PERFECT INDUCTION HEAT TREATMENT

Revision 00
HEAT TREATMENT PROCEDURE – Status AFI
LOCALIZED METHOD
Revision Date: 01/08/2022

Document No: PIHT-HT-TRC-DOC-00001 Page: 1 of 15

HEAT TREATMENT PROCEDURE –

LOCALIZED METHOD

Rev. Status Date Revision memo Issued by, Reviewed by, Approved by,

00 IFR 1/08/2022 Approved for Issuance ABA MAM RS

 PERFECT INDUCTION HEAT TREATMENT

Revision 00
HEAT TREATMENT PROCEDURE – Status AFI
LOCALIZED METHOD
Revision Date: 01/08/2022

Document No: PIHT-HT-TRC-DOC-00001 Page: 2 of 15

Table of Contents

1. Introduction ................................................................................................................................. 3
2. Abbreviation ................................................................................................................................ 3
3. References ................................................................................................................................... 3
4. Heat Treatment Cycle ................................................................................................................ 4
5. Heating Machine ......................................................................................................................... 4
6. Temperature Controls ............................................................................................................... 4
7. Thermocouples ........................................................................................................................... 4
8. Thermocouple Positions .......................................................................................................... 4
9. Thermocouples Compensating Cable .................................................................................. 4
10. Temperature Recording........................................................................................................ 5
11. Insulation.................................................................................................................................. 5
12. Heat Treatment Interruption Process ............................................................................... 5
13. Safety Precaution ................................................................................................................... 6
Appendix 1: Local Heating Report ................................................................................................ 7
Appendix 2: Heat Treatment CyclE ............................................................................................... 9
Appendix 3: Thermocouple Location & Arrangement of Heating Hoses .......................... 12
Appendix 4: Sample Chart ............................................................................................................. 14
 PERFECT INDUCTION HEAT TREATMENT

Revision 00
HEAT TREATMENT PROCEDURE – Status AFI
LOCALIZED METHOD
Revision Date: 01/08/2022

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1. Introduction

This procedure describes the method for carry-out localized Heat Treatment to the welded
components.

2. Abbreviation

QA/QC – Quality Assurance / Quality Control

IFR – Issued for Review
DOC – Document
HT – Heat Treatment

3. References

ASME B31.3-2018 – Process Piping

ASME B31.1-2018 – Power Piping
AWS-D10-10-10M – Recommended Practices for Local Heating of Welds in
Piping and Tubing
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4. Heat Treatment Cycle

Heat treatment cycle and processes throughout the welding work with reference to design
code is provided by Main-Contractor. Appendix 2 illustrated the heat treatment cycle and
requirement in general as a reference.

5. Heating Machine

Electrical resistance heating by the application of ceramic heater pads (elements) or induction
heating by the application of a bundle of coil around the area to be heat treated.

6. Temperature Controls

The heating elements shall be grouped into independent control zone, each shall be attached
with a respectively numbered thermocouple (for control & monitor purposes).

Each circuit of the heating elements shall be controlled in manual/semi manual mode through
contactor or energy regulators or it shall be made automatic controlled by pre-set programmer
control unit.

7. Thermocouples

Thermocouples shall be K Type made from nickel-chromium/nickel/aluminium wire to BS1041,

Part IV, or equivalent. Certifications shall be made available and indicate a tolerance of less
than +/- 0.75% throughout the temperature range from 400°C to 800°C.

Thermocouples shall be attached to the work piece by the direct wire capacitance discharge
method. The gap between the two wires per work piece junctions shall not exceed 5mm.

8. Thermocouple Positions

The thermocouple recommended positions for PWHT on piping joints are detailed in Appendix
3.

9. Thermocouples Compensating Cable

Copper/constantan compensating cable shall be used for extension of the thermocouple to

the recording instrument.

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-
aluminium conductors (magnetic).
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10. Temperature Recording

Temperature recorders shall be calibrated at intervals not greater than 12 months. It shall have
certification traceable to a national standard and recorded with the certificate being kept and
a sticker should be stuck on the instrument.

The temperature recorder shall be of the potentiometric self-compensating type, calibrated in

degree Celsius with respect to a nickel-chromium /nickel-aluminium thermocouple, type K.

The recording chart speed shall be set at 25 or 50 mm/hour and shall be checked during
calibration.

11. Insulation

High temperature ceramic fibre blanket, minimum 25mm thick and density of 96kg/m3, shall
be provided for the purpose of insulation.

Insulation shall extend for a minimum distance of 200mm beyond the outer edges of the heater
zone, or as may be determined by the ruling specification.

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

Wherever possible, each end shall be blanked off internally before heat treatment to limit
convection effects.

12. Heat Treatment Interruption Process

An interruption to the heat treatment process is defined by the failure by one or more
thermocouples to maintain the specified heating, cooling rates, temperature differentials or to
achieve the soak temperature. This may be the result of power loss, equipment failure or
operator error.

Once the discrepancies have been identified, the heat treatment cycle shall be placed into
hold whilst investigation take place to determine if the fault can be rectified and remedial work
carried out safely with a minimum of delay. The heat treatment may be restarted afterward.

A check shall be made of the temperatures of all controlling thermocouples, whichever finding
had identified any of discrepancies i.e. below the set point, it shall be raised at a rate no greater
than that specified by the code or specific procedure until the overall temperature differential
is within the acceptable limits.

If the interruption occurs during the soak period, then the temperature of any thermocouple
which falls below the minimum specified soak temperature shall be re-established at a rate no
greater than that specified by the code or procedure.
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The soak time shall be extended to ensure all the thermocouples have recorded temperatures
within the soak range for the minimum soak time.

In the event that the heat treatment chart indicates discrepancies i.e. overall temperature
differentials are increasing between thermocouples which exceed the code / procedure given
value, then the heating or cooling rates shall be reduced or the process put on hold. A note
shall be made on the heat treatment chart and the client advised. If the differentials cannot be
corrected, the client is to be consulted as to whether or not the heat treatment is continued.

If remedial work cannot be carried out in time (to effectively restore the heat treatment cycle),
the process shall be aborted after consultation with the client. The heat treatment cycle shall
be re-started at another time.

A note of interruption and at a time it happened shall be made on the heat treatment chart. A
non-conformance report shall be raised.

13. Safety Precaution

Prior start works, all heat treatment equipment shall be inspected and tested by qualified
electrician inspector and approved for site work. The relevant machine certificate shall be
provided during inspection.

Power supply connection from DB board/electrical tapping point to machine shall be

established by qualified electrician with adequate power cable specs.

During heat treatment process, the work area shall be cordoned off with red white barricade
tape and safety hazard signage shall be displayed mentioned “Hot work in progress” Only
authorized personnel shall be allowed inside the work area.

Heat treatment personnel shall wear appropriate PPE such as hand glove and N95 dust mask
when fit-up the ceramic fibre insulation on the work piece. The MSDS shall be provided for
guideline during installation at site.
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Appendix 1: Local Heating Report

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Heat Treatment report will have minimum information listed as below.

Report Number
Procedure No.: _______________________ Revision No.: __________ Date: ________________

Governing Code: ___________________________________________________________________

Workpiece Identification Number:______________________________________________________

Material Specification: _______________________________________________________________

Component Dimensions: ____________________________________________________________

Thermocouple, Heater, and Insulation Layout Drawing Number:______________________________

Heat Treatment Cycle

Heating Rate: __________________°______/hour (specify max. or min.) above __________ ° ____

Hold Temperature Range: _______________ ___° to _______________________________ ° _____

Minimum Hold Time: ________________ hours Maximum Hold Time: __________________ hours

Cooling Rate: _______________°______/hour (specify max. or min.) above __________ ° _______

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HEAT TREATMENT PROCEDURE – Status AFI
LOCALIZED METHOD
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Appendix 2: Heat Treatment CyclE

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PREHEAT
In general, satisfactory qualification of the preheat to be used shall be performed in
accordance with the essential variables of the ASME B31.1 – 2016 for the preheating cycle,
Table 131.4.1 is minimum value required.

Preheating may be employed during welding to assist in completion of the welded joint. The
need for and the temperature of preheat are dependent on a number of factors such as
chemical analysis, degree of restraint of the parts being joined, elevated temperature
mechanical properties, and material thicknesses. Refer ASME BPVC.I-2017 PW-28
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POST-WELD HEAT TREATMENT CYCLE

Post weld Heat Treatment if necessary, shall be conducted after all welding work in
accordance with the conditions indicated in the following tables. The welding procedure
qualification test shall determine whether the temperature range and holding times are
adequate to meet the requirements.

For Production use, the heat treatment procedure shall be reviewed and approved by the
OWNER prior to PWHT. Any variation of PWHT temperature shall require OWNER’s approval

PWHT Heating and Cooling rates shall be governed under ASME B31.1 clause 132.5 as below

Cooling rate from 315°C down to ambient temperature for the weld may be allowed to
cool naturally. Whilst keeping the whole weld seam insulated, insulation may be
removed at 150 °C.

In general, PWHT Soaking temperature is defined in ASME B31.1 (Table 132) as table below:-
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Appendix 3: Thermocouple Location & Arrangement of Heating Hoses

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GENERIC PLACEMENT OF THERMOCOUPLE

Below figures shows the generic arrangement on locating thermocouples depending on NPS
of pipes. Thermocouple to be used to control the temperature (normally on the weld) is
compulsory while monitoring thermocouple is subjected to accessibility and equipment
environment. Min. Heated Band Width (7t)

t
(1)

Legend
D Nominal Diameter
(4) X O (3) O Rear
X Front

(2)

Figure 1: Filler Welds between Pipes of Equal Thickness

NOTES:
1. For D < 6” T/C (I) only required.
2. For 6” < D < 12.T/Cs (I) & (2) only required.
3. For 12” < D < 20”. T/C (1 to 4)
4. Additional thermocouples to be fitted at the weld centreline as required for control.
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HEAT TREATMENT PROCEDURE – Status AFI
LOCALIZED METHOD
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Appendix 4: Sample Chart

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PWHT sample chart for material P5A (SA335 P22)

Temperature
Soaking 2 hours 15 minutes (minimum) at
710˚C ± 40 ˚C
Soaking
Temperatur

Unrestricted
Heating Rate
below 315˚C

Heating Rate: Cooling Rate:

Ambient 110˚C/hr 120˚C/hr

Time

PWHT sample chart for material P1 (SA106C)

Temperature
Soaking 2 hours 15 minutes (minimum) at
620˚C ± 20 ˚C
Soaking
Temperatur

Unrestricted
Heating Rate
below 315˚C

Heating Rate: Cooling Rate:

Ambient 110˚C/hr 120˚C/hr

Time

*Cooling period/RATE is subjected to external (environment)