Document No:- 9560/NBEL/SITE/QAC/027, REV.

PROJECT : 500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations

LOCATION: 10th of Ramadan City, Industrial Area A1, Egypt

CLIENT EPC CONTRACTOR

SPREA MISR NUBERG ENGINEERING LIMITED

DOCUMENT TITLE

JOB PROCEDURE FOR PWHT OF STORAGE TANKS

DOCUMENT NUMBER

9560/NBEL/SITE/QAC/027, REV.0

Document Category Document Review Status (by Owner/PMC)

(Submission Purpose)
Approval ☐ 1. Approved / Reviewed
☐ Review ☐ 2. Approved / Reviewed with comments as marked
☐ Information ☐ 3. Not Approved / Resubmit
☐ FOR REVIEW AND
Implementation ANAND
00 ☐ R. Retained for Information / Records
ASHWANI RAJEEV SHARMA
APPROVAL SHARMA
TYAGI
Date: ___/____/____ Name: ____________________
Rev Checked By
Date DocumentThis
Status
approval doesPrepared
not absolve the ByContractor from meeting their contractual obligations
Approved By a
of delivering
. complete, safe and efficiently operating units/facilities meeting all requirements of the contract
 Document No:- 9560/NBEL/SITE/QAC/027, REV.0

JOB PROCEDURE FOR PWHT OF STORAGE TANKS

CONTENTS

1. SCOPE

2. PURPOSE

3. RERENCE

4. GENERAL DESCRIPTION

5. STRESS RELIEVING HEAT TREATMENT SPECIFICATION

6. TEMPERATURE MEASUREMENT

7. HEATING SYSTEM

8. ELECTRIC SUPPLY

9. TEMPERATURE MEASUREMENT CABLE

10. THERMOCOUPLE & COMPENSATING CABLE

11. TEMPERATURE RECORDING

12. TEST PROCEDURE

13. SAFETY PROCEDURE

14. DOCUMENTATION

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 Document No:- 9560/NBEL/SITE/QAC/027, REV.0

JOB PROCEDURE FOR PWHT OF STORAGE TANKS

1. SCOPE

This test procedure shall be carried out to PWHT for Storage Tank

2. PURPOSE

The purpose of this procedure to reduce Stresses from Storage Tank.

3. REFRENCE

a) API 650
b) Drawing
c) NBEL ITP-9560/SITE/QAC/022/ITP-13

4) General Description

Material of Tank : IS 2062 Gr E 250 80

No of Thermocouples shall be used : 12 No s per Cycle
Placed of T/C’S : All Equally distributed or as per NBEL/Client/TPI
Minimum & Maximum Temp : AMBIENT & 620 0 C

Stress Relieving is called for Caustic Service Vessels and is conducted by electrical resistance
heating method. This method has gained wide acceptance as the thicknesses involved are less and
there is always a chance of kinking or buldge. The caustic tank shall be placed on a stress reliving
bed which means the tank is placed on wool and is insulated properly to avoid heat losses. General
arrangement of Stress Reliving is depicted in the attached sketch.
‘K’ type Chromel/Alumal thermocouples are attached in such a way that all the area of the tank are
covered and by equally distributing the thermocouples. Control and temperature monitoring is
achieved using these thermocouples connected to recording instrument.

The temperature distribution. Obtained by this method of stress Relieving is within the standard
cods API – 650.

5) Stress Relieving Heat Treatment Specification

Unrestricted heating from ambient up to 300 o c.

Restricted heating from 300 oc. at 100oC /Hr. max. With a temperature differential not more than 100
C between two thermocouples.

Soaking temperature : 620 0 C ± 100 C

Soaking period : 1 (one) Hour

Restricted cooling rate 100 oC / Hr (max) up to 300 o C

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 Document No:- 9560/NBEL/SITE/QAC/027, REV.0

JOB PROCEDURE FOR PWHT OF STORAGE TANKS

6) Temperature Measurement:

Calibrated thermocouples shall be attached on the tank by stitch welding. Meeting the code
requirement. Temperature shall be monitored by a calibrated time temperature chart/recorder.

7) Heating System:

The stress relieving operation shall be affected by using sufficient finger type porcelain beads
insulated Nicrome heating element. The whole exterior of the tank shall be covered completely with
96 density ceramic blanket (1” thick) or mineral wools 75 mm. thickness, 120 Kg/Cu.M The
insulation/blanket is capable of withstanding temperature up to 900 o C. Before placement of tank on
bed leveled ground or elevated platform/ support. One layer of insulation/blanket on the ground /
elevated platform. Before commencement of heat treatment all gaps in insulation are plugged with
loose insulation material. Back up heating is kept stand by to avoid any harmful temperature
gradient.

8) Electrical Supplies:

1) 200 KVA, 2 no DG set mobilize for PWHT.

9) Temperature measurement:

Thermocouples shall be made from pickle chromium/ Nickel – Aluminum wire to BS4937 part 4.
ANSI MC 96.1 Type K or other approved equivalent. A certificate of conformance may be made
available for each reel of wire used and shall indicate a tolerance of less than + 0.75% throughout
the temperature range of 400 to 800 C.

Thermocouple shall be attached to the vessel by tacking in an approved manner. Care shall be
taken to ensure that the thermocouple conductor wires do not touch each other or metallic
components. Away from the hot junction. The thermocouple to compensating lead connections shall
be a minimum 0.3 Mtrs. From the heated zone.

10) Thermocouple & Compensating cable:

Copper/Constant compensating cable shall be used for extension of the thermocouple to the
recording instrument. The copper lead (+ve) shall be connected to the nickel – chromium conductor
of the thermocouple (non – magnetic) and the constant lead (-ve) shall be connected to the nickel –
aluminums conductor (magnetic)

11) Temperature Recording;

Temperature recorders shall be calibrated in degree Celsius with respect to a nickel – chromium /
nickel-aluminum thermocouple, type ‘K’. Temperature recorders are calibrated at an internal not
exceeding 6 months. Should be calibration checks with information that the temperature recorder is
not within the manufacture‘s specified tolerances (i.e., +0.25% of full
Scale deflection). Recalibrations are performed. The calibrations shall be recorded and evidence to
this effect kept with the instrument. Instruments utilized for calibration purposes shall have
certification traceable to a National Standard and shall themselves be calibrated at intervals not
exceeding 12 months.

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 Document No:- 9560/NBEL/SITE/QAC/027, REV.0

JOB PROCEDURE FOR PWHT OF STORAGE TANKS

In the event that the calibration check reveals that the instrument has been used with an error
which would have led to the measured temperatures being outside the permitted tolerances as
specified in

heat treatment procedure, the full details of the thermocouples involve shall be reported to the
inspecting authority.

The chart speed shall be set at 20 mm/hr. and shall be checked during calibration. No artificial
restriction on pen travel shall be used.

12) Test Procedure:

Temp. Measurement system:

All thermocouples/ compensating cables circuits are to be checked for continuity prior to
commencement of starting electrical heaters. Immediately after starting heaters all
thermocouples are to be checked for correct polarity. As temperature control is very critical the
current are adjusted automatically by using auto panel. Sub-Contractor supervisor will monitor
the temperature constantly and actual process will be attended 24 hours basis.
Sub-Contractor Project Staffed as follows:
Senior technician = 2 No s
Assistant Technician = 3 No s

Senior site technician shall be site in charge and will coordinate with client and inspection
authority our assistant site technicians will operate the Heaters and will the process.
13) Safety Procedure:

All equipment shall be fully maintained and tested prior to dispatch to site, this shall include the
calibration of recorders and furnace. Senior Site Technician shall be designated as acting safety
officer.
Our safety officer will ensure:
i) All test certificates are up-to-date and valid.
ii) All equipment provided for the control is in god working order. Properly maintained and
suitable for the purpose of the intended works.
iii) All personnel deployed on the contractor fully conversant with safety rules and policies.
iv) All Personnel are issued with appropriate safety wear and personnel protection.
v) An necessary work permits are obtained at appropriate advance time.
Safety officer shall be authorized to enact all necessary disciplinary action in the event of
such breach of Safety Rules by personnel at site.

14) DOCUMENTATION:

Following documents shall be submitted to the client on completion of job:

i) PWHT Chart
ii) Hardness Readings
iii) Recorder Test Certificate
iv) Thermocouple wire calibration certificate.

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