Professional Documents
Culture Documents
APPLICATION: ONSHORE
CONTENTS
1.0 Scope ..........................................................................................................................3
2.0 References ..................................................................................................................3
2.1 ......Purchaser Documents ......................................................................................3
2.2 ......Industry Codes and Standards .........................................................................3
3.0 Acronyms ....................................................................................................................4
4.0 Design .........................................................................................................................4
4.1 ......Pressure Design ...............................................................................................5
4.2 ......Solid Alloy Components ...................................................................................5
4.3 ......Openings ..........................................................................................................5
4.4 ......Weld Details .....................................................................................................5
4.5 ......Internal Structural Supports ..............................................................................5
5.0 Materials ......................................................................................................................6
5.1 ......Base Materials ..................................................................................................6
5.2 ......Welding Consumables .....................................................................................6
5.3 ......Clad and Weld Overlay ....................................................................................6
5.4 ......Roll Bond or Explosive Bond Clad ...................................................................7
5.5 ......Weld Overlays ..................................................................................................8
6.0 Fabrication ..................................................................................................................8
6.1 ......Material Handling and Protection .....................................................................8
6.2 ......Material Marking ...............................................................................................9
6.3 ......Material Cutting and Clad Strip Back ...............................................................9
6.4 ......Material Forming ............................................................................................10
7.0 Welding .....................................................................................................................10
7.1 ......Base Metal Welding Procedure Qualification .................................................10
7.2 ......Clad Restoration and Repair Welding Procedure Qualification ......................10
7.3 ......Weld Overlay Procedure Qualification ...........................................................11
7.4 ......Welders and Welding Operator Qualifications ...............................................11
7.5 ......Production Weld Overlay, Clad Restoration, and Clad Repair .......................12
7.6 ......Weld Overlay, Clad Restoration, and Clad Repair Quality Control ................12
8.0 Preheat and Post Weld Heat Treatment .................................................................13
8.1 ......Preheat ...........................................................................................................13
8.2 ......Post Weld Heat Treatment .............................................................................13
9.0 Inspection .................................................................................................................13
9.1 ......Pressure-Containing Welds ............................................................................13
9.2 ......Clad Vessel Parts ...........................................................................................14
9.3 ......Weld Overlays, Clad Restoration, and Clad Repairs .....................................14
10.0 Hydrostatic Test .......................................................................................................16
11.0 Records .....................................................................................................................16
11.1 ....Explosion Bond Clad Alloys ...........................................................................17
11.2 ....Roll Bond Clad Alloys .....................................................................................17
11.3 ....Weld Overlays, Clad Restoration Welds, and Clad Repair Welds .................17
1.0 SCOPE
1. This specification shall be used when a corrosion-resistant clad alloy is required to protect the
carbon steel or low-alloy steel shell from severe corrosive attack by the process environment.
2. This specification provides for clad by high-alloy sheet bonded to the plate, or weld overlay on
the plate.
2.0 REFERENCES
1. The following documents are referenced herein and are considered part of this specification.
2. Use the latest edition of each document referenced below unless otherwise specified
SFA-5.14/SFA-5.14M
Specification for Nickel and Nickel-Alloy Bare Welding Electrodes and
Rods
SFA-5.22 Specification for Stainless Steel Electrodes for Flux Cored Arc Welding and
Stainless Steel Flux Cored Rods for Gas Tungsten Arc Welding
SFA-5.34/SFA-5.34M
Specification for Nickel-Alloy Electrodes for Flux Cored Arc Welding
American Welding Society (AWS)
A4.2M Standard Procedures for Calibrating Magnetic Instruments to Measure the
Delta Ferrite Content of Austenitic and Duplex Ferritic-Austenitic Stainless
Steel Weld Metal
Society for Protective Coatings (SSPC)
SP 5 White Metal Blast Cleaning
SP 10 Near-White Blast Cleaning
3.0 ACRONYMS
FN—Ferrite Number
ESW—Electroslag Welding
FCAW—Flux-Cored Arc Welding
GMAW—Gas Metal Arc Welding
GTAW—Gas Tungsten Arc Welding
MAWP—Maximum Allowable Working Pressure
PT—Liquid Penetrant Test or Examination
PWHT—Post Weld Heat Treatment
PMI—Positive Material Identification
SAW—Submerged Arc Welding
SMAW—Shielded Metal Arc Welding
UNS—Unified Numbering System
UT—Ultrasonic Testing (sometimes used for Ultrasonic Examination)
4.0 DESIGN
1. Standard drawings GD-C99663 and GF-C1030 shall be considered part of this specification.
2. Vessel drawings that are part of PVM-SU-4749 or PVM-SU-4750 shall be included with
purchase documents for high-alloy clad pressure vessels.
3. Only those alloys listed in ASME SA-263, S-264, or SA-265 shall be used for clad or weld
overlaid vessels or vessel parts.
a. Duplex and super duplex stainless steels shall be excluded.
b. Other alloys that may be used shall be subject to acceptance by Purchaser.
4.3 Openings
1. For clad vessels with a shell thickness of less than 2 inches (51 mm), nozzles and manways
shall conform to GD-C99663.
2. For clad or weld overlaid vessels with a shell thickness of 2 inches (51 mm) or greater, nozzles
and manways shall be weld overlaid or clad in accordance with GF-C1030.
3. Nozzle liners shall not be used unless specified on the purchase order vessel drawings.
5.0 MATERIALS
5.3.1 Applications
1. Weld overlay shall be the primary method of applying the internal corrosion resistant
lining.
2. Weld overlay shall be used for the following:
a. Base metal groove welds in clad (clad restoration welding).
b. Base materials such as nozzles, flange faces, and other small area weld overlays.
3. Weld repair areas shall be composed of clad plate or weld overlays.
4. Weld overlay shall be applied to plate after it has been formed into the shapes required
for the components of a pressure vessel.
5.3.2 Thickness
1. Weld overlay shall be used in lieu of roll bond clad for base metal thickness greater
than 4 inches (102 mm).
2. Roll bond clad materials shall not be used for base metal thickness greater than
4 inches (102 mm).
3. Explosive bond clad material may be used for base metal thickness of 1 inch (25 mm)
to 16 inches (406 mm).
4. Minimum clad or weld overlay thickness shall be 1/8 inch (3.2 mm) unless accepted
otherwise by Purchaser.
5. Maximum clad or weld overlay thickness shall not exceed 5/16 inch (8 mm) without
Purchaser written acceptance.
9. Clad materials produced by either roll bond or explosion bond process shall meet the Bond
Quality Level Class 1 required by the applicable ASME SA-263, SA-264 or SA-265
specification, whichever applies.
10. Ultrasonic examination (UT) shall meet ASME SA-578 using 3-inch (75-mm) parallel
scanning paths.
11. Type 300 series Austenitic stainless steel clad shall be supplied to the vessel manufacturer in
the solution annealed condition as this is the most corrosion-resistant condition.
a. Roll bond-produced clad materials shall be heat treated at 1675°F to 1725°F
(913°C to 941°C) for 1 hour per inch (25 mm) of thickness followed by individual air
cooling or by alternate heat treatment, subject to acceptance by Purchaser.
b. Explosion bond-produced clad shall not need to be heat treated if supplied in the solution
annealed condition. However, if the explosion bond clad manufacturer applies any heat
treatment above 800°F (427°C), the procedure shall be submitted to Purchaser for
acceptance.
c. Copper-nickel alloys and nickel alloys shall be supplied in a solution-annealed condition
or as specified in ASME SA-265.
12. Types 405 and 410S ferritic stainless steel shall be supplied to vessel manufacturer in the
normalized and tempered condition.
a. Roll bond produced clad materials shall be normalized at 1650°F ±25°F (989°C ± 14°C)
and tempered at 1250°F (677°C) for one hour per inch (25 mm) of thickness.
b. Explosion bond-produced clad should not need to be heat treated to be supplied in the
normalized and tempered condition. However, if the explosion bond clad manufacturer
applies any heat treatment above 800°F (427°C), the procedure shall be submitted to
Purchaser for acceptance.
6.0 FABRICATION
4. Clad and weld overlays shall also be protected from low-temperature melting elements such as
lead, bismuth, zinc, etc.
5. The procedure for material handling and protection of high alloy clad or weld overlaid vessel
parts and the completed vessel shall be submitted by the vessel manufacturer. This procedure
shall include steps to clean objectionable embedded carbon or low alloy steel, dirt, grease, oil,
or other surface contaminants.
6. Grinding disks shall be suitable for use with alloy clad or weld overlay deposit.
a. Disks shall be segregated from disks used for carbon steel and shall be marked for easy
identification.
b. Care shall be taken to prevent contamination of the grinding disks from carbon or low
alloy steel when repairs are made to clad or weld overlays.
c. If disks are contaminated with carbon or low alloy steels, they shall be discarded.
7. Clad removal (strip back or repairs) shall be verified using copper sulfate to ensure complete
removal of the clad before alloy welding begins.
8. Carbon steel tools shall not be used on clad or weld overlay surfaces unless protected by alloy
sheet or weld metal to limit exposure of the clad or weld overlay to embedded iron or surface
iron contamination.
7.0 WELDING
7.6 Weld Overlay, Clad Restoration, and Clad Repair Quality Control
1. Production high-alloy welding shall strictly adhere to welding procedure essential and
non-essential variables, including the following:
a. Bead-to-bead overlap
b. Preheat and interpass temperatures
c. Inter-layer or individual weld bead cleaning
d. Travel speed
2. Before starting to weld overlay base materials, the base metal shall be machined, ground, or
blast cleaned to SSPC-SP 10 near-white metal finish, except that an SSPC-SP 5 white metal
finish shall be required for weld overlay processes that do not use a flux (SAW and ESW).
3. Welding consumables shall be verified to be acceptable and to meet manufacturer’s brand
name, and applicable SFA specifications for the required alloy, including UNS number.
4. Electrodes, strip, fluxes, and shielding gases shall be controlled in accordance with the weld
consumable manufacturer’s recommendations.
8.1 Preheat
1. Base metal PWHT requirements of PVM-SU-4749 and PVM-SU-4750 shall apply to the
application of weld overlay, clad restoration, and clad repair welding.
2. For multiple-layer overlays using shielded metal arc welding (SMAW), gas metal arc welding
(GMAW), flux-cored arc welding (FCAW), or gas tungsten arc welding (GTAW) processes,
preheat is not required for layers after the first layer, provided that vessel manufacturer
demonstrates to Purchaser’s satisfaction that the initial layer is sufficiently thick to prevent
hardening of the underlying base steel.
9.0 INSPECTION
8. Check analysis of carbon content shall be furnished for all austenitic stainless steels,
clad, solid, and/or weld metal, in accordance with the applicable ASME Code
requirements and the following additional requirements:
a. Carbon check analysis shall be required only for alloy pressure-containing parts
such as nozzles and bosses and for clad in contact with the contents of the vessel.
b. Carbon check analysis shall be required for each individual clad plate in contact
with the contents of the vessel.
c. Carbon check analysis shall be required for each heat and each batch of electrode
flux combinations and a minimum of one check for each shell ring head and
nozzle.
d. For other weld processes, a minimum of one check per heat of electrodes (filler
metal) and one check for each longitudinal and girth seam and nozzles shall be
performed.
11.0 RECORDS
Records listed in this section supplement the records required by PVM-SU-4749 and
PVM-SU-4750.
11.3 Weld Overlays, Clad Restoration Welds, and Clad Repair Welds
The following minimum records shall be supplied upon completion of the vessel:
1. Weld consumable test certificates
2. Weld procedures and supporting procedure qualification records
3. PMI and chemical analysis records including portable analyzer calibration certification
4. Ferrite reports including instrument calibrations (as applicable)
5. UT reports
6. Liquid-penetrant test (PT) reports
7. Weld maps of clad restoration welds and repairs to clad or weld overlay
8. Heat treatment (over 80°F [27°C]) records
NiCrFe-3 N06082
W86182
410S S41008 X X 309L W30913 X X X X
308L W30813
NiCrFe-3 N06082
W86182
304L S30403 X X X 309L W30913 X X X X X X
308L W30813
310S S31008 X X X 309L W30913 X X X X X X
310 W31010
316L S316003 X X X X 309LMo W30923 X X X X X X X X
316L W31610
317L S31703 X X X X 309LMo W30923 X X X X X X X X
317L W31710
321 (4) S32100 X X X 309L W30913 X X X X X X
347 W34710
347 (4) S34700 X X X 309L W30913 X X X X X X
347 W34710
Inco N04400 X X X NiCu-7 N04060 X X X X X X
Monel W84190 (5) (5)
Inco 600 N06600 X X X NiCrFe-1 N06132 X X X X X X
PVM-SU-1322-G
W86132
NiCrFe-3 N06082
W86182
18 of 19
NiCrFe-5 N06062
Table 1: Clad and Weld Deposit Alloy Chemical Element Verification Requirements (2 of 2)
July 2010
PVM-SU-1322-G
19 of 19