Professional Documents
Culture Documents
INDEX
Sl.No. Description Page No.
01 Cover Sheet 01
02 Index 02
03 Preface 03
04 Foreword 04
05 Approval Sheet 05
06 Important Note 06
07 Status of Amendments 07
08 Table of Contents 08
3
BHEL – POWER SECTOR 5
IMPORTANT
3 General 26
4 Pre heat & PWHT of Critical Piping with Turbine & Auxiliaries 30
1.0 PURPOSE:
1.1 This procedure provides information, method and control for Pre-Heat, Post Heat 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 Pre-Heat ,Post Heat 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
of the thicker shall rule
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).
3.1.5.1 Preheating & Post Heating shall be applied by any of the methods given below:
a. Electrical resistance heating
b. Induction heating
3.2.1 The method shall be by locally heating a circumferential band including the entire weld
and adjacent area of base metal, by induction or electrical resistance heating.
3.2.2 Heat band for PWHT:
3.2.2.1 For Boilers:
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.
W = 3 times the wall thickness (of thickest part ) on each side from the centre of the
weld. 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.
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.
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.
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 actual parameters shall 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
The operator for the Heat Treatment shall be a qualified Electrician and should be
conversant in the operation & maintenance of heat treatment machines & Process. He
should be trained properly by the concerned Welding / Electrical Engineer in order to
handle/ maintain the machines / process without any trouble / problem.
Table-I Weld preheat and PWHT for tubes and pipes outside diameter 102 mm.
Table-III Weld preheat and PWHT for pipes outside diameter > 102 mm.
7.0 RECORDS :
7.1 Pertinent Records like Job card, PWHT Charts, shall be maintained.
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
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
P15 E Gr 1
All 220 750 – 770
(Note 4)
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.
TABLE - III
WELD PREHEAT AND PWHT FOR PIPES
OUTSIDE DIAMETER >102 mm
BUTT WELDS Stub and Attachment welds Post
Note 1 & 2 heat
P No. of Thickness
Throat 19 mm Throat > 19 mm C
Material (mm) Preheat PWHT
C C Preheat PWHT Preheat PWHT (Note
C C C C 3)
595 -
19 Nil Nil Nil Nil Nil Nil
625
P1 Gr 1 595 - 595 -
>1925 Nil Nil Nil Nil Nil
& SA106 Gr C 625 625
595 - 595 -
>2575 150 150 Nil 150 Nil
625 625
595 - 595- 595 -
>75 150 150 150 Nil
625 625 625
620 -
9 Nil Nil Nil Nil Nil Nil
650
P1 Gr 2
620 - 620- 620 -
& SA 106 Gr C >919 Nil Nil Nil Nil
650 650 650
150
620- 620- 620 -
>19 150 150 150 for 2
650 650 650
hrs
640- 640- 640-
All 150 150 150 Nil
P4 Gr 1 670 670 670
Pipes 250
680 - 680- 680-
150 150 150 for 2
Castings & 710 710 710
P5 A hrs
Forgings
280
750- 750- 750-
P15 E Gr1 All 220 220 220 for 2
770 770 770
hrs
280
P15 E Gr1 730- 730- 730-
All 220 220 220 for 2
+ 760 760 760
hrs
P5 A
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.
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.
TABLE - IV
P NUMBER AND GROUP NUMBER FOR BASE MATERIALS
Grou
P.No Common Name Tubes Pipes Plates Forgings Castings Fittings
p No.
SA192 SA106GRB SA36 SA266CL SA216WC SA234
SA210GRA1 SA515GR55 1 A
SA352LC WPB
Carbon
Steels SA515GR60 A
SA352LC
P1 1 SA515GR65 B
SA516GR55
SA516GR60
SA516GR65
SA210GRC SA106GRC SA515GR70 SA266CL SA216WC SA105
P1 2 Carbon Steels SA516GR70 2 B
SA216WC SA234
SA299 C
SA352LC WPC
SA209T1 SA335P1 C
SA217WC
Carbon-Moly
P3 1
Steels 1
½Cr½Mo Steels
P3 1 SA213T2 SA335P2 SA387GR2
1Cr½Mo/
SA213T12/ SA335P12 SA387GR12 SA182F1 SA217WC SA234
P4 1 1¼Cr½Mo Steels
SA213T11 SA335P11 2
SA387GR11 SA182F1 6 WP12
SA234
2¼Cr1Mo Steels 1 WP11
P5A 1 SA213T22 SA335P22 SA387GR22 SA182F2 SA217WC SA234
9Cr1MoV Steels 2 9 WP22
P15 SA213T91 SA335P91 SA387GR91 SA182F91 SA234
2
E WP91
Gr 1 18Cr-8Ni Steels
SA213TP304 SA376TP304 SA240TP304 SA182F3 SA351CF SA403
SA213TP304 SA376TP304H SA240TP321 04
SA182F3 3
SA351CF
H
SA213TP347 SA376TP321 SA240TP347 21
SA182F3 8
SA351CF
P8 1
SA213TP347 SA376TP347 47
SA336F3 3M
SA351CF
H
SA213TP321 SA376TP347H 04
SA336F3 8M
SA351CF
21
SA336F3 10
SA351CF
25Cr-20Ni Steel
P8 2 SA240TP310 47
SA182F310 10M
SA351CK
(Type 310)
20
Note : IS1239 & API 5L GR B Pipes, IS2062 Plates may be treated as P No.1 Gr No.1 material.
TABLE - V
PREHEAT AND PWHT FOR NON PRESSURE PARTS INCLUDING STRUCTURALS
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 A material shall be post heated at 250°C for 2 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
BHEL – POWER SECTOR
5 hours 22 thickness over 125mm.
+ 15 minutes for each 25mm
HEAT TREATMENT MANUAL FOR POWER SECTOR
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 A materials, except when the part is scheduled for hot forming, shall
be inter stage heat treated at 680-710°C for 30 minutes minimum after
flame cutting and prior to any welding. Subsequent to this heat
treatment, a minimum 3 mm of the gas cut edge shall be removed by
machining / grinding.
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 - 3
GENERAL
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.
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 :
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
Pre heat & PWHT of Critical Piping with Turbine & Auxiliaries
***********