Metal Cutting with Mechanical Waterjet: Applications in Opening Metal Tanks

Introduction

In industrial manufacturing and maintenance, cutting openings in large metal tanks is a challenging task that demands precision, safety, and minimal disruption to the surrounding structure. Traditional cutting methods such as plasma, laser, or oxy-fuel often generate high heat, which can deform the material, cause oxidation, and pose fire hazards—especially in flammable environments.

Mechanical waterjet cutting, powered by advanced water jet cutting machines, offers a cold-cutting alternative that addresses these limitations. This technology, widely adopted in sectors such as oil & gas, petrochemicals, and food processing, is now a leading choice for metal tank opening operations.

As one of the leading solution providers, HEADWATERJET has delivered numerous successful projects in this field, demonstrating the reliability and adaptability of modern waterjet cutting machines.

Why Mechanical Waterjet for Metal Tank Openings?

1. Cold Cutting Process

A mechanical water jet cutter operates without generating heat. This is critical in situations where tanks contain flammable residues or are in hazardous environments. By avoiding sparks and heat-affected zones, waterjet cutting minimizes safety risks.

2. Precision and Control

High-pressure water mixed with abrasive particles can cut through thick steel plates with millimeter-level accuracy. This precision ensures that openings are clean, burr-free, and meet engineering tolerances.

3. Versatility with Materials

Mechanical waterjet cutting is not limited to steel; it can handle stainless steel, aluminum, copper, and even composite layers without material distortion. This is particularly useful in multi-layered or coated tank walls.

4. Minimal Structural Stress

Unlike mechanical grinding or drilling, waterjet cutting applies no mechanical vibration to the tank, preserving the structural integrity of the vessel.

Case Study: Opening a Stainless Steel Storage Tank

In 2024, a large petrochemical plant in Southeast Asia faced the challenge of retrofitting a 50,000-liter stainless steel tank to accommodate new pipeline connections. Due to the presence of flammable chemical residues, traditional thermal cutting methods were prohibited.

HEADWATERJET’s Solution

The project team deployed a HEADWATERJET portable water jet cutting machine, featuring:

• Pressure Rating: 420 MPa

• Abrasive Delivery: Automatic feeding system with shortage alarm

• Cutting Head: Swivel mount for flexible positioning on vertical and curved surfaces

Using the portable water jet cutter, the team created two perfectly round openings (Ø600 mm) within four hours, without any sparks, heat damage, or deformation to the surrounding metal.

Advantages in Oil & Gas Applications

HEADWATERJET’s Mechanical Waterjet Solutions

HEADWATERJET offers a complete range of waterjet cutting machines for both factory and on-site operations:

• Industrial Gantry Waterjet Machines for large-scale tank panel cutting

• Portable Waterjet Cutters for in-situ maintenance and retrofits

• Five-Axis Waterjet Systems for bevel cutting and customized tank openings

By integrating robust high-pressure pumps, intelligent control systems, and advanced abrasive management, HEADWATERJET ensures cutting speed and accuracy while keeping operational costs competitive.

Future Trends in Mechanical Waterjet Tank Applications

• Automation & CNC Integration – Automated positioning systems to improve speed and repeatability

• Underwater Waterjet Cutting – Further reduction in noise and splash for confined spaces

• Eco-Friendly Abrasives – Recyclable abrasives to reduce environmental footprint

• Hybrid Systems – Combining waterjet cutting with robotic arms for fully automated tank maintenance

Conclusion

Mechanical waterjet cutting is transforming the way industries approach metal tank openings. With unmatched safety, precision, and versatility, this cold-cutting technology has become the go-to solution for sensitive environments where other cutting methods fall short. HEADWATERJET continues to lead this transformation, delivering reliable water jet cutting machines and expertise that empower manufacturers and maintenance teams to work faster, safer, and smarter.

Contact Us

For industrial operators seeking safe, efficient, and precise solutions for metal tank openings, Shenyang HEAD Technology Co., Ltd. provides cutting-edge waterjet cutting machines and expert engineering support.
Email: sale2@hdwaterjet.com
Our technical team is ready to help you select the best water jet cutter for your application and ensure optimal performance on every project.

References

1. Smith, J. (2022). Cold Cutting Technologies in Hazardous Environments. Journal of Industrial Maintenance, 34(2), 98–112.

2. Li, W. & Zhang, Y. (2023). Advances in Portable Waterjet Cutting Systems. International Journal of Manufacturing Science, 67(5), 445–457.

3. Thompson, L. (2021). Material Integrity in Cold Cutting Processes: A Comparative Study. Materials Science and Engineering: A, 823, 14174.

4. Anderson, P. (2020). Safety Considerations in Metal Tank Maintenance. Process Engineering Review, 19(4), 201–215.

5. Chen, X. et al. (2024). High-Pressure Waterjet Applications in Oil & Gas. Offshore Maintenance Journal, 12(1), 55–66.