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CASTI Handbook

Cladding Technology

2nd Edition on CD-ROMCASTI Publishing Inc.10566 - 114 StreetEdmonton, Alberta T5H 3J7 CanadaTel:(780) 424-2552 Fax:(780) 421-1308

E-Mail: [email protected] Web Site: www.casti.ca

CCASTI

CASTI HANDBOOK OFCLADDING TECHNOLOGY

2nd Edition

Liane M. Smith, Ph.D.Mario Celant, Ph.D.

Executive EditorJohn E. Bringas, P.Eng.

CASTI Publishing Inc.10566 114 Street

Edmonton, Alberta, T5H 3J7, CanadaTel: (780) 424-2552 Fax: (780) 421-1308

E-mail: [email protected] Web Site: http://www.casti.ca

ISBN 1-894038-30-4Printed in Canada

iii

CASTI Handbook of Cladding Technology 2nd Edition

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First printing, January 2000ISBN 1-894038-30-4 Copyright 2000

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iv


FROM THE PUBLISHER

IMPORTANT NOTICE

The material presented herein has been prepared for the generalinformation of the reader and should not be used or relied upon forspecific applications without first securing competent technicaladvice. Nor should it be used as a replacement for current completeengineering codes and standards. In fact, it is highly recommendedthat the appropriate current engineering codes and standards bereviewed in detail prior to any decision making.

While the material in this book was compiled with great effort and isbelieved to be technically correct, the authors, CASTI Publishing Inc.and its staff do not represent or warrant its suitability for any generalor specific use and assume no liability or responsibility of any kind inconnection with the information herein.

Nothing in this book shall be construed as a defense against anyalleged infringement of letters of patents, copyright, or trademark, oras defense against liability for such infringement.

ix


PREFACE

Cladding technology refers to the application of a relatively thin layerof an alloy (as the cladding) onto a substrate or backing material.

In many cases the cladding is selected for its resistance to corrosion.A wide range of alloys can be clad, including stainless steels andnickel base alloys to rare metals such as zirconium and tantalum.

The backing material is normally selected to meet the necessarymechanical requirements (strength and toughness). The backingmaterial is often a grade of carbon or low alloy steel, other metalsmay be used.

A key feature of clad products is that the backing material is oftensignificantly cheaper than the cladding alloy, so that clad productscan offer substantial cost savings over the use of solid alloy products.

The authors have been personally involved in the use of corrosion-resistant alloy cladding of carbon steel for various applications in theoil and gas industry for more than 10 years. This experienceprompted them to write this book covering wider aspects of cladproducts including the different means of manufacturing them, theirproperties, and their applications in various industries. Thesubstantial use of clad pipe in the oil and gas sector merits particularmention, and so Chapter 9 of the book is devoted entirely to projectexperience in that industry.

The principal units of measurements used are metric with imperialconversions. Where appropriate, figures are expressed in nominalimperial units with actual size metric conversion.

Alloys are identified principally by UNS numbers and abbreviatedterms are listed in the Appendix 1.

Liane SmithMario CelantJune1998

xi


TABLE OF CONTENTS

1. Introduction to Cladding TechnologyMaterials Selection Options for Corrosive Service 1Dimensions of Clad Products 3Economics of Clad Technology 4Optimising the Corrosion Properties 6Using Cladding Technology to Best Advantage 7

2. Clad PlateProduction Methods 9Hot Roll Bonding 9Backing Steel Types 10Manufacturing Sequence 12Optimizing Bonding 16Heat Treatment 19Inspection Requirements 22Explosive Bonding 23Weld Overlaying 29

3. Clad PipesDefinitions 33Longitudinally Welded Clad Pipe 34Centricast Clad Pipe 38Seamless Pipe Mill Clad Pipe 43Explosively Bonded Clad Pipe 48Lined Pipe 50

Thermo-Hydraulically Lined Pipe 51Hydraulically Lined Pipe 53Explosively Lined Pipe 55

4. Clad BendsManufacturing of Bends from Clad Pipe 57Manufacturing of Bends from Lined Pipe 61

5. Clad FittingsClad Fittings Made by Weld Overlaying 65Clad Fittings Made by Hot Isostatic Pressing 66Clad Fittings Made from Clad Plate or Pipe 69Clad Elbows 70Clad Tees 73Clad Manifolds 76Clad Reducers and Caps 77Clad Flanges and Valves 78

xii


6. Specification Requirements of Clad ProductsMaximum Allowable Stress Values 81Cladding Alloy 82Backing Steel 83Backing Steel Requirements for Application inH2S Containing Environments 84Mechanical Tests 85Corrosion Tests 87Demagnetising 90Dimensions and Tolerances of Clad Pipe 90

Cladding and Wall Thickness 90Diameter and Out of Roundness 92

Ultrasonic Inspection 93

7. Welding Clad ProductsFabricating Clad Vessels 95

Handling Clad Plate 95Welding Clad Vessels 96

Circumferential Welding of Clad Pipe 100Handling Clad Pipe 101Pipe End Dimensions/Fit-up 101Weld Preparation 102Demagnetising of Pipes 105Back Shielding 106Choice of Welding Process 107Choice of Filler Metal 109Control of Heat Input 111Weld Integrity Assessment 112

Welding Repairs During Pipelaying 112Developments in Clad Pipe Welding Technology 113Laying Clad Pipe 117Commissioning Clad Pipelines 121

8. Clad Product ApplicationsCladding Technology in the Oil & Gas Industry 123

Clad Production Tubing 124Valves, Pumps, and Joints 127Vessels and Heat Exchangers 129Backing Steel 134Cladding Alloy 134Line Pipe and Manifolds 135

Cladding Technology in the Petrochemical Industry 143Applications 143Backing Steel 146

xiii


8. Clad Product ApplicationsCladding Technology in the Petrochemical Industry (Continued)

Cladding Alloy 147Disbonding in Hot Hydrogen 148

Cladding Technology in the Chemical Industry 149Backing Steel 150Cladding Alloy 150

Cladding Technology in Chemical Tankers 153Cladding Technology in Metal Purification 154Cladding Technology in the Power Industry 154Cladding Technology in Air Pollution Systems 158Cladding Technology in Shipping Applications 163Cladding Technology in the Pulp and Paper Industry 165

9. Clad Pipe ProjectsADMA OPCO - Um-Shaif - 1993 167Agip UK - Thelma and South East Thelma - 1995 168ARCO Alaska Inc. - Prudhoe Bay - 1991 170ARCO - Thames Bacton - 1987 171Asamera Oil - Corridor - 1996 172BP International Ltd. - Ravenspurn to Cleeton - 1987 173BP International Ltd. - Forties - 1987 174BP International Ltd. - Miller - 1989 174BP International Ltd. - Cyrus - 1995 176Chevron - Ninian - 1992 180Clyde Petroleum - P2/P6 - 1997 180Louisiana Land and Exploration - Lost Cabin - 1991 182Mobil - Arun Booster Gas Compression - 1993 182Mobil - South Lho Sukon - 1996 188Mobil - Mobil 823 - 1995 188Mobil - Yellowhammer - 1994 189Mobil - 869 Field - 1995 190Mobil - Ras Laffan LNG Co. Ltd. - North Field - 1998 192Nederlandse Aardolie Maatschappij, NAM

- Early Field Trails - 1974-1975 192Nederlandse Aardolie Maatschappij, NAM

- Roswinkel, Zuidlaren - 1978 193Nederlandse Aardolie Maatschappij, NAM

- Emmen - 1987-1989 194Nederlandse Aardolie Maatschappij, NAM

- Twente, Schoonebeek - 1988 196Nederlandse Aardolie Maatschappij, NAM

- Dalen 6 And Dalen 9 - 1988 196Nederlandse Aardolie Maatschappij, NAM

- Grijpskerk - 1996 197

xiv


9. Clad Pipe Projects (Continued)ONGC - South Bassein - (1988 and 1993) 198Shell Offshore - Fairway - 1991 204Shell Todd Oil Services - Maui 'B' to 'A' - 1991 208

Pipe Production 209Laying the Line 210Welding 211Inspection 214

Statoil - sgaard - 1997 214Texaco - Erskine - 1997 215Total Oil Marine - Bruce - 1991 216

Appendix 1 Abbreviated Terms 217

Appendix 2 Hardness Conversion Numbers 219

Appendix 3 Unit Conversions 229

Appendix 4 Pipe Dimensions 237

Appendix 5 Bibliography 243

Appendix 6 List of Figures and Contributors 253

Index 257


Chapter

1INTRODUCTION TO

CLADDING TECHNOLOGY

Materials Selection Options for Corrosive Service

For many applications where a metallic material is needed, it isnormal to consider initially whether carbon or low alloy steels (totalalloying element content typically below 1% to 2%) would be suitable.Such steels are cheap, have a wide range of mechanical properties tosuit various demands, and are readily available from many sources ina wide range of product forms.

In aggressive environments, because of certain corrosive conditions, amore highly alloyed material may be necessary or justified forimproved reliability and extended service life compared to basic steels.Such alternative materials may include various grades of stainlesssteels, nickel alloys, copper alloys, or titanium alloys depending uponthe environment. Since such materials would be selected to beresistant to the environment in question, they may be referred togenerically as corrosion-resistant alloys or CRAs.

Any of these options would represent quite an increase in initialinstalled cost per tonne compared to basic steels. Whilst such a shift inmaterials selection may often be justified on a case-by-case basis(particularly when the cumulative life cycle cost over the full servicelife is considered), under many circumstances there is another optionto considerusing the selected CRA as a cladding or lining. The termcladding technology is widely used generically to refer to bothcladding and lining options.

2 Introduction to Cladding Technology Chapter 1


In a clad product, the CRA forms a complete barrier layer on thesurface of a carbon or low alloy steel (referred to as the backing steel).The CRA layer is fully metallurgically bonded to the backing steelwith some diffusion of alloying elements between the two metals atthe interface. A distinction is made between a cladding layer and ametallic coating applied by hot dipping (such as aluminizing orgalvanizing) or plating (such as nickel or electroless nickel-phosphorus). Such coatings are not discussed in this book.

In a lined product, the CRA is in sheet form attached to the backingsteel at intervals. The lining is not metallurgically bonded to thebacking steel over most of its surface but is normally fully sealed toform a complete barrier between the backing steel and the corrosiveenvironment.

The range of CRAs which can be clad by various techniques is verywide. A few of the more commonly selected cladding alloys areindicated in Table 1.1. In addition to these alloys, many other metalsincluding copper, titanium, and zirconium are available in clad form.

Table 1.1 Examples of CRAs Which Can Be Used as Cladding Alloys

Alloy UNSC

maxS

maxMnmax Cr Ni Mo Cu Fe Ti

410S S41008 0.08 1.00 1.00 12.014.0

304L S30400 0.030 1.00 2.00 18.020.0

10.012.5

-

316L S31603 0.030 1.00 2.00 16.518.5

11.014.0

2.02.5

321 S32100 0.08 1.00 2.00 17.019.0

9.012.0

5x%C0.70

317L S31700 0.030 1.00 2.00 17.519.5

14.017.0

3.04.0

22Cr S31803 0.030 - 2.00 21.023.0

4.506.50

2.504.50

904L N08904 0.020 0.70 2.00 19.021.0

24.026.0

4.05.0

1.02.0

926 N08926 0.020 1.00 2.00 19.021.0

24.026.0

6.07.0

0.51.5

825 N08825 0.025 0.50 1.00 19.523.5

38.046.0

2.53.5

1.53.0

bal. 0.61.2

625* N06625 0.025 0.50 0.50 2.023.0

61.065.0

8.010.0

63.0 - 28.034.0

1.02.5

* 3,15 - 4,15 Nb

6 Introduction to Cladding Technology Chapter 1


Optimizing the Corrosion Properties

The fact that the CRA layer is fairly thin does mean that certainprecautions are necessary to ensure optimum performance in service.The CRA selected should be fully resistant to corrosion in the serviceenvironment. If corrosion does occur, particularly localised pitting orcorrosion cracking, the thin layer of CRA may be breached, exposingthe underlying backing steel to the environment with the risk ofcorrosion.

Furthermore, once the appropriate CRA has been selected to avoidsuch a scenario, it is critical that its corrosion properties are notimpaired during production. This may arise if a clad layer isincorrectly heat treated, or if there is excessive diffusion of carbonfrom the backing steel into the CRA layers. Corrosion resistance mayalso be reduced if an inappropriate method is used for attaching aCRA lining or if incorrect parameters are used in making weldoverlaid clad products or in fabricating clad products such that thereis excessive dilution of the CRA by the underlying steel. Such dilution,or mixing, of the CRA with the backing steel should be limited,otherwise the final composition may be outside that needed to achievefull corrosion resistance. Further detail on these aspects andoptimising the properties of clad and lined products is given inChapter 2. Critical aspects covered in specifications are discussed inChapter 6.

With all CRA products, welding methods have to be carefullycontrolled in order not to destroy the properties of the CRA in andaround the weld zone. For many CRAs, this requires welding methodswhich have a low heat input (such as gas tungsten arc welding). Suchwelding methods tend to be slow and, as a result, welding costs can behigh. The technical aspects of welding clad products are discussed inChapter 7.


Chapter

2CLAD PLATE

Production Methods

The total production of metallurgically bonded clad plate by variousmethods is about 80,000 tonnes/year. There are three principalmethods of manufacturing clad plate:

hot roll bonding explosive bonding weld overlaying

The production approach varies within each of these methodsdepending upon the selected grade of backing steel, the selectedcorrosion-resistant alloy (CRA), and the specification requirements.Different manufacturers also vary somewhat in the approach theytake. Selecting the most appropriate route for clad plate manufacturedepends upon quantity, thickness, and alloy type.

Hot Roll Bonding

Hot roll bonding is the most widely adopted production method wherelarge clad areas are needed and accounts for about 85% of all cladplate production.

Quite a wide range of CRAs may be selected for the cladding layeralthough, as described later, some are technically easier to handle andtherefore more readily available. Specifically, many stainless steelsand nickel alloys may be produced in clad form using hot roll bonding.

26 Clad Plate Chapter 2


Figure 2.10 Explosion cladding of plate near Perpignon (Fance).

detonation front

explosive

frame

cladding metal

jet

backing metalcollision point

Figure 2.11 Schematic of explosive bonding process.

Explosively clad plates may require flattening in a press or rollerleveler.

Finishing and quality control of the product would be similar to rollbonded plates (Figure 2.13).


Chapter

3CLAD PIPES

Definitions

The American Petroleum Institute API defines clad and lined steelpipe in Section 2.1.a of API Specification 5LD as follows:

1. CLAD. Clad steel pipe is a bimetallic pipe composed ofan internal CRA layer metallurgically bonded to the basemetal.

2. LINED. Lined pipe is pipe in which a CRA layer isaffixed inside the carbon steel pipe, full length, byexpanding the liner and/or shrinking the pipe or by otherapplicable processes. The CRA layer and the carbon steelpipe shall be manufactured in accordance with Spec. 5LCand Spec. 5L, respectively, except as may be otherwisespecified herein.

Normally, the word clad is used generally to mean both productsexcept where a specific distinction is made.

Generally speaking, the CRA layer is inside the pipe as defined abovebut externally clad pipe is occasionally made for specific applications(e.g., nickel-copper UNS N04400 clad pipe for riser splash zoneprotection as discussed further under Line Pipe and Manifolds(Chapter 8).

34 Clad Pipes Chapter 3


Clad pipes may be produced using the following processes: longitudinally welding of clad plate centrifugal casting seamless pipe mill production methods explosive bonding

Lined pipes may be produced by: hydraulic or thermohydraulic expansion explosive lining

Clad pipes may be produced as full length or shorter lengths whichare generally welded in the shop and supplied as full 12.2 meters(40 foot) lengths.

Longitudinally Welded Clad Pipe

Longitudinally welded pipe is made from clad plate which should bethoroughly visually examined on the full surface before it is made intopipe to check for any possible mechanical damage or localisedcorrosion which might penetrate through the clad layer. Any suchdefects should be repaired by welding or be cut from the plate.

The edges of the clad plate are machined for welding and the plate isformed into pipe in a U-ing, O-ing, expansion (UOE), press bend orrolling mill (Figure 3.1). Pipe edges are generally pre-bent to help theplate obtain a good round shape after forming.

The seam weld has to be made by completing the weld in the carbonsteel first and completing the clad layer last. It might appear to besimpler to weld the CRA layer first and then change over to a carbonsteel filler material for the weld made in the backing steel part of thewall thickness. However, such a production route would givedeleterious hard microstructures in the carbon steel weld portionwhere a small amount of underlying CRA was dissolved into thecarbon steel weld bead. In contrast, completing the carbon steel andthen overlaying a CRA layer as the final weld pass means that only asmall amount of carbon steel dissolves into the CRA which does notresult in hard microstructures.


Chapter

4CLAD BENDS

Manufacturing of Bends from Clad Pipe

Manufacturing of clad bends is usually carried out using inductionheating of metallurgically bonded clad pipe. The clad pipe is put intothe bending machine: one end of the pipe is held with the clamp at thetop of the arm while the other end is fixed in a position with the tailstock. An induction heating coil heats a limited narrow portion of thepipe as it is pushed forward through this region. The pipe iscontinuously heated and bent around the centre of gyration of the armuntil the given angle of bend is reached (Figure 4.1). Some bendingequipment is capable of producing multiple bends in pipe which mayhelp reduce the number of welds in piping systems (Figure 4.2).

It is preferable if the bending machines can induction heat thetangent portions of the bend to avoid heat affected zones afterbending. Some machines have such continuous heat treat facilitiesover the bent portion and also the tangents with facilities for internaland external water quenching if required. Otherwise, bends may befurnace heat treated. Figure 4.3 shows a number of clad bends comingout of a furnace after heat treatment. If bends come from TMCP steel,tempering should be avoided as this may cause a loss of strength.Careful qualification of the bending and heat treatment process isnecessary in all cases.

Chapter 4 Clad Bends 61


Bends and elbows (down to 1.5 DR) can also be made using themandrel bending process (pushing the pipe over a bend former calleda mandrel) from 12.5-1219 mm (0.5-48 inch), and even largerdiameters up to 2540 mm (100 inch), with good dimensional tolerances(see Clad Elbows in Chapter 5).

Bends have been made using the cold forming method (flexiblemandrel process), from seamless or welded metallurgically bondedclad pipes. Although work hardening will occur, the formingequipment is high powered and strong enough to compensate for theincrease in yield strength with plastic deformation. After bending,final heat treatment (usually QT), if required by the specifications,can be carried out.

Manufacturing of Bends from Lined Pipe

Investigations of cold bending of lined pipe have shown that someminor wrinkling of the alloy liner arises at a bend radius of about25 D. Thus, simple cold bending of lined pipe is limited to a minimumradius of about 15 D before wrinkling of the liner becomes excessive.Cold bends were made at 1, 2, 5.8, and 10 angles, correspondingrespectively to DR = 63, 31, 11, 6, on 6 inch (168.2 mm) ODmechanically bonded pipes to observe possible disbonding or linerbuckling (Craig, 1994). Disbonding was judged by sectioning the bendand observing any separation between the liner and the backing steel.Some wrinkling started to appear in the liner at a 5.8 bend angle,whilst several buckles were identified at 10 bend angle. The bendswere done without a mandrel, which would help reduce wrinkling butnot stop separation. In spite of some concerns about the reducedcorrosion resistance of the liner as a consequence of the cold work, itwas not possible to obtain meaningful results in the adopted corrosiontests (ASTM G 48, and ASTM A 262). Further tests were madeaccording to ASTM G 28 on UNS N06625 lined mechanically bondedpipes, showing some weld line attack after a hydraulically expandingthe liner back into the outer steel pipe.


Chapter

5CLAD FITTINGS

Whilst there are many manufacturers of solid alloy fittings, there arerelatively few with wide experience producing clad fittings. This mayexplain why solid alloy fittings have sometimes been used to completea clad system. In other cases availability or cost factors may lead tothe selection of solid alloy fittings. Furthermore, certain design codesmay favour solid alloys over clad steel because of higher allowablestresses. Essentially each project has to be considered separately todecide whether clad or solid fittings will be the most appropriate.

In spite of the relatively limited use of clad fittings to date, severalmanufacturers are now capable of producing all the items necessary tofulfill the needs of typical processing systems.

All types of fittings are available with internal cladding includingelbows, bends, tees, manifolds, reducers, eccentrics, and caps.Manufacturing methods include:

weld overlaying hot isostatic pressing (HIP) manufacturing from clad plate or pipe.

Clad Fittings Made by Weld Overlaying

A key benefit of weld overlaying is that there are many suppliersaround the world and so lead time for supply is normally fairly shortcompared to some other manufacturing routes. Various weldoverlaying techniques, as described previously for clad plate


Chapter

6SPECIFICATION REQUIREMENTS

OF CLAD PRODUCTS

This chapter is not intended to give a rigorous breakdown of cladproduct specifications but simply to comment on a few aspects.

Typical roll bonded clad plate production specifications are ASTMA 264 (Stainless chromium-nickel steel clad plate, sheet and strip),ASTM A 265 (Nickel and nickel-base alloy clad steel plate), andJIS G 3602 (Nickel and nickel alloy clad steels).

There is an API specification, API 5LD, for CRA Clad or Lined SteelPipe.

Maximum Allowable Stress Values

The codes for vessel design allow the wall thickness calculations toinclude some credit for the thickness of any cladding. Such claddinghas to be fully metallurgically bonded, and normally reference is madeto specifications for clad plate (e.g., ASTM A 263, A 264, A 265) or toweld overlay cladding with specific requirements for quality controland inspection of the weld overlay layer. Where linings are applied tovessels, the thickness of the lining material is not included in the wallthickness computation. In these cases the maximum allowable stressvalues given are for the base material.

82 Specification Requirements of Clad Products Chapter 6


The proportion of the applied cladding thickness that can be takeninto account in determining the wall thickness for design purposes isexplained in individual codes. As an example, ASME Section VIII -Division 1 defines the allowed wall thickness equal to the nominalthickness of the base material plus (Sc/Sb) x the nominal thickness ofthe cladding after any allowance provided for corrosion has beendeducted, where:

Sc = the maximum allowable stress value for the integralcladding at the design temperature, or for corrosion-resistantweld metal overlay cladding, that of the wrought materialwhose chemistry most closely approximates that of thecladding at the design temperature.Sb = the maximum allowable stress value for the basematerial at the design temperature.

Where Sc is greater than Sb, the multiplier Sc/Sb shall be taken equalto unity. The maximum allowable stress values are listed in the codes.

Pipeline design follows different codes and to date it has not beenusual for the cladding thickness to be included in the designcalculation of the wall thickness. Individual cases may be made wheresome allowance for the cladding thickness could reasonably be made.

Cladding Alloy

The specifications for clad plate and clad pipe are limited to a smallselection of cladding alloys but with the option for purchaser andmanufacturer to agree on other grades or modified compositionsbetween. Thus, in principal, any cladding alloy may be selected whilstin practice there are technical and economic limitations. Purchasersmay therefore find that what appears to be a cheaper alloy selectionmay result in a more costly clad pipe because of the productiondifficulties in heat treating certain alloys and optimising backing steeltoughness while achieving good corrosion resistance of the cladding.

90 Specification Requirements of Clad Products Chapter 6


Demagnetising

Using magnetic grips to hold clad plates or pipes at various stages ofmanufacturing and transportation can result in residual magnetismwhich can interfere with welding by causing arc blow. Residualmagnetism may also arise form electromagnetic inspection in the mill.Demagnetising of products at the mill is often requested in purchasespecifications but this can be a waste of time since they may re-magnetise in transit. In the case of clad pipes, re-magnetising arisesbecause of pipe being knocked in transit or even by being stored in aNorth-South orientation. In many cases pipes have had to be de-magnetised on site immediately before welding to avoid arc blowproblems during welding.

Dimensions and Tolerances of Clad Pipe

Cladding and Wall Thickness

In terms of past production, about 40% of the produced pipes havebeen purchased specifying 3 mm (0.12 inch) minimum claddingthickness, and about 35% with 2 mm (0.08 inch) minimum. Inprinciple there is no problem in manufacturing a strictly controlledproduct even as low as 1.6 mm (0.06 inch) in cladding thickness,particularly with longitudinally welded pipes, but this will producepossible problems in field welding. The fit-up problems would increasethe risk of possible iron dilution during the root pass, as the bevel endfor the root is generally set at about 1.6 mm (0.06 inch).Manufacturers suggest a minimum cladding thickness of 2 mm(0.08 inch) when using hydraulic line-up clamps for field welding, and2.5 mm (0.1 inch) with conventional clamps. The reduction of thecladding thickness from 3 mm (0.12 inch) to these levels would givesome economic benefit.

A typical tolerance on the cladding thickness is 0.5 mm (0.02 inch),or rather, -0 mm, +1.0 mm (0.04 inch).


Chapter

7WELDING CLAD PRODUCTS

The key factor which has to be considered in welding clad products ismaintaining the corrosion resistance of the inner cladding layer inand around the weld zone. This has an impact on all aspects of thewelding procedure including the type of weld preparation, the choiceof welding process, the filler material, the shielding gas, and the heatinput.

Fabricating Clad Vessels

Handling Clad Plate

Clad plates should be stored in a clean and dry condition and treatedbasically in the same way as solid CRAs. Where plates have to be coldformed, the working surfaces of the forming equipment should beclean to avoid contaminating the alloy surface.

Care should be taken to avoid damage to the clad surface during anyshearing, punching, or cutting operations. Clad plates can be flamecut, usually from the backing steel side, or plasma cut, usually fromthe cladding metal side. Powder cutting can also be used, generallyfrom the cladding side. Drilling is usually begun from the claddingsurface with tools and drilling conditions selected to be suitable for thecladding material.

In producing vessel shells and heads, standard hot or cold formingmethods, depending upon clad plate size and thickness, are used withsomewhat more gradual pressure application than with solid steel.

Chapter 7 Welding Clad Products 97


in the last pass. Weld overlay techniques with low dilutioncharacteristics, like electroslag overlaying, have been accepted withjust a single pass.

Thickness (mm) Base steel side Cladding metal side

up to 15( ")

over 15 up to 22( " ~ ")

over 22 up to 38( " ~ 1 ")

over 38(1 ")

Cladding ratio ofover 20%In case ofdifficulty at edgepreparation min. 5 min. 5 min. 5 min. 5

65 5

0 ~ 1

1.5

o o

65 5

0~1

2.0

o o

65 5

1.51.5~2.5

o o

60 5

90 5

a2.0b'

2~3a:b = 1:3

o o

o o

15 5

8 R2

2.0

o o0~12.0

82R

15 5 oo

Note: 1) Edge preparation can be done by machining, gas-cutting, or plasma-arc cutting.2) Edge prepared surfaces should be smooth, and the surface of edge prepared

by gas-cutting should be ground smoothly.3) Dimensions in mm.

Figure 7.1 Typical weld joint designs for clad vessels.

The welding method described above is appropriate when the claddingalloy and backing material are compatible as dissimilar metal welds.Some metals cannot be directly welded to each other as they formbrittle phases or suffer other cracking problems such as liquationcracking in the weld zone. In such cases a strip of the cladding metalis fillet welded over the completed internal weld seam to give acontinuous corrosion-resistant alloy surface. This method is typicallyused when vessels are fabricated from titanium clad plate. In this casethe titanium cladding is cut back from the carbon steel along the weldline. The carbon steel is then welded using standard techniques. Abatten of copper is then positioned on the carbon steel weld and


Chapter

8CLAD PRODUCT APPLICATIONS

Cladding Technology in the Oil & Gas Industry

Clad products have been used extensively in the oil and gas industryto counteract corrosive conditions. Major applications have been in theform of clad pipes, vessels, and heat exchangers but there are alsoother components that are routinely supplied in clad form such aswellheads and other valves.

Clad products have to compete against carbon steel and solid CRAs.Where the duration of a project is short, the amount of corrosionarising on carbon steel may be tolerated by allowing extra wallthickness, or corrosion allowance, which is consumed during theproject. Chemicals (corrosion inhibitors) may be injected into theenvironment to reduce the corrosion rate.

In some cases, however, the anticipated rate of corrosion may be toohigh or the life of the project too long to simply allow the corrosion totake place. In such cases, CRAs may be selected which will suffernegligible corrosion over the duration of the project. The choice of solidor clad is then a matter of which is more economical, but clad steelmay offer some specific advantages in this industry in some cases.

One example is offshore projects developed by means of a fixed orfloating structure. In such cases it is beneficial to save weight in thetopside facilities to reduce the cost of the support structure. The useof backing steels with higher strength than solid CRAs then allows areduction in wall thickness of the topside facilities (vessels and piping,etc.) which reduces the weight of those items with correspondingeconomic benefits for the structure.

Chapter 8 Clad Product Applications 153


It is very common to find chemical reactor vessels internally clad withUNS S31603, even where the corrosion conditions may not beextremely aggressive. An example is the production of polypropylene.Cladding is required here because of the need to produce really pureuntainted products without any colour contamination. There is someuse of UNS S30400 cladding in systems handling dry products such aspolymer particles, again for requirements of cleanliness and lack ofcontamination.

The electrochemical industry makes some use of titanium clad plate inprocesses for the production of caustic soda and chlorine.

Cladding Technology in Chemical Tankers

The typical corrosive products carried by shipping tankers arehydrogen peroxide, oxypropylene, and various acids in concentratedform. Austenitic stainless steel (mostly type 304 or 316), duplexstainless steels, or occasionally higher alloys are selected for thechemical container.

Clad steel has often been used in the wing and end bulkheads, whilsttransverse and centre line bulkheads are solid alloy inhorizontally/vertically corrugated configuration. The clad plate isnormally 8-15 mm (0.3-0.6 inch) thick with 1.5-3 mm (0.06-0.12 inch)of stainless steel. The outer surface of the chemical cargo tank formsthe inner surface of the ballast space and, since this is filled withseawater, the corrosion of the carbon steel surface (both the clad steeland the outer tank construction) is conveniently controlled byprotective coatings and cathodic protection. There is some preferencefor clad steel over solid stainless to avoid problems of galvaniccorrosion of the carbon steel tanker wall in the ballast space and toprevent any risk of localised corrosion or stress corrosion cracking ofthe stainless steel.

In the 1993 Rules for the Manufacture, Testing and Certification ofMaterials published by Lloyds Register of Shipping (formerly Part 2 ofthe Rules for Ships), clad plates are listed as optional materials for theconstruction of cargo or storage tanks for chemicals. Approved

154 Clad Product Applications Chapter 8


manufacturing processes are roll-bonding and explosive cladding. Thebacking steel should be carbon or carbon manganese steel clad withaustenitic steels type UNS S30403, S30453, S31603, S31653, S31703,S31753, S32100, S34700, S31254 or N08904.

With the development of duplex stainless steels over the last twentyyears, there has been a strong shift toward their use for chemicaltankers instead of clad plate (Leffler, 1991) (Hilkes, et. al., 1991).

Cladding Technology in Metal Purification

High pressure acid leaching of metal ores such as gold, nickel, andcopper in hydrometallurgy extraction methods requires autoclavesresistant to concentrated acids and metal ions. Titanium andzirconium explosively clad autoclaves are very cost effective comparedto solid where the wall thickness is often around 100 mm (4 inch).There are examples in service for more than 25 years (Banker andForrest, 1996).

A primary metal manufacturer has used zirconium clad plates for arotary kiln (1.2 meters (48 inch) diameter and 12 meters (40 foot)long) for manufacturing zirconium oxide from zirconyl sulfate. Thekiln is lined with bricks on top of the zirconium cladding. Thezirconium surface is exposed to sulfuric acid and sulfates and cyclingtemperatures up to 200C (390F). No major problems have beenreported in over 17 years of service.

Cladding Technology in the Power Industry

Flow accelerated corrosion (FAC) is an erosion-corrosion mechanismthat occurs in high purity steam/condensate lines.

FAC in nuclear power plants primarily affects carbon steel extractionsteam lines, heater drains, and feed water piping. The plant waterchemistry and other factors destabilize the normally protective ironoxide (magnetite) layer, leading to the continuous FAC of theunderlying carbon steel with significant loss of wall thickness. This


Chapter

9CLAD PIPE PROJECTS

The oil and gas industry has made the most extensive use of clad pipeof any industrial sector. The clad pipe is most often selected for theflowlines, i.e. the pipe carrying the untreated produced fluids from thewellhead to the treatment facilities.

An overview of the types of clad pipe products and the materialsselected was given in Chapter 8 (Line Pipe and Manifolds). Thepresent chapter describes some individual projects or experiences ofparticular operators with clad pipe installations. The aim is tohighlight key issues for selecting a particular pipe material, e.g., thenature of the cladding, the way in which the pipe was welded or laid,and any operating experience to guide future potential users.

The projects are described in alphabetical order of the operatingcompany with the year of installation.

ADMA OPCO - Um-Shaif - 1993

This project, engineered by Bechtel in 1993, involved installing a204 meters (670 foot), 323 mm (12 inch) diameter flowline from afixed unmanned platform and tying it in to an existing 762 mm(30 inch) diameter pipeline made of carbon steel (protected byinhibitor injection). The flowline was to carry gas with 6% CO2 and0.06% H2S; the design temperature was 93C (200F), and the design

pressure 93.1 bar (1350 psi).

168 Clad Pipe Projects Chapter 9


UNS N06625 cladding material was selected because commissioningconditions would require seawater to be present in the line, afterhydrotesting, for at least six months. The 323.9 mm (12 inch)diameter, 7.1 mm (0.28 inch) wall thickness pipe with 3 mm(0.12 inch) of cladding was supplied from Kubota and 10 bends ofradius 3DR were made by high frequency induction bending by DHF.Difficulties with casting UNS N06625 at that time resulted in pipeshaving to be cut short so that most 12 meter lengths contained anumber of girth welds.

Agip UK - Thelma and South East Thelma - 1995

Thelma and South East Thelma are located in the North Sea in theT-Block, approximately 12 km (7.5 miles) South-East of the Tiffanyprocess platform. The fields have a sub-sea production template andmanifold connected to the Tiffany platform by a 273 mm (10 inch)production flowline and a 168 mm (6 inch) production or welltesting flowline. A 114.3 mm (4 inch) service flowline links theThelma field to the Toni water injection template for fluid disposalwhen required.

The wellhead design temperature is 110C (230F), design pressure is290 bar (4200 psi), operating pressure between 48.3 bar (700 psi) and276 bar (4000 psi), the formation water pH is between 5.1 and 5.6,formation water TDS about 95,000 ppm, of which about 57,000 ppmare chlorides. Maximum CO2 content is 15.5%, and H2S is 500 ppm in

the oil phase (0.1 bar (1.5 psi) partial pressure) in one well and100 ppm in the remaining 4 wells, bringing the average content to170 ppm.

Duplex stainless steel was originally selected for all the pipelines etc.,handling untreated fluids (Calvarano, et. al., 1995) as it wasconsidered suitable for normal operating conditions. Duringshutdown, when the design pressure is reached, the H2S partial

pressure would rise beyond the normally accepted values for safeexposure of duplex stainless steels. Fortuitously, this situation seldomoccurs and is of limited duration because of cooling of the flowlinesafter shutdown. Selection of duplex stainless steel would, however,

Chapter 9 Clad Pipe Projects 183


The original piping in the plant was centricast 13% Cr but the gradualdrop in pressure of the field necessitated an increase in the pipediameter and 13% Cr piping was not available in 762 mm (30 inch)diameter required. Hence clad pipe was selected. The installation of762 mm (30 inch) OD clad piping was cost effective since it meant thatthere was no need to install compressor stations in the manifold tocarry the gas to the treatment units (Akabane, 1994).

This field development consists of 4 well clusters each with twoheaders requiring a total of 10.2 km (6.3 miles) of 762 mm (30 inch)diameter, 12.7 mm (0.5 inch) wall thickness (API 5L X60) with 2 mm(0.08 inch) UNS N08825 cladding pipe and some 219 mm (8 inch)diameter clad pipe (Figure 9.6). The pipes were supplied by JSW aswere 64 tees (762 x 219 mm, 30 x 8 inch). The clad lines collect gasand condensate which are then dehydrated.

The gas is compressed to an LNG plant 20 miles away through a1066.8 mm (42 inch) pipeline and the condensates are transported in a406 mm (16 inch) line (Figure 9.7).

The backing steel for the clad pipe was not specified to be SWCresistant, but the welds were limited to 250 HV maximum hardnesssince the conditions are judged to be slightly sour. All the pipe endswere bevelled by the manufacturer (JSW) and supplied with endprotectors. Considerable planning went into the design of the clusterlayout to suit joint lengths so that only 44 field cuts and bevels wererequired out of about 1,000 joint lengths supplied. The average timeper cut and bevel was 6.5 hours.

Some solid UNS N08825 flanges and 114.3 mm (4 inch) and60.3 mm (2 inch) weld-o-lets were also used in the project.


Appendix

1ABBREVIATED TERMS

AAI Arco Alaska Inc.AISI American Iron and Steel InstituteANSI American National Standards InstituteAPI American Petroleum InstituteASME American Society of Mechanical EngineersASTM American Society for Testing and MaterialsBS British StandardCII Lined pipe product produced by NSCCITHP Closed in tubing head pressureCLI Creusot Loire IndustrieCPT Critical pitting temperatureCRA Corrosion-resistant alloyCRC CRC-Evans Automatic WeldingCTOD Crack tip opening displacementDHF Dai-Ichi High FrequencyDIN Deutsche Institut fr NormungDR Radius of bend expressed as multiple of pipe diameterDWTT Drop weight tear testEFC European Federation of CorrosionENP Electroless nickel platingESW Electroslag weldingFAC Flow accelerated corrosionFCAW Flux cored arc weldingFGD Flue Gas DesulphurisationGMAW Gas metal arc weldingGTAW Gas tungsten arc weldingHAZ Heat-Affected ZoneHIP Hot isostatic pressing

218 Abbreviated Terms Appendix 1


HSLA High strength low alloyID Internal diameterJSW Japan Steel WorksLIDB Liquid interface diffusion bondingLNG Liquefied natural gasNACE National Association of Corrosion Engineers

(now NACE International)NAM Nederlandse Aardolie MaatschappijNDE Non-destructive examinationNKK NKK CorporationNSC Nippon Steel CorporationOCTG Oil Country Tubular GoodsOD Outside diameterOOR Out-of-roundnessPASSO Processo Arcos Saipem Saldatura OrbitalePGMAW Pulsed gas metal arc weldingPGTAW Pulsed gas tungsten arc weldingPQR Procedure Qualification RecordPTA Pure Terephthalic AcidPWHT Post welding heat treatmentPWR Pressurised Water ReactorQT Quenched and temperedRT Radiographic testingSAW Submerged arc weldingSCC Stress corrosion crackingSDH Side drilled holeSMAW Shielded metal arc weldingSMYS Specified minimum yield strengthSSC Sulfide stress corrosion crackingSSCV Semi-submersible crane vesselSWC Stepwise crackingTDS Total dissolved solidsTMCP Thermo-mechanical control processUNS Unified Numbering SystemUO U-ing, O-ing, (pipe forming)UOE U-ing, O-ing, Expansion, (pipe forming)UT Ultrasonic testingV-A Voest-Alpine


Appendix

2HARDNESS CONVERSION NUMBERS



APPROXIMATE HARDNESS CONVERSION NUMBERS FOR NONAUSTENITIC STEELSa, b

Rockwell C Brinell Rockwell A Rockwell Superficial Hardness Approximate150 kgf 3000 kgf Knoop 60 kgf 15 kgf 30 kgf 45 kgf TensileDiamond Vickers 10 mm ball 500 gf Diamond Diamond Diamond Diamond StrengthHRC HV HB HK HRA HR15N HR30N HR45N ksi (MPa)68 940 --- 920 85.6 93.2 84.4 75.4 ---67 900 --- 895 85.0 92.9 83.6 74.2 ---66 865 --- 870 84.5 92.5 82.8 73.3 ---65 832 739d 846 83.9 92.2 81.9 72.0 ---64 800 722d 822 83.4 91.8 81.1 71.0 ---63 772 706d 799 82.8 91.4 80.1 69.9 ---62 746 688d 776 82.3 91.1 79.3 68.8 ---61 720 670d 754 81.8 90.7 78.4 67.7 ---60 697 654d 732 81.2 90.2 77.5 66.6 ---59 674 634d 710 80.7 89.8 76.6 65.5 351 (2420)58 653 615 690 80.1 89.3 75.7 64.3 338 (2330)57 633 595 670 79.6 88.9 74.8 63.2 325 (2240)56 613 577 650 79.0 88.3 73.9 62.0 313 (2160)55 595 560 630 78.5 87.9 73.0 60.9 301 (2070)54 577 543 612 78.0 87.4 72.0 59.8 292 (2010)53 560 525 594 77.4 86.9 71.2 58.6 283 (1950)52 544 512 576 76.8 86.4 70.2 57.4 273 (1880)51 528 496 558 76.3 85.9 69.4 56.1 264 (1820)50 513 482 542 75.9 85.5 68.5 55.0 255 (1760)49 498 468 526 75.2 85.0 67.6 53.8 246 (1700)48 484 455 510 74.7 84.5 66.7 52.5 238 (1640)47 471 442 495 74.1 83.9 65.8 51.4 229 (1580)



APPROXIMATE HARDNESS CONVERSION NUMBERS FOR NONAUSTENITIC STEELSa, b (Continued)Rockwell C Brinell Rockwell A Rockwell Superficial Hardness Approximate150 kgf 3000 kgf Knoop 60 kgf 15 kgf 30 kgf 45 kgf TensileDiamond Vickers 10 mm ball 500 gf Diamond Diamond Diamond Diamond StrengthHRC HV HB HK HRA HR15N HR30N HR45N ksi (MPa)46 458 432 480 73.6 83.5 64.8 50.3 221 (1520)45 446 421 466 73.1 83.0 64.0 49.0 215 (1480)44 434 409 452 72.5 82.5 63.1 47.8 208 (1430)43 423 400 438 72.0 82.0 62.2 46.7 201 (1390)42 412 390 426 71.5 81.5 61.3 45.5 194 (1340)41 402 381 414 70.9 80.9 60.4 44.3 188 (1300)40 392 371 402 70.4 80.4 59.5 43.1 182 (1250)39 382 362 391 69.9 79.9 58.6 41.9 177 (1220)38 372 353 380 69.4 79.4 57.7 40.8 171 (1180)37 363 344 370 68.9 78.8 56.8 39.6 166 (1140)36 354 336 360 68.4 78.3 55.9 38.4 161 (1110)35 345 327 351 67.9 77.7 55.0 37.2 156 (1080)34 336 319 342 67.4 77.2 54.2 36.1 152 (1050)33 327 311 334 66.8 76.6 53.3 34.9 149 (1030)32 318 301 326 66.3 76.1 52.1 33.7 146 (1010)31 310 294 318 65.8 75.6 51.3 32.5 141 (970)30 302 286 311 65.3 75.0 50.4 31.3 138 (950)29 294 279 304 64.6 74.5 49.5 30.1 135 (930)28 286 271 297 64.3 73.9 48.6 28.9 131 (900)27 279 264 290 63.8 73.3 47.7 27.8 128 (880)26 272 258 284 63.3 72.8 46.8 26.7 125 (860)25 266 253 278 62.8 72.2 45.9 25.5 123 (850)24 260 247 272 62.4 71.6 45.0 24.3 119 (820)


Appendix

3UNIT CONVERSIONS



METRIC CONVERSION FACTORSTo Convert From To Multiply By To Convert From To Multiply ByAngle Mass per unit timedegree rad 1.745 329 E -02 lb/h kg/s 1.259 979 E - 04Area lb/min kg/s 7.559 873 E - 03in.2 mm2 6.451 600 E + 02 lb/s kg/s 4.535 924 E - 01in.2 cm2 6.451 600 E + 00 Mass per unit volume (includes density)in.2 m2 6.451 600 E - 04 g/cm3 kg/m3 1.000 000 E + 03ft2 m2 9.290 304 E - 02 lb/ft3 g/cm3 1.601 846 E - 02Bending moment or torque lb/ft3 kg/m3 1.601 846 E + 01lbf - in. N - m 1.129 848 E - 01 lb/in.3 g/cm3 2.767 990 E + 01lbf - ft N - m 1.355 818 E + 00 lb/in.3 kg/m3 2.767 990 E + 04kgf - m N - m 9.806 650 E + 00 Powerozf - in. N - m 7.061 552 E - 03 Btu/s kW 1.055 056 E + 00Bending moment or torque per unit length Btu/min kW 1.758 426 E - 02lbf - in./in. N - m/m 4.448 222 E + 00 Btu/h W 2.928 751 E - 01lbf - ft/in. N - m/m 5.337 866 E + 01 erg/s W 1.000 000 E - 07Corrosion rate ft - lbf/s W 1.355 818 E + 00mils/yr mm/yr 2.540 000 E - 02 ft - lbf/min W 2.259 697 E - 02mils/yr /yr 2.540 000 E + 01 ft - lbf/h W 3.766 161 E - 04Current density hp (550 ft - lbf/s) kW 7.456 999 E - 01A/in.2 A/cm2 1.550 003 E - 01 hp (electric) kW 7.460 000 E - 01A/in.2 A/mm2 1.550 003 E - 03 Power densityA/ft2 A/m2 1.076 400 E + 01 W/in.2 W/m2 1.550 003 E + 03



THE GREEK ALPHABET, - Alpha , - Iota , - Rho, - Beta , - Kappa , - Sigma

, - Gamma , - Lambda , - Tau, - Delta , - Mu , - Upsilon

, - Epsilon , - Nu , - Phi, - Zeta , - Xi , - Chi, - Eta , - Omicron , - Psi

, - Theta , pi - Pi , - Omega


Appendix

4PIPE DIMENSIONS



DIMENSIONS OF WELDED AND SEAMLESS PIPEaNominal Outside Nominal Wall Thickness (in.)Pipe Size Diameter Schedule Schedule Schedule Schedule Schedule Schedule Schedule

(in.) (in.) 5S 10S 10 20 30 Standard 401/8 0.405 --- 0.049 --- --- --- 0.068 0.0681/4 0.540 --- 0.065 --- --- --- 0.088 0.0883/8 0.675 --- 0.065 --- --- --- 0.091 0.0911/2 0.840 0.065 0.083 --- --- --- 0.109 0.1093/4 1.050 0.065 0.083 --- --- --- 0.113 0.1131 1.315 0.065 0.109 --- --- --- 0.133 0.133

1 1/4 1.660 0.065 0.109 --- --- --- 0.140 0.1401 1/2 1.900 0.065 0.109 --- --- --- 0.145 0.1452 2.375 0.065 0.109 --- --- --- 0.154 0.154

2 1/2 2.875 0.083 0.120 --- --- --- 0.203 0.2033 3.5 0.083 0.120 --- --- --- 0.216 0.216

3 1/2 4.0 0.083 0.120 --- --- --- 0.226 0.2264 4.5 0.083 0.120 --- --- --- 0.237 0.2375 5.563 0.109 0.134 --- --- --- 0.258 0.2586 6.625 0.109 0.134 --- --- --- 0.280 0.2808 8.625 0.109 0.148 --- 0.250 0.277 0.322 0.32210 10.75 0.134 0.165 --- 0.250 0.307 0.365 0.36512 12.75 0.156 0.180 --- 0.250 0.330 0.375 0.406

14 O.D. 14.0 0.156 0.188 0.250 0.312 0.375 0.375 0.43816 O.D. 16.0 0.165 0.188 0.250 0.312 0.375 0.375 0.50018 O.D. 18.0 0.165 0.188 0.250 0.312 0.438 0,375 0.56220 O.D. 20.0 0.188 0.218 0.250 0.375 0.500 0.375 0.59422 O.D. 22.0 0.188 0.218 0.250 0.375 0.500 0.375 ---



DIMENSIONS OF WELDED AND SEAMLESS PIPEa (Continued)Nominal Outside Nominal Wall Thickness (in.)Pipe Size Diameter Schedule Schedule Schedule Schedule Schedule Schedule Schedule

(in.) (in.) 5S 10S 10 20 30 Standard 4024 O.D. 24.0 0.218 0.250 0.250 0.375 0.562 0.375 0.68826 O.D. 26.0 --- --- 0.312 0.500 --- 0.375 ---28 O.D. 28.0 --- --- 0.312 0.500 0.625 0.375 ---30 O.D. 30.0 0.250 0.312 0.312 0.500 0.625 0.375 ---32 O.D. 32.0 --- --- 0.312 0.500 0.625 0.375 0.68834 O.D. 34.0 --- --- 0.312 0.500 0.625 0.375 0.68836 O.D. 36.0 --- --- 0.312 0.500 0.625 0.375 0.75042 O.D. 42.0 --- --- --- --- --- 0.375 ---

a. See next page for heavier wall thicknesses


Appendix

5BIBLIOGRAPHY

The following is an alphabetical list of sources consulted in preparingthis book.

Akabane, H. Mobil Arun Field Debottlenecking, 2nd InternationalSeminar on Clad Engineering, Houston, May 6th, 1994.

ANSI/ASME B16.9 Factory Made Wrought Steel Buttwelding Fittings.

ANSI/ASME B31.3 Process Piping.

API Specification for Corrosion Resistant Alloy Line Pipe (Spec. 5LC).

API Specification for CRA Clad or Lined Steel Pipe (Spec. 5LD).

API Specification for Line Pipe (Spec. 5L).

API 1104 Welding of Pipelines and Related Facilities.

ASME B31.3 Chemical Plant and Petroleum Refinery Piping.

ASME Section VIII Pressure Vessels.

ASTM A204 Specification for Pressure Vessel Plates, Alloy Steel,Molybdenum.

ASTM A262Practices for Detecting Susceptibility to IntergranularAttack in Austenitic Stainless Steels.

244 Bibliography Appendix 5


ASTM A263 Specification for Corrosion-Resisting Chromium Steel-Clad Plate, Sheet, and Strip.

ASTM A264 Specification for Stainless Chromium-Nickel Steel CladPlate, Sheet, and Strip.

ASTM A265 Standard Specification for Nickel and Nickel-Base AlloyClad Steel Plate.

ASTM A387 Specification for Pressure Vessel Plates, Alloy Steel,Chromium-Molybdenum.

ASTM A516 Standard Specification for Pressure Vessel Plates,Carbon Steel, for Moderate and Lower-Temperature Service.

ASTM A533 Standard Specification for Pressure Vessel Plates, AlloySteel, Quenched and Tempered, Manganese-Molybdenum andManganese-Molybdenum-Nickel.

ASTM A578 Standard Specification for Straight-Beam UltrasonicExamination of Plain and Clad Steel Plates for Special Applications.

ASTM G28 Test Methods of Detecting Susceptibility to IntergranularCorrosion in Wrought, Nickel-Rich, Chromium-Bearing Alloys.

ASTM G39 Practice for Preparation and Use of Bent-Beam Stress-Corrosion Test Specimens.

ASTM G48 Test Method for Pitting and Crevice Corrosion Resistanceof Stainless Steels and Related Alloys by Use of Ferric ChlorideSolution.

ASTM G146 Practice for Evaluation of Disbonding of BimetalicStainless Alloy/Steel Plate for use in High-Pressure, High-Temperature Refinery Hydrogen Service.

Avery, R.E. and Schillmoller, C.M. Development of Mechanized FieldGirth Welding of High Alloy Corrosion Resistant Pipeline Materials,NiDI Technical series N 10061, 1991.

Appendix 5 Bibliography 245


Banker, J.G. Commercial Applications of Zirconium Explosion Clad,Journal of Testing and Evaluation, ASTM, Mar. 1996.

Banker, J.G. Try Explosion Clad Steel for Corrosion Protection,Chemical Engineering Progress, July 1996.

Banker, J.G. and Cayard, M. Evaluation of Stainless SteelsExplosion Clad for High Temperature, High Pressure HydrogenService, Materials Property Council Conference on Hydrogen Effectson Materials for Refinery Applications, Wien, Oct. 1994.

Banker, J.G. and Forrest, A.L. Titanium/Steel Explosion BondedClad for Autoclaves and Reactors, MMS Annual Meeting, TMS,Warrendale PA., Feb. 1996.

Belloni, A. et al. Large Diameter Clad Pipes, Production, Weldingand Offshore Laying Experience, 11th International Conference onOffshore Mechanics and Arctic Engineering, OMAE/92, Calgary, June1992, Vol. 5, p. 383.

Belloni, A. ONGC - BE Project, 2nd International Seminar on CladEngineering, Houston, May 6th, 1994.

Belloni, A. Welding Clad Pipes in CRA Materials RecentExperience, Stainless Steel World, Jan./Feb. 1996.

Belloni, A. Full GMAW Proved for CRA Pipeline Welding, Duplex'97, Maastricht, Oct. 1997.

Belloni, A. and Celant, M. Development of an Advanced System toWeld Corrosion Resistant Alloys and Clad Pipes, 12th InternationalConference on Offshore Mechanics and Arctic Engineering,OMAE/'93, Glasgow, July 1993.

Belloni, A., Dall'Aglio, D., Celant, M. and Tsuji, M. Large DiameterClad Pipes: Production, Welding and Offshore Laying Experience,11th International Conference on Offshore Mechanics and ArcticEngineering, OMAE/92, Calgary, June 7-12th, 1992, Vol. 5, p.383.

246 Bibliography Appendix 5


Breinan, E.M., Kear, B.H. and Banas, C.M. Physics Today, November1976, Vol. 44, Issue 23.

BS 1501, Steels for Fired and Unfired Pressure Vessels: Plates,British Standards Institute.

BS 4515, Process of Welding of Steel Pipelines on Land and Offshore,British Standards Institute.

BS 5500, Specification for Unfired Pressure Vessels, BritishStandards Institute.

Butler, P. et al., Welding the Maui A-B Pipeline, Welding Journal,Nov. 1993, pp. 31-38.

Calvarano, M., Fassina, P. and Ghielmetti, A. A Review of CostEffective Alternatives for Sealines in Marginal Field with CorrosiveFluids, OMC - Offshore Mediterranean Conference, 1995.

Chakravarti, B. and Dobis, J. Plant Maintenance Repairs UtilizingClad Piping Spools to Improve Reliability, Stainless Steel World,Jan./Feb. 1997, Vol. 9, Issue 1, p.39.

Clay, K. Use of Cladding Materials in the Power GenerationIndustry, Stainless Steel World, Oct. 1996, Vol. 8, Issue 8, p. 32-35.

Colwell, J.A., Martin, C.J. and Mack, R.D. Evaluation of Full ScaleSections of Bimetallic Tubing in Simulated ProductionEnvironments, Corrosion, 45 (5) 1989, p. 429.

Craig, B.D. Field Experience with Alloy Clad API Grade L-80Tubing, Materials Performance, 25 (6) 1986 p.48.

Craig, B.D., Corrosion Testing of Clad and Lined Bends, 2ndInternational Seminar on Clad Engineering, Houston, May 6th, 1994.

Currie, D.M. Yellowhammer Project, 2nd International Seminar onClad Engineering, Houston, May 6th, 1994.


Appendix

6LIST OF FIGURES

AND CONTRIBUTORS

Figure No. Contributor(s)

Front cover The Japan Steel Works Ltd. and Saipem S.p.AFigure 1.2 Creusot Loire IndustrieFigure 2.1 Voest-Alpine Stahl Linz GmbHFigure 2.2 Voest-Alpine Stahl Linz GmbHFigure 2.3 Voest-Alpine Stahl Linz GmbHFigure 2.4 The Japan Steel Works Ltd.Figure 2.5 The Japan Steel Works Ltd.Figure 2.6 The Japan Steel Works Ltd.Figure 2.7 The Japan Steel Works Ltd.Figure 2.8 Dynamic Materials CorporationFigure 2.9 Dynamic Materials CorporationFigure 2.10 NobelcladFigure 2.11 Dynamic Materials CorporationFigure 2.12 NobelcladFigure 2.13 NobelcladFigure 2.15 NiDIFigure 3.1 NKK CorporationFigure 3.2 The Japan Steel Works Ltd.Figure 3.3 Kubota CorporationFigure 3.4 Kubota CorporationFigure 3.5 Kubota CorporationFigure 3.6 Kubota CorporationFigure 3.7 Kubota CorporationFigure 3.8 NKK Corporation

254 List of Figures and Their Contributors Appendix 6


Figure 3.9 Wyman-Gordon Ltd.Figure 3.10 Wyman-Gordon Ltd.Figure 3.11 TubacexFigure 3.12 Nippon Steel CorporationFigure 3.13 H. Butting GmbH & Co. and UPLFigure 4.1 Dai-Ichi High Frequency Co. Ltd.Figure 4.2 Dai-Ichi High Frequency Co. Ltd.Figure 4.3 Kubota CorporationFigure 5.1 Not requiredFigure 5.2 TecphyFigure 5.3 TecphyFigure 5.4 Kubota CorporationFigure 5.5 Coprosider S.p.AFigure 5.6 Coprosider S.p.AFigure 5.7 Coprosider S.p.AFigure 5.8 Coprosider S.p.AFigure 5.9 Coprosider S.p.AFigure 5.10 Coprosider S.p.AFigure 5.11 Coprosider S.p.AFigure 5.12 Kubota CorporationFigure 5.13 Scomark Engineering Ltd.Figure 5.14 Dynamic Materials CorporationFigure 5.15 Scomark Engineering Ltd.Figure 5.16 ABB Vetco Grey UK Ltd.Figure 5.17 Scomark Engineering Ltd.Figure 6.2 NKK CorporationFigure 7.1 The Japan Steel Works Ltd.Figure 7.2 The Japan Steel Works Ltd.Figure 7.3 NobelcladFigure 7.5 Kubota CorporationFigure 7.6 SaipemFigure 7.7 Allseas Engineering B.V.Figure 7.8 Coflexip Stena Offshore Ltd.Figure 7.9 Rockwater Ltd.Figure 8.1 Nippon Steel CorporationFigure 8.2 Forth Tool and Valve Ltd.Figure 8.3 Strachan and Henshaw Ltd. & Borsig Valves of BerlinFigure 8.4 Creusot-Loire IndustrieFigure 8.5 Soudometal and NEI International Combustion Ltd.

Appendix 6 List of Figures and Their Contributors 255


Figure 8.6 Verbundmetalle GmbHFigure 8.7 Head Robinson Engineering Ltd.Figure 8.8 NEI International Combustion Ltd.Figure 8.15 Scomark Engineering Ltd.Figure 8.16 Kubota Corporation and Highland FabricatorsFigure 8.17 Kubota Corporation and Highland FabricatorsFigure 8.18 Klad Inc.Figure 8.19 Creusot-Loire IndustrieFigure 8.20 NobelcladFigure 8.21 NobelcladFigure 8.22 NobelcladFigure 8.23 Klad Inc.Figure 8.24 VEAG KraftwerkFigure 8.25 W.H.D. Plant, Edenbridge Metals Ltd.Figure 8.26 NiDI and W.H.D. Plant, Edenbridge Metals Ltd.Figure 8.27 NiDI and W.H.D. Plant, Edenbridge Metals Ltd.Figure 8.28 W.H.D. Plant, Edenbridge Metals Ltd.Figure 9.1 Scomark Engineering Ltd.Figure 9.2 BP Exploration Operating Company Ltd.Figure 9.3 Rockwater Ltd. and UPLFigure 9.4 Rockwater Ltd.Figure 9.5 Rockwater Ltd.Figure 9.6 Mobil Oil Indonesia Inc.Figure 9.7 The Japan Steel Works Ltd.Figure 9.8 CRC- Evans Pipeline International, Inc.

CASTI Handbook of Cladding Technology - 2nd Edition

INDEXA

Absorber, 158-163

Allseas, 115-116

Aluminium, 164

ASTM A 262, 61, 87-88, 197, 199

ASTM G 48, 61, 87-89, 115, 180, 199, 212

Autoclaves, 88, 154

B

Batten, 97-98

Black Liquor, 165

C

Casting Factor, 40

Centrifugal Casting, 34, 38-40

Chimney, 158

Clad BendsManufacturing of Bends from Clad Pipe, 57-61Manufacturing of Bends from Lined Pipe, 50, 61-63

Clad FittingsClad Elbows, 70-73Clad Fittings Made by Weld Overlaying, 65-66Clad Fittings Made by Hot Isostatic Pressing, 66-69Clad Fittings Made from Clad Plate or Pipe, 69-70Clad Flanges and Valves, 78-80Clad Manifolds, 76-77Clad Reducers and Caps, 77-78Clad Tees, 73-75

258 Index


Clad PipesCentricast Clad Pipe, 38-43Definitions, 33-34Explosively Bonded Clad Pipe, 48-50Lined Pipe, 50-56

Explosively Lined Pipe, 55-56Hydraulically Lined Pipe, 53-55Thermo-Hydraulically Lined Pipe, 51-53

Longitudinally Welded Clad Pipe, 34-38Seamless Pipe Mill Clad Pipe, 43-48

Clad PlateBacking Steel Types, 10-11Explosive Bonding, 23-28Heat Treatment, 19-22Hot Roll Bonding, 9-10Inspection Requirements, 22-23Manufacturing Sequence, 11-16Optimising Bonding, 16-19Production Methods, 9Weld Overlaying, 29-32

Clad Product, ApplicationsCladding Technology in Air Pollution Systems, 157-162Cladding Technology in the Oil & Gas Industry, 123-124

Clad Production Tubing, 124-127Line Pipe and Manifolds, 135-142Valves, Pumps, and Joints, 127-129Vessels and Heat Exchangers, 129-135

Backing Steel, 134Cladding Alloy, 134-135

Cladding Technology in the Chemical Industry, 149-153Backing Steel, 150Cladding Alloy, 150-153

Cladding Technology in Chemical Tankers, 153Cladding Technology in Metal Purification, 154Cladding Technology in the Petrochemical Industry, 142-149

Applications, 142-146Backing Steel, 146Cladding Alloy, 147-148Disbonding on Hot Hydrogen, 148-149

Cladding Technology in the Power Industry, 154-157Cladding Technology in the Pulp and Paper Industry, 165Cladding Technology in Shipping Applications, 163-164

Index 259


Clad Products, Specification Requirements ofBacking Steel, 83Backing Steel Requirements for Application inH2S Containing Environments, 84-85

Cladding Alloy, 82-83Corrosion Tests, 87-89Demagnetising, 89-90Dimensions and Tolerances of Clad Pipe, 90-93

Cladding and Wall Thickness, 90-92Diameter and Out of Roundness, 92-93Ultrasonic Inspection, 93

Maximum Allowable Stress Values, 81-82Mechanical Tests, 86-87

Cladding ProjectsADMA OPCO - Um-Shaif - 1993, 167-168Agip UK - Thelma and South East Thelma - 1995, 168-169Arco Alaska Inc. - Prudhoe Bay - 1991, 170-171ARCO - Thames Bacton - 1987, 171-172Asamera Oil - Corridor - 1996, 172-173BP International Ltd. - Cyrus - 1995, 176-179BP International Ltd. - Ravenspurn to Cleeton - 1987, 173BP International Ltd. - Forties - 1987, 174BP International Ltd. - Miller - 1989, 174-175Chevron - Ninian - 1992, 180Clyde Petroleum - P2/P6 - 1997, 180-182Louisiana Land and Exploration - Lost Cabin - 1991, 182Mobil - Arun Booster Gas Compression - 1993, 182-187Mobil - South Lho Sukon - 1996, 188Mobil - Mobil 823 - 1995, 188-189Mobil - Yellowhammer - 1994, 189-190Mobil - 869 Field - 1995, 190-192Mobil - Ras Laffan Lng Co. Ltd. North Field - 1998, 192Nederlandse Aardolie Maatschappij, NAM -

Early Field Trails - 1974-1980, 192-193Nederlandse Aardolie Maatschappij, NAM -

Roswinkel, Zuidlaren - 1978, 193-194Nederlandse Aardolie Maatschappij, NAM -

Emmen - 1987-1989, 194-196Nederlandse Aardolie Maatschappij, NAM -

Twente, Schoonebeek - 1988, 196Nederlandse Aardolie Maatschappij, NAM -

Dalen 6 And Dalen 9 - 1988, 196-197Nederlandse Aardolie Maatschappij, NAM -

Grijpskerk - 1996, 197

260 Index


Cladding Projects (Continued)ONGC - South Bassein - 1988 and 1993, 198-204Shell Offshore - Fairway - 1991, 204-208Shell Todd Oil Services - Maui 'B' To'a' - 1991, 208-214

Pipe Production, 209-210Laying the Line, 210-211Welding, 211-213Inspection, 214

Statoil - sgaard - 1997, 214Texaco - Erskine - 1997, 215Total Oil Marine - Bruce - 1991, 216

Cladding TechnologyDimensions of Clad Products, 3Economics of Clad Technology, 4-5Materials Selection Options for Corrosive Service, 1-2Optimising the Corrosion Properties, 6Using Cladding Technology to Best Advantage, 7-8

Copper, 1-2, 28, 33, 37, 60, 97, 98, 116, 147, 150, 154, 181

Corrosion Inhibitors, 123, 129, 188, 194, 215

Corrosion Resistant Alloys (CRA), 1, 4, 6, 9, 33-35, 38, 40, 43-46, 48,51, 53-55, 66, 78, 81, 84-85, 91, 100-101, 104, 111, 112-114, 116,124-126, 131, 144, 149, 197

Corrosion Resistance, 6, 13, 17, 19-20, 32, 35-36, 47, 51, 54, 61-63,82-83, 89, 95-97, 100-104, 129, 145, 147, 150, 152, 160, 164, 169, 173,175, 178, 202, 215

Corrosion Tests, 19-20, 22, 70, 87-89, 110, 115, 197, 200, 202-203, 212Intergranular Corrosion Tests, 87-88Pitting Corrosion Tests, 87Stress Corrosion Test, 88

Crack Tip Opening Displacement (CTOD), 21, 115

Crevice Corrosion, 114, 163-164, 181, 197

Critical Pitting Temperature (CPT), 19, 21, 127, 162, 180

Index 261


D

Digester, 165

Drop Weight Tear Test (DWTT), 21, 83, 198

Duplex Stainless Steel, 20, 28, 54, 110-111, 125, 153, 154, 165, 168-169, 173, 176, 181, 197

E

Extrusion, 43-46, 75, 90, 180, 206

F

Flux Cored Arc Welding (FCAW), see Welding Processes

G

Gas Tungsten Arc Welding (GTAW), see Welding Processes

H

Hastelloy, 18, 150

Heat Exchanger, 123, 129, 131-135, 143, 146-147, 151-152, 156,204-205

Hot Hydrogen, 87, 146, 148-149

Hot Isostatic Pressing (HIP), 65, 66-69, 75, 77-78, 189

Hydrogen Disbonding, 87, 127

Hydrometallurgy, 154

I

Inconel, 150, 193

262 Index


J

Japan Steel Works (JSW), 171, 173-174, 183, 185, 188, 192, 200,209-211, 216

JointAlignment, 185Design, Clad Vessels, 96-100J-Bevel, 178J-Preparation, 103Line, 12Misalignment, 102Types

Swivel, 129Transition, 164Universal, 129

K

Kawasaki Heavy Industries (KHI), 124, 193

Kiln, 154

L

Liners, see also Clad PipesAPI 5LD, 33Bends, 61-63, 207Buckling, 51, 61, 63, 207Collapse, 50-51Fatigue, 119-120Incomplete Penetration, 190Inconel 82, 192Inspection, 56, 205Repairs, 112-113, 208Seal Welding, 55, 169, 190-191, 193Tube Liner, 163UNS N08825, 54, 169, 190-191, 214UNS S31600, 193-194Weld Preparation, 104

Liquation Cracking, see Welding Processes, GTAW

Index 263


Liquid Interface Diffusion Bonding (LIDB), 13, 17, 45-46

Liquefied Natural Gas (LNG), 164, 183, 192

Lloyds Register of Shipping, 153

M

Magnetic, 23, 89, 105, 110, 115, 193, 213

Magnetic Particle, 40, 59

Mooring Buoys, 129

N

NACE TM0177, 87-88, 199

Nippon Steel Corporation (NSC), 21, 118, 170, 182, 189, 191, 193, 205

NKK Corporation, 198, 206

Nuclear Plant, 156

O

Oxidation, 12, 35, 106, 111, 158, 181, 186, 195, 197

P

Plug Mill, 43-44

Polythionic Acid, 147-148

Post Weld Heat Treatment (PWHT), 83, 175

Processo Arcos Saipem Saldatura Orbitale (PASSO), see WeldingProcesseses

264 Index


R

Radiographic Testing, 195, 213

Recrystallization, 20-21

Reel Laying, 118-119

Residual Magnetism, 89, 105, 110, 195, 199-200, 202, 213

Rockwater, 119, 169, 177-178

S

Saipem, 105, 113, 172, 192, 199-201

Sandwich, 12-14, 16, 19, 21-22

Scrubber, 100, 158, 161-162

Sensitisation, 62

Separator, 129-131, 145, 156-157

Shielded Metal Arc Welding (SMAW), see Welding Processes

Slurry, 158

Stress Corrosion Cracking (SCC), 62, 144-145, 147, 151-153Chloride Stress Corrosion Cracking (CSCC), 144, 148Stepwise Cracking (SWC), 84, 175Sulphide Stress Corrosion Cracking (SSCC), 84

Submerged Arc Welding (SAW), see Welding Processes

T

Tantalum, 28

Titanium, 1-2, 10, 28, 43, 96-99, 132, 135, 147-148, 150-154, 158,164-165

Index 265


TolerancesBacking Steel, 83Bends, 60-61

Bend Angle, 60Centricast Clad pipe, 40, 42, 174Clad pipe, 90-93, 208

Wall Thickness, 90-92, 197Diameter, 92Out-of-Roundness, 92-93, 186

Elbows, 61Explosively Lined Pipe, 55-56Fittings, 69Hydraulically Lined Pipe, 53Laying Clad Pipe, 119Out-of-Plane, 60

Tolerances (Continued)Ovality, 60Pipe

Ends, 209Fit-Up, 101-102, 104, 113

External Clamps, 182-183Internal Diameter, 170

Seamless Pipe, 44, 47Thermo-Hydraulically Lined Pipe, 51Wall Thickness, 60

Transition Joint, 164

Towing, 119, 179, 206

Tubeplate, 132-133, 156

U

Ultrasonic Testing (UT), 16, 37

V

Vapour Deposition, 127

266 Index


W

Wallpapering, 160-161

Welding Clad ProductsFabricating Clad Vessels, 95-100

Handling Clad Plate, 95-96Welding Clad Vessels, 96-100

Circumferential Welding of Clad Pipe, 100-112Handling Clad Pipe, 101Pipe end Dimensions/Fit-up, 101-102Weld Preparation, 102-105Demagnetising of Pipes, 105-106Back Shielding, 106-107Choice of Welding Process, 107-108Choice of Filler Metal, 108-111Control of Heat Input, 111Weld Integrity Assessment, 111-112

Welding Repairs During Pipelaying, 112-113Developments in Clad Pipe Welding Technology, 113-116Laying Clad Pipe, 116-120Commissioning Clad Pipelines, 120-121

Welding ProcessesFlux Cored Arc Welding (FCAW), 107Gas Metal Arc Welding (GMAW), 29, 105, 107, 181, 190, 199, 201,206

Clad Fittings, 66Clad Valve, 79Fit-Up, 102Overlay, 140-141PGMAW, 107, 111, 113, 189, 206Power Plant Applications, 156Plug Welds, 161Repairs, 116Root Pass, 114-115, 172, 186, 201, 211-212Welding Speed, 113-114

Gas Tungsten Arc Welding (GTAW), 6, 29, 35, 107-108, 178, 187,192

Alloy 625, 170, 189, 191, 194Autogeneous, 208Back Shielding, 106-107Clad Fitting, 66Centricast Clad Pipe, 108Demagnetising of Pipes, 105-106

Index 267


Welding ProcessesGas Tungsten Arc Welding (GTAW) (Continued)

Heat Input, 107, 111-112J-Laying, 105Liner Pipe, 51,53Liquation Cracking, 132Machines, 186

Settings, 186Overlay, 128, 133, 198, 209Pipe Fit-Up, 101-102PGTAW, 186, 189, 201, 206Power Plant Application, 156Repair Welding, 112-113, 198Root Pass, 186-187, 190, 199, 211-212Welding Technology, 113-116

Processo Arcos Saipem Saldatura Orbitale (PASSO), 181, 199-201Shielded Metal Arc Welding (SMAW), 29, 66, 105, 107, 112, 172,178, 187, 191, 202-203Submerged Arc Welding (SAW), 35, 156, 189, 198, 206

Z

Zirconium, 2, 12, 28, 98, 148, 151-152, 154

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