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Pressure Vessels with High-Alloy Cladding or Overlay
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Neither the whole nor any part of this document may be reproduced, stored in any retrieval system, or
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without the prior written consent of Chevron U.S.A. Inc.
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Pressure Vessels with High-Alloy Clad Pressure Vessels PVM-SU-1322-H.1
Summary of Changes
1. Revised technical content is indicated by change bars in the right margin.
2. Added, deleted, moved, and combined items are listed below.
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Pressure Vessels with High-Alloy Clad Pressure Vessels PVM-SU-1322-H.1
Contents
1.0 Scope............................................................................................................................................... 5
2.0 References ...................................................................................................................................... 5
2.1 Owner Documents .............................................................................................................. 5
2.2 Industry Codes and Standards ........................................................................................... 5
2.3 Conflict Resolution .............................................................................................................. 6
3.0 Acronyms ........................................................................................................................................ 6
4.0 Design ............................................................................................................................................. 7
4.1 Pressure Design.................................................................................................................. 7
4.2 Solid Alloy Components ...................................................................................................... 7
4.3 Openings ............................................................................................................................. 7
4.4 Weld Details ........................................................................................................................ 7
4.5 Internal Structural Supports ................................................................................................ 8
5.0 Materials .......................................................................................................................................... 8
5.1 Base Materials .................................................................................................................... 8
5.2 Welding Consumables ........................................................................................................ 8
5.3 Clad and Weld Overlay ....................................................................................................... 9
5.4 Roll Bond or Explosive Bond Clad ...................................................................................... 9
5.5 Weld Overlays ................................................................................................................... 11
6.0 Fabrication .................................................................................................................................... 11
6.1 Material Handling and Protection ...................................................................................... 11
6.2 Material Marking................................................................................................................ 12
6.3 Material Cutting and Clad Strip Back ................................................................................ 12
6.4 Material Forming ............................................................................................................... 12
7.0 Welding ......................................................................................................................................... 13
7.1 Base Metal Welding Procedure Qualification ................................................................... 13
7.2 Clad Restoration and Repair Welding Procedure Qualification ........................................ 13
7.3 Weld Overlay Procedure Qualification .............................................................................. 13
7.4 Welders and Welding Operator Qualifications .................................................................. 14
7.5 Production Weld Overlay, Clad Restoration, and Clad Repair ......................................... 14
7.6 Weld Overlay, Clad Restoration, and Clad Repair Quality Control .................................. 15
8.0 Preheat and Post Weld Heat Treatment ..................................................................................... 16
8.1 Preheat .............................................................................................................................. 16
8.2 Post Weld Heat Treatment ................................................................................................ 16
9.0 Inspection ..................................................................................................................................... 16
9.1 Pressure-Containing Welds .............................................................................................. 16
9.2 Clad Vessel Parts.............................................................................................................. 17
9.3 Weld Overlays, Clad Restoration, and Clad Repairs ........................................................ 17
10.0 Hydrostatic Test ........................................................................................................................... 19
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Pressure Vessels with High-Alloy Clad Pressure Vessels PVM-SU-1322-H.1
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Pressure Vessels with High-Alloy Clad Pressure Vessels PVM-SU-1322-H.1
1.0 Scope
1. This specification is to be used when corrosion-resistant alloy is required to protect the
carbon steel or low-alloy steel shell from severe corrosive attack by the process environment.
2. This specification addresses cladding by high-alloy sheet bonded to the plate or weld overlay
on the plate.
2.0 References
1. The following documents are referenced herein and are considered part of this specification.
2. Unless otherwise specified in Section 2.1 or Section 2.2, use the latest edition of the
referenced documents.
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Pressure Vessels with High-Alloy Clad Pressure Vessels PVM-SU-1322-H.1
3.0 Acronyms
ESW Electroslag Welding
FCAW Flux-Cored Arc Welding
FN Ferrite Number
GMAW Gas Metal Arc Welding
GTAW Gas Tungsten Arc Welding
ID Inside Diameter
MAWP Maximum Allowable Working Pressure
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Pressure Vessels with High-Alloy Clad Pressure Vessels PVM-SU-1322-H.1
4.0 Design
1. Standard drawing GD-C99663 shall be considered part of this specification.
2. Vessel drawings that are part of PVM-SU-4750, PVM-SU-5290, or PVM-SU-5291 shall be
included with purchase documents for high-alloy clad pressure vessels.
3. Only those alloys listed in ASME Code Section II, SA-263, SA-264, or SA-265 shall be used
for clad or weld overlaid vessels or vessel parts.
a. Duplex and super duplex stainless steels shall be excluded.
b. Other alloys that may be used shall be subject to review and authorization by Purchaser.
4.3 Openings
1. For clad vessels with a shell thickness of less than 2 inches (50 mm), nozzles and manways
shall conform to GD-C99663.
2. Nozzle liners shall not be used unless specified on the purchase order vessel drawings.
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Pressure Vessels with High-Alloy Clad Pressure Vessels PVM-SU-1322-H.1
5.0 Materials
5.1 Base Materials
Base materials as shown on vessel drawings shall be furnished according to the requirements of
PVM-SU-4750, PVM-SU-5290, or PVM-SU-5291, whichever applies.
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Pressure Vessels with High-Alloy Clad Pressure Vessels PVM-SU-1322-H.1
2. The non-matching alloy chosen shall be compatible with the clad chemistry for the vessel
service.
3. In addition to SFA specifications, vessel manufacturer may use the appropriate alloy
electrode and flux combinations for the submerged arc welding (SAW) process and
electroslag welding (ESW) process for weld overlay or clad restoration welding.
4. The electrode alloy, diameter or strip size, and flux combinations are manufacturer and brand
name specific and no intermixing of different brands shall be used in production without
requalification.
5. For Type 300 series stainless steels and Alloy 400 (Monel), the welding consumables listed
in API RP 582, may be used for weld overlay and clad restoration.
6. For Types 300/400 series stainless steels, copper-nickel, and nickel-base alloys, refer to
API RP 582, for typical consumables that can be used for combinations of these alloys (clad
restoration) to carbon steel or low-alloy steels.
7. Weld consumables and their applications shall be accepted by Purchaser. See Table 1 (at the
end of this specification) for typical weld consumables for each vessel alloy specified as a
guide for weld consumable selection.
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13. 405 and 410S ferritic stainless steel shall be supplied to vessel manufacturer in the
normalized and tempered condition.
a. Roll bond-produced clad materials shall be normalized at 1650°F ±25°F (900°C ±15°C)
and tempered at 1250°F (675°C) for one hour per inch (25 mm) of thickness.
b. Explosion bond-produced clad should not need to be heat treated to be supplied in the
normalized and tempered condition. However, if the explosion bond clad manufacturer
applies any heat treatment above 800°F (425°C), the procedure shall be submitted to
Purchaser for authorization.
6.0 Fabrication
6.1 Material Handling and Protection
1. Clad materials shall be handled with care and protected during vessel manufacturing
activities.
2. Clad surfaces and the as-welded surfaces of weld overlay shall be protected from the
following activities:
a. Arc gouging and grinding of carbon or low-alloy base metals that allow the splatter or
grinding debris to impact the clad surface.
b. Lifting or moving materials in a manner that causes carbon steel clamps or lifting chains
to contact and abrade the cladding.
c. Personnel walking on the clad surface.
d. Use of carbon steel fitting tools that come in contact with the clad surfaces.
3. Weld overlaid surfaces that have been machined shall be protected from carbon steel or low
alloy steel contact by covering and taping.
4. Clad and weld overlays shall also be protected from low-temperature melting elements
(e.g., lead, bismuth, zinc).
5. The procedure for material handling and protection of high-alloy clad or weld-overlaid
vessel parts and the completed vessel shall be submitted by the vessel manufacturer. This
procedure shall include steps to clean objectionable embedded carbon or low alloy steel, dirt,
grease, oil, or other surface contaminants.
6. Grinding disks shall be suitable for use with alloy clad or weld overlay deposit.
a. Grinding disks shall be segregated from disks used for carbon steel and shall be marked
for easy identification.
b. Care shall be taken to prevent contamination of the grinding disks from carbon or
low-alloy steel when repairs are made to clad or weld overlays.
c. Disks contaminated with carbon or low alloy steels, shall be discarded.
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2. Weld overlays shall not be formed in any manner. Weld overlays shall be applied after base
metal forming and heat treatment, if required.
3. Clad materials may be roll formed, press formed, spun formed, or press brake formed
provided that the alloy clad is protected from roll or press/spinning, die indentations, and iron
contamination.
4. Forming operations shall take into account thinning of the base metal and/or alloy clad
materials. Formed parts shall be checked for thickness after forming to ensure that minimum
thickness has been met for base metal and alloy clad.
5. Forming may be done hot or cold. If done hot (above 800°F [427°C]), clad material shall be
either post-formed heat treated to a condition equal to mill flat plate supply condition or hot
formed in a temperature range and cooled to a condition equal to mill flat plate supply
condition.
6. If formed, the vessel parts shall be heat treated per ASME Code after forming when extreme
fiber of the base material exceeds the limit identified in PVM-SU-4750, PVM-SU-5290, or
PVM-SU-5291.
a. The ASME formulas for determining extreme fiber shall be used for all forming methods
except spin forming.
b. Spin forming of head percent extreme fiber elongation shall be determined by the
following formula:
Where:
t = Nominal thickness of the base metal in inches (or mm)
Db = Diameter of the starting blank in inches (or mm)
De = External diameter of the formed head in inches (or mm)
ln = Natural logarithm
7.0 Welding
7.1 Base Metal Welding Procedure Qualification
Welding procedures and procedure qualifications for welded joints in the base metal shall be in
accordance with PVM-SU-4750, PVM-SU-5290, or PVM-SU-5291.
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Pressure Vessels with High-Alloy Clad Pressure Vessels PVM-SU-1322-H.1
2. Details of the weld overlay procedure shall be established by fabricator and submitted for
acceptance by Purchaser and shall include the following:
a. Weld process
b. Wire
c. Flux
d. Number of layers
e. Welding parameters
3. Single pass procedures, whereby the filler metal-base metal mix results in an equivalent
chemical analysis at the specified minimum thickness, shall be considered, provided that
fabricator can demonstrate the reliability of the proposed procedure and freedom from
interface micro-cracking.
4. SAW and ESW procedure qualifications shall be made using the specified base material and
the same type and brand of flux and weld wire/strip to be used in production overlay.
5. Before bend and liquid penetrant testing (PT), the weld overlay procedure qualification test
plate and weld overlay shall be subjected to the total thermal history planned for the
completed vessel.
6. After heat treatment, the weld overlay procedure qualification test plate shall be examined by
liquid penetrant in accordance with ASME Code, Section IX, as a minimum, and ASME
Code, Section VIII, Division 1 or 2, as applicable.
7. After PT of the weld overlay procedure qualification test plate has been completed and
accepted, bend specimens shall be examined as follows:
a. Removed from the test plate and tested per ASME, Code Section IX.
b. Liquid-penetrant examined on the convex surface in addition to the ASME Code
required visual exam.
8. PT results shall meet a “snow white” condition when viewed within the timeframe indicated
in the supplied NDE procedure.
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2. Maximum total weld overlay thickness shall not exceed 5/16 inch (8 mm) without written
Purchaser authorization.
3. Composition of the finished weld overlay deposit from the surface to the specified minimum
overlay depth shall conform to requirements of the applicable ASME SFA specifications for
the high alloy as listed in Section 2.2.
4. These requirements shall be specified on the drawings for matching or overmatching the
chemistry of base metal clad or equivalent weld metal alloy.
5. For the SAW and ESW processes, the finished weld deposit composition shall meet the
equivalent chemistry for the specified or vessel manufacturer’s chosen alloy and Purchaser
authorization, as required for vessel service.
6. Ferrite content of 300 series stainless steel deposited weld metal shall be between 3 and 10
ferrite number (FN) (8 FN is preferred for post weld heat treated vessels) as determined by a
magnetic instrument calibrated according to AWS A4.2 standard procedure.
7. Ferrite content shall be measured prior to any heat treatment.
8. Weld overlays shall be applied to base metal, which has been machined, ground, or blast
cleaned to SSPC SP 10 near-white metal finish, except that a SSPC SP 5 white metal finish is
required for weld overlay processes that do not use a flux (SAW and ESW).
9. Weld overlays shall be applied after forming and heat treatment of the base metal with the
exception of post weld heat treatment (PWHT).
10. Weld overlay shall be applied circumferentially to shell, heads, and nozzles. For long or
small nozzles where it is impractical to apply the weld overlay circumferentially, it may be
applied longitudinally with Purchaser acceptance.
7.6 Weld Overlay, Clad Restoration, and Clad Repair Quality Control
1. Production high-alloy welding shall strictly adhere to welding procedure essential and
non-essential variables, including the following:
a. Bead-to-bead overlap
b. Preheat and interpass temperatures
c. Inter-layer or individual weld bead cleaning
d. Travel speed
2. Before starting to weld overlay base materials, the base metal shall be machined, ground, or
blast cleaned to SSPC-SP 10 near-white metal finish, except that an SSPC-SP 5 white metal
finish shall be required for weld overlay processes that do not use a flux (SAW and ESW).
3. Welding consumables shall be verified to be acceptable and to meet manufacturer’s brand
name, and applicable SFA specifications for the required alloy, including UNS number.
4. Electrodes, strip, fluxes, and shielding gases shall be controlled in accordance with the weld
consumable manufacturer’s recommendations.
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Pressure Vessels with High-Alloy Clad Pressure Vessels PVM-SU-1322-H.1
9.0 Inspection
9.1 Pressure-Containing Welds
1. Category A, B, C, and D pressure-containing welds shall be inspected according to the
requirements of PVM-SU-4750, PVM-SU-5290, and PVM-SU-5291.
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4. Check analysis of carbon content shall be furnished for all austenitic stainless steels, clad,
solid, and/or weld metal, in accordance with the applicable ASME Code requirements and
the following additional requirements:
a. Carbon check analysis shall be required only for alloy pressure-containing parts such as
nozzles and bosses and for clad in contact with the contents of the vessel.
b. Carbon check analysis shall be required for each individual clad plate in contact with the
contents of the vessel.
c. Carbon check analysis shall be required for each heat and each batch of electrode flux
combinations and a minimum of one check for each shell ring head and nozzle.
d. For other weld processes, a minimum of one check per heat of electrodes (filler metal)
and one check for each longitudinal and girth seam and nozzle weld shall be performed.
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Pressure Vessels with High-Alloy Clad Pressure Vessels PVM-SU-1322-H.1
11.0 Records
Records listed in this section shall supplement the records required by PVM-SU-4750,
PVM-SU-5290, or PVM-SU-5291.
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11.3 Weld Overlays, Clad Restoration Welds, and Clad Repair Welds
The following minimum records shall be supplied upon completion of the vessel:
1. Weld consumable test certificates.
2. Weld procedures and supporting procedure qualification records.
3. PMI and chemical analysis records including portable analyzer calibration certification.
4. Ferrite reports including instrument calibrations (as applicable).
5. UT reports.
6. PT reports.
7. Weld maps of clad restoration welds and repairs to clad or weld overlay.
8. Heat treatment (over 800°F [427°C]) records.
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Table 1: Clad and Weld Deposit Alloy Chemical Element Verification Requirements
Clad Sheet and Solid Acceptable Filler Clad Restoration and Repair
Product Form Weld Overlay Deposits (3)
Materials (1) Metals (2) Weld Deposits (3)
Chemical Elements C Cr Ni Mo Cu Fe C Cr Ni Mo Cu Fe C Cr Ni Mo Cu Fe
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High-Alloy Clad Pressure Vessels PVM-SC-1322-H.1
Clad Sheet and Solid Acceptable Filler Clad Restoration and Repair
Product Form Weld Overlay Deposits (3)
Materials (1) Metals (2) Weld Deposits (3)
Chemical Elements C Cr Ni Mo Cu Fe C Cr Ni Mo Cu Fe C Cr Ni Mo Cu Fe
Notes:
1. Chemical elements shall meet the applicable ASME SA or SB material specification chemistry limits.
2. Limited example SMAW and bare filler metals listed. Other equivalent filler metals for SAW, ESW, and FCAW may be used.
3. Chemical elements shall meet the applicable ASME SFA filler metal specification chemistry limits. For those equivalent filler metals and flux combinations not covered by SFA specifications, chemical elements shall
meet the solid alloy requirements specified for the vessel or by agreement with Purchaser for non-matching chemistry weld deposits.
4. Stabilized alloys shall be analyzed for Carbon and Titanium or Niobium (Nb or Cb) and the carbon to stabilizing element ratio determined to be within applicable ASME specification for solid material or weld deposits.
5. For Monel (N04400) weld deposits, the Iron (Fe) content shall be limited to 5.0%.
6. Aluminum shall be determined for Alloy 625.
7. Cobalt shall be determined for these alloys.
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