Pressure tanks play a key role in many industries – from chemical and food to energy and fuel. They are used to store and transport gases and liquids under high pressure, which requires their solid construction and compliance with rigorous UDT standards. Due to intensive use and the influence of external factors, pressure tanks may wear out, and their components, such as welded joints or welds, may require regeneration or repair.
Many entrepreneurs wonder whether repairing pressure tanks is cost-effective or whether replacing them would be a better solution. The degree of damage and the scope of tank welding are of key importance here – in some cases it is possible to weld pressure tanks using modern methods, such as MIG welding, TIG welding, orbital welding or MAG welding. However, if the damage is too serious or the pressure test shows a lack of tightness, it may turn out that replacing the tank is the only safe solution.
What are pressure tanks and what are their functions?
Pressure vessels are devices used to store and transport substances under high pressure, such as technical gases, compressed air, steam or chemicals. They are used in many industries, including the chemical, food, pharmaceutical, energy and fuel industries. There are different types of tanks, including fuel tanks, process tanks and storage tanks, which must meet strict safety standards.
Key materials for pressure vessel components
The selection of appropriate materials for pressure vessel components affects their durability and resistance to corrosion and pressure changes. The most commonly used materials are:
- Stainless steels – used in tanks storing chemically aggressive substances, e.g. in the food industry.
- Carbon steels – popular in heavy industry, require appropriate anti-corrosion protection.
- Aluminum and nickel alloys – used in specialist tanks, e.g. in the aviation industry.
Impact of UDT standards on the operation of pressure vessels
The safety of the operation of pressure vessels is regulated by the regulations of the Office of Technical Inspection (UDT standards), which specify, among others:
- Requirements for the design of tanks, including strength calculations.
- Criteria for repair and regeneration – including pressure tests and inspection of welded joints.
- Scope of permissible welding methods – including submerged arc welding, MIG welding, TIG welding or MAG welding.
- Requirements for certificates – including a CE certificate confirming the compliance of the tank with European safety standards.
Compliance with these standards is crucial for the long-term and safe operation of pressure vessels and minimizing the risk of failure.
When is pressure vessel repair cost-effective?
Pressure vessel repair can be a cost-effective solution as long as the damage is not severe enough to compromise safety and performance. In many cases, proper tank welding services can extend the life of the equipment and avoid costly replacement.
Assessing the extent of damage
A detailed analysis of the weld surface, weld seams and welded joints is essential before making a repair decision. Key criteria include:
- The degree of wear and corrosion of the tank walls.
- Cracks or leaks in welded joints.
- Deformations resulting from long-term use of pressure tanks.
Types of Pressure Vessel Repairs
Depending on the type of damage, different repair methods are used, including:
- Welding of stainless steel tanks – precise repair of tanks used in the food and pharmaceutical industries.
- Welding of pipe joints – especially important for technological installations and pressure systems.
- Tank surface regeneration – including welding and grinding of damaged elements.
Various welding technologies are used for repairs, such as TIG welding, MIG welding, MAG welding or submerged arc welding.
Pressure test – a key test after repair
After the repair is completed, a pressure test is carried out to check the tightness and strength of the tank. This is a key stage that ensures the device complies with the applicable UDT standards and confirms that the tank is suitable for further use.
Benefits of pressure tank repair
Repairing a tank instead of replacing it brings a number of benefits, such as:
- Lower costs – repair is usually cheaper than buying a new tank.
- Shorter downtime – tank modernization allows for a quick return to service.
- Compliance with CE certificates and UDT standards – professionally performed repair ensures safe use of the tank.
When is pressure vessel replacement a better option?
While pressure vessel repair is often a cost-effective solution, in some cases replacement with a new tank becomes necessary. The decision to replace an old tank with a new one should be based on a detailed technical analysis, compliance with standards, and economic calculation.
Damage not eligible for repair
Not all defects can be effectively repaired with tank welding services. Replacement is necessary when:
- Strength calculations indicate a serious weakening of the tank structure.
- Structural cracks are present, which may lead to leakage and the risk of explosion.
- Corrosion is advanced, and the regeneration of the welded joint surface will not provide the required durability.
- Welded joints or welded joints are repeatedly repaired, which weakens their mechanical properties.
In such cases, even the use of modern welding technologies (e.g. orbital welding, submerged arc welding or laser welding) does not guarantee full operational safety.
Safety standards and the operation of pressure vessels
Replacing the tank may be necessary if the device does not meet current UDT standards or there is no possibility of modernizing it to meet new requirements. The operation of pressure vessels is subject to strict regulations, and a tank that fails the pressure test may be excluded from use.
Additionally, older models may not have a CE certificate, which limits their use in modern industrial plants.
Long-term costs – will the new tank be more efficient?
Although replacing the tank involves higher initial costs, it may prove more profitable in the long run. Modern tanks often offer:
- Greater energy efficiency – better insulation and lower heat loss.
- Lower operating costs – longer service life without the need for frequent repairs.
- Better compatibility with modern technologies – the possibility of using modern welding methods and materials with greater resistance.
Welding technologies used in the regeneration of pressure vessels
Repair and regeneration of pressure vessels require the use of advanced welding technologies that ensure durability, tightness and compliance with UDT standards. The selection of the appropriate method depends on the type of material, the degree of damage and the purpose of the tank. Below we present the most commonly used technologies.
TIG and MIG welding – precise methods for pressure vessel elements
TIG welding (Tungsten Inert Gas) and MIG welding (Metal Inert Gas) are methods that are characterized by high quality of welds. They are used to regenerate pressure vessel elements, especially those made of stainless steel and aluminum alloys.
- TIG welding – ideal for thin-walled structures, provides the highest precision and aesthetics of welds.
- MIG welding – a fast and effective method used in the repair of industrial tanks, especially where efficiency and durability count.
MAG welding – widely used in industrial repairs
MAG welding (Metal Active Gas) is a popular method used for the regeneration and repair of pressure vessels, especially those made of carbon steel.
- Used in places requiring high strength welds.
- Perfect for work in industrial conditions and thicker structures.
Orbital welding – application in welding pipe joints
When welding pipe joints in pressure vessels, the key method is orbital welding, which ensures high repeatability and tightness of welds.
- Process automation allows for minimizing errors and increasing durability.
- Ideal for the regeneration of pressure systems in the food and pharmaceutical industries.
Submerged Arc and Argon Arc Welding – Advantages and Limitations
- Submerged arc welding – used for thick-walled industrial tanks, provides strong, high-quality welds.
- Argon arc welding – used where high weld cleanliness and minimal oxygen exposure are required.
Modern methods such as laser welding – when is it worth using them?
Laser welding is a modern technology used in the regeneration of tanks requiring exceptional precision.
- It minimizes thermal deformations, which is important in thin-walled tanks.
- It works well in the repair of components with complex geometry and high technical requirements.
How to Choose a Pressure Vessel Repair Company?
Choosing the right pressure vessel repair company is crucial for the safety and durability of the tank. To avoid problems related to poor repair quality, it is worth paying attention to several important aspects.
WPS and welder certificates – why do they matter?
WPS (Welding Procedure Specification) is a document specifying welding procedures in accordance with technical standards. A professional company should use approved WPS procedures that ensure high quality repairs.
- Welders should have appropriate certificates confirming their qualifications in the welding of pressure vessels using various methods, such as TIG, MIG, MAG, orbital welding or submerged arc welding.
- The presence of certificates in accordance with UDT standards and a CE certificate guarantees that repairs will be carried out in accordance with applicable regulations.
Tank Welding Range – What Services Should Be Available?
A repair company should offer a wide range of tank welding services, including:
- Tank surface regeneration, including repair of welded joint surfaces.
- Welding of stainless steel tanks and pipe connections.
- Pressure testing, confirming the tightness and strength of the tank after repair.
A professional company should also provide individual repair and modernization projects tailored to the specifics of the tank.
Welding quality – how to evaluate a service provider?
To be sure that the repair will be performed at the highest level, it is worth paying attention to:
- The company’s experience in the tank welding industry.
- References and customer reviews that can confirm the quality of the services performed.
- The use of modern welding technologies, such as laser welding, argon arc welding or metal arc welding.
Fuel welding services with Deffor
Pressure tank regeneration and repair is a solution that allows you to extend their service life and avoid costly replacement. In many cases, welding pressure tanks using modern technologies such as TIG, MIG, MAG or orbital welding effectively restores the full functionality of the device. However, if the tank shows serious structural damage, does not pass the pressure test or does not meet current UDT standards, its replacement may be the best and safest solution.
Choosing the right company to repair tanks is crucial – it is worth choosing specialists with welder certificates, WPS procedures and experience in the tank welding industry. Professional repair will allow for safe operation of pressure tanks and ensure their long-term efficiency.
Do you need professional repair or modernization of a pressure tank? Contact Deffor experts for professional consultation and comprehensive service. We offer tank welding services that comply with the highest quality and safety standards. Call today and see how we can help you restore your tank!
