TCM Division

THERMAL PROCESS PROCEDURE 030309-01, Rev. 0

BULL’S EYE POST WELD HEAT TREATMENT (PWHT)

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

NOZZLES K1 & K2 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

March 3, 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 Nozzles K1 & K2 Attachment Welds on Vessel C6-11 M. Goita
Rev.: Date:
PAGE 1 of 10 Field Procedure 030309-01 0 3/3/09

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
Nozzles K1 & K2 attachment welds
SA-516-70 & SA-106-B (ASME P-No. 1) CS
1-7/16-inch (36.5 mm) & 15-1/2-ft (4727 mm)
4-inch NPS K1 & 6-inch NPS K2
Section VIII, ASME BPVC, and NBIC
Electric Resistance Heat Treating System
1150 °F ± 25 °F
2-1/2 hours, minimum
100 °F/hr
130 °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 nozzles
K1 and K2 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 030309-01, 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
2 adjacent nozzle repads, 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 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 PWHT quality.

3.0 VESSEL AND NOZZLE DETAILS

Vessel C6-11 and nozzles K1 & K2 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 Diam. & Thickness:
• Nozzle Material:
• Nozzle Sizes & Positions:
• Nozzle K1 Thickness:
• Nozzle K2 Thickness:
• K1 Centerline Location:
• K2 Centerline Location:
• K1 Repad Diam. & Thick.:
• K2 Repad Diam. & Thick.:
• Max Total Weld Thickness:
SA-516-70 (ASME P-No. 1) carbon steel
15-1/2-ft (4.727-m) I.D. by 1-7/16-inch (36.5-mm) thickness
SA-106-B (ASME P-No. 1) carbon steel
K1 4-inch NPS, K2 6-inch NPS, along vessel top centerline
Schedule 80, 0.337-inch (8.6 mm) wall thickness
Schedule 80, 0.432-inch (11 mm) wall thickness
38-1/8-inches (968.5 mm) from existing manway M-1
15-3/4-inches (400 mm) from new nozzle K1
9-inch outer diameter by 1-1/2-inch thick
14-inch outer diameter by 1-3/4-inch thick
Shell & repad thicknesses & 3/8-inch fillet in & out = 3-15/16
Team PWHT Procedure 030309-01, Rev. 0 Page 3 of 10

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

 Team PWHT Procedure 030309-01, 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 the 14-inch diameter by 1-3/4-
inch thick K2 repad, the SB diameter should be at least 20-3/8 inches (518 mm), and for the 9-inch
diameter by 1-1/2-inch thick K1 repad, the SB diameter should be at least 14-7/8 inches (378 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, for both K1 and K2.

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 030309-01, Rev. 0 Page 5 of 10

A
B

CP10
CP10

CP10

CP10
B
A

B
C

CP10
CP10

CP10
CP10

C
K2
CP

CP
24

24
CP10
CP10

CP10

24 CP10
A

B
K1
CP

CP
24

CP10

CP10

CP10
CP10
A

B
C

C
CP10

CP10

CP10
CP10
B

B
M-1

Figure 3 – Plan View of Bull’s Eye Thermocouple & Heater Arrangement on Shell for Nozzle N5
 Team PWHT Procedure 030309-01, 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 for Nozzle Necks

A 12-inch wide band of a single CP10 heater is to be pinned to a nominal 3-inch

diameter cylindrical plug of thermal insulation and inserted into the bore of nozzle
K1 where it will be held tightly during PWHT. The single-zone heater will have a
3/4-inch circumferential space between ends.

A 5-inch wide band of a single CP24 heater is to be wrapped around the neck of
nozzle K2, 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 somewhat rectangular band of nearly
25-inch circumferential length by 42-1/2-inch axial length. It consists of four
single-heater zones of 1 CP24 each interspersed between three 2-heater zones of
CP10 heaters each, with a nominal 1-inch space between adjacent heaters.

6.2.3 Outermost Shell GCB

Surrounding the inner HB on the shell will be a rectangular band of nearly 51-inch
circumferential length by 64-1/2-inch axial length. It consists of a 3-heater zone of
CP10 heaters in each corner, and a single-heater zone of a CP 10 in the middle of
the top and bottom circumferential edges.

7.0 TEMPERATURE MEASUREMENT

7.1 Thermocouple Type and Quantity

Each of the 15 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. They involve 2 on the nozzle necks, 7 on the edges of the
SB, and 6 on the GCB centerlines at a distance of 1-ft from the edges of the SB, while
being as close to the center of each heater zone as possible.
 Team PWHT Procedure 030309-01, Rev. 0 Page 7 of 10

7.3 Thermocouple Set-Point Temperatures

The 2 nozzle neck heat zones and the 7 inner shell HB heater zones with their control
thermocouples on the edge of the SB are to have PWHT soak temperature set-points. The
6 outer GCB heater control zones have their control thermocouples at a distance of 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 the 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 K1
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 030309-01, 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 the requirements of
article UCS-56 and Table UCS-56.1 for P-No. 1 carbon steel welds with a maximum total thickness
of 3-15/16-inches (100-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 100 °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 030309-01, 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 2-1/2 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 GCB 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 130 °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 030309-01, 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.