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HT Manual-R01-Nov 2006 PDF
HT Manual-R01-Nov 2006 PDF
INDEX
This document has been prepared to provide basic guidelines to all construction
personnel in ensuring effective process management of welding and allied
activities. The various aspects of process control covering the stages of planning &
preparation for welding, controls during welding and post welding requirements are
brought out in the form of specifications, norms and procedures/instructions in this
document. This manual has been updated to reflect the newer materials and
processes developed by BHEL.
The requirements specified in this document are based on the relevant codes/
specifications like IBR, ASME and AWS and also consolidates the experience of
BHEL good welding practices based on more than three decades of manufacturing
and erection. The document also provides DO s and DON’T s for the benefit of
users, which would help in better process control and prevention of defects.
I am sure that this Manual would enable the construction activities in a big way to
manage their welding processes effectively to produce defect free quality.
A.V. Krishnan
General Manager (Corporate Quality)
3
4
FOREWORD
The present revision of the Heat Treatment Manual has been made with the contribution
from a team of BHEL Engineers having long experience in the areas like Construction Management,
Quality, Welding Technology & Heat treatment of manufacturing units and Power sector.
In this revision, the comments / suggestions offered by Power Sector / Regions, BHEL
HPBP Trichy, Piping Centre, HPEP Hyderabad & HEEP Haridwar and the minimum requirements of
This manual deals with, apart from Heat Treatment requirements for BHEL-Trichy complex,
HEEP Haridwar & HPEP Hyderabad packages also. Heat treatment requirements for the new
material P91/T91 are dealt in detail for the benefit of site engineers.
We hope that the present volume will be very much handy and useful for all our site
engineers.
Any further feedback or suggestion is welcome to improve upon the the present
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HEAT TREATMENT M A N U A L
FOR
POWER SECTOR
ISSUED BY
ISSUED TO :
Page 5
6
IMPORTANT
Page 6
7
STATUS OF AMENDMENTS
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HEAT TREATMENT MANUAL FOR POWER SECTOR 8
CHAPTER - 1
TABLE OF CONTENTS
3 General 25
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HEAT TREATMENT MANUAL FOR POWER SECTOR 9
CHAPTER - 1
CHAPTER-1
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HEAT TREATMENT MANUAL FOR POWER SECTOR 10
CHAPTER - 1
1.0 PURPOSE:
1.1 This procedure provides information, method and control for Pre-Heat (PH) and Post
Weld Heat Treatment (PWHT) of welds at sites.
2.0 DOCUMENT:
- Contract drawings
- Erection Welding Schedule or equivalent
2.2.1 Where parameter for preheating 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:
3.1.1 When parts of two different thicknesses are welded together, the preheating requirements
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HEAT TREATMENT MANUAL FOR POWER SECTOR 11
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 Preheating shall be checked using thermal chalk (temperature indicating crayons) prior
to start of welding as well as at frequent intervals during welding. It is preferable to
have a thermocouple and a temperature recorder in case of alloy steels of
thickness > 50 mm.
3.1.4 In case of any interruption during welding, preheating temperature shall be maintained
at joint by wrapping dry thermal insulating blankets to ensure slow and uniform cooling.
3.1.5 Preheating Methods:
3.1.5.1 Preheating shall be applied by any of the methods given below:
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. 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.
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HEAT TREATMENT MANUAL FOR POWER SECTOR 12
CHAPTER - 1
3.5.1 Thermocouples shall be used for recording Post Weld Heat Treatment temperatures.
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.
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HEAT TREATMENT MANUAL FOR POWER SECTOR 13
CHAPTER - 1
3.5.2 The following guidelines may be used for attaching thermocouples to job:
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.
3.6.1 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.
3.7.1 Wherever not specified, the heating rate above 300°C and cooling rate after soaking
upto 300°C shall be as follows: This is applicable for all materials.
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HEAT TREATMENT MANUAL FOR POWER SECTOR 14
CHAPTER - 1
≤ 25 mm 220°C/hour 220°C/hour
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 actuals may be recorded on the job card.
5.1 Please refer Welding Manual vide document No. PSQ-WDM-COM for heat treatment of
welds in P-91 materials.
5.3 Please refer Welding Manual vide document No. PSQ-WDM-COM for heat treatment of
welds in T-91 materials
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HEAT TREATMENT MANUAL FOR POWER SECTOR 15
CHAPTER - 1
7.0 RECORDS :
7.1 Pertinent Records like Job card, PWHT Charts, shall be maintained.
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HEAT TREATMENT MANUAL FOR POWER SECTOR 16
CHAPTER - 1
Project : ____________________
Thermocouple Locations :
Minimum 2
d = 1.5 x t from weld centre
Heating Band = 6 x t
Insulation Band = 12 x t
Required Actual
Soaking Temperature °C
Contractor BHEL
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HEAT TREATMENT MANUAL FOR POWER SECTOR 17
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 Thickness
Preheat °C PWHT °C
Material (mm)
P1 Gr 1& SA 106
≤ 19 Nil Nil
Gr C (Note 1)
≤9 Nil Nil
P1 Gr 2
>9 Nil 620 - 650
≤ 13 Nil Nil
P3 Gr 1
> 13 80 (Note 2) 620 - 650
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HEAT TREATMENT MANUAL FOR POWER SECTOR 18
CHAPTER - 1
TABLE - II
WELD PREHEAT AND PWHT FOR BOILER HEADER WELDS
(NOTE - 3)
(Applicable For Welding of Header to Header Joints)
1. All P5A headers shall be inter stage heat treated at 700 - 750°C 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 700-750°C 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.
4. For P number and Group number refer Table - IV.
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HEAT TREATMENT MANUAL FOR POWER SECTOR 19
CHAPTER - 1
TABLE - III
WELD PREHEAT AND PWHT FOR PIPES
OUTSIDE DIAMETER >102 mm
BUTT WELDS Stub and Attachment welds Note 1
&2 Post
P No. of Thickness heat °C
Throat ≤ 19 mm Throat > 19 mm
Material (mm) Preheat PWHT
°C °C (Note 3)
Preheat PWHT Preheat PWHT
°C °C °C °C
595 -
≤ 19 Nil Nil Nil Nil Nil Nil
625
P1 Gr 1
& 595 - 595 -
>19≤25 Nil Nil Nil Nil Nil
SA106 625 625
Gr C 595 - 595 -
>25≤75 150 150 Nil 150 Nil
625 625
595 - 600- 595 -
>75 150 150 150 Nil
625 650 625
620 -
P1 Gr 2 ≤9 Nil Nil Nil Nil Nil Nil
650
&
SA 106 620 - 600- 620 -
>9≤19 Nil Nil Nil Nil
Gr C 650 650 650
620- 600- 620 - 150 for
>19 150 150 150
650 650 650 2 hrs
640- 650- 640-
≤75 125 125 125 Nil
670 680 670
P4 Gr 1
640- 650- 640-
>75 150 150 150 Nil
670 680 670
680 - 700- 680- 250 for
Pipes 150 150 150
750 750 750 2 hrs
P5 A
Castings & 220 680- 150 700- 150 680- 250 for
Forgings 750 750 750 2 hrs
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.
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HEAT TREATMENT MANUAL FOR POWER SECTOR 20
CHAPTER - 1
4. For butt welds of different P group combinations, PWHT temp. may be as follows:
P1 + P3 - 620 to 650°C
P1 + P4 - 640 to 670°C
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.
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HEAT TREATMENT MANUAL FOR POWER SECTOR 21
CHAPTER - 1
TABLE - IV
P NUMBER AND GROUP NUMBER FOR BASE MATERIALS
SA515GR60 SA352LCB
P1 1 SA515GR65
SA516GR55
SA516GR60
SA516GR65
Carbon
Steels SA210GRC SA106GRC SA515GR70 SA266CL2 SA216WCB SA105
SA299 SA352LCC
½Cr½Mo
P3 1 Steels SA213T2 SA335P2 SA387GR2
1Cr½Mo/
1¼Cr½Mo SA213T12/ SA335P12 SA387GR12 SA182F12 SA217WC6 SA234WP12
P4 1 Steels
SA213T11 SA335P11 SA387GR11 SA182F11 SA234WP11
2¼Cr1Mo
P5A 1 Steels SA213T22 SA335P22 SA387GR22 SA182F22 SA217WC9 SA234WP22
9Cr1MoV
P5B 2 Steels SA213T91 SA335P91 SA387GR91 SA182F91 SA234WP91
18Cr-8Ni
Steels SA213TP304 SA376TP304 SA240TP304 SA182F304 SA351CF3 SA403
SA336F347 SA351CF10M
25Cr-20Ni
P8 2 Steel (Type 310) SA240TP310 SA182F310 SA351CK20
Note : IS1239 & API 5L GR B Pipes, IS2062 Plates may be treated as P No.1 Gr No.1 material.
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HEAT TREATMENT MANUAL FOR POWER SECTOR 22
CHAPTER - 1
TABLE - V
PREHEAT AND PWHT FOR NON PRESSURE PARTS INCLUDING STRUCTURALS
650-700
≤ 25 Nil a)All butt welds in
tension member
P4 All 150
b)All fabricated com-
> 25 150 ponents > 16mm
thick (Note 3)
680-730
P5 All 150 All 150 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 material shall be post heated at 250°C for 2 hours or 150°C for
4 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
5 hours + 15 minutes for each 25mm thickness over 125mm.
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HEAT TREATMENT MANUAL FOR POWER SECTOR 23
CHAPTER - 1
TABLE - VI
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 materials, except when the part is scheduled for hot forming, shall be
inter stage heat treated at 700-750°C for 30 minutes minimum after
flame cutting and prior to any welding. As an alternative to this heat
treatment, a minimum 3 mm of the gas cut edge may be removed by
machining, grinding, chipping, etc.
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HEAT TREATMENT MANUAL FOR POWER SECTOR 23
CHAPTER -2
1 Procedure for Post Weld Heat Please refer Plant Standard, HEEP,
treatment of Pressure Vessel as Haridwar - HW 0980814
per ASME code Section VIII,
Div.I
CHAPTER -2
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HEAT TREATMENT MANUAL FOR POWER SECTOR 24
CHAPTER -2
1 Procedure for Post Weld Heat Please refer Plant Standard, HEEP,
treatment of Pressure Vessel as Haridwar - HW 0980814
per ASME code Section VIII,
Div.I
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HEAT TREATMENT MANUAL FOR POWER SECTOR 25
CHAPTER -3
CHAPTER - 3
GENERAL
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HEAT TREATMENT MANUAL FOR POWER SECTOR 26
CHAPTER -3
3. GENERAL
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.
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HEAT TREATMENT MANUAL FOR POWER SECTOR 27
CHAPTER -3
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.
2.1 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 :
4.0 RECORDS :
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HEAT TREATMENT MANUAL FOR POWER SECTOR 28
CHAPTER -3
Date :
Make:
Model:
Sl. No.:
Range:
Test Results
Temperature Reading °C
Sl. No. t/c No. C/C. No. Difference °C Results*
Recorder Thermometer
Witnessed by
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