High-Strength Centrifugal Casting Components for Power Plants

Product Application: High-Strength Centrifugal Casting Components in Power Plants

High-strength centrifugal casting components are vital for power plants, where they withstand extreme conditions in steam, gas, and cooling systems. WALKSON’s components are tailored for the following applications:

· Power Generation Industry:

Boiler Systems: Components like tubes and fittings operate in superheated steam environments at temperatures up to 700°C, resisting oxidation and creep.

Gas Turbines: Support high-pressure gas flow in turbine exhaust systems, enduring thermal cycling and corrosive combustion byproducts.

Heat Recovery Steam Generators (HRSGs): Facilitate efficient heat transfer in high-pressure steam circuits, maintaining integrity under pressures up to 100 bar.

· Petrochemical and Refining Integration:

Hydrogen Reformers: Components handle high-temperature hydrogen and syngas, resisting carburization and hydrogen-induced cracking.

Catalytic Cracking Units: Support piping systems in integrated refining-power plants, enduring corrosive hydrocarbons.

· Additional Applications:

Cooling Water Systems: Components like elbows and connectors resist corrosion in saline and chemical-laden water environments.

Pressure Vessels and Heat Exchangers: Provide reliable performance in power plant auxiliary systems, ensuring leak-free operation.

These components are engineered to perform under severe conditions, including temperatures up to 750°C, pressures up to 100 bar, and exposure to corrosive gases and liquids, delivering exceptional reliability in power plant operations.

Functions of WALKSON High-Strength Centrifugal Casting Components

WALKSON’s high-strength centrifugal casting components deliver critical functionality in power plants:

· Robust Fluid Management: Precision-engineered components ensure secure, leak-free transport of steam, gases, and liquids, optimizing system efficiency.

· Extreme Condition Endurance: Crafted from high alloy and nickel-based materials (e.g., Inconel 600, Hastelloy C276, HP alloys), components withstand high temperatures and pressures.

· Corrosion and Wear Resistance: Nickel-based alloys protect against oxidation, sulfidation, and erosion, ensuring long-term durability in aggressive environments.

· Mechanical Strength: The centrifugal casting process produces a dense, uniform microstructure, enhancing creep resistance and structural integrity.

· Tailored Configurations: Available as tubes, fittings, elbows, and connectors in various sizes and shapes to meet specific power plant requirements.

Manufacturing Process: Precision and Standards Compliance

WALKSON’s high-strength centrifugal casting components are manufactured using advanced technology and strict adherence to international standards, reflecting our ISO 9001, ISO 14001, ISO 45001, and O/TSY 1002.1 certifications. Below is a detailed 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 Selection 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 C22).

· Process: Materials are sourced 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 Refining

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

· Process: Alloys are melted in electric arc or induction furnaces, purified 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 ASME Section III for casting integrity.

· Process: Molten alloy is poured into a rotating mold tailored to the component’s geometry. Centrifugal force compacts the material, forming a dense, defect-free structure with a refined microstructure. This process, refined through our collaboration with the Chinese Academy of Sciences, ensures exceptional quality.

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

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

4. Heat Treatment

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

· Process: Components 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 Finishing

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

· Process: Components are machined to exact specifications using CNC equipment, with surface finishes optimized for performance. Flanges, threads, 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’s stringent testing protocols, supported by our comprehensive quality management system and partnerships with research universities, ensure component 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 components 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, ASME Section III, and client requirements.

· Purpose: Confirms the component’s ability to withstand design pressures (e.g., up to 100 bar for power plant systems).

· Process: Components 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 centrifugal casting components to global power and refining projects.

Advantages of Choosing WALKSON

Choosing WALKSON for high-strength centrifugal casting components offers distinct advantages, positioning us as the preferred supplier for power plant applications:

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

2. Customized Solutions: Tailored component designs, alloy formulations, and configurations to meet specific power plant requirements, leveraging our 11 state invention patents.

3. Global Trust: Trusted by industry leaders like SINOPEC, CNPC, and CNOOC, with a reference list highlighting successful deliveries to large power and refining 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 components reduce maintenance and downtime, lowering long-term operational costs for power plants.

Consult with WALKSON Today

Enhance your power plant operations with WALKSON’s high alloy and nickel-based centrifugal casting components. Engineered for strength, corrosion resistance, and compliance with rigorous industry standards, our components deliver outstanding performance in the most demanding power generation environments.

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