Centrifugal Cast Alloy Pipes for High-Corrosion Environments

Product Application: Centrifugal Cast Alloy Pipes in High-Corrosion Environments

Centrifugal cast alloy pipes are essential for piping systems exposed to highly corrosive substances, ensuring reliable performance in aggressive industrial settings. WALKSON’s pipes are designed for the following applications:

· Petrochemical Industry:

Catalytic Cracking Furnaces: Pipes transport corrosive hydrocarbons at temperatures up to 700°C, resisting sulfur compounds and acidic gases.

Styrene Steam Superheaters and EDC Cracking Furnaces: Maintain integrity in high-corrosion environments involving chlorinated hydrocarbons and steam.

· Oil Refining Industry:

Hydrogen Reformers: Handle high-pressure hydrogen and corrosive gases, ensuring durability under temperatures up to 900°C.

Atmospheric-Vacuum Distillation Units: Support crude oil processing in corrosive saltwater and sulfur-rich conditions.

· Metallurgical Industry:

Cold Rolling Continuous Annealing Lines: Pipes convey corrosive gases in radiant tube systems, enduring thermal cycling and oxidation.

Rotary Hearth Furnaces: Facilitate gas flow in screw discharging systems, resisting abrasive and corrosive residues.

· Additional Applications:

Pressure vessels, heat exchangers, and towers in refining projects, where pipes ensure leak-free performance in corrosive chemical environments.

These pipes are built to withstand extreme conditions, including temperatures up to 900°C, pressures up to 60 bar, and exposure to acidic, sulfurous, and chlorinated media, delivering long-lasting reliability in high-corrosion environments.

Functions of WALKSON Centrifugal Cast Alloy Pipes

WALKSON’s centrifugal cast alloy pipes deliver critical functionality in high-corrosion environments:

· Reliable Fluid Transport: Precision-crafted pipes ensure secure, leak-free flow of corrosive gases or liquids, maintaining system efficiency.

· Outstanding Corrosion Resistance: Made from high alloy and nickel-based materials (e.g., Inconel 600, Hastelloy C22, HP alloys), pipes resist acid attack, sulfidation, and pitting corrosion.

· High-Temperature Stability: Nickel-based alloys maintain structural integrity under elevated temperatures, preventing deformation or cracking.

· Enhanced Durability: The centrifugal casting process creates a dense, uniform microstructure, boosting creep resistance and mechanical strength.

· Customizable Designs: Available in various diameters, wall thicknesses, and lengths to meet specific piping system requirements.

Manufacturing Process: Precision and Standards Adherence

WALKSON’s centrifugal cast alloy pipes are manufactured with advanced technology and strict compliance with international standards, reflecting our ISO 9001, ISO 14001, ISO 45001, and O/TSY 1002.1 certifications. Below is a comprehensive overview of the production stages, leveraging our expertise as a high-tech enterprise with 11 state invention patents, including centrifugal casting technology for Inconel 600:

1. Material Sourcing and Analysis

· Standards: ASTM A351, ASTM A494, DIN EN 10295, and client-specific requirements.

· Materials: High alloy steels (e.g., HH, HK) and nickel-based alloys (e.g., Inconel 625, Hastelloy B2).

· Process: Materials are procured from certified suppliers and tested for chemical composition per ASTM E350 to verify alloy purity and compliance.

· Equipment: Advanced optical emission spectrometers for precise material analysis.

2. Melting and Alloy Purification

· Standards: ISO 9001 and ASME Section IX for melt quality control.

· Process: Alloys are melted in electric arc or induction furnaces, refined to eliminate impurities, and conditioned for uniform composition.

· Equipment: High-efficiency electric arc furnaces (EAF) and vacuum induction melting systems.

· Quality Control: Melt samples are analyzed to meet ASTM E350 standards.

3. Centrifugal Casting

· Standards: ASTM A781, EN 12680, and API 934 for casting quality.

· Process: Molten alloy is poured into a rotating mold, where centrifugal force compacts the material, forming a dense, defect-free pipe with a refined microstructure. This process, enhanced through our collaboration with the Chinese Academy of Sciences, ensures superior performance.

· Equipment: Automated horizontal centrifugal casting machines with precise control over rotation and temperature.

· Benefits: Produces pipes with exceptional strength, corrosion resistance, and accurate geometry.

4. Thermal Processing

· Standards: ASTM A703, ASME Section VIII, and client-defined protocols.

· Process: Pipes undergo heat treatments like solution annealing or quenching to optimize corrosion resistance, toughness, and creep properties.

· Equipment: Programmable heat treatment furnaces with real-time monitoring.

· Quality Control: Thermal cycles are tracked to comply with ISO 9001 standards.

5. Machining and Surface Finishing

· Standards: ISO 2768 for dimensional accuracy, ASME B16.9 for fittings, and ASTM A999 for surface quality.

· Process: Pipes are machined to exact specifications using CNC equipment, with surface finishes optimized for corrosion resistance. Fittings or flanges are added as needed.

· Equipment: CNC lathes, boring machines, and polishing systems.

· Quality Control: Dimensional checks are performed using coordinate measuring machines (CMM).

6. Quality Control and Testing

WALKSON’s stringent testing protocols, supported by our comprehensive quality management system and partnerships with research universities, ensure pipe reliability. We offer full transparency to clients and third-party inspectors (e.g., SGS, Bureau Veritas), with clients invited to witness all tests as outlined in our Inspection and Test Plan (ITP).

Non-Destructive Testing (NDT)

· 100% X-Ray Inspection:

Standard: ASTM E142, EN 12681.

Purpose: Detects internal flaws like voids, cracks, or inclusions.

Equipment: High-resolution digital X-ray systems.

Process: Full scanning of pipes with detailed reporting of results.

· 100% Eddy Current Testing:

Standard: ASTM E309, EN 1971.

Purpose: Identifies surface and near-surface defects, such as micro-cracks or pitting.

Equipment: Multi-frequency eddy current testing units.

Process: Comprehensive surface testing for defect-free assurance.

· Ultrasonic Testing (UT):

Standard: ASTM A388, EN 12680.

Purpose: Verifies wall thickness consistency and internal integrity.

Equipment: Automated ultrasonic scanners with high-frequency probes.

Process: Full-length scanning to ensure structural compliance.

Destructive Testing (where applicable)

· Tensile Strength Testing:

Standard: ASTM E21.

Purpose: Evaluates strength and ductility under stress.

Equipment: High-capacity tensile testing machines.

· Creep Resistance Testing:

Standard: ASTM E292.

Purpose: Assesses performance under sustained high-temperature loads.

Equipment: Specialized creep testing ovens.

· Microstructure Analysis:

Standard: ASTM E1351.

Purpose: Verifies grain structure and material uniformity.

Equipment: Metallographic microscopes with digital imaging.

Hydraulic Pressure Testing

· Standard: ASME B31.3, API 934, and client requirements.

· Purpose: Confirms the pipe’s ability to withstand design pressures (e.g., up to 60 bar for high-corrosion systems).

· Process: Pipes are pressurized with water to 1.5 times the design pressure and held to check for leaks or deformation.

· Equipment: Automated hydraulic testing systems with digital pressure gauges.

· Client Witnessing: Clients or third-party inspectors are invited to observe testing for compliance verification.

Documentation

· Inspection and Test Plan (ITP): Detailed ITP outlines all inspection and testing phases, available for client review.

· Welding Procedure Specification (WPS) and Procedure Qualification Record (PQR): Pre-qualified per ASME Section IX for welded components, provided upon request.

· Material Test Reports (MTR): Issued per EN 10204 Type 3.1 or 3.2, documenting chemical, mechanical, and test data.

· Inspection Reports: Comprehensive records of NDT, pressure tests, and dimensional checks, certified by third-party inspectors if required.

· Reference List: Available to showcase WALKSON’s successful delivery of alloy pipes to global refining and metallurgical projects.

Advantages of Choosing WALKSON

Choosing WALKSON for centrifugal cast alloy pipes offers distinct advantages, positioning us as the preferred supplier for high-corrosion environments:

1. Superior Quality: Our pipes meet stringent international standards, backed by 100% NDT and a robust quality management system certified to ISO 9001, ISO 14001, and ISO 45001.

2. Tailored Solutions: Custom pipe designs, alloy formulations, and configurations to meet specific corrosion challenges, leveraging our 11 state invention patents.

3. Global Credibility: Trusted by industry leaders like SINOPEC, CNPC, and CNOOC, with a reference list highlighting successful deliveries to large refining and industrial projects worldwide.

4. Transparent Processes: Third-party inspections (e.g., SGS, BV) and client-witnessed testing ensure trust and accountability.

5. Innovative Technology: Advanced centrifugal casting, CNC machining, and NDT systems, developed in collaboration with the Chinese Academy of Sciences, deliver precision and durability.

6. Expert Support: Our expert team, backed by our Academician Workstation, provides end-to-end guidance from design to installation.

7. Timely Delivery: Streamlined production and logistics ensure fast turnaround without compromising quality, supporting critical project timelines.

8. Sustainable Practices: Eco-friendly manufacturing aligns with ISO 14001 standards, minimizing environmental impact.

9. Cost Efficiency: Durable pipes reduce maintenance and downtime, lowering long-term operational costs for refining and metallurgical plants.

Consult with WALKSON Today

Enhance your high-corrosion systems with WALKSON’s high alloy and nickel-based centrifugal cast alloy pipes. Engineered for unmatched corrosion resistance, thermal stability, and compliance with rigorous industry standards, our pipes deliver outstanding performance in petrochemical, oil refining, and metallurgical applications.

Contact WALKSON now to explore your project requirements, request a quote, or arrange a consultation with our technical specialists. Visit www.walkson.com or email info@walkson.com (mailto:info@walkson.com). Partner with WALKSON, a high-tech enterprise recognized by Jiangsu Province, for high-quality centrifugal casting solutions trusted by global industry leaders.