GENERAL PROCEDURE Document Number

FOR GMS-SG-PR-M-005
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT TREATMENT OF
Revision: 0 Status: IFA
BUTT WELD IN CARBON STEEL PIPE WORK
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 1-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE Page 1 of xx

ENGINEERING, PROCUREMENT &

CONSTRUCTION (EPC)

GAS METERING STATION PROJECT

PROCEDURE

GENERAL PROCEDURE
FOR
LOCALIZED ELECTRICAL RESISTANCE POSTWELD
HEAT TREATMENT OF BUTT WELDS IN
CARBON STEEL PIPE WORK

Issued Checked COMPANY

Rev. Status Date Revision Memo Approved by
by by Approval
26-Nov-
0 IFA Issued For Approval PS AS AGF
2010
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 26-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 2 of 12

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 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 26-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 3 of 12

CONTENTS

SECTION TITLE PAGE

1. SCOPE

2. REFERENCE

3. APPLICATION

4. METHOD

5. ARRANGEMENT OF ELEMENT

5.1. PIPE TO PIPE WELDS

5.2. PIPE / FLANGE WELDS

5.3. PIPE TO BRANCH WELDS

5.4. COMPLEX GEOMETRY

5.5. GENERAL

6. TEMPERATURE CONTROL

7. TERMOCOUPLE

8. THERMOCOUPLE POSITION

9. TERMOCOUPLE COMPENSATING CABLE

10. RECORDERS

11. INSULATION

12. PROCEDURE REQUIREMENTS

13. DOCUMENTATION
ATTACHMENT
BUTT WELDS BETWEEN PIPES OF EQUAL THICKNESS

PIPE TO BRANCH WELD

JOB SAFETY ANALYSIS (JSA)

 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 26-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 4 of 12

1. SCOPE

1.1. This procedure states explicitly in detail the minimum requirement for the
external load, Post Weld Heat Treatment (PWHT) shall be carried out by the
electrical resistance method for vessels, nozzles, pipes & exchanges.

1.2. This procedure covers description of the equipment, method of heating,

location and type of heating elements temperature measurement and
thermocouple location.

2. REFERENCE
Unless stated otherwise all codes and standards referenced in this
procedure shall be of the latest issue (including revisions – addenda and
supplements) and the following documents shall be referred to along with
this procedure.
a) ASME Section VIII Division 1 - Boiler & Pressure Vessels code.
b) ASME B31.3 - Chemical Plant and Petroleum Refinery Piping.
c) ASME B31.4 - Liquid Petroleum Transportation Piping Systems.
d) ASME B31.8 - Gas Transmission and Distribution Piping Systems.
e) Spesification for Welding – DOC. NO. GL – SP – Q – 064 Rev. 0
f) Spesification Welding Procedure – 003/WPS/SAE/ASME IX/2010.

3. APPLICATION

External local post-weld heat treatment of pipe butt welds for temperatures
up to 650°C, in carbon steel (P-No. 1 material), to meet the requirements of
ASME 831.3 -'Specification for Chemical Plant and Petroleum Piping'.

4. METHOD

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

pads of standard rating 2700 watts, 60 volts.
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 26-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 5 of 12

5. ARRANGEMENT OF ELEMENT

5.1. PIPE TO PIPE WELDS

5.1.1. The heating elements shall be fixed symmetrically about the centerline of
the weld seam, either as a single band or as two discrete bands. Post weld
heat treatment in the specified temperature range (for the entire pipe
section, and 25mm beyond the edges of the weldment) will be achieved by
the application of a total heated zone of minimum width 7t. (t = wall
thickness at weld, in mm.

5.1.2. 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 a wall thickness below 10mm, the maximum gap shall be
10mm

5.1.3. Longitudinal gaps between individual elements shall be limited to 50mm or

't, whichever is the lesser, for thicknesses above 10mm. For a wall thickness
below 10mm, the maximum longitudinal gap shall be 10mm.

5.1.4. 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.

5.1.5. Where the wall thickness of the two joint members differs, the elements
shall be arranged so as to give side to side temperature control in addition to
circumferential control.

5.2. PIPE / FLANGE WELDS

5.2.1. Pipe/flange welds shall be heat treated in accordance with the general
principles of butt welds between pipe members of unequal thickness, i.e, the
provision of independent control circuits each side of the weld

5.2.2. If necessary, an additional band of heating elements shall be applied to

the outside diameter of the flange to compensate for heat losses.
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 26-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 6 of 12

5.3. PIPE TO BRANCH WELDS

5.3.1. The heating system to be applied to the main pipe member shall comprise
a full circumferential zone extending for a minimum distance each side of
the branch 3.5 x t-, (t, = thickness of main pipe member).

5.3.2. The heating system applied to the branch shall comprise an independent
circumferential band extending for a minimum distance of 3.5 x t; down the
branch pipe. (t2 = thickness of branch).

5.3.3. Gaps shall be limited insofar as is practicable with respect to pipe attitude
and dimensions as detailed under Section 3.1 and 3.2, as shall instructions
for independent control of heater circuits.

5.4. COMPLEX GEOMETRY

5.4.1. Special procedures shall be raised for the PWHT of butt welds more
complex than those otherwise defined under paragraph 3.

5.5. GENERAL

5.5.1. Elements shall be securely fixed in contact with the work piece by soft iron
wire, stainless steel banding tape, or mild steel banding tape to suit the
application.

5.5.2. Heating elements shall be thoroughly examined before use in order to

ensure that the element wire is not exposed. Examination to be made for
broken beads in either the pad or the leads. “Twistlok” connections should
also be examined to ensure that the insulation is sound, and that a good
electrical joint is made

5.5.3. 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.
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 26-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 7 of 12

6. TEMPERATURE CONTROL

Each circuit of heating elements shall be controlled by a contactor. In turn

this circuit shall be controlled by one of the following systems:

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

percentage time/energy regulator. The set-point temperature controller shall
be employed to ensure correct temperature control during the soaking
period.

6.2. An automatic pre-set programmed control unit, to control automatically the

heat treatment throughout its cycle.

6.3. No single control zone will comprise more than three heating elements. All
elements in anyone control circuit shall have the same nominal power
density rating (watts/m2).

7. THERMOCOUPLE

7.1. Thermocouples shall be made from nickel-chromium nickel aluminum wire

to 8S4937 Parts 4 and 20, or equivalent. Certification shall be made
available for each reel of wire utilized, and shall indicate a tolerance of less
than ±0.75% throughout the temperature range 400°C to 800°C.

7.2. Thermocouples shall be attached to the work piece by the direct wire
capacitance discharge method in accordance with Procedure HTP009. The
gap between the two wire/work piece junctions shall not exceed 5mm.

7.3. Care shall be taken to ensure that the thermocouple conductor wires do
not touch each other, or metallic components, away from the hot junction.

7.4. Thermocouple hot junctions shall be protected by the application of a

minimum 5mm layer of high temperature putty, applied locally.

7.5. Wherever possible, thermocouples shall not 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.

7.6. The thermocouple to compensating lead connections shall be a minimum

of O.5m from the heated zone.
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 26-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 8 of 12

7.7. Following each heat treatment a minimum of 150mm wire measured from
the hot zone, shall be discarded.

8. THERMOCOUPLE POSITION

8.1. The minimum thermocouple arrangements for a particular configuration

shall be as shown in Figure 1, and 2. Additional thermocouples shall be
fitted where required for control purposes.

8.2. 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 systems (and may coincide
with the mandatory thermocouples), and at a distance of 1% x t from the
weld centerline, for non symmetrical heating systems. Furthermore, they
shall be located at the mid-position of each element circuit.

9. THERMOCOUPLE COMPENSATING CABLE

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

thermocouple to the recording instrument.

9.2. 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-aluminum conductors (magnetic).

10. RECORDERS

10.1. Temperature recorders shall be of the potentiometric self compensating

type, calibrated in degrees Celsius with respect to a nickel-chromium nickel-
aluminum thermocouple, Type K.

10.2. Temperature recorders shall be calibrated at intervals not exceeding 6

months. The calibrations shall be recorded and evidence to this effect kept
with the instrument. The Calibration Certificate must show both the 'as
found' and 'as left' conditions of the instrument. Instruments utilized for a
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 26-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 9 of 12

calibration purposes shall carry certification traceable to a National Standard

and shall themselves be calibrated at intervals not to exceed 12 months.
Such instruments shall exhibit accuracy within ±1°C of the recognized
standard.

10.3. 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, and specified in the
heat treatment procedure, then full details of the welds involved shall be
reported to the inspecting authority.

10.4. The chart speed shall be set at 50mmlhour or other agreed standard and
shall be checked during calibration. No artificial restriction on pen travel shall
be used.

11. INSULATION

11.1. Ceramic fibre blanket, 25mm thick, shall be provided for the purpose of
insulation.

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

alternative where approved by the Engineer.

11.3. Insulation shall extend for a minimum distance of 300mm beyond the
outer edges of the heated zone, or as may be practicable.

11.4. The number of layers may be adjusted to meet the variations of wall
thickness, pipe diameter, gradient requirements and site conditions.

11.5. Wherever possible, pipe ends shall be blanked off internally before heat
treatment to limit convection effects.

12. PROCEDURE REQUIREMENTS

12.1. The weld subject to heat treatment shall be raised uniformly to a '. 'hold
temperature in the range 593-649°C, and held in this range for a minimum
period of 60 minutes per inch of nominal wall thickness, or for a period of 60
minutes, whichever is the greater. The governing thickness shall be that of
the thicker component measured at the joint, except as detailed under
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 26-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 10 of 12

paragraph 331.1.3 of the standard ASME 831.3.12.2 After completion of the

soaking period, the weld may be cooled under insulation. Insulation may be
removed when all thermocouples register a temperature below 150°C.

12.1.1. Heating Process

From ambient to 350°C shall be unrestricted from 350°C to

soaking/holding temperature heating rate 200°C/hr divided by
material thickness.

12.1.2. Cooling Process

Shall be 150°C/hr divided by material thickness from 350°C to

ambient shall be by air cooling.

12.2. HARDNESS TEST PROCEDURE

Hardness Tests. Hardness tests of production welds and of hot bent and
hot formed piping are intended to verify satisfactory heat treatment. The
hardness limit applies to the weld and to the heat affected zone (HAZ)
tested as close as practicable to the edge of the weld.

12.2.1. Where a hardness limit is specified in Table 331.1.1, at least 10% of

welds, hot bends, and hot formed components in each furnace heat
treated batch and 100% of those locally heat treated shall be
tested.
12.2.2. When dissimilar metals are joined by welding, the hardness limits
specified for the base and welding materials in Table 331.1.1 shall
be met for each material.

13. DOCUMENTATION

13.1. The temperature chart shall be fully identified and referenced with respect
to the thermocouple/trace arrangement. The chart shall also identify the heat
treatment temperature specification chart speed, date(s) and time(s).

13.2. The name(s) of the technician(s) shall accompany the chart.

13.3. Reference shall be made to the client, weld identity and where possible
the drawing number.
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 26-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 11 of 12

13.4. A sketch shall accompany the chart to indicate the thermocouples

positions and heating arrangement.

13.5. Any discrepancy shall be reported.

ATTACHMENT

BUTT WELDS BETWEEN PIPES OF EQUAL THICKNESS

NOTE : 5.1
1. For D < 2” T/C 2 only required.
2. For 2” < D < 10” T/C 1 & 2 only required.
3. For 10” < D < 20” T/C 1, 2 & 3 equispaced.
4. For D > 20” T/C 1 to 4.
5. Additional thermocouples to fitted at centreline.

NOTE :
1. For D < 2” T/C 2 only required.
 GENERAL PROCEDURE Document Number
FOR GMS-SG-PR-M-004
LOCALIZED ELECTRICAL RESISTANCE POSTWELD HEAT Status:
Revision: 0
TREATMENT OF BUTT WELD IN CARBON STEEL PIPE WORK IFA
Document Type: PR System / Subsystem: 00 Discipline: Q Rev. Date: 26-Nov-2010
CONTRACTOR Document: 21119 – PT. SAE-BPK Page 12 of 12

2. For 2” < D < 10” T/C 1 & 2 only required.

3. For 10” < D < 20” T/C 1, 2 & 3 equispaced.
4. For D > 20” T/C 1 to 4.
5. Additional thermocouples to fitted at 1.5 t1 & 1.5t2.

Figure 1
PIPE TO BRANCH WELDS

NOTES :
1. Additional Thermocouple may be fitted on rows A, B, C & D as required for
control purposes.
2. For D1 < 2” T/C 2, 3 & 4 not required.
3. For 2” < D1 < 10” T/C 3 & 4 not required.
4. For 10” < D1 < 20” T/C 4 not required.

Figure 2