High-Performance Manifolds for Delayed Coking Heaters

Product Application: High-Performance Manifolds in Delayed Coking Heaters

High-performance manifolds are indispensable in delayed coking heaters, which thermally crack heavy oil residues into valuable products like diesel, gasoline, and petroleum coke. WALKSON’s manifolds are tailored for demanding applications, including:

· Oil Refining Industry:

Delayed Coking Units (DCUs): Manifolds manage the flow of hot gases or heavy feedstocks through heater tubes, operating at temperatures up to 750°C and enduring cyclic coking/decoking thermal shocks.

Coke Drum Inlet Systems: Ensure consistent feedstock distribution, resisting high-pressure and erosive coke particles.

· Petrochemical Sector:

Support secondary processes like visbreaking, where manifolds handle high-temperature hydrocarbons and corrosive residues.

· Additional Applications:

Heavy oil upgrading and other thermal cracking systems requiring durable, erosion-resistant manifolds.

These manifolds are designed to perform under harsh conditions, including temperatures up to 800°C, pressures up to 40 bar, and exposure to abrasive and corrosive environments, delivering exceptional longevity in delayed coking operations.

Functions of WALKSON High-Performance Manifolds

WALKSON’s high-performance manifolds provide critical functionality in delayed coking heaters:

· Streamlined Flow Distribution: Precision-designed manifolds ensure even distribution of gases or feedstocks, optimizing heater efficiency and minimizing pressure losses.

· Extreme Temperature Resilience: Crafted from high alloy and nickel-based materials (e.g., Inconel 718, Hastelloy C22, HP alloys), manifolds maintain stability under intense thermal cycles.

· Erosion and Corrosion Protection: Nickel-based alloys shield against abrasion from coke particles, sulfidation, and carburization, prolonging operational life.

· Robust Structural Design: The centrifugal casting process yields a dense, uniform microstructure, enhancing resistance to creep and mechanical stress.

· Tailored Configurations: Available in various sizes, shapes, and connection types to integrate seamlessly into specific coking heater designs.

Manufacturing Process: Precision and Standards Adherence

WALKSON’s high-performance manifolds are produced with cutting-edge technology and strict compliance with international standards, ensuring top-tier quality. Below is a comprehensive overview of the production stages:

1. Material Procurement 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 601, Hastelloy B2).

· Process: Materials are sourced from trusted vendors and subjected to chemical composition testing per ASTM E350 to ensure alloy purity and compliance.

· Equipment: High-precision spectrometers for material verification.

2. Melting and Refining

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

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

· Equipment: Advanced 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 553 for casting quality.

· Process: Molten alloy is poured into a rotating mold tailored to the manifold’s geometry. Centrifugal force compacts the material, forming a dense, flaw-free component with a refined microstructure.

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

· Benefits: Produces manifolds with superior strength, thermal stability, and accurate geometry.

4. Heat Treatment

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

· Process: Manifolds undergo heat treatments like solution annealing or tempering to enhance creep resistance, toughness, and corrosion 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: Manifolds are machined to precise specifications using CNC equipment, with surface finishes optimized for durability. Flanges or welded joints are added as needed.

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

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

6. Quality Control and Testing

WALKSON implements rigorous testing protocols to ensure manifold reliability, offering complete transparency to clients and third-party inspectors (e.g., SGS, Bureau Veritas). Clients can 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 manifolds 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 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 553, and client requirements.

· Purpose: Confirms the manifold’s ability to withstand design pressures (e.g., up to 40 bar for coking applications).

· Process: Manifolds 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): Comprehensive ITP details 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: Detailed 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 manifolds to global refining projects.

Advantages of Choosing WALKSON

Choosing WALKSON for high-performance manifolds offers distinct advantages, making us the preferred supplier for delayed coking heater components:

1. Top-Tier Quality: Our manifolds adhere to stringent international standards, backed by 100% NDT and thorough quality assurance.

2. Customized Engineering: Tailored manifold designs, alloy formulations, and configurations to meet specific coking heater needs.

3. Global Credibility: Trusted by leading refineries worldwide, with a reference list highlighting successful project deliveries.

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

5. Cutting-Edge Technology: Advanced centrifugal casting, CNC machining, and NDT systems deliver precision and durability.

6. Expert Support: Our skilled engineers provide comprehensive guidance, from design to installation, ensuring optimal performance.

7. Prompt Delivery: Streamlined production and logistics ensure fast turnaround without compromising quality.

8. Eco-Friendly Practices: Sustainable manufacturing reduces environmental impact, aligning with global green standards.

9. Cost Efficiency: Durable manifolds minimize maintenance and downtime, reducing long-term operational costs.

Consult with WALKSON Today

Enhance your delayed coking heaters with WALKSON’s high alloy and nickel-based high-performance manifolds. Built for resilience, erosion resistance, and compliance with rigorous industry standards, our manifolds deliver outstanding performance in the harshest refining environments.

Contact WALKSON now to discuss your project requirements, request a quote, or schedule a consultation with our technical specialists. Visit www.walkson.com or email info@walkson.com (mailto:info@walkson.com). Partner with WALKSON for high-quality centrifugal casting solutions.