Document No.

Applicability Date

GIS 36-107 Group 24 August 2006

Guidance on Industry Standard for Integral Cladding, Weld Overlay, and Limited Loose Lining of Pressure Vessels and Components

GIS 36-107

BP GROUP
ENGINEERING TECHNICAL PRACTICES

24 August 2006 GIS 36-107 Guidance on Industry Standard for Integral Cladding, Weld Overlay, and Limited Loose Lining of Pressure Vessels and Components

Foreword
This revision of Engineering Technical Practice (ETP) BP GIS 36-107 consists of the addition of clause 5.5 to cover integral cladding with reactive metals including titanium and zirconium. This Guidance on Industry Standard (GIS) is based on parts of heritage documents from the merged BP companies as follows:

BP OUS
RP 7-1-4 Metal Lining and Cladding.

Amoco
A MM-GEN-00-G A MM-GEN-00-E PTA FE-VE-TI-P PTA FE-HE-TI-P PTA FE-VE-LINE-P Metallic MaterialsGeneralGuide. Metallic MaterialsGeneralSelection Specification. Fabricated EquipmentPressure VesselsTi CladProcurement Specification. Fabricated EquipmentHeat ExchangersTitanium Fixed Tubesheet Procurement Specification. Fabricated EquipmentPressure VesselsCorrosion Resistant Liners Procurement Specification.

Copyright 2006, BP Group. All rights reserved. The information contained in this document is subject to the terms and conditions of the agreement or contract under which the document was supplied to the recipients organization. None of the information contained in this document shall be disclosed outside the recipients own organization without the prior written permission of Director of Engineering, BP Group, unless the terms of such agreement or contract expressly allow.

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24 August 2006 GIS 36-107 Guidance on Industry Standard for Integral Cladding, Weld Overlay, and Limited Loose Lining of Pressure Vessels and Components

Table of Contents
Page Foreword ........................................................................................................................................ 2 1. 2. 3. 4. 5. Scope .................................................................................................................................... 4 Normative references............................................................................................................. 4 Terms and definitions............................................................................................................. 5 Symbols and abbreviations .................................................................................................... 5 General considerations .......................................................................................................... 6 5.1. General....................................................................................................................... 6 5.2. Materials ..................................................................................................................... 7 5.3. Corrosion barrier application process.......................................................................... 7 5.4. Integrally clad linings................................................................................................... 7 5.5. Integral cladding with reactive metals including titanium and zirconium ...................... 7 5.6. Loose or strip linings ................................................................................................... 9 5.7. Loose lining of nozzles................................................................................................ 9 5.8. Weld overlay process................................................................................................ 10 5.9. Weld overlay with Alloy 400 UNS N04400 (such as Monel) for hydrofluoric acid service ...................................................................................................................... 12 5.10. PWHT considerations ............................................................................................... 12 General design and fabrication ............................................................................................ 13 6.1. Fabrication details..................................................................................................... 13 6.2. Integrally clad equipment .......................................................................................... 13 6.3. Inspection ................................................................................................................. 13

6.

Bibliography .................................................................................................................................. 17

List of Tables
Table 1 Typical filler metal requirements for back cladding of clad plate and weld overlay of vessels and components ..................................................................................................... 10

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24 August 2006 GIS 36-107 Guidance on Industry Standard for Integral Cladding, Weld Overlay, and Limited Loose Lining of Pressure Vessels and Components

1.

Scope
This GIS contains requirements for providing a metallic barrier on equipment, such as but not limited to pressure vessels, exchangers, exchanger tubesheets, nozzles, valve bodies, subsea components, and other appropriate equipment. Typically, a high cost alloy barrier is applied over a low cost base metal, such as carbon or low alloy steels, as a low cost option to solid alloy construction. However, many combinations of barrier and base metals have been used to meet specific design needs. The barrier may be desired for numerous reasons, such as corrosion resistance, wear resistance, prevent product contamination (from corrosion products from a low alloy base metal), or make repairs to or improve existing assets. Alloy materials include ferritic stainless steel, austenitic stainless steel, nickel and cobalt base alloys, titanium, and zirconium. Integral cladding or weld overlay is preferred. However, loose lining is permitted for some applications, specifically nozzles, wear plates, and in-service repairs.

2.

Normative references
The following normative documents contain requirements that, through reference in this text, constitute requirements of this technical practice. For the purpose of this document, only information related to materials selection and application is intended for reference. For dated references, subsequent amendments to, or revisions of, any of these publications do not apply. Parties to agreements based on this technical practice are encouraged to investigate the possibility of applying the most recent editions of the normative documents indicated below. For undated references, the latest edition of the normative document referred to applies.

BP
GIS 36-103 GIS 43-316 GIS 46-010 GP 36-10 GP 46-01 GP 18-02 Guidance on Industry Standard for Positive Material Identification. Guidance on Industry Standard for the Manufacture of CRA Clad or Lined Steel Pipe. Guidance on Industry Standard for New Pressure Vessels. Guidance on Practice for Materials Selection. Guidance on Practice for New Pressure Vessels. Guidance on Practice for Storage and Control of Welding Consumables.

American Petroleum Institute (API)

API Spec 6A API Spec 17D Specification for Wellhead and Christmas Tree Equipment. Specification for Subsea Wellhead and Christmas Tree Equipment.

American Society of Mechanical Engineers (ASME)

ASME (BPVC) Section II ASME SA-264 ASME SA-578 Section V ASME SE-165 Boiler and Pressure Vessel Code Materials Specification for Stainless Chromium-Nickel Steel-Clad Plate, Sheet, and Strip. Specification for Straight-beam Ultrasonic Examination of Plain and Clad Steel Plates for Special Applications. Nondestructive Examination Standard Test Method for Liquid Penetrant Examination.

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24 August 2006 GIS 36-107 Guidance on Industry Standard for Integral Cladding, Weld Overlay, and Limited Loose Lining of Pressure Vessels and Components

Section VIII

Rules for Construction of Pressure Vessels, Divisions 1 and 2.

American Society for Testing and Materials (ASTM)

ASTM A380 ASTM B898 Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems. Specification for Reactive and Refractory Metal Clad Plate.

3.

Terms and definitions

For the purposes of this GIS, the following terms and definitions apply: Corrosion barrier General term used for adding a metallic layer onto a base metal to improve corrosion, erosion, or wear resistance, add hard facing, or to add base metal thickness to maintain mechanical thickness requirements or corrosion allowance. In most cases, the corrosion barrier is of higher alloy than the base metal. A metal barrier may also be added for hard facing, to prevent mechanical wear, such as on mixer, valve, pump shafts, and similar applications. Although this is not technically a corrosion barrier, as the two are identified separately in ASME Section IX, it is included in this category so it gets the same quality control requirements of corrosion barriers. Integral cladding Refers to metallic lining material that forms a metallurgical bond with the base metal during manufacture. This is typically accomplished using hot roll bonding or explosion bonding techniques. Weld overlaying Refers to the application of a metallic lining material using a weld deposition process that forms a metallic bond with the base metal. Typical processes include ESW, SAW, SMAW, GMAW, strip overlaying, and similar techniques. ESW overlaying or SAW strip overlaying techniques should be used for large surface areas whilst hot wire GTAW should be used for precision components. SAW wire or SMAW processes may be used for intermediate areas. The use of GMAW or FCAW processes shall be subject to BP approval. Loose lining Refers to the application of a metallic lining material that is not integrally bonded with the base metal. These lining are typically attached to the base metal by fillet welds and possibly some plug welds. Back cladding Term used for weld overlaying the exposed base metal at weld joints, such as circumferential and longitudinal seams and nozzles, of integrally clad equipment. The weld overlay provides the corrosion barrier over the base metal joints. Back cladding is typically not applicable for reactive metals, such as titanium, zirconium, and tantalum. Back cladding generally follows the same requirements as weld overlaying.

4.

Symbols and abbreviations

For the purpose of this GIS, the following symbols and abbreviations apply: AWS CRA American Welding Society corrosion resistant alloy
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24 August 2006 GIS 36-107 Guidance on Industry Standard for Integral Cladding, Weld Overlay, and Limited Loose Lining of Pressure Vessels and Components

ESW FCAW FN GMAW GTAW HAZ HRC PMI PWHT PT PTA SAW SCC SMAW TEMA UT

electro slag welding flux cored arc welding ferrite number gas metal arc welding gas tungsten arc welding heat affected zone hardness Rockwell C positive materials identification post weld heat treatment liquid dye penetrant testing purified terephthalic acid submerged arc welding stress corrosion cracking shielded metal arc welding Tubular Exchanger Manufactures Association ultrasonic testing

5.

General considerations
Integral clad plate and weld overlay are generally acceptable alternatives to solid alloy construction if they reduce the cost of equipment or provide other agreed upon benefits for the application.

5.1.

General a. In service environments with pitting as a probable damage mechanism for the selected material, the use of a corrosion barrier shall be approved by BP. In some pitting environments, such as the PTA process, localized pitting penetration rates can be quite rapid. This could lead to early and unexpected penetration of the corrosion barrier followed by rapid and large area damage of base metals with low corrosion resistance. CRA cladding with near immunity to pitting or solid alloy construction is preferred. Solid alloy generally allows for full wall penetration without affecting mechanical integrity. Thus, detectability and repair are more probable before a leak occurs. b. c. d. The corrosion barrier thickness shall not be considered in pressure boundary calculations unless approved by BP. For clad pipeline applications, refer to GIS 43-316. Any deviation from this GIS shall be approved by a BP materials specialist.

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24 August 2006 GIS 36-107 Guidance on Industry Standard for Integral Cladding, Weld Overlay, and Limited Loose Lining of Pressure Vessels and Components

5.2.

Materials a. b. c. d. The base metal and corrosion barrier material shall be specified by BP. Suggestions for use of alternative materials are encouraged, but alternative materials shall be approved by BP. Base metal and cladding materials shall meet GP 36-10. Integral cladding, loose linings, and weld overlay and back cladding consumables shall meet Codes and Standards, such as ASME, ASTM, AWS, or appropriate international specifications.

5.3.

Corrosion barrier application process a. b. Weld overlay, roll cladding, and explosion bonding are acceptable unless specifically restricted by BP. Loose linings are acceptable for only limited applications that shall be approved by BP. Fabrication details for loose linings shall be approved by BP. The main concerns with loose liners are fillet weld quality that allows leakage behind the lining. In some cases, these leaks may not be overly corrosive to the base metal. However, the process fluid can create flammable hazard and/or environment hazards for workers during downtimes and cause contamination of repairs. c. Loose liners, such as for nozzles, that accumulate greater than 5% strain during forming shall be reheat treated, after forming and before welding into the nozzle, per the materials original specification, unless waived by BP. High forming strains can make a material, such as 300 series stainless steel, susceptible to SCC in some environments. However, many materials, such as titanium and zirconium, do not become susceptible to SCC in most of their intended environments. Linings are formed and welded prior to installing into nozzles. Thus, heat treating is easily accomplished.

5.4.

Integrally clad linings a. b. The minimum integral cladding thickness shall be 3 mm (0,125 in), unless otherwise specified or approved by BP. Bond strength testing is required for roll or explosion bonded plates except as approved by BP. The bond strength between cladding and base metal shall be the minimum specified in ASME specifications for the appropriate material combinations. Materials combinations that are not covered by a specific ASME specification shall meet the mechanical, bond strength, and other appropriate requirements of ASME SA-264 or a similar ASME specification agreed upon or specified by BP. Some materials do not have specific ASME specifications that govern cladding quality. In those cases, pertinent requirements, such as bond strength and inspection, in ASME SA-264 can be used. d. e. Back cladding shall follow the guidelines for the weld overlay process. In some cases, weld overlaying of nozzles is impractical and loose linings are preferred. Refer to sub-clause 5.7 for specific requirements for use of loose linings in nozzles.

c.

5.5.

Integral cladding with reactive metals including titanium and zirconium Integral cladding with reactive metals, such as titanium and zirconium, is most widely accomplished by explosion bonding typically based on the Detaclad process originally developed by Dupont. Many companies now offer this product but are at various stages of technical capability, especially with large size plates. A few
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24 August 2006 GIS 36-107 Guidance on Industry Standard for Integral Cladding, Weld Overlay, and Limited Loose Lining of Pressure Vessels and Components

companies now offer roll clad titanium on carbon steel which has proved successful up to about 50 mm (2 in) base metal thickness. There are many special requirements for reactive metal clad plate compared to other material combinations and for fabricating these into vessels. Equipment design requirements are provided in GP 46-01 and GIS 46-010 and other appropriate ETPs. a. b. Approval of the clad plate supplier and cladding procedure shall be obtained from BP before start of fabrication. If carbon steel is the base metal, it shall conform to ASME SA-516 Gr 70 or a BP approved alternative specification. Other base metals, such as stainless steels, may be used if specified or approved by BP. Before cladding, the base plate to be used for cladding shall be UT tested per ASTM A578 and meet Level B. Cladding shall be commercially pure titanium conforming to ASME SB-265 Gr 1, unless otherwise specified or approved by BP. Thickness of cladding as bonded shall be 90% of nominal thickness specified on the data sheets or 2 mm (0,075 in), minimum, whichever is more. Requirements of ASTM B898 shall be met. 1. 2. UT examination of the clad plate shall meet Class B. Supplementary Requirement S1 Bond Shear Strength Testing is required. The sample/s shall be removed and tested after heat treatment of clad plate. The sample shall be taken from an edge or corner that represents a final area of bonding (area opposite the explosion bonding initiation site). For clad plate manufactures that have a proven record of supplying quality clad plate to BP, testing frequency shall be as described in S1. For new suppliers or manufacturers that have had problems providing consistently good quality clad plate, a test sample shall be taken from each plate manufactured. If clad plate is manufactured as rolled or bang and rolled plate, testing shall be in both directions of rolling. If the clad plate does not require heat treatment by the supplier, the supplier shall perform a simulated heat treatment of 2 hours at 565C 15C (1 050F 25F) and then test per ASTM B898. Note: waiver of testing every plate shall be approved by BP. This can be done by getting a prewaiver at time of bid or providing separate prices for meeting S1 requirement versus testing every clad plate. For the explosion bonding process, each plate shall be given a heat treatment at 607 C 14C for 1 hour, minimum, plus 15 minutes per 25 mm above 25 mm (1 125F 25F for 1 hour, minimum, plus 15 minutes per inch above one inch) of composite thickness in a gas-fired oxidizing atmosphere furnace. Removal of titanium surface oxide penetration shall be accomplished by means of sand blasting with virgin 100-180 Grit Silica 10, 99,756% Silica Dioxide, 0,020% iron oxide, or power buffing with a 120 Grit alumina Flap-Wheel. Use of multiple layers of cladding as allowed in ASTM B898 para 5.1.5 to achieve required cladding thickness is not acceptable for heads or shell courses unless approved by BP.

c. d. e. f.

3.

4.

g. h.

Heat treating shall be done in a gas-fired oxidizing atmosphere furnace. Heat treatment in furnaces employing other sources of fuel (e.g., gas oil) is prohibited without BP approval. Heat treatment after bonding is not required for titanium for the following two manufacturing techniques: 1. The explosion bonding process is performed in a vacuum chamber. Bonding in a vacuum chamber eliminates contamination between the titanium and base metal that occurs during open-air explosion bonding.
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24 August 2006 GIS 36-107 Guidance on Industry Standard for Integral Cladding, Weld Overlay, and Limited Loose Lining of Pressure Vessels and Components

2.

For roll bonding by an approved supplier. Roll cladding of titanium to carbon steel is a relatively new process. NKK is the only supplier approved for PTA process applications. New suppliers need to be qualified.

i.

Bang and roll manufacturing process is acceptable, but ASTM B898 requirements in sub-section 5.5e shall be met after rolling. Bang and roll is explosion bonding greater thicknesses of base plate and cladding material followed by rolling. This provides larger plate size than can be explosion bonded and, thus, reduces vessel fabrication costs.

j.

Subject to the above requirements and final approval by BP, roll clad plate is acceptable for shell courses or flange faces. The forming of heads and similar highly deformed components results in high stresses between the base metal and cladding. Roll bonded titanium plate has somewhat less shear strength than explosion bonded products. To minimize the potential for low shear strength at the base metal/cladding interface, roll clad products are not permitted at this time.

5.6.

Loose or strip linings a. Loose or strip linings shall only be used for repair of existing assets and approved applications for new construction. Applications shall be approved by BP. Loose or strip liners used in the new construction or repair of equipment shall consider the effect of process fluid breaching the loose liner or welds and being trapped between the liner and base metal. Some examples of services requiring this consideration are flammable hydrocarbons. b. c. Loose or strip lining designs shall be reviewed by BP before the start of work. Venting of the cavity between the lining and base metal to the outside of the vessel insulation shall be reviewed with a BP materials specialist. For loose lined nozzles, refer to clause 5.7 for specific requirements. Different processes have different considerations as to whether venting of the cavity is preferred. For example, linings used in corrosive chemical streams are typically vented to prevent rapid, widespread corrosion of underlying base metal if lining leaks occur. Refining operations generally prefer that no weep hole be used even for nozzles, especially in applications where H2 and/or H2S are present. Thus, each application for loose lining should be reviewed for the benefits of venting and then discussed with BP. d. Loose or strip linings shall not be used in the following applications, unless approved by BP: 1. 2. 3. 4. 5. Non-vented liners in hydrogen or hydrogen rich service. Vessels subject to PWHT unless special procedures for design and installation can be used. Vessels with design temperature greater than 371C (700F). Vessels that operate at negative pressure or, that cycle between positive and negative pressure. Vessels that are designated as Lethal Service per the ASME Code.

5.7.

Loose lining of nozzles For some applications loose lining of nozzles may be the preferred method of adding a metallic barrier. If loose lining is used, the following shall be required:

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24 August 2006 GIS 36-107 Guidance on Industry Standard for Integral Cladding, Weld Overlay, and Limited Loose Lining of Pressure Vessels and Components

For some applications, integral cladding or weld overlay of nozzles are not practical or cost effective. For example: nozzles may be too small to weld overlay or integrally clad; titanium and zirconium cannot be weld overlayed to other materials. Some of the high nickel alloys, such as the B alloys and alloy C276, are difficult to weld overlay onto carbon steel and maintain optimum corrosion resistance and/or ductility properties. As a result, loose linings often provide a better fabrication approach. a. b. c. The minimum thickness of the liner shall be 3 mm (0,125 in). For chemical plant applications, the cavity between the lining and base metal shall be vented to the outside of the vessel insulation, unless venting is specifically prohibited. If possible, the nozzle sleeve welds shall be air tested at 1,8 kg/cm2 (25 psig). The air pressure shall be applied between the outside diameter of the sleeve and inside diameter of the nozzle, i.e. the cavity. 1. 2. 5.8. If the equipment is PWHT, testing shall be after PWHT. Defects shall be repaired.

Weld overlay process a. b. The overlay thickness shall be a minimum of 4,5 mm (3/16 in) unless otherwise agreed by BP. A minimum of 3 mm (0,125 in) of the overlay top layer (process side) shall meet the chemistry of the specified wrought material, unless otherwise agreed by BP. This requirement does not apply to wellhead and Christmas tree components, refer to API Spec 6A and API Spec 17D. Note, if some of the overlay is removed, such as by machining for ring grooves, there still needs to be a minimum of 3 mm (0,125 in) of remaining overlay that meets the chemistry requirement. c. Unless otherwise agreed with BP, the consumables to be used for common corrosion barriers are shown in Table 1.

Table 1 Typical filler metal requirements for back cladding of clad plate and weld overlay of vessels and components
Cladding or weld overlay material AISI Type 405, 410S (clad material only) Filler metal Material 1, 2, 3 Stainless steel Alloy 625 (Inco 82) Alloy 625 (Inco A, Inco 82) AISI Type 304 or 304L AISI Type 316 or 316L AISI Type 317 or 317L AISI Type 321 or 347 Alloy 400 Alloy C276 Alloy C22 Alloy 600/625 AISI Type 308L AISI Type 316L AISI 317L AISI Type 309 Alloy 400 Alloy C276 Alloy C22 Alloy 600 Alloy 625 1st Pass consumable E/ER 309L ERNiCR-3 ERNiCRFe-2 ERNiCRFe-3 E/ER 309L or 308L E/ER 316L E/ER 317L E/ER 309 E/ERNi-1 ENiCrMo-4 ENiCrMo-10 ERNiCR-3 or ENiCRFe-2 ERNiCR-3 or E/ERNiCRMo-3 or ENiCRFe-2 2nd Pass consumable E/ER 309L ERNiCR-3 ERNiCRFe-2 ERNiCRFe-3 E/ER 308L E/ER 316L E/ER 317L E/ER 347 E/ERCu-7 ENiCrMo-4 ENiCrMo-10 ERNiCR-3 or ENiCRFe-2 E/ERNiCRMo-3

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24 August 2006 GIS 36-107 Guidance on Industry Standard for Integral Cladding, Weld Overlay, and Limited Loose Lining of Pressure Vessels and Components Cladding or weld overlay material Filler metal 1, 2, 3 Material 1 Pass consumable
st

nd

Pass consumable

Notes 1) For 300 series stainless steels, low carbon or stabilized weld consumables shall be used. Welding consumables that are subject to PWHT shall be selected to minimise sigma phase formation during the heat treatment. 2) For niobium (columbium) bearing grades (e.g., 347 and 309 Nb (Cb)), the niobium to carbon ratio of the deposited metal shall not exceed 16:1. 3) The initial layer may be deposited with a more highly alloyed welding consumable than that employed for the subsequent layer(s) in order to take into account dilution of the cladding by the base material.

d.

For pressure vessels and other components, weld overlay shall be a minimum of two layers unless approved by BP. This requirement does not apply to wellhead and Christmas tree components, refer to API Spec 6A and API Spec 17D. Certain welding techniques, such as SAW strip or ESW, may be capable of achieving the required overlay analysis in a single layer.

e.

Weld overlay, including back cladding and cladding repair, procedures shall be qualified in accordance with Section IX of the ASME Code, or approved alternative Code, including the following requirements: 1. 2. 3. Use the same P-number base material and type or brand of flux, weld wire, or electrode as that to be used in production welding. The thermal treatment used on the overlay qualification test plates shall be the same as that to be used in production. The PWHT temperature and time for the qualification test plate shall be the same as that to be used for production and with the addition of sufficient time to accommodate at least one repair with heat treatment for the purchaser. Once approved, no changes to the essential variables shall be made without prior approval of BP. The test welds shall be subject to 100% PT and 100% UT in accordance with ASME Section VIII Division 1. Anomalies, such as loss of back reflections indicating slag, lack of fusion, etc. shall be recorded and reported to BP. The achievement of the required weld overlay thickness shall be demonstrated. Chemical analysis shall be verified by drilling samples from three separated areas of the overlay. Drillings shall be to a minimum depth of 3 mm (0,125 in). The measurement of ferrite content shall be by an instrumental technique, such as a ferrite scope. Also, chemical analysis shall be used to calculate the ferrite content per the Schaeffler-DeLong diagram. The allowable range is as stated in 6.3.2.4 If there is a deviation of greater than 3 in the FN between the two techniques, results shall be reported to BP. Weld beads shall run circumferential around the vessel or nozzle type components. Weld beads may run longitudinally in nozzles with an inside diameter of 300 mm (12 in) or smaller and for pipe elbows if followed by blend grinding or GTAW wash pass where interfacing with the vessel or piping, respectively. The surface contour shall be relatively smooth. Adjacent weld beads shall fuse and blend to create a flat surface without any inter-bead anomalies, such as grooving, porosity, or slag retention. It is important that weld overlayed surfaces should be as smooth as possible to minimise the retention of process fluids, to minimize flow turbulence, to optimise

4. 5.

6. 7. 8.

f.

Weld beads of weld overlays shall be applied as follows: 1. 2.

3.

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24 August 2006 GIS 36-107 Guidance on Industry Standard for Integral Cladding, Weld Overlay, and Limited Loose Lining of Pressure Vessels and Components

time and accuracy of nondestrutive inspection, such as PT and UT, and to reduce the risk of interface anomalies acting as stress raisers for fatigue. g. Strip or multiple wire weld overlay techniques with minimum weld widths of 25 mm (1 in) shall be used unless other techniques are approved by BP. These techniques reduce the number of passes, significantly reducing the amount of interpass length in a vessel and are preferred to single wire techniques. The inter-pass area (HAZ in the previous pass caused by the current pass) often has reduced corrosion resistance because of thermal stability problems with alloy materials. Strip overlay reduces the number of weld passes: it also provides a very smooth uniform surface that improves internal inspection capability. h. The welding process shall not transfer alloying elements via the flux to achieve the specified weld metal composition. Flux shall not be re-used unless agreed by BP. Refer to GP 18-02 for additional guidelines. For some applications, used flux can be recirculated if the fabricator has an approved procedure. However, flux that has become slag cannot be reground and reused. i. 5.9. In some cases, weld overlaying of nozzles is impractical and loose linings are preferred. Refer to sub-clause 5.7 for specific requirements for use of loose linings in nozzles.

Weld overlay with Alloy 400 UNS N04400 (such as Monel) for hydrofluoric acid service a. b. c. The overlay chemistry shall have a maximum of 5% iron content in the top 1,5 mm (1/16 in) of the final deposit. Overlays deposited with a manual process shall have a minimum of three layers. ERNi-1 filler metal is required for the first pass when welding with GTAW or GMAW process. However, GMAW may be used only with BP approval. The GMAW process is limited because of its high heat input.

5.10.

PWHT considerations For equipment and components that require PWHT or stress relief, the following shall be required: a. b. c. For 300 series stainless steels, the corrosion barrier shall be L grade or stabilized grade. For 300 series stainless steel weld overlay or back cladding, the FN shall be limited to a maximum of 11. Welding consumables, such as austenitic stainless steel and nickel base alloys, for weld overlays and back cladding and repair of integral clad plates that are susceptible to thermal degradation during PWHT exposures, shall be selected to minimise sigma phase and other deterioration mechanisms during the heat treatment, unless restricted by Code or alternative is approved by BP. For materials, such as 300 series stainless steels and some nickel base alloys, that lose corrosion resistance when exposed to PWHT, PWHT shall be done after the first layer is applied, followed by the second layer and no additional PWHT. This is the preferred technique for multi-layer weld overlays since it minimized loss of corrosion resistance and other deterioration mechanisms in alloys with thermal stability concerns. e. For titanium and zirconium clad equipment, if PWHT is required, the following guidelines shall be followed:

d.

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24 August 2006 GIS 36-107 Guidance on Industry Standard for Integral Cladding, Weld Overlay, and Limited Loose Lining of Pressure Vessels and Components

1. 2.

Maximum temperature of 565 15C (1 050 25F) is preferred with the longer time allowed by ASME Code. Between 200C (390F) and the hold temperature, the heating and cooling rates shall not exceed 55C (100F) per hour. Below 200C (390F) the equipment may be aircooled. There is a large difference in coefficients of expansion between ferritic alloys and titanium and zirconium. This difference can cause a weakening of the interface bond with high temperature exposures.

6.
6.1.

General design and fabrication

Fabrication details a. Fabrication details at nozzles, such as back cladding, batten strips, and gasket surfaces, at internal attachments, and at similar anomalies in equipment shall be in accordance with GIS 46-010 and GP 46-01. If a GP or GIS is not available, fabrication details shall be approved by BP.

b. 6.2.

Integrally clad equipment a. For vessels made from clad plate, lightly loaded attachments (e.g. tray support rings) may be welded directly to the cladding without stripping back to the base material providing the area is checked with UT for lack of bond prior to welding. If the conditions of a) are not met, the cladding shall be cut back. The attachment shall be directly welded to the shell by an appropriate procedure before cladding re-instatement. PWHT may be required depending upon the material of the shell. This does not apply to titanium or zirconium clad equipment. c. For integrally clad equipment, nozzles may be manufactured from clad plate or weld overlay. Use of loose liners requires BP approval. Loose linings are not generally desired for nozzles, except in special cases. d. For some applications, solid alloy nozzles may be considered for small diameter nozzles, typically DN 50 (NPS 2) and smaller, instead of using a lining on low alloy base metal. These applications shall be approved by BP. Additional guidelines for use of solid CRA nozzles are as follows: With solid nozzles, there could be a risk of through wall cracking if the material is susceptible to environmental cracking in the specific process stream. Also, differential thermal expansion could be a concern at higher temperatures. 1. 2. Vessel design temperature is maximum 300C (570F) for stainless steel alloys and 426C (800F) for Cr-Ni and Cr-Ni-Mo alloy. For 11-13% Cr alloys, nozzles shall be Ni base alloy or austenitic stainless steel welded with ENiCrFe-2 electrodes.

b.

6.3.
6.3.1.

Inspection
Integrally clad equipment

a.

Before fabrication, integrally clad plates shall be inspected by UT for disbonding between the cladding and the base metal and meet the appropriate Code or Specification. However, the minimum acceptance criterion for integrally clad plate shall be as follows: 1. Ultrasonic scanning shall be over 100% of the plate surface. The minimum requirement shall be ASME SA-578 Level A.

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24 August 2006 GIS 36-107 Guidance on Industry Standard for Integral Cladding, Weld Overlay, and Limited Loose Lining of Pressure Vessels and Components

This requirement is for material combinations that have their own specific standard, but do not specify the acceptance criterion and for material combinations that are not covered by a specific standard. 2. If unacceptable lack of bond occurs, the area shall be repaired by removing the disbonded cladding and weld overlay using the same procedure as used for back cladding. This sub-clause does not apply to titanium, zirconium, and tantalum clad plate. a) b) 3. After removing the disbonded cladding, the exposed base metal shall be checked to insure there is no alloy contamination remaining on the base metal surface. CuSO4 or ferroxyl tests per ASTM A380 may be used. The use of alternative confirmation tests shall be approved by BP.

For hydrogen service, ASME SA-578 Supplement S7 is required with the following additions: a) b) c) Scanning shall be from the cladding side. 75 mm (3 in) centres shall be used. Weld repair is required for disbonded areas that cannot be encompassed within a 25 mm (1 in) diameter circle. If the vessel had been PWHT before repair, the need for re-PWHT shall be reviewed with BP before repairs are started. Areas with unacceptable bonding shall be reported to BP. Repairs shall not be done without review and approved by BP.

4.

For titanium, zirconium, and tantalum clad plate, refer to clause 5.5. a) b)

b.

For integrally clad heads and vessels, final UT and PT shall be performed after forming and any associated heat treatment. Back clad seams in the heads shall be inspected for lack of bond at the weld to clad interface along the seam length.

6.3.2. 6.3.2.1.

Weld overlays and back cladding Ultrasonic examination

a.

Weld overlay deposit shall be examined with UT to verify cladding thickness. 1. At least two locations per plate or head and one location per weld seam shall be tested. If forged rings are used for the vessel shell, at least four readings, about 90 apart shall be taken. Areas of overlay that have been ground or machined shall be tested to confirm compliance of thickness.

2. b.

Weld overlay deposit shall be examined with UT to identify disbonding per the following criteria: 1. 2. 3. UT shall be per ASME SA-578. A 25 mm (1 in) transducer shall be used, except for nozzles, which may use a smaller transducer. Inspection shall be done before PWHT, but after at least one hydrogen degassing heat treatment, if needed. For plates used for vessel shells and heads, exchanger tubesheets, and similar components, UT shall be performed on each plate. a) b) The inspection shall be along two 150 mm (6 in) paths across the entire plate. The path shall be perpendicular to the direction of weld overlay and shall be within 300 mm (12 in) of each end of the plate.

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4. 5. 6.

For heads, each head shall be inspected. Inspection shall be along two 150 mm (6 in) wide paths tested at 90 such that they intersect at the centre of the head. For nozzles, the inspection shall be from either the inside or outside diameter. The inspection shall be a 75 mm (3 in) wide path around the nozzle circumference. For weld seams, inspection shall be 10% of the total weld seam area equally distributed among the number of seams. BP retains the right to designate the specific inspection locations. Areas of major structural attachment, such as distributor support and beam and catalyst support rings and beams, shall be inspected for overlay disbonding before welding of the attachment. a) b) Indications of disbonding greater than 12 mm (0,5 in) in any direction shall be cause for rejection and repair. If a test area is rejected, the entire shell, head, nozzle, or weld seam shall be UT inspected.

7.

c.
6.3.2.2.

API Spec 6A and API Spec 17D requirements as appropriate shall be applied for wellhead and Christmas trees.

PMI Inspection

a. b.

PMI shall be conducted on weld consumables before start of work. Refer to GP 18-02 and GIS 36-103 for guidance. Chemical analysis of weld overlay deposits shall be taken to a minimum depth of 3 mm (0,125 in) below the final surface. Results shall meet the requirements of the specified wrought material, unless alternative agreed with BP. For production welds of overlay and back cladding, the following test frequency is required: 1. 2. 3. One sample shall be taken from every 5 m (16 ft) along the shell. Two samples from each head or end enclosure. One check per nozzle.

c.
6.3.2.3.

Nozzle checks may be reduced to one per nozzle size if application technique and supplier are the same and approved by BP.

PT examination

a. b.

Completed weld overlay and back cladding shall be 100% liquid penetrant inspected in accordance with ASME SE-165 following any PWHT and hydraulic testing. Crack indications shall be reported to BP for review of extensiveness and repair options. PT is particularly important when Cr-Mo is the base metal and austenitic stainless steel is the overlay. These metal combinations usually indicate high temperature hydrogen service in which direct hydrogen exposure of the base metal can be a concern and repairs may need to use temper bead techniques or PWHT.

6.3.2.4.

Ferrite measurements

For austenitic stainless steels, weld overlay and back cladding shall be checked using a ferrite scope. The FN in production welds shall be in the range of 3 12 FN. Testing shall be done before any PWHT. Testing shall be as follows: a. b. c. One measurement every 1 m2 (10 ft2) on every vessel section, head, manway, and nozzle. A minimum of 2 measurements shall be made on each individual component. One measurement on each longitudinal and two measurements on each circumferential back clad weld seam.
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d.

One measurement of the weld deposit for each new spool of continuous overlay strip or wire.

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Bibliography
American Petroleum Institute (API)
[1] API RP 582 Welding Guidelines for the Chemical, Oil, and Gas Industries.

American Society of Mechanical Engineers (ASME)

[2] [3] ASME SA-263 Specification for Corrosion-resisting Chromium Steel-clad Plate, Sheet, and Strip. ASME SA-265 Specification for Nickel and Nickel Alloy-clad Steel Plate.

NACE International (NACE)

[4] [5] NACE MR0175 Petroleum, Petrochemical and Natural Gas Industries Materials for Use in H2Scontaining Environments in Oil and Gas Production (ISO 15156). NACE RP0170 Protection of Austenitic Stainless Steels and Other Austenitic Alloys from Polythionic Acid Stress Corrosion Cracking during Shutdown of Refinery Equipment.

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