HEAT TREATMENT PROCEDURE

Applicable Location
Department PWHT Services

TABLE OF CONTENTS

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1.0 SCOPE-------------------------------------------------------------------------------------------------3

2.0 REFERENCE DOCUMENTS (ALL LATEST EDITIONS)------------------------------3

3.0 SAFETY-----------------------------------------------------------------------------------------------3

3.1 General----------------------------------------------------------------------------------------------------------------------------------3

3.2 Specific----------------------------------------------------------------------------------------------------------------------------------3

4.0 PERSONNEL----------------------------------------------------------------------------------------3

5.0 EQUIPMENT----------------------------------------------------------------------------------------3

6.0 MATERIALS----------------------------------------------------------------------------------------4

7.0 PREPARATION-------------------------------------------------------------------------------------4

8.0 METHOD---------------------------------------------------------------------------------------------4

8.1 General----------------------------------------------------------------------------------------------------------------------------------6

8.2 Thermocouple-------------------------------------------------------------------------------------------------------------------------6

8.3 Heating Elements--------------------------------------------------------------------------------------------------------------------7

8.4 Thermal Insulation-------------------------------------------------------------------------------------------------------------------8

8.5 Temperature Recording------------------------------------------------------------------------------------------------------------8

9.0 REPORTING----------------------------------------------------------------------------------------9

10.0 RECORDS--------------------------------------------------------------------------------------------9

11.0 ATTACHMENTS-----------------------------------------------------------------------------------9

1.0 SCOPE

This procedure details the minimum requirements for external local post weld heat
treatment (PWHT) and pre heating on welds and associated heat effected zones made
of carbon and alloy steels in pipe work up to 750C by the electrical resistance method

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 in accordance with ASME / ANSI requirements.

2.0 REFERENCE DOCUMENTS (ALL LATEST EDITIONS)

 ASME B31.3 Processing Piping

 ASME B31.1 Power Piping
 ASME Sec IX Welding & Brazing Qualification
 ASME Boiler & Pressure Vessel Code Section VIII
 API Standard 650 Welded Steel Tanks for Oil Storage

3.0 SAFETY

All personnel shall be aware at all times of hazards both of site and method in order
to prevent accident or injury to self or others the technicians responsible shall be
capable of understanding and applying the relevant heating procedure and
specification set by the applicable fabrication drawings or governing documents.
3.1 General
Care shall be taken when using the following, Electrical items, undamaged
wiring, correct plug for socket, correct voltage.
Scaffolding, safe and suitable for application with ladders lashed.
Lighting, adequate for full illumination of work area.
3.2 Specific
High voltage electrical equipment, Materials at elevated temperatures, insulating
materials

4.0 PERSONNEL

Formal training in electronics and / or electrical related subject(s) or completion of

appropriate apprenticeship or experience and demonstrated skill in operation of heat
treating equipment shall be deemed suitable qualification for personnel performing site heat
treatment in addition at least one technician attending the work site may have completed
a diploma in electrical engineering or possess a competency certificate as an electrical.
5.0 EQUIPMENT

Power supply 03 phase 380/440VAC x 100 AMP with neutral and earth required for input
of heat treatment equipment. Temperature controller shall in semi-automatic controlled and
the temperature use sock and cooling temperature shall be recorded on a time V/S
temperature chart recorder.

Temperature control equipment may be either manually operated through input energy
regulation or by automatic control units using modular controls. Temperatures are recorded
using chart recorders that are regularly calibrated within the maximum period of one year
between calibrations.

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6.0 MATERIALS

Consumable and associated materials used for the purpose of heat treatment shall be
of a quality that will produce acceptable results. Materials of sub-standard quality or
defective materials shall not be used.

7.0 PREPARATION

The surface of the materials to be heated shall be prepared adequately to allow intimate
contact of heating pads. Heat treatment shall be performed only on the welds unless
formally instructed otherwise. The surface shall be free from foreign matter, oil, grease,
lose or tight solids, dust, rust, or other material that are extraneous to the metal
surface or may have a detrimental effect on the process or materials used.

8.0 METHOD

All carbon steel pipe work when the thickness of material through the butt
welded joint exceeds 20.0mm
Carbon steel piping subject to vibration such as compressor piping when the material
through the butt welded joint exceeds 12.7mm
Carbon steel branch connections when the thickness in any plane through the branch
weld exceeds 40.0mm 25.00mm in case of compressor piping.
Whenever specified in the company approved contract document.
Post weld heat treatment shall be carried out as soon as possible after the completion
of the weld.
The temperature controls during heating and cooling shall meet the requirement as
ASME Section VIII Division1 UCS-56.

Normal Up to 2 inch Over 2 inch

Over 5 inch
Table Material Holding 5 inch to 5 inch
(125 mm)
Temperature (50 mm) (50 mm)
Ucs-56 P-1 1,100 F 1 hr / in 2 hr plus 15 2 hr plus 15
(Group.1,2,3) 595 C (25mm) 15 min for each min for each
min minimum additional additional
inch inch (25mm)

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 (25 mm) 2 in.(50mm)
over 2 in .
(50mm)
Ucs-56 P-3 1,100 F 1 hr / in 2 hr plus 15 2 hr plus 15
(Group.1,2,3) 595 C (25mm) 15 min for each min for each
min minimum additional additional
inch inch (25mm)
(25 mm) 2 in.(50mm)
over 2 in .
(50mm)
Ucs-56 P-4 1200 F 1 hr / in 1 hr / in 5 hr plus 15
(Group.1,2,) 650 C (25mm) 15 (25mm) min for
min minimum each
additional
inch
(25mm)
Ucs-56 P-5A, 5 B 1250 F 1 hr / in 1 hr / in over
5 5 in. 15
hr plus
(Group. 2) 670 C (25mm) 15 (25mm) min for
min minimum each
additional
inch
(25mm)
Ucs-56 P-, 5B 1350 F (max) 1 hr / in 1 hr / in over
5 5 in.15
hr plus
(Group.1& 730 C (max) (25mm) 15 (25mm) min for
5C) min minimum each
** additional
inch
(25mm)
over 5 in.
Ucs-56 (A) If Ni + Mn <1.50 % but > 1.0 % the maximum PWHT temp is 1,450 F (790 C)
(B) if Ni + Mn <1.0, the maximum PWHT temp is 1,470 F (800C)

The surface of the materials to be heated shall be prepared adequately to allow

intimate contact of heating pads. Heat treatment shall be performed only on the welds
unless formally instructed otherwise. The surface shall be free from foreign matter, oil,
grease, lose or tight solids, dust, rust, or other material that are extraneous to the metal
surface or may have a detrimental effect on the process or materials used.
8.1 General
All cables shall be connected incorporating standard plug and
sockets Care shall be taken to avoid mechanical damage to both
power and thermocouple cables, and insulation
8.2 Thermocouple
The thermocouple(s) shall be type K nickel-chromium / nickel-
aluminum. Thermocouple shall have the following tolerances:

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  0 to 400C 3C
 400 to 1100C 0.75%
All permanent thermocouples and thermocouple wire shall have
calibration checks and relevant certificates from the manufacturer.
a) Thermocouple attachment shall be by capacitance discharge method of
welding thermocouple wires directly to the part. The gap between the poles
of the thermocouple wire shall not to exceed 6 mm. The junction of
the thermocouple wire to the part shall be insulated using high temperature
putty to protect from direct heating by the resistance heaters. This situation
ensures reading of part temperature rather than heating element
temperature
b) The thermocouple to extension cable connection shall be located minimum
of 0.5 m outside the heated zone. Thermocouple extension cable shall
be cooper-constantan compensating cable with connection through plus and
socket as:
 Copper lead (+ve) to nickel-chromium (non-magnetic)
 Constantan lead (-ve) to nickel-aluminium (magnetic)
c) The thermocouple positions shall be identified on the temperature chart. The
following table shall be a guide for thermocouple distribution and placement.

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 NO. OF
OD (in) POSITION
THERMOCOUPLES
Up to 8 1 Top
8 to 12 2 Top / bottom
12 to 24 3 120 apart
Over 24 4 90 apart

8.3 Heating Elements

a) The width of the circumferential band to be heated shall be at least
three times the width of the widest part of the welding groove but in no
case less than twice the width of the weld reinforcement.
b) The preferred element arrangement for welds on pipes 250 mm (10 in)
diameter or greater, shall be to divide the elements into two or more
control zones (i.e. top and bottom) with pads applied symmetrically about
the part within the control zones.

As an alternative, in the event the preferred element arrangement not

being possible for the part configuration one of the following conditions shall be
met.

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The center line circumferential gap between two bands of elements shall not exceed 30 mm
(1.25 in) or ‘t’ whichever is less, the longitudinal gap between elements shall not exceed the
wall thickness or 50 mm (2 in) whichever is less
c) Where the weld is of two substantially different wall thickness, then
elements shall be arranged to give longitudinal control in addition to
circumferential control.
d) For inclined or vertical welds, the pads shall be arranged about the
weld to give independent control above and below weld centreline.
e) Heating elements shall be attached with black annealed iron wire,
stainless or mild steel 12 mm wide banding strap.
8.4 Thermal Insulation
a) Thermal insulation shall be achieved by placing one of the following around
the heat treating assembly
 Mineral wool, as slab or blanket, minimum density 80 kg / m3
 Ceramic fiber, as mat or blanket, with or without protective stainless
steel mesh, minimum density 96 kg / m3
 Knitted silica mat, minimum density 200 kg / m3
b) The insulation shall extend a minimum distance of 305 mm (12 in)
beyond the edges of the heating band, or the distance as determined by
the product of bore radius times the maximum wall thickness, whichever is
less
c) The number of layers and extent of insulated area shall be dependent
upon the following:
 Wall thickness, Pipe or fitting diameter, Gradient requirements, Site
conditions
In all cases the minimum requirement shall be two (2) layers for the
materials stated above.
d) Open ends to pipe and/or fittings shall be blanked (packed) with insulation to
avoid through draft cooling during the heating cycle.
e) Insulation shall be fixed using black annealed iron wire, taking care not
to damage or cut the insulation.
f) Following post weld heat treatment cycles, the insulation shall not be
removed before the lower controlled temperature level has been reached.
The insulation may be left in place until the part reaches ambient
temperature.
8.5 Temperature Recording
a) Temperature recorders shall be of the potentiometric self-compensating type
with chart feed recording. Hand-held temperature indicators, thermometers,
and the like, may be used for local monitoring of temperature but shall not
be used for control.
b) Temperature recorders shall be calibrated at intervals not exceeding one

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 year, after repair or when faulty performance suspected. Calibration
certificate shall always accompany the instrument.

d) The chart speed shall be set to 25 or 50 mm / hr. The chart record shall
provide information on temperature differences and trends during the
heating / cooling cycles.
e) Any section of the time / temperature chart shall only record the heat
treatment of those joints undergoing the same thermal cycle.
f) Temperature Cycle for Post Weld Heat Treatment.
g) Post weld heat treatment cycle shall be as per applicable drawing and WPS
requirement It shall be clearly instructed through a heat treatment
Instruction Sheet as per the code of construction requirements, material
grade and thickness ranges by the welding Engineer along with the PWHT
request.
9.0 REPORTING
The resulting time / temperature chart shall represent the actual executed heating cycle.
The associated report shall include the following information

Report shall contain the following information as minimum,

 Report no, Client, Job no. / work order no, Item description, Acceptance criteria,
Length of weld / diameter of weld, Thickness and reinforcement, Welder No, welding
process, Heat treatment procedure, Heat treatment technique, chart no, Weld
identification, Thermocouple location(s), Soak (holding) time, Date of cycle with
technician name and signature

10.0 RECORDS
Following acceptance of chart and report by Client, copy shall be filed, together
with copies of sketch (es), specific procedure(s), photograph(s) or other relevant
material, in such manner to allow easy retrieval if and when required.
11.0 ATTACHMENTS

 Table 1
 Graph Sample
Table-1

Maximum Maximum PWHT Max Brinnel

Soaking Time Hardness
Material P.No Heating Rate Cooling Rate Temp
(Minutes/mm
°C/h °C/h °C thickness)
HB
2.5
CS 1 200 200 593-649 225
(Minimum 1 Hour)
2.5
CS Sour 1 200 200 600-625 200
(Minimum 2 Hour)
Alloy Steel 2.5
4 200 200 704-746 225
(1 ¼ Cr- ½ Mo) (Minimum 1 Hour)

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 Alloy Steel 200 or 5000/t 150 or 5000/t 5
(2 ¼ Cr-1 Mo) 5A whichever is whichever is 704-746 241
less less
(Minimum 2 Hour)
P-22
2.5
CS with Inconel 1 200 200 600-625 200
(Minimum 2 Hour)

Holding
Time

Cooling
Rate
Heating
Rate

PWHT Graph Cycle

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