CLAD VESSEL

CLAD VESSELS ARE USED IN THE FOLLOWING ENVIRON:

HIGHLY CORROSIVE CONDITIONS

ELEVATED TEMPERATURES

COST EFFECTIVE
 CLAD PLATES

CLAD PLATES REPRESENTS TWO COMPOSITE

MATERIALS SUCH AS LAS/ CS INTEGRATED
WITH SS

MANUFACTURING OF CLAD PLATES:

ROLL BONDING
EXPLOSION WELDING
 MANUFACTURE OF CLAD
PLATES
PLATE 1

PLATE
ALL SCALES/ IMPURITIES ARE REMOVED BY GRINDING 2

SS STRIP IS LAID ON PLATE - TWO PLATES ARE PREPARED

SIMULTANEOUSLY

NICKEL COATING IS APPLIED BETWEEN BOTH PLATES

& PLATES ARE SENT FOR HOT ROLLING AT HIGH TEMP
& PRESSURE

UT IS PERFORMED AS PER SA 435 FOR CHECKING BONDING

 CLAD STRIPPING
LAS

9 ss
METHODS FOR WEP:
EDGE PLANER FOR SHELL COURSES
GRINDING
IMPORTANT:
COPPER SULPHATE TEST SHOULD BE PERFORMED TO
ENSURE
REMOVAL OF SS
 SET - UP
LAS

ss

ID OF LAS (NOT SS) TO BE CONSIDERED FOR

SET UP
 WELDING TECHNIQUES
LAS

CLAD
OVERLAY
SMAW
FCAW
ALL WELD OVERLAYS TO BE DONE
IN 1G / 2G POSITION AS PER WPS
 COMPARISION OF FCAW &
SMAW

FCAW SMAW
HIGHER RATES OF DEPOSITION LOWER RATES OF
DEPOSITION
OF WELD METAL OF WELD METAL
(3.2 kg/ arc hr) (1.2 kg/ arc hr)

SLAG ENTRAPMENT IS MORE SLAG ENTRAPMENT IS LESSER

WELDING MOSTLY IN 1G WELDING IN ALL

POSITIONS
 AUTOMATED ID OVERLAY FOR
NOZZLES

d d2
1

ID OVERLAY OF FLANGE # PIPE (FCAW)

ALL ID OVERLAYED NOZZLES SHOULD
BE MACHINED AFTER OVERLAY
 INCONEL JOINT FOR ID
OVERLAYED NOZZLES

GENERALLY USED FOR SINGLE SIDE FULL

PENETRATION JOINT ELBOW# PIPE
ROOT RUN ER 347 & SUBSEQUENT LAYER IS INCONEL
UTMOST CARE TO BE TAKEN TO AVOID ANY DILUTION
OF SS & LAS WHICH WOULD LEAD TO CRACKS
 WELDING TECHNIQUES FOR
OVERLAY OF GASKET FACE

MIN. 50% BEAD OVERLAP IS TO BE

MAINTAINED TO AVOID BLACK SPOTS
AFTER MACHINING
ARC DISTANCE TO BE KEPT MINIMUM TO
AVOID POROSITIES
DEPOSITION SEQUENCE OF WELD
BEADS :

3
1 2
 PREHEATING FOR LOW ALLOY
STEELS

ALLOY STEELS HARDEN WHEN HEATED TO HIGH

TEMPERATURES & COOL RAPIDLY CAUSING
HARDENING & ENBRITTLEMENT IN HAZ.

PREHEATING DELAYS COOLING RATE SO THAT

WELD METAL/ HAZ WILL NOT HARDEN EXCESSIVELY
& ALSO PREVENTS WELD CRACKS CAUSED BY
SHRINKAGE STRESSES.
 POSTHEATING FOR LOW ALLOY
STEELS

POST HEATING INCREASES THE RATE AT WHICH

HYDROGEN DIFFUSES AWAY FROM THE WELD & HAZ

RAISING TEMPERATURE SUFFICIENTLY WILL HELP

REDUCE TIME REQUIRED FOR HYDROGEN REMOVAL

POST HEATING IS DONE TO AVOID HYDROGEN

INDUCED CRACKING
II HYDROTEATING REACTOR
 II HYDROTEATING REACTOR

MATERIAL :SA 387 Gr 11 Cl 2 + SA 240 Gr

321

SIZE :DIA. 1.8M X 8.06M (TL TO

TL)

WEIGHT :18.03 TON

THICKNESS :18 thk + 3 thk clad

 GOOD ENGG. PRACTICES

ALL GRINDING WHEELS/ WIRE BRUSH TO BE

SEGREGATED FOR SS / LAS
FOR ALL CLAD VESSELS, DIRECT CONTACT OF SHOES
ON CLAD PORTION SHOULD BE AVOIDED. USAGE OF
PLASTIC COVERS/ SHOE COVERS TO BE ENCOURAGED
ALL HOLDERS TO BE INSULATED TO AVOID ARC STRIKES
FOR ALL TEMPORARY ATTACHMENTS, ONLY IDENTIFIED
PLATES TO BE USED
 GOOD ENGG. PRACTICES

CASE STUDY I
SPATTER ON CLAD SURFACE WHILE WELDING CHIPBACK (LAS) OF
SEAMS.

COPQ:
ALL SPATTER IS TO BE REMOVED BY GRINDING TO ENSURE
CLEARANCE OF FERROXYL TEST.
TIME REQUIRED FOR GRINDING - APPROX. 3-4 DAYS.
JOB DELAY - 1 WEEK

GEP:
BEFORE STARTING WELDING, ADJOINING AREA OF CLAD
SURFACE SHALL BE COVERED BY CHALK PASTE/ SUITABLE
COATING/ ASBESTOS TO PREVENT WELD METAL SPATTER
DEPOSIT ON CLAD SURFACE.
 GOOD ENGG. PRACTICES

CASE STUDY IIa

NOZZLE OVERLAY - ID
IN CASE NOZZLE ID OVERLAY IS MORE THAN SPECIFIED,
PROBABILITY OF INTERNALS/ LINERS FOULING WITH NOZZLES
EXISTS.

IMPLICATON:
REWORK.

GEP:
ID OF NOZZLE TO BE MAINTAINED AS PER DRAWING.
GOOD ENGG. PRACTICES
 GOOD ENGG. PRACTICES

CASE STUDY IIb

NOZZLE OVERLAY - GASKET FACE/ GROOVE
BLACK SPOTS/ UNCLEAN CUT
POROSITIES

IMPLICATION:
REWORK
EXTRA CONSUMABLES
EXTRA MACHINING HOURS REQUIRED FOR EACH NOZZLE
 GOOD ENGG. PRACTICES

2
R
1 4

3
 GOOD ENGG. PRACTICES

CASE STUDY IIb

NOZZLE OVERLAY

GEP:
MIN. 3-4 MM MACHINING ALLOWANCE SHALL BE PROVIDED TO
HAVE CLEAN CUT ON FACE..
MIN. 50% BEAD OVERLAP IS TO BE MAINTAINED TO AVOID
BLACK SPOTS AFTER MACHINING
ARC DISTANCE TO BE KEPT MINIMUM TO AVOID POROSITIES
DEPOSITION SEQUENCE OF WELD BEADS
 GOOD ENGG. PRACTICES

CASE STUDY III

NOZZLE BOLT HOLE STRADDLING

GEP:
IN CASE OF ID OVELAYED NOZZLES (WHERE FLANGE,PIPE & PROFILE FORGIN
ARE IN SINGLE PIECE), TRIAL SET UP OF FLANGE # PIPE # FORGING TO BE
TAKEN ON VESSEL BEFORE FINAL WELDING TO ENSURE CORRECT BOLTHOLE
STRADDLING.
 GOOD ENGG. PRACTICES

CASE STUDY IV
NOZZLE RADIUS

IMPLICATION:
REWORK.

GEP:
RADIUS ON ID OF NOZZLE IS TO BE ENSURED BY MACHINING
BEFORE ID OVERLAY. THIS IS TO ENSURE THAT THERE IS
SUFFICIENT WELD OVERLAY ON THROAT TO PREVENT
CORROSSION
 GOOD ENGG.PRACTICES
NOZZLE RADIUS

NOZZLE

SHELL

NOZZLE RADIUS OF
LAS
 GOOD ENGG. PRACTICES

CASE STUDY V
CLAD STRIPPING

GEP:
ALL CLAD STRIPPING IS TO CONTINOUSLY MOITORED BY
TEMPLATE TO
AVOID REDUCING PARENT METAL THICKNESS
.
 INTERNAL ATTACHMENTS
SUPPORT RING FOR TRAYS

OVERLAY

MACHINING

LAS
CLAD RESTORATION
THANK YOU