see ATTiCHED Comments ( 3 PAGES) » fe mcs neers ley strona oi areolar ncaa extern aneiee fimbvatony ¢ SNC*LAVALIN Engincers & Constructors AMBATOVY PROJECT, POWER PLANT Ames = @keangnam —_ AHyuNDAL sae TE Hove METHOD STATEMENT FOR SITE SE ee POSTWELD HEAT TREATMENT ‘APPROVED BY | __ DATE. (PWHT)@ keangnam AMBATOVY PROJECT, POWER PLANT METHOD STATEMENT FOR SITE POSTWELD HEAT TREATMENT (PWHT) Document No: APP-QAQC-PROC-014 Revision Number: 0 1 2 3. 4 5. ‘Table Page 2 of 7 TABLE OF CONTENTS Postweld Heat Treatment. Practices. ‘Heating Temperature. QA Monitoring/Inspection Documentation «ss... binnintrin® bab ibe 1 Treatment Temperatures...AMBATOVY PROJECT, POWERPLANT 1.0 Scope 1.1 This method statement describes applicable methods, procedures, and equipment for heat treatment in Ambatovy Project, Power Plant. 1.2 This method statement shall be used in conjunction with applicable codes and standards which refer to specific preheat, and postweld heat treatment in metals and pipe required for obtaining adequate weld and base metal properties. 2. References Reference is made in this method statement to the following documents. The latest issues, amendments, and supplements to this document shall apply unless otherwise indicated. 2.1 Design Criteria Mechanical, 334488-0000-4SEC-0001-0 2.2 American Society of Mechanical Engineers (ASME) 2.3 “Issued for Construction” Drawings 3. General 3.1 The installation of commercial furnaces or the usé of commercial heat-treating facilities shall be considered for extensive heat treatment. 3.2. Preheat treatment and PWHT temperatures are described in Table I. Heat treatment of a weldment is not always necessary. Heat treatment is required to prevent cracking and achieve a better measure of dimensional stability where compliance to code or alloy content or high carbon content (greater than 0.30 percent) of material to be welded makes it necessary. Stress relief becomes more important when thick sections or rigid designs are involved. 3.3 Field heat treatment shall not be attempted unless specifically called for in the basic welding standards or design. This applies particularly to hardening of steel or stress relief of critical materials. 3.4 Furnace heat treatment shall be considered for unsymmetrical weldments of ‘nonuniform thickness. 4, Safety Page 3 of 7 Safee practices shall always be observed in the conduct of this method statement.@ Keangnam AMBATOVY PROJECT, POWER PLANT 5. Treatments Page 4 of 7 51 Preheating reheating is the uniform application of heat to the base metal to at least 152 mm (6 in) on each side of the weld prior to welding and the maintenance of this temperature throughout the welding operation, 52 Preheating slows the cooling rate in the deposited metal and heat-affected zone resulting from welding. Preheating is required for steels as specified in Table 1. Preheating, where required, is done immediately prior to welding. the metal to be welded is at a ¥y of the weld shall be heated For material thicker than 19 mm (3/4 in) wi ‘temperature of less than 10°C (50°F), the vi to hand warmth prior to initiating the welding. Postweld Heating ‘The structure, or a portion thereof, is uniformly heated to a specific temperature below the critical range, and subsequently cooled under tmiform controlled conditions. 521 5.2.2 By heating the weld zone to the specified temperature, the yield strength of the material is lowered and plastic flow can occur to a degree commensurate with reduction in yield strength. When the structure is subsequently uniformly cooled, the level of residual stress will be lowered to the yield strength at the heat treatment temperature. Local stress relief of butt welds is usually performed with oxyfuel torches; this consists of heating a circumferential band containing the weld at the center and a width of weld area at least three times the width (each side) of the weld. Local postheat treatment of welded branch connections shall be performed by heating a circumferential band of the pipe to which the branch is welded. The width of the heated band shall extend at least 25.4 mm (1 in) beyond the weld joining the branch (refer to Table 1 for PWHT temperature requirements). Hold this temperature for ten minutes and wrap the joint which is being treated in a heat resistant blanket or other suitable insulating material to obtain slow uniform cooling, Retain this wrapping for one hour. Remove the wrapping and allow the parts to cool in ambient air. 52.2.1 Heat treatment of carbon steel to remove residual stresses is frequently required where the weldment will be in contact with hot caustics.@ Keangnam 6. Practices Page 5 of 7 6.1 AMBATOVY PROJECT, POWER PLANT Heating Temperature Since temperature is the most critical factor involved in heating operations, suitable ‘means shall be used to ensure accuracy. The following are several methods that can. be used. 6.1.1 613 62 ‘Temperature-indicating Crayons. These sticks are used for preheating which are available as crayon like materials for numerous temperatures in the 45 to 1093°C (113 to 2000°F) range. ‘They are wiped or scratched on the heated surface, and shall not be exposed to direct heat, When the metal reaches the desired temperature, the crayon corresponding within 1 percent to that temperature melts and develops a wet or oily appearance. It is desirable to initiate heating and periodically check the temperature by drawing the crayon aeross the metal until such heating results in the mark melting. Common practice is to heat and use several different temperature crayons until melting is obtained with the one closest to the desired temperature, and no melting is observed using the next highest melting stick. Marks shall not be made on or near the surface to be welded, since volatilization of the indicator will cause porosity. ‘Temperature-indicating Pellets. Small aspitin-tablet size pellets of the same ‘material as crayons are frequently used. These are placed on the metal surface; and, when their indicating temperature is reached, they melt. Direct torch application will melt these prematurely. These are suitable for furnace work, Surface Pyrometer. A. surface pyrometer is usually a portable instrument comprising a direct reading temperature scale and probe. The probe is placed on the surface, at desired temperature, and indication is observed immediately on the scale. The probe is limited to use within a short distance from the meter. This equipment is normally used for preheating and can also be used {in heat treatment in a furnace which does not have an indicator. Heating Methods 62.1 Gas Torches 621.1 Oxyfuel and gas torches are the most widely used source of heat for preheating, and sometimes also used for short term heat treatments. 6212 Large tips are normally used and bulbous type flames are recommended. It is mandatory to keep the flame moving all over the required area ‘on the pieces being heated to prevent hot spots. It is also mandatory that soaking be practiced, that is, allowing the heat to penetrate all pieces to provide uniform heating through the thickness of pieces.AMBATOVY PROJECT, @ keangnam pedvi 6213 The use of flame descaling (multi-orifice on a straight bar) tips is advantageous in providing broad heat coverage. 7. Personnel 7.1 Two to three Technicians are involved in PWHT operation. Each of the Technicians must have sufficient training prior conduct of PWHT. 7.2 The duties and responsibilities of the Technicians include among others: a) To ensure that proper conduct of PWHT is practiced at all times, and b) To report immediately to the concemed any problems encountered during operation. 8. Quality Monitoring 8.1. The conduct of PWHTT shall be monitored using the attached sample of Heat Treatment Instruction, 9. Documentation 9.1 The following shall form part of the documents in the conduct of PWHT (minimum): 9.1.1 Heat Treatment Instruction 9.1.2 Calibration Report 9.13 Photos TABLET ‘Treatment Temperatures P=No. Thickness, mm NPS |___Prebeat. Postweld 1 Above 19mm 93°C 605°C to 650°C. 4 ‘Above 19mm | Above 100mm 121°C 700°C to 730°C. Page 6 of 7@reongran| HEAT TREATMENT INSTRUCTION PAGE: 1 OF 1 PROJECT NAME. : Ambatovy Project, Power Plant Work Order No, : T-1005-2 TEM NAME / NO. PROCEDURE NO. TYPE OF HEAT TREATMENT. © POST FORMINGBENDING = POSTWELD HEAT TREATMENT ANNEALING © QUENCHING Do TeMPERING HEAT TREATMENT CONDITION HEAT TREATMENT METHOD: © FULL 3 "PARTIAL COOLING METHOD © FURANCE = ELECTRIC RESISTANCE © OIL OWATER HEATING SOURCE °GAS IL ELECTRIC RESISTANCE ‘THERMOCOUPLE ALUMEL CHROMEL 3 OTHERS(CA THERMOCOUPLE) THERMOCOUPLE CONTACT = DIRECT CONTACT 8 OTHERS. (WITH WELDING) MAX ALLOWABLE VARIATION IN TEMP DURING HEATING AND COOLING 30°C HEAT-TREATMENT HT(*C) (Hours 10 MN ) HEATING RATE COOLING RATE (MAX. __ 84 °C/HR) HOLDING TEMP, (MAX _105 *C/HR) ABOVE 427% 625°C4 25 ABOVE _ 427 TEIN) LOCATION OF THEROCOUPLE"T" : THERMOCOUPLE MATERIAL $299 WITHIN 50 1M FROM WELD METAL NOMINAL THICKNESS MAX 10 mm DISTRIBUTION qty _ | REMARKS PREPARED BY QUALITY CONTROL DEPT. 1 QA/QC ENGINEER MECHANICAL FABRICATION DEP] 1 ‘APPROVED BF QA/QC MANAGER REVIEWED BYCOMMENTS Crete (3) PAGES) ATTACH 2D TO DocumesT 4+ 334488- T-100S-2-4674-o01 APP-BAQC- PRoC-~O14 Revo) REVIEW OF CONTRACTOR SUBMITT) Name of reviewer SABINO VITAMOG TOVA sot suiatie, suit tere cation Date of review November 30, 2008 LIVB modify a noted, resubmit before fabrication Contract reference # 7-4005-2 ve moi soled, commence ibristin and rest 5 stale, st faction, resi certified Doc Contri Transmittal # | T-1005-2-ES-0389 (ve me AVE fiat, no ther sbi COMMENTS APP-QAQC-PROC-014 rev 0: METHOD STATEMENT FOR SITE POSTWELD HEAT TREATMENT (PWHT) 2, REFERENCES: ~ Clause 2.2. Indicate specific ASME code reference (. Piping) Include related reference issued by designer if any. ASME Section | & ASME B31.1 Power 3, General Requirements ~ Clause 3.2 Rephrase as “PWHT shall be carried out when required, as soon as possible after completion of welding and shall be conducted in accordance with ASME B31.1, Clause 132 or ASME 1, PW- 39 and the relevant WPS." - Revise Table 1 following ASME 1, Table PW 39 (P1 & PA materials) and ASME B31.1, Table 132(P1 & P4 materials) depending on the jointicomponent requiring PWHT. Check consistency with the WPS to be used. = , Clause 3.3 delete (already implied in 3.2) - _ Add- The contractor shall prepare a table listing each joint or component requiring heat treatment, and submitted fo SLI for review. The table includes the following information for each joint or component:-location, drawing number, diameter, wall thickness, material, heating rate, cooling rate, soak temperature, and soak time, 4, SAFETY: = Clause 4: Add- Protective measures shall be taken to prevent damage to the pipe surface or injury to the workers resulting from a short circuit of the lead wire, and to prevent persons, other than the operator, from entering the work area 5, HEAT TREATMENT: 5.1 PREHEATING = Clause 5.1.2 Rephrase as ‘the minimum preheat temperature shall be in accordance with the WPS. or ASME 1, PW-38 or ASME B31.1, 131.4. In case of any conflict between the specs the most stringent relevant specification takes precedence.’ - Clause 5.1.4 Delete (requir pment already stated in clause 5.1.2) - Add this clause as 5.1.5 Heat shall be applied by using a gas bumer such as propane torches or a induction coil or electric resistance. The use of an oxyfuel for cutting shall not be permitted since it tends to overheat locally. - Add this clause as 5.1.6 Temperature control of preheating, interpass temperature, and post heating shall be performed by use of temperature indicating crayons (tempilstick), thermocouple pyrometers or other suitable means, and it shall be checked that the specified temperature is obtained and maintained, Signature Date Page 1 of 35.2 PWHT - Clause 5.2 should define the PWHT requirement. ( Oxyfuel torches stated in 5.2.2 is not permitted as indicated in 6.1.5 above. 5.2.2.1 already implied in 3.2 above Le. depending on line class, ASME requirement & or relevant WPS) Rephrase to include below Unless otherwise specified, PWHT shall be performed in accordance with the following: 5.2.1. Prior to the start of PWHT, components are checked to ensure all restraints are removed, and that the component is free to expand and contract, and that suitable and sufficient supports are used, 5.2.2 For branch connections, filet welds, seal welds, and welds for attachment of pipe supports, the thickness effect on heat treatment shall be considered in accordance with the requirements specified in ASME 831.1 & ASME 1 whichever is applicable. 5.2.3 Allthe machined surfaces shall be protected adequately by the use of paint or compound to prevent damage from scaling during heat treatment. 5.2.4 In principle, after heat treatment has been completed, neither rewelding nor reheating shall be performed. However, f rewelding is performed because of repairs, etc., heat treatment shall be performed again. 5.2.5 When heat treatment is performed, the holding temperature, holding time, rate of heating and cooling, and the hardness after heat treatment shall be recorded and the records shall be submitted to SLI for review. 5.2.6 All temperatures within the heated zone for furnace or localized PWHT shall exceed the specified minimum holding temperature. Note: to determine ifthe heat treatment has been performed satisfactorily, very and confirm if hardness testis to be performed. If so, describe the method and equipment to be used. Clause 6, 6.1, 6.1.1, 6.1.2 & 6.1.3 delete (already implied in §.1.6 above) 6.2 HEATING METHODS # Clause 6.2 should describe the equipment, method of heating, location and type of heating elements, temperature measurement, and thermocouple locations. (Clause 6.2 to 6.2.1.2 already implied in 5.1.5 above) ‘Add below comment Local PWHT .Equipment -" The measurement of heat treatment temperature shall be performed by measuring the metal temperature by use of thermocouple pyrometers, or by other suitable methods and a calibrated {temperature chart recorder are used to provide an accurate and legible record of all PWHT. Bul measuring meters shall be calibrated. - Thermocouples are attached to the component by capacitive discharge welding, (Note: Other methods of attachment are not permitted). - The thermocouples are not in direct contact with electrical heating elements or subjected to flame impingement by gas or oil burners. - After completion of PWHT all thermocouples shall be removed, and the attachment areas ground ‘smooth to clean sound metal. - Allcharts are marked with the date and sufficient information to uniquely identify the jointcomponent. being heat treated. Signature Date Page 2 of 3Wiuitipoint chart recorders shail clearly differentiatelidentify each channelpoint by use of different colored inks or automatic number stamping. 2. Materials Heating by Electrical resistance coil, electrical element shaped strap or finger element type with a programmed mobile control unit should be applied. Heating materials used shall be free from any defects, 3.Surface Condition ‘Weld joint area shall be free from grease, oll dirt, any foreign materials to avoid any short circuiting of the system. 4.Method ‘Where local PWHT is done, the weld being post weld heat treated shall be in the centre of the heated band. Special attention shall be given to the following items; ~The width to be heated band/soak band shall be defined following ASME 1, PW-39.3 and ASME 831.1, Clause 132.7 depending on the joint/component requiring PWHT. ~The heating and cooling rates shall be defined following ASME 1, PW-39.4 and ASME 831.1, Clause 432.5 depending on the joint/component requiring PWHT. Eurnace PWHT = Give details I there is an intention to utilize furnace PWHT. State the method, equipment used, etc.. such as the manner of loading, stacking inside the furnace, monitoring, controlling the heat treatment throughout the cycle, measuringirecording furnace temperature/ uniformity...Etc.... : Clause 7. Include whose RESPONSIBILITY? What section/department shall be responsible for PWHT? Who will monitor the PWHT activities? Who shall prepare/provide the PWHT request instruction? % Attached PHWT report form with complete data block indicating the following; - ISO NoJ/Drawing No.; Weld No.; Line Class; Code/Spec Used; Material Type; Diameter/Size; ‘Schedule or Wall Thickness/ = Date of PWHT; Report No.; - Type of PWHT Device Used! Type of Temperature Monitoring used; Type of Thermocouples Used; Number and Position of thermocouples used: - Heated Band Width; Insulation Band Width; Heating Rete; Holding Temperature; Holding Time; Cooling Rate = Chart no.; Sketch - Equipment Description; Recorder No.; Calibration Date Sabino Vitamog December 01, 2008 SLI QA — Inspector (Mech’l/ Welding) Signature Date Page 3 of 3