Engineering Services Sandhya Offers for Expansion Tanks

1. Expansion volume calculation

2. ASME mechanical design

3. Piping and valve layout

4. Civil foundation design

5. P&ID development

6. Material specification and procurement

7. Bladder tank pre-charge setting

8. PRV sizing and location

9. Surge and safety relief study

10. Instrumentation hook-up

11. 3D modeling and fabrication drawings

12. Expansion tank for thermal oil design

13. Water hammer study for closed loops

14. Day tank integration

15. Condensate or overflow management

16. Level and pressure control systems

17. NDT and quality inspections

18. Thermal insulation design

19. Fabrication inspection and support

20. Commissioning and documentation support

 

Expansion Tank Engineering – Comprehensive Guide

Sandhya Design Consultancy –

✅ What is an Expansion Tank?

An expansion tank is a pressure vessel used to accommodate the thermal expansion of fluids in a closed-loop system. It prevents overpressure and damage by absorbing the increased volume when a liquid (usually water or other process fluids) is heated.

Expansion tanks are essential in boiler systems, chilled water systems, solar thermal applications, and industrial hot oil or steam circuits.

🧪 20 Expansion Tank Applications

Here’s a list of 20 common types of expansion tanks used across various industries:

1. Boiler Expansion Tank – For central heating and process boilers

2. Chilled Water Expansion Tank – Used in HVAC systems for air conditioning

3. Solar Thermal Expansion Tank – Accommodates fluid expansion in solar water heaters

4. Hot Water System Expansion Tank – Prevents overpressure in domestic systems

5. Glycol Expansion Tank – For TEG or MEG-based closed-loop systems

6. High-Pressure Steam Expansion Tank – Used in industrial steam systems

7. Condenser Water Expansion Tank – In cooling towers and chiller loops

8. Thermal Oil Expansion Tank – For hot oil systems in chemical or pharma plants

9. Hydronic Heating Expansion Tank – In radiant and baseboard heating systems

10. Closed-Loop Chemical Expansion Tank – In chemical dosing or loop circulation

11. Fire Suppression Expansion Tank – Accommodates pressure rise in sprinkler systems

12. Refrigerant Expansion Tank – Absorbs volume changes in refrigeration loops

13. Power Plant Expansion Tank – High-temperature boiler feed or condensate

14. LPG Expansion Tank – For safe storage in pressurized gas systems

15. Molten Salt Expansion Tank – Used in CSP plants and high-temp energy systems

16. Engine Jacket Water Expansion Tank – In marine and generator cooling systems

17. Evaporative Cooling Expansion Tank – Balancing volume in air-cooled systems

18. Process Water Expansion Tank – Used in industrial water circulation

19. Geothermal System Expansion Tank – In ground source HVAC setups

20. Thermal Storage System Expansion Tank – For heat or chilled water storage buffering

🔧 Process Design for Expansion Tanks

At Sandhya Design Consultancy, we focus on safe, efficient, and customized process design of expansion tanks suited to client specifications and fluid system behavior.

Key Process Design Steps:

• Thermal Expansion Volume Calculation

  • Based on temperature rise, fluid type, system volume

• System Pressure Analysis

  • Ensuring tank accommodates peak pressure without overloading system

• Pre-charge Pressure Determination

  • For bladder or diaphragm tanks, to maintain proper expansion volume

• Fluid Compatibility

  • Selection of tank lining or materials based on fluid corrosiveness

• Integration with Pumps, Piping & Valves

  • Positioning in suction/discharge lines for maximum efficiency

• Control Philosophy

  • Level/pressure sensors for automation and alarm logic

• Simulation (if needed)

  • Aspen HYSYS, DWSIM for heat balance and fluid dynamics

🧱 Mechanical Design for Expansion Tanks

We design expansion tanks following ASME Section VIII, API 650, or IS 2825, depending on pressure and size.

Mechanical Considerations:

Design Aspect

Description

Design Pressure

Must handle max system pressure + surge

Temperature Range

Based on process fluid and max heat input

Shell Thickness

Calculated using ASME code

Corrosion Allowance

1.5 to 3 mm depending on fluid

Support Type

Saddle, skirt, or leg support

Orientation

Vertical (common) or horizontal

Material Selection

CS, SS304/316, Duplex, FRP for corrosive media

Inspection Access

Manways and nozzles as per code

Relief Devices

Pressure relief valve, rupture disc, vent lines

Bladder/Diaphragm Design

For systems using internal gas charge

🔩 Instrumentation and Control

Expansion tanks often include instrumentation for monitoring and system protection:

• Pressure Transmitters (PT)

• Level Transmitters (LT)

• Temperature Gauges (TG)

• Safety Relief Valves (PRV)

• Pressure Switches (PSH/PSL)

• Sight Glass or Level Indicators

📈 Integration Scope

We integrate expansion tanks with:

• ✅ Piping systems (suction/discharge loops)

• ✅ Pumps (chilled water, boiler feed, condensate)

• ✅ Heat Exchangers (thermal oil, glycol systems)

• ✅ Temporary Storage Tanks (if needed for overflow or drain)

• ✅ Instrumentation Panels and PLC

• ✅ Civil and Structural Foundation

📋 20 Engineering Services Sandhya Offers for Expansion Tanks

1. Expansion volume calculation

2. ASME mechanical design

3. Piping and valve layout

4. Civil foundation design

5. P&ID development

6. Material specification and procurement

7. Bladder tank pre-charge setting

8. PRV sizing and location

9. Surge and safety relief study

10. Instrumentation hook-up

11. 3D modeling and fabrication drawings

12. Expansion tank for thermal oil design

13. Water hammer study for closed loops

14. Day tank integration

15. Condensate or overflow management

16. Level and pressure control systems

17. NDT and quality inspections

18. Thermal insulation design

19. Fabrication inspection and support

20. Commissioning and documentation support

🔍 Why Sandhya Design Consultancy?

• 🇮🇳 Based in Hyderabad, serving India & global clients

• 💡 Experts in custom pressure vessel design

• 🛠️ Equipped with tools like HYSYS, DWSIM, AutoCAD

• 🧩 Strong interdisciplinary team: process, piping, civil, mechanical

• 📦 One-stop solution from design to commissioning