Precision Centrifugal Cast Pipes for Oil Refining Applications

Product Application: Precision Centrifugal Cast Pipes in Oil Refining

Precision centrifugal cast pipes are indispensable in oil refining, where they facilitate the safe and efficient transport of hydrocarbons and gases in extreme conditions. WALKSON’s pipes are engineered for the following applications:

· Oil Refining Industry:

Catalytic Cracking Furnaces: Pipes handle high-pressure hydrocarbon flows at temperatures up to 750°C, resisting corrosion from sulfur and carbon compounds.

Hydrogen Reformers: Support hydrogen-rich gas transport, enduring pressures up to 60 bar and high-temperature corrosive environments.

Atmospheric-Vacuum Distillation Units: Ensure reliable crude oil processing, maintaining integrity in saline and acidic conditions.

· Petrochemical Industry:

Reforming Furnaces: Facilitate feedstock flow in high-temperature reforming processes, resisting carburization and thermal cycling.

EDC Cracking Furnaces: Transport chlorinated hydrocarbons, withstanding aggressive chemical exposure and heat.

· Additional Applications:

Pressure vessels, heat exchangers, and towers in large refining projects, where pipes ensure leak-free performance in critical systems.

Styrene steam superheaters and hydrogenation heaters, supporting robust piping for high-pressure operations.

These pipes are built to perform under severe conditions, including temperatures up to 800°C, pressures up to 60 bar, and exposure to corrosive and erosive media, delivering exceptional durability in oil refining applications.

Functions of WALKSON Precision Centrifugal Cast Pipes

WALKSON’s precision centrifugal cast pipes deliver essential functionality in oil refining systems:

· Efficient Fluid Transport: Precision-engineered pipes ensure smooth, leak-free flow of hydrocarbons and gases, optimizing refining efficiency.

· High-Temperature Resilience: Made from high alloy and nickel-based materials (e.g., Inconel 600, Hastelloy C276, HP alloys), pipes maintain stability under extreme heat.

· Corrosion Resistance: Nickel-based alloys protect against sulfidation, carburization, and hydrogen-induced cracking, ensuring long-term performance.

· Structural Integrity: The centrifugal casting process creates a dense, uniform microstructure, enhancing creep resistance and mechanical strength.

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

Manufacturing Process: Excellence and Standards Compliance

WALKSON’s precision centrifugal cast pipes 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 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 Selection and Verification

· 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 analyzed for chemical composition per ASTM E350 to ensure 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 remove impurities, and treated for uniform composition.

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

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

3. Centrifugal Casting

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

· 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, 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 pipes with superior strength, corrosion resistance, and accurate geometry.

4. Heat Treatment

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

· Process: Pipes 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: Pipes are machined to exact specifications using CNC equipment, with surface finishes optimized for performance. Flanges or welded ends 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 oil refining 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 centrifugal cast pipes to global refining projects.

Advantages of Choosing WALKSON

Choosing WALKSON for precision centrifugal cast pipes offers distinct advantages, positioning us as the preferred supplier for oil refining applications:

1. Uncompromising 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 Engineering: Custom pipe designs, alloy formulations, and configurations to meet specific refining system needs, 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 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 plants.

Consult with WALKSON Today

Elevate your oil refining operations with WALKSON’s high alloy and nickel-based precision centrifugal cast pipes. Engineered for corrosion resistance, thermal stability, and compliance with rigorous industry standards, our pipes deliver outstanding performance in the most demanding refining 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.