PT.

BARATA INDONESIA
Jln. Veteran 241 Gresik - Indonesia Phone : 031 - 3990555 ; Fax : 031 - 3990666
ENGINEERING
Costumer : Project :

PT. FL Smidth Indonesia

Repair Main shaft of Gyratory Crusher

Document No. : ED70.720.008 & ED70.720.003

No. of Sheet Order No : PLG. 9. 10. 206

:15 (include cover)

HEAT TREATMENT PROCEDURE

1 REV

27-08-2010 DATE

All PAGE

DESCRIPTION RMA
PREPD

DEDY WIWEKO
CHECKED

DEDY WIWEKO
REVIEWE D

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1.0 SCOPE This procedure provides information, methods and controls for preheat and Post Weld Heat Treatment (PWHT) used in welding operations. For Fabrication Repair main shaft & Core of Gyratory Crusher, ordered by PT. FL, Smidth Indonesia. 2.0 REFERENCE 2.1. ASME Boiler and Pressure Vessel Code : Section I Section II Section VIII Section IX Power Boiler Material Specification, Parts A, B and C Pressure Vessels, Division 1 Welding and Brazing Qualification

2.2. PT Barata s Quality Assurance Manual 2.3. Customers Specifications

3.0 RESPONSIBILITIES 3.1 The Engineering Manager shall be responsible for the performance and

control of all heat treatment in accordance with this procedure. 3.2 The preheat temperatures maintenance during welding, post weld heat treatment temperatures and holding time shall be as per those specified on the applicable WPS 3.3 When heat treatment operations are to be subcontracted, the subcontractor must perform the work according to reference 2.3 and this procedure.

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4.0 GENERAL INFORMATION 4.1 The information contained in this procedure meets the requirements of documents referenced in paragraph 2.0 4.1
No. 1 -

Item Shall be heat treated are :

Item No. SHAFT & CORE Description Material CARBON STEELS Qty 1

]5.0 POST WELD HEAT TREATMENT (PWHT) 5.1 Quick Reference Table 2 (Attachment II) provides information for the minimum PWHT requirements of welds as required by the documents reference in paragraph 2.0. In all cases, the temperature shall be indicated on the WPS.

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5.2

Heat Band 5.2.1 ASME Section VIII Div.1 5.2.1.1 The heat band width, the placement of thermocouples, and preheat and PWHT information shall be determined on an individual basis for compliance with section VIII div.1.

5.3. Temperature Measurement 5.3.1 PWHT temperature shall be measured and monitored by the use of temperature indicating crayons, optical pyrometers, thermocouples with calibrated chart recorders, potentiometers or an equivalent method. 5.3.2. A minimum of three (3) thermocouples shall be used on all weldments larger than 6 OD or 0.750 (19 mm) wall thickness. The position of thermocouple on bottom, center and on top. Additional thermocouples should be considered for use on large diameters and wall thickness in the event of primary thermocouple failure, when a component of assembly is subject to PWHT as a complete unit, the furnace must be equipped with at least 6 thermocouples. Location of the thermocouples is dependent upon the size of the load, thickness of component and anticipated cold and hot areas of the various units in the furnace. 5.3.3. All thermocouples used for heat treatment shall be type K chromylalumel. Chromyl wire is slightly magnetic and positive (+), alumel wire is more magnetic and negative (-). Potentiometer and chart recorder connections and marred accordingly. The outside cover of the

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chromyl-alumel wire is yellow. The chromyl wire has red covering. It is essential that the correct lead wire and plug connections be used. Another type wire will cause errors in readings. 5.3.4. Thermocouples shall be placed on opposite side of the weld at the other boundaries of the required heat band. 5.3.5. Thermocouples wires shall be completely insulated except at the hot junction. When attach, the hot junction shall be protected from direct radiation from heat source. 5.3.6. Thermocouples shall be attached to the weldment either by welding to assure that the wire is in metallic contact with the weldment or by a mechanical method, which weldment. 5.3.7. Removal of thermocouple by grinding and visual Examined by QC. 5.4.Temperature Rise and Cooling 5.4.1.ASME Section VIII, Div. 1 5.4.1.1. The temperature of the furnace shall not exceeded 425 oC, at the time the vessel or part is placed in it. 5.4.1.2. Above 425 oC, the rate of temperature rise shall not be more than 222 oC per hour divided by the maximum thickness of the thicker part in inches but in no case more than 222 oC . 5.4.1.3. During the heating cycle, there shall be no greater variation in temperature than 139 oC within any 4.6 meters interval of the length of the component. will assure metallic contact with the

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5.4.1.4. During the holding cycle, there shall be no greater variation in temperature than 83 oC between the highest and lowest temperature throughout the portion of the vessel being heated, except where the range is further limited in table UCS-56. 5.4.1.5. Above 425 oC , cooling shall be done in a close furnace or cooling chamber at a rate no greater than 278 oC per hour divided by the maximum metal thickness of the thicker part in inches, but no more than 278 oC. From 425 oC the vessel may be cooled in still air. 5.4.1.6. ASME section I , refer to PW-39 and Table PW-39. 5.5. Holding Time / Temperature 5.5.1. The weldment shall be held for the required time and at a temperature specified in the applicable ASME code. 5.5.2. When pressure parts of two different P-No. are welded together, the holding temperature shall be of the material requiring the higher post weld heat treatment temperature. When non-pressure parts are joined to pressure part, the pressure part temperature shall be used. 5.5.3. During the holding time, the maximum temperature between any two thermocouples shall be the temperature range specified on the WPS. 5.5.4. The holding time at the heat treatment temperature may be an accumulation of time of multiple post weld heat treatment cycles.

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5.6. Documentation 5.6.1. A time-temperature record shall be provided for each PWHT operation. 5.6.2. More than one PWHT may be recorded on a single record provided each operation can be distinguished from the others. 5.6.3. The time-temperature record shall be either by calibrated chart recorder or by a heat treatment recorder, recorded at intervals not exceed 5 minutes, prepared from temperature measurements taken using temperature indicating crayons, optical pyrometers,

potentiometer attached to the thermocouples or an equivalent method. 5.6.4. Each automatically controlled recording chart be stamped as shown in Attachment III, Figure 1, and the required information and signatures provided for assurance that the PWHT is complete and satisfactory. When a recording chart is used in connection with a calibrated chart recorder, the speed of the chart shall be indicated. The number of the calibrated instrument used to measure the PWHT temperature shall be shown in the record or recording chart. 5.6.5. The records required by this procedure shall be maintained in accordance with the Barata Quality Assurance Manual. 6.0 METHOD OF POST WELD TREATMENT 6.1 Electric Resistance 6.1.1 This section shall be used with paragraph 6.0 to perform post weld heat treatment using electric resistance as the heat source.

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6.1.2

The heat source shall include, but not limited to ceramic covered finger elements, flexible ceramic pads, braided pads, wrap-around, channel elements and ceramic covered length of wire.

6.1.3

Calibrated time-temperature chart recorders and controllers are recommended but are not mandatory. The method used shall maintain control within temperature parameters specified in the applicable WPS.

6.1.4

When using an electric resistance heat source, PWHT temperature shall be measured using thermocouples and recorded on a calibrated chart recorder or shall be measured at 3 minutes interval using a potentiometer. Record shall be maintained on the temperature measurement. Progressively through the required holding time. Refer to the paragraph 6.0 for detailed recording requirements.

6.1.5

The material on each side of the heat source shall be sufficiently insulated to minimize heat loss and to prevent a sharp temperature gradient at the edge of the heated core.

6.2 Furnace 6.2.1 This section shall be used with paragraph 6.0 to perform PWHT using burner as the heat source. 6.2.2 The fuel may be diesel oil or kerosene. 6.3 Quartz Lamps 6.3.1 This section shall be used with paragraph 6.0 to perform PWHT using quartz lamps as the heat source.

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6.3.2

Calibrated time-temperature chart recorder and controller attached to thermocouples shall be used to measure, control and record the PWHT operation using quartz lamps.

6.3.3

The quartz lamps shall be positioned circumferentially around the weldment in a manner that will assure the required heat bandwidth. Refer to paragraph 6.2.

6.3.4

A recording thermocouple shall be placed where it will record the temperature of the weldment directly and dimensionally at the center of each circumferential band of quartz lamps used. Additional recording thermocouples shall be placed at the outer boundaries of the required heat band and at the center of the weld.

6.3.5

There shall be no greater than 83 oC different between any two thermocouples during the rise to the PWHT holding temperature. Holding time shall start when all thermocouples register temperature within the parameter stated in the WPS.

6.3.6

When installed on a weldment, the hot tip of the quartz lamps shall not be more than 5-1/2 circumferentially from the tip of the lamps in the adjacent bank.

6.3.7

The temperature rise, the holding time and the cooling down to 600 oF shall be controlled and recorded within the parameters specified in the WPS and the requirement of this procedure.

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Paragraph 6.4.2.1. does not apply when using quartz lamps as the heat source. 6.3.8 The material adjacent to the quartz lamps heat band shall be insulated to minimize heat loss and prevent a sharp temperature gradient at the edge of heated area.

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ATTACHMENT I TABLE I PREHEAT QUICK REFERENCE

ASME IX P-No.
Sect. I,ed 2004ad 2005 App.A 100.4 Sect. VIII,ed 2004ad 2005 App.R B.311,ed 2004 Part 131

Spec Gr.1,2,3 Over 0.3% C, T > 1" All other Gr.1,2,3 > 70000 psi, T > 1" All other Gr.1,2,3 > 60000 psi, t > 1/2" All other A,B,C > 60000 psi, t > 1/2" Cr% > 6% All other Gr.1,2,3 Gr.1,2 Gr.1,2 -

Min F C) 175 (80) 50 (10) 175 (80) 50 (10) 250 (120) 50 (10) 400 (205)

Spec Gr.1,2,3 Over 0.3% C, T > 1" All other Gr.1,2,3 > 70000 psi, T > 5/8 " (16 mm) All other Gr.1,2,3 > 60000 psi, t > 1/2" All other A,B,(Gr.1) > 60000 psi, t > 1/2" Cr% > 6% All other Gr.1,2,3 Gr.1,2 Gr.1,2 A,Gr.1 B,Gr.1 A,Gr.1

Min F C) 175 (80) 50 (10) 175 (80) 50 (10) 250 (120) 50 (10) 400 (205)

Spec Over 0.3% C, T > 1" (may be based on actual carbon content) > 60000 psi, > 1/2" ,

Min F(C) 175 (80)

175 (80)

All materials

250 (121)

6 7 8 9

300 (149) 400 (205) None None 175 (80) 300 (150)

A,Gr.1

300 (149) 400 (205) None None 250 (120) 300 (149) 175 (80) 250 (120)

A,B,C > 60000 psi, t > 1/2" Cr% > 6% All other All materials A B I ; Inter-pass temp. max 450F (230C) ~

400 (205)

400 (200)

250 (120) 300 (150) 300 (150)

10

E,Gr.5 Inter-pass temp. maintained 350F (175C) ~ 450F (230C) ~

B,Gr.2

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ASME IX P-No.

Sect. I,ed 2004ad 2005 App.A 100.4

Sect. VIII,ed 2004ad 2005 App.R

B.311,ed 2004 Part 131

Spec

Min F (C) -

Spec

10

11

C.Gr.3 With note*) F.Gr.6 . D.Gr.4 & E.Gr.5 Inter-pass temp. maintained 350F (177C) ~ 450F (232C) ~ A.Gr.1 A.Gr.2,3 with note*) A.Gr.4 B A.Gr.1,2,3,4,5 With note*) A.Gr.1,2,3,4,5

Min F (C) 175 (80) 250 (120) 300 (149)

Spec

Min F (C)

None Same as P.5 250 (121) Same as P.3 Same

Note: *) consider to the limitation of inter-pass temp. for various thickness to avoid detrimental effects on the mechanical properties of heat treated materials. **) Although temperature shown will usually satisfy ANSI and ASME requirements, temperature shown on applicable WPS shall be used. NOTES: 1. Thickness referred to are nominal at weld for parts to be joined. 2. When pressure parts or two different P-No. grouping are to be joined by welding, higher preheat requirement shall control. When non-pressure parts (attachment) are joined by welding to pressure parts, preheat requirements for the pressure parts shall control.

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3. Welding on P-3, P-4, P-5A, P-5B and P-6 material, with 3% Cr. max. may be interrupted provided: A min. of at least 3/8 thickness of weld is deposited or 25% or welding groove is filled, whichever is greater. The weld is cooled slowly to room temperature. For P-5B with Cr % > 3% & P-6 material, weld is subjected to an adequate intermediate heat treatment with controlled cooling rate. Before welding is resumed, there shall be a visual examination of the weld to ensure that no cracks have occurred. The required preheat must be resumed before welding is continued. 4. When different thickness are welded together, preheat temperature shall be measured and maintain in a manner that will assure the preheat temperature in the thicker part. 5. Preheat requirements listed are not mandatory. If used, temperature values will not in it self ensure satisfactory completion of weld.
6. Preheat requirements listed are code minimum requirement and must be followed.

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ATTACHMENT II TABLE II POST WELD HEAT TREATMENT QUICK REFERENCE Sect. I; ed2004, add.2005 B 31.1; ed2004 Sect. VIII Div.1; PW-39 Part-132 ed2004, add.2005.

UCS-56
Sect. IX P-NO. Min. wall & other Temp. oF range Min. wall & other Temp . oF range Min. wall & other Temp. oF range

P-1 Carbon steel P-3 1 % Carbon Molyb. P-4 1 % Cr.

Over Gr. 1, 2, 3

1100-1330

Over Gr. 1, 2, 3

1100-1330

Over 5/8 Gr. 1, 2, 3 Over 0.15% C or less than 250 oF preheat Gr. 1

1100-1330

Over 5/8 Gr. 1, 2, 3 Over thick or over 4 nom. pipe size or over 0.15% C max. or less than 300 oF preheat Over thick or over 4 nom. pipe size or over 0.15% C max. or less than 300 oF preheat All All All

1100-1330

1200-1360

1300-1360

Over 1 w/ preheat less than 200 oF Over 1 5/8 & over Gr. 1 & 2, All thickness Gr. 3 Over 4 nom. OD or over 0.15% C or over 5/8 or less than 250 oF preheat Over 4 nom. OD or over 0.15% C or over 5/8 or less than 300 oF preheat All All All

1100-1330

1100-1330

1200-1360

P-5 A 2 % Cr.

Over 0.15% C or over 5/8 thick or less than 300 oF preheat Gr. 1

1250-1470

1250-1470

1250-1470

P-5 B 5% Cr. P-5B 9% Cr. P-8

All Gr. 1 All Gr. 2 All Gr. 1, 2, 3,4

1250-1490 1300-1470 None

1300-1490 1300-1470 None

1300-1490 1300-1400 None

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ATTACHMENT OF
No Dokument : HT/FLS/01 SPESIFIKASI PROCEDUR PERLAKUAN PANAS Document No HEAT TREATMENT PROCEDURE SPECIFICATION No Revisi : 0 Revision No Pemesan No. Item Gambar : : PT.FLS Drawing No. Item Customer Proyek Nama Peralatan : Shaft & Core : Repair shaft & core Equipment Name Project No. Order Pek. Bahan : Carbon Steel : PLG. 9.10.206 Material Job Order No. Macam Perlakuan panas Jumlah Thermocopel : PWHT : Min 4 Kind of Heat Treatment Number of Thermocopel Ukuran Dapur Tebal : 6000 x 6000 x 12000 : T~60 mm Size of Furnace Thicness SKET DRAWING Tanggal /Date : 27-08-10

DIAGRAM HOLDING TEMPERATUR (1" Thk / Hour) 550C 10C

200C Max. 200C / Hour

Keterangan Remark Disetujui oleh Approved by PROSES ENGINEERING Dikaji ulang oleh Reviewed by

Holding 2.5 Hours

Max. 200C / Hour

Reference

Disiapkan oleh Prepared by

(DEDY WA)

(DEDY WA)

(RMA)

Heat Treatment procedure