DCLAD
Cladding and Machining Specialist
Table of Content
➢
Company Profile, Vision & Goal
➢
DClad Equipment list
➢
Cladding Capabilities
➢
Machining Capabilities
➢
NDT Capabilities
➢
Qualifications & Weld
Overlaying Procedures / R&D
➢
Health, Safety and Environment
➢
DClad Certification
➢
Key Customers
Company Profile, Vision and Goals
➢
➢
Regional model of excellence for partners
looking for top level of industrial services
offered by an action-oriented team and
state of the art technologies.
Specialized in Weld Overlay for all
components of Wellheads, X-mas
tree, Flanges, Fittings and Pipes
along with repair solutions and
other services for the industrial
sector.
✓
✓
✓
Supply quality products on time
Full compliance with customer
requirements
Cost effective price.
DClad Equipment – Cladding ETRs
❑
❑
❑
Fronius PFA 9000 ETRs
Compact Cladding Cell
Automated ButtWelding Machine
DClad Equipment – Pipe Cladding
❑
Fronius Pipe Cladding
Machines
DClad Process – Tungsten Inert Gas - Pulsed Hot Wire
DClad Equipment
❑
Manual Welding
Power Source
❑
➢
Duty Cycle:
➢
200A / 100%
➢
➢
250A / 60%
➢
300A / 35%
Electrical Heating Systems Ceramic Pads - StorkCooperheat
❑
PWHT Furnace – Stork
Cooperheat
❑
PWHT Capability:
Transformer Rating 70 KVA.
➢
3m x 2.5m x 2.5m
➢
Max Load/Output 180 A.
➢
8 tons
➢
Max Elements/Output 6X4.5 A.
Machining Capability
➢ DCLAD has an impressive machine shop with CNC controlled machines.
➢
DCLAD Machining equipment:
➢
➢
Mill/Turn 5-Axis Machine
Boring Center
➢
➢
Turning Center
Vertical Machining Center
➢
➢
Puma 400 MB
Valve Center 5 VT
Fronius FPA9000 ETR – Capability
➢ I Blocks
➢ Y Blocks
➢ Casing/Tubing Spool
➢ Gate Valve Body
➢ Gate Valve Bonnet
ETR Fronius
Cladding Machines
❑
❑
Cladding capability:
➢
ID – ~30 mm
➢
OD – ~1500+ mm
➢Tree cap body
➢Tree cap plug
➢Studded Tee/Cross
➢Tubing Head Adapter
➢Adapter Flange
➢Blind flange
➢Blanking Plug
➢Weld Neck Flange
➢Elbow
➢Pipe Flange
Fronius FPA9000 ETR – Capability
Fronius FPA9000 ETR – Capability
❑
Tubing Head Spool
❑
❑
Weld Neck Flange
Swivel Flange – full clad
❑
❑
Gate Valve Body – full clad
Tree Cap Body
Fronius ETR/CCC – Saipem(Aramco) flanges
❑
❑
Receiving and before
cladding
Weld Neck Flanges and Swivel Flanges
❑
❑
Cladding
During Inspection
with TPI
❑
After coating – ready for
packing
ETR Software - Macro: Weld Overlaying Parameters
➢
✓
✓
✓
✓
✓
✓
✓
✓
Contains all the welding
parameters:
Parameter's description
Welding speed
AVC parameter group
Actual values display
parameter group
Welding torch parameter
group
Hot / cold wire parameter
group
Oscillation parameter
Axis parameter
ETR Software – The Program Editor
✓
✓
✓
✓
✓
✓
Select the macro program
The program line number
Starting / ending position of
the weld
Specifies what step the
step axis must make
Contain the number of
layers
The torch downslope
function
ETR Software – 3D Process Visualization
➢
3D visualization and information related to program:
✓
✓
Line program / layer number / position / step / runtime
The program parameter: height / step / and diameter of the seat pocket.
ETR Software – The Actual Values Indication
➢
✓
✓
✓
✓
✓
On the Actual Values screen
we have information related
to:
Welding amps
Welding volts
Travel speed
Wire speed
Gas flow
Fronius Compact Cladding Cell – Capability
❑
Blanking Plug
❑
❑
3 x Compact Cladding
Machines
❑
Cladding capability:
➢
ID – ~30 mm
➢
OD – 1000 mm
➢
2 T capability
❑
Tubing Head Adapter
Tree Cap Body
❑
Bonnet
Fronius Welding Machine Capability
➢ Compact Cladding Cell (CCC) have been converted to Welding Machine for joining and welding of swivel
adapter flange as per API 6A and NACE requirements.
➢ The structure of turn table holder has been designed and stress analyzed by DCLAD.
Fronius Welding Machine
➢ Welding wire (AK-10) has been developed to joining and welding of AISI 4130 to AISI 4130,
specially for the swivel adapter flange as per ARAMCO’s specifications.
Fronius Pipe Cladding Machine
❑
2 x Fronius Pipe Cladding
Machines
❑
Cladding Capability:
➢
Min. ID – 6” (~155 mm)
➢
Max. ID – 36” (~920 mm)
➢
Length: 6 m & 12 m
➢
Depos. rate: ~ 3 Kg/h
NDT Capability
➢ DCLAD provide customers with Non-Destructive testing, including: MPI, DPI,
PMI, & ultrasonic testing.
➢
DCLAD NDT equipment:
➢
➢
➢
➢
➢
➢
➢
➢
➢
➢
Dye Penetrant Inspection
Magnetic Particle Test
Positive Material Identification (PMI)
Thickness Measurement
Side Bend Tests
Ultrasonic Test
Hardness Testing
Ferrite Determination
3D Measurement (Portable CMM)
Metallographic Examination
NDT Capability – Pipe Inspection Machine
➢ Pipe Inspection Machine (Fluorescent PT) for Cladded Pipe
➢
➢
➢
➢
➢
➢
➢ Pipe Inspection Capability:
❖ Min. ID – 6” (150 mm)
❖ Max. ID – 40” (1000 mm)
❖ Length – 12 m
Fluorescent PT inspection machine
Semi-automated system
Control system / Software
Recording movies / screen shots
Indications measuring in real time
Spray Process Rotary Selector Switch:
❑ High Pressure Water Wash
❑ Air Blast Dry
❑ Penetrate Spray
❑ Low Pressure Water Wash
❑ Air Blast Dry
❑ Developer Spray
❑ Camera Inspection
➢ Reduced inspection time compared
with conventional equipment (manual).
NDT Capability – Pipe Inspection Machine
Camera used for inspection
Software cladding inspection
High pressure water wash
➢
Screen shot from software
with a measurement of
discontinuity
NDT Capability – Pipe Inspection Machine
The Main Control Screen:
➢ provides all basic operating conditions in real-time.
➢ provide information as a process occurs and allow
the user to easily navigate the software.
➢ ability to monitor various operating parameters.
Camera Inspection Window:
➢ Date/Time & Job Number
➢ Pipe Serial# and Operator Name
➢ Measurement Values
➢ Option to Record / Screen shot
NDT Capability - Immersion Ultrasonic Testing
➢
IUT Machine is a turn-key, multi-axis, computer-controlled gantry / immersion scanning system
for cladding inspection.
➢ IUT Inspection Capability (tank):
❖ L: ~ 86” (2200 mm)
❖ W: ~ 54” (1370 mm)
❖ H: ~ 89” (2260 mm)
IUT (Immersion Ultrasonic Testing) Software
➢ We can see on-screen A-Scan display (RF Waveform Display per Location), B and C-Scan
collection (A Color Mapped Peak Amplitude and Time-Of-Flight Representation).
IUT (Immersion Ultrasonic Testing) Scan Example
Research & Development Capabilities
➢
➢
DCLAD is a highly technical company that has full R & D capabilities
We developed weld overlaying procedures for:
❖
❖
❖
❖
❖
Ni based alloys (625, 825, Monel
400 Alloy).
Stainless Steel (309L, 309LMo,
309LSi, 316L, 347Si).
AK-10 on AISI 4130.
Automated Butt Welding for
joining of AISI 4130 to AISI 4130
with AK 10 (filler wire).
WPS / PQR based on customer
specification, ASME Sec. IX &
API 6A.
Health, Safety and Environment – HSE
➢ DCLAD is committed to excellence in operations
standards of Health, Safety and Environment (HSE)
throughout its activities.
❖ Zero Lost Time
❖ Zero Accidents
DClad Certification
ISO 3834-Part 2
The Welding Institute
European Federation for
Welding, Joining and Cutting
DClad Certifications
ISO 9001:2015
ISO 14001:2015
ISO 45001:2018
DClad Certifications
API Specification Q1
API 5LD
DClad Approval Letters – Key Customers
Qatar Energy
Qatar Gas
Saudi Aramco
DClad Approval Letters – Key Customers
ADCO Approval
Key Customers
➢
Kuwait Oil Company
➢
ExxonMobil
➢
Delta Corporation
➢
Qatar Gas
➢
Qatar Petroleum
➢
British Petroleum
➢
Moderate General Trading
➢
Total
➢
Gazprom
➢
Lukoil
➢
Al Khorayef
➢
Shell/BlackCat
➢
Kalhour Oilfield Equipment
➢
McDermott
➢
Aramco
➢
Al Mana
Group
➢
Saipem
Thank You !