Cryogenic Tank Manufacturing and Industrial Gas Systems

Analysis

The design and analysis of pressure vessels is a critical process to ensure safe and maximum efficient operation.

Stress analysis is conducted considering material strength, thermal expansion, and internal and external pressure effects.

• Material selection: The yield strength, ductility, and corrosion resistance of the material are analyzed according to standards such as ASME, EN 13445, AD 2000. Calculations are made in compliance with international pressure vessel codes like ASME BPVC, EN 13445, PED 2014/68/EU.
• Finite Element Analysis (FEA); Software such as ANSYS, Abaqus, SolidWorks Simulation are used for complex geometries and irregular load distributions. Yield limit is evaluated using the Von Mises criterion. Thermal stress analyses identify stresses caused by temperature changes.
• After modeling, thermal analyses are performed using COMSOL Multiphysics, Compress – Pressure Vessel Mechanical Design Software, HTRI: Thermal Rating Calculation Software and others.
• The design is approved and certified according to the requirements of NoBo companies.

Procurement

After engineering design, the procurement process progresses according to an effective purchasing procedure that fits production options, considering material, equipment, and service duration, cost, and design quality.

• The relevant department (engineering, project management, production, etc.) creates a purchase request form. Technical specifications (material classes like 304, 316, AL6xxx, P355 GH, L245, and X42), quantity, and delivery time are specified, including specific technical requirements if necessary.
• Standards to be applied in the project, such as PED 2014/68/EU, ASME, EN 13445 or AD 2000, are followed, and purchases are made after certification approval of materials used in the project. When certification is insufficient, destructive and non-destructive tests are applied according to PMI (Positive Material Identification) and EN 10204-3.1/3.2 requirements. Inspection tests are certified and documented under NO-BO supervision.
• Materials, equipment, and services are purchased on time, at appropriate cost, and with proper quality capacity without deviating from standard requirements, controlling costs and increasing efficiency to reduce project risks.

Production

After producing quality and standards-compliant approved technical drawings, 3D models, and detailed production drawings, pre-production planning and control stop points are determined. The features to be used include mechanical and characteristic properties.

The production plan and project plan, including welding, machining, assembly, surface treatments, work orders, and production instructions, are prepared and communicated to the field.

• Cutting, Shaping, and Preprocessing

Materials are shaped according to design lines. Laser, plasma, water jet or mechanical cutting methods and machining operations (turning, drilling, grinding, etc.) are used to size and prepare the materials for production. Traceability is ensured by stamping or heat number transfers for sized and subsequently processed products.

• Welding and Joining

Welding methods are determined and carried out according to manufacturing standards and approved Welding Procedure Specifications (WPS). Fit-up checks are approved, and welding is performed by personnel certified with Welder Performance Qualifications (WPQ). After welding, non-destructive tests such as penetrant test (PT), magnetic particle test (MT), radiographic test (RT), and ultrasonic test (UT) are conducted and approval reports are prepared.

• Heat Treatment and Surface Processes

Heat treatments such as heating and hardening are applied according to customer requirements and to extend the service life. Corrosion protection processes (sandblasting, painting, passivation, coating, etc.) are performed.

• Assembly and Integration

The produced scope is assembled, and mechanical, electrical, and hydraulic systems are integrated according to project changes.

Quality Control

Quality control process after production.

• Dimensional Controls

Dimensional features, tolerances, and geometric shapes of parts are controlled and tracked.

• Non-Destructive Testing (NDT) and Certification

Necessary non-destructive tests such as radiography (RT), ultrasonic testing (UT), magnetic particle testing (MT), and liquid penetrant testing (PT) are performed and reported under the supervision of NDT Level-II Inspectors. Material and manufacturing certificates (EN 10204-3.1/3.2, PED 2014/68/EU, ASME, ISO 9001, etc.) are prepared.

• Functional and Pressure Tests

After approval by dimensional inspectors, produced parts undergo hydrostatic or pneumatic pressure and mechanical strength tests using calibrated equipment, and certification is issued.

Certification – QTP

In engineering equipment, QTP (Quality Test Plan) documents the workflow, quality control tests, and audit procedures of a product, production, assembly, and test details. It is archived for traceability. This certification method is performed in a procedural plan that complies with product or system design, customer expectations, and international distribution and can be accepted by NO-BO organizations.

• Documents and approvals related to design and calculations,
• Visual and dimensional control reports
• Material tests (chemical analyses, mechanical tests, performance tests)
• Material traceability and certification documents
• Welding inspections (Magnetic Particle Testing (MT), Liquid Penetrant Testing (PT), Radiography (RT), Ultrasonic Testing (UT)) and reports
• Pressure and leak tests and reports
• Functional and performance tests