TCM Division

THERMAL PROCESS PROCEDURE 022809-01, Rev. 0

BULL’S EYE POST WELD HEAT TREATMENT (PWHT)

Per
ASME BPVC SECTION VIII DIV. 1
NBIC RD-1100

NOZZLE N1 ATTACHMENT WELDS

VESSEL C6-11
SA-516-70 & SA-106-B (ASME P-No. 1) CARBON STEELS

For
PETROLEOS DE VENEZUELA S.A. (PDVSA)
Cardon, Venezuela

By
TEAM INDUSTRIAL SERVICES, INC.
Estado Falcon, Venezuela

February 28, 2009

PDVSA Approval: ______________________ ____________________ _______

Signature Title Date

Team Approval: ______________________ ____________________ _______

Signature Title Date
 Written By:
BULL’S EYE PWHT STRESS RELIEF
TCM ASME BPVC SEC. VIII & NBIC RD-1100
Thompson/Martin
Approved By:
DIVISION Nozzle N1 Attachment Weld on Vessel C6-11 J. Borges
Rev.: Date:
PAGE 1 of 10 Field Procedure 022809-01 0 2/28/09

1.0 OVERVIEW

The following table summarizes the specifications for this thermal processing procedure.

PARAMETER
Client
Location
Work Piece Identification
Weld Identification
Shell & Nozzle Material
Shell Thickness & Inner Diameter
Nozzle Dimensions
Governing Codes
Heating Method
PWHT Soak Temperature
PWHT Soak Time
Max. Heating Rate above 800 °F
Max. Cooling Rate above 800 °F
SPECIFICATION
Petroleos De Venezuela S. A. (PDVSA)
Cardon, Venezuela
Vessel C6-11
Nozzle N1 attachment weld
SA-516-70 & SA-106-B (ASME P-No. 1) CS
1-7/16-inch (36.5 mm) & 15-1/2-ft (4727 mm)
6-inch NPS
Section VIII, ASME BPVC, and NBIC
Electric Resistance Heat Treating System
1150 °F ± 25 °F
2-1/4 hours, minimum
140 °F/hr
180 °F/hr

2.0 SCOPE

2.1 Background

Welding produces high temperatures, severe temperature gradients, and rapid cooling and
solidification which increase residual stresses, grain size, and brittleness in the weld and its
adjoining base material, which in turn can reduce fatigue life, corrosion resistance, and
dimensional stability of the weldment assembly. Post weld heat treatment (PWHT) can
relieve these ill effects by reducing residual stress and hydrogen content, and by restoring
ductility and corrosion resistance.

2.2 Purpose

The purpose of this procedure is to define specifications for a Bull’s Eye PWHT of nozzle
N1 attachment welds on vessel C6-11 in compliance with ASME BPVC Section VIII Div. 1
and NBIC requirements. This procedure identifies the locations and attachment methods for
thermocouples, electric resistance heaters, and thermal insulation, to ensure that client and
code requirements for heating, soak, cooling, and gradient control are achieved.
 Team PWHT Procedure 022809-01, Rev. 0 Page 2 of 10

2.3 Governing Documents

• The 2007 edition of Section VIII, Division 1 of the American Society of Mechanical
Engineers (ASME) Boiler and Pressure Vessel Code (BPVC)
• Paragraph UW-40 for soak band width requirements
• Table UCS-56.1 for PWHT soak temperature and time
• Article UCS-56 for heating and cooling rates
• The 2004-06 edition of the National Board Inspection Code (NBIC) RD-1100
• An as yet unidentified PDVSA welding procedure specification (WPS)

2.4 Technical Approach

Electronically controlled electric resistance heaters, in conjunction with thermocouples and

thermal insulation will be utilized to create a bull’s eye heated band (HB) concentric to the
attachment welds, of sufficient size to ensure that the soak band (SB) achieves PWHT soak
temperature. The HB and insulation gradient control band (GCB) are utilized to avoid
exceeding NBIC maximum allowable radial temperature gradients.

2.5 Procedural Tasks

The majority of the tasks described in this procedure are within Team's scope of activity.
However, the purpose of this document is to describe those tasks or activities, and not to
assign responsibility for them. The Team supervising technician will coordinate with the
client to assign these duties, and is empowered to make minor alterations to this procedure,
such as heater selection, in order to improve the quality of the PWHT by accommodating
variations in available equipment and space. Major revisions must be approved by the
client and Team’s Technical Support Group (TSG), to ensure that the PWHT is not
compromised in any way.

3.0 VESSEL AND NOZZLE DETAILS

Vessel C6-11 and nozzle N1 are illustrated in PDVSA drawing RCN-523.798, Sheet 1, Rev. 5, of
December 14, 2005. Primary details are summarized below.

• Vessel Configuration: Horizontal cylindrical bullet on 2 saddle supports

• Shell & Repad Material:
• Shell Thickness:
• Shell Inner Diameter:
• Nozzle Material:
• Nozzle Size & Position:
• Nozzle Thickness:
• Nozzle Centerline Location:
• Repad Diam. & Thickness:
• Repad Edge Distance:
SA-516-70 (ASME P-No. 1) carbon steel
1-7/16-inch (36.5-mm)
15-1/2-ft (4.727-m)
SA-106-B (ASME P-No. 1) carbon steel
6-inch NPS on vessel bottom centerline
Schedule 80 (0.432-inch)
14-13/16 inches from tangent weld centerline
12-15/16 inches outer diameter by 1-3/8-inch thick
8-5/16 inches to tangent weld centerline
Team PWHT Procedure 022809-01, Rev. 0 Page 3 of 10

Figure 1 – Elevation View of C6-11 Showing All Nozzles

 Team PWHT Procedure 022809-01, Rev. 0 Page 4 of 10

4.0 UW-40 REQUIREMENT FOR ATTACHMENT WELD SOAK BAND (SB) WIDTH

Paragraph UW-40 (a) (7) requires that the local PWHT of a nozzle attachment weld employ a soak
band that shall extend beyond the weld in all directions a minimum distance of the wall thickness
or 2 inches, whichever is less, as illustrated in Figure 2, below.

The Lesser The Lesser

of t or 2" of t or 2"

t
The Lesser of t or 2" The Lesser of t or 2"

Figure 2 – Nozzle Attachment Weld Soak Band Width

Therefore, for a shell thickness of 1-7/16-inch, the PWHT soak band (SB) must extend beyond the
edges of the attachment weld a distance of at least 1-7/16-inch. For a repad diameter of 12-15/16
inches, and a 1-inch fillet weld, the SB diameter should be at least 17-13/16 inches (450 mm)

5.0 TEMPERATURE GRADIENT CONTROL

NBIC RD-1100 requires that the radial gradient from the SB not exceed 250 °F/ft. Therefore, at a
distance of 1-ft from the edge of the SB, the temperature in the HB must not be below 900 oF, for a
PWHT soak temperature set-point of 1150 oF.

6.0 HEATER ARRANGEMENT

Figure 3 on the following page illustrates the bull’s eye PWHT heater and thermocouple
arrangement for the nozzle and repad attachment welds, incorporating code-mandated SB
requirements as defined above.

6.1 FCP Heaters

Each FCP heater has a surface area of 120 in². When powered by 80-VAC from a standard
Team 6-zone power and control (6-PAC) console, it will develop a thermal power capacity
of 3.6 kW, which is a uniform area power density of 30 W/in². Heaters are identified by
their flexible width dimension. For example, a CP12 heater is has a flexible 12-inch width,
and a rigid 10-inch length. Up to three heaters can be powered in parallel in a single
temperature control zone, in accordance with Team Standard Practice SP-08.

All heaters are to be attached to the shell by means of capacitor discharge welded stud pins
and friction washers, in compliance with Team Standard Practices SP-01 and SP-08.
 Team PWHT Procedure 022809-01, Rev. 0 Page 5 of 10

CP12 CP10 A B
CP24

A CP18 A B
CP12
CP10
B CP12
CP10 A
A B
CP10
CP15
N1
B

CP10 CP18 CP18 CP18

C
A B
A CP10
CP18
B CP12 CP12

CP12 CP10
CP24
A B

TAN LINE HEAD WELD

Figure 3 – Plan View of Bull’s Eye Thermocouple & Heater Arrangement on Shell for Nozzle N1
 Team PWHT Procedure 022809-01, Rev. 0 Page 6 of 10

6.2 Bull’s Eye HB Heater & Thermocouple Pattern

The bull’s eye HB heater and thermocouple pattern is illustrated in Figure 3 on the previous
page. It consists of three heater bands, as described below.

6.2.1 HB Inside Nozzle Bore

A 5-inch wide band of a single CP24 heater is to be wrapped around the neck of
nozzle N1, with a 2-inch circumferential overlap. It is to be located on the neck as
close to the shell as possible.

6.2.2 Innermost Shell HB

Surrounding the nozzle on the shell will be a rectangular band consisting of the
following temperature control zones:
• A CP18 heater above and below the nozzle, each its own zone
• 3 CP10 heaters to the left of the nozzle, arranged into a 3-heater zone
• 2 CP18 heaters to the right of the nozzle, arranged into a 2-heater zone

6.2.3 Outermost Shell GCB

Surrounding the inner HB on the shell will be a rectangular band consisting of the
following temperature control zones:
• A CP10 & a CP24 above and below the nozzle, each its own 2-heater zone
• A CP15 heater to the left of the inner HB as its own zone
• ACP10 & CP12 in upper & lower left corners, each its own 2-heater zone
• A CP18 heater to the right of the inner HB as its own zone
• 2 CP12 heaters in upper & lower right corners, each its own 2-heater zone

7.0 TEMPERATURE MEASUREMENT

7.1 Thermocouple Type and Quantity

Each of the 13 temperature control zones is to be instrumented with a Type K control

thermocouple, attached to the shell or nozzle neck surface by means of capacitor discharge
welding, to ensure accurate temperature measurement, in compliance with Team Standard
Practice SP-02. A spare thermocouple is to be located within ½-inch of each control
thermocouple.

7.2 Thermocouple Locations

The precise thermocouple locations are illustrated in Figure 3, on the previous page, and
described in Sub-section 6.2. Basically, each thermocouple is to be as close to the
geographic center of its 1-heater, 2-heater, or 3-heater zone as possible.
 Team PWHT Procedure 022809-01, Rev. 0 Page 7 of 10

7.3 Thermocouple Set-Point Temperatures

The heater band on the nozzle neck, and the 4 inner shell HB heater control zones with
their control thermocouples on the edge of the soak band (SB) are to have PWHT soak
temperature set-points. The 8 outer GCB shell heater control zones have their control
thermocouples approximately 1 ft from the edge of the SB. Consequently, those control
thermocouples are to have a set-point temperature 250 oF lower than the PWHT soak
temperature, for a value of 900 oF. This will place the temperature at e outer edge of the
HB at a value of approximately 800 oF.

8.0 THERMAL INSULATION

The entire bull’s eye is to be covered with a layer of 1-inch thick 6-lb/ft3-density non refractory
ceramic fiber (Non-RCF) thermal insulation, which is to extend 2-ft. beyond the edges of all
heaters. It is to be secured to the shell with the same type of capacitor discharge welded stud pins
and friction washers that hold the heaters in place. The insulation plug that is inserted into the
nozzle, with its attached heaters, is to consist of the same insulation material rolled into a
cylindrical plug.

9.0 EQUIPMENT INSTALLATION

9.1 Equipment Access

Scaffolding or man-lifts are to be provided as needed for personnel to install

thermocouples, heaters, and insulation. The three 6-PAC (6-zone power and control)
consoles are to be placed within 50 ft from the weld, with secondary cables positioned out
of harms way. All zone cabling is to be clearly identified, and supported to prevent any
pulling on heater tails. Each of the three 6-PAC consoles requires a 100-Amp, 480-VAC,
3-phase electric power supply.

9.2 Safety

Team site personnel will work with the client’s safety personnel, to ensure that the
following on-site safety steps are taken:

9.2.1 Permit Requirements

All necessary hot-work permits are to be acquired by Team’s supervising

technician, and all Team site personnel shall be familiar with permit requirements.

9.2.2 Personnel Protective Equipment (PPE)

All Team personnel shall wear protective clothing and equipment, as described in
the Team Safety Manual, and shall satisfy all site-specific safety requirements.
 Team PWHT Procedure 022809-01, Rev. 0 Page 8 of 10

9.2.3 Fire Extinguisher

A type ABC fire extinguisher shall be available to Team personnel within ready
access to the PWHT location.

10.0 RELEVANT TEAM STANDARD PRACTICES

Equipment specifications and preparation instructions relevant to this field procedure are provided
in the Team Standard Practices listed on the following page.

SP-01: Attachment of Stud Pins by Means of Capacitor Discharge Welding

SP-02: Attachment of Thermocouples by Means of Capacitor Discharge Welding
SP-05: Thermal Insulation – Specifications and Usage Guidelines
SP-06: Temperature Measurement and Recording Equipment - Specifications & Usage
SP-08: Low Voltage Electric Resistance Heating – Specifications, Usage, and Safety Guidelines

11.0 PWHT TEMPERATURE REQUIREMENTS

The following heating, soak, and cooling specifications are in accordance with Chevron PWHT
Procedure Guidelines, which are somewhat more stringent than those of article UCS-56 and Table
UCS-56.1 for P-No. 1 carbon steel fillet welds with a total thickness of 2-13/16-inchs (71.5-mm).

11.1 Heating

11.1.1 Below and at 800 °F

From ambient to 800 °F, Team recommends that the heating rates not exceed 400
°F/hr, in an effort to minimize temperature differences within concentric heater
bands.

11.1.2 Above 800 °F

Above 800 °F, heating rates shall not exceed 140 °F/hr.

11.1.3 Temperature Differential

While heating above 800 °F, there shall not be a greater variation in temperature than
150 ºF among thermocouples within any given concentric heater band. The heating
rate may be reduced to ensure that these differentials are not exceeded.

11.1.4 Maximum Temperature

During the heating period, there shall not be a temperature greater than 1175 ºF.
Team PWHT Procedure 022809-01, Rev. 0 Page 9 of 10

11.1.5 Thermocouple Failure

In the event of a thermocouple failure during the controlled portion of the heating
cycle, the cycle may be held at that point until the transfer to a spare thermocouple is
completed.

11.2 Soak

11.2.1 Temperature

Soak temperature shall be between 1125 ºF and 1175 ºF. The soak period is to begin
when the core HB soak temperature reaches 1125 ºF. At no time shall the
temperature of these thermocouples either exceed 1175 ºF, or fall below 1125 ºF.

11.2.2 Time

The minimum soak time shall be 2-1/4 hours.

11.2.3 Thermocouple Failure

In the event of a thermocouple failure during soak, the transfer to the spare
thermocouple is to be done immediately. If the temperature of the soak
thermocouple falls below 1125 ºF at any time during the transfer, the soak period is
to be resumed when it reaches 1125 ºF. The total accumulated time above 1125 ºF is
to be the soak time.

11.2.4 GCB Control Thermocouple Set-Point Temperatures

The set-point temperature for the control thermocouples in the outermost heater band
is to be not less than 900 oF, as defined in Subsection 7.3, in compliance with the
NBIC mandated maximum allowable temperature gradient.

11.3 Cooling

11.3.1 Above 800 °F

Above 800 °F, the maximum cooling rate shall not exceed 180 °F/hr.

11.3.2 Temperature Differential

While cooling above 800 °F, there shall not be a greater variation in temperature than
150 ºF among thermocouples in any given concentric heater band. Cooling rates
may be reduced to ensure that these differentials are not exceeded.
 Team PWHT Procedure 022809-01, Rev. 0 Page 10 of 10

11.3.3 At and Below 800 °F

At and below 800 °F, the cooling rate need not be restricted, and cooling can be
completed in still air. Thermal insulation can be removed whenever it is deemed
safe to do so.

11.3.4 Thermocouple Failure

In the event of a thermocouple failure during the controlled portion cooling, the
cycle may be held at that point until the transfer to the spare thermocouple is made.

12.0 DOCUMENTATION

A Team Job Folder is to be submitted to the client, containing the following documents:

12.1 Temperature-Time Record

Each thermocouple is to have its temperature/time history recorded on a dedicated channel

of a strip chart recorder. The strip chart label is to identify the correlation of thermocouple
numbers and strip chart recorder channels, and is to contain the information listed on the
following page:
• Date
• Identification of work piece
• Thermocouple type
• Stress relieving company
• Stress relieving operator and signature
• Chart recorder serial number and date of latest calibration

12.2 Recorder Calibration

Each recorder is to be accompanied by its certificate of calibration.

12.3 Job Report Log

In the event of a non-conformance, a manual log is to be maintained by Team technicians

to document pertinent details, and the Team supervising technician and the PDVSA quality
control manager are to be notified as soon as possible to help define corrective action.

12.4 Heat Treatment Record (HTR)

A daily HTR shall be submitted to document personnel, time, material, and equipment.

12.5 Approvals

This procedure requires approval signatures by an authorized representative of the client

and by the Team supervising technician before any Team site work can begin.