In the petrochemical industry, as the core components of pressure vessels and pipeline systems, the quality of cylinder forgings directly affects the safety and stability of equipment operation. Jianing Forging provided a high-standard tube forging solution tailored to the specific needs of a petrochemical parts factory in Qingpu, Shanghai, helping the client successfully upgrade key equipment.

Case Summary

The partner for this cooperation is a company specializing in petrochemical parts production in the Qingpu area of Shanghai (hereinafter referred to as "the parts factory"). When the plant undertook a batch of large petrochemical unit orders, it urgently needed a batch of stringently specified and reliable cylinder forgings for manufacturing reactor and heat exchanger housings. Due to tight schedules and high technical requirements, customers have high requirements for forgings in dimensional tolerances, internal microstructure density, and delivery times.

Customer pain points

A parts factory encountered three prominent issues during the procurement process:

• Strict dimensional accuracy requirements: Cylinder forgings must be closely coordinated with subsequent machining processes, and the tolerance for diameter and wall thickness is recommended to be controlled within 0.5mm, which conventional forging processes cannot stably meet.
• Insufficient internal quality consistency: Forgings used by customers in early trials have local segregation or microcracks, resulting in a flaw detection pass rate below 95%, leading to increased rework rates in subsequent welding processes.
• Tight delivery times: The upstream unit commissioning date has been set, leaving about 30% less time for forging production than normal cycles, making supplier response speed a key bottleneck.

Product advantages

To address these pain points, Jianing Forging provides systematic solutions covering process design, process control, and delivery support:

• Precision forging process: Using multi-directional forging combined pre-deformation technology and specialized tooling, the roundness and wall thickness deviation of the cylinder forgings are stably controlled within 0.3mm, meeting customers' requirements for high-precision assembly.
• Full-process non-destructive testing: Each forging sequentially undergoes ultrasonic phased array and magnetic particle flaw detection, ensuring uniform internal structure and no excessive defects. The final flaw detection pass rate reaches 99.8%, reducing subsequent processing risks for customers.
• Agile production scheduling and delivery: Relying on its own forging production line and flexible scheduling mechanism, the normal 35-day production cycle was compressed to 22 days, allowing all deliveries to be completed one week ahead of schedule, allowing ample machining time for a parts factory.

Ultimately, this batch of cylinder forgings passed the customer's factory re-inspection in one go and performed stably during subsequent assembly and pressure tests, helping the parts factory complete the project delivery on time. With solid technical capabilities and reliable delivery performance, Jianing Forging continuously provides high-value forging products to customers in the petrochemical sector.