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Product Introduction: Alloy Tubes for High-Pressure Applications

Overview

Alloy tubes are essential components in high-temperature and high-pressure applications, specifically designed for the efficient transfer of heat and substances in critical infrastructures such as boilers, superheaters, and heat exchangers. These tubes are crafted from high-performance alloy steels that exhibit superior mechanical properties and excellent resistance to thermal and pressure stresses, making them a preferred choice in various industries including power generation, petrochemical, and manufacturing.

Applications

1. Boiler Systems

Alloy tubes are extensively utilized in boiler systems where high-pressure and temperature conditions prevail. They facilitate the efficient transfer of heat generated during combustion processes. The resilience of these tubes against corrosion and thermal fatigue significantly enhances the operational lifespan of boiler systems.

2. Superheaters

In superheaters, alloy tubes are integral to the process of converting water into steam at high temperatures. The tubes' robust characteristics prevent failures under extreme conditions, ensuring the reliability and efficiency of the superheating process.

3. Heat Exchangers

Heat exchangers, which are vital in various industrial processes, benefit from alloy tubes due to their excellent thermal conductivity and durability. These tubes optimize heat transfer rates, leading to improved energy efficiency and overall system performance.

Production Standards and Steel Grades

Alloy tubes are produced following stringent industry standards that ensure optimal performance and safety. The notable standards include:

• ASTM A213: This standard specifies seamless ferritic alloy-steel tubing for high-temperature service, with grades such as T11, T12, T22, T5, and T9.
• ASTM A335: This covers seamless ferritic alloy-steel pipes suitable for high-temperature service, including grades P11, P12, P22, P5, and P9.
• ASTM A199: This standard includes seamless alloy-steel tubing specifically for high-temperature service with emphasis on T11 and T22 measures.
• ASTM A209: Addressing low-alloy steel grades like T1 and its variations (T1a and T1b), this standard focuses on the applications requiring specific mechanical properties at elevated temperatures.
• EN10216-2: European standard covering alloy steel tubes for pressure purposes with specifications like 10CrMo5-5 and X11CrMo5+1.
• JIS G3462: Japanese Industrial Standard that covers alloy steel tubes used for boilers and heat exchangers, including grades STB A12, STB A13, and STB A24.

Delivery Condition

Alloy tubes are typically delivered in a Normalized and Tempered condition, which enhances their mechanical properties and overall performance characteristics. This treatment process improves the strength and toughness of the tubes, allowing them to perform effectively under high-stress environments.

Inspection and Testing

To ensure product reliability and safety, a series of comprehensive inspections and tests are performed on alloy tubes, including:

• Chemical Composition Inspection: Verifying adherence to specified chemical requirements to ensure material integrity.
• Mechanical Properties Tests: Conducting tests for tensile strength, yield strength, elongation, flaring, flattening, hardness, and impact resistance to assess the mechanical capabilities of the tubes.
• Surface and Dimension Tests: Ensuring that surface quality and dimensions meet the required specifications.
• Non-destructive Testing (NDT): Implementing methods to detect internal flaws without damaging the tubes.
• Hydrostatic Testing: Testing the strength of the tubes under high-pressure conditions.

Surface Treatment

Surface treatment is crucial for enhancing the performance and durability of alloy tubes. Common treatments include:

• Oil-dip: A method to prevent corrosion during storage and transportation.
• Varnish: Provides an additional barrier against environmental factors.
• Passivation: Enhances corrosion resistance by chemically treating the surface.
• Phosphating: Improves adhesion and corrosion resistance.
• Shot Blasting: Cleans and prepares the surface for additional treatments.

Size Range

The alloy tubes come in various sizes, with an outer diameter (OD) range from 19.05 mm to 101.60 mm and a wall thickness that varies. The following are some standard sizes with corresponding wall thickness options available:

• 19.05 mm OD with thickness options ranging from 2.00 mm to 12.00 mm
• 25.40 mm OD with thickness options available
• 33.70 mm OD available in multiple thicknesses
• 60.30 mm OD in various thickness configurations
• 101.60 mm OD as the maximum standard size.

Conclusion

Alloy tubes are vital components in high-pressure and high-temperature applications across various industries. With adherence to industry standards and rigorous testing procedures, these tubes ensure reliable performance in critical systems. Their diverse applications in boilers, superheaters, and heat exchangers underscore their importance in maintaining operational efficiency and safety in industrial process environments