Post Weld Heat Treatment Instruction For Shell Nozzle of Storage Tanks

Correct PO No: ARUP-CN-C-046
ABADAN REFINERY
UPGRADING PROJECT
DOCUMENT .NO :
DOCUMENT TITLE : Cost

Proj PO.No Disc Type Ser. No Rev PAGE 1 of 27
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PWHT PROCEDURE FOR
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CONE ROOF STORAGE TANKS 1071 CNC046 ME VPRC 4101 010 06
Sep -2020
POST WELD HEAT TREATMENT INSTRUCTION

FOR SHELL NOZZLE OF STORAGE TANKS
Approved: Vendor shall issue “AFC”/ ”FIN”

Code1 status.
Approved as noted: Vendor to amend and
Code2 submit the “Issued for Approval” status.
Commented: Vendor to amend and submit
Code3 the “Issued for Approval” status.
Rejected: (vendor to resubmit with same
Code4 revision
The above checking result by Purchaser shall in no way
relieve Vendor of any liability, obligation and responsibility out
of the purchase order and the mutual agreement in writing
Date: 30.Sep.2020
Dept.: ME
Signature: F.Lak
Only for internal review

CV PI EL IN ME MA
ST MC PR SF HV TC
06 29-Sep-2020 FINAL S.E A.Y A.R.Yegane
30 15-Aug-2020 FINAL S.E A.Y A.R.Yegane
02 08-Jan-2019 FINAL S.P A.Y A.R.Yegane
01 01-Jan-2019 ISSUED FOR APPROVAL S.P A.Y A.R.Yegane

00 09-oct-2018 ISSUED FOR APPROVAL S.P A.Y A.R.Yegane
REV. DATE DESCRIPTION PREPARED CHECKED APPROVED
This document belongs to NIOEC and is confidential and shall be used according to provisions of Abadan Refinery Upgrading Project, Islamic Republic of Iran.
Contract No.: 1071/GC-GN/CON/EPC8
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TABLE OF CONTENT
1. Scope ................................................................................................................................................... 4
2. Definition .............................................................................................................................................. 4
3. Applicable, Code, Standards And Specification ............................................................................... 4
4. Preparation .......................................................................................................................................... 4
4.1. Equipment list............................................................................................................................... 4
4.2 Tank preparation .......................................................................................................................... 4
4.3 Thermocouple installation ........................................................................................................... 4
4.4 Heating elements .......................................................................................................................... 5
4.5 Insulation ...................................................................................................................................... 5
5. Post Weld Heat Treatment .................................................................................................................. 5
5.1. Standard........................................................................................................................................ 5
5.2 Notifacation .................................................................................................................................. 5
5.2.1 Before PWHT ................................................................................................................................ 5
5.2.2 Duration of PWHT ......................................................................................................................... 5
5.2.3 After Pwht ..................................................................................................................................... 5
5.3 Heating Operation ....................................................................................................................... 6
5.4 Temperature Measurement .......................................................................................................... 7
6. Hardness test....................................................................................................................................... 8
7. Records ................................................................................................................................................ 8
8. ATTACHMENTS .................................................................................................................................................... 9
8.1 Attachment # 1: ............................................................................................................................................. 9
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1- SCOPE
This Instruction covers the method and requirements for applying local Heat Treatment nozzles of
storage tanks which will be erected by petrosaz Company for Abadan Refinery Project.
2- DEFINITION
The following defines the meaning of specific words used in this document:
Project: Abadan Refinery Upgrading Project, Phase-1

Owner/Employer: National Iranian Oil Engineering And Construction Company (NIOEC)
Purchaser: Consortium Of Sei Co. And ODCC Co.
Vendor: Fara Petrosazan Energy Company
3- APPLICABLE, CODE, STANDARDS AND SPECIFICATION

API 650 Editions 12, 2013 Welded Steel Tanks for oil Storage
ASME SEC. 8, DIV1 The American Society of Mechanical Engineers
Welding procedure
NDE procedure
4- PREPARATION
4-1- Equipment list
- Programmer 6 channel (Brand Name: BATEC)
- Capacitor discharge attachment device
- Recorder 12 canal (Brand Name: CHINO)
- Element ceramic 8x15
- Thermocouples of Type K
- Generator 155 KVA
4-2- Tank preparation

b) All construction works on nozzles and pads include welding; grinding and pneumatic air test
shall be done and completed before PWHT.
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4-3- Thermocouple installation

a) The number and arrangement of thermocouples shown on attached sketch and distance
between each two thermocouples should be in accordance with the standard API 650 and the
opinion of the employer.
b) Equivalent pipe size less than NPS 6 (DN 150) One control zone, with the control
thermocouple at 12 o’clock.
c) Equivalent pipe size NPS 6 (DN 150) up to and including NPS 12 (DN 300) :Two control zones,
with control thermocouples at 12 o’clock and 6 o’clock.
d) Equivalent pipe size NPS 14 (DN 350) up to and including NPS 30 (DN 750): Four control
zones, with control thermocouples at 12 o’clock, 3 o’clock, 6 o’clock, and 9 o’clock.
e) The thermocouples are welded to the tank body by thermocouple welder.
f) Each thermocouple shall be connected to the recorder separately. No connection between
thermocouples is permitted.
4-4- Heating elements

Element ceramic 8x15 will be lain down on weld lines and they support by welded spikes on pad
or shell plates.
4-5- Insulation
a) The insulation material is fiber ceramic with density 128 Kg/m3 and thickness of at least 50 mm
and width of 600mm
b) Soak band (width of the volume of the material where the holding temperature equals or
exceeds the minimum and equals or is below the maximum required):Ð(b) For opening less than
or equal to NPS 4 (DN 100), the soak band shall be 1.5t on each side of the weld at its greatest
width.Ð(c) For opening greater than NPS 4 (DN 100) but less than or equal to NPS 8 (DN 200),
the soak band shall be 6t on each side of the weld at its greatest width.Ð(d) For opening greater
than NPS 8 (DN 200), the soak band shall be 10t on each side of the weld at its greatest
width.ÐHeat band (width of heat source),:Ðhe minimum requirement for the heated-band width
shall be the soak-band width plus 2 in. (50 mm).ÐGradient control band (minimum width of
insulation and/or gradient heat source):Ðhe gradient-control-band width shall as a minimum be
equal to or greater than the heated-band width plus 4t on each side of the weld.
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c) The insulation panel will be kept by welded spike to pad or shell plates.
d) Insulation shall be held in position using steel wires.
When any problem is happened or the work is interrupted in the period of PWHT, the QC inspector
shall be informed. He will evaluate the situation and take necessary remedial action. Details of
remedial action shall be indicated in the PWHT report.
5- POST WELD HEAT TREATMENT

5-1- Standard
Post weld heat treatment will be performed before installation, according to API650 for the nozzles
that require PWHT.
5-2-Notifications
5-2-1- Before PWHT
a) The arrangement and status of equipment shall be checked according to procedure.
b) The release note or check list shall be issued and approved by owner. (Attachment)
c) The calibration certificates shall be submitted for instrument tools.
5-2-2- Duration of PWHT
a) The deformation action of shell shall be controlled during the PWHT.
b) The rate of heating, holding period and rate of cooling shall be controlled and reported.
c) A temperature programmer shall be used to control the heat treatment cycle.
5-2-3- AFTER PWHT

a) The temporary tools and materials should be removed from inside and outside of shell.
b) All temporary attachments shall be removed, smoothened and PT tested.
c) Completed welds of stress-relieved assemblies shall be examined by visual, as well as by
magnetic particle or penetrant methods, after stress relief, but before hydrostatic test. Regard to
method of prefabrication plate assembly, the butt-weld around the periphery of an insert plate or
thickened insert plate that extends less than the adjacent shell course height and that contains
shell openings and their reinforcing elements shall be completely radiographed.
When any problem is happened or the work is interrupted in the period of PWHT, the QC inspector
shall be informed. He will evaluate the situation and take necessary remedial action. Details of
remedial action shall be indicated in the PWHT report.
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5-3- Heating Operation

shell-plate
NO. TANK NO. NOZZLE / OPENING NAME SIZE
thickness
1 M1 24” 14 mm
2 M2 24” 14 mm
3 A2 8” 14 mm
TK-4251
4 B1 16” 14 mm
6 D1 4” 14 mm
7 D2 4” 14 mm
8 B1 12” 14 mm
9 D1 4” 14 mm
6
10 D2 4” 14 mm
TK-4102
11 M1 24” 14 mm
12 M2 24” 14 mm
13 A2 4” 14 mm
All Weld Of Tank In Contact With Process Fluid
14 TK-5101
Shall Be Post Weld Heat Treated Completely
All Weld Of Tank In Contact With Process Fluid

15 TK-5701
Shall Be Post Weld Heat Treated Completely
Note: Nozzles and manholes of TK-4251 & 4102 shall be stress relieved within a temperature
range of 600 °C to 650 °C for 1 hour per 25 mm (1 in.) of shell thickness.
- TK 5101 & 7501shall be stress relieved within a temperature range of 635 ± 14 °C (1,175 ± 25
°F) and hold at that temperature for one hour for each 25 mm (1.0 in), or fraction thereof, of metal
thickness, with a minimum holding time of one hour.
A Until 300°c, heating operation will be done freely and after that, the heating rate should be
controlled and recorded as the following table:
Temperature C
Phase Time Note
Start Finish
O
0 - 0 c 300Oc
1 113 min 300Oc 600Oc
According to API 650
2 85 min 600Oc 600Oc
3 100 min 600Oc 300Oc
4 - 300Oc 30Oc
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Thickness according to API 650 5.7.4 Thermal Stress Relief

5.7.4.1 All flush-type cleanout fittings and flush-type shell connections shall be thermally
stress-relieved as an assembly prior to installation in the tank shell or after installation into
the tank shell if the entire tank is stress-relieved.
The stress relief shall be carried out within a temperature range of 600 °C to 650 °C (1100
°F to 1200 °F) (see 5.7.4.3 for quenched and tempered materials) for 1 hour per 25 mm (1
in.) of shell thickness. The assembly shall include the bottom reinforcing plate (or annular
plate) and the flange-to-neck weld.
5.7.4.3 When the shell material is Group IV, IVA, V, or VI, all opening connections
requiring reinforcement in a shell plate or thickened insert plate more than 13 mm (1/2 in.)
thick shall be prefabricated into the shell plate or thickene insert plate, and the
prefabricated assembly shall be thermally stress relieved within a temperature range of
600 °C to 650 °C (1100 °F to 1200 °F) for 1 hour per 25 mm (1 in.) of thickness prior to
installation.
B The cooling rate should be controlled up to 300oC and after that it is allowed to cool down until
ambient temperature.
5-3-3- Before removing of insulation and PWHT equipment, the effectiveness of PWHT will be
checked by hardness test.
C The maximum difference between highest and lowest temperature in heating time period within
the heated band is 70oc, in holding time is 50°c and in cooling time period within the heated band
is 110°c.
D During the heating, holding time, and cooling, the maximum axial temperature gradient for
PWHT shall be limited such that the temperature at the edge of the heated band shall be no less
than one-half the temperature at the edge of the soak band.
ACCORDING TO API 650 PARAGRAPH 5.4.3 ALL NOZZLE AND MANHOLE CONNECTED TO
SHELL PLATE TO GROUP IV AND V WITH THICKNESS THAN 13mm SHALL BE
PREFABRICATED INTO THE SHELL PLATE OR THICKEN INSERT PLAT AND STRESS
RELIVED BEFORE WELDING TO SHELL PLATE.
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NOTE:
-The radiograph of the bottlenecks, after the completion of the construction process and the
installation on the site, is determined according to the opinion of the employer and NDT map.
- In case of any welding after PWHT, related NDT and PWHT shall be repeated after welding.
Tl: The heating rate should be controlled above it. (oc)

T2: Holding temperature. (oc)
RH: Heating Rate. (oc/hr)
Rc: Cooling Rate. (oc/hr)
Hp: Heating period. (hr)
H : Holding period. (hr)
Hc: Cooling period. (hr)
5-4- Temperature Measurement

a) K-type thermocouples (Nickel chromium type) shall be used for temperature measurement.
b) Thermocouples shall be attached so that a firm metallic contact between the sensing tip and
pad/shell being heat treated is formed, using a capacitor discharge attachment device.
c) A qualified welder shall be used for thermocouples welding and the manufacturer's instruction
should be followed and qualification is not required.
d) Thermocouples shall be placed on outside surface as following sketch, with a Minimum of
thermo cable used for each heating circuit:
e) According to API 650 Editions 12, 2013
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f) Proper insulation shall be applied on the thermo cable joint so that the thermocouples tip is
separated from the heating band.
g) Each recorder shall have constant voltage unit fitted to it in such a way to show a consistent
functioning during heat treatment.
h) Heat treating surfaces shall be free from any oil, grease and metals with low melting
temperature.
i) Damaged or repaired thermocouples shall not be used.
j) Each thermocouple shall be connected to the recorder separately. No connection between
6- Hardness test
hardness of HAZ, BM, WM for caustic storage tank, amine storage tank, sulphur storage tank and
sour water reservoir storage tank shall not exceed 200HBW.
for other services
Hardness of weld metal and the related heat affected zone (HAZ) of all welds shall not exceed 225
Brinell.
7- Records
7-1- Upon completion of the PWHT operation, the subcontractor supervisor shall attach the PWHT
report to the recorder chart and submit them to the QC inspector for review and approval.
7-2- The quality of PWHT is evaluated by hardness test of the weld metal and heat affected zone.
7-3- The record and /or report of PWHT shall include the following information:
- The date of PWHT
- Nozzle no
- Element type
- Time – temperature recorder no
- Number and placement of thermocouples
- Heating and cooling rates
- Holding time and temperature
- PWHT Subcontractor Name.
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- ATTACHMENT 1
CHECK LIST FOR PWHT

PETROSAZ Consultant Owner
No. DESCRIPTION
ACCEPT REJECT ACCEPT REJECT ACCEPT REJECT
1 Welding
2 Attachment
3 Insulation
4 Surface insulation nozzles
5 Thermocouple
6 Burner
7 Fire extinguisher
8 Fuel Tank & Gasoil
9 Access Rode
10 Recorder
11 Generator
12 Stand by Generator
13 PWHT Personal
14 Projector with legs
15 Uncouple anchor chair
16 Permit
17 Punch list
18 Weather report
19 Start Work
Contractor Employer
DATE : DATE :
SIGN : SIGN :
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- ATTACHMENT: Location of Thermocouple Nozzle
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DOCUMENT TITLE:
POST WELD HEAT TREATMENT PROCEDURE FOR

STORAGE TANK (5101 A/B, 7501A/B)
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TABLE OF CONTENTS:
1- SCOPE
2- DEFINITION
3- APLICABLE CODE, STANDARDS AND SPECIFICATION
4- MOBILIZATION
5- PREPARATION WORKS
5-1 Tank preparation
5-2 Assembly and welding works
5-3 Thermocouple installation
5-4 Insulation
6-1 Notification
6-2 Heating
6-3 Temperature controlling
- ATTACHMENT 1: Sample of Thermocouple arrangement

- ATTACHMENT 2: Sample of Check List for PWHT
- ATTACHMENT 3: Check List for PWHT
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1- SCOPE
This Procedure covers the stepwise functions for applying Post weld Heat Treatment on Storage
Tank (5101 A/B, 7501A/B) which will be erected by FARA PETROSAZ Company.
The descriptions of activities in this procedure are intended to be a guideline for the heat treatment
group and shall be detailed in the execution step by them.
2- DEFINITION
The following defines the meaning of specific words used in this document:
Project: Abadan Refinery Upgrading Project, Phase-1

Owner/Employer: National Iranian Oil Engineering and Construction Company (NIOEC).
Purchaser: Consortium of Sei Co. And ODCC Co.
Vendor: Fara Petrosazan Energy Company.
3- APPLICABLE, CODE, STANDARDS AND SPECIFICATION

API 650 Editions 2013
NDE procedure
4- MOBILIZATION
4-1- High velocity burner installation
a- High velocity gasoline burners with suitable capacity shall be employed to heat up the tank.
They install in horizontal manhole of the tank and will be massed fire appropriately into the tank.
For shell protection during the firing, a plate should be installed in front of the flame.
b- In normal conditions, exhaust opening should be on top of the tank that has a hand operated
damper to control the internal pressure and hence the heat distribution in the tank will be steady.
An exhaust opening through which the burner is fired into the shell and should be insulated well.
c. Gasket contact surface of flanges must be protected by resistant paint to high temperature
against oxidation during Post Weld Heat Treatment.
d. For best temperature distribution, an electrical circulator should be installed inside the roof
manhole.
4-2- Gasoline and air pressure systems
A stationary or mobile gasoline tank shall be employed to supply the fuel for burner. The
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containers shall be placed at the safe of at least 10 meters form the tank being heat treated.
Firefighting service must be ready for 15 Hours. During heat treatment electric power with 50
amperes and constant 3 phases shall be provided.
The burner is ignited by electric spark and, a centrifugal fan supplies the combustion air to the
burner. The air supply to the burner is manually adjusted by a graduated butterfly valve.
4-3- Other responsibilities

a) Review and submit equipment & tools arrangement on tanks includes burners, exhaust
openings, thermocouples and other detail as requirement by owner.
b) Review and submit recommendation for prevent and picket of tanks distortion duration of
PWHT.
c) Temporary bracing/column shall be considered for prevent distortion of tanks according
engineer recommendation.
d) The bottom movement shall be monitored duration of PWHT.
e) The roof structure shall be allowed to movement duration of PWHT with using of slot holes on
clip or rafters.
5- PREPARATION WORKS
5-1- Tank preparation

a) All bolts and nuts should be changed with temporary pieces.
b) The shell & roof of tanks shall be braced and supported duration of PWHT according to
engineer recommendations.
5-2- Assembly and welding

a) All accessories that connected to the tanks body should be assembly and welded before
PWHT.
b) All repair works on tank body include welding and grinding activities shall be done before
PWHT.
c) The some parts such as anchor chair, steam coil, bolt & nut shall be erected after PWHT.
d) After completion of welding works, the tanks shall be pressurized by air for leakage test.
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5-3- Thermocouple installation

a) Per-selected areas of the insulating blanket should be cut out and removed to expose an area
of the tank body of 20*20 mm at these places, and thermocouples will be welded on the tank.
b) The arrangement, distribution and number of thermocouples shall be specified for each tank,
distance between each two thermocouples should be 4.5 meters (l5feet).
c) On vertical face of the tank, none of the thermocouples on neighbor sections should be on the
same line and should be in 60° diverse by each other.
d) The thermocouples are welded to the tank body by thermocouple welder.
e) Damaged or repaired thermocouples shall not be used.
f) Each thermocouple shall be connected to the recorder separately. No connection between
5-4- Insulation
a) Before erection start of (5101 A/B, 7501A/B), the insulation material shall be lay down under
bottom plates and protected up PWHT completed.
b) The main insulation material is Mineral Wool .The density of them shall be 128 Kg/m 3 with
thickness of at least 70 mm after compellation the inside bottom insulation.
c) Total surface of tank (including bottom) shall be insulated, as well as tanks must be completely
enclosed with insulating material.

6-1- Notifications
Before PWHT
a) The arrangement and status of equipment shall be checked for ability, quantity and quality.
b) The release note or check list shall be issued and approved by owner. (Attachment 2)
c) The calibration certificates shall be submitted for instrument tools.
d) Tools & equipment’s of PWHT should be pre-operating for a tentative cycle.
e) The flange face shall protect against of heat or direct fire.
Duration of PWHT
a) The deformation action of tank shall be controlled during the PWHT on bottom and top of tank.
b) The heat up period and the rate of heating of the tank is controlled by manual adjustment of the
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flame intensity. The cooling rate is again controlled by manual adjustment of the firing rate. As an
alternative to the above mentioned controlling operation, a temperature programmer shall be used
to control the heat treatment cycle.
AFTER PWHT
a) The temporary tools and materials should be removed from inside and outside of thank.
b) The jig trace shall be tested by MT or PT for %5 of total points.
c) Pad plate shall be considered for connection of all temporary supports / bracings and lifting
lugs. These pads will not be removed after P.W.H.T.
6-2- Heating
a) Heating and cooling rate in 50oc/hr (divided by the maximum metal thickness of the plate in
inches, or fraction thereof, of metal thickness, but in no case more than 50°C/hr), maximum
difference between highest and lowest temperature in heating step is l30oc, in socking time is 30°c
and in cooling step is 60°c.
b) During the heat treatment process appropriate precautions shall be considered for protection of
stainless steel parts from heating.
c) Heat treating surfaces shall be free from any oil, grease and metals with low melting
temperature.
D) During heating from 300oC & during cooling up to 300oC, the tank shall be lifted and kept by
crane according to attachment 1 & 2.
6-3- Temperature controlling

6-3-1- By 300°c heating rate may be done freely and after that, heating rate should be controlled
and recorded as the following table:
Phase Time Starting time Finishing time Note

0 - 30°C 300°C Heating and cooling rate is
50°c/hr divided by the
1 360 min 300°C 635 ± 14 °C maximum metal thickness of
the plate in inches, or fraction
2 60min 635 ± 14 °C 635 ± 14 °C thereof, of metal thickness, but
3 360min 635 ± 14 °C 300°C in no case more than
50°C/hr.ÐFrom or up to 300°C
4 - 300°C 30°C controlling is not needed.
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5-3-2- On completion of heat treatment operation the tank is allowed to cool down until ambient
temperature and after this stage, the insulation may be removed.
Note: TK 5101 & 7501shall be stress relieved within a temperature range of 635 ± 14 °C (1,175 ±
25 °F) and hold at that temperature for one hour for each 25 mm (1.0 in), or fraction thereof, of
metal thickness, with a minimum holding time of one hour.
Tl: The temperature that heating rate should be controlled above it. (oc)
T2: Holding temperature. (oc)
RH: heating Rate. (oc/hr)
Rc: Cooling Rate. (oc/hr)
Hp: Heating period. (hr)
H: Holding period. (hr)
Hc: Cooling period. (hr)
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- ATTACHMENT 1: SAMPLE OF Thermocouple arrangement
T1, T2, T3 & T4 Around of the bottom

T5, T6, T7 , T8 , T9, T10, T11 & T12 middle of the tank
T13, T14, T15, T16 & T17 Near of the roof
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- ATTACHMENT 2: SAMPLE OF LIFTING METHOD
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- ATTACHMENT 1
CHECK LIST FOR PWHT

PETROSAZ Consultant Owner
No. DESCRIPTION
ACCEPT REJECT ACCEPT REJECT ACCEPT REJECT
1 Welding
2 Attachment
3 Insulation
4 Surface insulation nozzles
5 Thermocouple
6 Burner
7 Fire extinguisher
8 Fuel Tank & Gasoil
9 Access Rode
10 Recorder
11 Generator
12 Stand by Generator
13 PWHT Personal
14 Projector with legs
15 Uncouple anchor chair
16 Permit
17 Punch list
18 Weather report
19 Start Work
Contractor Employer
DATE : DATE :
SIGN : SIGN :
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Post Weld Heat Treatment Instruction For Shell Nozzle of Storage Tanks

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