1

INDEX
Sl.No.
01
02
03
04
05
06
07
08

Description
Cover Sheet
Index
Preface
Foreword
Approval Sheet
Important Note
Status of Amendments
Table of Contents

Page No.
01
02
03
04
05
06
07
08

BHEL POWER SECTOR

IMPORTANT
THIS HEAT TREATMENT MANUAL PROVIDES BROAD BASED GUIDELINES FOR
HEAT TREATMENT WORK AT SITES. HOWEVER, SITES MUST ENSURE
ADHERENCE TO THE PRIMARY DOCUMENTS LIKE CONTRACT DRAWINGS,
ERECTION

WELDING

SCHEDULE,

PLANT

CORPORATE

STANDARDS,

WHEREVER SUPPLIED, STATUTORY DOCUMENTS, WELDING PROCEDURE

SPECIFICATIONS,

CONTRACTUAL

OBLIGATIONS,

IF

ANY

AND

SPECIAL

INSTRUCTIONS ISSUED BY RESPECTIVE MANUFACTURING UNITS SPECIFIC TO

THE PROJECT.

BHEL POWER SECTOR

STATUS OF AMENDMENTS

Sl.No.

BHEL POWER SECTOR

Description

Remarks

TABLE OF CONTENTS
Chapter

Description

Page No.

Heat Treatment Procedure - Boiler and Auxiliaries

8 - 23

Heat Treatment Procedure - Steam Turbine, TurboGenerator and Auxiliaries

24 - 25

General

26

1.

Testing of Temperature Indicating Crayons

27

2.

Compatibility Test for Heat Treatment System

Pre heat & PWHT of Critical Piping with Turbine & Auxiliaries

BHEL POWER SECTOR

28 - 29

30

CHAPTER-1
HEAT TREATMENT PROCEDURE - BOILER AND AUXILIARIES

BHEL POWER SECTOR

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -1

1.0

PURPOSE:

1.1

This procedure provides information, method and control for Pre-Heat, Post Heat and
Post Weld Heat Treatment (PWHT) of welds at sites.

2.0

DOCUMENT:

2.1

The following documents are referred in preparation of this procedure:

2.1.1

ASME Sec.I

2.1.2

ASME B31.1

2.1.3

Indian Boiler Regulations

2.1.4

AWS D1.1

2.1.5

Welding Manual

2.2

The following are to be referred as Primary Documents:

-

Contract drawings
Erection Welding Schedule or equivalent

Plant / Corporate standards, where supplied

Welding procedure specification

Contractual obligations, if any.

2.2.1

Where parameter for Pre-Heat ,Post Heat and PWHT are not available in the primary
documents, reference may be made to this procedure.

2.2.2

Where such parameters are not contained either in the primary documents or in this
procedure, reference may be made to Manufacturing Units.

3.0

PROCEDURE:

3.1

Pre Heating :

3.1.1

When parts of two different thicknesses are welded together, the preheating requirements
of the thicker shall rule

BHEL POWER SECTOR

10

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -1

3.1.2 When parts of two different P numbers are joined together, the material requiring higher
preheat shall govern (please refer Welding Manual for P numbers).
3.1.3

It is recommended to use thermocouples with temperature recorder for recording

pre heating . Where temperature recorder is not possible to use, Preheating shall be
checked using thermal chalk (temperature indicating crayons) prior to start of
welding as well as at frequent intervals during welding

3.1.4

In case of any power interruption during welding, the joint shall be wrapped with dry
thermal insulating blankets to ensure slow and uniform cooling. Requirement of
uninterrupted power supply shall be ensured for materials like P-91, T-91 &
BS EN 10025

3.1.5

Preheating & Post Heating Methods:

3.1.5.1 Preheating & Post Heating shall be applied by any of the methods given below:
a.

Electrical resistance heating

b.

Induction heating

c.

Oxy-acetylene or other gas torches

3.2

Post Weld Heat Treatment (PWHT):

3.2.1

The method shall be by locally heating a circumferential band including the entire weld
and adjacent area of base metal, by induction or electrical resistance heating.

3.2.2

Heat band for PWHT:

3.2.2.1 For Boilers:

a.

When heat treating welded joints in components in the boiler proper, width of the
heated circumferential band (W) on either side of the weld, W = 3 times the width
of the widest part of the weld groove but in no case less than twice the width of
weld at reinforcement.

b.

When used in post weld heat treatment in sections - W = 3 times the plate
thickness.

c.

For nozzle and other welded attachments - W must be wider than the nozzle or
attachment or 3 times the wall thickness.

3.2.2.2 For Piping:

W = 3 times the wall thickness (of thickest part ) on each side from the centre of the
weld. In case of nozzles and attachment welds, the width of the heat band shall extend
beyond the nozzle or the attachment wall on each side by at least twice the higher
thickness and shall extend completely around the header.

BHEL POWER SECTOR

11

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -1

3.2.2.3 Other Pressure Vessels:

Heat bandwidth, placement of thermocouple, preheat and PWHT information shall be
obtained from the supplier.
3.3

Condition of Welded Joints:

3.3.1

The weldment shall be free of grease, oil etc. prior to Pre-Heat / PWHT.

3.4

Temperature Measurement for PWHT:

3.4.1

Post weld heat treatment temperature cycle shall be measured and monitored by use
of thermocouples with calibrated recorders.

3.4.2

The periodicity of calibration of the equipment shall be as per calibration procedure.

3.4.3

Where the soaking temperature is found to be lesser than specified, the PWHT cycle
shall be repeated.

3.4.4

In case of interruption during PWHT, the following actions are to be taken, depending
on the stage during which interruption occurred.
a.Interruption during heating cycle:
-

The whole operation to be repeated from the beginning.

b.Interruption during soaking:

-

The joint can be treated subsequently for the balance left over soaking
period.

c.Interruption during cooling:

- Ensure slow cooling by covering with insulation to a minimum width of 1.5 times
the outer diameter applied equally about the centre line of weld, till the
temperature reaches around 300C.
3.5

Thermocouple (t/c) Fixing:

3.5.1

Thermocouples shall be used for recording Post Weld Heat Treatment temperatures.

3.5.1.1 Following are guidelines regarding number and placement of thermocouples:

3.5.1.2 Minimum of two thermocouples per weld joint.
3.5.1.3 Thermocouples located 180 apart.
3.5.1.4 Thermocouples located at top and bottom of weld joint.
3.5.1.5 Thermocouples located at a distance of approximately 1.5 times of the wall thickness
about the centre line of weld.
3.5.1.6 One point of the 6/12 points recorder shall be used for recording ambient temperature.

BHEL POWER SECTOR

12

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -1

3.5.2

3.5.3

The following guidelines may be used for attaching thermocouples to job:

a.

For capacitor discharge method: Thermocouple elements should be attached

within 6 mm of each other.

b.

For other type of t/c: Insert the elements in a SS tube of internal diameter
approximately 6 mm. Apply force on tube and crimp it. Place this t/c and weld the
crimped button to the pipe in area of interest. Do not weld the elements.

c.

Insulate the t/c leads suitably and protect t/c ends from direct radiation from
heating elements.

For Bunched Tubes:

3.5.3.1 Where a bunch of closely placed tube welds (e.g. Super Heater / Reheater Coils)
require to be Post Weld Heat Treated, the same shall be grouped together as if they
form a single component.
3.5.3.2 In such cases attachment of a minimum of three thermocouples, two at the end tubes
and one at the middle is recommended.
3.6

Soaking Time:

3.6.1

Wherever not specified the soaking time shall be as per Tables I, II and III.

3.6.2

The following guidelines shall be used to determine the thickness and subsequent
selection of the soaking time of PWHT:
a.

For butt welds, the thickness shall be the thickness of the material at the weld.
For bar stock, the thickness shall be the diameter.

b.

For fillet welds, the thickness shall be the throat thickness.

c.

For partial penetration branch welds, the thickness shall be the depth of the
groove prior to welding.

d.

For repairs, the thickness shall be the depth of the groove as prepared for repair
welding.

e.

For combination of different welds in a component, the maximum thickness in the

definitions given above shall govern.

3.6.3

Soaking time is to be reckoned from the time temperature of the joint crosses the
recommended lower temperature of the cycle, to the time it comes down below the
same recommended lower temperature of the cycle.

3.7

Heating and Cooling Rates:

3.7.1

Wherever not specified, the heating rate above 300C and cooling rate after soaking
upto 300C shall be as follows: This is applicable for all materials.

BHEL POWER SECTOR

13

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -1

Thickness of Material

Maximum Heating Rate Above

300C

Maximum Cooling
Rate Upto 300C

25 mm

220C/hour

220C/hour

> 25 50 mm

110C/hour

110C/hour

> 50 75 mm

75C/hour

75C/hour

> 75mm

55C/hour

55C/hour *

* For structural - 65C/ hour (Max.)

3.8

Temperature Records:

3.8.1

All the heat treatment cycles may be controlled within 10C around the
midpoint of the recommended range of temperature for the material.

4.0

POST WELD HEAT TREATMENT (PWHT) JOB CARD:

4.1

Prior to start of PWHT operations, a job card may be prepared including details of
weld reference, soaking time, soaking temperature, maximum rates of heating and
cooling, temperature recorder details, date of PWHT as per sample format.

4.2

On completion of PWHT the actual parameters shall be recorded on the job card.

4.3

A chart number shall be given to each chart.

5.0

HEAT TREATMENT OF P-91 WELDS :

5.1

Please refer Welding Manual vide document No. PSQ-WDM-COM for heat treatment of
welds in P-91 materials.

5.2

HEAT TREATMENT OF T-91 WELDS:

5.3 Please refer Welding Manual vide document No. PSQ-WDM-COM for heat treatment of
welds in T-91 materials

BHEL POWER SECTOR

14

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -1

5.4

HEAT TREATMENT OPERATOR REQUIREMENTS:

The operator for the Heat Treatment shall be a qualified Electrician and should be
conversant in the operation & maintenance of heat treatment machines & Process. He
should be trained properly by the concerned Welding / Electrical Engineer in order to
handle/ maintain the machines / process without any trouble / problem.

6.0

LIST OF TABLES:
Table-I Weld preheat and PWHT for tubes and pipes outside diameter 102 mm.
Table-II Weld preheat and PWHT for Boiler Header welds.
Table-III Weld preheat and PWHT for pipes outside diameter > 102 mm.
Table-IV P Number and Group Number for Base Materials.
Table-V Pre-heat and PWHT for Non-Pressure Parts including Structural.
Table-VI Preheat for Flame Cutting.

7.0

RECORDS :

7.1

Pertinent Records like Job card, PWHT Charts, shall be maintained.

BHEL POWER SECTOR

15

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -1

POST WELD HEAT TREATMENT (PWHT) JOB CARD

Project : ____________________
Card No. : ____________________

Date : ________________________

Unit No. : _____________________

Package : _____________________

Description : ___________________

Temp. Recorder Details :

Weld Reference : _______________

1. Make : _____________________

Material Spec. : ________________

2. Type : _____________________

Size : Dia __________________ mm

3. Sl.No.: _____________________

Thick (t) ______________ mm

NDE Cleared on :_______________
Report No. :
_______________

4. Chart speed: ________ mm / hour

5. Calibration Due on : __________

Thermocouple Locations :
Minimum 2
d = 1.5 x t from weld centre
Heating Band = 6 x t
Insulation Band = 12 x t
Date of PWHT _________________
Start Time : ___________________

Chart No. : _____________________

End Time : _____________________

Required

Actual

Rate of Heating (Max) C/h

Soaking Temperature C
Soaking Time (Minutes)
Rate of cooling (Max) C

Ambient temperature recorded on the PWHT Chart: ____________

Contractor

BHEL

Results : Accepted / Not Accepted

BHEL POWER SECTOR

Released for further processing

16

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -1
TABLE - I
WELD PRE HEAT AND PWHT FOR TUBES & PIPES
OUTSIDE DIAMETER 102 mm
(Applicable For Butt Welds And Socket Welds)
P. No. of
Material

Thickness
(mm)

Preheat C

PWHT C

P1 Gr 1& SA 106
Gr C (Note 1)

19

Nil

Nil

Nil

Nil

>9

Nil

620 - 650

13

Nil

Nil

> 13

80 (Note 2)

620 - 650

13

150

Nil (Note 3)

> 13

150

640 - 670

150

Nil (Note 3)

>8

150

680 -710

P15 E Gr 1
(Note 4)

All

220

750 770

P8

All

Nil

Nil

12 x 1M

All

220

730 - 760

P1 Gr 2

P3 Gr 1

P4 Gr 1

P5 A Gr 1

Note 1 : For SA 106 Gr .C with less than 0.25 % carbon content .

Note 2 : Pre-heating is necessary for t >16mm.
Note 3 : Less than 0.15 % carbon content .
Note 4 : 9 Cr 1 Mo V Steel ( P-91, T-91 )

BHEL POWER SECTOR

17

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -1
TABLE - II
WELD PREHEAT AND PWHT FOR BOILER HEADER WELDS
(NOTE - 3)
(Applicable For Welding of Header to Header Joints)
P. No. of
Header Material

Thickness
(mm)

Preheat
C

Post Heating
C

PWHT
C

t 19

Nil

Nil

Nil

19 < t 5

Nil

Nil

595 - 625

25 < t 75

100

Nil

595 - 625

t > 75

150

Nil

595 - 625

t 9

Nil

Nil

620 650

19 < t 5

Nil

150
for 2 hours

620 - 650

25 < t 75

100

150
for 2 hours

620 - 650

t > 75

150

P4 Gr 1

All

P5 A (Note 1)
12 x 1M

P1Gr 1

P1Gr 2

150

150
for 2 hours
Nil

640 - 670

All

150

250 for 2 hours

680 - 710

All

220

Nil

710-740

620 - 650

Note :
1.

All P5A headers shall be inter stage heat treated at 700 - 750C for 30 minutes
soaking prior to any cold straightening operation. In lieu of this, the straightening
can be done after final PWHT. Any P5A Header with weld thickness above
50mm requires inter stage H.T. at 700-750C for 30 minutes soaking minimum
(max. shall be limited to 2.5 minutes/mm of thickness).

2.

Soaking for PWHT shall be at the rate of 1 hour per 25 mm of thickest weld (but
not less than 30 minutes for carbon steel and 1 hour for alloy steel). Soaking
time for 12 x 1 M header material shall be 4 minutes per mm of the applicable
thickness with a minimum of 180 minutes.

3.

Seal welding of Hand Hole Plates, Radiographic plugs and Screws can be
carried out after final PWHT, provided the preheat is carried out as per the
table.
For P number and Group number refer Table - IV.

4.

BHEL POWER SECTOR

18

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -1

P No. of
Material

P1 Gr 1
& SA106 Gr C

P1 Gr 2
& SA 106 Gr C

P4 Gr 1

TABLE - III
WELD PREHEAT AND PWHT FOR PIPES
OUTSIDE DIAMETER >102 mm
Stub and Attachment welds
BUTT WELDS
Note 1 & 2
Thickness
Throat 19 mm
Throat > 19 mm
Preheat
PWHT
(mm)
C
C
Preheat
PWHT
Preheat
PWHT
C

C
595 625

(Note
3)

19

Nil

Nil

Nil

Nil

Nil

>1925

Nil

595 625

Nil

Nil

Nil

595 625

Nil

>2575

150

595 625

150

Nil

150

595 625

Nil

>75

150

595 625

150

595625

150

595 625

Nil

Nil

Nil

Nil

Nil

Nil

620 650

Nil

>919

Nil

620 650

Nil

620650

Nil

620 650

Nil

>19

150

620650

150

620650

150

620 650

150
for 2
hrs

All

150

640670

150

640670

150

640670

Nil

150

680 710

150

680710

150

680710

250
for 2
hrs

All

220

750770

220

750770

220

750770

280
for 2
hrs

All

220

730760

220

730760

220

730760

280
for 2
hrs

Pipes
P5 A

Post
heat
C

Castings &

Nil

Forgings

P15 E Gr1

P15 E Gr1
+
P5 A
Note :
1.

Irrespective of the stub or attachment materials, the PWHT cycle shall be governed by the pipe
material.

2.

Throat shall be specified in the drawing. Wherever flanges are welded to pipes combined throat
shall be taken into consideration.

3.

Post heating shall be done immediately after welding.

BHEL POWER SECTOR

19

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -1

4.

For butt welds of different P group combinations, PWHT temp. may be as follows:
P1 + P3

620 to 650C

P1 + P4

640 to 670C

P4 + P5A

680 to 710C

(For other P Group combinations, refer to Engineering)

5.

a.

For P1 & P3 materials soaking time shall be 1 hour per 25mm up to 50mm
thickness and 2 hours + 15 minutes for each 25mm thickness over 50mm.

b. For P4 & P5 materials, soaking time shall be 1 hour per 25mm up to 125mm
thickness and 5 hours + 15 minutes for each 25mm thickness over 125mm.

6. For P number and Group number refer Table IV.

BHEL POWER SECTOR

20

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -1

TABLE - IV
P NUMBER AND GROUP NUMBER FOR BASE MATERIALS
P.No

Grou
Common Name
p No.

Tubes
SA192

Carbon
Steels
P1

Pipes
SA106GRB

SA210GRA1

Plates
SA36

Forgings

Castings

SA266CL

SA216WC SA234

SA515GR55 1

A
SA352LC

SA515GR60

A
SA352LC

SA515GR65

Fittings

WPB

SA516GR55
SA516GR60
SA516GR65
SA210GRC
P1

P3

P3

P4

P5A
P15

1
2

SA106GRC

Carbon Steels

Carbon-Moly
Steels
CrMo Steels

SA209T1

SA515GR70 SA266CL

SA216WC SA105

SA516GR70 2

B
SA234
SA216WC

SA299

C
SA352LC
C
SA217WC

SA335P1

1
SA213T2

1CrMo/
SA213T12/
1CrMo Steels
SA213T11
2Cr1Mo Steels
SA213T22
9Cr1MoV Steels
SA213T91

SA335P2

SA387GR2

SA335P12

SA387GR12 SA182F1

SA217WC SA234

SA335P11

2
SA387GR11 SA182F1

SA335P22

1
SA387GR22 SA182F2

WP11
SA217WC SA234

SA335P91

2
9
SA387GR91 SA182F91

P8

P8

18Cr-8Ni Steels

WP12
SA234
WP22
SA234
WP91

E
Gr 1

WPC

SA213TP304

SA376TP304

SA240TP304 SA182F3

SA351CF

SA213TP304

SA376TP304H SA240TP321 04
SA182F3

3
SA351CF

H
SA213TP347

SA376TP321

SA240TP347 21
SA182F3

8
SA351CF

SA213TP347

SA376TP347

47
SA336F3

3M
SA351CF

H
SA213TP321

SA376TP347H

04
SA336F3

8M
SA351CF

21
SA336F3

10
SA351CF

25Cr-20Ni Steel
(Type 310)

SA240TP310 47
SA182F310 10M
SA351CK
20

Note : IS1239 & API 5L GR B Pipes, IS2062 Plates may be treated as P No.1 Gr No.1 material.

BHEL POWER SECTOR

21

SA403

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -1

TABLE - V
PREHEAT AND PWHT FOR NON PRESSURE PARTS INCLUDING STRUCTURALS
P.No. of
Material /
Material
Specification

Gas Cutting

Welding

Thickness
(mm)

Preheat
C

Thickness
(mm)

Preheat
C

25

Nil

38

Nil

> 38 63

100

> 63

150

150

P1 / IS 2062
> 25
IS 8500
Fe 540
( Ceiling
Girder )
BS EN
10025 Gr
420 N
( Ceiling
Girder )

100

220

PWHT
C
595-625
a)All butt welds > 50
mm thick
b)Any welds to a
tension member
620- 650 ( Soaking
time 2.5 Mts. Per mm.
Minimum 120 Mins)

620 650 ( Soaking

time 2.5 Mts. Per mm.
Minimum 120 Mins. )
640-670

P4 Gr 1

All

150

All

150

a)All butt welds in

tension member
b)All fabricated components > 16mm
thick (Note 3)

P5 A

All

150

All

(Note 3)
150

680-710
All welds
(Note 4)

NOTE :
1.

All gas cut edges may be chipped off, ground or machined to remove the HAZ with
3mm minimum removal.

2.

Clip angles above 10mm, used for beam connections, which are sheared to length,
shall require heat treatment.

3.

All fabricated structural components of P-4 material, with any member above
16mm thickness, the entire assembly shall be post weld heat treated.

4.

All welds of P5 A material shall be post heated at 250C for 2 hours immediately
following welding.

5.

Soaking time shall be as below :

a. P1 and P3 materials one hour per 25mm up to 50mm thickness and
2 hours + 15 minutes for each 25mm thickness over 50mm.

b. P4 and P5 materials one hour per 25mm up to 125mm thickness and

BHEL POWER
SECTOR
22 thickness over 125mm.
5 hours
+ 15 minutes for each 25mm

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -1

TABLE - VI
PREHEAT FOR FLAME CUTTING
P.No. of Material

Thickness (mm)

Preheat C

P1 Gr 1

< 25

Nil

(Note 1)

25

100

All

150

All

150

All

150

All

150

P1 Gr 2
(Note 1)
P3
(Note 1)
P4
(Note 1)

P5 A
(Note 2)

NOTE :
1. For P1, P3 and P4 materials, when the flame cut edge will be machined
after cutting and when no forming operation is required after cutting, no
preheat is required for flame cutting.
2. P5 A materials, except when the part is scheduled for hot forming, shall
be inter stage heat treated at 680-710C for 30 minutes minimum after
flame cutting and prior to any welding. Subsequent to this heat
treatment, a minimum 3 mm of the gas cut edge shall be removed by
machining / grinding.

BHEL POWER SECTOR

23

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -2

CHAPTER -2
HEAT TREATMENT PROCEDURE STEAM TURBINE, TURBO-GENERATOR AND AUXILIARIES

BHEL - POWER SECTOR

24

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -2

2. HEAT TREATMENT PROCEDURE STEAM TURBINE, TURBO-GENERATOR AND AUXILIARIES

Procedure for Post Weld Heat Please refer Plant Standard,

treatment of Pressure Vessel as Haridwar - HW 0980814
per ASME code Section VIII,
Div.I

For other Components

BHEL POWER SECTOR

HEEP,

Please refer Heat treatment ProcedureBoiler and Auxiliaries of Chapter-I

25

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -3

CHAPTER - 3
GENERAL

BHEL - POWER SECTOR

26

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -3
3. GENERAL
1. TESTING OF TEMPERATURE INDICATING CRAYONS
1.0

SCOPE :

1.1

This procedure details the method of batch testing of Temperature indicating Crayons
(Thermal chalks).

2.0

PROCEDURE :

2.1

Setup:

2.1.1

Rig a test heating arrangement including a test pipe/plate heating arrangements with
controls and a calibrated temperature recorder/thermometer.

2.2

Heat the test pipe / plate (specimen) to a temperature 10 lower than the rated
temperature of the thermal chalk in study, monitoring the temperature through
thermometer/recorder.

2.3

Stroke the thermal chalk as close to the sensing point on the specimen.

2.4

Raise the temperature of the specimen gradually up to 10% higher than the rated
temperature of the thermal chalk in study, stroking the thermal chalk on the specimen
during this period.

2.4.1

When the thermal chalk changes to the specified colour or melts (depending on the
type), within 5 of the rated temperature, the thermal chalk is acceptable.

2.5

Consistent results for 2% of any brand and temperature will qualify the brand for the
rated temperature.

2.6

Where thermal chalks are accepted brand wise, they shall undergo this test at least
once a year.

3.0

RETESTS :

3.1

Any failure in the 2% sample chosen, will call for additional 4% for qualification of the
brand for the rated temperature.

3.2

Where retest results in further non-acceptance, the brand shall stand rejected for the
particular temperature.

4.0

RECORDS :

4.1

Records of testing and brands accepted/rejected including details of calibrated

devices used in the setup shall be maintained.

BHEL - POWER SECTOR

27

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -3

2. COMPATIBILITY TEST FOR HEAT TREATMENT SYSTEM

1.0

SCOPE :

1.1

This

procedure

provides

for

checking

the

compatibility

and

accuracy

of

thermocouples, compensating cables, temperature recorder, connected in Heat

Treatment (HT) operations at sites.
2.0

HT TEST SYSTEM :

2.1

The thermocouple (type k-chromal-Alumel is generally used at sites) attached to a test

specimen with heating arrangements and controls, compensating cables, a calibrated
temperature recorder rigged together for the test HT system.

2.2

A calibrated (accuracy 0.5%) direct-reading thermometer (like a digital thermometer

with sensor) is used for verification.

2.0

PROCEDURE :

3.1

Attach the thermocouple as detailed in Chapter I of this manual.

3.2

Raise the temperature of the test specimen to around 200 C and maintain the same.

3.3

Place the sensor of the direct reading thermometer as close to the thermocouple
junction as possible.

3.4

Wait till the temperature is stabilized.

3.5

Note reading of the thermometer and that of the temperature recorder.

3.6

Repeat steps 3.2 to 3.5 for test specimen temperatures of 400 C and 600 C

3.7

Where the temperature read by the temperature recorder is within 10 C with

respect to the thermometer, the HT system is compatible.

3.7.1

Where the results are not within the tolerance specified above, further tests are to be
repeated to identify the fault either in thermocouple or compensating cable or both.

3.8

Adequate insulation of thermocouple, sensor from direct radiation of heat elements

shall be ensured as a precaution throughout the test.

3.9

This compatibility is recommended for each of the thermocouple available for use; this
procedure validates the thermocouple also.

4.0

RECORDS :

4.1

Records pertaining to the test shall be prepared and maintained.

BHEL - POWER SECTOR

28

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -3

Compatibility Test for HT System

Site:

Report No.
Date :

Details

Temperature Recorder

Thermometer

Make:
Model:
Sl. No.:
Range:

Test Results
Temperature Reading C
Sl. No. t/c No. C/C. No.

Recorder Thermometer

Difference C Results*

Record results (Accepted/Rejected) where rejected, record the faulty component as

required by 3.7.1

Witnessed by

(Name & Signature)

BHEL - POWER SECTOR

29

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -3

Pre heat & PWHT of Critical Piping with Turbine & Auxiliaries
Sl
no

Material
Spec 1

Material
Spec 2

OD

Thic Type Pre

knes of
heat
s
Weld Deg. C

GS 17
CrMoV 511
G17 CrMo 9
10
21 Cr Mo Ni
V47

SA335
P91
SA335
P22
SA335
P22

110

>30

110

>30

110

>30

2
3

Notes :-

PWHT
Temp.
Deg. C

200 TO 690+10
300
(Notes)
200 TO 690+10
300
(Notes)
200 TO 690+10
300
(Notes)

Rate of heating 50 Deg. C per hour above 300 C

Rate of cooling 30 Deg. C per hour up to 300 C
This is as per BHEL HEEP - Hardwar recommendation.

***********
BHEL - POWER SECTOR

30

Holding
time
minimum
(minutes)
240
240
240