From pipe fabrication and a broad array of pressure vessels to precision laser cutting, Bassett Mechanical leverages engineering and design expertise, state-of-the-art equipment, and the skills of our highly-trained trades associates to create just about anything you can imagine out of metal—and a few things you haven’t imagined yet!

Bassett Mechanical took on a critical project for a legacy food and beverage customer, fabricating two buffer vessels and a stratification vessel within an expedited timeline. Although this customer has partnered with us before, it was the first time we directly provided our fabrication and vessel design services for such a pivotal project. This project underscores our commitment to delivering innovative, high-quality solutions under tight deadlines.

WE LISTEN

The customer presented Bassett with the opportunity to fabricate three roughly 13’ diameter x 40’ long stainless-steel vessels to support the customer’s new factory in Arizona.

In early March 2023, we provided a budgetary quote for the three vessels and discovered that the project timeline was already significantly behind schedule, necessitating expedited processes. Two of the vessels were required in the building by July, but the initial material lead times, even with expediting, extended into October. However, we were committed to accelerating the delivery as much as possible.

It took approximately three months to finalize the vessel’s design and details, which required applying API and ASME code. Our Engineers collaborated closely with the customer’s process and project teams during the design phase to identify creative solutions. Notably, we eliminated the need for elliptical heads by using flat plates for the top and bottom of the two low-pressure vessels, reducing a 20-week lead time and cutting costs.  Through multiple design iterations and structural analysis, we optimized weight and cost by incorporating stiffening rings and custom shell plates. The final challenge was fitting the vessels within the 14×14 shipment restrictions on width and height, which required adjustments to the design. Collaborating closely with the customer, we ensured the vessels met process specifications while accommodating the shipping constraints to be able to deliver to Arizona, cost effectively.

WE DISCOVER & LOOK AHEAD

Two of the vessels were fabricated from ¼” stainless steel plate. Because of Bassett’s continuous focus on equipment and technology investment, we could utilize stock 5’x10’ sheets of material and our automated seam welding equipment to create 10’ x 40’ shell sections efficiently. This allowed us to receive materials within days of placing orders versus weeks while reducing the number of manual circumferential weld seams and overall project costs and timeline.

When fabricating large projects like this, planning for the floor space needed for vessel assembly and handling the components as they progress through fabrication is crucial. This project came during an extremely busy time for our shop. Our team needed to execute additional hours quickly to meet the required ship dates. When working on a vessel, it’s difficult to have more than a couple of people working simultaneously due to the constant repositioning for welding and assembly. One team might need to rotate clockwise, while another may need to rotate counterclockwise, creating inefficiencies.  Our project foremen coordinate the work to ensure our fabricators are set up for success throughout the build.  With Bassett’s large fabrication plant, we could adjust other projects to accommodate the space needed for these vessels. Our experience with similar-sized vessels enabled the team to plan all phases of this project effectively.

The first vessel was released for fabrication in mid-June 2023, the second at the end of June, and the third in late July. The shop fabricated, tested and loaded the first vessel on a truck in six weeks. Thanks to design optimization for the schedule and the hard work of our fabrication team, we pulled up the delivery date by 11 weeks. The second vessel shipped in early October, five weeks ahead of the original plan, and the third vessel shipped an impressive 15 weeks ahead of schedule in November of 2023.  The fabrication team processed over 70 tons of metal in just five months!

Despite the proximity of other vessel fabricators to the project site, Bassett Mechanical completed the project faster and more efficiently, shipping well ahead of the due date and providing cost savings back to the customer.  The Bassett Mechanical fabrication team stands by our promised delivery dates and will, where required, do everything possible to deliver ahead of schedule.

Shipping Facts:

• HVAC Buffer Vessel (built to ASME Code), 13’ Nominal OD x 521” OAH, 60,800 lbs.
• Process Buffer Vessel (non-code), 13’ Nominal OD x 486” OAH, 47,000 lbs.
• Stratification Vessel (non-code), 12’-6” Nominal OD x 692” OAH, 38,000 lbs.

WE DELIVER COMPLETE SOLUTIONS

Bassett Mechanical’s comprehensive approach to this project utilized various services, all of which were intricately involved, including Thermatech ASME Engineering, Quality Control, Non-destructive Testing/Examination, Local 18 sheet metal fabricators, Local 400 pipe fabricators, ASME fabrication, logistics, and project management. Our breadth of services highlights our ability to handle complex projects with confidence and expertise.

WE ARE CREATING CUSTOMERS FOR LIFE®

At Bassett Mechanical, we are committed to pushing the boundaries of what’s possible in engineering, pressure vessels, and metal fabrication. This successful project showcased our technical capabilities and commitment to quality and reinforced our dedication to building enduring relationships. By overcoming significant challenges, finding cost savings for our customer, and delivering ahead of schedule, we demonstrated that no project is too big or too small for us. Our consistent ability to deliver on time and within budget exemplifies our unwavering commitment to Creating Customers for Life®.