CASTI Handbook

Cladding Technology
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CASTI HANDBOOK OF
CLADDING TECHNOLOGY
2nd Edition

Liane M. Smith, Ph.D.

Mario Celant, Ph.D.

Executive Editor
John E. Bringas, P.Eng.

CASTI Publishing Inc.

10566 114 Street
Edmonton, Alberta, T5H 3J7, Canada
Tel: (780) 424-2552 Fax: (780) 421-1308
E-mail: [email protected]
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ISBN 1-894038-30-4
Printed in Canada

iii

CASTI PUBLICATIONS
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CASTI Handbook of Cladding Technology 2nd Edition

iv

FROM THE PUBLISHER

IMPORTANT NOTICE
The material presented herein has been prepared for the general
information of the reader and should not be used or relied upon for
specific applications without first securing competent technical
advice. Nor should it be used as a replacement for current complete
engineering codes and standards. In fact, it is highly recommended
that the appropriate current engineering codes and standards be
reviewed in detail prior to any decision making.
While the material in this book was compiled with great effort and is
believed to be technically correct, the authors, CASTI Publishing Inc.
and its staff do not represent or warrant its suitability for any general
or specific use and assume no liability or responsibility of any kind in
connection with the information herein.
Nothing in this book shall be construed as a defense against any
alleged infringement of letters of patents, copyright, or trademark, or
as defense against liability for such infringement.

CASTI Handbook of Cladding Technology 2nd Edition

ix

PREFACE
Cladding technology refers to the application of a relatively thin layer
of an alloy (as the cladding) onto a substrate or backing material.
In many cases the cladding is selected for its resistance to corrosion.
A wide range of alloys can be clad, including stainless steels and
nickel base alloys to rare metals such as zirconium and tantalum.
The backing material is normally selected to meet the necessary
mechanical requirements (strength and toughness). The backing
material is often a grade of carbon or low alloy steel, other metals
may be used.
A key feature of clad products is that the backing material is often
significantly cheaper than the cladding alloy, so that clad products
can offer substantial cost savings over the use of solid alloy products.
The authors have been personally involved in the use of corrosionresistant alloy cladding of carbon steel for various applications in the
oil and gas industry for more than 10 years. This experience
prompted them to write this book covering wider aspects of clad
products including the different means of manufacturing them, their
properties, and their applications in various industries. The
substantial use of clad pipe in the oil and gas sector merits particular
mention, and so Chapter 9 of the book is devoted entirely to project
experience in that industry.
The principal units of measurements used are metric with imperial
conversions. Where appropriate, figures are expressed in nominal
imperial units with actual size metric conversion.
Alloys are identified principally by UNS numbers and abbreviated
terms are listed in the Appendix 1.
Liane Smith
Mario Celant
June1998

CASTI Handbook of Cladding Technology 2nd Edition

xi

TABLE OF CONTENTS
1. Introduction to Cladding Technology
Materials Selection Options for Corrosive Service
Dimensions of Clad Products
Economics of Clad Technology
Optimising the Corrosion Properties
Using Cladding Technology to Best Advantage

1
3
4
6
7

2. Clad Plate
Production Methods
Hot Roll Bonding
Backing Steel Types
Manufacturing Sequence
Optimizing Bonding
Heat Treatment
Inspection Requirements
Explosive Bonding
Weld Overlaying

9
9
10
12
16
19
22
23
29

3. Clad Pipes
Definitions
Longitudinally Welded Clad Pipe
Centricast Clad Pipe
Seamless Pipe Mill Clad Pipe
Explosively Bonded Clad Pipe
Lined Pipe
Thermo-Hydraulically Lined Pipe
Hydraulically Lined Pipe
Explosively Lined Pipe

33
34
38
43
48
50
51
53
55

4. Clad Bends
Manufacturing of Bends from Clad Pipe
Manufacturing of Bends from Lined Pipe

57
61

5. Clad Fittings
Clad Fittings Made by Weld Overlaying
Clad Fittings Made by Hot Isostatic Pressing
Clad Fittings Made from Clad Plate or Pipe
Clad Elbows
Clad Tees
Clad Manifolds
Clad Reducers and Caps
Clad Flanges and Valves

65
66
69
70
73
76
77
78

CASTI Handbook of Cladding Technology 2nd Edition

xii
6. Specification Requirements of Clad Products
Maximum Allowable Stress Values
Cladding Alloy
Backing Steel
Backing Steel Requirements for Application in
H2S Containing Environments
Mechanical Tests
Corrosion Tests
Demagnetising
Dimensions and Tolerances of Clad Pipe
Cladding and Wall Thickness
Diameter and Out of Roundness
Ultrasonic Inspection

81
82
83
84
85
87
90
90
90
92
93

7. Welding Clad Products

Fabricating Clad Vessels
Handling Clad Plate
Welding Clad Vessels
Circumferential Welding of Clad Pipe
Handling Clad Pipe
Pipe End Dimensions/Fit-up
Weld Preparation
Demagnetising of Pipes
Back Shielding
Choice of Welding Process
Choice of Filler Metal
Control of Heat Input
Weld Integrity Assessment
Welding Repairs During Pipelaying
Developments in Clad Pipe Welding Technology
Laying Clad Pipe
Commissioning Clad Pipelines

95
95
96
100
101
101
102
105
106
107
109
111
112
112
113
117
121

8. Clad Product Applications

Cladding Technology in the Oil & Gas Industry
Clad Production Tubing
Valves, Pumps, and Joints
Vessels and Heat Exchangers
Backing Steel
Cladding Alloy
Line Pipe and Manifolds
Cladding Technology in the Petrochemical Industry
Applications
Backing Steel

123
124
127
129
134
134
135
143
143
146

CASTI Handbook of Cladding Technology 2nd Edition

xiii
8. Clad Product Applications
Cladding Technology in the Petrochemical Industry (Continued)
Cladding Alloy
147
Disbonding in Hot Hydrogen
148
Cladding Technology in the Chemical Industry
149
Backing Steel
150
Cladding Alloy
150
Cladding Technology in Chemical Tankers
153
Cladding Technology in Metal Purification
154
Cladding Technology in the Power Industry
154
Cladding Technology in Air Pollution Systems
158
Cladding Technology in Shipping Applications
163
Cladding Technology in the Pulp and Paper Industry
165
9. Clad Pipe Projects
ADMA OPCO - Um-Shaif - 1993
Agip UK - Thelma and South East Thelma - 1995
ARCO Alaska Inc. - Prudhoe Bay - 1991
ARCO - Thames Bacton - 1987
Asamera Oil - Corridor - 1996
BP International Ltd. - Ravenspurn to Cleeton - 1987
BP International Ltd. - Forties - 1987
BP International Ltd. - Miller - 1989
BP International Ltd. - Cyrus - 1995
Chevron - Ninian - 1992
Clyde Petroleum - P2/P6 - 1997
Louisiana Land and Exploration - Lost Cabin - 1991
Mobil - Arun Booster Gas Compression - 1993
Mobil - South Lho Sukon - 1996
Mobil - Mobil 823 - 1995
Mobil - Yellowhammer - 1994
Mobil - 869 Field - 1995
Mobil - Ras Laffan LNG Co. Ltd. - North Field - 1998
Nederlandse Aardolie Maatschappij, NAM
- Early Field Trails - 1974-1975
Nederlandse Aardolie Maatschappij, NAM
- Roswinkel, Zuidlaren - 1978
Nederlandse Aardolie Maatschappij, NAM
- Emmen - 1987-1989
Nederlandse Aardolie Maatschappij, NAM
- Twente, Schoonebeek - 1988
Nederlandse Aardolie Maatschappij, NAM
- Dalen 6 And Dalen 9 - 1988
Nederlandse Aardolie Maatschappij, NAM
- Grijpskerk - 1996

167
168
170
171
172
173
174
174
176
180
180
182
182
188
188
189
190
192
192
193
194
196
196
197

CASTI Handbook of Cladding Technology 2nd Edition

xiv
9. Clad Pipe Projects (Continued)
ONGC - South Bassein - (1988 and 1993)
Shell Offshore - Fairway - 1991
Shell Todd Oil Services - Maui 'B' to 'A' - 1991
Pipe Production
Laying the Line
Welding
Inspection
Statoil - sgaard - 1997
Texaco - Erskine - 1997
Total Oil Marine - Bruce - 1991

198
204
208
209
210
211
214
214
215
216

Appendix 1 Abbreviated Terms

217

Appendix 2 Hardness Conversion Numbers

219

Appendix 3 Unit Conversions

229

Appendix 4 Pipe Dimensions

237

Appendix 5 Bibliography

243

Appendix 6 List of Figures and Contributors

253

Index

257

CASTI Handbook of Cladding Technology 2nd Edition

Chapter

1
INTRODUCTION TO
CLADDING TECHNOLOGY
Materials Selection Options for Corrosive Service
For many applications where a metallic material is needed, it is
normal to consider initially whether carbon or low alloy steels (total
alloying element content typically below 1% to 2%) would be suitable.
Such steels are cheap, have a wide range of mechanical properties to
suit various demands, and are readily available from many sources in
a wide range of product forms.
In aggressive environments, because of certain corrosive conditions, a
more highly alloyed material may be necessary or justified for
improved reliability and extended service life compared to basic steels.
Such alternative materials may include various grades of stainless
steels, nickel alloys, copper alloys, or titanium alloys depending upon
the environment. Since such materials would be selected to be
resistant to the environment in question, they may be referred to
generically as corrosion-resistant alloys or CRAs.
Any of these options would represent quite an increase in initial
installed cost per tonne compared to basic steels. Whilst such a shift in
materials selection may often be justified on a case-by-case basis
(particularly when the cumulative life cycle cost over the full service
life is considered), under many circumstances there is another option
to considerusing the selected CRA as a cladding or lining. The term
cladding technology is widely used generically to refer to both
cladding and lining options.

CASTI Handbook of Cladding Technology 2nd Edition

Introduction to Cladding Technology

Chapter 1

In a clad product, the CRA forms a complete barrier layer on the

surface of a carbon or low alloy steel (referred to as the backing steel).
The CRA layer is fully metallurgically bonded to the backing steel
with some diffusion of alloying elements between the two metals at
the interface. A distinction is made between a cladding layer and a
metallic coating applied by hot dipping (such as aluminizing or
galvanizing) or plating (such as nickel or electroless nickelphosphorus). Such coatings are not discussed in this book.
In a lined product, the CRA is in sheet form attached to the backing
steel at intervals. The lining is not metallurgically bonded to the
backing steel over most of its surface but is normally fully sealed to
form a complete barrier between the backing steel and the corrosive
environment.
The range of CRAs which can be clad by various techniques is very
wide. A few of the more commonly selected cladding alloys are
indicated in Table 1.1. In addition to these alloys, many other metals
including copper, titanium, and zirconium are available in clad form.
Table 1.1 Examples of CRAs Which Can Be Used as Cladding Alloys

Alloy UNS
410S S41008

C
max
0.08

S
max
1.00

Mn
max
1.00

304L

S30400

0.030

1.00

2.00

316L

S31603

0.030

1.00

2.00

321

S32100

0.08

1.00

2.00

317L

S31700

0.030

1.00

2.00

22Cr

S31803

0.030

2.00

904L N08904

0.020

0.70

2.00

926

N08926

0.020

1.00

2.00

825

N08825

0.025

0.50

1.00

625*

N06625

0.025

0.50

0.50

400

N04400

0.150

0.50

1.25

Cr
12.0
14.0
18.0
20.0
16.5
18.5
17.0
19.0
17.5
19.5
21.0
23.0
19.0
21.0
19.0
21.0
19.5
23.5
2.0
23.0
-

Ni

Mo

10.0
12.5
11.0
14.0
9.0
12.0
14.0
17.0
4.50
6.50
24.0
26.0
24.0
26.0
38.0
46.0
61.0
65.0
> 63.0

* 3,15 - 4,15 Nb
CASTI Handbook of Cladding Technology 2nd Edition

Cu

Fe

Ti

2.0
2.5
5x%C
0.70
3.0
4.0
2.50
4.50
4.0
5.0
6.0
7.0
2.5
3.5
8.0
10.0
-

1.0
2.0
0.5
1.5
1.5
3.0

28.0
34.0

bal.
<
3.0
1.0
2.5

0.6
1.2
< 0.4

Introduction to Cladding Technology

Chapter 1

Optimizing the Corrosion Properties

The fact that the CRA layer is fairly thin does mean that certain
precautions are necessary to ensure optimum performance in service.
The CRA selected should be fully resistant to corrosion in the service
environment. If corrosion does occur, particularly localised pitting or
corrosion cracking, the thin layer of CRA may be breached, exposing
the underlying backing steel to the environment with the risk of
corrosion.
Furthermore, once the appropriate CRA has been selected to avoid
such a scenario, it is critical that its corrosion properties are not
impaired during production. This may arise if a clad layer is
incorrectly heat treated, or if there is excessive diffusion of carbon
from the backing steel into the CRA layers. Corrosion resistance may
also be reduced if an inappropriate method is used for attaching a
CRA lining or if incorrect parameters are used in making weld
overlaid clad products or in fabricating clad products such that there
is excessive dilution of the CRA by the underlying steel. Such dilution,
or mixing, of the CRA with the backing steel should be limited,
otherwise the final composition may be outside that needed to achieve
full corrosion resistance. Further detail on these aspects and
optimising the properties of clad and lined products is given in
Chapter 2. Critical aspects covered in specifications are discussed in
Chapter 6.
With all CRA products, welding methods have to be carefully
controlled in order not to destroy the properties of the CRA in and
around the weld zone. For many CRAs, this requires welding methods
which have a low heat input (such as gas tungsten arc welding). Such
welding methods tend to be slow and, as a result, welding costs can be
high. The technical aspects of welding clad products are discussed in
Chapter 7.

CASTI Handbook of Cladding Technology 2nd Edition

Chapter

2
CLAD PLATE
Production Methods
The total production of metallurgically bonded clad plate by various
methods is about 80,000 tonnes/year. There are three principal
methods of manufacturing clad plate:
hot roll bonding
explosive bonding
weld overlaying
The production approach varies within each of these methods
depending upon the selected grade of backing steel, the selected
corrosion-resistant alloy (CRA), and the specification requirements.
Different manufacturers also vary somewhat in the approach they
take. Selecting the most appropriate route for clad plate manufacture
depends upon quantity, thickness, and alloy type.

Hot Roll Bonding

Hot roll bonding is the most widely adopted production method where
large clad areas are needed and accounts for about 85% of all clad
plate production.
Quite a wide range of CRAs may be selected for the cladding layer
although, as described later, some are technically easier to handle and
therefore more readily available. Specifically, many stainless steels
and nickel alloys may be produced in clad form using hot roll bonding.
CASTI Handbook of Cladding Technology 2nd Edition

26

Clad Plate

Chapter 2

Figure 2.10 Explosion cladding of plate near Perpignon (Fance).

detonation front
explosive

frame

cladding metal
jet
backing metal
collision point

Figure 2.11 Schematic of explosive bonding process.

Explosively clad plates may require flattening in a press or roller

leveler.
Finishing and quality control of the product would be similar to roll
bonded plates (Figure 2.13).
CASTI Handbook of Cladding Technology 2nd Edition

Chapter

3
CLAD PIPES
Definitions
The American Petroleum Institute API defines clad and lined steel
pipe in Section 2.1.a of API Specification 5LD as follows:
1. CLAD. Clad steel pipe is a bimetallic pipe composed of
an internal CRA layer metallurgically bonded to the base
metal.
2. LINED. Lined pipe is pipe in which a CRA layer is
affixed inside the carbon steel pipe, full length, by
expanding the liner and/or shrinking the pipe or by other
applicable processes. The CRA layer and the carbon steel
pipe shall be manufactured in accordance with Spec. 5LC
and Spec. 5L, respectively, except as may be otherwise
specified herein.
Normally, the word clad is used generally to mean both products
except where a specific distinction is made.
Generally speaking, the CRA layer is inside the pipe as defined above
but externally clad pipe is occasionally made for specific applications
(e.g., nickel-copper UNS N04400 clad pipe for riser splash zone
protection as discussed further under Line Pipe and Manifolds
(Chapter 8).

CASTI Handbook of Cladding Technology 2nd Edition

34

Clad Pipes

Chapter 3

Clad pipes may be produced using the following processes:

longitudinally welding of clad plate
centrifugal casting
seamless pipe mill production methods
explosive bonding
Lined pipes may be produced by:
hydraulic or thermohydraulic expansion
explosive lining
Clad pipes may be produced as full length or shorter lengths which
are generally welded in the shop and supplied as full 12.2 meters
(40 foot) lengths.

Longitudinally Welded Clad Pipe

Longitudinally welded pipe is made from clad plate which should be
thoroughly visually examined on the full surface before it is made into
pipe to check for any possible mechanical damage or localised
corrosion which might penetrate through the clad layer. Any such
defects should be repaired by welding or be cut from the plate.
The edges of the clad plate are machined for welding and the plate is
formed into pipe in a U-ing, O-ing, expansion (UOE), press bend or
rolling mill (Figure 3.1). Pipe edges are generally pre-bent to help the
plate obtain a good round shape after forming.
The seam weld has to be made by completing the weld in the carbon
steel first and completing the clad layer last. It might appear to be
simpler to weld the CRA layer first and then change over to a carbon
steel filler material for the weld made in the backing steel part of the
wall thickness. However, such a production route would give
deleterious hard microstructures in the carbon steel weld portion
where a small amount of underlying CRA was dissolved into the
carbon steel weld bead. In contrast, completing the carbon steel and
then overlaying a CRA layer as the final weld pass means that only a
small amount of carbon steel dissolves into the CRA which does not
result in hard microstructures.
CASTI Handbook of Cladding Technology 2nd Edition

Chapter

4
CLAD BENDS
Manufacturing of Bends from Clad Pipe
Manufacturing of clad bends is usually carried out using induction
heating of metallurgically bonded clad pipe. The clad pipe is put into
the bending machine: one end of the pipe is held with the clamp at the
top of the arm while the other end is fixed in a position with the tail
stock. An induction heating coil heats a limited narrow portion of the
pipe as it is pushed forward through this region. The pipe is
continuously heated and bent around the centre of gyration of the arm
until the given angle of bend is reached (Figure 4.1). Some bending
equipment is capable of producing multiple bends in pipe which may
help reduce the number of welds in piping systems (Figure 4.2).
It is preferable if the bending machines can induction heat the
tangent portions of the bend to avoid heat affected zones after
bending. Some machines have such continuous heat treat facilities
over the bent portion and also the tangents with facilities for internal
and external water quenching if required. Otherwise, bends may be
furnace heat treated. Figure 4.3 shows a number of clad bends coming
out of a furnace after heat treatment. If bends come from TMCP steel,
tempering should be avoided as this may cause a loss of strength.
Careful qualification of the bending and heat treatment process is
necessary in all cases.

CASTI Handbook of Cladding Technology 2nd Edition

Chapter 4

Clad Bends

61

Bends and elbows (down to 1.5 DR) can also be made using the
mandrel bending process (pushing the pipe over a bend former called
a mandrel) from 12.5-1219 mm (0.5-48 inch), and even larger
diameters up to 2540 mm (100 inch), with good dimensional tolerances
(see Clad Elbows in Chapter 5).
Bends have been made using the cold forming method (flexible
mandrel process), from seamless or welded metallurgically bonded
clad pipes. Although work hardening will occur, the forming
equipment is high powered and strong enough to compensate for the
increase in yield strength with plastic deformation. After bending,
final heat treatment (usually QT), if required by the specifications,
can be carried out.

Manufacturing of Bends from Lined Pipe

Investigations of cold bending of lined pipe have shown that some
minor wrinkling of the alloy liner arises at a bend radius of about
25 D. Thus, simple cold bending of lined pipe is limited to a minimum
radius of about 15 D before wrinkling of the liner becomes excessive.
Cold bends were made at 1, 2, 5.8, and 10 angles, corresponding
respectively to DR = 63, 31, 11, 6, on 6 inch (168.2 mm) OD
mechanically bonded pipes to observe possible disbonding or liner
buckling (Craig, 1994). Disbonding was judged by sectioning the bend
and observing any separation between the liner and the backing steel.
Some wrinkling started to appear in the liner at a 5.8 bend angle,
whilst several buckles were identified at 10 bend angle. The bends
were done without a mandrel, which would help reduce wrinkling but
not stop separation. In spite of some concerns about the reduced
corrosion resistance of the liner as a consequence of the cold work, it
was not possible to obtain meaningful results in the adopted corrosion
tests (ASTM G 48, and ASTM A 262). Further tests were made
according to ASTM G 28 on UNS N06625 lined mechanically bonded
pipes, showing some weld line attack after a hydraulically expanding
the liner back into the outer steel pipe.

CASTI Handbook of Cladding Technology 2nd Edition

Chapter

5
CLAD FITTINGS
Whilst there are many manufacturers of solid alloy fittings, there are
relatively few with wide experience producing clad fittings. This may
explain why solid alloy fittings have sometimes been used to complete
a clad system. In other cases availability or cost factors may lead to
the selection of solid alloy fittings. Furthermore, certain design codes
may favour solid alloys over clad steel because of higher allowable
stresses. Essentially each project has to be considered separately to
decide whether clad or solid fittings will be the most appropriate.
In spite of the relatively limited use of clad fittings to date, several
manufacturers are now capable of producing all the items necessary to
fulfill the needs of typical processing systems.
All types of fittings are available with internal cladding including
elbows, bends, tees, manifolds, reducers, eccentrics, and caps.
Manufacturing methods include:
weld overlaying
hot isostatic pressing (HIP)
manufacturing from clad plate or pipe.

Clad Fittings Made by Weld Overlaying

A key benefit of weld overlaying is that there are many suppliers
around the world and so lead time for supply is normally fairly short
compared to some other manufacturing routes. Various weld
overlaying techniques, as described previously for clad plate
CASTI Handbook of Cladding Technology 2nd Edition

Chapter

6
SPECIFICATION REQUIREMENTS
OF CLAD PRODUCTS
This chapter is not intended to give a rigorous breakdown of clad
product specifications but simply to comment on a few aspects.
Typical roll bonded clad plate production specifications are ASTM
A 264 (Stainless chromium-nickel steel clad plate, sheet and strip),
ASTM A 265 (Nickel and nickel-base alloy clad steel plate), and
JIS G 3602 (Nickel and nickel alloy clad steels).
There is an API specification, API 5LD, for CRA Clad or Lined Steel
Pipe.

Maximum Allowable Stress Values

The codes for vessel design allow the wall thickness calculations to
include some credit for the thickness of any cladding. Such cladding
has to be fully metallurgically bonded, and normally reference is made
to specifications for clad plate (e.g., ASTM A 263, A 264, A 265) or to
weld overlay cladding with specific requirements for quality control
and inspection of the weld overlay layer. Where linings are applied to
vessels, the thickness of the lining material is not included in the wall
thickness computation. In these cases the maximum allowable stress
values given are for the base material.

CASTI Handbook of Cladding Technology 2nd Edition

82

Specification Requirements of Clad Products

Chapter 6

The proportion of the applied cladding thickness that can be taken

into account in determining the wall thickness for design purposes is
explained in individual codes. As an example, ASME Section VIII Division 1 defines the allowed wall thickness equal to the nominal
thickness of the base material plus (Sc/Sb) x the nominal thickness of
the cladding after any allowance provided for corrosion has been
deducted, where:
Sc = the maximum allowable stress value for the integral
cladding at the design temperature, or for corrosion-resistant
weld metal overlay cladding, that of the wrought material
whose chemistry most closely approximates that of the
cladding at the design temperature.
Sb = the maximum allowable stress value for the base
material at the design temperature.
Where Sc is greater than Sb, the multiplier Sc/Sb shall be taken equal
to unity. The maximum allowable stress values are listed in the codes.
Pipeline design follows different codes and to date it has not been
usual for the cladding thickness to be included in the design
calculation of the wall thickness. Individual cases may be made where
some allowance for the cladding thickness could reasonably be made.

Cladding Alloy
The specifications for clad plate and clad pipe are limited to a small
selection of cladding alloys but with the option for purchaser and
manufacturer to agree on other grades or modified compositions
between. Thus, in principal, any cladding alloy may be selected whilst
in practice there are technical and economic limitations. Purchasers
may therefore find that what appears to be a cheaper alloy selection
may result in a more costly clad pipe because of the production
difficulties in heat treating certain alloys and optimising backing steel
toughness while achieving good corrosion resistance of the cladding.

CASTI Handbook of Cladding Technology 2nd Edition

90

Specification Requirements of Clad Products

Chapter 6

Demagnetising
Using magnetic grips to hold clad plates or pipes at various stages of
manufacturing and transportation can result in residual magnetism
which can interfere with welding by causing arc blow. Residual
magnetism may also arise form electromagnetic inspection in the mill.
Demagnetising of products at the mill is often requested in purchase
specifications but this can be a waste of time since they may remagnetise in transit. In the case of clad pipes, re-magnetising arises
because of pipe being knocked in transit or even by being stored in a
North-South orientation. In many cases pipes have had to be demagnetised on site immediately before welding to avoid arc blow
problems during welding.

Dimensions and Tolerances of Clad Pipe

Cladding and Wall Thickness
In terms of past production, about 40% of the produced pipes have
been purchased specifying 3 mm (0.12 inch) minimum cladding
thickness, and about 35% with 2 mm (0.08 inch) minimum. In
principle there is no problem in manufacturing a strictly controlled
product even as low as 1.6 mm (0.06 inch) in cladding thickness,
particularly with longitudinally welded pipes, but this will produce
possible problems in field welding. The fit-up problems would increase
the risk of possible iron dilution during the root pass, as the bevel end
for the root is generally set at about 1.6 mm (0.06 inch).
Manufacturers suggest a minimum cladding thickness of 2 mm
(0.08 inch) when using hydraulic line-up clamps for field welding, and
2.5 mm (0.1 inch) with conventional clamps. The reduction of the
cladding thickness from 3 mm (0.12 inch) to these levels would give
some economic benefit.
A typical tolerance on the cladding thickness is 0.5 mm (0.02 inch),
or rather, -0 mm, +1.0 mm (0.04 inch).

CASTI Handbook of Cladding Technology 2nd Edition

Chapter

7
WELDING CLAD PRODUCTS
The key factor which has to be considered in welding clad products is
maintaining the corrosion resistance of the inner cladding layer in
and around the weld zone. This has an impact on all aspects of the
welding procedure including the type of weld preparation, the choice
of welding process, the filler material, the shielding gas, and the heat
input.

Fabricating Clad Vessels

Handling Clad Plate
Clad plates should be stored in a clean and dry condition and treated
basically in the same way as solid CRAs. Where plates have to be cold
formed, the working surfaces of the forming equipment should be
clean to avoid contaminating the alloy surface.
Care should be taken to avoid damage to the clad surface during any
shearing, punching, or cutting operations. Clad plates can be flame
cut, usually from the backing steel side, or plasma cut, usually from
the cladding metal side. Powder cutting can also be used, generally
from the cladding side. Drilling is usually begun from the cladding
surface with tools and drilling conditions selected to be suitable for the
cladding material.
In producing vessel shells and heads, standard hot or cold forming
methods, depending upon clad plate size and thickness, are used with
somewhat more gradual pressure application than with solid steel.
CASTI Handbook of Cladding Technology 2nd Edition

Chapter 7

Welding Clad Products

97

in the last pass. Weld overlay techniques with low dilution

characteristics, like electroslag overlaying, have been accepted with
just a single pass.

Thickness (mm)

Base steel side

Cladding metal side

1.5~2.5

up to 15
(")

65 o 5 o

1.5
65o 5o

1.5

over 15 up to 22
(" ~ ")

90o 5 o

0~1

a
2.0

65 o 5 o

over 22 up to 38
(" ~ 1")

b'

2~3

2.0

60 o 5 o

0~1
15o 5 o

over 38
(1")

a:b = 1:3

2.0

82R

82R
2.0
15 o 5 o

0~1

Cladding ratio of
over 20%
In case of
difficulty at edge
preparation

min. 5

min. 5

min. 5

min. 5

Note: 1) Edge preparation can be done by machining, gas-cutting, or plasma-arc cutting.

2) Edge prepared surfaces should be smooth, and the surface of edge prepared
by gas-cutting should be ground smoothly.
3) Dimensions in mm.

Figure 7.1 Typical weld joint designs for clad vessels.

The welding method described above is appropriate when the cladding

alloy and backing material are compatible as dissimilar metal welds.
Some metals cannot be directly welded to each other as they form
brittle phases or suffer other cracking problems such as liquation
cracking in the weld zone. In such cases a strip of the cladding metal
is fillet welded over the completed internal weld seam to give a
continuous corrosion-resistant alloy surface. This method is typically
used when vessels are fabricated from titanium clad plate. In this case
the titanium cladding is cut back from the carbon steel along the weld
line. The carbon steel is then welded using standard techniques. A
batten of copper is then positioned on the carbon steel weld and
CASTI Handbook of Cladding Technology 2nd Edition

Chapter

8
CLAD PRODUCT APPLICATIONS
Cladding Technology in the Oil & Gas Industry
Clad products have been used extensively in the oil and gas industry
to counteract corrosive conditions. Major applications have been in the
form of clad pipes, vessels, and heat exchangers but there are also
other components that are routinely supplied in clad form such as
wellheads and other valves.
Clad products have to compete against carbon steel and solid CRAs.
Where the duration of a project is short, the amount of corrosion
arising on carbon steel may be tolerated by allowing extra wall
thickness, or corrosion allowance, which is consumed during the
project. Chemicals (corrosion inhibitors) may be injected into the
environment to reduce the corrosion rate.
In some cases, however, the anticipated rate of corrosion may be too
high or the life of the project too long to simply allow the corrosion to
take place. In such cases, CRAs may be selected which will suffer
negligible corrosion over the duration of the project. The choice of solid
or clad is then a matter of which is more economical, but clad steel
may offer some specific advantages in this industry in some cases.
One example is offshore projects developed by means of a fixed or
floating structure. In such cases it is beneficial to save weight in the
topside facilities to reduce the cost of the support structure. The use
of backing steels with higher strength than solid CRAs then allows a
reduction in wall thickness of the topside facilities (vessels and piping,
etc.) which reduces the weight of those items with corresponding
economic benefits for the structure.
CASTI Handbook of Cladding Technology 2nd Edition

Chapter 8

Clad Product Applications

153

It is very common to find chemical reactor vessels internally clad with

UNS S31603, even where the corrosion conditions may not be
extremely aggressive. An example is the production of polypropylene.
Cladding is required here because of the need to produce really pure
untainted products without any colour contamination. There is some
use of UNS S30400 cladding in systems handling dry products such as
polymer particles, again for requirements of cleanliness and lack of
contamination.
The electrochemical industry makes some use of titanium clad plate in
processes for the production of caustic soda and chlorine.

Cladding Technology in Chemical Tankers

The typical corrosive products carried by shipping tankers are
hydrogen peroxide, oxypropylene, and various acids in concentrated
form. Austenitic stainless steel (mostly type 304 or 316), duplex
stainless steels, or occasionally higher alloys are selected for the
chemical container.
Clad steel has often been used in the wing and end bulkheads, whilst
transverse and centre line bulkheads are solid alloy in
horizontally/vertically corrugated configuration. The clad plate is
normally 8-15 mm (0.3-0.6 inch) thick with 1.5-3 mm (0.06-0.12 inch)
of stainless steel. The outer surface of the chemical cargo tank forms
the inner surface of the ballast space and, since this is filled with
seawater, the corrosion of the carbon steel surface (both the clad steel
and the outer tank construction) is conveniently controlled by
protective coatings and cathodic protection. There is some preference
for clad steel over solid stainless to avoid problems of galvanic
corrosion of the carbon steel tanker wall in the ballast space and to
prevent any risk of localised corrosion or stress corrosion cracking of
the stainless steel.
In the 1993 Rules for the Manufacture, Testing and Certification of
Materials published by Lloyds Register of Shipping (formerly Part 2 of
the Rules for Ships), clad plates are listed as optional materials for the
construction of cargo or storage tanks for chemicals. Approved
CASTI Handbook of Cladding Technology 2nd Edition

154

Clad Product Applications

Chapter 8

manufacturing processes are roll-bonding and explosive cladding. The

backing steel should be carbon or carbon manganese steel clad with
austenitic steels type UNS S30403, S30453, S31603, S31653, S31703,
S31753, S32100, S34700, S31254 or N08904.
With the development of duplex stainless steels over the last twenty
years, there has been a strong shift toward their use for chemical
tankers instead of clad plate (Leffler, 1991) (Hilkes, et. al., 1991).

Cladding Technology in Metal Purification

High pressure acid leaching of metal ores such as gold, nickel, and
copper in hydrometallurgy extraction methods requires autoclaves
resistant to concentrated acids and metal ions. Titanium and
zirconium explosively clad autoclaves are very cost effective compared
to solid where the wall thickness is often around 100 mm (4 inch).
There are examples in service for more than 25 years (Banker and
Forrest, 1996).
A primary metal manufacturer has used zirconium clad plates for a
rotary kiln (1.2 meters (48 inch) diameter and 12 meters (40 foot)
long) for manufacturing zirconium oxide from zirconyl sulfate. The
kiln is lined with bricks on top of the zirconium cladding. The
zirconium surface is exposed to sulfuric acid and sulfates and cycling
temperatures up to 200C (390F). No major problems have been
reported in over 17 years of service.

Cladding Technology in the Power Industry

Flow accelerated corrosion (FAC) is an erosion-corrosion mechanism
that occurs in high purity steam/condensate lines.
FAC in nuclear power plants primarily affects carbon steel extraction
steam lines, heater drains, and feed water piping. The plant water
chemistry and other factors destabilize the normally protective iron
oxide (magnetite) layer, leading to the continuous FAC of the
underlying carbon steel with significant loss of wall thickness. This
CASTI Handbook of Cladding Technology 2nd Edition

Chapter

9
CLAD PIPE PROJECTS
The oil and gas industry has made the most extensive use of clad pipe
of any industrial sector. The clad pipe is most often selected for the
flowlines, i.e. the pipe carrying the untreated produced fluids from the
wellhead to the treatment facilities.
An overview of the types of clad pipe products and the materials
selected was given in Chapter 8 (Line Pipe and Manifolds). The
present chapter describes some individual projects or experiences of
particular operators with clad pipe installations. The aim is to
highlight key issues for selecting a particular pipe material, e.g., the
nature of the cladding, the way in which the pipe was welded or laid,
and any operating experience to guide future potential users.
The projects are described in alphabetical order of the operating
company with the year of installation.

ADMA OPCO - Um-Shaif - 1993

This project, engineered by Bechtel in 1993, involved installing a
204 meters (670 foot), 323 mm (12 inch) diameter flowline from a
fixed unmanned platform and tying it in to an existing 762 mm
(30 inch) diameter pipeline made of carbon steel (protected by
inhibitor injection). The flowline was to carry gas with 6% CO2 and
0.06% H2S; the design temperature was 93C (200F), and the design
pressure 93.1 bar (1350 psi).

CASTI Handbook of Cladding Technology 2nd Edition

168

Clad Pipe Projects

Chapter 9

UNS N06625 cladding material was selected because commissioning

conditions would require seawater to be present in the line, after
hydrotesting, for at least six months. The 323.9 mm (12 inch)
diameter, 7.1 mm (0.28 inch) wall thickness pipe with 3 mm
(0.12 inch) of cladding was supplied from Kubota and 10 bends of
radius 3DR were made by high frequency induction bending by DHF.
Difficulties with casting UNS N06625 at that time resulted in pipes
having to be cut short so that most 12 meter lengths contained a
number of girth welds.

Agip UK - Thelma and South East Thelma - 1995

Thelma and South East Thelma are located in the North Sea in the
T-Block, approximately 12 km (7.5 miles) South-East of the Tiffany
process platform. The fields have a sub-sea production template and
manifold connected to the Tiffany platform by a 273 mm (10 inch)
production flowline and a 168 mm (6 inch) production or well
testing flowline. A 114.3 mm (4 inch) service flowline links the
Thelma field to the Toni water injection template for fluid disposal
when required.
The wellhead design temperature is 110C (230F), design pressure is
290 bar (4200 psi), operating pressure between 48.3 bar (700 psi) and
276 bar (4000 psi), the formation water pH is between 5.1 and 5.6,
formation water TDS about 95,000 ppm, of which about 57,000 ppm
are chlorides. Maximum CO2 content is 15.5%, and H2S is 500 ppm in
the oil phase (0.1 bar (1.5 psi) partial pressure) in one well and
100 ppm in the remaining 4 wells, bringing the average content to
170 ppm.
Duplex stainless steel was originally selected for all the pipelines etc.,
handling untreated fluids (Calvarano, et. al., 1995) as it was
considered suitable for normal operating conditions. During
shutdown, when the design pressure is reached, the H2S partial
pressure would rise beyond the normally accepted values for safe
exposure of duplex stainless steels. Fortuitously, this situation seldom
occurs and is of limited duration because of cooling of the flowlines
after shutdown. Selection of duplex stainless steel would, however,
CASTI Handbook of Cladding Technology 2nd Edition

Chapter 9

Clad Pipe Projects

183

The original piping in the plant was centricast 13% Cr but the gradual
drop in pressure of the field necessitated an increase in the pipe
diameter and 13% Cr piping was not available in 762 mm (30 inch)
diameter required. Hence clad pipe was selected. The installation of
762 mm (30 inch) OD clad piping was cost effective since it meant that
there was no need to install compressor stations in the manifold to
carry the gas to the treatment units (Akabane, 1994).
This field development consists of 4 well clusters each with two
headers requiring a total of 10.2 km (6.3 miles) of 762 mm (30 inch)
diameter, 12.7 mm (0.5 inch) wall thickness (API 5L X60) with 2 mm
(0.08 inch) UNS N08825 cladding pipe and some 219 mm (8 inch)
diameter clad pipe (Figure 9.6). The pipes were supplied by JSW as
were 64 tees (762 x 219 mm, 30 x 8 inch). The clad lines collect gas
and condensate which are then dehydrated.
The gas is compressed to an LNG plant 20 miles away through a
1066.8 mm (42 inch) pipeline and the condensates are transported in a
406 mm (16 inch) line (Figure 9.7).
The backing steel for the clad pipe was not specified to be SWC
resistant, but the welds were limited to 250 HV maximum hardness
since the conditions are judged to be slightly sour. All the pipe ends
were bevelled by the manufacturer (JSW) and supplied with end
protectors. Considerable planning went into the design of the cluster
layout to suit joint lengths so that only 44 field cuts and bevels were
required out of about 1,000 joint lengths supplied. The average time
per cut and bevel was 6.5 hours.
Some solid UNS N08825 flanges and 114.3 mm (4 inch) and
60.3 mm (2 inch) weld-o-lets were also used in the project.

CASTI Handbook of Cladding Technology 2nd Edition

Appendix

1
ABBREVIATED TERMS
AAI
AISI
ANSI
API
ASME
ASTM
BS
CII
CITHP
CLI
CPT
CRA
CRC
CTOD
DHF
DIN
DR
DWTT
EFC
ENP
ESW
FAC
FCAW
FGD
GMAW
GTAW
HAZ
HIP

Arco Alaska Inc.

American Iron and Steel Institute
American National Standards Institute
American Petroleum Institute
American Society of Mechanical Engineers
American Society for Testing and Materials
British Standard
Lined pipe product produced by NSC
Closed in tubing head pressure
Creusot Loire Industrie
Critical pitting temperature
Corrosion-resistant alloy
CRC-Evans Automatic Welding
Crack tip opening displacement
Dai-Ichi High Frequency
Deutsche Institut fr Normung
Radius of bend expressed as multiple of pipe diameter
Drop weight tear test
European Federation of Corrosion
Electroless nickel plating
Electroslag welding
Flow accelerated corrosion
Flux cored arc welding
Flue Gas Desulphurisation
Gas metal arc welding
Gas tungsten arc welding
Heat-Affected Zone
Hot isostatic pressing
CASTI Handbook of Cladding Technology 2nd Edition

218

Abbreviated Terms

HSLA
ID
JSW
LIDB
LNG
NACE
NAM
NDE
NKK
NSC
OCTG
OD
OOR
PASSO
PGMAW
PGTAW
PQR
PTA
PWHT
PWR
QT
RT
SAW
SCC
SDH
SMAW
SMYS
SSC
SSCV
SWC
TDS
TMCP
UNS
UO
UOE
UT
V-A

Appendix 1

High strength low alloy

Internal diameter
Japan Steel Works
Liquid interface diffusion bonding
Liquefied natural gas
National Association of Corrosion Engineers
(now NACE International)
Nederlandse Aardolie Maatschappij
Non-destructive examination
NKK Corporation
Nippon Steel Corporation
Oil Country Tubular Goods
Outside diameter
Out-of-roundness
Processo Arcos Saipem Saldatura Orbitale
Pulsed gas metal arc welding
Pulsed gas tungsten arc welding
Procedure Qualification Record
Pure Terephthalic Acid
Post welding heat treatment
Pressurised Water Reactor
Quenched and tempered
Radiographic testing
Submerged arc welding
Stress corrosion cracking
Side drilled hole
Shielded metal arc welding
Specified minimum yield strength
Sulfide stress corrosion cracking
Semi-submersible crane vessel
Stepwise cracking
Total dissolved solids
Thermo-mechanical control process
Unified Numbering System
U-ing, O-ing, (pipe forming)
U-ing, O-ing, Expansion, (pipe forming)
Ultrasonic testing
Voest-Alpine

CASTI Handbook of Cladding Technology 2nd Edition

Appendix

2
HARDNESS CONVERSION NUMBERS

CASTI Handbook of Cladding Technology 2nd Edition

Appendix 2

220

Hardness Conversion Numbers

APPROXIMATE HARDNESS CONVERSION NUMBERS FOR NONAUSTENITIC STEELSa, b

Rockwell C
150 kgf
Diamond
HRC
68
67
66
65

Vickers
HV
940
900
865
832

64

800

63

772

62

Brinell
3000 kgf
10 mm ball
HB
------739d

Knoop
500 gf
HK
920
895
870
846

Rockwell A
60 kgf
Diamond
HRA
85.6
85.0
84.5
83.9

Rockwell Superficial Hardness

15 kgf
30 kgf
45 kgf
Diamond
Diamond
Diamond
HR15N
HR30N
HR45N
93.2
84.4
75.4
92.9
83.6
74.2
92.5
82.8
73.3
92.2
81.9
72.0

Approximate
Tensile
Strength
ksi (MPa)
---------

722d

822

83.4

91.8

81.1

71.0

---

706d

799

82.8

91.4

80.1

69.9

---

746

688d

776

82.3

91.1

79.3

68.8

---

61

720

670d

754

81.8

90.7

78.4

67.7

---

60

697

654d

732

81.2

90.2

77.5

66.6

---

59

674

634d

710

80.7

89.8

76.6

65.5

351 (2420)

58
57
56
55
54
53
52
51
50
49
48
47

653
633
613
595
577
560
544
528
513
498
484
471

615
595
577
560
543
525
512
496
482
468
455
442

690
670
650
630
612
594
576
558
542
526
510
495

80.1
79.6
79.0
78.5
78.0
77.4
76.8
76.3
75.9
75.2
74.7
74.1

89.3
88.9
88.3
87.9
87.4
86.9
86.4
85.9
85.5
85.0
84.5
83.9

75.7
74.8
73.9
73.0
72.0
71.2
70.2
69.4
68.5
67.6
66.7
65.8

64.3
63.2
62.0
60.9
59.8
58.6
57.4
56.1
55.0
53.8
52.5
51.4

338 (2330)
325 (2240)
313 (2160)
301 (2070)
292 (2010)
283 (1950)
273 (1880)
264 (1820)
255 (1760)
246 (1700)
238 (1640)
229 (1580)

CASTI Handbook of Cladding Technology 2nd Edition

Appendix 2

Hardness Conversion Numbers

221

APPROXIMATE HARDNESS CONVERSION NUMBERS FOR NONAUSTENITIC STEELSa, b (Continued)

Rockwell C
150 kgf
Diamond
HRC
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24

Vickers
HV
458
446
434
423
412
402
392
382
372
363
354
345
336
327
318
310
302
294
286
279
272
266
260

Brinell
3000 kgf
10 mm ball
HB
432
421
409
400
390
381
371
362
353
344
336
327
319
311
301
294
286
279
271
264
258
253
247

Knoop
500 gf
HK
480
466
452
438
426
414
402
391
380
370
360
351
342
334
326
318
311
304
297
290
284
278
272

Rockwell A
60 kgf
Diamond
HRA
73.6
73.1
72.5
72.0
71.5
70.9
70.4
69.9
69.4
68.9
68.4
67.9
67.4
66.8
66.3
65.8
65.3
64.6
64.3
63.8
63.3
62.8
62.4

Rockwell Superficial Hardness

15 kgf
30 kgf
45 kgf
Diamond
Diamond
Diamond
HR15N
HR30N
HR45N
83.5
64.8
50.3
83.0
64.0
49.0
82.5
63.1
47.8
82.0
62.2
46.7
81.5
61.3
45.5
80.9
60.4
44.3
80.4
59.5
43.1
79.9
58.6
41.9
79.4
57.7
40.8
78.8
56.8
39.6
78.3
55.9
38.4
77.7
55.0
37.2
77.2
54.2
36.1
76.6
53.3
34.9
76.1
52.1
33.7
75.6
51.3
32.5
75.0
50.4
31.3
74.5
49.5
30.1
73.9
48.6
28.9
73.3
47.7
27.8
72.8
46.8
26.7
72.2
45.9
25.5
71.6
45.0
24.3

Approximate
Tensile
Strength
ksi (MPa)
221 (1520)
215 (1480)
208 (1430)
201 (1390)
194 (1340)
188 (1300)
182 (1250)
177 (1220)
171 (1180)
166 (1140)
161 (1110)
156 (1080)
152 (1050)
149 (1030)
146 (1010)
141 (970)
138 (950)
135 (930)
131 (900)
128 (880)
125 (860)
123 (850)
119 (820)

CASTI Handbook of Cladding Technology 2nd Edition

Appendix

3
UNIT CONVERSIONS

CASTI Handbook of Cladding Technology 2nd Edition

Appendix 3
METRIC CONVERSION FACTORS
To Convert From
To
Angle
degree
rad
Area
in.2
mm2
in.2
cm2
in.2
m2
2
ft
m2
Bending moment or torque
lbf - in.
N-m
lbf - ft
N-m
kgf - m
N-m
ozf - in.
N-m
Bending moment or torque per unit length
lbf - in./in.
N - m/m
lbf - ft/in.
N - m/m
Corrosion rate
mils/yr
mm/yr
mils/yr
/yr
Current density
A/in.2
A/cm2
2
A/in.
A/mm2
A/ft2
A/m2

Multiply By
1.745 329 E -02
6.451 600
6.451 600
6.451 600
9.290 304

E + 02
E + 00
E - 04
E - 02

1.129 848
1.355 818
9.806 650
7.061 552

E - 01
E + 00
E + 00
E - 03

4.448 222 E + 00
5.337 866 E + 01
2.540 000 E - 02
2.540 000 E + 01
1.550 003 E - 01
1.550 003 E - 03
1.076 400 E + 01

To Convert From
To
Mass per unit time
lb/h
kg/s
lb/min
kg/s
lb/s
kg/s
Mass per unit volume (includes density)
g/cm3
kg/m3
3
lb/ft
g/cm3
3
lb/ft
kg/m3
lb/in.3
g/cm3
3
lb/in.
kg/m3
Power
Btu/s
kW
Btu/min
kW
Btu/h
W
erg/s
W
ft - lbf/s
W
ft - lbf/min
W
ft - lbf/h
W
hp (550 ft - lbf/s)
kW
hp (electric)
kW
Power density
W/in.2
W/m2

Unit Conversions

230

Multiply By
1.259 979 E - 04
7.559 873 E - 03
4.535 924 E - 01
1.000 000
1.601 846
1.601 846
2.767 990
2.767 990

E + 03
E - 02
E + 01
E + 01
E + 04

1.055 056
1.758 426
2.928 751
1.000 000
1.355 818
2.259 697
3.766 161
7.456 999
7.460 000

E + 00
E - 02
E - 01
E - 07
E + 00
E - 02
E - 04
E - 01
E - 01

1.550 003 E + 03

CASTI Handbook of Cladding Technology 2nd Edition

Appendix 3
THE GREEK ALPHABET
, - Alpha
, - Beta
, - Gamma
, - Delta
, - Epsilon
, - Zeta
, - Eta
, - Theta

, - Iota
, - Kappa
, - Lambda
, - Mu
, - Nu
, - Xi
, - Omicron
, - Pi

Unit Conversions

235

, - Rho
, - Sigma
, - Tau
, - Upsilon
, - Phi
, - Chi
, - Psi
, - Omega

CASTI Handbook of Cladding Technology 2nd Edition

Appendix

4
PIPE DIMENSIONS

CASTI Handbook of Cladding Technology 2nd Edition

Appendix 4
DIMENSIONS OF WELDED AND SEAMLESS PIPEa
Nominal
Outside
Pipe Size
Diameter
Schedule
Schedule
(in.)
(in.)
5S
10S
1/8
0.405
--0.049
1/4
0.540
--0.065
3/8
0.675
--0.065
1/2
0.840
0.065
0.083
3/4
1.050
0.065
0.083
1
1.315
0.065
0.109
1 1/4
1.660
0.065
0.109
1 1/2
1.900
0.065
0.109
2
2.375
0.065
0.109
2 1/2
2.875
0.083
0.120
3
3.5
0.083
0.120
3 1/2
4.0
0.083
0.120
4
4.5
0.083
0.120
5
5.563
0.109
0.134
6
6.625
0.109
0.134
8
8.625
0.109
0.148
10
10.75
0.134
0.165
12
12.75
0.156
0.180
14 O.D.
14.0
0.156
0.188
16 O.D.
16.0
0.165
0.188
18 O.D.
18.0
0.165
0.188
20 O.D.
20.0
0.188
0.218
22 O.D.
22.0
0.188
0.218

Nominal Wall Thickness (in.)

Schedule
Schedule
Schedule
10
20
30
--------------------------------------------------------------------------------------------0.250
0.277
--0.250
0.307
--0.250
0.330
0.250
0.312
0.375
0.250
0.312
0.375
0.250
0.312
0.438
0.250
0.375
0.500
0.250
0.375
0.500

Pipe Dimensions

Schedule
Standard
0.068
0.088
0.091
0.109
0.113
0.133
0.140
0.145
0.154
0.203
0.216
0.226
0.237
0.258
0.280
0.322
0.365
0.375
0.375
0.375
0,375
0.375
0.375

238

Schedule
40
0.068
0.088
0.091
0.109
0.113
0.133
0.140
0.145
0.154
0.203
0.216
0.226
0.237
0.258
0.280
0.322
0.365
0.406
0.438
0.500
0.562
0.594
---

CASTI Handbook of Cladding Technology 2nd Edition

Appendix 4
DIMENSIONS OF WELDED AND SEAMLESS PIPEa (Continued)
Nominal
Outside
Pipe Size
Diameter
Schedule
Schedule
(in.)
(in.)
5S
10S
24 O.D.
24.0
0.218
0.250
26 O.D.
26.0
----28 O.D.
28.0
----30 O.D.
30.0
0.250
0.312
32 O.D.
32.0
----34 O.D.
34.0
----36 O.D.
36.0
----42 O.D.
42.0
----a. See next page for heavier wall thicknesses

Nominal Wall Thickness (in.)

Schedule
Schedule
Schedule
10
20
30
0.250
0.375
0.562
0.312
0.500
--0.312
0.500
0.625
0.312
0.500
0.625
0.312
0.500
0.625
0.312
0.500
0.625
0.312
0.500
0.625
-------

Pipe Dimensions

Schedule
Standard
0.375
0.375
0.375
0.375
0.375
0.375
0.375
0.375

239

Schedule
40
0.688
------0.688
0.688
0.750
---

CASTI Handbook of Cladding Technology 2nd Edition

Appendix

5
BIBLIOGRAPHY
The following is an alphabetical list of sources consulted in preparing
this book.
Akabane, H. Mobil Arun Field Debottlenecking, 2nd International
Seminar on Clad Engineering, Houston, May 6th, 1994.
ANSI/ASME B16.9 Factory Made Wrought Steel Buttwelding Fittings.
ANSI/ASME B31.3 Process Piping.
API Specification for Corrosion Resistant Alloy Line Pipe (Spec. 5LC).
API Specification for CRA Clad or Lined Steel Pipe (Spec. 5LD).
API Specification for Line Pipe (Spec. 5L).
API 1104 Welding of Pipelines and Related Facilities.
ASME B31.3 Chemical Plant and Petroleum Refinery Piping.
ASME Section VIII Pressure Vessels.
ASTM A204 Specification for Pressure Vessel Plates, Alloy Steel,
Molybdenum.
ASTM A262Practices for Detecting Susceptibility to Intergranular
Attack in Austenitic Stainless Steels.

CASTI Handbook of Cladding Technology 2nd Edition

244

Bibliography

Appendix 5

ASTM A263 Specification for Corrosion-Resisting Chromium SteelClad Plate, Sheet, and Strip.
ASTM A264 Specification for Stainless Chromium-Nickel Steel Clad
Plate, Sheet, and Strip.
ASTM A265 Standard Specification for Nickel and Nickel-Base Alloy
Clad Steel Plate.
ASTM A387 Specification for Pressure Vessel Plates, Alloy Steel,
Chromium-Molybdenum.
ASTM A516 Standard Specification for Pressure Vessel Plates,
Carbon Steel, for Moderate and Lower-Temperature Service.
ASTM A533 Standard Specification for Pressure Vessel Plates, Alloy
Steel, Quenched and Tempered, Manganese-Molybdenum and
Manganese-Molybdenum-Nickel.
ASTM A578 Standard Specification for Straight-Beam Ultrasonic
Examination of Plain and Clad Steel Plates for Special Applications.
ASTM G28 Test Methods of Detecting Susceptibility to Intergranular
Corrosion in Wrought, Nickel-Rich, Chromium-Bearing Alloys.
ASTM G39 Practice for Preparation and Use of Bent-Beam StressCorrosion Test Specimens.
ASTM G48 Test Method for Pitting and Crevice Corrosion Resistance
of Stainless Steels and Related Alloys by Use of Ferric Chloride
Solution.
ASTM G146 Practice for Evaluation of Disbonding of Bimetalic
Stainless Alloy/Steel Plate for use in High-Pressure, HighTemperature Refinery Hydrogen Service.
Avery, R.E. and Schillmoller, C.M. Development of Mechanized Field
Girth Welding of High Alloy Corrosion Resistant Pipeline Materials,
NiDI Technical series N 10061, 1991.
CASTI Handbook of Cladding Technology 2nd Edition

Appendix 5

Bibliography

245

Banker, J.G. Commercial Applications of Zirconium Explosion Clad,

Journal of Testing and Evaluation, ASTM, Mar. 1996.
Banker, J.G. Try Explosion Clad Steel for Corrosion Protection,
Chemical Engineering Progress, July 1996.
Banker, J.G. and Cayard, M. Evaluation of Stainless Steels
Explosion Clad for High Temperature, High Pressure Hydrogen
Service, Materials Property Council Conference on Hydrogen Effects
on Materials for Refinery Applications, Wien, Oct. 1994.
Banker, J.G. and Forrest, A.L. Titanium/Steel Explosion Bonded
Clad for Autoclaves and Reactors, MMS Annual Meeting, TMS,
Warrendale PA., Feb. 1996.
Belloni, A. et al. Large Diameter Clad Pipes, Production, Welding
and Offshore Laying Experience, 11th International Conference on
Offshore Mechanics and Arctic Engineering, OMAE/92, Calgary, June
1992, Vol. 5, p. 383.
Belloni, A. ONGC - BE Project, 2nd International Seminar on Clad
Engineering, Houston, May 6th, 1994.
Belloni, A. Welding Clad Pipes in CRA Materials Recent
Experience, Stainless Steel World, Jan./Feb. 1996.
Belloni, A. Full GMAW Proved for CRA Pipeline Welding, Duplex
'97, Maastricht, Oct. 1997.
Belloni, A. and Celant, M. Development of an Advanced System to
Weld Corrosion Resistant Alloys and Clad Pipes, 12th International
Conference on Offshore Mechanics and Arctic Engineering,
OMAE/'93, Glasgow, July 1993.
Belloni, A., Dall'Aglio, D., Celant, M. and Tsuji, M. Large Diameter
Clad Pipes: Production, Welding and Offshore Laying Experience,
11th International Conference on Offshore Mechanics and Arctic
Engineering, OMAE/92, Calgary, June 7-12th, 1992, Vol. 5, p.383.

CASTI Handbook of Cladding Technology 2nd Edition

246

Bibliography

Appendix 5

Breinan, E.M., Kear, B.H. and Banas, C.M. Physics Today, November
1976, Vol. 44, Issue 23.
BS 1501, Steels for Fired and Unfired Pressure Vessels: Plates,
British Standards Institute.
BS 4515, Process of Welding of Steel Pipelines on Land and Offshore,
British Standards Institute.
BS 5500, Specification for Unfired Pressure Vessels, British
Standards Institute.
Butler, P. et al., Welding the Maui A-B Pipeline, Welding Journal,
Nov. 1993, pp. 31-38.
Calvarano, M., Fassina, P. and Ghielmetti, A. A Review of Cost
Effective Alternatives for Sealines in Marginal Field with Corrosive
Fluids, OMC - Offshore Mediterranean Conference, 1995.
Chakravarti, B. and Dobis, J. Plant Maintenance Repairs Utilizing
Clad Piping Spools to Improve Reliability, Stainless Steel World,
Jan./Feb. 1997, Vol. 9, Issue 1, p.39.
Clay, K. Use of Cladding Materials in the Power Generation
Industry, Stainless Steel World, Oct. 1996, Vol. 8, Issue 8, p. 32-35.
Colwell, J.A., Martin, C.J. and Mack, R.D. Evaluation of Full Scale
Sections of Bimetallic Tubing in Simulated Production
Environments, Corrosion, 45 (5) 1989, p. 429.
Craig, B.D. Field Experience with Alloy Clad API Grade L-80
Tubing, Materials Performance, 25 (6) 1986 p.48.
Craig, B.D., Corrosion Testing of Clad and Lined Bends, 2nd
International Seminar on Clad Engineering, Houston, May 6th, 1994.
Currie, D.M. Yellowhammer Project, 2nd International Seminar on
Clad Engineering, Houston, May 6th, 1994.

CASTI Handbook of Cladding Technology 2nd Edition

Appendix

6
LIST OF FIGURES
AND CONTRIBUTORS
Figure No.

Contributor(s)

Front cover
Figure 1.2
Figure 2.1
Figure 2.2
Figure 2.3
Figure 2.4
Figure 2.5
Figure 2.6
Figure 2.7
Figure 2.8
Figure 2.9
Figure 2.10
Figure 2.11
Figure 2.12
Figure 2.13
Figure 2.15
Figure 3.1
Figure 3.2
Figure 3.3
Figure 3.4
Figure 3.5
Figure 3.6
Figure 3.7
Figure 3.8

The Japan Steel Works Ltd. and Saipem S.p.A

Creusot Loire Industrie
Voest-Alpine Stahl Linz GmbH
Voest-Alpine Stahl Linz GmbH
Voest-Alpine Stahl Linz GmbH
The Japan Steel Works Ltd.
The Japan Steel Works Ltd.
The Japan Steel Works Ltd.
The Japan Steel Works Ltd.
Dynamic Materials Corporation
Dynamic Materials Corporation
Nobelclad
Dynamic Materials Corporation
Nobelclad
Nobelclad
NiDI
NKK Corporation
The Japan Steel Works Ltd.
Kubota Corporation
Kubota Corporation
Kubota Corporation
Kubota Corporation
Kubota Corporation
NKK Corporation

CASTI Handbook of Cladding Technology 2nd Edition

254

List of Figures and Their Contributors

Figure 3.9
Figure 3.10
Figure 3.11
Figure 3.12
Figure 3.13
Figure 4.1
Figure 4.2
Figure 4.3
Figure 5.1
Figure 5.2
Figure 5.3
Figure 5.4
Figure 5.5
Figure 5.6
Figure 5.7
Figure 5.8
Figure 5.9
Figure 5.10
Figure 5.11
Figure 5.12
Figure 5.13
Figure 5.14
Figure 5.15
Figure 5.16
Figure 5.17
Figure 6.2
Figure 7.1
Figure 7.2
Figure 7.3
Figure 7.5
Figure 7.6
Figure 7.7
Figure 7.8
Figure 7.9
Figure 8.1
Figure 8.2
Figure 8.3
Figure 8.4
Figure 8.5

Appendix 6

Wyman-Gordon Ltd.
Wyman-Gordon Ltd.
Tubacex
Nippon Steel Corporation
H. Butting GmbH & Co. and UPL
Dai-Ichi High Frequency Co. Ltd.
Dai-Ichi High Frequency Co. Ltd.
Kubota Corporation
Not required
Tecphy
Tecphy
Kubota Corporation
Coprosider S.p.A
Coprosider S.p.A
Coprosider S.p.A
Coprosider S.p.A
Coprosider S.p.A
Coprosider S.p.A
Coprosider S.p.A
Kubota Corporation
Scomark Engineering Ltd.
Dynamic Materials Corporation
Scomark Engineering Ltd.
ABB Vetco Grey UK Ltd.
Scomark Engineering Ltd.
NKK Corporation
The Japan Steel Works Ltd.
The Japan Steel Works Ltd.
Nobelclad
Kubota Corporation
Saipem
Allseas Engineering B.V.
Coflexip Stena Offshore Ltd.
Rockwater Ltd.
Nippon Steel Corporation
Forth Tool and Valve Ltd.
Strachan and Henshaw Ltd. & Borsig Valves of Berlin
Creusot-Loire Industrie
Soudometal and NEI International Combustion Ltd.

CASTI Handbook of Cladding Technology 2nd Edition

Appendix 6

Figure 8.6
Figure 8.7
Figure 8.8
Figure 8.15
Figure 8.16
Figure 8.17
Figure 8.18
Figure 8.19
Figure 8.20
Figure 8.21
Figure 8.22
Figure 8.23
Figure 8.24
Figure 8.25
Figure 8.26
Figure 8.27
Figure 8.28
Figure 9.1
Figure 9.2
Figure 9.3
Figure 9.4
Figure 9.5
Figure 9.6
Figure 9.7
Figure 9.8

List of Figures and Their Contributors

255

Verbundmetalle GmbH
Head Robinson Engineering Ltd.
NEI International Combustion Ltd.
Scomark Engineering Ltd.
Kubota Corporation and Highland Fabricators
Kubota Corporation and Highland Fabricators
Klad Inc.
Creusot-Loire Industrie
Nobelclad
Nobelclad
Nobelclad
Klad Inc.
VEAG Kraftwerk
W.H.D. Plant, Edenbridge Metals Ltd.
NiDI and W.H.D. Plant, Edenbridge Metals Ltd.
NiDI and W.H.D. Plant, Edenbridge Metals Ltd.
W.H.D. Plant, Edenbridge Metals Ltd.
Scomark Engineering Ltd.
BP Exploration Operating Company Ltd.
Rockwater Ltd. and UPL
Rockwater Ltd.
Rockwater Ltd.
Mobil Oil Indonesia Inc.
The Japan Steel Works Ltd.
CRC- Evans Pipeline International, Inc.

CASTI Handbook of Cladding Technology 2nd Edition

INDEX
A
Absorber, 158-163
Allseas, 115-116
Aluminium, 164
ASTM A 262, 61, 87-88, 197, 199
ASTM G 48, 61, 87-89, 115, 180, 199, 212
Autoclaves, 88, 154

B
Batten, 97-98
Black Liquor, 165

C
Casting Factor, 40
Centrifugal Casting, 34, 38-40
Chimney, 158
Clad Bends
Manufacturing of Bends from Clad Pipe, 57-61
Manufacturing of Bends from Lined Pipe, 50, 61-63
Clad Fittings
Clad Elbows, 70-73
Clad Fittings Made by Weld Overlaying, 65-66
Clad Fittings Made by Hot Isostatic Pressing, 66-69
Clad Fittings Made from Clad Plate or Pipe, 69-70
Clad Flanges and Valves, 78-80
Clad Manifolds, 76-77
Clad Reducers and Caps, 77-78
Clad Tees, 73-75
CASTI Handbook of Cladding Technology - 2nd Edition

258

Index

Clad Pipes
Centricast Clad Pipe, 38-43
Definitions, 33-34
Explosively Bonded Clad Pipe, 48-50
Lined Pipe, 50-56
Explosively Lined Pipe, 55-56
Hydraulically Lined Pipe, 53-55
Thermo-Hydraulically Lined Pipe, 51-53
Longitudinally Welded Clad Pipe, 34-38
Seamless Pipe Mill Clad Pipe, 43-48
Clad Plate
Backing Steel Types, 10-11
Explosive Bonding, 23-28
Heat Treatment, 19-22
Hot Roll Bonding, 9-10
Inspection Requirements, 22-23
Manufacturing Sequence, 11-16
Optimising Bonding, 16-19
Production Methods, 9
Weld Overlaying, 29-32
Clad Product, Applications
Cladding Technology in Air Pollution Systems, 157-162
Cladding Technology in the Oil & Gas Industry, 123-124
Clad Production Tubing, 124-127
Line Pipe and Manifolds, 135-142
Valves, Pumps, and Joints, 127-129
Vessels and Heat Exchangers, 129-135
Backing Steel, 134
Cladding Alloy, 134-135
Cladding Technology in the Chemical Industry, 149-153
Backing Steel, 150
Cladding Alloy, 150-153
Cladding Technology in Chemical Tankers, 153
Cladding Technology in Metal Purification, 154
Cladding Technology in the Petrochemical Industry, 142-149
Applications, 142-146
Backing Steel, 146
Cladding Alloy, 147-148
Disbonding on Hot Hydrogen, 148-149
Cladding Technology in the Power Industry, 154-157
Cladding Technology in the Pulp and Paper Industry, 165
Cladding Technology in Shipping Applications, 163-164

CASTI Handbook of Cladding Technology - 2nd Edition

Index

259

Clad Products, Specification Requirements of

Backing Steel, 83
Backing Steel Requirements for Application in
H2S Containing Environments, 84-85
Cladding Alloy, 82-83
Corrosion Tests, 87-89
Demagnetising, 89-90
Dimensions and Tolerances of Clad Pipe, 90-93
Cladding and Wall Thickness, 90-92
Diameter and Out of Roundness, 92-93
Ultrasonic Inspection, 93
Maximum Allowable Stress Values, 81-82
Mechanical Tests, 86-87
Cladding Projects
ADMA OPCO - Um-Shaif - 1993, 167-168
Agip UK - Thelma and South East Thelma - 1995, 168-169
Arco Alaska Inc. - Prudhoe Bay - 1991, 170-171
ARCO - Thames Bacton - 1987, 171-172
Asamera Oil - Corridor - 1996, 172-173
BP International Ltd. - Cyrus - 1995, 176-179
BP International Ltd. - Ravenspurn to Cleeton - 1987, 173
BP International Ltd. - Forties - 1987, 174
BP International Ltd. - Miller - 1989, 174-175
Chevron - Ninian - 1992, 180
Clyde Petroleum - P2/P6 - 1997, 180-182
Louisiana Land and Exploration - Lost Cabin - 1991, 182
Mobil - Arun Booster Gas Compression - 1993, 182-187
Mobil - South Lho Sukon - 1996, 188
Mobil - Mobil 823 - 1995, 188-189
Mobil - Yellowhammer - 1994, 189-190
Mobil - 869 Field - 1995, 190-192
Mobil - Ras Laffan Lng Co. Ltd. North Field - 1998, 192
Nederlandse Aardolie Maatschappij, NAM Early Field Trails - 1974-1980, 192-193
Nederlandse Aardolie Maatschappij, NAM Roswinkel, Zuidlaren - 1978, 193-194
Nederlandse Aardolie Maatschappij, NAM Emmen - 1987-1989, 194-196
Nederlandse Aardolie Maatschappij, NAM Twente, Schoonebeek - 1988, 196
Nederlandse Aardolie Maatschappij, NAM Dalen 6 And Dalen 9 - 1988, 196-197
Nederlandse Aardolie Maatschappij, NAM Grijpskerk - 1996, 197
CASTI Handbook of Cladding Technology - 2nd Edition

260

Index

Cladding Projects (Continued)

ONGC - South Bassein - 1988 and 1993, 198-204
Shell Offshore - Fairway - 1991, 204-208
Shell Todd Oil Services - Maui 'B' To'a' - 1991, 208-214
Pipe Production, 209-210
Laying the Line, 210-211
Welding, 211-213
Inspection, 214
Statoil - sgaard - 1997, 214
Texaco - Erskine - 1997, 215
Total Oil Marine - Bruce - 1991, 216
Cladding Technology
Dimensions of Clad Products, 3
Economics of Clad Technology, 4-5
Materials Selection Options for Corrosive Service, 1-2
Optimising the Corrosion Properties, 6
Using Cladding Technology to Best Advantage, 7-8
Copper, 1-2, 28, 33, 37, 60, 97, 98, 116, 147, 150, 154, 181
Corrosion Inhibitors, 123, 129, 188, 194, 215
Corrosion Resistant Alloys (CRA), 1, 4, 6, 9, 33-35, 38, 40, 43-46, 48,
51, 53-55, 66, 78, 81, 84-85, 91, 100-101, 104, 111, 112-114, 116,
124-126, 131, 144, 149, 197
Corrosion Resistance, 6, 13, 17, 19-20, 32, 35-36, 47, 51, 54, 61-63,
82-83, 89, 95-97, 100-104, 129, 145, 147, 150, 152, 160, 164, 169, 173,
175, 178, 202, 215
Corrosion Tests, 19-20, 22, 70, 87-89, 110, 115, 197, 200, 202-203, 212
Intergranular Corrosion Tests, 87-88
Pitting Corrosion Tests, 87
Stress Corrosion Test, 88
Crack Tip Opening Displacement (CTOD), 21, 115
Crevice Corrosion, 114, 163-164, 181, 197
Critical Pitting Temperature (CPT), 19, 21, 127, 162, 180

CASTI Handbook of Cladding Technology - 2nd Edition

Index

261

D
Digester, 165
Drop Weight Tear Test (DWTT), 21, 83, 198
Duplex Stainless Steel, 20, 28, 54, 110-111, 125, 153, 154, 165, 168169, 173, 176, 181, 197

E
Extrusion, 43-46, 75, 90, 180, 206

F
Flux Cored Arc Welding (FCAW), see Welding Processes

G
Gas Tungsten Arc Welding (GTAW), see Welding Processes

H
Hastelloy, 18, 150
Heat Exchanger, 123, 129, 131-135, 143, 146-147, 151-152, 156,
204-205
Hot Hydrogen, 87, 146, 148-149
Hot Isostatic Pressing (HIP), 65, 66-69, 75, 77-78, 189
Hydrogen Disbonding, 87, 127
Hydrometallurgy, 154

I
Inconel, 150, 193

CASTI Handbook of Cladding Technology - 2nd Edition

262

Index

J
Japan Steel Works (JSW), 171, 173-174, 183, 185, 188, 192, 200,
209-211, 216
Joint
Alignment, 185
Design, Clad Vessels, 96-100
J-Bevel, 178
J-Preparation, 103
Line, 12
Misalignment, 102
Types
Swivel, 129
Transition, 164
Universal, 129

K
Kawasaki Heavy Industries (KHI), 124, 193
Kiln, 154

L
Liners, see also Clad Pipes
API 5LD, 33
Bends, 61-63, 207
Buckling, 51, 61, 63, 207
Collapse, 50-51
Fatigue, 119-120
Incomplete Penetration, 190
Inconel 82, 192
Inspection, 56, 205
Repairs, 112-113, 208
Seal Welding, 55, 169, 190-191, 193
Tube Liner, 163
UNS N08825, 54, 169, 190-191, 214
UNS S31600, 193-194
Weld Preparation, 104
Liquation Cracking, see Welding Processes, GTAW

CASTI Handbook of Cladding Technology - 2nd Edition

Index

263

Liquid Interface Diffusion Bonding (LIDB), 13, 17, 45-46

Liquefied Natural Gas (LNG), 164, 183, 192
Lloyds Register of Shipping, 153

M
Magnetic, 23, 89, 105, 110, 115, 193, 213
Magnetic Particle, 40, 59
Mooring Buoys, 129

N
NACE TM0177, 87-88, 199
Nippon Steel Corporation (NSC), 21, 118, 170, 182, 189, 191, 193, 205
NKK Corporation, 198, 206
Nuclear Plant, 156

O
Oxidation, 12, 35, 106, 111, 158, 181, 186, 195, 197

P
Plug Mill, 43-44
Polythionic Acid, 147-148
Post Weld Heat Treatment (PWHT), 83, 175
Processo Arcos Saipem Saldatura Orbitale (PASSO), see Welding
Processeses

CASTI Handbook of Cladding Technology - 2nd Edition

264

Index

R
Radiographic Testing, 195, 213
Recrystallization, 20-21
Reel Laying, 118-119
Residual Magnetism, 89, 105, 110, 195, 199-200, 202, 213
Rockwater, 119, 169, 177-178

S
Saipem, 105, 113, 172, 192, 199-201
Sandwich, 12-14, 16, 19, 21-22
Scrubber, 100, 158, 161-162
Sensitisation, 62
Separator, 129-131, 145, 156-157
Shielded Metal Arc Welding (SMAW), see Welding Processes
Slurry, 158
Stress Corrosion Cracking (SCC), 62, 144-145, 147, 151-153
Chloride Stress Corrosion Cracking (CSCC), 144, 148
Stepwise Cracking (SWC), 84, 175
Sulphide Stress Corrosion Cracking (SSCC), 84
Submerged Arc Welding (SAW), see Welding Processes

T
Tantalum, 28
Titanium, 1-2, 10, 28, 43, 96-99, 132, 135, 147-148, 150-154, 158,
164-165

CASTI Handbook of Cladding Technology - 2nd Edition

Index

265

Tolerances
Backing Steel, 83
Bends, 60-61
Bend Angle, 60
Centricast Clad pipe, 40, 42, 174
Clad pipe, 90-93, 208
Wall Thickness, 90-92, 197
Diameter, 92
Out-of-Roundness, 92-93, 186
Elbows, 61
Explosively Lined Pipe, 55-56
Fittings, 69
Hydraulically Lined Pipe, 53
Laying Clad Pipe, 119
Out-of-Plane, 60
Tolerances (Continued)
Ovality, 60
Pipe
Ends, 209
Fit-Up, 101-102, 104, 113
External Clamps, 182-183
Internal Diameter, 170
Seamless Pipe, 44, 47
Thermo-Hydraulically Lined Pipe, 51
Wall Thickness, 60
Transition Joint, 164
Towing, 119, 179, 206
Tubeplate, 132-133, 156

U
Ultrasonic Testing (UT), 16, 37

V
Vapour Deposition, 127

CASTI Handbook of Cladding Technology - 2nd Edition

266

Index

W
Wallpapering, 160-161
Welding Clad Products
Fabricating Clad Vessels, 95-100
Handling Clad Plate, 95-96
Welding Clad Vessels, 96-100
Circumferential Welding of Clad Pipe, 100-112
Handling Clad Pipe, 101
Pipe end Dimensions/Fit-up, 101-102
Weld Preparation, 102-105
Demagnetising of Pipes, 105-106
Back Shielding, 106-107
Choice of Welding Process, 107-108
Choice of Filler Metal, 108-111
Control of Heat Input, 111
Weld Integrity Assessment, 111-112
Welding Repairs During Pipelaying, 112-113
Developments in Clad Pipe Welding Technology, 113-116
Laying Clad Pipe, 116-120
Commissioning Clad Pipelines, 120-121
Welding Processes
Flux Cored Arc Welding (FCAW), 107
Gas Metal Arc Welding (GMAW), 29, 105, 107, 181, 190, 199, 201,
206
Clad Fittings, 66
Clad Valve, 79
Fit-Up, 102
Overlay, 140-141
PGMAW, 107, 111, 113, 189, 206
Power Plant Applications, 156
Plug Welds, 161
Repairs, 116
Root Pass, 114-115, 172, 186, 201, 211-212
Welding Speed, 113-114
Gas Tungsten Arc Welding (GTAW), 6, 29, 35, 107-108, 178, 187,
192
Alloy 625, 170, 189, 191, 194
Autogeneous, 208
Back Shielding, 106-107
Clad Fitting, 66
Centricast Clad Pipe, 108
Demagnetising of Pipes, 105-106
CASTI Handbook of Cladding Technology - 2nd Edition

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267

Welding Processes
Gas Tungsten Arc Welding (GTAW) (Continued)
Heat Input, 107, 111-112
J-Laying, 105
Liner Pipe, 51,53
Liquation Cracking, 132
Machines, 186
Settings, 186
Overlay, 128, 133, 198, 209
Pipe Fit-Up, 101-102
PGTAW, 186, 189, 201, 206
Power Plant Application, 156
Repair Welding, 112-113, 198
Root Pass, 186-187, 190, 199, 211-212
Welding Technology, 113-116
Processo Arcos Saipem Saldatura Orbitale (PASSO), 181, 199-201
Shielded Metal Arc Welding (SMAW), 29, 66, 105, 107, 112, 172,
178, 187, 191, 202-203
Submerged Arc Welding (SAW), 35, 156, 189, 198, 206

Z
Zirconium, 2, 12, 28, 98, 148, 151-152, 154

CASTI Handbook of Cladding Technology - 2nd Edition