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T
ogether with the lower price compared to solid CRAs
and improved availability, clad products are now a seri-
ous third piping material option. Stainless Steel World got
in touch with President Dr Bhaven Chakravarti, VP Sales &
Marketing Robert Jenkerson and VP Manufacturing Keith
Oliver to learn more about
KLAD
’s activities and the compa-
ny’s plans for the future.
It becomes clear early in the interview that
KLAD
has gone
through quite a development since the last time we spoke
with them, two years ago. At that time, the company was
focussing heavily on working to gain acceptance of clad pip-
ing as an option for corrosive applications, and investing in
research and development work. The marketplace respond-
ed positively to
KLAD
' s marketing efforts and
KLAD
moved
to a larger facility with more capabilities to properly
respond to the market's needs ensuring that clad piping
materials are available. Maintaining the versatility and flexi-
bility of the production facilities is paramount for
KLAD
.
Until a few years ago the material options for piping
systems were more or less confined to solid corro-
sion-resistant alloys and carbon steel. Using clad pip-
ing material was not often considered a serious
option because of availability problems and unfamil-
iarity with the material. But things have changed
over the years, not in the least as a result of the
development and marketing efforts that Houston
based KLAD Manufacturing Company has put in clad
piping components. The company is convinced that
clad now offers the best of both worlds: corrosion
resistance that equals solid CRAs and the high
strength of a backing steel.
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KLAD Manufacturing Co.
Versatile producer of clad piping components
C
OMPLETE
Dr Chakravarti told us that in the beginning, before he
started his company, lack of availability and technical
difficulties caused by the unfamiliarity of most engineers
with clad piping materials had often made clad products
difficult to use. As a result it prevented the option from
being accepted as a solution to a plant engineer’s corro-
sion or erosion problems. In order to get the material
accepted and to guarantee optimal service to the end user,
the company had to master a variety of production
techniques to manufacture a wide range of piping compo-
nents.
KLAD
currently produces seamless clad pipes,
seam-welded clad pipes and fit-
tings from roll and explo-
sion-bonded clad plates
and weld-overlaid clad
pipes, fittings, flanges,
nozzles and other vessel
components. Each of
the techniques offers
clients options, per the
scope and schedule require-
ments of
the project.
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KLAD
in alliance with Wyman Gordon in Houston produces
the seamless clad pipes. Wyman Gordon, with its massive
seamless production capabilities make supplying large clad
piping projects for oil and gas production systems, refinery
revamps and other large projects feasible.
Dr. Chakravarti pointed out that the
KLAD
weld overlay
facility has grown immensely and considers the welding
techniques utilised in the shop crucial to its success.
While pulsed spray GMAW process is central to much of
the overlay performed, other welding processes are also
utilised to meet other requirements. The P-
GMAW ensures excellent bonding
KLAD
manufacturing shop for overlay and spool fabrication.
X65/SS309LMo overlaid subsea piping with TSA OD coating for
GOM project.
KLAD
manufacturing shop for overlay and spool fabrication.
with low-dilution, such that,
KLAD
routinely provides a
single layer deposit meeting the wrought alloy chemistry.
Mr Jenkerson adds: "We are able to break down a project
and select the best production method for each of its con-
stituent parts to meet the highest quality standards and
economic criteria for the project. We are listening to our
client's needs of a better product made less expensive"
T
HIRD OPTION
But how have things been in
the past two years? Dr
Chakravarti: "We have
made 'clad' a practical,
third piping material
option, covering the full
range of materials, sizes and at
improved availability. We
have made it easy for the
industry to work with clad,
so it now is a much more
accepted product than it
was a few years ago. It has
truly found its way in the
minds of people. I think that
that is one of the most
important developments we have seen.
End users have started to realise that clad allows them to
combine high strength with corrosion resistance and pro-
vides them with material solutions opportunities not avail-
able previously. For example, the oil and gas industry is
now drilling for deep-water wells, requiring essential
material strength to withstand collapse and corrosion
resistance. Due to their relatively lower strength, CRAs
are cost and design prohibitive, but clad now gives them
the opportunity to combine high-strength steel with cor-
rosion-resistant cladding, in the sizes and quantities
required to make the project viable. From a cost point of
view, clad is the attractive alternative, making it substan-
tially more economic for projects to go ahead."
According to Dr Chakravarti, this has led to a clear move
within the market from CRAs and carbon steel piping
equipment to clad materials, and he thinks there are
tremendous growth opportunities: "Everyone is reducing
costs, driving the maintenance world to upgrade their pip-
ing materials. Clad has become an important parameter in
people's considerations. When you look at the total pip-
ing market, the vast majority consists of carbon steel. Only
a small part is made of CRAs, and what we have really
done is create a third piping material option to choose
from, which is clad." The market growth means that
KLAD
has to grow as well if the company wants to service all its
clients. Dr Chakravarti explained that the company’s pro-
duction facilities are quite well adapted to this develop-
ment: "In the past few years we have expanded our pro-
duction capacity tremendously. The fact that we are now
able to manufacture every piping component, from weld
overlay to seamless pipe has been the most important
development in our company recently.
T
HREE TECHNIQUES
Mr Oliver continues: "Our
organisational struc-
ture has given us
tremendous
flexibility in
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Given the versatility of
KLAD
’s production techniques and the range of
capabilities that exist,
KLAD
actively works with client to solve their
material performance problems.
Fabrication of X60/alloy
625 3D bend gooseneck.
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our production procedures and enables us to comply with
the fluctuations in market demand. Whether someone asks
for ten feet of pipe or five thousand feet of pipe we can
handle it. In order to do so we have three different pro-
duction techniques that are interchangeable: manufactur-
ing clad piping components from clad plates, or by weld
overlaying seamless carbon or low alloy steel components
and from seamless clad pipe. The weld overlay capacity
gives us the flexibility to adjust to market demand." Mr
Jenkerson added that this sets
KLAD
apart from its com-
petitors because they mostly concentrate on one produc-
tion technique. According to Mr Jenkerson,
KLAD
is prob-
ably the only company to manufacture clad piping systems
through all of the production techniques: "Our clad and
overlay stations are very versatile. They can be broken
down in a pipe welding station, a pipe overlay station and
a fitting station, and once the components have been made
they enter into the fabrication part of our facilities. From
here we can supply one or two parts or a complete spool,
as well as a complete piping project. Given the versatility
of
KLAD
’s production techniques and the range of capabili-
ties that exist,
KLAD
actively works with client to solve
their material performance problems. For example, here
is a case where working with a large OEM valve supplier,
we helped develop a product line, that made the product
possible." Mr Jenkerson described where
KLAD
weld over-
laid the entire low alloy valve body with HASTELLOY®
Alloy C22. It would have been impractical from a design
and cost point of view to make the body from a solid C22.
Mr Jenkerson: "We worked hand in hand with them in the
manufacture of the valve, which eventually improved their
process and will keep costs down. That’s the direction
we’re moving into: giving end users the opportunity to
look at their plant designs and help them improve it."
Building up a long-term relationship with plant engineers
and maintenance managers is one of the most important
ways for
KLAD
to do business. They are the ones who
know what’s going on in their plants and who can get in
touch with
KLAD
to discuss problems. The company then
develops the most cost-effective solution for that particu-
lar problem. Developing solutions to critical corrosion
problems is
KLAD
’s core business. As a matter of fact, the
company is now working on a number of clad applications
for high-temperature corrosive environments and chemi-
cal plants as well as a number of other areas that will bring
advantages to the engineering community in the field of
costs and performance. A solution to erosion problems is
another area that
KLAD
has started work. As there are
many piping systems that can benefit from applying a
wear-resistant material. That’s what we’re working on
right now." And that ended our interview. Asked about
KLAD
’s future expectations, Dr Chakravarti replied that
their goal now is to make
KLAD
synonymous for clad pip-
ing systems and to make clad, the third piping material
option, commonplace in the industry. For
KLAD
, the sky is
the limit when it comes to clad applications and combined
with the ongoing maintenance cost reductions and carbon
steel upgrades in the industry it looks like the company is
heading for a bright future.
➛
Name:
KLAD
Manufacturing Company, Ltd.
Founded:
1995
Products:
KLAD
is a single-source supplier of metal-
lurgically bonded clad pipe, clad fittings
and weld overlaid piping components,
flanges, nozzles, and pressure vessel com-
ponents. Additionally,
KLAD
fabricates
clad piping spools.
Location:
KLAD
is located in Houston, Texas..
Methods:
Pipe and fittings made from roll bond
and explosion bonded clad plates
Seamless co-extruded clad piping
Low-dilution weld overlay clad pipe, fit-
tings, flanges and valves
Induction bending of clad pipes
Hot formed heavy wall clad fittings
Grades:
KLAD
offers an extensive range of backing
materials such as carbon steels, chrome
moly grades and high-yield grades com-
bined with a wide range of corrosion-
resistant cladding alloys including 300
series stainless steels, Alloys 825 and 6Mo,
Nickel alloys 200, 400, 625 and C276 and
wear-resistant grades.
Markets:
Refining, Oil & Gas Production, Nuclear
Power, Environmental, Chemical Process
Industries
F A C T S & F I G U R E S
1. SS304L
KLAD
nuclear plant feedwatere heater shell
replacements.
2. Alloy C276
KLAD
safety valve relief header.
3. Fabrication of alloy 825
KLAD
piping for sour gas plant.