INDEX

CONTENTS PAGE NO
1.0 SCOPE 1

2.0 REFERENCES 1

3.0 EQUIPMENT 1

4.0 SETTING UP PROCEDURE 3

5.0 POST WELD HEAT TREATMENT 4

6.0 DIS ASSEMBLY 5

7.0 PRECAUTIONS 5

8.0 DOCUMENTATION AND RECORDS 5

9.0 APPENDICES/ATTACHMENTS 5

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NDT Corrosion Control Services Co Examination Procedure
Document # NDT/HD/PWHT/026 Page 1 of 7
Approved By : Operations Manager Rev : 5 Date: 9th Nov-2015
Title: POST WELD HEAT TREATMENT PROCEDURE
1.0 SCOPE

This procedure specifies general requirements of Post Weld Heat Treatment (PWHT) of weld
joints between P4 to P4, P4 to P1 and P1 to P1 material of piping fabricated in accordance with
ASME Sec 1, ASME B31.1 and ASME B31.3

2.0 REFERENCES

1.0 ANSI/ASME B 31.1, 2012 Edition

2.0 ANSI/ASME Sec 1, 2013 Edition,
3.0 SAES W – 011 WELDING REQUIREMENTS FOR ON-PLOT PIPING – 2013 Edition
4.0 ANSI/ASME B31.3 2012 Edition (Process Piping)
5.0 NACE RP- 0472-2010
6.0 ASTM A 833 – 2008
7.0 SAEP-1160 –July-2011
8.0 SAIC-W-2003

3.0 EQUIPMENT

3.1 POWER SOURCE

Power source used for post weld heat treatment shall be a 3 phase 65KVA double wound class
“H” insulated dry type power transformer suitable for primary supply of 380/415/440 V and gives
3 phase output voltage of either 60V or 80V AC between phase and neutral. Output from the
power source is taken through connectors and made available on the output sockets. The unit is
fitted with circuit breaker and panel mounted camlock output terminals.

3.2 PROGRAMMABLE TEMPERATURE CONTROLLER

Programmable temperature controller is a proportional controller used for controlling the

temperature during post weld heat treatment. The magnitude of control signal is proportional to
the deviation between work piece temperature and set point temperature. Power is applied in an
ON-OFF mode but the set point is shifted electronically by a measure at how far the process
temperature is above or below the set point. “K” type thermocouples attached to the work piece
shall be connected to the temperature controller using compensating cables. Programmer is
provided with automatic cold junction compensation.
The 6 channel controller energizes the contractorised heating circuits of the power source. Time
proportional action is used to control heating/cooling rates and “Dwell” action to maintain
soaking temperature.

3.3 TEMPERATURE RECORDER

PWHT Temperature shall be progressively recorded using a multipoint, potentiometric type strip
chart recorder with built in thermocouple reference junction compensation circuit. 12 point
“SEKONIC” recorder with indicating accuracy of +/- 0.5% of full span will be used. Effective
recording width is 180mm and printing frequency is 5 sec. at 60 HZ.
Chart speed shall be selected either on 25mm/hr. Or 50mm/hr. and can be verified by using a stop
watch. Inputs shall be “K” type thermocouples connected using copper constantan compensating
cable of 30m length via programmable temperature controller. 12 Nos. Thermocouples can be
connected to the recorder and each channel will be printed in different colours. Chart shall be
Fully identified with date, chart speed, joint identification, temperature-time cycle, name of the
NDT Corrosion Control Services Co Examination Procedure
Document # NDT/HD/PWHT/026 Page 2 of 7
Approved By : Operations Manager Rev : 5 Date: 9th Nov-2015
Title: POST WELD HEAT TREATMENT PROCEDURE

Operator, heat treatment specification and chart receipt number.

Temperature recorder shall be calibrated every three months and carry the certificate of
calibration and sticker. Calibration frequency shall be extended up to 12 months with the approval
of Saudi Aramco Inspection Department if the documented calibration checks for that particular
recorder demonstrate acceptable accuracy for a suitable period.

3.4 THERMO COUPLE WIRE

Type “K” (chromel – alumel) thermocouple wire (22 SWG, pair) shall be used for measuring
temperature of PWHT. Thermocouple wire shall be covered with high temperature glass fibre
material which acts as an electrical and thermal insulation as well as protect the wire from
atmospheric contamination.
Standard Limits of error shall be  2C for 0 - 275C and  0.75% for 275-1260C range as per
ANSI MC-96-1-1975.
Copper-Constantan compensating cables shall be used to connect TC to instrument terminals.
Thermocouple wires shall be attached to the job using a thermocouple attachment unit.
Thermocouple putty shall be used on hot junction to eliminate the chances of error due to radiant
heat. Care shall be taken to ensure that the thermocouple wires do not touch, away from the hot
junction. The thermocouple to extension cable connection shall be clear off heating zone.
Thermocouple plug and sockets shall be used for connecting TC wires to compensating cables
and compensating cables to the instruments.

3.5 THERMOCOUPLE WELDING AND ATTACHMENT

“K” type thermocouple wire (nickel-chromium and nickel-aluminum pair) shall be fixed to the job
using thermocouple attachment unit working on capacitance discharge principle.
Proper cleaning of the area where the thermocouple to be attached shall be done (with wire brush
or file) to make sure that it is smooth and free from dirt, grease, oil etc. Nickel chromium and
nickel-aluminum wires shall be fixed with a distance of separation 4-6mm for accurate
measurements. No preheating is required for fixing the thermocouple wire by using this
equipment.

3.6 COMPENSTING CABLES

Copper-Constantan compensating cables shall be used to connect “K” type thermocouples to the
programmable temperature controllers and temperature recorders. The copper lead (positive, blue)
shall be connected to the nickel-chromium conductor (non-magnetic) and constantan lead
(negative, white) to the nickel-aluminium conductor (magnetic) of “K” type thermocouple. For
Type K thermocouples, copper-Constantan (Type T) compensating cables may be used with the
following conditions:

a) The junction between the copper-Constantan compensating cable and the

Type K thermocouple lead shall be a minimum of 0.5 m outside the
insulated area.

b) The acceptable temperature range of the junction between the

compensating cable and the thermocouple lead is from 0 to +80°C.
NDT Corrosion Control Services Co Examination Procedure
Document # NDT/HD/PWHT/026 Page 3 of 7
Approved By : Operations Manager Rev : 5 Date: 9th Nov-2015
Title: POST WELD HEAT TREATMENT PROCEDURE

3.7 FLEXIBLE CERAMIC MAT HEATERS.

Heating elements used for PWHT shall be flexible ceramic mat heaters of 60V, 2.7KW. Standard
sizes are 205 x 250 mm, 255 x 205 mm, 305 x 165 mm, 380 x 145 mm and 1220 x 45 mm.
Flexible ceramic mat heaters are designed to use up to 1050C. Ends of the heaters are provided
with camlock plug and socket connections. All heaters are rated 45 Amps. Flexible ceramic mat
heaters are flexible and can easily be wrapped around pipes. Continuity checks shall be done for
each heating elements before connecting it in the circuit.

3.8 INSULATION:
Ceramic fiber mats of thickness 25mm and size 1800x600mm or 900x600mm with stainless steel
wire mesh cover shall be used as thermal insulation. Density of ceramic fiber shall be 120kg/m3.
Minimum two layers of insulation shall be used.

4.0 SETTING UP PROCEDURE

4.1 PRE START-UP

NDT & CCS heat treatment engineer / supervisor shall visit site 15 days before starting the job to
assess the location of joints, accessibility, arrangement for power connections, whether protection
for equipment, schedule of PWHT etc.
List of joints to be stress relieved shall be made with weld identification, drawing number,
location, diameter, thickness, material, heat treatment cycle etc and submitted to client/Aramco
inspector at site.

4.2 CLEANING PROCEDURE

Metal surface shall be cleaned prior to PWHT to remove contaminates such as grease, oil, paint,
dirt etc.

4.3 SURFACE PROTECTION

All machined surfaces such as flange faces, bolt holes, threads etc. shall be protected from
oxidation during heat treatment by coating with deoxyaluminate or other suitable material.
Ceramic fiber insulation shall be fixed and tightened using banding straps/binding wires to
prevent air ingress at elevated temperatures.

4.4 PROTECTION FROM EXTREME WEATHER

Proper protection to the job and equipments shall be done in case of extreme weather conditions.
Tarpaulin roof/side cover shall be used in case of heavy wind or rain.

4.5 PROCEDURE TO AVOID CHIMNEY EFFECTS

The ends of open pipes shall be closed off using ceramic fiber insulation mats in order to
eliminate drafts or air circulation that could lower the temperature on the inside of the joint, unless
the internal surface also insulated.
All the valves on the line shall be kept closed during PWHT to avoid chimney effect.
NDT Corrosion Control Services Co Examination Procedure
Document # NDT/HD/PWHT/026 Page 4 of 7
Approved By : Operations Manager Rev : 5 Date: 9th Nov-2015
Title: POST WELD HEAT TREATMENT PROCEDURE
4.6 EQUIPMENT CHECKING

All equipment used for PWHT shall be checked for ensuring integrity before starting the job.
Control circuit of power sources shall be checked before connecting the heating load.
Calibration of temperature recorder shall be cross- checked using calibrated `CROPICO'
thermocouple potentiometer. Thermocouple attachment unit shall be checked for battery `charge'
condition. All flexible ceramic mat heaters shall be checked for `continuity’ before connecting in
heating circuit. All the electrical connections shall be checked before switching on.

5.0 POST WELD HEAT TREATMENT

5.1 The PWHT heating and cooling rates above 316C shall not exceed 222C/hr. divided by the weld
thickness in inches, but no case shall be more than 222C/hr.

5.2 Soaking period shall be minimum one hour for P1 material and minimum two hours for P4
material and also per inch of nominal wall thickness of the pipe. Welding or heating after the final
PWHT is not permitted if the PWHT is required for service. Post weld heat treatment shall follow
all welding and repairs but shall be performed prior to any hydro test.

5.3 Below 315C, natural cooling under insulation in still air. During heating and cooling, there shall
not be a greater variation in temperature than 120C between any two points in the heating zone.

5.4 If localized PWHT is used, the following minimum number of equally spaced recording
thermocouples (T/C) shall be used:

a) Pipe diameter of 305 mm or less: 1T/C

b) Pipe diameter above 305 mm up to and including 610 mm: 2 T/C
c) Pipe diameter above 610 mm ; 4 T/C
Additional thermocouples are required if multiple heat control zones are used, in which a control
zone is not monitored by any of the primary T/Cs.
(See attachment 9.1 for details)

5.5 The specified PWHT shall be applied over an area extending at least 3 times the thickness of the
material being welded from each edge of the weld but not less than 25 mm from each edge of the
weld, whichever is greater..

5.6 Where the butt joint constitutes two separate material thicknesses, the heating elements shall be
arranged in two circumferencial bands with independent control.

5.7 A minimum of 2 layers ( 50 mm ) ceramic fiber insulations shall be applied , extending to a

minimum distances of 300 mm on either side of the weld.

5.8 In case of premature termination of heat treatment (due to power failure etc) it shall be recorded
and repeated from the point of termination.

5.9 Any reduction in post weld heat treatments or alternative temperatures below normal holding
temperatures, listed in the codes shall not be permitted.

5.10 Ends of open lines shall be closed off in order to eliminate drafts or air circulation that could
lower temperatures on inside surface of joints unless the internal surface is also insulated.
NDT Corrosion Control Services Co Examination Procedure
Document # NDT/HD/PWHT/026 Page 5 of 7
Approved By : Operations Manager Rev : 5 Date: 9th Nov-2015
Title: POST WELD HEAT TREATMENT PROCEDURE

5.11 All temperatures within the heated zone for furnace or localized PWHT shall exceed the specified
minimum holding temperature.

5.12 The actual temperature range for the soak period, as recorded by TC’s, shall not have a spread of
more than 40° C.

6.0 DIS ASSEMBLY

Power source shall be electrically isolated before dismantling the secondary power cabling
system. Ceramic fiber insulation shall be removed only after the temperature has cooled below
150C.
After completion of PWHT, all thermocouples shall be removed and the attachment areas ground
smooth to clean sound metal. MT/PT should be applied to those areas when requested by Aramco
Inspection.

7.0 PRECAUTIONS

Prior to the start of PWHT, components shall be checked to ensure that all restraints are removed
and the component is free to expand and contract. The suitable and sufficient supports shall be
used during PWHT. For safety reasons, job shall be perfectly earthed during PWHT. The
immediate area of the job shall be roped off.
General safety aspects of `Hot Work' shall be strictly followed.
Care shall be taken when shifting the equipment from one place to another. Electronic equipments
like recorders, programmers etc shall be transported suitably packed in shock proof containers.
Heat treatment equipments shall be placed at site in covered space, which protects it from extreme
weather conditions.

8.0 DOCUMENTATION AND RECORDS:

Every day morning, a list of joints heat-treated previous day along with all the relevant details
including Time-Temperature graphs (chart) shall be submitted to Q.C. department for approval.
All the identification of joints must be noted in chart and signed, mentioned start time by the
technician prior to start of PWHT.

9.0 APPENDICES/ATTACHMENTS

9.1 Thermocouple positions for PWHT.

9.2 Local Post Weld Heat Treatment Report Form.

ATTACHMENT 9.1
NDT Corrosion Control Services Co Examination Procedure
Document # NDT/HD/PWHT/026 Page 6 of 7
Approved By : Operations Manager Rev : 5 Date: 9th Nov-2015
Title: POST WELD HEAT TREATMENT PROCEDURE

THERMOCOUPLE LOCATIONS

 


`DIA  305 MM DIA > 305 MM  610 MM

 


DIA > 610 MM
NOTE:

1. "" is Thermocouple Location

2. Additional Thermocouple will be used if multiple heat
control zones are used, in which a control zone is
monitored by any of the Primary Thermocouple.
NDT Corrosion Control Services Co Examination Procedure
Document # NDT/HD/PWHT/026 Page 7 of 7
Approved By : Operations Manager Rev : 5 Date: 9th Nov-2015
Title: POST WELD HEAT TREATMENT PROCEDURE
ATTACHMENT 9.2