5-PWHT Procedure - PW005

STSSB/PCE/TA14/PW005
PWHT Rev
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PROCEDURE Page : 1 of 12
PWHT
PROCEDURE
PROCEDURE DEFECT RECTIFICATION WORKS

FOR PCESB TA 2014
0 25/2/14 JEFF ZULFADLI
REV DATE PREPARED BY CHECKED BY APPROVED BY DESCRIPTION

PWHT Rev
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TABLE OF CONTENTS
1.0 SCOPE
2.0 REFERENCES
3.0 METHOD
4.0 HEATING SYSTEM
5.0 TEMPERATURE CONTROL
6.0 THERMOCOUPLES
7.0 THERMOCOUPLE POSITIONS
8.0 THERMOCOUPLE COMPENSATING CABLE
9.0 TEMPERATURE RECORDING
10.0 INSULATION
11.0 PROCEDURE REQUIREMENTS
12.0 DOCUMENTATION AND RECORDS
13.0 SAFETY
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1.0 SCOPE
External localized post weld heat treatment (PWHT) of pipe work, tubes, header,
flanges joints, valve and branches for temperatures up to 800 degree C..
2.0 REFERENCES
2.1 ASME section II – Materials

2.2 ASME section V – Non – Destructive Examination
2.3 ASME section IX – Welding and Brazing Qualifications
2.4 ASME section VIII – Boiler and pressure Vessel Code
2.5 ASME B31.3 – Process piping
3.0 METHOD
Application of electrical resistance elements, in the form of ceramic heater pads.

The elements detailed in table 1 may be utilized to meet the requirements of this
procedure. If may occasionally be necessary to employ non-standard elements to
accommodate the requirement of particular joint geometries.
4.0 HEATING SYSTEM.
4.1 Horizontal Pipe work.
4.1.1 For pipe diameters of 12.7mm (0.5”) and above, the heating
elements shall be applied either as a single band, or two discrete bands, arranged
symmetrically about the centerline of the weld seam. The heated bandwidth shall
be a minimum of 6t, inclusive of any centerline gap, where ‘t’ is the maximum
thickness at the joint and/or otherwise as required by the pertinent standard.
4.1.2 The centerline circumferential gap between two bands of elements

shall be limited to a maximum of 30mm or ‘t’, whichever is the lesser. (t = wall
thickness) for wall thickness above 10mm. For a wall thickness below 10mm, the
maximum gap shall be 10mm.
4.1.3 Longitudinal gaps between individual elements shall be limited to

50mm or‘t’, whichever is the lesser, for wall thickness above 10mm. For wall
thickness below 10mm, the maximum longitudinal gap shall be 10mm.
4.1.4 For a two band heating system, the heater pads on one side of the
weld should be rotated one quarter of a pad width, with respect to the heaters on
the opposite side.
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4.1.5 Where the nominal pipe outside diameter is equal to or greater than
250mm (10”), the heating pads shall be arranged so as to give independent control
of temperature on the top and bottom valves.
4.1.6 Where the wall thickness of the two joint members differ, the
elements shall be arrange so as to give side-to-side temperature control in addition
to top and bottom control should this be required under para 3.1.5.
4.2 Inclined & Vertical Pipe-work.
4.2.1 The heating pads shall be applied as two discrete bands, with a
centerline circumferential gap limited to a maximum of 30mm or ‘t’ whichever is
the lesser for wall thickness above 10mm. For a wall thickness below 10mm, the
maximum longitudinal gap shall be 10mm. The heating pads shall be arranged so
as to give independent control above and below the weld centerline. The total
heated bandwidth shall be a minimum of 6t, inclusive of the centerline gap, and
otherwise as required by the pertinent standard.
4.2.2 Longitudinal gaps between individual elements shall be limited to

a maximum of 50mm or ‘t’; whichever is the lesser for wall thickness above
10mm. For a wall thickness below 10mm the gap shall be a maximum of 10mm.
The heater pads above the weld centerline shall be rotated one quarter of a pad
width with respect to the heater below the weld centerline.
4.3 Pipe/Flange Welds.
4.3.1 Pipe/flange welds shall be heat treated in accordance with the

general principles of butt welds between pipe numbers of unequal thickness, ie.
The provision of independent control circuit on each side the weld.
4.3.2 It may be necessary to fit an additional band of heating elements to

the outside diameter of the flange to compensate for heat losses.
4.4 Pipe to Branch Weld.
4.4.1 The heating system to be applied to the main pipe member shall
comprise of a full circumferential band extending for a minimum distance each
side of the branch of 3 x t1 and / or otherwise as required by the pertinent
standard. (t1 = thickness of main pipe).
4.4.2 The heating system applied to the branch shall comprise of an

independent circumferential band extending for extending for a minimum distance
of 3-x t2 along the branch pipe, and / or otherwise as required by the pertinent
standard. (t2= thickness of branch).
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4.4.3 Gaps shall be limited in so far as is practicable with respect to pipe

attitude and dimensions as detailed under section 2.2.1 and 2.2.2, as shall
instructions for independent control of heater circuits.
4.5 General.
4.5.1 There shall be a maximum of three heating elements per circuit and
controlled from any one thermocouple.
4.5.2 Elements shall be securely fixed in contact with the work-piece by

soft iron wire, 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.
4.5.3 Where elements are manufactured with cold tails, care should be
taken to avoid trapping the cold tail and power supply cable between the work-
piece and the insulation. Element tails should be adequately supported to avoid
undue strain at the element/tail junction and at the hot /cold tail junction.
4.5.4 Prior to the start of solution annealing heat treatment the components
shall be checked to ensure that all restraints are removed and that the pipe is free
to expand and contract.
4.5.5 During solution annealing heat treatment the components shall be

properly supported to prevent sagging and distortion.
4.5.6 Where practicable, pipe ends shall be closed off to prevent the
cooling effects associated with drafts (chimney effects).
4.5.7 During heat treatment the work shall be protected from all types of
inclement weather.
4.5.8 All machined surfaces that may reach soak temperature, such as
flanges, faces fitted bolt-holes, threads, etc., and should be protected from
oxidation during heat treatment by coating these surfaces with suitable oxide
inhibiting paint.
4.5.9 Where valves or other specialist items are affected by the heat
treatment of associated welds, the recommendations of the manufacturers shall be
followed with regards to the removal and/or positioning of internals.
4.6 Complex Geometries.
Where weld joint geometry is more complex than a butt weld as defined in
para’s 4.1 to 4.5, special procedures shall be raised for approval.
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5.0 TEMPERATURE CONTROL
The heating elements shall be grouped into independent control zones, each controlled
and monitored by a respectively numbered thermocouple, so as to provide the required
temperature profiles. Each circuit of heating elements shall be controlled either by a contractor or
suitable solid state switching circuit. In turn these circuits shall be controlled by one of the
following systems:-
5.1 Semi-automatic control using a combination of a set-point controller and a

percentage timer/energy regulator. The set-point temperature controller shall be employed
to ensure correct temperature control during the soaking period.
5.2 An automatic pre-set program control unit, to control automatically the

heat treatment throughout its cycle.
6.0 THERMOCOUPLES.
6.1 Thermocouples shall be made from nickel-chromium/ nickel-aluminium

wire to BS4937, Part 4, ANSI MC96.1 Type K or other approved equivalent. A
Certificate of Conformance may be made available for each reel of wire utilized, and
shall indicate a tolerance of less than + or – 0.75% throughout the temperature range
400°C to 800°C.
6.2 Thermocouples shall be attached to the work-piece by the direct wire

capacitance discharge method. The gap between the two wire/work-piece junctions shall
not exceed 6mm.
6.3 Care shall be taken to ensure that the thermocouple conductor wires do not
touch each other, or metallic components, away from the hot junction.
6.4 Wherever possible, the thermocouples shall no be located under a heating

pad; thermocouples shall be routed between heating pads or out through the insulation, to
avoid close contact with the heating pad.
6.5 The thermocouple to compensating lead connections shall be a minimum

of 0.5m from the heated zone.
6.6 Following each heat treatment a minimum of 150mm of wire measured

from the hot zone shall be discarded.
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7.0 THERMOCOUPLE POSITIONS
7.1 The minimum thermocouple arrangements for a particular configuration

shall be as shown in the specific heat treatment procedure.
7.2 A minimum of one thermocouple shall be fitted to control each

independent circuit of heating elements. These thermocouples may be fitted at the weld
centerline for symmetrical heating system, and at a distance of 1½ x t for nonsymmetrical
heating systems and inclined/vertical pipe attitudes. Furthermore, they shall be located at
the mid-position of each zone.
7.3 Confirmatory or gradient thermocouples required by the prevailing

specification maybe omitted when the technique is shown to be both acceptable and
repeatable.
8.0 THERMOCOUPLE COMPENSATING CABLE
8.1 Copper/constantan compensating cable shall be used for extension of the

thermocouple to the recording instrument.
8.2 The copper lead (+ve) shall be connected to the nickel-chromium

conductor of the thermocouple (non-magnetic), and the constantan lead (-ve) shall be
connected to the nickel-aluminium conductors (magnetic).
9.0 TEMPERATURE RECORDING.
9.1 Temperatures recorders shall be of the potentiometric self-compensating

type, calibrated in degreed Celsius with respect to a nickel-chromium/nickel-aluminium
thermocouple, type K.
9.2 Temperature recorders shall be calibrated at intervals not exceeding 6

months. Should the calibration checks yield information that the temperature recorder is
not within the manufacturer’s specified tolerances (ie + or – 0.25% of full scale
deflection), recalibration will be performed. The calibrations shall be recorded and
evidence to this effect kept with the instrument. The calibrations certificate must show
both the ‘as found’ and ‘as left’ conditions of the instrument. Instruments utilized for
calibration purposes shall have certification traceable to a National Standard and shall
themselves be calibrated at intervals not to exceed 12 month.
9.3 In the event that the calibration check reveals that the instrument has been
used with an error that would have led to the measured temperatures being outside the
permitted the permitted tolerances, as specified in the heat treatment procedure, then full
details of the welds involved shall be reported to the inspecting authority.
9.4 The chart speed shall be set at 25 or 50mm/hour and shall be checked
during calibration. No artificial restriction on pen travel shall be used.
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9.5 A clear print out of data shall be demonstrated before commencement of a

heat treatment. Any section of the time-temperature chart must only record the heat
treatment of butt welds subjected to the same temperature cycle.
9.6 In the event that it is required by the contract, a constant reference voltage
shall be continuously injected on one trace of the recorder, to demonstrate correct
recorder functioning throughout the heat treatment cycle.
10.0 INSULATION.
10.1 Ceramic fibre blanket with a minimum thickness of 19mm and a

minimum density of 96kg/m3, or an equivalent thickness of silica fibre TMT mats, shall
be used for insulation.
10.2 Mineral wool 50mm thick, density 90 kg/m3 may be utilized as an

alternative where approved by the Engineer.
10.3 Insulation shall extend for a minimum distance of 5√Rt each side of the
weld centerline (R = bore radius; t = maximum wall thickness at weld), or for a minimum
distance of 300mm beyond the outermost edges of the heated band,whichever is the
greater. Special procedures shall be written for heat treatments where it is desirable or
necessary to reduce the extent of gradient insulation, e.g. complex geometry or
stub/branch welds.
10.4 The number of layers may be adjusted to meet variations of wall thickness,
pipe diameter, gradient requirements and site conditions.
10.5 Wherever possible, pipe ends shall be blanked off internally before heat
treatment.
11.1 Limitation on the rates of heating/cooling soak time and temperature shall
be defined in the prevailing standard or specified heat treatment procedure or other
authorized instruction and shall be strictly observed. It shall be the aim of the operator to
achieve a soak temperature at the upper limit of the specified temperature range, except
for welds between dissimilar materials.
11.2 Thermocouples fitted at the weld centerline shall all record temperatures
within the specified temperature range during the soak period.
11.3 Where the pertinent standard specifies that the longitudinal gradient
temperature shall be recorded at a distance of 2.5√Rt from the weld centerline, the
temperature recorded shall not be less than one half of the specified heat treatment
temperature during the soak period.
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12.0 DOCUMENTATION & RECORDS.
12.1 The documented information will comprise of the following:
12.1.1 Specific approved heat treatment procedure and/or specification

and chart receipt form.
12.1.2 Details of thermocouple layout, either on specific approved heat

treatment procedure, or as a diagram on the time/temperature charts.
12.1.3 Heat treatment record sheet where appropriate.
12.1.4 Time/Temperature chart fully identified and referenced. The chart

shall also identify the heat treatment specification, chart speed, date of operation.
12.1.5 Heat treatment record, where appropriate.
12.1.6 Recorder Test Certificate where appropriate.
13.0 SAFETY
13.1 All heating elements shall be thoroughly examined before use in order to
ensure that the element wire is not exposed. Examination to be also made for broken
beads in both the heater pad and the element hot lead.
13.2 Twist-lock connections shall also be examined to ensure that the insulation
is sound and that a good electrical joint is made.
13.3 All cable connections shall be properly insulated.
13.4 The component surface shall be free of contaminants.
13.5 Before a Heat Treatment is switched on particular attention shall be paid to

the work area to ensure that there are no combustible materials present which can be
affected by the heated zone, and that fire protection measures are available.
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TABLE ONE
Pad Identity Dimensions Volts Kw
WL
CP 3 -- 75 x 670 60V 2.70kW
CP 4 -- 100 x 500 60V 2.70kW
CP 6 Thick Wall Pad 150 x 330 60V 2.70kW
CP 8 -- 205 x 250 60V 2.70KW
CP10 -- 255 x 205 60V 2.70KW
CP12 Standard Pad 305 x 165 60V 2.70KW
CP15 -- 380 x 145 60V 2.70KW
CP16 -- 410 x 125 60V 2.70KW
CP21 -- 535 x 100 62V 2.70KW
CP24 Long Strip 610 x 85 60V 2.70KW
CP48 -- 1200 x 45 60V 2.70KW
CP10L Short Strip 255 x 85 30V 1.35KW
CP20L -- 500 x 45 30V 1.35kW
CP24H -- 635 x 330 20V 9.90kW
The width W - denotes the distance across the tails
Therefore recommend the following number of thermocouples per circumferential heated band
Up to 6 inch : 1 thermocouple (control zone)

8 to 12 inch : 2 thermocouple (control zone)
For diameters above 24 inch a minimum of one thermocouple for every three heater is required.
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APPENDIX A
The location for the standard number of thermocouple shall be as shown below;
x = thermocouple point
NOTE: For horizontal pipes one thermocouple must always be located at the top of the
pipe.
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13.1 Limitation pertaining to heating rates, hold time and temperature range,
and cooling rates shall be strictly observed and shall be in accordance to the following
ASME B31.3 requirement.
PWHT FOR ALLOY STEEL (SA335 Grade P11, P22. P- No 4, P-No 5a)
Temp.
Deg C
Holding Time/Holding
Temp= 706-760 deg C.
700 deg C
Heating Rate
Cooling Rate
100 deg C
100 deg C/Hour
300 deg C
Temperature
Time (Hour)
(C)

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STSSB/PCE/TA14/PW005

PROCEDURE DEFECT RECTIFICATION WORKS

0 25/2/14 JEFF ZULFADLI

REV DATE PREPARED BY CHECKED BY APPROVED BY DESCRIPTION

2.1 ASME section II – Materials

Application of electrical resistance elements, in the form of ceramic heater pads.

4.0 HEATING SYSTEM.

4.1 Horizontal Pipe work.

4.1.2 The centerline circumferential gap between two bands of elements

4.1.3 Longitudinal gaps between individual elements shall be limited to

4.2 Inclined & Vertical Pipe-work.

4.2.2 Longitudinal gaps between individual elements shall be limited to

4.3 Pipe/Flange Welds.

4.3.1 Pipe/flange welds shall be heat treated in accordance with the

4.3.2 It may be necessary to fit an additional band of heating elements to

4.4 Pipe to Branch Weld.

4.4.2 The heating system applied to the branch shall comprise of an

4.4.3 Gaps shall be limited in so far as is practicable with respect to pipe

4.5.2 Elements shall be securely fixed in contact with the work-piece by

4.5.5 During solution annealing heat treatment the components shall be

4.6 Complex Geometries.

5.0 TEMPERATURE CONTROL

5.1 Semi-automatic control using a combination of a set-point controller and a

5.2 An automatic pre-set program control unit, to control automatically the

6.1 Thermocouples shall be made from nickel-chromium/ nickel-aluminium

6.2 Thermocouples shall be attached to the work-piece by the direct wire

6.4 Wherever possible, the thermocouples shall no be located under a heating

6.5 The thermocouple to compensating lead connections shall be a minimum

6.6 Following each heat treatment a minimum of 150mm of wire measured

7.0 THERMOCOUPLE POSITIONS

7.1 The minimum thermocouple arrangements for a particular configuration

7.2 A minimum of one thermocouple shall be fitted to control each

7.3 Confirmatory or gradient thermocouples required by the prevailing

8.0 THERMOCOUPLE COMPENSATING CABLE

8.1 Copper/constantan compensating cable shall be used for extension of the

8.2 The copper lead (+ve) shall be connected to the nickel-chromium

9.0 TEMPERATURE RECORDING.

9.1 Temperatures recorders shall be of the potentiometric self-compensating

9.2 Temperature recorders shall be calibrated at intervals not exceeding 6

9.5 A clear print out of data shall be demonstrated before commencement of a

10.1 Ceramic fibre blanket with a minimum thickness of 19mm and a

10.2 Mineral wool 50mm thick, density 90 kg/m3 may be utilized as an

11.0 PROCEDURE REQUIREMENTS

12.0 DOCUMENTATION & RECORDS.

12.1 The documented information will comprise of the following:

12.1.1 Specific approved heat treatment procedure and/or specification

12.1.2 Details of thermocouple layout, either on specific approved heat

12.1.3 Heat treatment record sheet where appropriate.

12.1.4 Time/Temperature chart fully identified and referenced. The chart

12.1.5 Heat treatment record, where appropriate.

12.1.6 Recorder Test Certificate where appropriate.

13.3 All cable connections shall be properly insulated.

13.4 The component surface shall be free of contaminants.

13.5 Before a Heat Treatment is switched on particular attention shall be paid to

Pad Identity Dimensions Volts Kw

CP 3 -- 75 x 670 60V 2.70kW

CP 4 -- 100 x 500 60V 2.70kW

CP 6 Thick Wall Pad 150 x 330 60V 2.70kW

CP 8 -- 205 x 250 60V 2.70KW

CP10 -- 255 x 205 60V 2.70KW

CP12 Standard Pad 305 x 165 60V 2.70KW

CP15 -- 380 x 145 60V 2.70KW

CP16 -- 410 x 125 60V 2.70KW

CP21 -- 535 x 100 62V 2.70KW