I.T.S Heat Treatment Services Ltd. Co.

69/4 Phan Chu Trinh Vung Tau City

Tel: 84-64-810279 Fax: 84-6-523249

PROJECT:

PIPING CONSTRUCTION WORK FOR PHU MY 3

COMBINED POWER PLANT OF SIEMENS AG
POWER GENERATION

DOCUMENT TITLE:

POSTWELD HEAT TREATMENT PROCEDURE

DOCUMENT No.:

ITS/QA/01

CONTENTS
1.0 INTRODUCTION............................................................................................ 3
2.0 SCOPE......................................................................................................... 3
3.0 PERSONNEL................................................................................................. 3
4.0 METHOD...................................................................................................... 3
5.0 ARRANGEMNT OF ELEMENTS.........................................................................3
6.0 TEMPERATURE CONTROL..............................................................................5
7.0 THERMOCOUPLE........................................................................................... 6
8.0 THERMOCOUPLE POSITION...........................................................................6
9.0 THERMOCOULE COMPENSATION CABLE..........................................................7
10.0

RECORDER................................................................................................ 7

11.0

INSULATION.............................................................................................. 7

12.0

PROCEDURE REQUIREMENTS......................................................................7

13.0

REPORTING............................................................................................... 8

14.0

SAFETY..................................................................................................... 8

15.0

APPENDIX 1: PWHT REPORT.....................................................................10

1.0

INTRODUCTION
The purpose of procedure to ensure that post weld heat treatment of piping welds Is
carried out correctly and in accordance with the requirements of the applicable
codes / standards and project specification.

2.0

SCOPE
2.1 This procedure covers the minimum requirement for post weld heat treatment
of weld joints on pip works.
2.2 This general procedure refers to the application of controlled heated bad
encompassing a butt welded joint in pipe to effect a pot weld heat treatment in
accordance with the governing code of practice, specification, or drawing

3.0

PERSONNEL
All technician conduct post weld heat treatment activities have at least 6
months experience in post weld heat treatment and supported by a group of
trained workers.

4.0

METHOD
Electrical resistance heating using modular, flexible ceramic pads, either of
standard rating and dimension or otherwise as maybe be necessary to suit
particular weld geometry.

5.0

ARRANGEMNT OF ELEMENTS
5.1 Horizontal Pipe Work: Pipe to Pipe Butt Weld.
5.1.1 For pipe to pipe butt welds, where the members are equal
thickness, the heating elements shall be applied systematically
about the weld centerline, either as one or more discrete bands.
5.1.2 Each band will comprise pads of equal width, and the same nomina
heating intensity.

5.1.3 The width if the heated band shall not be less than:
Rxt
3

Where R: is the internal radius and t: is the wall thickness.

The welding being in the center. The width of the insulated
bands shall not be less than: Rxt in figure 1, page 9.
5.1.4 Where more than one band of elements is applied, the
circumferential gap between bands shall be limited to a maximum of
30mm or the pipe wall thickness, whichever is lesser. For a wall
thickness of 10mm or below, the gap shall be limited to 10mm
maximum.
5.1.5 Longitudinal gaps between individual elements shall be limited to
maximum of 50mm or the pipe wall thickness, whichever is the
lesser. For a wall thickness of 10mm or below, the gap shall be
limited to 10mm maximum.
5.1.6 For heating system, which comprises more than one circumferential
band, the heater pads in adjacent bands shall be rotated one
quarter of a pad width with respect to each other.
5.1.7 Where the wall thickness of the two pipe members differ, or for pipe
to flange joint, the elements shall be arranged as a minimum of two
circumferential bands, such as to provide independently controllable
heating systems on each side of the weld center line. For pipe to
flange welds, an additional band of heaters may be applied to the
inside of the flange to compensate for heat loses.
5.2 Inclined and Vertical Pipe Work: Pipe to Pipe Butt Work.
5.2.1 For nominal pipe diameter up to 6(150mm), and where the parent
members are of equal thickness, the heating elements maybe
applied as a single band about the weld circumference. The band
shall be inclined downward by 25mm of the wall thickness,
whichever is the lesser.
5.2.2 For nominal pipe diameter above 6(150mm), the heating elements
shall be applied as two (or ore) discrete bands, arranged
systematically above and below the weld center line to leave a
center gap.
5.2.3 The requirement pertaining to element arrangements detailed in
paragraph 5.1.2, 5.1.3, 5.1.4, 5.1.5, 5.1.6, 5.1.7. shall also apply for
inclined and vertical pipework.

5.3 A limits list of elements arrangements that will satisfy the requirements of
paragraph 5.1, 5.2. It is recognized that the listing provide one solution only
for a given weld geometry, other option being possible, and may be made
relevant in the prevailing circumstances. The listing also provide data for
pipe/pipe butt weld.
5.4 Complex geometry
Special elements and thermocouple arrangement shall be produced for pipe
joint more complex than those shall be defined within paragraph 5.1
5.5 General
5.5.1 Elements shall be securely fixed in contact with the work piece with
soft iron wire, stainless steel banding tape, or mild steel banding
tape to suit the application.
5.5.2 Heating elements shall be thoroughly examined before use in order
to ensure that the element wire is not exposed. Examination to be
made for broken beads in either the pad or leads. Twist lock
connection should also be examined to ensure that the insulation if
sound, and the electrical joint is made.
5.5.3 Where elements are manufactured with cold tails, care should be
taken to avoid trapping the cold tail and power supply cable
between the work piece and the insulation. Element tails should be
adequately supported to avoid undue strain at the element tail
junction and at the bot cold tail junction.
6.0

TEMPERATURE CONTROL
Each circuit heating elements shall be controlled by a contactor. In turn this circuit
shall be controlled by one of the following system:
6.1 Semi-automatic control using a combination of a set point controller and a
percentage time/energy regulator. The set point temperature controller shall
be employed to ensure the correct temperature control during the soaking
period.
6.2 An automatic pre-et program control units to control automatically the heat
treatment throughout the cycle.

6.3 No single control zone will comprise more than three heating elements All
elements in one control circuit shall have the same nominal power density
rating. (wall/m2).
7.0

THERMOCOUPLE
7.1 Thermocouple shall be made for Nickel-Chromium/Nickel-Aluminum wire to
BS1041, Part IV or equivalent.
7.2 Thermocouple shall be attached to the work piece by the direct wire
capacitance discharge method. The gap between to wire/work piece junction
shall not exceed 5mm.
7.3 Care shall be taken to ensure that thermocouple conductor wires do not touch
each other, or metallic components. Away from the hot junction.
7.4 Thermocouple hot junctions shall be protected by the application of a
minimum 5mm of layer temperature putty, applied locally.
7.5 Whenever possible, thermocouple shall not be located under a heating pad;
thermocouple shall be routed between heating pads or out through the
insulation to avoid close contact with the heating pads.
7.6 The thermocouple to compensating lead connections shall be minimum to
0.5m from the heating zone.
7.7 Following each heat treatment, a minimum of 150mm wire measured frm the
hot zone, shall be discarded.

8.0

THERMOCOUPLE POSITION
8.1 The minimum thermocouple position for pipe/pipe welds shall be as detailed in
figure 2. Additional thermocouples shall be fitted as necessary for control
purposes and to confirm ant other temperature requirements peculiar to the
ruling specification.
8.2 A minimum of one thermocouple shall, in any case, be fitted to correspond
with each independent circuit of heating elements. Thermocouple fitted for
control purposes shall be fitted at weld centerline and shall be located as per
figure 2.

9.0

THERMOCOULE COMPENSATION CABLE

9.1 Copper/constantan compensation cable shall be used for extension of the
thermocouple to the recording instrument.
6

9.2 The copper lead (+ve) shall be connected to the nickel-chromium conductor of
the thermocouple (non-magnetic), and the constantan lead (-ve) shall be
connected to the nickel-chromium conductors (magnetic).
10.0

RECORDER.
10.1 Temperature recorders shall be of the potentionmetric self-compensating
type, calibrated in degrees Celcius with respect to nickel-chromium/nickelaluminum thermocouple, type K.
10.2 Temperature recorders shall be calibrated at interval not exceeding 12
months. The calibrations shall be done by a competent Organization and
recorded and evidence to this effect kept with the instrument. The Calibration
Certificate must show both the as found and as left condition of the
instrument.
10.3 The chart speed shall be set at 50mm/h or other agreed standard ad shall
be checked during calibration. No artificial restriction on pen travel shall be
used.

11.0

INSULATION
11.1Ceramic fiber blanket, 25 or 50mm thick or equivalent material, shall be
provided for insulation. The use of asbestos-type insulating material is not
allowed.
11.2The number of layers maybe adjusted to meet the variation of wall thickness,
pipe diameter, gradient requirements and site conditions.
11.3Wherever possible, pipe and shall be blanked off internally before heat
treatment to limit convection effect.

12.0

PROCEDURE REQUIREMENTS
12.1

Post weld heat treatment

12.1.1 All weld parts of the item shall be completely welded before heat
treatment.
12.1.2 The PWHT rate of heating from 400oC upward shall not exceed
200oC per hour for thickness up to including 25mm; or 550/e oC/h or
55o/hr, which is greater, for thickness on over 25mm.
12.1.3 The pipe shall be soaked at a temperature of 580 cC to 620oC for a
period equal to 2.5min/mm of wall thickness.

12.1.4 The rate of cooling shall not exceed:

- 275oC/hr for thickness up to and including 25mm.
- 6875/eoC/hr or 55oC/hr, whichever is greater, for thickness of
over 25mm.
12.1.5 Below 400oC the pipe maybe cooled in open air.
12.1.6 One or two thermocouple would be applied to ensure that the job
being treated is within the range specified, on each weld.
12.1.7 During the heating/soaking/cooling sown cycle, the maximum
difference in temperature reading from each thermocouple on the
same wed shall not exceed 50oC.
13.0

REPORTING
13.1 Reporting and recording of results shall be in accordance with relevant
procedures and recorded of PWHT Report (sample of report on page 10)
13.2 The PWHT temperature recorded shall have the following data recorded
on the chart:
- ISO drawing number.
- Line number.
- Joint number.
- Heating, soaking and cooling data.
- Material.
The chart shall be signed off and dated by QC Inspector.

14.0

SAFETY
14.1 All tools and equipment for the task are to be in sate condition and fi for
the purpose. Where possible registration papers and certification are to be
produced.
14.2 Dust masks and safety glasses shall be worn when working with thermal
insulation.

FIGURE 1

FIGURE 2: THERMOCOUPLE POSITIONS

Note:
1.
2.
3.
4.

Thermocouples to be fitted at the weld centerline as required for control.

For D<8, T/c (1) is required.
For 8<D<12, T/c (1), (2) are required.
For D>12, T/c (1), (2) and (3) or (4) are required.

15.0

APPENDIX 1: PWHT REPORT

POST WELD HEAT TREAT MENT REPORT
Client:
Procedure no.:
Method of PWHT:
Location:

Reprt No.:
Page

Form: QF-001
Project:
Code/specification:
Chart no:
Date:

of

Item:
Material grade:
Chart speed:
Start time:
Finish time:

EQUIPMENT
Description: MANNING 65 KVA Power Unit, 6 Channel
Recorder No: ChinoEH-100, 12 channels

Date of Calibration: March 2002

RESULTS
Unrestricted rate of rise to:
o
C
Soaking temperature:
o
C
Restricted rate of cooling:
o
C per hour
No.

DWG No./Line No.

Joint No

Restricted rate of rise of:

o

C per hour

Soaking time:

Dia. x Thk

Hours
Unrestricted rate of Fall to:
o
C
TC No

Sketch of thermocouple

Technician
Date:
Name:
Signature:

Client
Date:
Name:
Signature:

Client
Date:
Name:
Signature:

Cert. Authority
Date:
Name:
Signature:

10