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Manufacturing Process of Pressure Vessels

The manufacturing of pressure vessels is a critical process requiring strict adherence to engineering standards, safety regulations, and quality assurance.

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Manufacturing Process of Pressure Vessels

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  1. Manufacturing Process of Pressure Vessels The manufacturing of pressure vessels is a critical process requiring strict adherence to engineering standards, safety regulations, and quality assurance. Here's a detailed step-by-step explanation: • 1. Design and Engineering • Blueprint Development: Engineers design the vessel based on the intended application, operating pressure, temperature, and stored material. • Code Compliance: The design adheres to industry standards like ASME Boiler and Pressure Vessel Code (BPVC), ISO, or API codes. • Stress Analysis: Structural calculations ensure the vessel can withstand internal and external pressures. • Material Selection: Metals such as carbon steel, stainless steel, or alloys are chosen based on strength, corrosion resistance, and operating conditions. • 2. Material Procurement • High-quality raw materials, usually plates or sheets of metal, are sourced. • Certification of materials ensures compliance with design specifications and safety standards.

  2. 3. Cutting and Shaping • Metal Cutting: Plates are cut into required sizes and shapes using methods like: • Plasma cutting • Laser cutting • Water jet cutting • Forming: • Plates are bent into cylindrical or spherical shapes using rolling machines. • Heads (end caps) are formed through spinning, pressing, or deep drawing processes. • 4. Welding • Preparation: Edges of plates are beveled to prepare for welding. • Joining Sections: Welders join the sections (shells, heads, nozzles) using methods such as: • TIG (Tungsten Inert Gas) welding • MIG (Metal Inert Gas) welding • Submerged Arc Welding (SAW) for thicker sections. • Weld Quality Checks: Welds are inspected using ultrasonic testing (UT) or radiography to ensure structural integrity. • 5. Heat Treatment • Stress Relieving: Post-weld heat treatment (PWHT) is conducted to: • Reduce residual stresses. • Improve ductility and toughness. • Heat treatment may involve processes like annealing or normalizing.

  3. 6. Surface Preparation • The vessel surface is cleaned through: • Sandblasting: To remove impurities and scale. • Pickling: For chemical cleaning. • Surface preparation ensures proper adhesion of protective coatings. • 7. Inspection and Testing • To ensure safety and compliance, multiple tests are performed: • Hydrostatic Test: The vessel is filled with water and pressurized to check for leaks. • Pneumatic Test: Used for smaller vessels with compressed air. • Non-Destructive Testing (NDT): Includes: • Radiographic testing for weld quality. • Ultrasonic testing for thickness and defect detection. • Dye penetrant testing for surface cracks. • Dimensional Checks: Ensure the vessel matches design dimensions. Challenges in Manufacturing Material Quality: Ensuring the use of certified materials. Welding Precision: Maintaining high-quality welds to prevent defects. Safety Compliance: Meeting stringent safety codes during manufacturing and testing.

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