Industrial X-Ray & Allied Radiographers L.L.C.

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

Tel: +968 24541291,Fax:+968 24541281
Email: [email protected]

PRE-HEATING & POST WELD HEAT TREATMENT EXAMINATION PROCEDURE

Procedure No: : IXAR/DR/UNISCO/PKG-2/PWHT/07 Rev.0 Page No.: 1 of 13

PROJECT DUQM REFINERY PROJECT EPC Package-2

CLIENT DUQM REFINERY & PETROCHEMICAL INDUSTRIES COMPANY (DRPIC)

EPC CONTRACTOR Petrofac Samsung JV

FABRICATOR United Industrial Services Company L.L.C (UNISCO)

CONTRACT NO. CNT-1100-1000-007

DRPIC CONTRACT NO. --

NDT CONTRACTOR INDUSTRIAL X-RAY & ALLIED RADIOGRAPHERS L.L.C.

Babu Patwekar
0 21/07/2019
ASNT NDT LEVEL-III
Prepared by Reviewed Approved by
Revision Date
IXAR UNISCO Client
 Industrial X-Ray & Allied Radiographers L.L.C.
P.O.Box 3130,P.C.111,CPO,Sultanate of Oman
Tel: +968 24541291,Fax:+968 24541281
Email: [email protected]

PRE-HEATING & POST WELD HEAT TREATMENT EXAMINATION PROCEDURE

Procedure No: : IXAR/DR/UNISCO/PKG-2/PWHT/07 Rev.0 Page No.: 2 of 13

TABLE OF CONTENTS

Description Page No.

Cover Page 1
Table of contents 2
1.0 Purpose 3
2.0 Scope 3
3.0 References 3
4.0 Definitions 3
5.0 Abbreviations 4
6.0 Personnel Qualification 4
7.0 Responsibilities 4
8.0 Procedure Qualification 5
9.0 Equipment 5
10.0 Surface Preparation 5
11.0 Placement Of Heating Elements 5
12.0 Thermocouples 6
13.0 Thermocouple Extension Cable (Compensating Cables) 7
14.0 Thermal Insulation 7
15.0 Temperature Records 8
16.0 Temperature Control System 9
17.0 Heat Treatment Cycle 9
18.0 Precautions 10
19.0 Pre Heating 10
20.0 Documentation 10
21.0 Safety 11
Attachment-1 Hardness Control Method 12
Attachments-2 Post Weld Heat Treatment Report 13
 Industrial X-Ray & Allied Radiographers L.L.C.
P.O.Box 3130,P.C.111,CPO,Sultanate of Oman
Tel: +968 24541291,Fax:+968 24541281
Email: [email protected]

PRE-HEATING & POST WELD HEAT TREATMENT EXAMINATION PROCEDURE

Procedure No: : IXAR/DR/UNISCO/PKG-2/PWHT/07 Rev.0 Page No.: 3 of 13

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 process piping, related fittings and attachments.

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.

PWHT activities are performed in accordance applicable project specifications and code.

3.0 References :

1 ASME B31.3, 2016 Edition Process Piping

2 ASME B31.1, 2016 Edition Power Piping

Welding Guidelines for the Chemical, Oil, and

3 API 582 2nd Edition ,2009
Gas Industries

4 DRP001-OUF-SPE-Q-000-507 QAQC Implementation during Construction

5 DRP001-OUF-SPE-U-000-005 Inspection Requirements

Specification for Welding & NDE of Pressure

6 DRP001-OUF-SPE-W-000-006
Equipment’s and Piping

4.0 Definitions:

Term Definition
Client End User
Any private or public entity responsible for Detailed Engineering
Contractor and Design, Procurement, Construction and (pre-) Commissioning
of this project
A construction contractor is responsible for the day-to-day
oversight of a construction site, management of vendors and
Construction Contractor
trades, and communication of information to involved parties
throughout the course of a project.
Sub-Contractor Person or entity to whom/which the Contractor subcontracts any
 Industrial X-Ray & Allied Radiographers L.L.C.
P.O.Box 3130,P.C.111,CPO,Sultanate of Oman
Tel: +968 24541291,Fax:+968 24541281
Email: [email protected]

PRE-HEATING & POST WELD HEAT TREATMENT EXAMINATION PROCEDURE

Procedure No: : IXAR/DR/UNISCO/PKG-2/PWHT/07 Rev.0 Page No.: 4 of 13

part of the service.

Is to be understood as mandatory.
Shall
An individual or collaborative enterprise that is carefully planned
Project and designed to achieve a particular aim.

Is to be understood as strongly recommended.

Should
Is to be understood as giving a freedom of choice.
May Be

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 Responsibilities:

Welding Inspector shall be responsible for inspection and testing of all piping welding
activities. He shall be responsible for identifying the joints to be PWHT and requesting for
PWHT.

PWHT Inspector shall be responsible for ensuring the requirements of the procedures are
fully understood and followed by all persons that are responsible for its implementation in
shop and field environments
 Industrial X-Ray & Allied Radiographers L.L.C.
P.O.Box 3130,P.C.111,CPO,Sultanate of Oman
Tel: +968 24541291,Fax:+968 24541281
Email: [email protected]

PRE-HEATING & POST WELD HEAT TREATMENT EXAMINATION PROCEDURE

Procedure No: : IXAR/DR/UNISCO/PKG-2/PWHT/07 Rev.0 Page No.: 5 of 13

PWHT Technician shall be the responsible for heat treatment and heat treatment equipment
operation. He is responsible to ensure personal safety &to ensure that the facilities with
respect to lighting are adequate, before commencement of any job. All cables shall be tied up
neatly to avoid damage to cables & injuries to operators. Fire Extinguishers shall be provided
and the technician must be capable of operating the Extinguishers in case of any fire.

8.0 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.

9.0 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.

The heating elements shall be insulated with ceramic beads and free from direct contact with
the material surface.

10.0 Surface Preparation:

The surface should be cleared to remove all scale, weld spatter, loose particles or any other
foreign material & free from oxide scale, paint, lubricants, oil, plastic coating due to corrosion
protection, or metal coating, flush and smooth.

11.0 Placement of Heating Elements:

The preheat temperature shall be applied, and, for low-alloy steels, maintained until PWHT
throughout the entire thickness of the weld and at least 3 in. (75 mm) on each side of the
weld. Consideration should be given to lowering the preheat temperature below Mf prior to
PWHT.
 Industrial X-Ray & Allied Radiographers L.L.C.
P.O.Box 3130,P.C.111,CPO,Sultanate of Oman
Tel: +968 24541291,Fax:+968 24541281
Email: [email protected]

PRE-HEATING & POST WELD HEAT TREATMENT EXAMINATION PROCEDURE

Procedure No: : IXAR/DR/UNISCO/PKG-2/PWHT/07 Rev.0 Page No.: 6 of 13

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.

12.0 Thermocouples:

1)The thermocouples should have initial check.

2) For K type thermocouple, color code for positive as yellow and red as negative.
3) The + ve & - ve charges should be marked properly.

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.
 Industrial X-Ray & Allied Radiographers L.L.C.
P.O.Box 3130,P.C.111,CPO,Sultanate of Oman
Tel: +968 24541291,Fax:+968 24541281
Email: [email protected]

PRE-HEATING & POST WELD HEAT TREATMENT EXAMINATION PROCEDURE

Procedure No: : IXAR/DR/UNISCO/PKG-2/PWHT/07 Rev.0 Page No.: 7 of 13

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.

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.
Where electric resistance elements thermocouple shall be used for each heating circuit to
ensure overheating cannot occur.

Pipe Dia No. of T/C Clock Position

Below 4” 1 12
4” to 12” 2 6 & 12
Above 12” 4 3,6,9 &12

13.0 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

14.0 Thermal Insulation:

The insulation shall not be removed before the temperature has cooled.
 Industrial X-Ray & Allied Radiographers L.L.C.
P.O.Box 3130,P.C.111,CPO,Sultanate of Oman
Tel: +968 24541291,Fax:+968 24541281
Email: [email protected]

PRE-HEATING & POST WELD HEAT TREATMENT EXAMINATION PROCEDURE

Procedure No: : IXAR/DR/UNISCO/PKG-2/PWHT/07 Rev.0 Page No.: 8 of 13

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.

Insulation shall be fixed using black annealed iron wire taking care, not damaging or cutting
into the insulation.

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.

15.0 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.
 Industrial X-Ray & Allied Radiographers L.L.C.
P.O.Box 3130,P.C.111,CPO,Sultanate of Oman
Tel: +968 24541291,Fax:+968 24541281
Email: [email protected]

PRE-HEATING & POST WELD HEAT TREATMENT EXAMINATION PROCEDURE

Procedure No: : IXAR/DR/UNISCO/PKG-2/PWHT/07 Rev.0 Page No.: 9 of 13

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.

16.0 Temperature Control System:

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.

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.

17.0 Heat Treatment Cycle:

The typical details of Heat Treatment Cycle for Carbon Steel, in general is as under. Actual
Heat Treatment Cycle shall be in accordance with contractor’s approved WPS for a specific
project.

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.

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).
 Industrial X-Ray & Allied Radiographers L.L.C.
P.O.Box 3130,P.C.111,CPO,Sultanate of Oman
Tel: +968 24541291,Fax:+968 24541281
Email: [email protected]

PRE-HEATING & POST WELD HEAT TREATMENT EXAMINATION PROCEDURE

Procedure No: : IXAR/DR/UNISCO/PKG-2/PWHT/07 Rev.0 Page No.: 10 of 13

3000C to ambient temperature: Cool in still air.

18.0 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.

19.0 Pre Heating:

Pre heating shall be done as per client specification requirement.

OR
Preheating method & temperature shall as per PQR run & approved WPS. Resistance
heating should follow for heating of split tee with continues temperature recording facility.

Temperature of material shall be increased up to 250°C at location of thermocouple.

Temperature of material shall be maintained up to 150°C minimum on bevel before start of

welding.

After pre heating cooling shall be done in still air (environmental air cooling).

20.0 Documentation:

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
 Industrial X-Ray & Allied Radiographers L.L.C.
P.O.Box 3130,P.C.111,CPO,Sultanate of Oman
Tel: +968 24541291,Fax:+968 24541281
Email: [email protected]

PRE-HEATING & POST WELD HEAT TREATMENT EXAMINATION PROCEDURE

Procedure No: : IXAR/DR/UNISCO/PKG-2/PWHT/07 Rev.0 Page No.: 11 of 13

21.0 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.

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
 Industrial X-Ray & Allied Radiographers L.L.C.
P.O.Box 3130,P.C.111,CPO,Sultanate of Oman
Tel: +968 24541291,Fax:+968 24541281
Email: [email protected]

PRE-HEATING & POST WELD HEAT TREATMENT EXAMINATION PROCEDURE

Procedure No: : IXAR/DR/UNISCO/PKG-2/PWHT/07 Rev.0 Page No.: 12 of 13

Attachment-1 Hardness Control Method (NACE SP0472)

 Industrial X-Ray & Allied Radiographers L.L.C.
P.O.Box 3130,P.C.111,CPO,Sultanate of Oman
Tel: +968 24541291,Fax:+968 24541281
Email: [email protected]

PRE-HEATING & POST WELD HEAT TREATMENT EXAMINATION PROCEDURE

Procedure No: : IXAR/DR/UNISCO/PKG-2/PWHT/07 Rev.0 Page No.: 13 of 13

Attachment-2 Post Weld Heat Treatment Report