Amigos Technical PWHT Procedure

AMIGOS TECHNICAL SERVICES ( S ) PTE LTD POST WELD HEAT TREATMENT PROCEDURE
Doc No
: ATS-PWHT-001
Revision No : 01 Date :
POST WELD HEAT TREATMENT PROCEDURE
DESCRIPTION
NAME
SIGNATURE
PREPARED BY
REVIEWD BY
APPROVED BY
REVISION STATUS
S.NO
REVISION No.
DATE
DESCRIPTION
Page 1 of 11
Doc No
: ATS-PWHT-001
CONTENTS
Page 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Scope Heating Item / Work Volume, Location, Schedule. Applicable Code & Specification.. Heat Treatment ( PWHT ) Method Temperature Monitoring. Precautions.. Important Measures During PWHT..... Temperature Ranges.... Temperature Control System Personnels Qualification.. Report / Documentation Heat Treatment Equipment. 3 3 3 34 4 4 5 5 6 6 6 7
Appendix 1 Appendix 2
Sketch : Width of Heated & Insulted Zone ( LOCAL PWHT ) Thermocouple Locations ( LOCAL PWHT )
Attachments
PWHT Report Form
( Specimen )
Page 2 of 11
Doc No
: ATS-PWHT-001
1.
Scope
This document covers the procedure for PWHT Work of High Pressure Piping system Weld joints by localized heating method for carbon and manganese steel, alloy steel materials and castings.
2.
HEATING ITEM / WORK VOLUME, LOCATION, SCHEDULE
HEATING ITEM Various sizes of piping welds range from 0.75 ~ 16 Thickness range : Less than 50.8mm Also structural weld joints of varying thickness
3.
APPLICABLE CODE & SPECIFICATION

1. 2. 3. 4. 5. ASME code Section VIII Div.1 2001 ED , chapter UCS-56 ASME B31.3 DNV-OS-C101 or DNV-OS-C201 AWS D1.1 Clients Specification
4.
HEAT TREATMENT ( PWHT ) METHOD

41 Weld Joints shall be locally heat-treated in such manner that the entire Band be brought up uniformly to the required temperature and held for the specified period of time, in accordance with the codes specifications stated in the above section 3.
42
Minimum Required Heated Band Width:

1. In Local PWHT of Butt Weld Joint, the minimum width of the Circumferential Heat Band, measured from CENTRE of the Weld, shall extend 2.5RT beyond the edge of the weld. ( R = inside Diameter in mm ; T = pipe wall thickness in mm ) 2. In Local PWHT of welded Branch Connection, the minimum Width of the heated band shall extend at least 2.5RT beyond The edge of the weld joining the branch or attachment to the run pipe. In local PWHT of Bend or formed sections, the minimum width Of the heated band shall extend to 2.5RT on each side of the Bent or formed area.
3.
Page 3 of 11
Doc No
: ATS-PWHT-001
4.
HEAT TREATMENT ( PWHT ) METHOD CONT
43
Thermal Insulation:
(a) The insulation width, measured from the center of the weld, Shall extend at least 5RT beyond the edge of the weld. (b) Density of 128Kg/m3 Ceramic fiber insulation blanket shall be Used the thermal insulation. (c) The insulation blanket will be kept in position with iron or steel Wire. (d) Wherever possible, the ends of piping should be sealed to Prevent internal air currents from creating excessively high Thermal gradients through the thickness of the piping. (e) After heat treatment , all materials shall be cooled in still air, Protected from rain and draught.
44
Thermocouple Location: (a) Thermocouple shall be firmly attached to the center of the Weld zone using a capacitance-discharge type thermocouple Welder. A demonstration will be carried out upon clients Request. (b) When tack welding thermocouple onto the work piece, Precautions shall be taken so as not to create defects such as Undercuts, arc strike, etc and the welded zone shall be Smoothly finished by grinder after heat treatment. (c) All thermocouple attachments shall be adequately insulated by High temperature misreading caused by the effect of radiation. (d) The miminum number/location of the thermocouple to be Attached to the work place shall be as follows:
Weld sizes ( NPS ) (a) D6
No.of T/C 1 no
Locations 9 Oclock ( center )
(b) 6<D<16
2 no
1800 apart ( top & bottom )
(c) D 16
3 or more
Every 600mm from each other, or in of the outer Circumference, whichever Distance is the smallest. (pls refer to APPENDIX-2)
Page 4 of 11
Doc No
: ATS-PWHT-001
4-4-1
For Structural Joints :
Thermocouple can be placed as per the clients requirement or at a Regular intervals of 0.5m whichever is suitable
5.
TEMPERATURE MONITORING
51 Temperature monitoring shall be done by the thermocouples and Temperature shall be recorded continuously on temperature record Chart.
6.
PRECAUTIONS
61
It is vital to highlight the need for adequate support of work piece Prior to commencing any heat treatment to minimize possible Misalignment, distortion, collapse or deformation. Exposed, machined and threaded surface shall be protected from Oxidation by applying Anti-Seize and Lubricating Compound prior to PWHT.
62
7.
IMPORTANT MEASURES DURING PWHT
Upon the occurrence of below-mentioned problems during LOCAL PWHT Operation, the following should be observed:
FAULT / PROBLEM
ACTION NOT ALLOWED No weather protection Provided before heating
CORRECTIVE ACTION Provide proper and Adequate weather Protection before heating
RAIN
Page 5 0f 11
Doc No
: ATS-PWHT-001
8.
TEMPERATURE RANGES :
The procedure for PWHT has to be followed for the various steel grades as mentioned below.
Material Grade
Alloy Steels ASTM A 335 P4
Temperature Range
705 - 749
Heating / Soaking TIme

2 Hrs / 25mm wall Thickness soaking 2 hrs minimum 2 Hrs / 25mm wall Thickness soaking 2 hrs minimum 2 Hrs / 25mm wall Thickness soaking 2 hrs minimum 2 Hrs / 25mm wall Thickness soaking 2 hrs minimum 1 Hrs / 25mm wall Thickness soaking 1 hrs minimum
Rate of Heating
100C / Hrs / 25mm wall thickness 100C / Hrs / 25mm wall thickness 100C / Hrs / 25mm wall thickness 100C / Hrs / 25mm wall thickness 222C / Hrs / 25mm wall thickness
Rate of Cooling
100C / Hrs / 25mm wall thickness 100C / Hrs / 25mm wall thickness 100C / Hrs / 25mm wall thickness 100C / Hrs / 25mm wall thickness 222C / Hrs / 25mm wall thickness
705 - 760
705 - 749
730 - 790
590 - 650
Doc No
: ATS-PWHT-001
Page 6 of 11
9.
TEMPERATURE CONTROL SYSTEM

Temperature will be controlled by combination of program setter (1) which Generates voltage (mv) equivalent to the electromotive force of k Thermocouple with temperature controller (2), and the Heater (4) will be Controlled by the difference of thermal electromotive force of thermocouple (5).
Schematic Sketch of Heat Treatment process
Workpiece Power Source
k type mV Program Setter (1) Temperature Controller pulse (2) On/off pulse Power Regulator (3) Heater (4) +
Temperature Recorder
10.
PERSONNELS QUALIFICATION
Heat Treatment operator shall have at least one year of field experience in the Heat treatment work described in this Procedure.
Doc No
: ATS-PWHT-001
Page 7 of 11
11.
REPORT / DOCUMENTATION
11 1
A Time-Temperature Record Chart shall be provided for each heat Treatment operation. Each chart is to show: (a) Item Identification Number ( Job, Unit, System, ISO, Tag/Piece No.etc (b) Number of Thermocouples (c) Time and Date Started (d) Chart Speed ( inches/hr) (e) Heating / cooling Rates, Soak Temperature & Soak Time (f) Model & serial number of temperature recorder , including date of calibration (g) Name of operator (h) The Approval signature of Clients site representive
11 2
A copy of Thermocouple Certificate provided by the supplier and Calibration Certificate of Temperature Recorder will be attached Together with the heat treatment Report and temperature chart.
12.
HEAT TREATMENT EQUIPMENTS
12 1
Temperature Recorder It is Chino 12pts recorder calibrated for type k chromel / alumel Temperatures. The instrument shall be calibrated every 12 months by a third party. Calibration Certificate shall be submitted to Clients before commencing Work.
12 2
Program Controller It consists of Chino Program Setter and Chino Temperature Controller. Thermocouple It shall be Chromel-Alumel type k thermocouple (consumable type, 0.8mm, glass fiber varnish finished) for temperature range up to 900C. Thermocouple will be attached directly onto metal surface of the work piece Using a thermocouple Welder. This consumable type of thermocouple gives The greatest accuracy and weld penetration will be only 0.2mm to 0.3mm.
12 3
Doc No
: ATS-PWHT-001
Page 8 of 11
12 4
Thermocouple Welding Unit When counsumable type of thermocouple is to used for monitoring Temperature, it will be attached to the metal surface by capacitance Discharge from this instrument.
12 5
Thermocouple Compensating Lead It shall be Copper / Constantan when used in conjunction with type k Thermocouple.
12 6
Electric Resistance Heater 2.7Kw Ceramic Pad Heaters.
12 7
Power Regulator 60Kva Step down Transformer c/w built in ELCB x 6 channels 60 Kva output
12 8
High Temperature Ceramic Putty This is used to insulate the hot junction of thermocouple, so as to avoid Temperature misreading caused by the effect radiation.
12 9
Insulation Blanket Density of 128Kg/m3 ceramic fiber blanket Size: 7200L x 600W x 25T (mm) per roll Maximum services temperature: 1200C
Doc No
: ATS-PWHT-001
Page 9 of 11
APPENDIX 1
WIDTH OF HEATED & INSULATED ZONES ( FOR LOCAL PWHT )
Heated Band Width

Weld Centre Line Heating Element
2.5RT
2.5RT
Insulation
5RT
5RT
Insulation Width
Where R = Inside Diameter in mm, T = Pipe Wall thickness in mm.
Doc No
: ATS-PWHT-001
Page 10 of 11 APPENDIX 2
THERMOCOUPLE LOCATIONS ( LOCAL PWHT )
All thermocouples are to be attached on the center of the weld. 1) D 6 : 1 thermocouple 9 O clock ( CENTRE)
2) 6 < D < 16
: 2 thermocouple ( TOP & BOTTOM )
3) D 16
: 3 or more thermocouples ( Every 600mm from each other or in of The outer circumference, whichever Distance is the smallest )
600mm
600mm
Doc No
: ATS-PWHT-001
Page 11 of 11

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AMIGOS TECHNICAL SERVICES ( S ) PTE LTD POST WELD HEAT TREATMENT PROCEDURE

POST WELD HEAT TREATMENT PROCEDURE

PWHT Report Form

HEATING ITEM / WORK VOLUME, LOCATION, SCHEDULE

APPLICABLE CODE & SPECIFICATION

HEAT TREATMENT ( PWHT ) METHOD

Minimum Required Heated Band Width:

HEAT TREATMENT ( PWHT ) METHOD CONT

Weld sizes ( NPS ) (a) D6

Locations 9 Oclock ( center )

1800 apart ( top & bottom )

For Structural Joints :

IMPORTANT MEASURES DURING PWHT

ACTION NOT ALLOWED No weather protection Provided before heating

Heating / Soaking TIme

TEMPERATURE CONTROL SYSTEM

Schematic Sketch of Heat Treatment process

Workpiece Power Source

HEAT TREATMENT EQUIPMENTS

Electric Resistance Heater 2.7Kw Ceramic Pad Heaters.

WIDTH OF HEATED & INSULATED ZONES ( FOR LOCAL PWHT )

Heated Band Width

Where R = Inside Diameter in mm, T = Pipe Wall thickness in mm.

THERMOCOUPLE LOCATIONS ( LOCAL PWHT )

: 2 thermocouple ( TOP & BOTTOM )

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