Power Generation Parts Manufacturing Service

Use advanced materials such as Inconel 718, Hastelloy X, or titanium alloys for components exposed to high temperatures (>700°C). For turbine blades and exhaust systems, consider nickel-based superalloys with resistance to thermal fatigue and creep. Ensure that materials meet relevant standards such as ASTM B637 for alloy compositions and heat treatment specifications.

Design parts with fatigue and thermal cycling resistance, ensuring a fatigue life of at least 100,000 cycles under operating conditions. Use FEA (Finite Element Analysis) to simulate thermal and mechanical stresses, and ensure safety margins ≥2.0 for critical components like rotors, shafts, and casings.

For high-stress components, apply full penetration welding with controlled heat input. Ensure that welding procedures follow ASME Section IX and that post-weld heat treatments (PWHT) are conducted to reduce residual stresses. Use non-destructive testing (NDT) such as ultrasonic testing (UT) and radiographic testing (RT) to inspect welds for integrity.

Ensure effective heat dissipation by integrating cooling channels or heat exchangers in high-thermal-load components. For steam turbines and power generators, ensure that all parts exposed to hot gases have high thermal conductivity and thermal shock resistance. Materials such as copper alloys and aluminum composites are ideal for heat exchangers and cooling plates.

Use corrosion-resistant alloys such as stainless steel, duplex steels, and titanium in components exposed to water, steam, or aggressive chemicals. Apply protective coatings like ceramic thermal barrier coatings (TBCs) for turbine blades and high-temperature alloys. Ensure coatings meet ASTM B733 standards for durability.

Design for high-pressure containment and optimized fluid flow. Use materials and components that meet API 6A or ASME B16.5 standards for pressure vessels and piping. Perform pressure testing (hydrostatic or pneumatic) to verify pressure resistance, ensuring that components meet specified pressure ratings under operational conditions.

Apply precise dimensional tolerances for critical components, such as turbine rotors, blades, and compressor blades. Use GD&T (Geometric Dimensioning and Tolerancing) per ASME Y14.5 to control form, fit, and function. Ensure that key dimensions are measured with CMM (Coordinate Measuring Machines) or laser scanning systems.

Use high-performance seals such as metal-to-metal, O-rings, or spiral-wound gaskets for fluid-tight interfaces. Ensure seal integrity by specifying materials that are resistant to high pressures and extreme temperatures. Perform leak testing (e.g., helium leak testing) to validate sealing effectiveness in critical components.

Perform routine NDT, including ultrasonic testing (UT), eddy current testing (ET), and X-ray or CT scanning for critical components. Conduct surface and sub-surface inspections to detect cracks, weld defects, or material inconsistencies. Ensure all testing is in compliance with ASME Section V and API 510 standards.

Ensure all designs and manufacturing processes comply with applicable codes and standards, including ASME Boiler & Pressure Vessel Code, API standards, and ISO 9001 for quality management. Prepare all necessary documentation, including material certifications, inspection reports, and weld maps for compliance audits.

Select materials such as Inconel 718, Hastelloy X, and titanium alloys for components exposed to high temperatures (>800°C). For power plant turbines and heat exchangers, use alloys with excellent creep resistance and high-temperature strength. Ensure compliance with ASTM B637 and ASME SA-213 for heat-resistant materials.

Conduct fatigue analysis under thermal and mechanical loading per API 579 or ASME Boiler and Pressure Vessel Code. Components such as turbine blades, rotors, and gas compressor blades should have a life expectancy of ≥10⁶ cycles at operating temperatures and dynamic loading conditions. Ensure fatigue analysis considers cyclic thermal expansion.

Follow ASME Section IX welding procedures for critical components. Ensure full penetration welds and perform post-weld heat treatment (PWHT) to relieve stresses. Use non-destructive testing (NDT) such as ultrasonic testing (UT) and radiographic testing (RT) to verify weld quality and structural integrity in high-pressure components.

Use materials with high thermal conductivity, such as copper alloys for heat exchangers and cooling systems. Design components with integrated cooling channels or heat sinks to improve heat dissipation in areas exposed to extreme thermal cycling. Ensure that thermal expansion is accounted for in high-temperature environments to prevent warping.

Apply corrosion-resistant coatings, such as ceramic coatings or HVOF (High-Velocity Oxygen Fuel), for components exposed to high temperatures and aggressive chemicals. Ensure materials are compatible with both acidic and alkaline environments in cooling towers, boiler tubes, and gas turbines. Follow ASTM G48 and ISO 12944 standards for corrosion resistance testing.

For pressure containment components such as pressure vessels, valves, and heat exchangers, follow ASME Boiler and Pressure Vessel Code or API 650 for pressure ratings and design. Perform pressure testing (hydrostatic or pneumatic) and helium leak testing (<1×10⁻⁹ Pa·m³/s) for leak-proof integrity, especially in critical systems like steam lines and reactors.

Use precise dimensional control for critical components that interact with seals, bearings, or rotating parts. Apply GD&T per ASME Y14.5 to control flatness, concentricity, and perpendicularity. Maintain machining tolerances to ±0.01 mm for tight-fit components such as turbine rotors and valve seats.

For components exposed to high-pressure gas or steam, use metal-to-metal sealing or spiral-wound gaskets. Conduct leak detection tests, including pressure decay tests and helium leak tests, to ensure zero leakage at interfaces between flanges, valves, and critical seals. Follow ASME B16.5 for gasket design and installation.

Conduct routine NDT, including ultrasonic testing (UT), eddy current testing (ET), and X-ray inspections for critical welds and pressure vessels. Ensure compliance with ASME V and API 570 standards for inspection and acceptance criteria. Document and store NDT results for audit and traceability purposes.

Ensure that all components comply with industry standards such as ASME Section VIII, API 6A, and ISO 9001. Maintain complete design documentation, including material certifications, stress analysis reports, and manufacturing process specifications. Prepare for third-party audits and regulatory approval, including API, CE, and ASME certifications.