Sales Support

Marianna Huntley is project man-ager. In this role, she manages all cus-tomer interactions, sets expectations,and coordinates the tanks’ productionschedule, which is organized in her of-fice on a massive board. “Projects can take three to sixmonths. It depends on the job size,”Huntley said. She keeps open lines ofcommunication in quoting lead timesand providing status updates. Sales and Marketing Director LizShearer creates proposals each week tomeet specific brewery needs, includinglong-term goals, and gets in touchwith many departments for estimates. “We work with award-winningbrewers. That’s a real honor,” Shearersaid.

Installation Impact

In the United States, tanks get fromthe shop to their new homes by semitractor-trailers. During the winter, ac-cordion covers might be used as pro-

tection from salt on snowy roads, butthe rest of the year there are no tarpsbecause they can mar finishes andhave iron particles that can cause rust. For installation, certified riggersand equipment operators are em-ployed. Customers’ architects, electri-cians, construction contractors, steamfitters, and refrigeration techniciansare also part of the process. In addition, purge GTAW is used foron-site process piping of stainlesssteel. This is most common betweenbrewhouse vessels, given there’s aneed to transfer liquid from one tankto another. Brewing Process Specialist WaylonMcAllister assists customers with newtanks and choosing the right equip-ment. Locally, he goes on-site to makesure everything is set correctly andhandles inaugural brews, but for bigprojects, he will travel. He also emphasized cleanliness.Owners need to first passivate theirtanks before any brews. This chemicalprocess will remove any debris gainedduring transportation and help pre-vent corrosion. Then, after everybatch, they need to use clean-in-placemethods. He further mentioned tanksshould have fixed or spinning sprayballs, and caustic solutions (typicallysodium hydroxide) should be used tobreak down organic matter and liquifymaterial off of the tanks. “Brewing is ninety-five percent


Fig. 6 — While constructing a 9-ft-tall conical bottom for a large fermenter, which isbuilt upside down, Jorge Gamez starts GTAW to join two formed pieces of stainlesssteel.


cleaning. Very little is tasting beer andnew recipes [although that is unique].It’s a labor of love,” McAllister said,dispelling myths. “One brew takeseight hours, and three of those arespent sanitizing and cleaning.”

Cheers to the Future

Big things are in store for MCF nextyear. “We’re working on a standard

product line with a 2017 projection,”Frye said, that will allow for morecompetitive lead times. Continuing to design efficienttanks, build strong company founda-tions, implement more modern manu-facturing (perhaps robots, but not toreplace staff), and achieve new goalsare also in store. “Lots of towns would like brew-eries. It’s an exciting industry to bein,” Frye concluded.

With that notion, welded tanks willbe required for this booming industry,leading to more knowing your nameand glad you came moments.


WJ

All around Portland, Ore., breweries make their drinksin stainless steel tanks constructed by MCF Craft BrewingSystems. Gigantic Brewing Co., an independent, craftbrewery that produces seasonal beers, is in this group. Atpress time, its cleverly named, flavorful mixtures included“Kiss the Goat,” a black doppelbock, and “Hearts & Stars,” asaison with hüll melon hops. Owners Van Havig and Ben Love felt buying locally wasimportant. While working with MCF President/FounderCharlie Frye, his attention to detail and customized workstood out. “They listen to what we as brewers want and maketanks accordingly. Other manufacturers will try to tell youhow to do your job, even though they’ve never actuallymade beer. MCF takes your input and incorporates it intotheir designs, making their stuff essentially designed overtime by working brewers,” Havig said. Gigantic has these tanks: six 45-bbl fermenters (14 fttall), one 15-bbl fermenter (10 ft tall), one 45-bbl bright

tank (8 ft tall), a 30-bbl hot liquor tank (about 12 ft), a 15-bbl mash/lauter tun with bottom mount plow, a 15-bblkettle (25-bbl total volume), and a hop back with a totalvolume of 21 bbl. “The fermenters are all custom geometry to fit the spaceand to give a close to 1:1 aspect ratio,” Havig said. He con-tinued, “The bright tank is custom geometry, trying to getthe shape as close to spherical as possible, to help with set-tling of yeast, as well as with conservation of thermal ener-gy. The mash tun is also custom geometry, basically de-signed for the kinds of beer we brew (mainly stronger).” Any small problems after installation, like a fitting end-ing up in the wrong place, were quickly fixed. And while Gigantic Brewing doesn’t have its tanksshowcased on display, some others do for ambiance. “It’s been over 30 years since the first small brewerieswere built in Portland, so there’s little ‘wow’ factor locallyin seeing tanks. Best just to put them in the back whereyou can keep them clean and well maintained,” Havig said.

Ben Love (left) and Van Havig, owners of Gigantic Brewing Co., Portland, Ore., pose by some of their MCF stainless steel tanks thatenable them to brew seasonal beers. (Photo courtesy of Gigantic Brewing Co.)

Raise Your Glass to Breweries

KRISTIN CAMPBELL([email protected]) is features editor of the Welding Journal.


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