Since 1965, the petrochemical industry has gained rapid progress in Japan, among them LDPE plant as high pressure process has been highlighted, and number of manufacturer has come up to ten companies and 13 factories in 1970.
  SUPERO KIKAI KOGYO has changed manufacturing system out of all round manufacturer of fasteners progressively to the manufacturer of high pressure parts to cope with the situation covering on LDPE industry.
  Generally, almost the LDPE plants are running their facilities under the severe condition exceeding 300MPa super high pressure with continuous attention to secure the preventive maintenance.
  The company has being engaged to study the working, testing material against the high pressure parts continuously day and night. Thus, nowadays the company has established ourselves on firm ground, and been accepted our abilities by all user of LDPE manufacturers as the excellent high pressure parts maker.
  The Quality Contorol Systemas as the backbone of our manufacyuring systems shall be described as follows.
   
  ESTABLISHMENT OF FOUNDAMENTAL SPECIFICATION ON HIGH PRESSURE PARTS
  (1) Drawing up of Basic Working Specifications (for individual main parts, shall be submitted tocustomer by request)
  (2) Material Procurement Inspections (Shall be attached to the material purchasing order.)
  (3) Heat Treatment Working Standard
  (4) Controlling Standard For Gage and Measurement Tools
  (5) Testing and Inspection Standard
  (6) Making Drawings (Shall be submitted to the customer, for approve, finals)
  (7) Making Test and Inspection Reports with Mill Sheet
   
  UNIQUE QUALITY CONTROL
(1) MATERIAL CONTROL
  @ Complete Quality Control must be enforced even in all the steel manufacturer concerned.
  A In any case receiving materials ordered by us from the steel manufacturer receiving inspection shall be performed for the mill heat No., marking of identification and the mill sheet with the documents concerned.
  B Preventing from intermixing of foreign materials through the manufacturing process. All the transferring of materials during process shall be performed with the container provided. Against the uncertain materials appeared shall be inspected with microscopic analyzer to identify.
  C In 1980, the company developed new exclusive steel for the ultra high pressure use only, which was patented.
  D Utilized Precipitation Hardening Stainless Steel on the high pressure parts to be used in the process of manufacturing LDPE require anti corrosion.
(2) HEAT TREATMENT CONTROL
  The heat treatment shall be performed in our factory with the automatic atmospherecontrolling electric furnace, installed, occasionally in the condition of non-oxidizationatmosphere according to the customer's request. Our furnace is designed in very usefulcapacity, therefore inside temperature of the furnace are fixed in the uniform values regardlessof position, consequently it gives definite result to the products after heat treatment. All theheat treatment shall be performed according to our specified standard, however treatmentshall be also performed according to the customer's requirement.
(3) VARIOUS SURFACE TREATMENT
  Surface hardening, Anti-corrosion and Prevent rusting treatment such as gas nitriding,hard-chrome plating, stellite facing, tufftriding, defric coating etc. shall be performed accordingto the customer's request.GAS NITRIDING: This gas nitriding surface hardening treat. Method is the backbone of ourQuality Control, and its efficiency has being accepted by he all customers manufacturingLDPE in Japan. In case of our recommendation, gas nitriding shall be performed on thematerial, nitriding steel(JIS SACM645) with ammonium gas under 530 ℃ for 72hours, after thetreatment the surface hardness shall be ≧mHv1,000, however the treatment shall be appliedon any steel according to the customer's request.
(4) SKILFULL LAPPING WORK
  The company secure the delivering of parts with the proper flatness be brought by theexcellent work and inspecting system supported by optical flat.
(5) Adopting the 『Traveler』 system used for the transferring materials through working andinspection process, which based on the ASME CODE, USA.
(6) HIGH PRESSURE TESTING EQUIPMENT
  Ranging 500MPa pressure test is available to the piping parts involving valves, blocks andcone ring etc. with the equipment installed in our factory.

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MATERIALS

 MATERIALS FOR HIGH PRESSURE PARTS

QUALITY CONTROL

 QUALITY CONTROL

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The photograph of the main products
MAIN PRODUCTS

 MAIN PRODUCTS

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 As the specialist manufacturer for the high pressure parts, it is important to pay a attention on thematerials to be used for the supplying the excellent products to the customers utilizing theskillful work and the excellent working machines and installations.
 Although little described in the description of Quality Control already, furthermore, shall be explainedon the high pressure parts materials we recommend as follows.
 The following materials are generally used, however we are ready any time to accept customer'srequirement to select the other materials. Any materials shall be used according to the customer'sspecifications, generally strength and toughness of the materials are against each other, thereforethe option of either one shall be depended on the customer's specification. Our excellent furnacecan afford to accept any sort of specifications.
 
SELECTION OF VACUUM ARC REMELTED MATERIALS
   For the materials of high pressure parts exceeding 300MPa anti corrosion and anti fatigue arerequired to be bearable for severe condition. To secure those properties the vacuum meltingmethod are desirable to exclude impurity elements and non-metallic inclusions which be caused ofcorrosion and fatigue.
   Remelted in vacuum and highly purified steel are so called VA Materials. Vacuum arc remeltingmethod is generally well-known as the smelting way to grade up the quality of metals.
 
MERIT OF A MATERIALS
  (1) Much effective for the melting and casting for the active metal without contamination by air.
  (2) Characteristic for degasification available to remove gas, and impurity elements.
  (3) As impurity elements hydrogen is one of impurity which appears by the heat resolving ofmoisture contained in iron manufacturing materials in the process of steel refining.Increasing of hydrogen content shall be brittle forsteel, extreme small quantity of hydrogenmakes cause for the planting brittleness, flake and delayed fracture.
  (4) Phosphorous element is same to Sulphur element be most hateful impurity in the contentso steel, accordingly, the composition of both elements are restricted less 0.03%. Phosphorousmakes increasing of strength of steel, however, while it makes decrease the elongation andreduction of area, particularly decrease the impact value
. Sulphur element is one of injurity, shall be remained in the shape of MnS after combining withwith the element of Mn added in the process of melting.S is not able to solid solute with Fe, under the insufficient existence of  Mn shall be precipitatedin the shape of FeS in crystal boundaries, resultedly remarkably decrease the strength  and toughness of steel. Such Sulphur element shall be removed by VA Remelting.
  (5) Si is a element can be solid soluted with ferrite and makes steel strong, however on the otherhand makes increase the brittleness and it promotes to makes the grain size to be large, anddecrease the mechanical properties, must be removed by the process of VA Remelting.
  (6) Non-metallic inclusions usually exist in the shape of oxide sulfide, silicate, and alumina in thesteel, and shall be classified to the three categories according to the sorts, shapes anddistributions in JIS. There are sulphide of Fe and Mn. Al2O3nitride.
 
STEEL BEING USED AND RECOMMENDABLE
(1) AISI E4340VA (Equivalent to JIS SNCM439)
  In the most common types of steel, our company is to meet the needs of the user, VAR assteelmaking material for ultra-high pressure, always in stock holdings in the text of thematerial dimension (law vacuum arc remelting: Vacuum Arc Remelting). Also couductednitriding treatment.
(2) Our exclusively developed steel (SMUP, Patented steel Patent NO. 1124226)
  In 1975, the company developed the new steel for suitable large and forged materials, excellentin the properties of strength, toughness and impact in low temperature and weldability.Mitsubishi Steel Manufacturing Co. progressed this study as collaborator with us.The differences of mechanical property between the surface part of material and inside partsshows small variation, also there are small difference of mechanical property among the X, Yand Z directions. Nitriding treatment are also available.
(3) Nitriding Steel (JIS SACM645)
  Shall be used for the parts which particularly requires the surface hardness, shall be deliveredafter gas nitriding. In addition, we also stock material in steelmaking VAR.
(4) Precipitation Hardening Stainless Steel
  Nowadays, in the LDPE industry the producing amount of complex resin such as EVA and EAAare on the increase, resultedly demand for the steel have a characteristics against the strength,anti-corrosion and toughness is rising. Complying with such demand Precipitation HardeningStainless is much recommendable as the most suitable material for those high pressure parts.To respond to this initially, 15-5PH from the United States, Inc. Armco, Inc., has raised materialwas material and now, led to the procurement from Hitachi Metals Co., Ltd. Factory Yasugi, wasthat we gained experience.In our company, PH stainless steel as a material for ultra-high pressure, has been produced bya steelmaking VAR, We have purchased, and "17-4PH (SUS630)" a "15-5PH (AMS5659)".PH stainless steel, in the strict specifications, we have under the conditions of purchase (A)solution treatment.Heart treatment furnace at an excellent in-house installation, we have carried out theprocessing corresponding to the specifications of up to artificial aging treatment H1150M fromH900, the needs of more users.
ALLOY BOLTS AND NUTS
(1) Use for pressure vessels and various valves in nuclear power station.
(2) Use for high pressure, high temperature vessels and valves in power station.
(3) Use for turbines and heavy electric equipment's.
(4) Use for super high pressure service in petrochemical industry.
(5) Use for the service of heat resistance, corrosion resistance and pressure resistance in chemical industry.
(6) Use for heat resistance of gas turbines.
 
・ANTI SEIZING COMPOUND FOR THREADS NAMED "SMOCON"
 
・PARTS OF SUPER HIGHT PRESSURE EQUIPMENT(MAX.400MPa)
(1) Various Super High Pressure service valves.
Stop Valve Safety Valve
Let Down Valve (Angle Type) Gage Valve
Check Valve Main Parts of Special Spec. Valve(stem, disk, seat etc.)
(2) Fitting Parts
Flange Block(T, L, Y, Type)
Bolts and Nuts Lens Ring (With Nozzle)
Bend Pipe Cone Ring
T-pipe Thermocouple Cone Ring
Gasket Reducer
Rupture Disk Holder
     
PARTS OF HYPER GAS COMPRESSOR
(1) Parts connected with Cylinder
Plunger (nitrided) Retaining Ring (Oiler, Standard, Bushing)
Outer Head Oil Quil (Oil Injector)
Sleeve Frame End-Stud (Big End Bolt) Nut
Valve Core Stop Plate
Outer Head Bolt and Nut Oil Injector Cylinder
Inlet Plate Cylinder Valve (Complete)
Cylinder Body Poppet
Packing Cup (Pressure Cup) Discharge Plate
Bottom End Spacer (Base Ring) Big End Bolt
(2) Parts of Equipment's surrounding Hyper Cylinder
Driver Rod Catalyst Pump Sealing Head
Piston Rod Intensifier Burrell (Inner, Outer)
Cross Shoe Catalyst Sparger
Plunger Connector Stirrer shaft
Cross Head Drive Yoke Autoclave (Authorized High Pressure Gas Controlling Regulation)
Catalyst Pump Cylinder
※Postscript
For the purpose of surface hardening treatment gas nitriding shall be applied on the parts according to customer's requirement. Such nitriding treatment has been developed with a well known skilled accepted now by all the LDPE manufacturers in Japan.
  MAIN PRODUCTS QUALITY CONTROL  MATERIALS FOR HIGH PRESSURE PARTS
Copyright 2009, SUPERO KIKAI KOGYO CO.,LTD

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