Pressure vessels are essential equipment in the production of FMCG products, where safety and efficiency are paramount.Given their critical role, it is imperative to select reputable pressure vessel fabricators and ensure compliance with prescribed safety regulations.
In this blog, we will discuss the factors you need to consider when choosing a fabricator for pressure vessels in the FMCG industry and understand the different pressure vessels used in the sector.
What are pressure vessels?
Pressure vessels are closed industrial vessels that hold gases or liquids at pressures that are significantly greater or lower than the atmospheric pressure. Pressure vessels required in the FMCG sector depend on the process requirements.
The ratio of the mean radius of the vessel to the wall thickness determines whether it is a thick-walled or thin-walled pressure vessel. A thin pressure vessel is one in which this ratio exceeds 10. A thick-walled pressure vessel is one in which the ratio is less than 10.
Pressure vessels used in the FMCG sector are:
Storage tanks:
These vessels store products such as food, beverages, and cleaning supplies
Process vessels
These vessels carry out a variety of processes, such as mixing, purification, heating, and cooling. A high-pressure reactor should be able to withstand longitudinal and hoop stresses. The inner surface of the reactor should be corrosion-resistant.
Heat Exchanger
These vessels help transfer heat from one fluid to another.
Autoclave
The food industry uses autoclaves for sterilization. The operating autoclave pressure and temperature are around 1.02 atm and 121o C respectively.
Classification of pressure vessel types:
- Cylindrical Pressure Vessels
- Spherical Pressure Vessels
- Horizontal Pressure Vessels
- Vertical Pressure Vessels
In India, pressure vessels are subject to government regulation. Fabricators and manufacturers must follow the appropriate quality standards in pressure vessel design, construction, and inspection. The standards ensure the vessels are safe and will not malfunction and cause injury or death.
Select the Right Material for Your Pressure Vessel
| Material of Construction | Properties | Pressure vessel Applications |
| Titanium pressure vessel | Corrosion resistant Easy to clean Non-toxic Strong and durable High tensile strength (210–1380 MPa) High melting point (1668 °C) | Energy Chemical Oil and Gas Pharmaceuticals Agriculture Fertiliser |
| Nickle Alloys pressure vessels (Monel, Hastelloy, Inconel, Alloy 20, and Haynes Alloys) | Corrosion-resistance Can be used in inhospitable conditions | Chemical Fine-chemicals Fertiliser |
| Stainless Steel pressure vessel | Can withstand high and low temperatures and pressures. Can withstand direct sunlight and high humidity Rust and stain resistance Easy maintenance | Food and Beverage Pharmaceutical Energy Chemicals Cosmetics Dairy |
| Carbon Steel pressure vessels | Strong – resistant to cracking and melting High tensile strength Durable and can withstand pressure Cheaper than stainless steel Can be made corrosion-resistant by galvanization or coating | Fuel Storage Oil and gas Mining Paper and pulp Power |
| Aluminum and Aluminum alloy 5154 and 5454 pressure vessels | High tensile strength between 70 and 700 Mpa More cost-effective than stainless steel. Large coefficient of expansion. | Compressed gases Oil and gas industry Chemical industry Hydraulic and pneumatic systems Aeronautics |
| FRP (Fibreglass Reinforced Plastics) Pressure vessels | Durable Light-weight High-strength Corrosion resistant Low costs | Chemical Water & wastewater, Food & beverage, mining & metals, power, energy, high-purity applications. |
Steps to Choose Pressure Vessel Fabricators
A pressure vessel is a critical capital expenditure for your plant. The vessels are subject to high temperature and pressure conditions, and any failure can have catastrophic consequences. Choosing the right fabricator for your pressure vessels is an important decision. Following the steps outlined can increase your chances of selecting pressure vessel fabricators that will provide you with a safe, high-quality product.
Define the project requirements.
As with any project, you need to start by documenting the project requirements for the pressure vessel fabricators, such as:
- Operating conditions: The fabricator needs to know the operating pressure, temperature, and capacity of the pressure vessel. These are input parameters to design pressure vessels with adequate safety margins.
- Material selection: the material of construction used for fabrication is one of the most important factors and will significantly impact the cost. Some pressure vessel fabrication materials are carbon steel, nickel alloys, high-temperature stainless steel, and aluminium.
- Industrial Standards: When purchasing a pressure vessel, ensure it conforms to applicable industry standards like IS 2825, ASME Section 8, and IBR.
- Type of support and loading: If your pressure vessel operates in a seismic zone or is subject to heavy wind loads, mention it in your RFQs.
- Fluid Conditions: It is crucial to consider the chemical and physical properties of the fluid that will be stored in the vessel.
Experience and expertise
Look for a fabricator with a proven track record and experience in designing and fabricating pressure vessels. The fabricator must know applicable industry standards and norms and best fabrication practices.
A reliable fabricator will have a team of experienced and knowledgeable engineers, designers, and welders. All welders should be certified. Study their portfolio of past projects; they should have worked in diverse industries and completed similar projects.
Loading capacity:
The loading capacity of pressure vessel fabricators is important because it indicates how much work they can handle on their shop floor. This can become critical if the project is large. The fabricator must have enough capacity to complete it on time. You can ask the fabricator about their current workload and plans.
The loading capacity should consider elements including the size and weight of the pressure vessels they handle, the number of pressure vessels the fabricator can simultaneously handle, and any lifting or transportation equipment they may have.
Certification and Compliance
Pressure vessel fabricators must have statutory certificates. The certification will depend on the operating conditions of the pressure vessel. This may include IS 2825, IBR, EN 13445, and ASME Section 8 Div 1. Welders should have up-to-date certifications. AP510-certified inspectors, or boiler inspectors, are certified to check pressure vessels.
Ask about the fabricator’s quality assurance program and whether they have quality control measures. Apart from compliance with statutory bodies, the pressure vessel should pass your in-house quality control systems. Certifications like ISO 9001 show the fabricator’s commitment to quality.
Visit the manufacturing facility
It is a good idea to visit the fabricator’s manufacturing facilities. You could review their facilities, equipment, and machinery. A well-organized and clean workspace reflects their commitment to high-quality standards. Manufacturers use different fabrication methods while manufacturing pressure vessels.
Commonly used equipment in pressure vessel manufacturing includes:
- Cutting tools: The manufacturing plant must have cutting tools like plasma lasers or CNC cutters for precise cutting and a smooth finish.
- Forming machines: Manufacturers use forming machines like plate rolling machines and flanging machines to give uniform bending to the plate to obtain a cylindrical shape.
- Welding machines: Fabricators use welding technologies like plasma welding, shielded metal arc welding, and pressure welding.
- Grinding and finishing equipment: Fabricators use these machines to give a smooth finish.
- Material-moving equipment: Material-moving equipment like cranes and forklifts is used to move and position components during fabrication.
References and reviews
Review the fabricator’s references and reviews of their past clients. The feedback from old clients indicates their commitment to customer satisfaction and service.
Compare Pricing
Pressure vessels are expensive capital investments. You need to evaluate quotes from multiple vendors. Get written quotes from multiple vendors. While comparing prices, ensure the pressure vessels have the same specifications. You can opt for the company that offers the most competitive prices. You may have to consider factors such as:
- Cost of ownership,
- Shipping charges
- Reliability
- Payment terms and conditions, and discounts.
- Warranty
How can Venwiz help?
Venwiz is a CapEx and industrial services procurement partner to help you find the perfect fabricator to meet your requirements. The user-friendly platform allows you to shortlist fabricators based on different parameters.
With Venwiz’s cutting-edge project management tools, you can monitor the main milestones to guarantee quality and on-time delivery. You can compare fabricators based on their credentials, certificates, completed projects, and client testimonials. The portal also promotes transparency in the procurement process.
Venwiz offers services like third-party inspectors to inspect the pressure vessels on your behalf.
Some of our go-to vendors in this sector are
Startech Projects & Engineers
Startech Projects & Engineers is a one-stop engineering service provider for the oil & gas, chemical, pharmaceutical, sugar, food processing and beverages, and cryogenic industries. SPE offers design, engineering, manufacturing, and project execution services for a range of products, including storage tanks, pressure vessels, LPG gas distribution plants, and more.
Exolloys Engineering Pvt Ltd
Exolloys Engineering Pvt. Ltd. is an ISO 9001:2015 and 14001:2015 certified company. The company specializes in the fabrication, installation, and commissioning of pressure vessels, heat exchangers, vertical steel columns, and chemical storage tanks. Some of the industries served by them include power and energy, chemical, metal, and mining.
Fabaron Engitech Private Limited
Fabaron Engitech Private Limited is involved in the manufacture, supply, installation, and erection of process equipment like pressure vessels, bag filters, and reactor vessels. They have served the chemical, oil and gas, industrial, and machine tool industries.
Contact us: contact@venwiz.com
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