Small Pressure Vessels
Small Pressure Vessels

Key Steps In Manufacturing Reaction Vessels And Small Pressure Vessels

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Industrial equipment manufacturing is a very complicated process that requires a highly skilled and trained workforce. Plus, it must be done as per specialized and well-defined processes.  Manufacturing reaction vessels as well as small pressure vessels of any kind involves a series of key steps to ensure their safe and efficient operation. These vessels are widely used in various industries, including chemical, pharmaceutical, and petrochemical sectors, to contain and control reactions, store liquids or gases under pressure, and perform critical processes. This is why their manufacturing is to be done as per well-defined processes, guidelines, and standards. 

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Pre-production steps

  • Design and Engineering: The beginning of manufacturing any kind of reaction vessel is always the phase of design and engineering activities. This phase involves the selection of appropriate materials, determining the vessel’s size and shape, and accounting for factors such as pressure, temperature. And corrosive nature of the substances to be contained. Design engineers use computer-aided design (CAD) software and simulation tools to model and analyze the vessel’s structural integrity and performance under different operating conditions.
  • Materials Selection: Choosing the right materials is crucial to ensure that the small pressure vessel remains durable and highly resistant to corrosion and pressure. Materials with high strength, such as stainless steel, carbon steel, or alloys like Inconel, are commonly used. The material selection process takes into account factors such as chemical compatibility, thermal expansion characteristics, and the vessel’s intended application.

Production flow steps

  • Fabrication and Welding: Fabrication and welding are key steps in manufacturing reaction vessels and pressure vessels. Skilled welders and fabricators use approved welding techniques to join the vessel’s components together. They ensure proper fit and structural integrity. Welding procedures are carefully followed. Non-destructive testing techniques, such as radiographic or ultrasonic examination, may be employed to inspect the welds for any defects.
  • Heat Treatment: Heat treatment enhances the mechanical properties of a vessel’s materials. This involves heating the vessel to a specific temperature and holding it for a set duration, followed by controlled cooling. Heat treatment helps reduce residual stresses, improve material strength, and enhance resistance to corrosion and fatigue. The specific heat treatment process employed depends on the material used and the vessel’s design requirements.
  • Surface Treatment and Coating: Surface treatment and coating are essential for protecting the vessel from corrosion and extending its lifespan. Depending on the material and the application, various surface treatment methods may be employed, including passivation, pickling, or electro-polishing. Over this, corrosion-resistant coatings, such as epoxy or polyurethane paints, may also be applied to the vessel’s interior. And exterior surfaces to provide an extra layer of protection against corrosive substances.

Post-production steps: 

  • Quality Control and Inspection: Stringent quality control measures are implemented throughout the manufacturing process to ensure the vessel’s compliance with industry standards and specifications like ASME (American Society of Mechanical Engineers) standards. Quality control is a multi-step process, including material verification, dimensional checks, weld inspections, and pressure testing. Non-destructive testing techniques, such as visual inspection, ultrasonic testing, and pressure testing, are used to detect any defects or leaks that could compromise the vessel’s integrity.
  • Documentation and Certification: Manufacturing a small pressure vessel requires proper documentation and certification to ensure regulatory compliance and customer satisfaction. Detailed manufacturing records, including design calculations, material certifications, welding procedures, inspection reports, and test certificates, are compiled and maintained. Third-party inspections and certifications may also be obtained to verify the vessel’s compliance with industry codes and standards. Such as ASME or PED (Pressure Equipment Directive).

Finally, although not a part of the ‘manufacturing process’, it is still very important that vessels are carefully packaged and transported to the customer’s site, taking into account the vessel’s size, weight, and any specific handling requirements.

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