Clad Restoration

1
Weld Joints Of Clad Material

By L D Poyyara
POYYARA CONSULTANTS 2
Clad Material
What Is Clad Material / Clad Plate?
Non Corrosive SS / NFS Clad
CS / LAS Base Material
Any ferrous (CS / LAS) base plate which is integrally
bonded with a thin sheet / layer of non corrosive (SS
/ non ferrous) material on one side.

Clad Plate
Clad Plates
Bonding Process
Non Corrosive SS / NFS Clad
Clad Bonding by Explosion / Hot Rolling /
Fusion Welding.

Clad Plate
Clad Plates
Non Corrosive SS / NFS Clad CS / LAS Base Material
Base Material: CS / LAS
Clad Material:
SS -304, 304 L, 316, 316 L,317, 317 L, 318, 321, 347
NFM / NFA Copper, Aluminium, Titanium, Monel, Inconel,
Cupronickel
Clad Plate
Clad Plates
Where Clad Plates are In Use?
For Fabricating Pressure Vessels & Pipe
Lines which are subjected to high
pressure & corrosion from inside surface
Corrosion Resistant Part
3 to 5 mm thick
Corrosive
Media
Pressure Resistant Part
Weld Joint
Clad Restoration
Clad Plates
What is the advantage of using Clad Plates in
Pressure Vessel Fabrication?
Saving in Material Cost. Allows to use low cost CS /
LAS corrosive base material as pressure retaining pats for highly
corrosive fluid. An inside thin layer of non corrosive clad prevents
internal corrosion
2 to 5 mm thick
Corrosive
Media
Weld Joint
Clad Restoration
Clad Plates
What is the disadvantage of using Clad Plates in
Pressure Vessel Fabrication?
Additional Precautions in Fabrication.
Cutting, WEP, Rolling, Handling, Set up, Welding, PWHT
2 to 5 mm thick
Weld Joint
Clad Restoration
Corrosive
Media
Cladding By Weld Overlay
What is weld Overlay Clad?
One or more layers of corrosion resistant
weld metal is deposited on CS / LAS base
material
Dilution :- 5 to 8%
ESSC
Final Layer E 308L First Layer - E309
Weld Cladding Process:
ESSC Electro Slag Strip Cladding. Applicable to large
inside area of Shell, D/E, Cone, & TS

SASC Submerged Arc Strip Cladding Applicable to large
inside area of Shell, D/E, Cone, TS

FCAW Flux Cored Arc Welding. Applicable to Flange face,
Small size TS, Pipes of smaller diameter,

MIG Metal Inert Gas Welding. Applicable to Flange face,
Small size TS, Pipes of smaller diameter,

SMAW Shielded Metal Arc Welding. Applicable to small
components and repairs of clad
Typical Section Of Weld Overlay
SASC
Dilution :- 10 to 15%
Final Layer E 308L
Final Layer E 308L First Layer - E309
First Layer E 309
Dilution :- 5 to 8%
ESSC
FCAW / MIG
Typical Section Of Weld Overlay
SMAW
Final Layer
Final Layer First Layer
First Layer
E308L
E309
E308L
E309
What Is Overlap In Weld Overlay?
The extent of covering or over lapping on
previous weld bead by the adjacent bead.

40 to 50 % Over Lap
Less Dilution More Dilution
10 to 15 % Over Lap
More Thickness
Less Thickness
What Is Significant Of Overlap In
Weld Overlay?
Overlap of 40 to 50% in SMAW & FCAW results
in Less Dilution & more weld overlay
Thickness per layer

Less dilution results weld metal chemistry
more towards filler metal chemistry
40 to 50 % Over Lap 10 to 15 % Over Lap
Less Dilution More Dilution
More Thickness
Less Thickness
Overlap In ESSC & SASC
The extent of covering or over lapping on
previous weld bead by the adjacent bead.

4 to 5 mm Over Lap
Dilution
Minimum Overlay Thickness
Weld Joints In Clad Plates
Normally Only Base Metal Thickness Is Considered For
Design Calculations
Base Metal to be welded with qualified WPS
NDT (RT, UT, MT, PT) of weld joint on base metal to be
cleared prior to clad restoration
Clad to be restored by welding (SMAW, FCAW, SAW,
SASC, ESSC) with qualified WPS
Base Metal Joint
Clad Restoration Clad Base Metal
Typical Butt Weld In Clad Plate
Base Metal Weld Joint
Clad Stripping Clad Base Metal
Base Metal Butt Weld
Final Weld
Base Metal Joint
Clad Base Metal
Clad Restoration Final Layer
Base Metal Joint
Barrier Layer Clad Base Metal
Clad Restoration Barrier Layer
1
2
3
Typical Fillet Weld In Clad Plates
3
2
1
SS 304L Clad
SS 304L Clad
SS 304L Clad
SS 304L Support
SS 304L Support
SS 304L Support
Clad Stripping
CS
CS
CS
E309
E308L
18
Liner Attachment
By L D Poyyara
What Is Liner Attachment?
A thin sheet / Strip / Pipe of corrosion resistant
material (SS / non ferrous) is attached on corrosive
metal surface by welding along the outer edges.
Unlike clad, Liner is not an integral part of base
material
It is a substitute for Clad
Vent
Attachment Weld Liner
Liner Attachment
Advantages
- Easy to attach
- Cheaper than integral clad / weld overlay
Disadvantages
- Less durable compared to integral clad
- More chances for leakage through liner in service
- Frequent repair / replacement of liner in service
- Needs vent holes below each liner
Vent
Liner Attachment
Typical Liner Attachment Weld
Vent
Liner
Liner Final Layer
1
St
Fillet 2
nd
Fillet
1 2
3
22
Qualification Requirements For
Weld Joints In Clad Material
By L D Poyyara
Welding Qualification For Clad
Material
Generally Qualifications Separately Done For
1) Weld Joints On Base Material
2) Restoration Of Clad On Weld Joints In Base Metal
Base Metal Butt Weld
Final Weld
Base Metal Joint
Clad Base Metal
Clad Restoration Final Layer
1
2
Welding Qualification For Clad
Material
Qualifications For Welding Of Base Material
1) Procedure As Per QW 200 & QW 451
2) Performance As Per QW 300 & 452
Test Coupon May Be With or Without Clad
OR
Qualification For Weld Overlay / Clad
Restoration
Qualifications For Restoring Clad By Weld Overlay
1) Procedure & Performance As Per QW 217(b), QW 451.4 &
QW 453
Test Coupon may be with or without clad
Base Metal Without Cladding
Base Metal For Welding Qualification Weld
Overlay / Clad Restoration
OR
Base Metal With Cladding
Restoration
How to qualify procedure?
1 Prepare WPS Format available in ASME Sec. IX

2 Prepare a test coupon of P number in WPS

3 Coupon may be with or without clad

4 Coupon size minimum 150 mm X 150 mm

5 Coupon thickness minimum equal to production weld,
maximum need not be more than 25 mm
Restoration
Test Coupon For Qualification of Weld
OR
Clad Stripping
Clad
37 mm min
37 mm min
Restoration
Welding Of procedure Test Coupon
1. Clean the surface
2. Weld barrier layer as per WPS
3. Width minimum 37 mm and length minimum 150 mm
4. PT examine the barrier layer (optional) Acceptance as
per QW 195
5. Weld subsequent layers as per WPS
6. PT examine the final layer Acceptance as per QW
195
7. Each bead shall have uniform width and height
Restoration
Procedure / Performance Qualification Test Coupon
OR
Clad Stripping Clad
37 mm min
37 mm min
Min Job Size need not > 25 mm
Barrier Layer
Final Layer
Weld Area 37 X 150 mm Min
Procedure Qualification For Weld
Physical Tests , QW 453
1. Side Bends - Transverse to welding direction - 4
No, WQ 161
(Location of bend specimens as per QW 462.5)

Acceptance Standard, QW - 163
1. No open discontinuity more than 1.5 mm in any
direction within the weld overlay cladding.
2. No open discontinuity more than 3 mm along the
weld interface.
Chemical Analysis. QW 462.5 (a)
Requires only when WPS / Spec. Calls for
All elements specified in WPS / Spec. are to be
analyzed.
Location of chips based on minimum thickness
of clad / overlay envisaged on production
welds.
Acceptance Limit
Within the WPS / Spec / Clad Chemistry.
Procedure Qualification For Weld Overlay / Clad Restoration

Location Of Chemical Analysis & Minimum Thickness Qualified
1
st

2
nd

3
rd

X
Weld inter Face
Base metal
Fusion Face
1
st

2
nd

3
rd

Weld inter Face
Base metal
Fusion Face
Location of Chips for Chemical Analysis Depth Minimum Possible
X
X
X = Min. Overlay Thickness Qualified
Special Process Essential Variables. QW 251.4
Welding in each position requires separate
qualification

Welding in vertical up hill position qualifies all
position ( SMAW, GMAW, GTAW).

Welding with single layer and multilayer needs
separate qualification
Procedure Qualification Thickness range Base
metal & Overlay
Thickness Of Test
Coupon
Base metal thickness
Qualified
Weld Overlay
Thickness
Min Max Min Max
Less Than 25 mm
Test
Coupon
Thickness
Any
Minimum
thickness
where
chemical
analysis
found
within limit
Any
Above 25 mm 25 mm Any
Performance Qualification For Weld
How to qualify Welders Performance? QW-381
1 Prepare WPS & Qualify the procedure

2 Prepare a test coupon of P number in WPS

3 Coupon may be with or without clad

4 Coupon size minimum 150 mm X 150 mm

5 Coupon thickness minimum equal to production weld,
maximum need not be more than 25 mm
Restoration
Welding Of Performance Test Coupon
1. Clean the surface
2. Weld barrier layer as per WPS
3. Minimum three beads in first layer
4. Width minimum 37 mm and length minimum 150 mm
5. PT examine the barrier layer (optional) Acceptance as
per QW 195
6. Weld subsequent layers as per WPS
7. PT examine the final layer Acceptance as per QW
195
8. Each bead shall have uniform width and height
Physical Tests , QW 453
Side Bends - Transverse to welding direction - 4
No, WQ 161
(Location of bend specimens as per QW 462.5)

Acceptance Standard, QW - 163
No open discontinuity more than 1.5 mm in any
direction within the weld overlay cladding.
No open discontinuity more than 3 mm along the
weld interface.
Applicable Essential variables QW 350 & 360
No upper limit for thickness of overlay qualified

Welders qualified on Clad restoration or liner
attachment are also qualified in weld overlays
QW 381 (d)

No limits in pipe diameters, if welded in
longitudinal direction QW 381 (c)

Performance Qualification Thickness range Base
metal & Overlay
Thickness Of Test
Coupon
Base metal thickness
Qualified
Weld Overlay
Thickness
Min Max Min Max
Less Than 25 mm
Test
Coupon
Thickness
Any
Procedure
Qualified
Any
Above 25 mm 25 mm Any
Qualification Requirements for Liner Attachment
procedure :- WPS qualified on Groove / Fillet as
per QW 202.2 (a), (b) or (c) also
qualifies for liner attachments within
the essential variables, If chemical
analysis is not a requirement
Performance:- Welders those who are qualified for
groove / fillet welds as per QW 301 are
also qualified for liner attachments
within the essential variables
Vent
Liner Attachment
Alternate Qualification. QW 218.2, QW - 383.2 (b)
procedure & Performance
- Weld a liner attachment assembly as shown below as per
the WPS.
- Base plate thickness min. job size max. need not be more
than 25 mm
- One Cross Section from each position for macro exam
- Chemical analysis if required as per WPS only for
procedure
- Each position needs separate qualification
- Procedure in vertical up qualifies all position
Liner Attachment
Liner Final Layer

Clad Restoration

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Weld Joints Of Clad Material

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