The Saratov Reservoir Plant occupies an area of more than 4000 m2 for the production of tanks, pressure vessels, apparatus and other metal structures. The manufacturing department is divided into several sections:
- blank section;
- machine workshop;
- assembly-welding shop;
- spraying and coating department.
Each production shop is responsible for a certain range of technological tasks, thus optimizing the production process. The incoming material control and production quality control are carried out by the Saratov Reservoir Plant’s laboratory..
The internal logistics is carried out with the help of two single-beam travelling cranes with the lifting capacity of 12.5 and 20 tons, as well as with the help of an overhead track hoist for the transportation of structures weighing up to 5 tons. Simultaneously, up to 20 units can be produced in the manufacturing department.
Tanks and metal structures production process starts with the rolled stock cutting and the workpiece manufacture.
Cutting is performed on two plasma cutting machines with CNC program (Computerized numerical control),which are suitable for cutting sheets of up to 2000 x 8000 mm and up to 2000 x 6000 mm in size. Close control equipment allows to make a cut with a smooth edge face that does not require additional smooth machining.
For shell rolling and manufacturing, as well as other cylindrical and conical units, three-roll sheet bending machine with CNC program is used. The mangles provide enough pressure to metal castings up to 25 mm form a required shape without heating.
Flanged and ring-shaped workpiecеs, as well as small elements of metal structures are being made on turn-milling machines. The maximum diameter of the workpiecеs is 1020 mm.
Profiled metal cutting is carried out using a vertical bandsaw machine. For the auxiliary steel sheets guillotine shears with high cutting speed are used.
Machine workshop is the link between the Blank section and the assembly-welding shop.
The main technological operations are the external and internal surfacing, drilling and hole enlarging, threading, etc. The machinery is represented by universal equipment, which allows to work with the steady load without reducing the accuracy of processing, namely:
- vertical milling machines that provide work on a workpiece up to 1100 x 450 mm
- drilling machines designed for drilling holes with a circular cross-section up to 50 mm in diameter
- screw-cutting lathes have vibration resistance and strong links of kinematic chains
The technological capacity provides a high speed of batch machining of workpiece made of structural alloy steel, carbon and stainless rust-resisting steel, as well as their alloys.
At welding shop assembly and workpieces welding are performed. Inner and outer longitudinal and circumferential joints of metal structures are welded together by means of automatic/semi-automatic welding machines and welding key.
Sandblasted finish of tank shell provides surface preparation for decorative, protective and anti-corrosive coating application. Sandblasting machine consists of compressor, jet device and abrasive agents. In the course of sandblasting the compressor blows the air which moves the abrasive agent through the jet device. It provides an efficient metal refining.
Spraying and coating department
The final stage of equipment production is paint, corrosion-preventive compounds, waterproofing, and thermal insulating materials application.
Airless spraying is used to paint surfaces. In comparison with air atomizing the advantage of the airless method is the high drops homogeneity, the absence of paint drips and the ability to apply an even layer of a greater thickness.
To protect tanks from the negative impact of groundwater reinforced waterproofing is used. Waterproofing materials are sequentially fixed on the outer tank shell by the burning-in method. The layer is heated by a gas burner and smoothed over the surface mechanically. Material is lain on with overlap of 5-10 cm, then the seams are encapsulated with bitumen mastic. After a complete drying-out, layer interconnection ensures waterproof protection for the entire service life.
Thermal insulating is designed to maintain a constant temperature inside the vessel and smoothing variation in environment air temperature. Specialists of Saratov reservoir Plant carry out thermal insulating using mineral wool mats, galvanized sheets or foamed polyurethane.