IXAR-PECI-OQM-PWHT-05 Rev. 01

Industrial X-Ray & Allied Radiographers S.P.C.
P.O. Box 3130, P.C.111, CPO, Sultanate of Oman

Tel: +968 22078883, 24541291, Fax:+968 24541281
Email: ixaroman@gmail.com
PRE-HEATING & POST WELD HEAT TREATMENT EXAMINATION PROCEDURE
Procedure No: : IXAR-PECI-OQM-PWHT-05 Rev. 01 Page No.: 1 of 25
PROJECT OQ Methanol & Ammonia TA works 2023

CLIENT OQ
CONTRACTOR PEC INTERNATIONAL LLC
LOCATION OQ Downstream Plant, Salalah
Venkata Rao K Babu Patwekar

1 13/09/2023
ASNT NDT Level-II ASNT NDT Level-III
Venkata Rao K Babu Patwekar
0 05/08/2023
ASNT NDT Level-II ASNT NDT Level-III
Prepared by Reviewed by Reviewed Approved by

Rev. Date
IXAR IXAR PECI OQM
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Procedure Revision Status

Revision Date Description of Revision
0 05/08/2023 For approval
1 13/09/2023 Clients Comments Incorporated
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TABLE OF CONTENTS
Description Page No.

Cover Page 1
Procedure revision status 2
Table of contents 3
1.0 Purpose 4
2.0 Scope 4
3.0 References 4
4.0 Definitions 4
5.0 Abbreviations 5
6.0 Personnel Qualification 5
7.0 Procedure Qualification 5
8.0 Equipment 5
9.0 Placement Of Heating Elements 6
10.0 Thermocouples 6
11.0 Thermocouple Extension Cable (Compensating Cables) 8
12.0 Thermal Insulation 8
13.0 Temperature Records 10
14.0 Temperature Control System 10
15.0 Post weld heat treatment (PWHT) Cycle 11
16.0 Precautions 14
17.0 Pre Heating 14
18.0 Documentation 19
19.0 Safety 19
Attachment-1 Thermocouple location (monitoring and control zone) 21
Attachment-2 Post Weld Heat Treatment Report 25
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1.0 Purpose:
The purpose of this procedure is to define the requirement of the Pre Heating & Post-Weld
Heat treatment of butt welds in low pressure process piping, high pressure process piping,
and power piping, to be fabricated and installed for M&A TA2023 in OQ Downstream Plant,
Salalah, Oman.
2.0 Scope:
This procedure specifies the minimum requirements for Pre Heating, Post-Weld Heat
Treatment for all configurations and wall thickness by the electrical resistance method.
3.0 References: 1
1 ASME B31.3, 2022 Edition Process Piping

2 ASME B31.1, 2022 Edition Power Piping
3 ASME Section I , 2021 Edition Rules for Construction of Power Boilers
4 7S72-PIS-00-009 Rev.1 General Specification For Piping ( Amendment)
5 645295-0000-46EF-0001 Rev.1 Piping and Fabrication Installation and testing
6 645295-0000-46EF-0005 Rev.1 Construction/Installation Specification Welding & NDE
7 645295-C00101-0079-02-Rev.2 Ammonia Painting Specification
4.0 Definitions:
Term Definition
Client End User
Any private or public entity responsible for Detailed Engineering and
Contractor Design, Procurement, Construction and (pre-) Commissioning of this
project
A construction contractor is responsible for the day-to-day oversight of a
Construction
construction site, management of vendors and trades, and communication
Contractor
of information to involved parties throughout the course of a project.
Person or entity to whom/which the Contractor subcontracts any part of the
Sub-Contractor
service.
Shall Is to be understood as mandatory.
Project An individual or collaborative enterprise that is carefully planned and
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designed to achieve a particular aim.

Should Is to be understood as strongly recommended.
May Be Is to be understood as giving a freedom of choice.
5.0 Abbreviations:
NDT Non-Destructive Testing

ASME American Society of Mechanical Engineers
ASTM American Society of Testing and Materials
ASNT American Society of Non-Destructive Testing
BPV Boiler & Pressure Vessels
ISO International Organization for Standardization
SP Specification
PWHT Post Weld Heat Treatment
HT Hardness Test
AC Alternating Current
IXAR Industrial X-Ray & Allied Radiographers LLC
6.0 Personnel Qualification:
Although not essential formal related electrical qualification, apprenticeship shall be beneficial
for personnel undertaking on site heat treatment.
Only operators, familiar with the Post Weld Heat Treatment of welded joints shall perform the
PWHT.
7.0 Procedure Qualification:
Procedure Qualification test shall be performed in the presence of Company Authority to meet
the requirement of the referencing Code, before starting of the work.
The testing of WPS/ Welder qualifications may be used for PWHT procedure qualification.
8.0 Equipment:
The power generators shall be portable type 380 / 415 / 440V 3 phase, 65V secondary with
built in 6-way control modules.
Temperature regulators are automatically controlled and the temperature rise, soak & cooling
temperature shall be regulated with this unit.
The recording of the temperature is achieved by means of temperature v/s time plotters in the
calibrated chart type temperature recorder.
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The heating elements shall be insulated with ceramic beads and free from direct contact with
the material surface.
Certification should be provided for the calibration of heat treatment equipment that has been
obtained within the previous 6 months.
9.0 Placement of Heating Elements:
Heating elements shall be arranged over the weld seams so that the width of the band is not
less than 2.5√RT. Refer Figure 1.
For Nozzle welds and flanges welds sufficient heating elements shall be used to prevent loss
of temperature due to atmosphere interference.
For Pipe diameter more than 8” the heating elements shall be divided into two or more control
zones.
The heaters shall be set so that the gap between them is not more than the thickness of the
plate or 2” whichever is the lesser.
The heating elements shall be held together by means of banding strap or steel wire, so that
the overlap between adjacent heaters are not more than 1”.
Supplementary requirement for PWHT for the welded joint on a welded valve without pup
pieces
Ensure heating element is wrapped only on the welded joint which require PWHT (elements
should not be wrapped over the valve body).
Ensure only one joint at a time completes the PWHT cycle.
An additional thermocouple to be placed on to the valve body to monitor/ record the maximum
heat the valve body receives during the PWHT cycle.
10.0 Thermocouples:
Unless otherwise specified, thermocouple attachments should be capacitor discharge

connections or nuts and bolts. If the latter method is used, the materials should be of a
compatible composition and treated as a temporary attachment. Other type of thermocouple
attachments may be used approval of principle.
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All Thermocouples shall be of the nickel-chromium/nickel-aluminum, Type K. All

Thermocouples / Thermocouple wire shall be supplied with a valid certificate of conformance.
The thermocouples shall be fixed by wire capacity discharge method by using TC welding
unit.
If the Nut Bolt construction is used, the material should be of a compatible composition. The
Nut tack weld metal shall be removed by careful dressing following by MPI or DPI
examination after heat treatment to confirm omission of linear indications. The wires shall be
fixed to the work piece in such a way that the ends shall be at distance less than 5mm.
To enhance the mechanical strength of the Thermocouple hot-junction, chloride-free high

temperature cement / putty shall be applied to the hot junction.
The Thermocouple to thermocouple extension cable junction shall be kept clear from the
heated zone.
Monitoring Thermocouples- Monitoring thermocouples shall be placed to ensure 1

that all of the parameters specified to control the local heating operation are being achieved.
They shall be placed to measure the maximum and minimum anticipated metal temperatures.
To achieve this, thermocouples shall be placed at the centerline of the weld, the edge of the
soak band, and the edge of the heated band. These shall be located as described in
Attachment-1. There shall also be at least one thermocouple, either control or monitoring,
located under each heating pad.
A minimum of one thermocouple shall be applied per control zone. Additional TCs shall be
provided if specified by client.
The Thermocouple positions shall be identified in temperature chart. The following table shall
be used for TC distribution & locations.
The minimum number of thermocouples to be used shall be as per the list given below.
Thermocouples shall be equally placed around the weld circumference 25mm from the weld
to ensure that the heated circumferential band will extend at least 25mm beyond the weld on
either side.
Thermocouple location shall be (monitoring and control zone) as per either AWS D10 Clause 1
8.4.3 or ASME Section I , Edition 2021 Appendix VIII , Figure VIII-6.3.4-1, Figure VIII-6.3.4-2,
Figure VIII-6.3.4-3, Figure VIII-6.3.4-4 (Refer Attachment-1)
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Clock Position 1
Pipe Dia No. of T/C
Below 4” 1 6 & 12
4” to 12” 2 6 & 12
Above 12” 4 3,6,9 &12
11.0 Thermocouple Extension Cable (Compensating Cables):
Copper-Constantan compensating cables shall be used.
The Copper Lead (+ Ve) shall be connected to the nickel chromium conductor (non-magnetic)
and the Constantan lead (-Ve) to the nickel aluminum conductor (magnetic)
Care shall be taken to ensure that the compensating cable is not subject to:
A direct or indirect heating sources
Electrical Interference
Mechanical damage
12.0 Thermal Insulation:
The insulation consists of mineral wool wrapped around Heating Element and then covered
with a layer of Ceramic Blanket on entire length of heating zone.
The insulation shall extend a minimum distance of 300mm beyond the outermost edges of the
heated band.
The number of layers applied and extent is dependent on wall thickness, pipe diameter,
gradient requirements and site conditions. The overall width of insulation shall be minimum
5√RT. (R = Radius & T = Thickness)
Wherever possible, pipes / vessels open ends shall be blanked off before heat treatment
commences.
The insulation shall be bound with black annealed iron wire
The total insulation covering will be such to provide minimum heat loss.
Temperature crayons shall be used to ensure that the temperature do not exceed 3000 C at
any nearest point beyond insulation covering.
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Width of Band Heating

1
ASME B31.3,Clause 331.2.6, Edition ASME B31.1,Clause 132.7, Edition
2022 2022
Local Heat Treatment: Local Heating:

Welds may be locally postweld heat PWHT may be performed locally by
treated by heating a circumferential band heating a circumferential band around
around the entire component with the the entire component with the weld
weld located in the center of the band. located in the approximate center of the
The width of the band heated to the band. The width of the band heated to
specified temperature range shall be at the specified temperature range shall be
least three times the wall thickness at the at least three times the wall thickness at
weld of the thickest part being joined. For the weld of the thickest part being joined.
nozzle and attachment welds, the width For nozzle and attachment weld, the
of the band heated to the specified width of the band heated to the specified
temperature range shall extend beyond temperature range shall extend beyond
the nozzle weld or attachment weld on the nozzle weld or attachment weld on
each side at least two times the run pipe each side at least two times the run pipe
thickness, and shall extend completely thickness and shall extend completely
around the run pipe. Guidance for the around the run pipe. Guidance for the
placement of thermocouples on placement of thermocouples on
circumferential butt welds is provided in circumferential butt welds is provided in
AWS D10.10, Sections 5, 6, and 8. AWS D10.10, Sections 5, 6, and 8.
Special consideration shall be given to Special consideration shall be given to
the placement of thermocouples when the placement of thermocouples when
heating welds adjacent to large heat heating welds adjacent to large heat
sinks such as valves or fittings, or when sinks, such as valves or fittings, or when
joining parts of different thicknesses. No joining parts of different thicknesses. No
part of the materials subjected to the part of the materials subjected to the
heat source shall exceed the lower heat source shall exceed the lower
transformation temperature of the critical temperature of the material.
material except as permitted by Para . Particular care must be exercised when
331.2.1. Particular care must be the applicable PWHT temperature is
exercised when the applicable PWHT close to the material’s lower critical
temperature is close to the material’s temperature, such as for P-No. 15E
lower transformation temperature, such materials, or when materials of different
as for P-No. 15E materials or when P-Nos. are being joined. This method
materials of different P Nos. are being may not be used for austenitizing heat
joined. This method may not be used for treatments.
austenitizing heat treatments.
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13.0 Temperature Records:
Chino or equivalent potentiometric self-compensating type temperature recorders shall be

used. Continuous plotting of temperatures v/s time during the heat treatment cycle is done on
the charts. The records shall be of six points or twelve point type, suitable for 0 to 10000
C/12000 C having continuous recording chart and chopper bar with colour dots, with scanning
period of 20 seconds / dot with accuracy 1%. Maximum twelve thermocouples can be
connected in one twelve point chart recorder with respect to thermocouple arrangement as
specified in clause 7 of this procedure. Position of thermocouples to be shown on a sketch
and identified on chart recording.
With these recorders, a continuous graph chart of all the thermocouples is obtained, providing
information of temperature differences and trends during the heat treatment cycle. The charts
also provide proof of the heat treatment cycle on completion.
The chart speed shall be adjusted to 25 mm per hour and the time interval between cycles for
any particular thermocouple will be approximately 2 minutes.
Each recording instrument will give information and immediate indication of a thermocouple
open circuit condition.
The temperature recorders shall be calibrated at intervals not exceeding 12 months.

Calibration certificates shall be available for review and such calibrations can be witnessed by
client if required.
During a heat treatment cycle, the recorder shall be securely locked.
14.0 Temperature Control System:
PWHT temperature ranges and holding times for various materials shall be in accordance
with the design code. The welding procedure qualification test shall determine whether the
temperature range and holding times are adequate to meet the requirements.
The temperature control system shall be capable of providing 100C increments or more as
specified.
The temperature is controlled by the use of auto-Controller and also has the option of manual
control.
The temperature control system shall guarantee a post weld heat treatment within the limits of
the specification.
The manual mode of operation shall require adjustment of temperature controllers for heated
zones within the heated band to ensure temperature uniformity.
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Adjustments shall be made in increments of 100 C or as specifically required.
The heat shall be controlled by Timer or by ‘ON/OFF’ switch manually or by the auto-
Controller. Throughout the heat treatment cycle (restricted range) the temperature differential
between thermocouples registering peak temperatures shall be within the limits of + 200 C.
15.0 Post weld heat treatment (PWHT) Cycle:

Heating and cooling cycle shall be followed as per approved WPS. 1
Post weld heat treatment (PWHT) of welded or formed (bent) piping should be performed in
accordance with ASME B31.3, table 331.1.1 except as modified below.
All miscellaneous welded attachments including pipe shoes, on alloy or carbon steel pipe
should be welded before final heat treatment.
For local post weld heat treatment, temperature gradient should be maintained such that the
temperature is at least half the PWHT temperature on each side of the weld at a distance of
3½ x (R x t)0.5 (where ‘R’ is the bore radius and ‘t’ is the nominal pipe wall thickness at the
weld).
Dissimilar welding and Interruption of Welding. After welding commences, the minimum
preheat temperature shall be maintained until any required PWHT is performed on P-Nos. 3, 1
4, 5A, 5B, 6, and 15E, Refer and include for B31.1 also.
Care must be exercised when the applicable PWHT temperature is close to the material’s
lower critical temperature, such as for P-No. 15E materials or when materials of different P-
Nos. are being joined. This method may not be used for austenitizing heat treatments.
PWHT Requirement of P15E, P5A and dissimilar material joints must be reviewed and
approved by the Engineer prior to performing PWHT.
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Post weld heat treatment (PWHT) ASME B31.3, table 331.1.1, Edition 2022
1
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Post weld heat treatment (PWHT) ASME B31.1, table 132.1.1-1, Edition 2022 1
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The typical details of Heat Treatment Cycle , in general is as under.
Heating, Cooling ,Soaking, Holding to be followed as per approved WPS & Drawing. 1
Heating from ambient to 300 OC: Unrestricted.
Heating from 300 0C to soaking temperature: 2000C divided by wall thickness in inches
(2000C per hour maximum).
Soaking temperature: 6200 C, -100C + 200 C for Carbon Steel.

7200 C, -100C + 300 C for P91
Soaking period: 1 hour per inch of wall thickness (Minimum holding time 1 hour).
Cooling from soaking temperature to 3000C: 2000C divided by wall thickness in inches (2000C
per hour maximum).
3000C to ambient temperature: Cool in still air.
16.0 Precautions:
When performing PWHT on welded flange joints and welded valve joints confirm the material
type is carbon steel, and ensure that valve should be kept open.
17.0 Pre Heating:
The Code (ASME B31.3 table 330.1.1) recommended preheat temperatures must be the
minimum. For CS materials 10 °C (50°F) preheat (minimum) must be applied to ¾” to 1” thick
material. 95 °C (200°F) preheat (minimum) must be applied for materials in thickness above
1”. Higher preheat temperatures should be applied when designated in the WPS.
Preheat (where applicable) should be applied to all welds including tack welding and welding
of temporary attachments. Preheat requirements should be also applied to thermal gouging
and cutting operations. Preheat must be maintained for a minimum of 3 inch (76 mm) either
side of the joint.
Piping welds of Cr-Mo alloy steels (P11, P22, P5A, P5B, or P9) shall be slow cooled in
insulation followed by welding.
Temperatures should be recorded continuously and automatically on a chart. Each specific

1
spool should be identified on the chart.
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Exposed machined and threaded surfaces should be protected from oxidation during heat
treatment. Pipe ends should be closed during the localized heat treatment.
After final heat treatment subsequent welding or heating is not permitted.
Delayed Heat Treatment. If weldment is allowed to cool prior to heat treatment, the rate of
cooling shall be controlled or other means shall be used to prevent detrimental effects in the
piping.
Applicable NDE shall be carried out after PWHT as per specifications, drawing and piping
class. A hardness test shall be done at least 10% on the lot/joint from the furnace and 100 %
on the local heat-treated surface.
Mandatory Appendix VIII Local Heating Of Welds In Cylindrical Components Of P-No. 15e
Materials When Using Electric Resistance. – ASME Sec I. Clause III-6.4.4 , Clause III-6.4.5 &
PW39 can be followed as guideline.
Special Considerations:
1. Welds Joining Branch Connections or Attachments to Cylindrical Components.
(a) For welds joining branch connections or attachments to cylindrical components,

circumferential band PWHT practices shall be used on both the piping cylindrical components
and the connection. The entire nozzle or attachment shall be included in the soak band.
(b) For branch connections where the heating pads fitted to the weld will not contour to the
shape without leaving larger than normal gaps between the heaters, additional monitoring
thermocouples shall be placed in the expected cold spots to ensure that the cold spots
achieve the desired temperature.
(c) Where small branch connections, 1∕2 in. to 11∕2 in. (13 mm to 38.1 mm) diameter, are
welded to larger sections, circumferential bands around both the larger component and
smaller branch connection shall be heated using heaters with control thermocouples on the
larger component and with monitoring thermocouples on the smaller branch connection. If
separate control zones are used for the larger component and smaller branch connection,
they shall each have separate control thermocouples.
2. Intersection With Branch Connections and Attachments Not Requiring PWHT
(a) The soak band, heated band, and/or gradient control band of welds that require PWHT
may intersect branch connections or attachments that do not require PWHT. To avoid
distortion and/or induced residual stresses during PWHT, the temperature gradient
across the components that are intersected shall be minimized. This may require the
application of a supplementary heat source(s) to the branch connection or attachment.
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Alternatively, a reasonably uniform temperature shall be maintained across these

components. The soak band, heated band, or gradient control band, whichever intersects,
shall be extended in the axial direction such that it ends beyond the weld on the opposite side
connecting the attachment or associated pad to the component for at least half of the soak
band, heated band, or gradient control band, whichever is appropriate. Figure VIII-6.4.5-1
provides an example of such an approach when the heated band from a weld requiring PWHT
intersects a nozzle that does not require PWHT.
(b) Although the nonspecific term “reasonably uniform” is used in (a) to describe the
temperature drop across the intersected component, the aim is to maintain a reasonably
constant temperature drop across the intersected component. However, to provide a
measurable limit, a maximum temperature drop is recommended. The maximum temperature
drop across an intersected component shall be 100°F (56°C) or that resulting from application
of the maximum permissible axial temperature gradient (i.e., 50% of the temperature at the
edge of soak band divided by 2 √Rt ), whichever is less. Based on experience or analysis,
larger temperature gradients across nozzles or attachments may exhibit permissible levels of
distortion or residual stress.
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Preheat Temperature ASME B31.3, table 330.1.1, Edition 2022
1
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Preheat Temperature ASME B31.1, table 131.4-1, Edition 2022 1

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18.0 Documentation:
Standard Specification Mechanical Requirements for Packaged Equipment is not a project
document.
Each PWHT cycle shall be verified by heat-treatment chart. Each chart shall be marked with
the date of the PWHT, the weld or spool number(s), channel identification and signature(s) of
subcontractor personnel.
The plotted temperature / time chart shall be considered as a record of the complete heating
cycle. However the chart shall be supported with a Heat Treatment Report with the following
details.
• Client / Job order reference
• Job Number
• Report Number
• Date of Heat Treatment
• Specification
• Technician
• Project identification
• Part / Spool / Line Number
• Material
• Heating Cycle
• Thermo couple location
• Equipment details, Comments / Remarks if any
19.0 Safety:
Twist lock connections shall also be examined to ensure that the insulation is sound and that
a good electrical joint is made.
All cable connections shall be properly insulated.
The pipe surface shall be free of contaminants.
Reference shall be made to the Safety Plans, Task Risk Assessments and Safety Method
Statements pertinent to the work being carried out and to the work location.
Prior to switch-on for the heat treatment, the work area shall be inspected to ensure that there
no combustible materials are in contact with the furnace and that fire protection measures are
available.
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Figure-1
MINIMUM HEATED BAND WIDTH
2.5 Rt 2.5 Rt
5 Rt 5 Rt
MINIMUM INSULATION WIDTH

R - Inside Radius in mm
t - Wall thickness in mm
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Attachment-1 Thermocouple location (monitoring and control zone)

1
As per ASME Section I , Edition 2021 Appendix VIII
Local Heating Of Welds In Cylindrical Components Of P-No. 15E Materials When Using
Electric Resistance Heating
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1
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1
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1
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Attachment-2 Post Weld Heat Treatment Report

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Industrial X-Ray & Allied Radiographers S.P.C.

P.O. Box 3130, P.C.111, CPO, Sultanate of Oman

PROJECT OQ Methanol & Ammonia TA works 2023

Venkata Rao K Babu Patwekar

Prepared by Reviewed by Reviewed Approved by

Procedure Revision Status

Description Page No.

1 ASME B31.3, 2022 Edition Process Piping

5 645295-0000-46EF-0001 Rev.1 Piping and Fabrication Installation and testing

6 645295-0000-46EF-0005 Rev.1 Construction/Installation Specification Welding & NDE

7 645295-C00101-0079-02-Rev.2 Ammonia Painting Specification

designed to achieve a particular aim.

NDT Non-Destructive Testing

6.0 Personnel Qualification:

7.0 Procedure Qualification:

9.0 Placement of Heating Elements:

Ensure only one joint at a time completes the PWHT cycle.

Unless otherwise specified, thermocouple attachments should be capacitor discharge

All Thermocouples shall be of the nickel-chromium/nickel-aluminum, Type K. All

To enhance the mechanical strength of the Thermocouple hot-junction, chloride-free high

Monitoring Thermocouples- Monitoring thermocouples shall be placed to ensure 1

11.0 Thermocouple Extension Cable (Compensating Cables):

Copper-Constantan compensating cables shall be used.

12.0 Thermal Insulation:

The insulation shall be bound with black annealed iron wire

Width of Band Heating

Local Heat Treatment: Local Heating:

13.0 Temperature Records:

Chino or equivalent potentiometric self-compensating type temperature recorders shall be

The temperature recorders shall be calibrated at intervals not exceeding 12 months.

During a heat treatment cycle, the recorder shall be securely locked.

14.0 Temperature Control System:

Adjustments shall be made in increments of 100 C or as specifically required.

15.0 Post weld heat treatment (PWHT) Cycle:

The typical details of Heat Treatment Cycle , in general is as under.

Heating from ambient to 300 OC: Unrestricted.

Soaking temperature: 6200 C, -100C + 200 C for Carbon Steel.

3000C to ambient temperature: Cool in still air.

17.0 Pre Heating:

Temperatures should be recorded continuously and automatically on a chart. Each specific

After final heat treatment subsequent welding or heating is not permitted.

(a) For welds joining branch connections or attachments to cylindrical components,

2. Intersection With Branch Connections and Attachments Not Requiring PWHT

Alternatively, a reasonably uniform temperature shall be maintained across these

Preheat Temperature ASME B31.3, table 330.1.1, Edition 2022

Preheat Temperature ASME B31.1, table 131.4-1, Edition 2022 1

All cable connections shall be properly insulated.

The pipe surface shall be free of contaminants.

MINIMUM HEATED BAND WIDTH

MINIMUM INSULATION WIDTH

Attachment-1 Thermocouple location (monitoring and control zone)

Attachment-2 Post Weld Heat Treatment Report

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