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SPECIFICATION FOR

INCOLOY 825
AND
INCOLOY 825 CLAD
CARBON STEEL PLATE
MATERIAL

DOCUMENT No.
6347-40-06-41-SP-06 Rev. 0
Page 1 of 10

SPECIFICATION FOR INCOLOY 825


AND INCOLOY 825 CLAD
CARBON STEEL PLATE MATERIAL

24..12.04

Issued for bid

Rev.
No

Date

Purpose

Format No. EIL 1641-1924 Rev. 1

Prepared
by

Checked
by

Approved
by

Copyright EIL All rights reserved

SPECIFICATION FOR
INCOLOY 825
AND
INCOLOY 825 CLAD
CARBON STEEL PLATE
MATERIAL

DOCUMENT No.
6347-40-06-41-SP-06 Rev. 0
Page 2 of 10

CONTENTS
CLAUSE

TITLE

PAGE NO.

1.0

SCOPE

2.0

CODES AND STANDARDS

3.0

MATERIAL SELECTION AND

MANUFACTURING PROFESS
4.0

HEAT TREATMENT

5.0

PHYSICAL PROPERTIES AND TESTS

6.0

NON-DESTRUCTIVE INSPECTION

7.0

HYDROSTATIC TEST

8.0

SELECTION OF SUPPLIERS

9.0

PRODUCTION TEST AND REPORTS

10.0

WELDING / WELD REPAIR REQUIREMENTS

10

AND QUALIFICATIONS

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

SPECIFICATION FOR
INCOLOY 825
AND
INCOLOY 825 CLAD
CARBON STEEL PLATE
MATERIAL

1.0

DOCUMENT No.
6347-40-06-41-SP-06 Rev. 0
Page 3 of 10

SCOPE
This specification covers technical requirements for manufacture,
inspection, testing and supply of carbon steel plates (base metal) to which
is integrally and continuously bonded on one side a layer of Incoloy-825
material to be used for wet sour hydrocarbon liquid and vapours containing
H2S, CO2 and Chlorides. The material is generally intended for pressure
vessel use.

2.0

CODES AND STANDARDS


The manufacture, inspection, testing and supply of plates under this
specification shall comply with the latest revisions of the following codes
and standards besides this specification:

3.0

ASTM B 424

ASTM A 265

ASME Sec. VIII


Div. I & II
ASME Sec. IX
ASTM A 262

:
:
:

ASTM A 370

ASTM A 578

ASTM E 18

ASTM E 142
ASTM E 165
ASTM E 709

:
:
:

ASTM G 48

NACE MR-01-75

Standard specification for Ni-Fe-Cr-Mo-Cu


alloy plate, sheet and Strip
Standard specification for Nickel and Nickelbase alloy-clad steel plate
Boiler and Pressure vessel codes
Welding requirements.
Recommended
practices
for
detecting
susceptibility to inter-granular attack in
stainless steels.
Methods and definitions for mechanical testing
of steel products.
Straight beam ultrasonic examination of plain
and clad steel for special applications.
Methods for Rockwell hardness and Rockwell
superficial hardness of metallic materials.
Controlling quality of Radiographic testing.
Liquid - Penetrant inspection Method.
Recommended practice for Magnetic
Particle examination.
Pitting and crevice corrosion resistance of
stainless-steels and related alloys by the use
of Ferric Chloride solutions.
Sulfide stress cracking resistant metallic
material for oil field equipment.

MATERIAL SELECTION AND MANUFACTURING PROCESS


Clad plates shall be manufactured, inspected and tested in accordance with
ASTM A 265 and with the following additional requirements:

3.1

MATERIAL SELECTION

3.1.1

The carbon steel (base metal) plate material to be employed for making
clad plates shall conform to the ASTM specifications for steels for pressure
vessels. Carbon steel shall be fully killed and made to fine grain particle.

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

SPECIFICATION FOR
INCOLOY 825
AND
INCOLOY 825 CLAD
CARBON STEEL PLATE
MATERIAL

3.1.2

6347-40-06-41-SP-06 Rev. 0
Page 4 of 10

The physical and chemical properties of carbon steel plates shall conform
the ASTM specification for both, heat and product analysis, to which it is
ordered.
C.E = C +

Mn
6

3.1.3

DOCUMENT No.

Cr+V+Mo
5

Cu+Ni

= 0.42

15

The corrosion resistant cladding alloy shall meet the requirement of ASTM
B 424 (UNS N 08825) with the following additional stipulations:
a)
b)
c)

Maximum carbon content shall be 0.025 percent.


Minimum pitting index (% Cr + 3.3% Mo) shall be 32.
The minimum cladding thickness shall be 3.0 mm.

3.2

TECHNICAL REQUIREMENTS (CLAD PLATES)

3.2.1

Clad plates shall be made by using standard practice suitable to obtain


metallurgical bonding between carbon steel and corrosion resistant alloy. A
detailed procedure for production of clad plates shall be submitted for
Company's approval and shall include the following as a minimum:
Material traceability system
Steel and plate making process
Heating technique, rolling reductions, and working temperatures.
Cladding process
Procedure for heat treatment
Ultrasonic testing of plates and bond integrity check.

3.2.2

Each finished plate shall be subjected to automatic ultrasonic examination


for checking bonding integrity and soundness of carbon steel backing plate.
This test shall be carried out on 100% plate surface area on both sides, in
accordance with ASTM A 578 and its supplementary retirement S3. The
acceptance criteria for the finished clad plates shall be as per ASTM A 578
level II besides specific technical requirements mentioned below.

3.2.3

Discontinuity, causing complete loss of back reflection that cannot


encompass within 75 mm diameter circle shall be unacceptable.

3.2.4

Clad plates having a total area of discontinuity greater that 6000 sq.mm.
shall be rejected. Also where the lamination exceeds 6.35 mm in length
measured along the two longitudinal edges of the plate, shall be rejected.
Laminar defects in the backing plate is also unacceptable. Unbonded area
which cannot be encompassed within 25.0 mm diameter circle shall be
unacceptable.

3.2.5

Acceptance criteria for integrity of bond of the cladding material shall be as


per ASTM A 578, level S7 as modified by clause nos. 3.2.6 and 3.2.7
below.

3.2.6

No defect in corrosion resistant alloy is permitted. Minor defects, if any as


mentioned in clause 3.2.7 (a) and (b) below may be repaired with
company's prior approval by welding and shall be subsequently tested by
dye penetrant examination. The manufacturer shall submit welding
procedure for company's approval prior to undertaking such repair works.

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

SPECIFICATION FOR
INCOLOY 825
AND
INCOLOY 825 CLAD
CARBON STEEL PLATE
MATERIAL

3.2.7

3.2.8

DOCUMENT No.
6347-40-06-41-SP-06 Rev. 0
Page 5 of 10

a)

Finished clad plates having defects lower than 500 cm2 area and
total defect area lower than 1.5% of the total plate surface area are
only allowed to be repaired.

b)

The plates having defects lower than 500 cm2 area and total defects
greater than 1.5 % but lower than 3 % of the total surface area may
be repaired with company's prior approval.

c)

Plates having defective area greater than 3% or single defect greater


than 500 cm2 shall be rejected.

WALL THICKNESS
Permissible tolerances on nominal wall thickness shall be as follows :
On carbon Steel backing material
+
On Cladding (Incoloy 825) material +
On combined wall thickness
+

4.0

10%, - 5%
10%, negative tolerance NIL
10%, - 3%.

HEAT TREATMENT
After finish rolling for bonding, all clad plate produced shall be normalized in
the temperature range 900 0 C 1000 0 C followed by air cooling and water
quenching. This will be followed by tempering treatment at 620 - 650 0 C
followed by air cooling.
The detailed heat treatment procedure, including any alternatives
proposed, shall be submitted for Company's approval.

5.0

PHYSICAL PROPERTIES AND TESTS


Test tab of adequate length shall be attached to an adequate number of
plates so as to facilitate carrying out the specified mechanical and corrosion
tests.
The clad plate shall be subjected to the following tests to determine the
physical properties of the finished product. The test shall be carried out on
the full thickness of carbon steel, after removal of corrosion resistant alloy
Incoloy-825, on the finished plate. While removing corrosion resistant alloy,
care must be taken not to reduce the wall thickness of carbon steel backing
metal as far as possible.

5.1

MECHANICAL PROPERTIES
The carbon steel backing metal shall meet the requirements of mechanical
properties set forth in ASTM A 265. Carbon steel plates shall in addition
have fracture toughness of minimum 27 Joules, when subjected to charpy
V-notch test at 0 0 C, in accordance with ASTM A 370. Testing frequency
shall be as required for guided bend test in clause 5.3 below. Number of
test specimens, number of tests and retests shall be as per ASTM A 265.

Format No. EIL 1641-1924 Rev. 1

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SPECIFICATION FOR
INCOLOY 825
AND
INCOLOY 825 CLAD
CARBON STEEL PLATE
MATERIAL

5.2

DOCUMENT No.
6347-40-06-41-SP-06 Rev. 0
Page 6 of 10

WELD TENSILE TEST


The specimen shall represent the full wall thickness of carbon steel with
corrosion resistant alloy removed from specimen. The ultimate tensile
strength shall be higher than the minimum specified for the base material.
Testing frequency shall be as required for guided bend test in clause 5.3
below.

5.3

GUIDED BEND TESTS


The guided bend test shall be carried out on specimens taken from the
each of the two representative plates of each lot. The lot shall be defines as
a maximum of 50 plates belonging to the same heat of carbon steel and
manufactured with the same process.

5.4

MICROSCOPIC EXAMINATION AND HARDNESS TEST


Test specimen for microscopic examination shall be taken transverse to the
longitudinal weld, from the finished plates. The width of the specimen shall
be minimum of three times the width of the weld. The specimen shall then
be ground suitably and etched to reveal the microstructure. The specimen
shall be visually examined using a magnification of 5 to 10 times and shall
show a regular weld profile with smooth transition to base material. The
microstructure shall also be examined at a suitable, higher magnification to
ensure favourable distribution of micro-constituents. Chemical composition
shall be ascertained by appropriate methods to verify that in the top 2mm of
the cladding it is within the specified limits. Hardness test HV 10 according
to ASTM A 370 and at suitable locations as shown in figure 5.6, shall be
carried out on the test pieces already submitted to micro-structural
examination. In the heat affected zone indentations shall start as close to
the fusion line as possible. The maximum Vickers hardness value for each
single point shall not exceed 248 HV 10 on carbon steel portion and 285
HV 10 corrosion resistant alloy.

5.5

BOND EFFICIENCY TEST

5.5.1

Shear Tests
Shear test shall be performed according to ASTM A 265 and minimum
shear strength in the longitudinal direction shall be 140 MPa.

5.5.2

Ductility Tests
Ductility test in longitudinal direction shall be performed according to ASTM
A 265. No crack and no un-bounding shall be allowed.

5.6

CHARPY IMPACT TEST


This test shall be performed in accordance with ASTM A 370. From each
finished plate per lot representing same heat of carbon steel and
manufactured with the same process, five samples shall be taken
transverse to the principal rolling direction. From each sample three
specimens shall be machined. The specimens shall be notched as follows:
Weld Metal

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

SPECIFICATION FOR
INCOLOY 825
AND
INCOLOY 825 CLAD
CARBON STEEL PLATE
MATERIAL

DOCUMENT No.
6347-40-06-41-SP-06 Rev. 0
Page 7 of 10

Fusion line
Fusion Line + 2 MM
Fusion Line + 5 MM
Base metal

At the test temperature of 0 0 C, the fracture toughness values obtained


shall be consistent with those indicated in clause 5.1 above.
5.7

CORROSION TESTS
The specimen shall be machined only to remove the carbon steel portion
and shall contain the full weld on the corrosion resistant alloy in as welded
condition. Corrosion resistant alloy shall not be ground or picked and
surface of specimen shall approximate the same roughness as the finished
plate. Specimen shall be machined transverse to the weld with the following
dimensions:
Width (transverse to the weld)
Length (Parallel to the weld)
Thickness

:
:
:

50 mm
25 mm
1.5 mm (Minimum)

The following corrosion tests shall be carried out on the specimens


prepared as above.
5.7.1

Inter-granular Corrosion Test


The test shall be carried out in accordance with ASTM A 262 practice C
(Nitric acid) or ASTM G 28 (Ferric Sulphate). The average corrosion rate
shall be less than 36 mils/year (0.90 mm/year) for ASTM A 262 practice C
and 18 mils/Year (0.45 mm/year) for ASTM G 28.

5.7.2

Pitting Corrosion Test


This test shall be performed as per ASTM G 48 using a solution at (i) 22 0
C (ii) 50 0 C for a total time of 24 hours. In the test at 22 0 C, no pitting
shall occur on the internal plate surface. For the test at 50 0 C, weight loss
shall be reported to company for review.

5.7.3

Corrosion in Sour Gases (SSCC Test)


Sulphide Stress Corrosion Cracking (SSCC) test shall be carried out on the
cladding alloy as follows:
a.
Test as per NACE TM-01-77 at test temperatures.
i) Room / 24 0 C temperature.
b.

Test as per NACE TM-01-77 except that the test solution shall have
H2S partial pressure of 5 bars and CO2 partial pressure of 20 bars
and the test temperatures shall be:
i)
At 90 0 C.
ii)
At 120 0 C.

Note :
Format No. EIL 1641-1924 Rev. 1

Test solution - 5% NaC1 + 0.5% Acetic Acid.


Copyright EIL All rights reserved

SPECIFICATION FOR
INCOLOY 825
AND
INCOLOY 825 CLAD
CARBON STEEL PLATE
MATERIAL

DOCUMENT No.
6347-40-06-41-SP-06 Rev. 0
Page 8 of 10

Each of the test results shall be evaluated based on acceptance criteria of


Minimum stress for no cracking to occur after 720 hours equals to 95% of
SMYS of cladding material used.
6.0

NON- DESTRUCTIVE INSPECTION


The following non-destructive inspection shall be performed on each plate.
A detailed non-destructive testing specification shall be developed and
submitted to Company for qualification and approval.

6.1

RADIOGRAPHIC EXAMINATION
The weld seems shall be checked for detection of longitudinal and
transverse defects to the weld by radiographic method on the full length of
the plate. Acceptance criteria for the radiographs shall be as per ASME
Boiler and Pressure Vessel section VIII, Division I, and clause UW 51.
The film used for radiographic inspection of plate welds shall be class 1 and
2 referring to Table-II of ASTM E 94, with film density of 1.8 - 3.8 that allow
the sensitivity of at least 1.5% of the nominal total thickness of plate weld
bead.

6.2

SOUNDNESS OF BONDING
Each plate shall be inspected by ultrasonic method for the detection of
lamination and for bonding check on a circumferential band of 50 mm along
each side of the longitudinal weld.
No lamination and un-bonding are allowed on plates. plate ends of each
plate shall also be inspected by Ultrasonic examination with angle probe to
detect hair line crack defects on plate body, perpendicular to the surface,
for a length at least 50 MM. No defect shall be allowed.

6.3

MAGNETIC PARTICLE EXAMINATION


All plate welds shall be subjected to Magnetic particle examination. This
shall include full length of external surface of the weld bead of backing
material to be examined by Magnetic particle method. The test procedure
shall be in accordance with ASTM E 709 and acceptance criteria shall be
according to ASME Section VIII, Division 2 Appendix 9.

7.0

HYDROSTATIC TEST
Pressure vessels fabricated from the clad plates shall be subjected to mill
hydrostatic test pressures corresponding to 90% of the specified minimum
yield strength for Carbon Steel and the test pressure shall be held for at
least 30 seconds. Permanent test records (Pressure time Chart) shall be
maintained by the manufacturer and submitted for review of Company.

8.0

SELECTION OF SUPPLIERS
The tests specified in clauses 5.0 to 7.0 above shall be conducted by the
mill / supplier for the purpose of initial qualification. The test results shall be

Format No. EIL 1641-1924 Rev. 1

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SPECIFICATION FOR
INCOLOY 825
AND
INCOLOY 825 CLAD
CARBON STEEL PLATE
MATERIAL

DOCUMENT No.
6347-40-06-41-SP-06 Rev. 0
Page 9 of 10

submitted to the company for approval prior to placement of order. In case


the supplier has already carried out all above tests and the test results are
certified by a recognized independent inspection agency (viz. Lloyds, BV,
DNV etc.) all such test reports / certificates / documents shall be forwarded
to the Company for review and approval. The Company shall access the
capability of the supplier upon scrutiny and verification of the documents
submitted. Company's decisions in this regard shall be final and binding.
9.0

PRODUCTION TEST AND REPORTS


On placement of order, the manufacturer / mill shall carry out the following
production tests as per testing frequency defined below, and submit reports
to Company for acceptance and approval. The test reports shall be
submitted to Company before despatch of material from the mill.

9.1

PRODUCT ANALYSIS (Chemical Analysis and Physical Properties)


The test shall be carried out on each heat of steel used in manufacturing
carbon steel and Incoloy-825 plates separately. The chemical analysis and
physical properties so determined shall comply to the relevant ASTM
specifications for carbon steel and ASTM B 424 specification for Incoloy825 as amended by this specification.

9.2

MECHANICAL TESTS
Tests as defined in this specification from clause 5.0 to 5.6 shall be
conducted on the finished clad plates. The tests shall be carried out on
specimens drawn from each of two representative plates per lot. The lot
shall be defined as a maximum of 50 plates of same size, thickness and
belonging to same heat of carbon steel and manufactured with the same
manufacturing process.

9.3

CORROSION TESTS

9.3.1

Inter-granular corrosion and pitting test


Tests as defined in this specification from clause 5.7.1 and 5.7.2 shall be
conducted on two specimens drawn from the finished clad plates. The tests
shall be carried out on one heat out of every five heats produced by the mill
for manufacture of the finished product.

9.3.2

Corrosion in Sour Gases (SSCC Test)


The test as defined in this specification under clause 5.7.3 shall be
conducted or two specimens drawn from the finished clad plate
manufactured from the first heat produced by the mill on receipt of order.

9.3.3

In case the results of production tests conducted are not consistent and
satisfactory, the Company may ask Vendor / Contractor to repeat or
increase the testing frequencies defined above, for quality assurance at any
time during the manufacturing process without any cost/time implication to
the Company.

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

SPECIFICATION FOR
INCOLOY 825
AND
INCOLOY 825 CLAD
CARBON STEEL PLATE
MATERIAL

10.0

DOCUMENT No.
6347-40-06-41-SP-06 Rev. 0
Page 10 of 10

WELDING/WELD REPAIR REQUIREMENTS AND


QUALIFICATIONS
The manufacturer shall submit a detailed procedure for welding and weld
repair for Company's approval prior to commencement of production of
plates. The procedure shall include all requirements as required in clause
3.2.1 and 3.3.1 of this specification.
Welders and welding operators shall be qualified in accordance with ASME
Section IX or other applicable Codes as agreed upon. The Company's
inspector shall witness the test and certify the qualification of
welder/operator separately. Only those welders approved by the Company's
inspector shall be employed for welding. The Contractor shall submit
welder/welding operator qualification test reports in the standard AWS
format.

Format No. EIL 1641-1924 Rev. 1

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