PWHT PROCEDURE (11) Rev 0

NaserM.Al-Baddah& Partner General Trading & Contracting Co. w.l.l.
Technical Services Division Operating Procedures
Doc. Ref. No.: NBTC-OP/TS11

Procedure for Pre-Heating & Local Post Revision: 0
Weld Heat Treatment Date: 15-03-2018
Page 1 of 14
Procedure for Pre-Heating & Local Post Weld Heat Treatment

Document No : NBTC-OP/ TS 11
MEW Document No.: A/SM/TEST-GNL/400100
Project Name: SUPPLY,ERECTION,OPERATION AND MAINTENANCE FOR THE CONVERSION OF

THE FIRST STAGE SABIYA GAS TURBINE TO COMBINED CYCLE CCGT-1
Contract No: MEW/C/5168-2016/2017
Client: MINISTRY OF ELECTRICITY & WATER
Contractor: ALGHANIM INTERNATIONAL GENERAL TRADING & CONT. CO. W.L.L.


Page 2 of 14
TABLE OF CONTENTS
1. Scope
2. References
3. Personnel Qualification
4. PRE-HEATING
5. PWHT PROCEDURE
5.1. Equipment
5.2.Materials
5.3.Surface Conditions
5.4.Thermocouples
5.5.Extension Cable
5.6.Compensating cable :
5.7.Heating Elements
5.8.Method used for fixing heating bands on Carbon steel jobs:-
5.9.Thermal Insulation
5.10. Insulation width
5.11. Temperature Recorder & Temperature Control System
5.12. Thermal Cycle
6. Hard ness Test
7. Interrupted PWHT
8. Placement of Job and its Protection
9. Documentation
10. Safety
11. Reporting
12. Annexures:
PWHT Report form NBTC-FO/IS001 Rev.0

Preheating / PWHT chart Report NBTC-FO/IS002 Rev.1


Page 3 of 14
1 SCOPE
This Procedure specifies the minimum requirements for Pre-heating and local Post Weld Heat Treatment
( PWHT) of carbon steel piping welds by means of electrical resistance method.
This procedure covers description of the equipment, method of heating, location and type of heating
elements, temperature measurement and thermo couple location for the project “Supply Erection,
Operation and Maintenance for the conversion of the first stage Sabiya Gas Turbine to Combined Cycle
CCGT-1”.
2 REFERENCES
Latest revisions of the following documents shall be referred to in conjunction with this Procedure.
1. ASME B31.3 Edn. 2016 & 31.1 – ASME Code for Pressure piping - Process Piping.,Power
piping
2. ASME SEC VIII DIV 1 Edn. 2017 -Rules for construction of Pressure Vessels
3. Spec. 1089-WM-01 – General Welding Requirements
4. NBTC Hardness Test Procedure – NBTC-OP/TS12
5. MEW section 4
3 PERSONNEL QUALIFICATION
PWHT technician employed by NBTC shall have a minimum qualification of secondary school certificate
with additional technical education background and must have a minimum 5 years of respective
experience. If needed CVs shall be submitted for prior approval from the client.
Normally one PWHT crew comprises of one technician and one assistant and this assistant will have a
qualification of secondary education with a minimum of two years basic electrical background experience.
4 PRE-HEATING
Preheating Method
Preheat and inter pass temperature of material to be welded shall be applied and or / maintained in
accordance with the Owner approved welding Procedures.
The following methods shall be used for preheating:
 Oxy-fuel gas torch with heating tip

 Air-fuel gas torch
 Electric resistance heaters
Preheat shall be checked before starting to weld and before welding resumes after any extended Welding
interruption. Thermocouples or a contact pyrometer shall be used for measuring the temperature.


Page 4 of 14
The preheat temperature shall be applied throughout the entire thickness of the weld and at least 50mm. on
each side of the weld line.
When preheating is required for welding, it shall also be required for tack welds, repair welds and
attachment welds.
Where thickness is specified for pre heating, then preheating shall be applied according to thickness of the
thicker component measured at the joint.
5 PWHT PROCEDURE
5.1 EQUIPMENT
The electric power generators being used shall be portable type 380/415/440V, 3 phase 65V secondary
with built in 6 or 12 way control modules.
Temperature control units are either automatically controlled with modular controls or manually operated
through energy regulators. And the rising, soaking and cooling temperatures during operation shall be
recorded on a temperature chart recorder.
These chart recorders shall have valid calibration certificates and calibration frequency of these recorders
will be one year.
5.2 MATERIALS
The ceramic mat heaters (Heating pads), Thermocouple wire, copper/constantan compensating wire,
mineral wool etc. being used for the job will be of standard/ approved commercial quality.
The heating pad wires must be multi strand Nickel chrome element wire, insulated by interlocking alumina
beads providing a flexible high heat transfer capacity.
5.3 SURFACE CONDITIONS
The exterior and interior surface of the pipe to be heat treated shall be free from contaminant chemicals,
grease or other organic material. Sulphur bearing compounds, mastics and paints shall be removed by
solvent washing, grinding or other appropriate means.
Prior to start of the PWHT, component shall be checked to ensure that all restraints are removed and the
component is free to expand and contract and suitable and sufficient supports are used.
During heat treatment it shall be necessary to protect from oxidation the mechanical surfaces of line flange
faces, threaded holes, threads by the application of coating such as Deoxaluminite or any other suitable
coating material.
GENERAL REQUIREMENTS
PWHT shall follow all welding and repairs but shall be performed prior to any hydro test or other load test.


Page 5 of 14
Heating elements shall be securely fixed in contact with the work piece by stainless steel or mild steel
banding to suit the application. Under no circumstances shall galvanized wire or other fixings likely to be
detrimental to the pipe material be utilized.
Upon completion of the post weld heat treatment, the thermocouple shall be removed and the areas of
attachment dressed by either grinding or filling before being non-destructively examined using either dye
penetrate or magnetic particle inspection methods by client ( if required).
5.4 THERMOCOUPLES
Thermocouple wire:
Thermocouples shall be the nickel-chromium/nickel aluminium type “K” twin wire 0.711 mm. dia.. to BS
4937 or equivalent. All thermocouples shall have certificates of conformance.
The thermocouples shall be maintained in such a way to avoid touching each other than the welded
junction. The junction has to be insulated by using thermocouple high temperature putty in order to protect
it from direct heat source.
Thermocouple welding unit :
Thermocouples shall be attached to the pipe by capacitance discharge method. Thermo couple shall be
attached such that the gap between the wires should not be more than 6 mm.
Placement
Thermocouples shall be positioned exactly on the weld. (ref. AWS D10.10)
(Thermocouple(s) and position(s) shall be identified on the relevant temperature recording chart by
number and colour (Ref. Attachment # NBTC-FO/IS02 Rev. 0.)
The number, placement, and extension cable of thermocouples (T.C.) in the Local PWHT shall be as
follows:
Numbers
1. For pipe dia. up to 6" (Located at 6' O clock position)
2. For pipe dia. above 6" to 10" (Located at 6, 12' O Clock)
3. For pipe dia. above 10" to 22" (120º apart, one at 12' O Clock)
4. For pipe dia. above 24" (Located at 12, 3, 6 & 9' O Clock)
When required by Client following DEP 30.10.60.18-Gen shall be followed regarding number and
position of thermocouples.


Page 6 of 14
Figure :1
5.5 EXTENSION CABLE
The thermocouple extension cable connection shall be minimum of 0.5 m outside the heated zone & the
acceptable junction temperature should not be more than 80 deg C. Thermocouple extension cable shall be
nickel-chromium compensating cable with connection through plug and socket.
5.6 COMPENSATING CABLE:

The cable recommended shall be twin type PVC coated copper/constantan connection to thermocouple,
with proper plug & socket.
Note: Connect Copper lead (+ve) to nickel chromium ( non magnetic yellow), Constantan lead (-ve) to the
nickel aluminium conductor ( magnetic red)
5.7 HEATING ELEMENTS
Heating element / pad shall have the capability to with-stand a temperature up to 1050 deg. C and of
Multi-strand Nickel Chrome with insulation beads.
The width of the heater mat shall cover at least 3.5 t or 2", whichever is greater, on either side of the weld
Where t is the weld thickness. When weldment consists of two different wall thicknesses then the element
shall be so arranged as to give side to side control in addition to top to bottom control.
The width of the band heated to the specified temperature range shall be at least three times the wall
thickness at the weld of the thickest part being joined. For nozzle and attachment welds, the width of the
band heated to the specified temperature range shall extend beyond the nozzle weld or attachment weld
on each side at least two times the run pipe thickness, and shall extend completely around the run pipe.
( Ref. B31.3 Edn. 2014)


Page 7 of 14
When post weld heat treating a combination of two metals, the higher grade material temperature shall be
followed provided the actual temperature does not exceed the lower critical temperature of the lower
material.
For pipes having 200mm dia. or greater, the elements / pads shall be divided into two control zones being
top and bottom with pads applied systematically. Gap between heating elements shall be 30mm maximum
and longitudinal gaps shall be 50mm maximum. Double layer insulation will be provided to ensure that
there is no temperature variation at these places.
When the length of element arrangement is greater than perimeter of the pipe then elements overlap shall
be restricted to 25mm.
Heating elements shall be arranged in such a way that the weld under PWHT is placed exactly at the centre
of the heating pads and the pads will be covering a minimum of 25 mm on either side of the weld, so that
uniform heating will be carried out all around the welded area.
For nozzle welds & flange welds sufficient heating elements shall be used to prevent temperature loss due
to atmospheric interference.
The heating mats/elements shall be fastened to the work piece by steel bands or wires.
The Post Weld Heat Treatment of weld joint shall be performed gradually and uniformly so that the
temperature around the entire joint is uniform without any hot spots.
When required by Client following DEP 30.10.60.18-Gen shall be followed regarding width of heated
band and insulation width for soak band.
Figure :2
5.8 METHOD USED FOR FIXING HEATING PADS ON CARBON STEEL JOBS:
 -
Mild steel banking strap – 12mm wide.
 Blank annealed iron wire shall be used for fastening of elements on carbon steel weldments.


Page 8 of 14
For welded valves pre-and / or post weld heat treatment shall be executed on one side of Valve at a time,
with the valve in the open position. Under no circumstances shall both valve sides be heat treated at the
same time. The temperature shall be measured and recorded at the inside middle of Valve and Owner will
be notified if the temperature is rising above 4500C.
5.9 THERMAL INSULATION
Thermal Insulation can be carried out using ceramic fibre covered in stainless steel mesh to form a
minimum density of 96kg/m3 mat. Depending upon the various conditions mentioned below, the number
of layers may be decided.
i. Pipe or fitting diameter

ii. Wall thicknesses
iii. Gradient requirements
iv. Site conditions
A minimum of two layers of the density mentioned will have to be provided for normal service. Open end
of pipe and/or fittings shall be blanked to avoid through draught cooling during cycle. Flange face and
serrations shall be protected by applying high temperature grease on the face of the flange before starting
PWHT.
The thermal insulation is provided by wrapping the heaters and adjacent area with ceramic fibre with a
minimum of 20mm thick material. This can prevent heat loses and also work as a safety tool.
The insulation shall cover the whole heating band and extend beyond the heaters to a distance of a
minimum of 5 times the diameter of the pipe, measured longitudinally and centred on the weld.
Open pipe ends near areas to be heat treated shall be plugged with insulation.
5.10 INSULATION WIDTH
The following wall thickness group shall have minimum width of insulation on either side of the heat
bands.
Thickness Insulation
thickness up to 25mm 230mm on both sides
25 < thickness < 45mm 305mm on both sides
5.11 TEMPERATURE RECORDER & TEMPERATURE CONTROL SYSTEM
Potentiometric self-compensating type of recorders fed with chart are the ones used for temperature
recorders. Recorders shall always carry calibration certificates with proper validity. Unless otherwise


Page 9 of 14
recorders are subjected to some sudden impact or damage, where a definite recalibration is a must, the
calibration can be valid for one year.
The chart speed shall be set at 25mm/hr or any other appropriate speed and it shall be recorded on PWHT
chart & Report. The temperature recording system must record all thermocouples and provide information
on temperature differences and trends during the heating/cooling cycle.
The difference among the measurements performed by the various thermocouples shall not exceed 15ºC.
The registered temperature difference between thermocouples shall be within +/- 15 deg. C at any given
time.
The location and numbers of thermocouples shall be shown on weld map. Temperature time recording
chart must be made for all Heat Treatments.
POST HEATING:
By definition this process encompasses all heating performed immediately after welding has been
stopped. The primary objective for post heating is the removal of hydrogen and the prevention of
hydrogen assisted cold cracking, also known as delayed cracking that can occur 48 hours, or more, after
the weldment has been cooled to ambient temperature. This is of special concern when joining high
strength and alloyed steels such as Grades 22, 91 and 92.
The main purpose is to remove

Post heating is often referred to as hydrogen release or bake-out.
diffusible hydrogen from the completed weld. This process shall be applied immediately after completion
of welding for Grades 22,91 and 92 materials Temperature range of 280°C-350°C for 2 hours per 25mm
wall
thickness with 2 hours’ minimum is required.
The exception of post heating is applicable to small bore pipes and fittings limited to <100 mm (outside
diameter) with:10 mm (wall thickness) and weld completed by GTAW only. This exception of post heat is
only allowed under condition the welded joint was continuously preheated using electric resistance
heating elements (or induction coils) with permanent preheat chart records available.
Thermocouple recording post heating shall be placed in the center of the completed weld. The heating
element(s) should be relocated from the preheat position to cover the entire circumference.
The minimum soak band width shalt be 150 mm, or 3 times the governing wall thickness, whichever is
greater in all directions from the weld.
Continuous recording of post-heating is mandatory for Grades 91 and 92. Records of FQP shall form a part
of the final quality documentation.
Typical diagrams of Grade 91 and 92 with post-healing (hydrogen release) immediately after completion
of welding and without post-heating is shown in Figure 3.
Before beginning of Post Heating the completed weld joint shall be surrounded with Insulation band to
prevent exposure atmosphere and to decrease the loss of heat.


Page 10 of 14
Figure 3 (a) Typical heat treatment chart for Grades 91 and 92 weldments with hydrogen
release procedure immediately after completion of welding and mandatory cooling
below martensite finish temperature Mf (~90°C) and (b) without hydrogen release stage
after completion of welding permitted for small bore (≤4”, or 100NB), thin wall
thickness (≤10 mm) using GTAW welding method only.


Page 11 of 14
5.12 THERMAL CYCLE
The rising, holding and Cooling rate shall be as given below (per ASME B31.3-Edn2014) or as
per Client requirement / Specification or as required by Qualified WPS.
a. Unrestricted heating :up to 300 ° C

b. Maximum heating rate :150 ° C / Hr
c. Soaking Time (Holding :1 Hr per inch up to 50 mm control thickness
time) 2 Hr plus 15 minutes for each additional over 50 mm control thickness.
Thickness determined at the PWHT location with greatest cross
section.
d. Soaking / Holding Temp :595-650 ° C
e. Cooling Rate :150 ° C / Hr
f. Unrestricted cooling :below 300° C
Thickness of the weld, which is a factor in determining the control thickness, is defined as follows:
(1) groove welds (girth and longitudinal) — the thicker of the two abutting ends after weld preparation,
including I.D. machining
(2) fillet welds — the throat thickness of the weld
(3) partial penetration welds — the depth of the weld groove
(4) material repair welds — the depth of the cavity to be repaired
(5) branch welds — the dimension existing in the plane intersecting the longitudinal axes. (ref. para
331.1.3 of ASME B 31.3).


Page 12 of 14
6 HARD NESS TEST

In case of client requirement as a final check, and to verify that PWHT has been carried out satisfactorily,
hardness test of the welded joints (Weldment, HAZ and Base metal) will be carried out at least at four
locations as per Hardness Testing Procedure using EQUOTIP portable metal hardness tester type D.
7 INTERRUPTED PWHT
If the PWHT is interrupted during the heating / cooling cycle, weld will be allowed to cool down to
ambient temperature and repeat the PWHT. Also if the PWHT found unacceptable the entire operation will
be repeated.
In case of interruption during soaking / holding period, heating shall be started with specified heating rate,
held at holding temperature for the balance period required to fulfil the required holding time and cooled at
specified rate.
8 PLACEMENT OF JOB AND ITS PROTECTION
Job to be stress relieved shall be properly supported to prevent sagging or distortion during heat treatment.
Pipe ends, flanges, threads, machined surface, etc. which in case are coming in between the heating
operation, shall be protected against oxidation during post weld treatment by suitably wrapping them up
with ceramic fibre.
9 DOCUMENTATION
The chart shall be countersigned by the operator/client before starting and after completion of the
operation. Weld number, start time, date, etc. shall be written on the chart before commencement of the
work.
Refer para 11.0 and Annexures 1 & 2.
On completion of the job Thermocouple identification form shall be filled in and attached along with the
recorder chart. The time temperature curves on the recorder chart shall be marked to identify
corresponding thermocouples.
10 SAFETY
 Heat Treatment Personnel shall be trained in all safety aspects regarding potential electrical/fire
hazards while handling the Heat Treatment equipment.
 Ceramic beads in heater coils shall be checked for any damage, which would otherwise cause electric
short circuit. Care shall be taken to ensure that no low melting point metals, such as copper wire,
galvanized steel wire or galvanized scaffold poles come in intimate contact with steel during PWHT.


Page 13 of 14
 Sufficient training shall be given to all personnel regarding the general safety procedure in fabrication
yards and construction sites.
 Appropriate PPE shall be worn at all times.
 Appropriate signs and barricades are to be erected to keep unauthorized personnel out of area during
testing.
 Fire and safety regulations of the client shall be adhered to at all times.
11 REPORTING
Following format shall be used in addition to the charts referred in para 9.
PWHT Report form NBTC-FO/IS001 Rev.0

Preheating / PWHT chart Report NBTC-FO/IS002 Rev.1
Annexure # 1
NASER M. AL-BADDAH& PARTNER GENERAL TRDG. & CONT. CO. W.L.L

TECHNICAL INSPECTION SERVICES DIVISION
CHART NO: DATE OF PWHT:

REPORT NO: CODE:
PROJECT NAME: PROJECT NO:
QC PROCEDURE: THICKNESS
MATERIAL: STARTING TIME:
CHART SPEED: HEATING RATE: COOLING RATE:
RECORDER SL.NO: HOLDING TEMP: HOLDING TIME:
LINE NO WELD NO TC POINT COLOUR LINE NO WELD NO TC POINT COLOUR
NBTC SUB CONTRACTOR CONTRACTOR CLIENT

SIGN.
DATE.


Page 14 of 14
Annexure # 2

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NaserM.Al-Baddah& Partner General Trading & Contracting Co. w.l.l.

Technical Services Division Operating Procedures

Doc. Ref. No.: NBTC-OP/TS11

Procedure for Pre-Heating & Local Post Weld Heat Treatment

Project Name: SUPPLY,ERECTION,OPERATION AND MAINTENANCE FOR THE CONVERSION OF

Contract No: MEW/C/5168-2016/2017

Client: MINISTRY OF ELECTRICITY & WATER

Contractor: ALGHANIM INTERNATIONAL GENERAL TRADING & CONT. CO. W.L.L.

MEW Document No.: A/SM/TEST-GNL/400100

Doc. Ref. No.: NBTC-OP/TS11

PWHT Report form NBTC-FO/IS001 Rev.0

MEW Document No.: A/SM/TEST-GNL/400100

Doc. Ref. No.: NBTC-OP/TS11

The following methods shall be used for preheating:

 Oxy-fuel gas torch with heating tip

MEW Document No.: A/SM/TEST-GNL/400100

Doc. Ref. No.: NBTC-OP/TS11

5.3 SURFACE CONDITIONS

MEW Document No.: A/SM/TEST-GNL/400100

Doc. Ref. No.: NBTC-OP/TS11

Thermocouple welding unit :

MEW Document No.: A/SM/TEST-GNL/400100

Doc. Ref. No.: NBTC-OP/TS11

5.5 EXTENSION CABLE

5.6 COMPENSATING CABLE:

5.7 HEATING ELEMENTS

MEW Document No.: A/SM/TEST-GNL/400100

Doc. Ref. No.: NBTC-OP/TS11

MEW Document No.: A/SM/TEST-GNL/400100

Doc. Ref. No.: NBTC-OP/TS11

5.9 THERMAL INSULATION

i. Pipe or fitting diameter

5.10 INSULATION WIDTH

5.11 TEMPERATURE RECORDER & TEMPERATURE CONTROL SYSTEM

MEW Document No.: A/SM/TEST-GNL/400100

Doc. Ref. No.: NBTC-OP/TS11

The main purpose is to remove

MEW Document No.: A/SM/TEST-GNL/400100

Doc. Ref. No.: NBTC-OP/TS11

MEW Document No.: A/SM/TEST-GNL/400100

Doc. Ref. No.: NBTC-OP/TS11

5.12 THERMAL CYCLE

a. Unrestricted heating :up to 300 ° C

MEW Document No.: A/SM/TEST-GNL/400100

Doc. Ref. No.: NBTC-OP/TS11

6 HARD NESS TEST

8 PLACEMENT OF JOB AND ITS PROTECTION

Refer para 11.0 and Annexures 1 & 2.

MEW Document No.: A/SM/TEST-GNL/400100

Doc. Ref. No.: NBTC-OP/TS11

PWHT Report form NBTC-FO/IS001 Rev.0

NASER M. AL-BADDAH& PARTNER GENERAL TRDG. & CONT. CO. W.L.L

CHART NO: DATE OF PWHT:

NBTC SUB CONTRACTOR CONTRACTOR CLIENT

MEW Document No.: A/SM/TEST-GNL/400100

Doc. Ref. No.: NBTC-OP/TS11

MEW Document No.: A/SM/TEST-GNL/400100

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