High-Pressure and Heat-Resistant Steel 12Cr1MoV Steam Seperator with High Efficiency

Machinery Process

1. Drawing Review 

Organize joint drawing review by design, process, and production teams; verify dimensional tolerances, material (12Cr1MoV) performance requirements, and adaptability to high-temperature and high-pressure working conditions. Clarify manufacturing challenges (e.g., thick-wall welding, irregular flow channels), document technical disclosure records, and unify execution standards for all links.

2. 3D Modeling and Process Planning

Use CAD/CAM software to build a 3D digital model of the cone screen (Steam Seperator), simulating steam separation flow fields and structural stresses. Simultaneously plan forging blank shape, machining allowance, heat treatment furnace loading method, and welding sequence. Output process cards and tooling design schemes (e.g., special jigs and fixtures).

3. Raw Material Inspection and Blanking

4. Forging Process

Heat the blank to the austenite range (1150–1200°C), then form it through processes like upsetting, punching, and drawing to refine grains and optimize metal flow lines. Control cooling (air cooling + pit cooling) to avoid coarse grains that reduce high-temperature creep strength.

5. Rough Machining and Stress Relief

Remove forging allowance with lathes and milling machines to machine outer circles and inner hole datum surfaces; reserve 0.5–2 mm finish machining allowance. After rough machining, perform stress relief annealing (600–650°C holding followed by slow cooling) to eliminate residual forging stress and prevent subsequent deformation.

Semi-finishing

Semi-finishing

6. Overall Quenching and Tempering Heat Treatment

Execute quenching (860–890°C oil cooling) + high-temperature tempering (580–620°C air cooling) to obtain tempered sorbite structure. Test hardness (HB 210–240) and metallographic structure (sorbite content ≥90%) to ensure balance between strength (≥440 MPa) and toughness.

7. Finish Machining and Dimensional Control

Use CNC lathes to finish-machine outer circles and inner holes to design dimensions; machine nozzle flange hole systems with boring machines. Inspect with micrometers, inside diameter dial indicators, etc., ensuring wall thickness difference ≤0.1 mm, coaxiality ≤0.03 mm, and key surface roughness Ra ≤1.6 μm (e.g., sealing surfaces).

Quality Inspection

1. Appearance Quality Inspection

Conduct a visual inspection of the finished surface to identify defects such as cracks, folds, blowholes, scuffs, etc. Verify the surface finish and the uniformity of color after heat treatment (no abnormal oxidation or coating defects).

2. Dimensional Accuracy Inspection

Use tools like calipers, micrometers to measure key dimensions including inlet/outlet pipe diameter, cone angle of the cone body, wall thickness, overall length, and transition fillet. Strictly compare these measurements with the tolerance requirements specified in the design drawings.

3. Nondestructive Testing (NDT)

For the main forged/cast components :

Perform ultrasonic testing (UT) to detect internal defects (e.g., looseness, lamination, flake).

For high-risk areas, supplement with radiographic testing or time-of-flight diffraction for advanced flaw detection.

4. Mechanical Property Test

Cut test specimens to conduct the following:

• Tensile test: Verify tensile strength, yield strength, and elongation after fracture.

• Charpy V-notch impact test: Confirm toughness at room temperature or the design temperature. 

• Hardness test: Use Brinell or Rockwell hardness testers to ensure hardness matches the 12Cr1MoV material standard.

5. Pressure Test

Comply with standards like Pressure Vessels (GB150):

Conduct a hydrostatic test with water (pressure = 1.25×design pressure) and check tightness/structural integrity during the holding period.

If the medium is steam, add an air-tightness test (e.g., helium mass spectrometry leak detection).

6. Surface Treatment & Anti-corrosion Verification

If the surface has anti-corrosion coatings (e.g., paint, plating): 

• Measure coating thickness with a coating thickness gauge (meet the designed anti-corrosion grade).

• Use the cross-cut method to verify coating adhesion.

• For extreme environments, conduct a salt spray corrosion test (simulate corrosion resistance).

7. Geometric Tolerance Re-inspection

Use equipment like laser alignment tools and dial indicators to recheck form/positional tolerances (e.g., coaxiality, perpendicularity, roundness) to ensure assembly and operational precision. 

8. Documentation & Marking Verification

Inspect quality documentation (material composition report, heat treatment curve, inspection records) and confirm the product nameplate (specification, heat number, applicable standards) is complete and traceable for management purposes. 

These inspection procedures cover the entire process from “appearance → dimensions → internal quality → mechanical performance → pressure resistance → surface protection → documentation”, ensuring the Steam Separator’s reliability and safety under high-temperature and high-pressure conditions.

Packaging & Shipping

1, Inner Packaging

• Critical Component Cushioning Wrap: Use high - density pearl cotton and bubble wrap to wrap vulnerable parts such as the inner wall of the cone screen and flange interfaces in layers. After filling the gaps, fix them with adhesive tape.

• Transportation Advantages: Absorb vibration and impact, prevent impact dents and coating scratches on the metal surface, and ensure the integrity of precision structures.

• Rust - proof and Corrosion - resistant Encapsulation: Spray long - acting rust preventive oil on non - machined surfaces, then encapsulate the whole thing with rust - proof paper and seal the gaps with wax paper.

• Transportation Advantages: Block moisture, prevent rusting in maritime or humid environments, and maintain consistency in appearance and performance.

2,Outer Packaging

• Custom Rigid Frame Reinforcement: Adopt solid wood or steel packaging boxes, set wooden or steel brackets that match the cone screen inside, and fasten them with bolts to integrate the equipment with the frame.

• Transportation Advantages: Resist bumping and hoisting stress, prevent equipment toppling or frame collapse and damage.

• Full - enclosure Moisture - proof Treatment: Wrap the outer layer with waterproof canvas and then seal it with industrial PE film (focusing on covering the interface area).

• Transportation Advantages: Block rain, salt fog, and dust, adapt to complex climates across regions, and extend the outdoor storage duration.

• Standardized Application of Logistics Markings: Label the box with warning signs such as “This Side Up”, “Center of Gravity”, and “Rainproof”, and attach model and weight labels.

• Transportation Advantages: Guide precise loading and unloading, reduce the risk of rough handling and incorrect stacking, and improve warehousing and sorting efficiency.