Northern Europe Industrial Plant Expansion Project: Column, Heat Exchanger, and Tank Fabrication

Setting global benchmarks in industrial fabrication and engineering solutions, DRS Makina has successfully completed the detailed engineering and commenced fabrication for an extensive multi-equipment manufacturing program designated for the Denmark facility of a Northern Europe-based global technology leader in industrial evaporation and separation processes. Executed under project code DRS-A-25013, the mechanical design, design validation, raw material procurement, certified welded fabrication, non-destructive testing, and logistical dispatch preparation of 11 critical process equipment units—engineered to maximize plant operational efficiency—are being carried out at DRS Makina’s high-tech manufacturing complex located in Dilovası IMES OSB.

Advanced Engineering Calculations and Shell Thickness Analyses per EN 13445 Standards

During the mechanical design phase, structural integrity, finite element, and wall thickness calculations for all pressurized and non-pressurized process equipment were performed by the DRS Makina engineering department in strict accordance with EN 13445 standards. Beyond internal and external design pressures, site-specific environmental conditions—including seismic load calculations and local wind load criteria—were rigorously incorporated into the static analysis matrix pursuant to international norms. External nozzle loads imposed on the vessel and column shells were meticulously analyzed to deliver an engineered mechanical structure with superior structural rigidity and extended service life. Through this end-to-end engineering authority, DRS Makina operates not merely as an equipment fabricator, but as a fully integrated engineering partner with comprehensive mastery over international pressure equipment codes.

High-Corrosion-Resistant Metallurgical Material Selection and Material Traceability

To ensure superior chemical resistance and metallurgical stability across aggressive process media, 1.4404 (AISI 316L) and 1.4301 / 1.4307 (AISI 304 / 304L) austenitic stainless steels were selected for all equipment within the project scope. All plates, seamless/welded pipes, forged flanges, and bolting materials are fully traceable with EN 10204 3.1 inspection certificates, procured exclusively from tier-one Western mills of non-Russian origin in full compliance with international supply chain compliance standards. In accordance with process hygiene requirements, stainless steel plates were sourced with a certified No. 1 industrial surface finish, maintaining surface roughness tolerances of $Ra \ge 5 \mu m$. This metallurgical configuration fully satisfies the stringent cleanliness, chemical resistance, and operational reliability benchmarks required by the food, pharmaceutical, and petrochemical process sectors.

Certified Welding Technologies and ISO 3834-2 Quality Governance

In accordance with project-specific fabrication procedures, all process piping runs of 12 inches ($\ge DN300$) and above were formed from certified plate and longitudinally welded in-house at DRS Makina. All fabrication welding operations are carried out by our qualified welding personnel certified under EN ISO standards, strictly adhering to pre-approved WPS (Welding Procedure Specification) and PQR (Procedure Qualification Record) registers utilizing GTAW (TIG), GMAW (MIG/MAG), and SMAW processes. DRS Makina’s comprehensive ISO 3834-2 welding quality management certification guarantees that all welded assemblies offer optimal mechanical strength and metallurgical soundness. Furthermore, all critical inspection and assembly points—including main body flanges, sight glass ports, handholes, and manways—are engineered with premium virgin PTFE gaskets and high-tensile bolting sets to guarantee zero-leakage performance under thermal cycling.

Non-Destructive Testing (NDT), Hydrostatic Pressure Testing, and Quality Assurance

DRS Makina enforces a zero-defect policy across all its Pressure Vessel Fabrication and distillation column operations. In alignment with the approved Inspection and Test Plan (ITP), volumetric examination via 10% RT (Radiographic Testing) was conducted on critical weld seams, with focused coverage on circumferential-to-longitudinal T-joint intersections. Additionally, 100% PT (Liquid Penetrant Testing) and 100% VT (Visual Testing) were executed across all pressure-retaining and structural welds to detect surface discontinuities. To validate mechanical structural integrity, all vessels and columns were subjected to shop hydrostatic pressure testing in the horizontal position at pressures exceeding design thresholds. Following hydrotesting, internal and external stainless steel surfaces underwent full acid pickling and passivation to re-establish the protective chromium oxide film and stabilize the metallurgy against pitting corrosion.

CE Marking, Thermal Insulation, and Global Dispatch Engineering

Specified falling film reboilers, preheaters, and distillation vessels (W02, W03, B02, and B04) within the project battery limit have been certified with the CE mark under the European Pressure Equipment Directive (PED 2014/68/EU). To optimize thermal efficiency and minimize heat loss, 10 equipment items—excluding the Sealing Water Tank—were equipped with industrial thermal insulation ranging from 50 mm to 120 mm in thickness, executed with high-density rock wool fill and clad in stainless steel sheeting. Comprehensive Operation and Maintenance Manuals (O&M Instructions) were authored in Danish and incorporated into the final handover dossier. To safeguard the equipment from atmospheric corrosion and marine environments during international road and sea freight, units were sealed in heavy-duty weatherproof tarpaulin packaging engineered to “Winter transport packaging” standards and mounted securely on custom ISPM 15-compliant timber and fabricated steel shipping saddles. This integrated logistics delivery program underscores DRS Makina’s comprehensive engineering standards in complex Heat Exchanger Fabrication and process column contracts.