Home Manufacturing Production Processes

Production processes.

Six stages carry a steel plate from intake to a packed product. Each stage hands the next one parts that fit, and each stage is checked before it does.

Plate Intake Welded Fabrication Coating & Dispatch
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Six stages,
in production order.

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  1. 01

    Material Preparation

    Plate received, identified and staged against the order.
  2. 02

    Cutting and Forming

    Profiles cut and formed; edges prepared for the weld that follows.
  3. 03

    Welded Fabrication

    Parts welded into one oil-tight tank body.
  4. 04

    Surface Preparation

    Blast cleaning to the surface profile the coating needs.
  5. 05

    Painting and Coating

    Coating applied to the specification; thickness measured.
  6. 06

    Packing and Shipment

    Packed and documented so the product arrives as it left.
A CNC cutting machine positioned over steel plate on a slatted cutting table
Stage 01 · Intake

Identified steel, from receipt onward

TSY Energy works with structural and stainless grades used in transformer tank and clamping construction.

The grades in production include S235, S355 and S355NL, higher strength grades such as S690QL and S960QL for clamping structures, and stainless grades SS304 and SS316 where the application requires them.

Material identification is maintained from receipt onward, so that the steel used in a finished tank can be traced back to its source. Plates are stored and staged so that the correct grade and thickness reach the cutting stage in the sequence the production plan requires.

Where a customer specifies a particular grade, certificate type or supplier, that requirement is carried through material receipt and into the production documentation.

  • Plate received and checked against the order before production
  • S235 · S355 · S355NL · S690QL · S960QL · SS304 · SS316
  • Customer grade, certificate and supplier requirements carried into the production documentation
A CNC cutting head cutting a steel plate on the cutting table
Stage 02 · Plate to profile

Parts that fit before they are welded

Tank construction is built around flat wall geometry: side walls, base plates, covers, stiffeners and reinforcement members are cut from plate and prepared for welding.

Cut edges are prepared according to the weld type that follows, so that the welding stage receives parts that fit rather than parts that have to be persuaded into place.

Bending and forming produce the flanges, stiffeners and profiled sections that give the tank its structural rigidity. Parts are checked dimensionally before they move on; correcting a part at this stage is far less costly than correcting a welded assembly.

Cutting and forming are planned together with nesting and material use in mind, so that plate is used efficiently across an order.

  • Side walls, base plates, covers, stiffeners and reinforcement members cut from plate
  • Flanges, stiffeners and profiled sections formed for structural rigidity
  • Dimensional check before parts move to welding
Close-up of TIG welding on a flanged pipe section clamped in a vice
Stage 04 · Assembly

Two demands on every weld

Prepared plates, stiffeners, flanges and machined components are assembled and welded into the finished tank body.

Welds on a transformer tank carry two demands at once: they must hold the structure under handling, transport and service loads, and they must remain leak-free over the life of the transformer.

Welding sequence and fit-up are planned to control distortion, because a tank that distorts during welding will not seat its covers and flanges correctly, and a cover that does not seat is a leak waiting to be found.

Welded assemblies are checked before they leave the welding stage. Leakage and pressure testing confirm tightness; non-destructive testing is applied where the weld and the specification require it.

  • Plates, stiffeners, flanges and machined parts welded into one tank body
  • Welding sequence and fit-up planned to control distortion
  • Leakage and pressure testing; NDT where the specification requires it
A TSY worker grinding a weld on a tank wall, with sparks visible
Stage 05 · Before the coat

Where coating failures start and are prevented

Welded tanks are blast cleaned to remove mill scale, weld spatter, rust and contamination, and to create the surface profile the coating system needs to bond to.

Weld seams, edges and corners are prepared before blasting, since these are the areas where coating failures start. A coating that lifts at an edge does not stay at the edge.

Prepared surfaces are coated within the working window so that flash rust does not compromise adhesion.

Surface preparation is documented as part of the coating record for the tank, alongside the coating and inspection results that follow.

  • Mill scale, weld spatter, rust and contamination removed by blast cleaning
  • Weld seams, edges and corners prepared before blasting
  • Preparation documented in the coating record for the tank
A primed transformer tank standing inside the paint booth
Stage 06 · Protection

Applied coatings are verified, not assumed

Coating systems are applied according to the specification supplied with the order; customers in different markets and applications call for different systems, and the tank is coated to the system their project requires.

Dry film thickness is measured across the tank, and adhesion is checked to confirm that the coating has bonded to the prepared surface.

Results are recorded with the tank documentation, so the coating a customer specified and the coating a customer received are the same thing on paper as well as on steel.

  • Coating system applied to the specification supplied with the order
  • Protective coating systems up to CX
  • Water- and solvent-based coating systems
  • Dry film thickness measured across the tank
  • Adhesion checked and recorded with the tank documentation
A shrink-wrapped transformer tank loaded on a lowbed trailer beneath the TSY sign
Stage 07 · Dispatch

The last stage is still a manufacturing stage

Finished products are packed so that coated surfaces, machined faces and sealing surfaces reach the customer in the condition they left the factory.

Packing is prepared according to the product, the transport mode and the destination. Lifting and securing points are identified so that the product can be handled safely at each transfer along the route.

Shipping documentation is prepared with the product, including the inspection and coating records that accompany it.

  • Packing prepared for the product, transport mode and destination
  • Coated surfaces, machined faces and sealing surfaces protected in transit
  • Inspection and coating records dispatched with the product
Around the line

The work that
runs alongside.

Three of the nine stages are not part of this sequence: one comes before it, one feeds it from the machine shop, and one happens long after the tank has left.

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Technical Preparation

The documentation these six stages work from is prepared before the first cut, from the drawings supplied with the order.

Technical preparation

CNC Machining

Flanges, covers and sealing surfaces reach welded fabrication as machined parts, produced in-house alongside the assemblies they belong to.

CNC machining

Field Services

Repair work on a tank that is already installed is carried out on site rather than on this line.

Field services

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ready to build?

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