Condensate Tank Fabrication

In 2023, GSI fabricated a 76,000 pound deaerator, a large, pressure vacuum tank that cools and recycles water in a closed loop system. After fabrication, our client installed this tank at a power generation facility.

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Services

Fabrication

Industry

Power Generation

Location

East Coast, USA

Project Type

Tanks, ASME Pressure Vessels

Project Overview

In 2023, GSI fabricated a 76,000 pound deaerator, a large, pressure vacuum tank that cools and recycles water in a closed loop system. After fabrication, our client installed this tank at a power generation facility.

Return Customer

GSI has worked with this long-time customer on many fabrication projects, including condenser fabrications. Project after project, we have proven that we can meet our client’s specifications, and in turn, they can meet their clients’ expectations with timely and efficient installations.

Fabrication Considerations

This large deaerator vessel presented specific fabrication considerations that we are well equipped to manage at Goodhart Sons:

  • Large final dimensions: The final tank weighed 76,000 pounds and measured 56 feet long with a 12 foot outside diameter
  • Welds that must hold enormous amounts of pressure and meet our strict quality control standards
  • Strict customer specifications, including the fabrication of multiple attachments
  • Preparation for transportation, including coordinating a superload that required multiple cranes

 

Our Process

Comprehensive planning

Before procurement and fabrication, the Goodhart Sons team spent a significant amount of time planning this project. That included the following:

  1. The detailing phase that set the tone for the project. Our detailers ensured that the for fabrication drawings included all of the necessary information for seamless fabrication.
  2. A fabrication plan that ensured the following:
    • limited handling;
    • welder friendly and efficient assembly;
    • positioning for effective quality control measures, including spot x-ray and dye penetrant testing;
    • efficient handling and placement for final blasting and painting;
    • preparation for transportation to installation site

Building and Fabrication

The Goodhart Sons team specializes in welding tanks and vessels, including ASME pressure vessels. For portions of this project, our skilled welders utilized the submerged arc welding (SAW) process to complete full penetration welds on the vessel’s circumferential and longitudinal weld joints.

Our quality control team performed inspections throughout the course of the project: the team inspected incoming raw materials; fabrication, including weld joint fit-up; and orientation of all internal and external attachments to ASME Section VIII Div 1.

Finishing

Once all final weld inspections were completed, the vessel was prepped for external coatings and internal rust inhibitor application, performed by Goodhart Sons.

Transportation

Our client arranged transportation logistics to the installation site of the vessel. This process required extensive coordination and communication, including permitting with multiple state departments of transportation. Our team was responsible for rigging and loading the vessel onto the superload trailer with two yard cranes. Because of the vessel size and to ensure clear, effective communication and safety, the Goodhart team included one signal person on the ground, two crane operators, and two riggers.

Building a future workforce

We believe in doing what we can to shape the future fabrication and manufacturing work force. We shared aspects of this project with educators and students from a local high school. Students and their teachers were surprised and inspired by our use of low and high technology systems to manufacture and prepare this vessel for transport.

Project Spotlight: Condensate Tank Fabrication