Chapter 11

ASME VIII and API 510 Heat Treatment

Post-weld heat treatment (PWHT) is included in the API 510
examination syllabus, mainly in relation to vessel repairs.
This makes sense as one of the roles of an API 510 inspector
is to oversee repairs on behalf of the plant owner/user. Figure
11.1 shows the importance of this. Not all of the technical
information relevant to PWHT is actually included in the
API 510 document itself – most is contained in two well-
defined (but separated) sections of ASME VIII.
This is not the end of the story. API 510 now adds (as it
does with a few other topics) some requirements that can
override the PWHT requirements of ASME VIII. The logic
behind this is that whereas ASME VIII is a workshop-based
construction code, under which PWHT can be done in a
furnace under workshop conditions, API 510 deals with
repairs, many of which will be carried out on site, where such
closely controlled conditions are not possible. API 510
therefore provides easier alternatives that can be legitimately

Figure 11.1 Post-weld heat treatment (PWHT)

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used during repairs. We will look at these parts of the content

in turn.

11.1 ASME requirements for PWHT

Just about all of the main examination questions on PWHT
that relate to ASME VIII are taken from either sections
UCS-56 or UW-40. They are well separated in the code
document but are cross-referenced directly to each other.
11.2 What is in UCS-56?
UCS-56 contains a couple of pages of text surrounding a
group of seven or eight tables. Figure 11.2 shows a sample.
The main content is in the tables; their purpose is to specify
PWHT temperatures and holding times for different thick-
nesses of material. Each table covers different P-groups of
material – because simplistically, the P-group is related to the
tendency of a material to suffer post-weld cracking problems.
11.2.1 UCS-56 table notes
Don’t ignore the half-page or so of notes underneath the
various tables contained in UCS-56. They include informa-
tion on either mandatory requirements or overriding exemp-
tions, based mainly on material thickness.
Most exam questions (open book) will simply involve
looking up the relevant PWHT time and temperature for a
given material thickness in the correct ‘P-group’ table.
Strictly, the material thickness to use is that of nominal
thickness. This is defined not in UCS-56 but in UW-40 (f) –
Fig. 11.2 shows the main points.
11.2.2 The UCS-56 text sections
There are a number of good open-book examination
question subjects hidden away in the two pages of UCS-56
text. These relate to:
. The rate of heating of the PWHT furnace
. Allowable temperature variations in the furnace
. Furnace atmosphere

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Figure 11.2 A specimen PWHT table UCS-56 and UW-40

nominal thickness

In addition to these clauses UCS-56 (f) and beyond gives six

specific requirements relating to PWHT of weld repairs. In
brief they are:
. The need for notification of repairs
. Maximum allowable depths of repair weld (38 mm for P1
Grades 1, 2, 3 and 16 mm for P3 Grades 1, 2, 3 materials)

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. Excavation and PT/MT examination prior to repair

. Additional WPS requirements
. Pressure test after repair
Be careful not to misunderstand these requirements – ASME
VIII is a construction code only, so the repairs it is referring
to in UCS-56 (f) are repairs carried out as part of the original
manufacturing process, not repairs carried out after in-service
corrosion or some other damage mechanism. For in-service
repairs ASME VIII requirements are overridden by the less
stringent requirements of API 510 section 8, which does not
place any limit on repair weld depth and divides repairs into
temporary and permanent types.
11.2.3 The UW-40 text section
Whereas UCS-56 covers the times and temperature require-
ments for PWHT, UW-40 describes the procedures for how
to do it. There are eight main options, some more practical
than others.
11.3 API 510 PWHT overrides
API considers it a major advantage to be able to override the
ASME VIII requirements for PWHT. Remember the logic
behind this – API 510 relates to vessels once they are in use
where the practicalities of site working probably will not
allow manufacturing shop conditions to be reproduced so
easily, if at all.
API 510 section 8.1.6.4 says that, in principle, repair
welding must follow the requirements of ASME VIII (it
means UW-40 and UCS-56) but opens the door to two
overriding PWHT alternatives set out in API 510 section
8.1.6.4.2. This subsection has been progressively expanded
and elaborated over recent code editions – you can see this in
the out-of-balance subdivisions in the code clauses (it goes to
a concentration-popping seven levels of subhierarchy, e.g.
section 8.1.6.4.2.2.1).
The two methods of PWHT replacement (section 8.1.6.4.2)
are:

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. Replacement of PWHT by preheat

. Replacement of PWHT by controlled deposition (CD)
welding methods
These are shown in Figs 11.3 to 11.5. Both work on the
principle that the stress-relieving effects of PWHT can be
achieved (albeit imperfectly) by providing the heat required
in some other way than placing the repair in a furnace.
11.3.1 Replacement of PWHT by preheat
As the name suggests, this simply involves replacing PWHT
with preheating the weld joint and then maintaining the
temperature during the welding process. The maintained
temperature serves to give sufficient grain refinement to
reduce the chances of cracking when the weld is finished and
allowed to cool down. While this technique provides
sufficient grain refinement it is clearly not as good as full
PWHT, so it is limited to materials of P1(Grade 1, 2, 3) and
P3(Grade 1, 2) designations. These have a low risk of
cracking anyway, owing to their low carbon content. P2
Grade 2 steels containing manganese and molybdenum are
excluded, as they have a higher potential for cracking.
API exam questions normally centre around the para-
meters and restrictions of the preheat techniques. These are
listed in API 510 section 8.1.6.4.2.2.1, and illustrated in Fig.
11.4.
11.3.2 Controlled deposition (CD) welding
This is sometimes known as temper-bead welding and is
described in some detail in API 510 section 8.1.6.4.2.3. The
principle is simple enough – when one layer of weld metal is
laid down on top of another the heat from the upper one
provides some heat treatment (grain refinement) to the weld
underneath. A multilayer weld which is built up in this way
will therefore be given an amount of grain refinement
throughout its depth. The top layer of the final weld pass
will not have anything above it to provide it with heat

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Figure 11.3 PWHT replacement options

treatment, so the solution is to grind it off. Figure 11.5 shows

the idea.
The CD technique is considered to be a little better at
replacing full PWHT than the preheat only alternative. It is
therefore used for materials where the specification requires
impact (notch toughness or Charpy) testing as a condition of
their use in pressure equipment. The fact that impact tests
were required indicates that the material has a tendency
towards brittleness so the preheat method would not be good
enough.
These two PWHT replacement techniques, preheat and
CD welding, have become a mainstay of API codes. They are
now mentioned in API 510, 570 and 653 and, we can assume,

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are commonly used in practice, although more commonly in

the USA than elsewhere.
PWHT exam questions
PWHT replacement questions seem to be well-represented in
the API exam question book. Questions on the validity of the
two techniques, times, temperatures and heat-soak band
dimensions crop up time and time again.
Now try these familiarization questions.

Figure 11.4 PWHT replacement by preheat

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Figure 11.5 Controlled deposition (temper bead) welding

11.4 ASME VIII sections UCS-56 and UW-40:

PWHT familiarization questions
Q1. ASME VIII section UCS-56
Under what circumstance can PWHT be omitted?
(a) When it is only a service requirement &
(b) When it is below the minimum thickness specified for
the P-number in UCS-56 &
(c) When electron beam welding ferritic materials
> 18 in (3.2 mm) thick &
(d) When electroslag welding ferritic materials
> 112 in (38 mm) thick &

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Q2. ASME VIII section UCS-56 (d)(2)

What is the maximum temperature variation permitted in a vessel
during PWHT heating?
(a) 250 8F (139 8C) within any 15 ft (4.6 m) interval of
length &
(b) 400 8F (204 8C) within any 15 ft (4.6 m) interval of
length &
(c) 500 8F (260 8C) within any 15 ft (4.6 m) interval of
length &
(d) 150 8F (67 8C) within any 15 ft (4.6 m) interval of
length &

Q3. ASME VIII table UCS-56

A vessel is manufactured of P1 Group 2 material and is 4 in (102
mm) thick. What is the required PWHT holding temperature
and minimum time at temperature?
(a) 1100 8F (593 8C) for 2 hours &
(b) 1100 8F (593 8C) for 212 hours &
(c) 1100 8F (593 8C) for1 hour &
(d) None of the above &

Q4. ASME VIII table UCS-56

What is the PWHT minimum holding time for a 10 in (254 mm)
thick P4 Group 2 material?
(a) 2 hours &
(b) 3 hours 15 minutes &
(c) 5 hours &
(d) 6 hours 15 minutes &

Q5. ASME VIII section UW-40 (f)(1) and (f)(5)(a)

What is used as the nominal thickness dimension of a full
penetration butt weld joining a vessel head to a shell when the
materials are of unequal thickness?
(a) The thickness of the thinnest part including the
weld cap &
(b) The thickness of the thinnest part excluding the
weld cap &
(c) The thickness of the thickest part including the
weld cap &
(d) The thickness of the thickest part excluding the
weld cap &

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