Cryogenic Tank Manufacturer | Double Wall Tanks for Oil & Gas, Refinery

Cryogenic tank manufacturer for the temperatures others won't touch

Cryogenic storage is the most engineering-intensive part of any oil-gas, fertiliser or petrochemical plant. The inner shell sees -33 ×C to -196 ×C; the outer shell takes mechanical and atmospheric loads; perlite or foam-glass insulation must stay dry, settle predictably and survive 25 years of thermal cycling. Get any of these wrong and the tank either leaks, ices or fails fitness-for-service inspection. As a specialist cryogenic tank manufacturer India, HAIL takes single-point responsibility for design, fabrication, erection, insulation, helium leak test, cool-down and commissioning of cryogenic tanks across India. Whether the requirement is an ammonia cryogenic tank for a fertiliser complex or an LPG cryogenic tank for a coastal import terminal, our team delivers the complete scope from foundation to first cool-down.

Cryogenic services we deliver

Codes & design

• API 620 Appendix Q — low-pressure refrigerated tanks for liquefied hydrocarbons.
• API 620 Appendix R — low-pressure low-temperature tanks for refrigerated products.
• BS 7777 — flat-bottomed vertical cylindrical low-temperature storage.
• EN 14620 — site-built, vertical cylindrical, flat-bottomed cryogenic storage.
• IS 16071 / IS 14654 — Indian cryogenic standards.
• Welding: ASME Section IX qualified WPS/PQR for LTCS, 9% Ni and SS service.
• Inspection: 100% RT on shell joints, helium leak test on inner tank, vacuum-box on bottom, cool-down survey.

Cryogenic fluids we store

Each cryogenic fluid demands specific metallurgy, insulation thickness, and safety systems. As an experienced double wall tank manufacturer, HAIL designs and constructs storage for the full range of refrigerated products found in Indian industry:

• Ammonia (-33 ×C): The most common ammonia cryogenic tank application is fertiliser plant storage — typically 5,000 to 30,000 MT single- or double-containment tanks. Inner shell in fine-grain carbon steel or LTCS (SA 516 Gr.60N / SA 537 Cl.1), with cold-stretched or aluminium suspended deck roof. Ammonia vapour handling and scrubber systems are integrated into the tank design.
• LPG (-42 ×C): Refrigerated LPG cryogenic tank storage for import terminals, refinery tank farms, and LPG bottling plants. LTCS inner shell with full BOG (boil-off gas) compression and reliquefaction. Capacities range from 2,000 to 50,000 m3 for coastal and inland terminals.
• Liquid nitrogen — LN2 (-196 ×C): Cryogenic storage for air separation units (ASU), steel plants, and industrial gas facilities. Inner tank in SS 304/304L with perlite or vacuum insulation in the annular space.
• Liquid oxygen — LOX (-183 ×C): Oxygen storage for steel, medical, and industrial applications. Requires oxygen-clean fabrication procedures — all welds degreased and inspected for hydrocarbon contamination before service.
• Ethylene (-104 ×C): Cryogenic ethylene storage for cracker plants and downstream petrochemical complexes. 9% nickel steel (SA 553 Type I) inner shell with perlite insulation and nitrogen-purged annular space.
• LNG (-162 ×C): For LNG storage, HAIL works with consortium partners including RINA Consulting for design assurance on 9% Ni or membrane-type containment systems.

Double wall construction method

The double wall tank is the standard configuration for large-scale cryogenic storage. HAIL follows a proven construction sequence that applies to all API 620 tank designs:

1. Foundation with frost protection: RCC ring wall and slab foundation with embedded heating elements to prevent frost heave. Load-bearing insulation (foam-glass blocks or cellular glass) is installed on the slab before inner tank bottom erection.
2. Outer tank erection: Carbon steel outer shell (SA 516 Gr.70) erected course-by-course using hydraulic jacking. All shell butt welds receive 100% radiographic testing; bottom welds are vacuum-box tested.
3. Inner tank erection: The cryogenic-grade inner shell is erected inside the outer tank using a separate jacking system. All inner shell welds are completed with GTAW (TIG) for the root-quality required at cryogenic service temperatures.
4. Helium leak testing: The inner tank bottom and shell receive helium leak testing — a helium sniffer at each weld seam detects micro-leaks that conventional soap-bubble or pressure-decay methods would miss. This is the quality differentiator for any credible double wall tank manufacturer.
5. Roof construction: Inner suspended aluminium deck or steel dome roof for the product-side containment; outer carbon steel roof structure with vents, relief valves, and purge connections.
6. Annular insulation: The space between inner and outer tanks is filled with expanded perlite using a pneumatic blowing system, or alternatively with foam-glass blocks or resilient blanket insulation depending on temperature and settling requirements.
7. Hydrotest and settlement survey: Outer tank hydrotest at 100% fill with settlement readings at 8 cardinal points at 25%, 50%, 75%, and 100% fill stages. Differential settlement must remain within code tolerance.
8. Cool-down and commissioning: Nitrogen purge of annular space and inner tank, followed by controlled cool-down over 7-14 days using refrigerated product vapour to avoid thermal shock.

Insulation systems for cryogenic tanks

Insulation performance directly determines boil-off rate, operating cost, and product loss over the tank's 25-30 year design life. HAIL specifies and installs the following insulation systems based on service temperature and client preference:

• Expanded perlite: The most widely used annular-space fill for ammonia cryogenic tanks and LPG cryogenic tanks. Perlite is blown pneumatically to a controlled density, with settling compensation provisions at the top of the annular space. Thermal conductivity: approximately 0.04-0.06 W/m.K.
• Foam-glass (cellular glass): Pre-formed blocks installed in the annular space and under the tank bottom as load-bearing insulation. Higher compressive strength than perlite; preferred for foundation insulation and where settling cannot be tolerated.
• Polyurethane foam (PUF): Spray-applied or block PUF for smaller cryogenic vessels and piping insulation. Excellent thermal performance but limited to temperatures above -60 ×C for most formulations.
• Resilient blanket: Fibre-based blanket insulation used between inner and outer shells where perlite settling is a concern. Often used in combination with perlite as a top-fill settling compensator.
• Vacuum insulation: For very-low-temperature applications (LOX, LN2), vacuum-jacketed construction with multi-layer insulation (MLI) offers the lowest boil-off rates.

API 620 and BS 7777 compliance

Every cryogenic tank HAIL builds is designed and constructed to the applicable edition of API 620 with the relevant appendix for the stored product. As an API 620 tank specialist, we maintain qualified welding procedures, NDT capabilities, and engineering resources for full code compliance:

• API 620 Appendix Q: Covers low-pressure storage tanks for liquefied hydrocarbon gases (LPG, ethylene, propylene) at temperatures down to -168 ×C.
• API 620 Appendix R: Covers low-pressure, low-temperature storage for refrigerated products including ammonia.
• BS 7777: British standard for flat-bottomed, vertical, cylindrical storage tanks for low-temperature service. Widely specified by EPC contractors and process licensors in Indian fertiliser and petrochemical projects.
• EN 14620: European standard for design and manufacture of site-built, vertical, cylindrical, flat-bottomed steel tanks for cryogenic storage.
• IS 16071 / IS 14654: Indian standards for cryogenic tank design and construction.

Boil-off gas (BOG) management

No cryogenic tank operates without generating boil-off gas. The insulation, ambient temperature, and product volatility determine the BOG rate, and the tank's economics depend on managing it efficiently. HAIL's turnkey cryogenic scope includes BOG handling systems:

• BOG compressors: Reciprocating or screw compressors sized to handle normal and upset boil-off rates. Compressed BOG is returned to the process or reliquefied.
• Vaporisers: Ambient air vaporisers, steam-heated vaporisers, and water-bath vaporisers for controlled product send-out from the tank.
• Reliquefaction systems: For ammonia and LPG terminals where BOG must be returned to liquid phase for storage or sale.
• Safety relief and vent systems: Pressure-vacuum relief valves, emergency venting, and flare connections sized per API 2000 and API 521.

Locations we serve

As a cryogenic tank manufacturer India, HAIL operates from Vadodara, Gujarat with project reach across India's fertiliser and petrochemical corridor. Our active and past cryogenic projects span Dahej (Birla Copper ammonia tank facility), Hazira (ONGC and L&T complex), Jamnagar (Reliance petrochemical zone), and fertiliser plant locations across Gujarat, Rajasthan, and Bihar. Vadodara's central location in Gujarat gives us faster mobilisation and lower logistics costs for cryogenic projects in the western India industrial belt.

Reference experience

• Birla Copper Ltd., Dahej — Currently dismantling a double-wall ammonia tank facility (active reference for cryogenic tank engineering and execution discipline).
• Leadership-led cryogenic projects — Past experience across ammonia and LPG storage at fertiliser and refinery facilities.
• Consortium with RINA Consulting — Independent design assurance for cryogenic storage projects.

Why HAIL as your cryogenic tank manufacturer

• Owned crane fleet (200 / 100 / 50 / 20 MT) — large outer-shell lifts handled in-house.
• WPS/PQR for LTCS, 9% Ni and SS welding; full PMI traceability.
• Helium leak test, vacuum-box test and cool-down survey conducted in-house.
• RINA Consulting consortium for third-party design assurance.
• Same team also handles cryogenic dismantling — proof of full lifecycle command.

Frequently asked questions