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Success Stories

See how Gatekey Engineering helped others just like you!

Finite Element Analysis, Semiconductor, Data Centers

a large metal tank in a factory
a man wearing a safety vest and a hard hat, satisfied client

Ensuring Structural Integrity: A Tank Design Success Story

Finite Element Analysis

When a leading chemical processing company needed to verify the structural integrity of their tank system, they turned to our engineering analysis experts. Their tanks, which held water and various chemicals with densities up to 10% higher than water, were subject to cyclical filling and emptying on a weekly basis. The observed distortion in the tanks was very unsettling to the ultimate customer.

There was concern about stress, deformation, and fatigue of the tank components. Any structural failure could result in costly leaks, downtime, and environmental issues.
The client provided STEP files for each tank to be analyzed. Our team imported these 3D models into the powerful COMSOL Multiphysics finite element analysis software. This advanced simulation tool allowed us to model the stresses and distortions the tanks would experience under different loading scenarios.
A key area of investigation was the effect of recently added bracing elements – spacers along the sidewalls and square tubular framing – intended to reduce distortion from the tank contents. Our finite element models enabled precise comparisons between unmodified designs and those reinforced with spacers or framing.
In addition to visualizing distortions, we closely examined stress magnitudes and fatigue life predictions for the cyclically loaded tanks. COMSOL’s robust post-processing capabilities allowed us to create informative 1D, 2D and 3D plots highlighting critical results.
The analysis conclusively showed that while stresses remained within acceptable levels across all scenarios, the spacer modifications dramatically reduced sidewall distortions by over an order of magnitude compared to unbraced tanks. The supplemental framing also provided considerable distortion mitigation, though less effective than the spacers. In addition, fatigue was determined to be of no consequence.
Armed with these insights, the client could confidently move forward with tank reinforcement strategies to ensure safe, leak-free operation and extended service life. Our finite element modeling empowered data-driven decision making for this critical asset integrity issue.

Tanks Analyzed
1
Pages in final report
1
a grey rectangular object with black lines, steel vacuum chamber rendering for Finite Element Method
a man smiling at a laptop, satisfied customer

Ensuring Structural Integrity Under Extreme Conditions

Finite Element Method

A leading manufacturer of fiberglass composites needed to verify the design of a critical vacuum tunnel. They turned to our expertise in finite element analysis (FEA) and pressure vessel code compliance. The tunnel, subjected to an intense vacuum pressure of -21 inches Hg, had to meet stringent safety requirements while maintaining structural soundness.
The challenges were significant. With its non-cylindrical shape and rectangular inspection ports, the tunnel’s design fell outside the scope of traditional pressure vessel codes like ASME BPVC VIII. A conventional analysis wouldn’t provide the level of detail and accuracy required.
That’s when the power of FEA became invaluable. By constructing a precise 3D model based on the actual drawings, the analysis team could simulate the vacuum loading conditions with exceptional fidelity. Shell elements were used to model the tunnel geometry, enabling static loading scenarios that matched real-world operations.
But the analysis didn’t stop there. To ensure the tunnel could withstand the extreme vacuum without catastrophic failure, a comprehensive buckling analysis was performed. This cutting-edge technique pinpointed the critical load factors and buckling modes, quantifying precisely how close the structure was to potential collapse.
The results were clear – thanks to the finite element methodology, it was determined that the operating vacuum pressure was well below the calculated buckling loads, even after applying an ample safety factor. The tunnel’s design could withstand the harsh operating conditions while complying with pressure vessel safety standards.
With the FEA results in hand, the manufacturer could proceed with confidence, knowing their vacuum tunnel would operate reliably and safely for its demanding fabrication processes. This powerful example showcases how advanced engineering analysis can solve complex structural challenges, unlocking new frontiers in innovation and product excellence.

Inches Hg vacuum
- 1
Confidence in 24x7 operation
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a man sitting at a desk with a laptop showing frustration
a group of men in hard hats and vests looking at a blueprint, Rapid Response Team
a man in safety vests shaking hands with another man in safety vests, Rapid Response Team

Keeping Construction on Track: How We Overcame Communication Challenges

Semiconductors

On a large semiconductor Fab construction project, we faced a significant challenge that threatened to derail the entire schedule. The flow of information between the construction contractors and design professionals was causing delays and impacting our ability to keep the project moving forward efficiently.
We knew we had to act quickly to avoid costly overruns and missed milestones. After analyzing the root causes, we implemented a series of key process changes to improve communication and collaboration between all parties.

First, we established a dedicated rapid response team to shorten response times on critical issues. This allowed us to manage perceptions by responding within 48 hours to any contractor needs or queries. Our design personnel also increased their field presence, taking a more supportive approach and giving contractors the benefit of the doubt.

Perhaps most importantly, we changed how we handled issues. Instead of jumping to discuss liability, we waited until the full root cause was investigated before having those conversations. Our project managers then took the lead on communicating with the client about any liability matters.

While not easy, these process improvements paid off. By opening the lines of communication, responding rapidly, and taking a more collaborative stance, we were able to successfully achieve all major schedule milestones for this project.

Our responsive communication processes were the foundation to what evolved into integrated project delivery.

What started as a significant challenge became a defining success story. Through commitment to process improvement and open collaboration, we overcame the communication barriers and kept this critical construction initiative on track.

Rapid response and open communication are key!

48hr Response Target
1 %
Major milestones hit
1 %
a hallway or aisle with rows of computer servers
a group of men wearing safety vests and helmets, Commissioning Team
a man shaking hands with a satisfied client

Overcoming Obstacles: How the Commissioning Dream Team Delivered Success

Data Centers

A high performance data center construction project was in a precarious position as it neared completion. Despite the physical construction being nearly finished, the teams responsible for commissioning and taking over operations were simply not ready. A perfect storm of issues threatened to derail the entire project.

Punch lists remained unfinished as construction crews dispersed to new job sites across the country. The commissioning and operations personnel were severely understaffed, trying to juggle this new facility with existing responsibilities. To make matters worse, last minute change requests created even more chaos and confusion.

Recognizing the criticality of the situation, decisive action was required to get the project back on track. An elite “Commissioning Dream Team” was rapidly assembled, bringing together top engineering talent from multiple disciplines with diverse experience in construction, commissioning, and operations.

This cross-functional team quickly triaged the punch list items into critical and non-critical buckets, allowing commissioning to proceed on the most essential components and systems. A detailed commissioning sequence plan further focused efforts on the facility’s highest priority systems.

In parallel, the Dream Team spent time with the operations group, listening to their concerns around the change requests. This open dialogue allowed the requests to be refined and properly adjudicated through a formal change control processes.

With clear priorities and a defined, agreed-upon scope, the Commissioning Dream Team completed a comprehensive system testing process, working hand-in-hand with the operations staff. Through tremendous dedication and collaboration, this world-class squad of experts overcame seemingly insurmountable obstacles.

In the end, the high performance data center successfully commissioned on time, hitting all major milestones. The operations team gained valuable extra time to hire and train staff, ensuring a smooth transition and long-term operational success. This incredible comeback was a testament to the power of strategic prioritization, open communication and elite teamwork.

Changes adjudicated
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Major milestones hit
1 %