Engineering Standard

SAES-W-014 30 August 2022

Weld Overlays and Welding of Clad Materials
Document Responsibility: Welding Standards Committee

Previous Issue: 21 April 2019 Next Revision: 30 August 2027

Contact: Achilles Koutlis (koutax0a) Page 1 of 15

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 Document Responsibility: Welding Standards Committee SAES-W-014
Issue Date: 30 August 2022
Next Revision: 30 August 2027 Weld Overlays and Welding of Clad Materials

Contents

Summary of Changes.................................................................................................... 3

1 Scope ...................................................................................................................... 4

2 Conflicts and Deviations .......................................................................................... 4

3 References .............................................................................................................. 4

4 General ................................................................................................................... 6

5 Weld overlay procedure qualification....................................................................... 8

6 Production Welding and Inspection ....................................................................... 10

7 Hydrogen Disbonding Test Supplement ................................................................ 12

Document History ........................................................................................................ 15

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 Document Responsibility: Welding Standards Committee SAES-W-014
Issue Date: 30 August 2022
Next Revision: 30 August 2027 Weld Overlays and Welding of Clad Materials

Summary of Changes

Paragraph Number Change Type

(Addition, Modification, Technical Change(s)
Previous Revision Current Revision Deletion, New)
(21 April 2019) (30 August 2022)
Deliberate additions of principal
NA 5.11 New alloying elements through the
flux is prohibited.
Corrosion test rerquirment,
ASTM A262 Practrice E, for
NA 5.12 New
post weld heat treated stainless
steel weld overlay materials
Subjecting corrosion test
NA 5.13 New copoun to maxumnum PWHT
cycles.

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 Document Responsibility: Welding Standards Committee SAES-W-014
Issue Date: 30 August 2022
Next Revision: 30 August 2027 Weld Overlays and Welding of Clad Materials

1 Scope

1.1 This standard specifies the requirements for welding and testing of:

1.1.1 Corrosion-resistant and hardfacing weld overlays

1.1.2 The overlay portion of weld joints in materials with corrosion-resistant

cladding, either integral or weld overlay.

1.1.3 Cladding restoration of clad materials.

The application of this standard is for pressure vessels, including heat

exchangers. This standard is to be considered as a supplement to SAES-W-
010. These requirements are in addition to the requirements of ASME SEC
VIII, ASME SEC IX, API 934A, C and E (when applicable). The most stringent
requirements of ASME, API or this standard shall apply unless explicitly
modified by this standard.

This entire standard may be attached to and made part of purchase orders.

1.2 Additional requirements may be contained in Scopes of Work, Drawings, or

other Instructions or Specifications pertaining to specific items of work.

1.3 Any reference to Consulting Services Department (CSD) shall be interpreted as

the CSD Welding Specialist or a representative designated by CSD.

1.4 This standard is generally not applied retroactively to the maintenance and
repair of existing facilities unless there are safety, environmental protection,
health, or security concerns.

2 Conflicts and Deviations

Any conflicts between this document and other applicable Mandatory Saudi
Aramco Engineering Requirements (MSAERs) shall be addressed to the
EK&RD Manager.

Any deviation from the requirements herein shall follow internal company
procedure SAEP-302.

3 References

All referenced specifications, standards, codes, drawings, and similar material

are considered part of this engineering standard to the extent specified,
applying the latest version, unless otherwise stated.

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 Document Responsibility: Welding Standards Committee SAES-W-014
Issue Date: 30 August 2022
Next Revision: 30 August 2027 Weld Overlays and Welding of Clad Materials

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedure

SAEP-302 Waiver of a Mandatory Saudi Aramco Engineering

Requirement

Saudi Aramco Engineering Standard

SAES-W-010 Welding Requirements for Pressure Vessels

Saudi Aramco Standard Drawings

AB-036367 Joint Preparation and Welding Details - Alloy and Clad

Pressure Vessels and Heat Exchangers

AB-036386 Hardness Testing for Welding Procedure Qualifications

3.2 Industry Codes and Standards

American Petroleum Institute

API RP 582 Welding Guidelines for the Chemical, Oil, and Gas
Industries

API RP 934-A Materials and Fabrication of 2¼Cr-1Mo, 2¼Cr-1Mo-¼V,

3Cr-1Mo, and 3Cr-1Mo-¼V Steel Heavy Wall Pressure
Vessels for High-temperature, High-pressure Hydrogen
Service

API RP 934-C Materials and Fabrication of 1¼Cr – ½Mo Steel Heavy Wall
Pressure Vessels for High-pressure Hydrogen Service
Operating at or Below 825°F (441°C)

API RP 934-E Recommended Practice for Materials and Fabrication of

1¼Cr - ½Mo Steel Pressure Vessels for Service above
825°F (440°C)

American Society of Mechanical Engineers

ASME SEC VIII D1 Pressure Vessels

ASME SEC VIII D2 Pressure Vessels, Alternative Rules

ASME SEC IX Welding and Brazing Qualifications

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American Society for Testing and Materials

ASTM G146 Standard Practice for Evaluation of Disbonding of

Bimetallic Stainless Alloy/Steel Plate for Use in High
Pressure, High Temperature Refinery Hydrogen Service

ASTM A751 Standard Test Methods and Practices for Chemical

Analysis of Steel Products

American Welding Society

AWS A4.2 Standard Procedures for Calibrating Magnetic Instruments

to Measure Delta Ferrite Content of Austenitic and Duplex -
Ferritic-Austenitic Stainless-Steel Weld Metal

International Standardization Organization

ISO 10309 Metallic Coatings - Porosity Tests - Ferroxyl Test

National Association of Corrosion Engineers/International Standardization

Organization

NACE MR0175/ISO 15156

Petroleum and Natural Gas Industries-Materials for use in

H2S-Containing Environments in Oil and Gas Production

4 General

4.1 All corrosion-resistant weld overlays, including clad restoration, shall conform
with ASME SEC VIII requirements (Div. 1 or Div. 2, as appropriate) and the
requirements of this standard.

4.2 The minimum deposit thickness shall be specified in the engineering design but
shall not be less than 3.2 mm for corrosion-resistant overlays.

4.3 The direction of overlay deposition shall be circumferential. Only in the case of
components whose shape and dimensions prevent the use of circumferential
welding, longitudinal welding may be used subject to approval obtained through
WPS review and approval process. Supporting documentation such as
Inspection and Test Plan or Manufacturing Performance Qualification Test or
method statement shall be submitted to support the review.

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 Document Responsibility: Welding Standards Committee SAES-W-014
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Note:
Some components and geometries, such as small diameter nozzles, or special
applications may not permit welding in a circumferential direction.

4.4 The weld deposit chemistry shall be specified in the engineering design. Where
a nominal alloy designation for the overlay or cladding is listed (e.g., 316L);
then, the overlay deposit shall meet the equivalent filler metal composition
requirements unless otherwise specified or exempted in this standard. Non-low
carbon grades E/ER308 and E/ER316 are not permitted, refer to API RP 582,
Table B1 for guidance.

4.5 The cladding restoration portion of weld joints between clad materials or
attaching clad materials to other materials shall meet the requirements for weld
overlays.

4.6 Joint preparation and details for weld joints in clad vessels (including weld
overlays) shall be in accordance with Standard Drawing AB-036367.

4.7 Repairs to integrally clad material shall not be done unless the WPS (meeting the
requirements for weld overlays) is approved explicitly through WPS review and
approval process. Supporting documentation such as Inspection and Test Plan
and method statement shall be submitted to support the review.

4.8 Ferrite measurements shall be performed in accordance with AWS A4.2.

Note:
Calculation of the ferrite content using the Schaeffler or DeLong diagrams based on
the chemical composition is not sufficient for critical applications (to be determined
by CSD). Actual measurements using methods specified in
AWS A4.2 are required.

4.9 Single layer overlay is not permitted unless explicit approval of pWPS with full
matrix of procedure qualification testing, prior to procedure qualification is
obtained. Testing in addition to that specified by the Code may be requested,
depending on the application. Previously qualified WPSs will not be accepted.
Supporting documentation such as Inspection and Test Plan and method
statement shall be submitted to support the review.

4.10 All welders and welding operators for weld overlays shall be qualified in
accordance with ASME SEC IX.

4.11 All chemical analysis methods shall conform to ASME/ASTM A751.

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4.12 PWHT shall be carried out for clad and weld overlaid vessels and components
when mandated by the design and construction code (ASME VIII D1 or D2).
PWHT due to service is not required for clad and weld overlaid vessels.

5 Weld Overlay Procedure Qualification

5.1 All weld overlays shall be qualified in accordance with ASME SEC IX.
The Welding Procedure Specification (WPS) shall include a listing of the
specified range for the deposit chemical composition, including all of the
elements specified in paragraph 5.6. Repair of weld overlay using original weld
overlay process after complete removal of existing overlay can be carried out
using the original procedure. Weld overlay procedures shall be separately
qualified for repair of weld overlay with a process different from the original
overlay process or when the repair is on remaining overlay thickness of less
than 3 mm from the fusion line.

5.2 The WPS shall indicate the minimum deposit thickness qualified and the
minimum number of layers required. The number of layers used for the
Procedure Qualification Record (PQR) shall be recorded and shall be the
minimum number of layers specified on the WPS and used in production.

5.3 For all processes and all layers, the heat input and welding current specified on
the WPS shall not exceed the heat input and welding current recorded on the
PQR by more than 10%.

5.4 For the SAW and Electro-slag processes, any change in the flux brand, trade
name, or designation shall be considered an essential variable.

5.5 For single layer weld overlays, any increase in spacing between adjacent beads
(i.e., any decrease in overlap) shall be requalified. The overlap or spacing must
be measured and recorded on the PQR and specified on the WPS.

5.6 The following elements shall be analyzed and specified for the deposit
chemistry for all stainless steel and nickel-based alloy weld metal overlays:

C, Ni, Cr, Cu, Mo, Mn for all weld metal overlays and Fe (for nickel-based alloy
weld metal overlays only), plus any other significant elements that are
intentionally added to either the base metal or filler metal (e.g., Nb or Ti for
stabilized stainless steel grades).

5.7 For welding procedure qualification, the chemistry of the overlay shall be
measured at 1.5 mm below the minimum specified overlay thickness (refer to
clause 4.2). This is regardless of the thickness of the as-welded deposited
thickness in the procedure qualification. Alloy 625 overlays shall have a

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 Document Responsibility: Welding Standards Committee SAES-W-014
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maximum iron content of 10%. Alloy 400 overlays shall have a maximum iron
content of 4.5%.

5.8 The chemical composition of weld deposit shall be within the range specified for
the UNS number of the CRA clad material except for the iron.

5.9 For austenitic stainless-steel weld overlays, the ferrite content shall be checked
in the as-welded condition as per AWS A4.2. The Ferrite Number shall be
between 3 and 10 FN.

5.10 Welding Procedure Qualification Hardness Testing

5.10.1 PQR hardness testing is required for weld overlays in:

a) Hydrogen service components of any wall thickness.

b) Sour service components of any wall thickness.

c) For pressure vessels in any service if the base metal wall

thickness is greater than 38 mm.

5.10.2 Hardness testing shall be in accordance with Standard Drawing

AB-036386. The maximum allowable hardness is VHN 250 for the
base metal and HAZ of all overlays and for the weld metal deposit of
austenitic stainless steel corrosion-resistant overlays.
Note:
The hardnesses for the weld deposit of hardfacing overlays and nickel-based
corrosion-resistant overlays are not specified since this will depend on the overlay
material and the application. For sour service applications, NACE MR0175/ISO
15156 requirements for the weld metal overlay must be met.

Prior hardness test results may be accepted as equivalent to the

Standard Drawing if the the WPS and PWR are approved explicitly
through WPS review and approval process. The following conditions
shall also apply:

a) Only the Vickers method is acceptable, with a maximum test load

of 10 kg.

b) The location of the HAZ indents nearest the fusion line can be
demonstrated (by specification or actual measurement) to be
within 0.2 mm of the fusion line.

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 Document Responsibility: Welding Standards Committee SAES-W-014
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5.11 For SAW, with the exception of compensation of losses of alloying elements
due to the welding arc, deliberate additions of principal alloying elements
through the flux is prohibited.

5.12 When PWHT is required for base materials with austenitic stainless-steel weld
overlay, weld procedure qualifications shall include corrosion testing according
to ASTM A262 Practice E.

5.13 Test coupons for corrosion testing shall be heat treated prior to testing for at
least the maximum PWHT time specified for the equipment plus two additional
cycles.

6 Production Welding and Inspection

6.1 Production welding shall conform to the WPS, including all supplementary
essential variables and restrictions specified in this standard, such as heat input
restrictions (see 5.3), flux brand (see 5.4), and overlap (see 5.5).

6.2 The base metal shall be cleaned and this requires removal of the mill scales
and any adhering corrosion products.

6.3 The actual overlay thickness achieved, after any machining, shall be measured
by ultrasonic methods or by physical measurement. At least one thickness
measurement shall be made for each head, shell course, or other component.
Additional measurement locations shall be made at any changes in geometry or
cross-section (e.g., for a flange, the flange face and the bore would require
separate measurements). The method of measurement shall be submitted to
Inspection for review and approval. The minimum final thickness shall not be
less than the thickness specified in the engineering design.

6.4 The final weld overlay surface shall have the chemical composition checked
prior to final Post Weld Heat Treatment (PWHT) or hydrotest. The chemistry
shall be tested using either:

6.4.1 A physical sample (e.g., drillings) shall be removed for quantitative

analysis.

6.4.2 A portable spectrograph. If explicitly approved through a specific

procedure and/or Inspection and Test Plan, portable X-ray
fluorescence (PMI) machine may be used instead of a spectrograph.

All elements specified for the deposit chemistry shall be analyzed and
reported, except for carbon when using the X-ray fluorescence method.
The analysis method and accuracy limits for each element shall be
submitted to Inspection for review and approval. The repair method for
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areas where samples have been removed shall be submitted to

Inspection for review and approval.

6.5 The frequency of chemical composition analyses shall be as follows:

6.5.1 Automatic welding - One analysis for each overlay area or clad joint.
Separate analysis shall be made for each heat/batch of filler metal or
electrode.

6.5.2 Manual welding - One analysis for each 1 m² of area or one analysis
at intervals of 2 m or less for overlay restoration of clad joints.

6.6 Ferrite measurements shall be made for austenitic stainless-steel welds when
the design temperature exceeds 427°C (800°F). The ferrite content shall be
checked in the as-welded condition. The Ferrite Number shall be between 3
and 10 FN. The ferrite number checks shall be performed at the same
frequency as specified above (see 6.5) for chemical composition analyses.

For service temperatures below 427°C (800°F), the chemical analysis results
shall be used to calculate the ferrite content using the DeLong diagram. If the
calculated ferrite content is not between 3 and 10 FN; then, actual ferrite
measurements shall be taken on the production piece. The measured Ferrite
Number shall be between 3 and 10 FN.

6.7 Liquid Penetrant Testing

6.7.1 The first layer of multi-layer overlays shall be examined by liquid

penetrant in accordance with ASME SEC VIII D1, Appendix 8
(equivalent to ASME SEC VIII D2, Article 9-2). The area examined
shall be a 10% random coverage. If rejectable indications are found,
then the entire area shall be examined.

6.7.2 The final layer, including single layer overlays, shall be examined by
liquid penetrant over the entire area (100%) in accordance with
ASME SEC VIII D1, Appendix 8 or ASME SEC VIII D2 Part 7, as
applicable. The examination shall be conducted on the surface in its
final condition, i.e., as-welded or machined. The examination shall be
conducted after the final PWHT, if PWHT is specified.
Note:
The fabricator will normally perform an additional examination prior to PWHT in
order to find and repair any defects prior to PWHT.

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If determined by the Inspector that extensive cracking or fissuring has

occurred, then additional testing, such as a ferroxyl test shall be performed as
per ISO 10309 to determine the extent and nature of the cracking.
Note:
A ferroxyl or ferricyanide test is an iron contamination test to determine if the cracking
extends to the base metal. If iron contamination is found, then the overlay shall be
repaired by complete removal of the overlay to base metal in the area of fissuring prior
to rewelding. If iron contamination is not found, then only localized repairs are required
(i.e., the excavations only need to be large enough to completely remove the defect
indications).

6.8 Repairs to overlays shall be performed by removing the defect by machining or

grinding (thermal methods are not permitted). Removal of the overlay defect
shall not reduce the base metal thickness below the minimum design thickness.
The repair area shall be welded using an approved overlay procedure with a
nominal composition that shall match the original overlay composition.
See paragraph 5.1 for repair procedure qualification requirements.

6.9 The finished overlay surface shall be free of overlaps, undercutting, and
notches and shall be relatively smooth. All flux and slag shall be completely
removed. Only stainless steel brushes, ceramic (glass) beads, iron-free grit, or
stainless steel grit shall be used to mechanically clean the overlay surfaces.

6.10 Weld overlay to clad/overlay weld joints (see Standard Drawing AB-036367)

The base metal cladding or overlay shall be stripped back at least 10 mm from
each side of the weld joint prior to welding the base metal portion of the weld.
Complete removal of the cladding/overlay shall be verified by a suitable etching
test or chemical analysis of the stripped back surface.
Note:
Suitable etchants include nitric acid or nital.

After welding the base metal portion of the joint, the side of the weld to be
overlaid shall be ground flush using mechanical methods.

The overlay of the weld joint area shall be performed using a qualified overlay
procedure and shall comply with all of the other overlay requirements in this
standard.

7 Hydrogen Disbonding Test Supplement

7.1 General

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7.1.1 Hydrogen disbonding tests (HDTs) are required to qualify weld

overlay procedures in high temperature, high pressure hydrogen
service. These requirements are in addition to all of the other
requirements listed in this standard. This test procedure shall be
used when both the design temperature exceeds 350°C and the
hydrogen partial pressure exceeds 5 MPa. For design temperature
and hydrogen partial pressure conditions not exceeding the limits
specified above, HDT shall be in accordance with API RP 934
reference standards.

7.1.2 The general principles of ASTM G146 shall be followed, with the
following modifications and requirements as specified below.
Alternative test procedures may be submitted to CSD for
consideration. CSD has the sole approval authority to accept any
alternative test procedures or methods. Submission of any such
proposals shall include details of the test procedure and
representative data from previous test results.

7.1.3 Testing shall be performed specifically for each vessel (or set of
vessels if manufactured at the same time using the same materials
and welding procedures) as part of the welding procedure
qualification testing or, if existing procedure qualifications are to be
used, as a supplementary qualification test. Evidence of previous
disbonding tests on similar material using identical welding
procedures may be submitted for consideration. CSD has the sole
approval authority to accept previous test results.

7.1.4 All welding of the test specimens must be performed by the fabricator
using production equipment. The disbonding tests shall be
conducted by an organization experienced with such tests. The
fabricator shall nominate the testing organization to be used for
approval by CSD.

7.2 Specimen Preparation

7.2.1 A test coupon shall be prepared using the production overlay

procedure. A separate test coupon is required for each overlay
procedure. The size of the test coupon is not specified but shall be
large enough to obtain all of the required specimens from one
coupon. The test coupon shall also be sufficiently large so that the
welding conditions are fully representative of production welding. The
test coupon shall be prepared on the same base materials and using
the same welding consumables as will be used for actual production.
The coupon shall be welded and heat treated in accordance to the

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procedures to be used for production (including the maximum time

and same temperature that will be used for production).

7.2.2 At least six (6) test specimens shall be removed from the coupon,
with the size and shape as appropriate for the testing apparatus,
however, the minimum sizes shall be 50 mm diameter for round
specimens and 50 mm for length and width for rectangular
specimens. Half the number of specimens shall include the overlap
region between adjacent passes of the weld overlay across the
nominal center of the specimen surface. The results of all specimens
prepared or used shall be considered and shall be included in the test
report.

7.3 Test Apparatus and Exposure

7.3.1 Autoclaves using either single-sided or complete exposure are

permitted. If single-sided exposure is used, the test specimen must
have a stainless-steel overlay around all sides (excluding the “bottom”
side), in addition to the test overlay on the top (test) surface. The use
of cathodic charging is not permitted as an alternative to autoclave
exposure.

7.3.2 The specimens shall be hydrogen charged in an autoclave using

hydrogen gas on the clad side of the specimen at 500°C and 150
kg/cm² for 48 hours minimum. If the design temperature or pressure
of the particular vessel are higher than these values, then the test
values shall be increased to the design values.

7.3.3 After the charging period, the specimen shall be cooled to room
temperature at a minimum cooling rate of 200°C/hr for conventional
materials and 300°C/hr for V-modified steels.

7.4 Test Evaluation

7.4.1 The specimen shall be held at room temperature for 10 days.

7.4.2 The specimen shall be examined by UT. If the interface reflection is

more than 20% of the initial backwall reflection, disbonding is
considered to have occurred. The UT test procedure is subject to
approval by Saudi Aramco.

7.4.3 After UT examination, the specimens shall be cross-sectioned

perpendicular to the direction of welding. A minimum of 5 parallel
cross-sections shall be made with no more than 8 mm between each
section. The locations of the cross-sections shall be adjusted to
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include any potential areas of disbonding detected by the UT

examination.
Each section shall be polished and examined by microscope at 200x
magnification minimum.

7.4.4 For acceptance, none of the specimens shall show any disbonding by
either UT or cross-section methods.

7.4.5 Retests are not permitted unless specifically authorized by CSD and,
if authorized, may include additional restrictions or requirements as
determined by CSD.

7.4.6 The results of the UT examination and cross-sections shall be

submitted as part of the PQR.

Document History
30 August 2022 Major revision to include corrosion test requirmen for heat treated stainless steel
weld overlay materials.
21 April 2019 Editorial revision to confirm the content.
4 September 2019 Major revision.
1 January 2018 Editorial revision to modify and/or delete paragraphs 4.3, 4.7, 4.9, 5.10.2, and 6.4
(b).
29 September 2016 Major revision to clarify the minimum specified overlay thickness, the welding
current limitation, chemistry test, the repair welding procedure, and the hydrogen
disbonding test.
11 March 2013 Editorial revision to clarify the iron dilution requirement in weld overlay for Alloy
625 (UNS N06625) 625, and Monel 400 in paragraph 5.7, renumbered
subsequent paragraphs, and changed the primary contact person.
13 December 2011 Revised the "Next Planned Update." Reaffirmed the contents of the document,
and reissued with minor revisions.

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