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Cladded & Weld Overlayed Components for Oil & Gas, Refinery and Petrochemical Industry
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CLADDING & WELD OVERLAY
Cladding & Weld Overlay provides protection against corrosion and wear for process and pipeline equipment. Weld overlay can be applied to extend the service life of new parts, or refurbish parts that have corroded or worn surfaces .
TYPES OF CLADDING PROCESS :
Weld Overlay : Weld overlay is a fusion welding technique used to deposit weld metal on to component to achieve the desired dimensions or properties replacing lost material or providing a wear or corrosion resistance surface . Explosion Bond : Explosion bonding is a process of bonding two dissimilar materials with the help of pressure and heat produced by explosion . The explosive material is spread on the material to be cladded which is kept on top of the base material. On ignition of the explosive, resultant thrust bonds the clad plate on the base plate kept underneath. Various combination of clad plate and base plate thickness can be bonded, depending on the job requirements .
Crystals Integrated and advanced welding technologies provides effective welding solutions for: Oil & Gas Industries Sub-Sea Applications Petrochemicals & Refineries
CLAD & WELD OVERLAY MATERIALS : BASE MATERIAL CLAD MATERIAL WELD OVERLAY MATERIAL
Carbon Steel, Stainless Steel & Low Alloy Steel SS304, SS316L, SS317L, SS410, UNS N0 8825, UNS N0 6625, Hastelloy C22, Hastelloy C276, Hastelloy B3, UNS N0 4400 ER410S, 430, ER308L, 309L, ER309LMo, 316L, 317L, UNS N0 8825, UNS N0 6625, Hastelloy C22, Hastelloy C276, Hastelloy B3, UNS N0 4400
CLADDED PIPES, FITTINGS & FLANGES
Crystal offers following cladded & weldoverlayed components of various sizes & thicknesses with cladding by weld overlay or explosion bonding :
PIPES Welded Pipes Seamless Pipes FITTINGS Elbows Reducers Tees Weldolets Sockolets FLANGES WNRF, BLRF, WNRTJ VESSELS & HEADRES VESSELS
DIAMETER 2" NB to 42"NB 2" NB to 42"NB SIZE 2" & above 2" & above 2" & above 2" & above 2" & above SIZE 2" & above DIAMETER 600mm to 3500mm & upto 20mtr. Long
THICKNESS Minimum 7mm & above Minimum 7mm & above THICKNESS Minimum 7mm & above Minimum 7mm & above Minimum 7mm & above Minimum 7mm & above Minimum 7mm & above THICKNESS Minimum 7mm & above THICKNESS Minimum 7mm & above
CLAD / WELDOVERLAY THICKNESS 1.5 mm to 4.5 mm
WELDOVERLAY THICKNESS 1.5 mm to 4.5 mm 1.5 mm to 4.5 mm 1.5 mm to 4.5 mm 1.5 mm to 4.5 mm 1.5 mm to 4.5 mm WELDOVERLAY THICKNESS 1.5 mm to 4.5 mm (or as req.) WELDOVERLAY THICKNESS 1.5 mm to 4.5 mm
WELD SURFACING AND OVERLAY
Crystal has developed extensive range of procedures and techniques for weld overlay applications for the Oil & Gas, Petrochemical and Refineries .
Salient features of ETR-S Maximum Bore Depth Weldable Bore Dia. Welding Speed Deposition Rate : upto 4m : 45 to 320mm : 340 to 450mm/min. : 1.7 to 2.5kg/hr
To cater to the needs of its clients for weld overlayed items, Crystal has indigenous Automatic Overlaying Machines and Endless Torch Rotation (ETR) welding machine from Fronius which has advantage of overlaying on 3D curved surfaces .
Automatic Overlaying Machines ( 3 Nos.) Maximum Bore Depth : upto 3 mtrs : 100 to 1000mm : 100 to 250mm/min. : 1 to 2 kg/hr
The ETR-S combines the features of the conventional TIG Hot Wire Cladding System as regards weld quality, functionality and software features .
Weldable Bore Dia. Welding Speed Deposition Rate
Function of Arc Voltage Control (AVC) aids in deposition of uniform thickness of weld overlay on various surfaces
Pipe ID overlaying Machine: Maximum Pipe Length Size : 1 2 mtrs : 200 to 1000mm
QUALITY CONTROL SYSTEM
FOR Clad Fabrication :
Internal Ultrasonic Testing of plate before fabrication. Cleaning of clad surface after forming of head before heat treatment if required Heat treatment in electric or gas fired furnace in controlled atmosphere to avoid any Contamination and to prevent oxidation of surfaces . Ultrasonic testing of formed components for de-bond check between clad and base material. NDE testing, Radiography, Hydro test & PMI check
FOR Weld Overlayed Items
Prior to overlay, grinding, cleaning and dye penetrant testing of surface of base material to be overlayed Overlaying as per qualified welding procedure. Dye penetrant testing of overlayed surfaces. Ultrasonic Testing from opposite surface for checking un-fused / disbond areas.
QUALITY CONTROL SYSTEM
Crystal follows stringent quality control system so that all the parameters are complied and customer get high qualityproduct:
ULTRASONIC TESTNG
HARDNESS TESTING
DYE PENETRANT TESTING
MAGNETIC PARTICLE INSPECTION
RADIOGRAPHY
HYDROTESTING
POSITIVE MATERIAL IDENTIFICATION
DIMENSIONAL INSPECTION
ISO 9001 : 2008 Certificate ISO 14001:2004 Certificate OHSAS 18001 : 2007 Certificate Stamp Certificate National Board Registration IBR Approved
CLIENTS
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Regd. Office :
403, 404,412, Raheja Arcade, Sector No. 11, CBD Belapur, Navi Mumbai 400614 . Maharashtra, India.
Tel. Fax Email Web site
: +91 22 6511 3814 / 3815 : +91 22 6793 9439 : [email protected] : www.crystalindustrial.in
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