HFY 3800 0000 VED 192 QC PD 0005 - A Post Weld Heat Treatment Proce - Code B
HFY 3800 0000 VED 192 QC PD 0005 - A Post Weld Heat Treatment Proce - Code B
HFY 3800 0000 VED 192 QC PD 0005 - A Post Weld Heat Treatment Proce - Code B
HFY-CON/F&C0940-0964
HFY-CON/F&C0940-0964
27/05/21
CPECC QA/QC:
Reviewed with Minor Comments
CPECC-MEDC:
no comments
PWHT Procedure
PEG PO No : PE19518-050
ITEM DESCRIPTION : SHELL & TUBE HEAT EXCHANGERS (UNIT 1401, 1501)
DOCUMENT REF. :
PWHT Procedure: GPTI-SERCK-PRJ086981-PWHT-001, Rev.2
QA/QC Manager
REVIEWED & APPROVED_ Client /TPI
Document no: GPTI-SERCK-PRJ08691-PWHT-001
Rev No: 02
HEAT TREATMENT PROCEDURE Rev Date: 15/April/2021
Page No: Page 1 of 15
Signature
REVISION CONTROL
Incorporate client
02 15/April/2021 Changes done in sec 12
comments
Incorporate client
01 29/March/2021 Revised Sec -3, 4, 8, 12, 17
comments
00 04/Feb/2021 Initial Issue
Rev No. Date Changes Remarks
Document no: GPTI-SERCK-PRJ08691-PWHT-001
Rev No: 02
HEAT TREATMENT PROCEDURE Rev Date: 15/April/2021
Page No: Page 3 of 15
TABLE OF CONTENTS:
1. PURPOSE
2. SCOPE
3. REFERENCES
4. RESPONSIBILITIES
5. SPECIAL EQUIPMENTS
6. GENERAL REQUIREMENTS
7. HEATING METHOD
12. THERMOCOUPLE
16. SAFETY
17. INSPECTION
18. DOCUMENTATION
CPECC QA/QC:
Please update table as The purpose of this procedure is to provide requirements for Heat Treatment
Sl. No.,Train No., Vessel No.,Tag(HT) of weld joints & Materials for Heat Exchangers.
No., Drawing No. with Revidion,
Description of Item, Quantity - PTC (where required) shall be heat treated along the components.
2.0 SCOPE: - include Post Forming Heat Treatment details for heads and U-bend portion of tubes
exchangers.
This Procedure is to specify the minimum requirements for the preheating, post
weld heat treatment (PWHT) of welds and materials for the Heat Exchangers of
below Tag numbers by electric resistance, & Diesel furnace method.
D ( 03 TC Each
91501-E-13 NOT APPLICABLE YES
item)
YES (06 TC EACH
91401-E-14 YES A( 03 TC Each item)
ITEM)
YES (06 TC EACH
91401-E-15 YES B( 03 TC Each item)
ITEM)
3.0 REFERENCES:
4.0 RESPONSIBILITIES:
The GPTI Welding supervisor / Foreman has the responsibility for implementing
and ensuring this procedure.
Document no: GPTI-SERCK-PRJ08691-PWHT-001
Rev No: 02
HEAT TREATMENT PROCEDURE Rev Date: 15/April/2021
Page No: Page 5 of 15
GPTI Shall be responsible to protect the thread and gasket area by applying
high temperature grease or any suitable paste.
E
9.0 TIME AND TEMPARATURE REQUIREMENTS
The time and temperature requirements for PWHT application shall be based
as per below requirements in para 10 & and Design documents, governing
codes & project specifications as listed under Reference.
CPECC QA/QC:
During the heating period there shall not be a greater
10.0 Temperature Cycle for Post Weld Heat Treatment: For specific
variation tag/jobthroughout
in temperature cycle, the Please refer
portion of the
vessel being heated than 250°F (140°C) within any 15 ft
heat(4.6
treatment
m) interval. request at last
11.1 Soak Band: The region around the area of interest of the vessel or piping or
nozzle/ attachment that will be heated uniformly to the required PWHT
temperature. The soak band encompasses a circular region in the tangential
and radial direction starting from the edge of the welded nozzle, or repair area
or welded attachment that will be subjected to PWHT.
11.2 Heating Band: heating band is the region that encompasses the application of
heat for PWHT and is defined in length by the equation (SB+4√R*t), where R
is the outer radius of the spherical or cylindrical shell in inches(mm), and t is
equal to the nominal thickness of the spherical or cylindrical shell in
inches(mm).
11.3 The gradient Control Band (GCB) shall be kept as low as possible in all
directions to avoid harmful temperature gradients adjacent to nozzle or
geometric discontinuities.
11.4 For PWHT of nozzle welds, repair welds, and external attachment welds on
smooth spherical shells, heads, and cylindrical shells, the temperature
differential within Gradient control Band measured at the outside edge of the
SB and the temperature measured at the outside edge of the HB shall not
exceed one half of the peak soak PWHT temperature.
11.5 For heat treatment of Repair welds/ nozzle welds: Heat local area around the
nozzle, welded attachment, or repair area such that the area is brought up
uniformly to the required PWHT temperature. The application of Local PWHT
should be performed with controlled heating method, such as induction or
electric resistance heaters, and employing thermocouples to monitor PWHT
temperature. The soak band shall extend tangentially and radially from the
edge of the nozzle wall, or attachment weld or repair area equally by a
minimum distances as defined by the thickness of the shell, t or 2in. (50 mm),
whichever is less. Refer to attachment – 3 for details.
11.6 Heating elements shall be securely fixed in contact with the work piece by soft
iron wire, SS or mild steel banding to suit the application. Under no
circumstances shall galvanized wire or other fixing material likely to detrimental
to the pipe be used.
Document no: GPTI-SERCK-PRJ08691-PWHT-001
Rev No: 02
HEAT TREATMENT PROCEDURE Rev Date: 15/April/2021
Page No: Page 8 of 15
11.7 The weldment shall be clean and free of oil, grease and dirt, prior to PWHT
operation. All machined surfaces such as flange faces, bolt holes, thread etc.
shall be protected from oxidation by coating with deoxaluminite or other
suitable material (In the scope of client/ manufacturer).
11.8 Weather protection against rain and wind exposure shall be provided at all
times during periods of inclement weather.
11.9 Prior to start PWHT the piping/components shall be checked to ensure that all
restrains are removed and pipe is free to expand and contract. Also during
PWHT the piping/components shall be properly supported to prevent sagging
and distortion.
12.0 THERMOCOUPLE
Type K (Chemical alumel) or type joint J (Iron-Constantan) Thermocouples are
recommended. All extension cables, compensating cables and jumper cables
in the measurement or control circuit shall be specifies thermocouple wire.
Thermocouple shall be attached to the work piece by direct wire capacitance
discharge method. The gap between the two wire/work piece junctions shall not
exceed 6mm. Refer to attachment – 3 for details of WPS for thermocouple
attachment.
Alternately, when thermocouples are attached by welding, it shall be performed
using approved WPS, PQR and by a qualified welder as per ASME BPVC Sec
IX.
Care shall be taken to ensure that the thermocouple conductor wires do not
touch each other, or metallic components, away from the hot joints.
After completion of PWHT, all thermocouples shall be removed and attachment
areas ground smooth to clean sound metal. If specified by the contract, the area
shall be examined by MT or PT. the energy control of Thermocouple fixing shall
be Max125 Watt-sec.
extend beyond the nozzle weld on each side at least 2 times the header
thickness.
13.0 EXTENSION LEADS
While in use, extension leads shall positioned off the floor such that they are not
damage by being subjected to direct weight or abuse.
16.0 SAFETY
All the heating elements shall be thoroughly examined before use in order to
ensure that the element wire is not exposed.
Twist lock connection 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 component surface shall
be free of contaminants.
Technicians performing the PWHT shall be experienced in PWHT operation and
conversant with electrical Characteristics in resistance or induction heating.
Care should be taken to protect themselves and others working in the area.
CPECC QA/QC:
17.0 INSPECTION PWHT Chart shall be signed with
date and time by Serck QC prior to
Serck Service QC inspector shall be responsible forstart
inspection
PWHT of all attributes
defined in this section
That the joint has been properly prepared in accordance with this procedure.
That thermocouple has been attached in accordance with this procedure.
The Thermocouple placement is in accordance with section 11.0
The chart recorder is properly calibrated.
Upon completion of PWHT operation Serck Service QC Inspector shall verify
that all temporary attachements have been removed.
After completion of PWHT operation Serck Service QC Inspector shall submit
the PWHT Chart for client review.
Each equipment receiving PWHT shall be painted on both sides of the
equipment in lettering at least 2"inch high, "POST WELD HEAT TREATED, DO
NOT WELD,HAMMER, DEFORM OR STRIKE ARCS". The paint used must be
compatible with both the primer and the finish paint.
Document no: GPTI-SERCK-PRJ08691-PWHT-001
Rev No: 02
HEAT TREATMENT PROCEDURE Rev Date: 15/April/2021
Page No: Page 10 of 15
18.0 DOCUMENTATION
Documentation of PWHT shall consist of the PWHT Report (Attachment -1) with
chart, from the recorder. When the PWHT operation is completed successfully,
the PWHT chart along with PWHT Report shall be submitted to client.
Document no: GPTI-SERCK-PRJ08691-PWHT-001
Rev No: 02
HEAT TREATMENT PROCEDURE Rev Date: 15/April/2021
Page No: Page 11 of 15
ATTACHMENT - 3
Shell Side , Tube side all welds and parent material, EXCEPT TUBE TO
ITEM/JOINT NO TO BE HEAT TREATED
TUBESHEET JOINT
GOVERNING THICKNESS 20 MM
HEAT TREATMENT TYPE FURNACE PWHT
THERMOCOUPLE TYPE K TYPE
HEAT TREATMENT CYCLE
TOLERANCE ALLOWED
LOADING TEMPERATURE 250°C Maximum
RATE OF HEATING 140°C / Hr Maximum
SOAKING TEMPERATURE 630°C ±10°C
SOAKING TIME 1 Hour Minimum
RATE OF COOLING 170°C / Hr Maximum
UNLOADING TEMPERATURE 250°C Maximum
SKETCH FOR THERMOCOUPLE LOCATIONS AND NOTES REMARKS
1) THERMOCOUPLES SHALL BE FIXED TO THE JOB BY CAPACITOR DISCHARGE WELDING
2) THERMOCOUPLES SHALL BE REMOVED BY CUTTING THEN SMOOTH GRINDING
3)PLACE 2 THERMOCOUPLE AT SHELL COURSE 180° APART (BOTH INSIDE AND OUTSIDE MAKES TOTAL 2
THERMOCOUPLES )-See Attachment
GENERAL NOTES:
1. HEAT TREATMENT CHART SHALL BE SUBMITTED WITH FOLLOWING MINIMUM INFORMATIONS
SUBCONTRACTOR'S NAME, DATE OF HEAT TREATMENT, SERCK JOB NO., ITEM DESCRIPTION
ACTUAL RATE OF HEATING, RATE OF COOLING & SOAKING TIME, SOAKING TEMPERATURE.
Prepred By Approved By
QA/QC Engineer QA/QC Manager
Sign Sign
Date Date
provide signatures
HEAT TREATMENT REQUEST
Page: 1 of 1
ITEM/JOINT NO TO BE HEAT TREATED Channel side all welds and parent material
GOVERNING THICKNESS 20 MM
HEAT TREATMENT TYPE FURNACE PWHT
THERMOCOUPLE TYPE K TYPE
HEAT TREATMENT CYCLE
TOLERANCE ALLOWED
LOADING TEMPERATURE 250°C Maximum
RATE OF HEATING 200°C / Hr Maximum
SOAKING TEMPERATURE 630°C ±10°C
SOAKING TIME 50 Minutes Minimum
RATE OF COOLING 200°C / Hr Maximum
UNLOADING TEMPERATURE 250°C Maximum
SKETCH FOR THERMOCOUPLE LOCATIONS AND NOTES REMARKS
1) THERMOCOUPLES SHALL BE FIXED TO THE JOB BY CAPACITOR DISCHARGE WELDING
2) THERMOCOUPLES SHALL BE REMOVED BY CUTTING THEN SMOOTH GRINDING
3)PLACE 2 THERMOCOUPLE AT SHELL COURSE 180° APART (BOTH INSIDE AND OUTSIDE MAKES TOTAL 2
THERMOCOUPLES )-See Attachment
GENERAL NOTES:
1. HEAT TREATMENT CHART SHALL BE SUBMITTED WITH FOLLOWING MINIMUM INFORMATIONS
SUBCONTRACTOR'S NAME, DATE OF HEAT TREATMENT, SERCK JOB NO., ITEM DESCRIPTION
ACTUAL RATE OF HEATING, RATE OF COOLING & SOAKING TIME, SOAKING TEMPERATURE.
SPEED OF CHART IF APPLICABLE, IDENTIFICATION OF CHART RECORDER*IDENTIFICATION OF thermocouple details are missing,
provide in next revision
EACH THERMOCUPLE & NAME AND SIGNATURE OF HEAT TREATMENT OPERATOR.
Prepred By Approved By
QA/QC Engineer QA/QC Manager
Sign Sign
Date Date
provide signatures
HEAT TREATMENT REQUEST
Page: 1 of 1
Shell Side , Tube side all welds and parent material, EXCEPT TUBE TO
ITEM/JOINT NO TO BE HEAT TREATED
TUBESHEET JOINT
GOVERNING THICKNESS 22 MM
HEAT TREATMENT TYPE FURNACE PWHT
THERMOCOUPLE TYPE K TYPE
HEAT TREATMENT CYCLE
TOLERANCE ALLOWED
LOADING TEMPERATURE 250°C Maximum
RATE OF HEATING 140°C / Hr Maximum
SOAKING TEMPERATURE 630°C ±10°C
SOAKING TIME 1 Hour Minimum
RATE OF COOLING 170°C / Hr Maximum
UNLOADING TEMPERATURE 250°C Maximum
SKETCH FOR THERMOCOUPLE LOCATIONS AND NOTES REMARKS
1) THERMOCOUPLES SHALL BE FIXED TO THE JOB BY CAPACITOR DISCHARGE WELDING
2) THERMOCOUPLES SHALL BE REMOVED BY CUTTING THEN SMOOTH GRINDING
3)PLACE 2 THERMOCOUPLE AT SHELL COURSE 180° APART (BOTH INSIDE AND OUTSIDE MAKES TOTAL 2
THERMOCOUPLES )-See Attachment
GENERAL NOTES:
1. HEAT TREATMENT CHART SHALL BE SUBMITTED WITH FOLLOWING MINIMUM INFORMATIONS
SUBCONTRACTOR'S NAME, DATE OF HEAT TREATMENT, SERCK JOB NO., ITEM DESCRIPTION
ACTUAL RATE OF HEATING, RATE OF COOLING & SOAKING TIME, SOAKING TEMPERATURE.
SPEED OF CHART IF APPLICABLE, IDENTIFICATION OF CHART RECORDER*IDENTIFICATION OF thermocouple details are missing,
provide in next revision
EACH THERMOCUPLE & NAME AND SIGNATURE OF HEAT TREATMENT OPERATOR.
Prepred By Approved By
QA/QC Engineer QA/QC Manager
Sign Sign
Date Date
provide signatures
HEAT TREATMENT REQUEST
Page: 1 of 1
Shell Side , Tube side all welds and parent material, EXCEPT TUBE TO
ITEM/JOINT NO TO BE HEAT TREATED
TUBESHEET JOINT
GENERAL NOTES:
1. HEAT TREATMENT CHART SHALL BE SUBMITTED WITH FOLLOWING MINIMUM INFORMATIONS
SUBCONTRACTOR'S NAME, DATE OF HEAT TREATMENT, SERCK JOB NO., ITEM DESCRIPTION
ACTUAL RATE OF HEATING, RATE OF COOLING & SOAKING TIME, SOAKING TEMPERATURE.
SPEED OF CHART IF APPLICABLE, IDENTIFICATION OF CHART RECORDER*IDENTIFICATION OF thermocouple details are missing,
provide in next revision
EACH THERMOCUPLE & NAME AND SIGNATURE OF HEAT TREATMENT OPERATOR.
Prepred By Approved By
QA/QC Engineer QA/QC Manager
Sign Sign
Date Date
provide signatures
HEAT TREATMENT REQUEST
Page: 1 of 1
ITEM/JOINT NO TO BE HEAT TREATED Channel side all welds and parent material
GOVERNING THICKNESS 12 MM
HEAT TREATMENT TYPE FURNACE PWHT
THERMOCOUPLE TYPE K TYPE
HEAT TREATMENT CYCLE
TOLERANCE ALLOWED
LOADING TEMPERATURE 250°C Maximum
RATE OF HEATING 220°C / Hr Maximum
SOAKING TEMPERATURE 630°C ±10°C
SOAKING TIME 30 Minutes Minimum
RATE OF COOLING 220°C / Hr Maximum
UNLOADING TEMPERATURE 250°C Maximum
SKETCH FOR THERMOCOUPLE LOCATIONS AND NOTES REMARKS
1) THERMOCOUPLES SHALL BE FIXED TO THE JOB BY CAPACITOR DISCHARGE WELDING
2) THERMOCOUPLES SHALL BE REMOVED BY CUTTING THEN SMOOTH GRINDING
3)PLACE 2 THERMOCOUPLE AT SHELL COURSE 180° APART (BOTH INSIDE AND OUTSIDE MAKES TOTAL 2
THERMOCOUPLES )-See Attachment
GENERAL NOTES:
1. HEAT TREATMENT CHART SHALL BE SUBMITTED WITH FOLLOWING MINIMUM INFORMATIONS
SUBCONTRACTOR'S NAME, DATE OF HEAT TREATMENT, SERCK JOB NO., ITEM DESCRIPTION
ACTUAL RATE OF HEATING, RATE OF COOLING & SOAKING TIME, SOAKING TEMPERATURE.
SPEED OF CHART IF APPLICABLE, IDENTIFICATION OF CHART RECORDER*IDENTIFICATION OF thermocouple details are missing,
provide in next revision
EACH THERMOCUPLE & NAME AND SIGNATURE OF HEAT TREATMENT OPERATOR.
Prepred By Approved By
QA/QC Engineer QA/QC Manager
Sign Sign
Date Date
provide signatures
CPECC QA/QC:
Attach sample calibration certificate of recorder,thermocouples etc.