TCM Division

THERMAL PROCESS PROCEDURE 022509-01, Rev. 0

BULL’S EYE POST WELD HEAT TREATMENT (PWHT)

Per
ASME BPVC SECTION VIII DIV. 1
NBIC RD-1100

NOZZLE N3 & N4 ATTACHMENT WELDS

VESSELS C6-12, C6-13, & C6-14
SA-516-70 & SA-106-B (ASME P-No. 1) CARBON STEELS

For
PETROLEOS DE VENEZUELA S.A. (PDVSA)
Cardon, Venezuela

By
TEAM INDUSTRIAL SERVICES, INC.
Estado Falcon, Venezuela

February 25, 2009

PDVSA Approval: ______________________ ____________________ _______

Signature Title Date

Team Approval: ______________________ ____________________ _______

Signature Title Date
 Written By:
BULL’S EYE PWHT STRESS RELIEF
TCM ASME BPVC SEC. VIII & NBIC RD-1100
Thompson/Martin
Approved By:
DIVISION Nozzles N3 & N4 Welds on Vessels C6-12, C6-13, & C6-14 J. Borges
Rev.: Date:
PAGE 1 of 10 Field Procedure 022509-01 0 2/25/09

1.0 OVERVIEW

The following table summarizes the specifications for this thermal processing procedure.

PARAMETER
Client
Location
Work Piece Identification
Weld Identification
Shell & Nozzle Material
Shell Thickness & Inner Diameter
Nozzle Dimensions
Governing Codes
Heating Method
PWHT Soak Temperature
PWHT Soak Time
Max. Heating Rate above 800 °F
Max. Cooling Rate above 800 °F
SPECIFICATION
Petroleos De Venezuela S. A. (PDVSA)
Cardon, Venezuela
Vessels C6-12, C6-13, and C6-14
Nozzles N3 & N4 attachment weld
SA-516-70 & SA-106-B (ASME P-No. 1) CS
1-7/16-inch & 15-1/2-ft
8-inch NPS
Section VIII, ASME BPVC, and NBIC
Electric Resistance Heat Treating System
1150 °F ± 25 °F
2-1/4 hours, minimum
140 °F/hr
180 °F/hr

2.0 SCOPE

2.1 Background

Welding produces high temperatures, severe temperature gradients, and rapid cooling and
solidification, which increase residual stresses, grain size, and brittleness in the weld and its
adjoining base material. These, in turn, can reduce fatigue life, corrosion resistance, and
dimensional stability of the weldment assembly. Post weld heat treatment (PWHT) can
relieve these ill effects by reducing residual stress and hydrogen content, and by restoring
ductility and corrosion resistance.

2.2 Purpose

The purpose of this procedure is to define specifications for a Bull’s Eye PWHT of nozzles
N3 and N4 attachment welds on vessels C6-12, C6-13, & C6-14, in compliance with ASME
BPVC Section VIII Div. 1 and NBIC requirements. This procedure identifies the locations
and attachment methods for thermocouples, electric resistance heaters, and thermal
insulation, to ensure that code requirements for heating, soak, cooling, and gradient control
are achieved.
 Team PWHT Procedure 022509-01, Rev. 0 Page 2 of 10

2.3 Governing Documents

• The 2007 edition of Section VIII, Division 1 of the American Society of Mechanical
Engineers (ASME) Boiler and Pressure Vessel Code (BPVC)
• Paragraph UW-40 for soak band width requirements
• Table UCS-56.1 for PWHT soak temperature and time
• Article UCS-56 for heating and cooling rates
• The 2004-06 edition of the National Board Inspection Code (NBIC) RD-1100
• An as yet unidentified PDVSA welding procedure specification (WPS)

2.4 Technical Approach

Electronically controlled electric resistance heaters, in conjunction with thermocouples and

thermal insulation will be utilized to create a bull’s eye heated band (HB) concentric to the
attachment welds of nozzles N3 and N4, of sufficient size to ensure that their soak band
(SBs) achieve PWHT soak temperature. The HB and insulation gradient control band
(GCB) are utilized to achieve NBIC mandated radial temperature gradients.

2.5 Procedural Tasks

The majority of the tasks described in this procedure are within Team's scope of activity.
However, the purpose of this document is to describe those tasks or activities, and not to
assign responsibility for them. The Team supervising technician will coordinate with the
client to assign these duties, and is empowered to make minor alterations to this procedure,
such as heater selection, in order to improve the quality of the PWHT by accommodating
variations in available equipment and space. Major revisions must be approved by the
client and Team’s Technical Support Group (TSG), to ensure the quality of the PWHT.

3.0 VESSEL AND NOZZLE DETAILS

Vessels C6-12, C6-13, & C6-14 and nozzle N2 are illustrated in PDVSA drawing RCN-523.806,
Rev. 3, of July 17, 2006, containing the following features:

• Vessel Configuration: Horizontal cylindrical bullet on 2 saddle supports

• Shell Material:
• Shell Thickness:
• Shell Inner Diameter:
• Nozzle Material:
• Nozzle N4 Diam. & Thck.:
• Nozzle N4 Location:
• Nozzle N3 Diam. & Thck.:
• Nozzle N3 Location:
• M-1 Repad Diam & Thick:
• N4 Repad Diam. & Thick:
• M1-N4, & N3-N1 Dist’s:
SA-516-70 (ASME P-No. 1) carbon steel
1-7/16-inch (36.5-mm)
15-1/2-ft (4.727-m)
SA-106-B (ASME P-No. 1) carbon steel
8-inch NPS, Schedule 80 (1/2-inch thick)
On top centerline, 41-3/4-inch from M-1, center-to-center
2-inch NPS Schedule 80 (0.218-inch thick)
On top centerline, 18-1/8-inch from N-1, center-center
28 inches outer diameter and 3-inches thick
14-15/16-inch outer diameter, and 1-3/8-inches thick
20 inches, and 16 inches, respectively
 Team PWHT Procedure 022509-01, Rev. 0 Page 3 of 10

4.0 UW-40 REQUIREMENT FOR ATTACHMENT WELD SOAK BAND (SB) WIDTH

Paragraph UW-40 (a) (7) requires that the local PWHT of a nozzle attachment weld employ a soak
band that shall extend beyond the weld in all directions a minimum distance of the wall thickness
or 2 inches, whichever is less, as illustrated in Figure 1, below.

The Lesser The Lesser

of t or 2" of t or 2"

t
The Lesser of t or 2" The Lesser of t or 2"

Figure 1 – Nozzle Attachment Weld Soak Band Width

Therefore, the 2-inch NPS diameter nozzle N3 will have a 4-3/4-inch diameter SB based on a 1/2-
inch fillet weld and a 1-7/16-inch thick shell. Similarly, the 8-inch NPS diameter nozzle N4 will
have a 19-3/16-inch diameter SB based on a 14-15/16-inch diameter by 1-7/16-inch thick repad
and a 1-inch wide fillet weld.

5.0 TEMPERATURE GRADIENT CONTROL

NBIC RD-1100 requires that the radial gradient from the SB not exceed 250 °F/ft. Therefore, at a
distance of 1-ft from the edge of the SB, the temperature in the HB must not be below 925 oF, with
a maximum PWHT soak temperature of 1175 oF.

6.0 HEATER ARRANGEMENT

Figure 2 on the following page illustrates the bull’s eye PWHT heater and thermocouple
arrangement for both the N4 and the N3 nozzle and/or repad attachment welds, incorporating code
SB requirements as defined above. All heaters are to be attached to the shell by means of capacitor
discharge welded stud pins and friction washers, in compliance with Team Standard Practices SP-
01 and SP-08.

6.1 FCP Heaters

Each FCP heater has a surface area of 120 in². When powered by 80-VAC from a standard
Team 6-zone power and control (6-PAC) console, it will develop a thermal power capacity
of 3.6 kW, which is a uniform area power density of 30 W/in². Heaters are identified by
their flexible width dimension. For example, a CP12 heater is has a flexible 12-inch width,
and a rigid 10-inch length. Up to three heaters can be powered in parallel in a single
temperature control zone, in accordance with Team Standard Practice SP-08.
 Team PWHT Procedure 022509-01, Rev. 0 Page 4 of 10

TC4 4A
5A
4C

CP12 CP12
CP10 4B CP10 CP8 CP8
CP12
TC5 CP18
8B 10B
3B

5B CP15 TC3
TC8
2A TC10
1A
2CP10s 1CP29
5C N4 1B N3 TC9
TC1 N-1
CP12 3A

TC2 8A 10A 10C

2B
6A
CP18 CP15 CP4
CP12 7C CP8
CP8

TC6 TC7
6C 7A

6B CP12 CP10 CP10 7B CP12

Figure 2 – Plan View of Bull’s Eye Thermocouples & Heaters for PWHT of Nozzles N3 & N4
 Team PWHT Procedure 022509-01, Rev. 0 Page 5 of 10

6.2 Bull’s Eye HB Heater & Thermocouple Pattern

The bull’s eye HB heater and thermocouple pattern is illustrated in Figure 2 on the previous
page. It consists of three heater bands, as described below.

6.2.1 HB Inside Nozzle N4

A 12-inch wide band of 2 CP10 heaters are to be pinned to a plug of thermal

insulation and inserted into the bore of nozzle N4 to keep the heaters tightly against
the bore’s inner surface. The band is to be arranged into a single 2-heater
temperature control zone with a 1-1/4-inch circumferential space between heater
ends.

6.2.2 HB around Nozzle N3

A 4-1/8-inch wide band of 1 CP29 heater is to be wrapped around the neck of

nozzle N3. Excess heater length will be allowed to stick out through the insulation
covering.

6.2.3 Innermost Shell HB for Nozzles N4 & N3

Surrounding nozzle N4 on the shell will be an average 7-inch wide rectangular band
of 2 CP15 heaters alternated among 2 CP18 heaters, arranged into two 2-heater
temperature control zones, with a 1/2-inch space between heater ends. In addition,
an 8-inch wide heater band will be installed for N3, consisting of 1 CP8 heater on
each side of N3, arranged into a single 2-heater temperature control zone.

6.2.4 Outermost Shell HB

Immediately surrounding the innermost rectangular HB for nozzles N4 and N3, will
be nominal 1-ft wide band, consisting of 7 CP12 heaters, 4 CP10 heaters, 2 CP8
heaters, and a single CP4 heater. This band will be arranged into four 3-heater
temperature control zones, and a single 2-heater zone, with a nominal 1-inch space
between heaters.

7.0 TEMPERATURE MEASUREMENT

7.1 Thermocouple Type and Quantity

Each of the 10 temperature control zones is to be instrumented with a Type K control

thermocouple, attached to the shell or nozzle surface by means of capacitor discharge
welding, to ensure accurate temperature measurement, in compliance with Team Standard
Practice SP-02. A spare thermocouple is to be located within ½-inch of each control
thermocouple.
 Team PWHT Procedure 022509-01, Rev. 0 Page 6 of 10

7.2 Thermocouple Locations

The precise thermocouple locations are illustrated in Figure 2, and described in sub-section
6.2. Basically, each thermocouple is to be as close to the geographic center of its
temperature control zone as possible.

7.3 Thermocouple Set-Point Temperatures

The heater bands inside nozzle N4, around nozzle N3, and on the shell immediately
surrounding nozzles N4 and N3, as described in sub-sections 6.2.1, 6.2.2, and 6.2. are each
to have the PWHT soak temperature as set-point. The outermost shell heater band, as
described in sub-section 6.2.4, has its control thermocouples on average a distance of 1-ft
from the edge of the soak band (SB). Consequently, those control thermocouples are to
have a set-point temperature 250 oF lower than the PWHT soak temperature, for a value of
925 oF. This will place the temperature of the outer edge of the HB at a value of
approximately 800 oF.

8.0 THERMAL INSULATION

The entire bull’s eye is to be covered with a layer of 1-inch thick 6-lb/ft3-density non refractory
ceramic fiber (Non-RCF) thermal insulation, which is to extend 2-ft. beyond the edges of all
heaters. It is to be secured to the shell with the same type of capacitor discharge welded stud pins
and friction washers that hold the heaters in place, and banded to nozzle N3. The insulation that is
inserted into nozzle N4, with its attached heaters, is to consist of the same insulation material
rolled into a cylindrical plug.

9.0 EQUIPMENT INSTALLATION

9.1 Equipment Access

Scaffolding or man-lifts are to be provided as needed for personnel to install

thermocouples, heaters, and insulation. The two 6-PAC (6-zone power and control)
consoles are to be placed within 50 ft from the welds, with secondary cables positioned out
of harms way. All zone cabling is to be clearly identified, and supported to prevent any
tension on heater tails. Each 6-PAC requires a 100-Amp, 3-phase, 460-VAC service.

9.2 Removal of Walkways

The diamond plate walk-way with its flat-bar kick-plates must be removed from the top of
each vessel to enable the installation of thermocouples and heaters directly on the vessel
shell, and to avoid toxic out-gassing from their painted and/or oil soaked surfaces.

9.3 Repad Weep Hole

An 1/8-inch diameter weep hole must be drilled into the N4 repad before installing PWHT
thermocouples and heaters.
 Team PWHT Procedure 022509-01, Rev. 0 Page 7 of 10

9.4 Safety

Team site personnel will work with the client’s safety personnel, to ensure that the
following on-site safety steps are taken:

9.4.1 Permit Requirements

All necessary hot-work permits are to be acquired by Team’s supervising

technician, and all Team site personnel shall be familiar with permit requirements.

9.4.2 Personnel Protective Equipment (PPE)

All Team personnel shall wear protective clothing and equipment, as described in
the Team Safety Manual, and shall satisfy all site-specific safety requirements.

9.4.3 Fire Extinguisher

A type ABC fire extinguisher shall be available to Team personnel within ready
access to the PWHT location.

10.0 RELEVANT TEAM STANDARD PRACTICES

Equipment specifications and preparation instructions relevant to this field procedure are provided
in the Team Standard Practices listed on the following page.

SP-01: Attachment of Stud Pins by Means of Capacitor Discharge Welding

SP-02: Attachment of Thermocouples by Means of Capacitor Discharge Welding
SP-05: Thermal Insulation – Specifications and Usage Guidelines
SP-06: Temperature Measurement and Recording Equipment - Specifications & Usage
SP-08: Low Voltage Electric Resistance Heating – Specifications, Usage, and Safety Guidelines

11.0 PWHT TEMPERATURE REQUIREMENTS

The following heating, soak, and cooling specifications are in accordance with those of article UCS-
56 and Table UCS-56.1 for a combined repad and shell thickness of 2-13/16-inch (71.5-mm) P-No.
1 carbon steel.

11.1 Heating

11.1.1 Below and at 800 °F

From ambient to 800 °F, Team recommends that the heating rates not exceed 400
°F/hr, in an effort to minimize temperature differences within concentric heater
bands.
Team PWHT Procedure 022509-01, Rev. 0 Page 8 of 10

11.1.2 Above 800 °F

Above 800 °F, heating rates shall not exceed 140 °F/hr.

11.1.3 Temperature Differential

While heating above 800 °F, there shall not be a greater variation in temperature than
150 ºF among thermocouples within any given concentric heater band. The heating
rate may be reduced to ensure that these differentials are not exceeded.

11.1.4 Maximum Temperature

During the heating period, there shall not be a temperature greater than 1175 ºF.

11.1.5 Thermocouple Failure

In the event of a thermocouple failure during the controlled portion of the heating
cycle, the cycle may be held at that point until the transfer to a spare thermocouple is
completed.

11.2 Soak

11.2.1 Temperature

Soak temperature shall be between 1125 ºF and 1175 ºF. The soak period is to begin
when the core HB soak temperature reaches 1125 ºF. At no time shall the
temperature of these thermocouples either exceed 1175 ºF, or fall below 1125 ºF.

11.2.2 Time

The minimum soak time shall be 2-1/4 hours.

11.2.3 Thermocouple Failure

In the event of a thermocouple failure during soak, the transfer to the spare
thermocouple is to be done immediately. If the temperature of the soak
thermocouple falls below 1125 ºF at any time during the transfer, the soak period is
to be resumed when it reaches 1125 ºF. The total accumulated time above 1125 ºF is
to be the soak time.

11.2.4 GCB Control Thermocouple Set-Point Temperatures

The set-point temperature for the control thermocouples in the outermost heater band
is to be not less than 925 oF, as defined in Subsection 7.3, in compliance with the
NBIC mandated maximum allowable temperature gradient.
 Team PWHT Procedure 022509-01, Rev. 0 Page 9 of 10

11.3 Cooling

11.3.1 Above 800 °F

Above 800 °F, the maximum cooling rate shall not exceed 180 °F/hr.

11.3.2 Temperature Differential

While cooling above 800 °F, there shall not be a greater variation in temperature than
150 ºF among thermocouples in any given concentric heater band. Cooling rates
may be reduced to ensure that these differentials are not exceeded.

11.3.3 At and Below 800 °F

At and below 800 °F, the cooling rate need not be restricted, and cooling can be
completed in still air. Thermal insulation can be removed whenever it is deemed
safe to do so.

11.3.4 Thermocouple Failure

In the event of a thermocouple failure during the controlled portion cooling, the
cycle may be held at that point until the transfer to the spare thermocouple is made.

13.0 DOCUMENTATION

A Team Job Folder is to be submitted to the client, containing the following documents:

13.1 Temperature-Time Record

Each thermocouple is to have its temperature/time history recorded on a dedicated channel

of a strip chart recorder. The strip chart label is to identify the correlation of thermocouple
numbers and strip chart recorder channels, and is to contain the information listed on the
following page:

• Date
• Identification of work piece
• Thermocouple type
• Stress relieving company
• Stress relieving operator and signature
• Chart recorder serial number and date of latest calibration

13.2 Recorder Calibration

Each recorder is to be accompanied by its certificate of calibration.

Team PWHT Procedure 022509-01, Rev. 0 Page 10 of 10

13.3 Job Report Log

In the event of a non-conformance, a manual log is to be maintained by Team technicians

to document pertinent details, and the Team supervising technician and the PDVSA quality
control manager are to be notified as soon as possible to help define corrective action.

13.4 Heat Treatment Record (HTR)

A daily HTR shall be submitted to document personnel, time, material, and equipment.

13.5 Approvals

This procedure requires approval signatures by an authorized representative of the client

and by the Team supervising technician before any Team site work can begin.