Completed & delivered to site

Q4 2023 Gas stations – Ain Sokhna

Oil & Gas

Fabrication and assembly of high-pressure skids for gas stations

High-pressure skids fabricated and assembled to recognised standards for gas stations.

Technical Documentation & Operations Gallery

4 high-resolution photos

Client Requirement & Operating Constraints

A gas station operator ordered six high-pressure regulating and metering skids, fully assembled and tested in the workshop for direct installation on site.

Strict defined criteria:

  • Design and fabrication to ASME B31.3 process piping.
  • Hydrostatic test at 1.5 times the operating pressure.
  • 100% radiographic testing (RT) of welds.

Mega Steel Scope of Work (Execution Phases)

  1. Phase 01

    Design Review & Calculations

    Pipe thickness and stress-support calculations for each skid.

  2. Phase 02

    Base Frame Fabrication

    Steel-section base frames with certified lifting points for transport.

  3. Phase 03

    Piping Welding

    TIG root and MMA fill passes by certified welders.

  4. Phase 04

    Testing & Handover

    Hydrostatic test, radiography and final painting before shipping.

Engineering Materials & Alloys Used

Certified, documented engineering

  • ASTM A106 Gr.B carbon pipes
  • ASTM A105 forged flanges
  • Structural steel sections
  • Multi-coat epoxy painting

ENGINEERING BOTTLENECKS

The Project’s Complex Engineering Challenges

  • Tight Space Inside the Skid

    All valves and meters had to fit within standard transport dimensions while staying reachable for maintenance.

  • Site Tie-In Tolerances

    The tie-in points to the station network allowed no misalignment.

ENGINEERED RESOLUTION

Innovative Engineering Solutions Applied

  • Full 3D Modelling

    A 3D model of each skid checked maintenance access before any cutting.

  • Fixed Assembly Jigs

    End flanges assembled on fixed jigs so every tie-in point matches.

Custom Engineering Fabrication Solutions

Do you have a project that needs pressure vessels or specialised mechanical fabrication?

Send your materials list, engineering drawings or samples for immediate review by our engineers, who will define the best technical path and schedule.