Solutions & Case Studies
Coke Drum Unheading Device
Industry: Oil & Gas
Situation: A large manufacturer of specialty valves and unheading devices for the Oil & Gas industry came to DynaIndustrial with a challenging problem. Their Coke Drum Unheading Devices had an excessively short lifespan and some units in the field had failed catastrophically. The seventy-thousand pound device, with an opening diameter of sixty-three inches required a positive close in a slide-gate process. As it was, the materials of the gate created too much pressure and friction, resulting in deterioration of essential dynamic and static components of the valve, not to mention the extreme hydraulic force required to cycle the valve. When the customer came to DynaIndustrial, they needed a supplier to not only manufacture the valve components, but also to design and provide the coatings and processes to eliminate the material deterioration problem.
Challenges:
- To manufacture Coke Drum Unheading Components that withstand high pressure and friction without fail, and reduce the forces required to operate.
- To design and apply protective coatings that adhere to the base material while providing lubricity for the positive-close slide gate.
- To meet demanding turnaround times with a quality assured finished product.
Solution: DynaIndustrial analyzed the existing Coke Drum Unheading Device and worked with the customer to develop a process to meet the quality requirements, we decided that a Heef 25 Industrial Hard Chroming process would be used to provide a coating applied to the base metal, while satisfying the lubricity factors. The ideal thickness of the chrome was calculated for maximum hardness, cohesiveness and durability, and finish-ground to provide stability and consistancy to the part. To provide these processes, we designed custom jigs and fixtures and purchased specific equipment necessary for our customer’s application.
Results:
- Several components for the Coke Drum Unheading Device have been prototyped successfully. Production units are now being manufactured and deployed on a regular basis
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