GULF SPIC ENGINEERING L. L.

GS
E

PROCEDURE FOR POST WELD

HEAT TREATMENT

DOC No: GSE/PRO/PWHT-006 Rev 1

NAME

SIGNATURE

PREPARED BY

CHECKED BY

APPROVED BY

D. SATISH KUMAR

N. RAMANI

R. SUNDAR

GULF SPIC ENGINEERING L. L. C

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PROCEDURE FOR POST WELD HEAT TREATMENT

1.0

SCOPE
This procedure specifies the requirements for execution of local POST
WELD HEAT TREATMENT for piping systems for AL-AWEER GAS TURBINE
POWER STATION H PHASE III.

2.0

REFERENCE
ASME B 31.1
DEWA PROJECT SPECIFICATIONS G5.6

3.0

PERSONNAL

3.1

QUALIFICATION
Personnel undertaking Post Weld Heating Treatment will be qualified as
per Electrical & Safety knowledge applicable for this method and shall
be capable of undertaking the relevant procedure and specification
related to the heat treatment. If GSE sub-contacts PWHT scope, it shall
be verified that the sub-contractors are properly qualified to the
required norms.
SAFETY & HAZARDS
All necessary safety precautions will be undertaken by GSE while
carrying out PWHT. In case GSE sub-contracts the PWHT scope, the subcontractors will be instructed about our safety policies to be
implemented in the job site. Every precaution and consideration should
be taken to ensure all potential hazards associated with electrical
equipments are removed.

3.2

4.0

SURFACE CONDITION
Welds & HAZ shall be prepared only to the extent necessary to avoid
damage or short circuiting of elements i.e., free of coatings, grease in
the heated area.

5.0

EQUIPMENTS
Heating elements
Thermocouples

:
:

Controller

Electrical Resistance Heater

Ni-Cr / Ni-Al type K confirming
to BS4937
Automatic (pre-calibrated and
programmed) / Manual (potentiometric

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GULF SPIC ENGINEERING L. L. C

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PROCEDURE FOR POST WELD HEAT TREATMENT

Temperature recorders

Insulation

controller)
6 point or 12 point multi-dot printer
calibrated for type k thermocouples
Ceramic fiber mats, SS meshed 20mm
Thick or Cu knit mats 10mm thick.

6.0

CALIBRATION

6.1

Temperature Recorder shall be calibrated every 6 months and calibration

certificates will be submitted.
Controller shall be calibrated every 12 months and calibration
certificates will be submitted.
In case GSE sub-contracts the PWHT scope, the relevant calibration
certificates from the sub- contractors will be submitted to ETA.

6.2
6.3

7.0

PRE-REQUISITES

7.1

The work piece being heat treated shall be adequately supported along
its entire length to prevent any damage/collapse during thermal cycle.
The work piece shall have (and be ensured) un-restricted freedom of
movement in all directions.
Thermocouple should be attached by capacitor discharge method.
The Thermocouple wire shall have valid certificates of conformance and
shall indicate tolerances as specified below
0 0C to 400 0C
+ 3 0C
0
0
400 C to 1100 C
+ 0.75 0C
The Thermocouple orientation shall be so positioned to record thermal
variation at different zones of the pipe. The orientation of
thermocouples should be as follows,

7.2
7.3
7.4

7.5

Diameter of
Pipe
Upto 4
From 6 to 10
Above 10
7.6
7.7

No. of
Thermocouple
1
2
3

Position
12o clock
6 & 12o clock
4o, 8o & 12o clock
o

All machined surfaces such as flange face, threaded bolt holes & threads
shall be suitably protected by heat resistant coating to avoid oxidation
during heat treatment.
The temperature recorders shall be ensured of recording and monitoring
all thermocouples to provide information on temperature differences,
trends during heating/cooling cycle etc.
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GULF SPIC ENGINEERING L. L. C

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PROCEDURE FOR POST WELD HEAT TREATMENT

8.0

METHOD
Electrical Resistance Coil type heating elements are used for application
of heat on the weld joints which is sufficiently covered with insulation
pads / mats to enable retention of heat on the work piece. The
following heating, holding & cooling cycle shall be followed.
From Ambient to 300 0C the heating rate shall be unrestricted.

Above 300 0C the rate of heating shall be maximum of 150 0C per

hour.

Temperature ranges & Holding Periods

For Carbon Steel Group P1:
Temperature range shall be 600 0 650 0C.
Holding period 2.5min per mm nominal wall thickness but not less
than 1 hour, or as per the Project Tech. Specifications.

The item shall be cooled down to a temperature of 300 0C at a

rate not exceeding 150 0C per hour below which the item may be
cooled in still air.

During the heating, holding & cooling cycle the variation of

registered temperature between the thermocouples shall not
exceed + 20 0C.

The relative positions of the thermocouples will be indicated on a

chart.

The time temperature chart for the heat treatment is to be

adequately documented.

The number of traces of lines or chart record shall be such that

positive identification of each channel is assured.

9.0

ARRANGEMENT OF HEATING ELEMENTS

9.1

Heating elements shall be applied either as a single band or two or more

discrete bands depending on the size and geometry.

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GULF SPIC ENGINEERING L. L. C

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PROCEDURE FOR POST WELD HEAT TREATMENT

9.2
9.3
9.4
9.5

9.6
9.7

The heating band width shall be atleast 3 times the width of the widest
part of the welding groove but in no case shall be less than twice the
width of weld reinforcement.
The centerline circumferential gap between two bands shall not exceed
30mm or the thickness of the job whichever is lesser.
The longitudinal gap between the elements shall not exceed the wall
thickness or 50mm, whichever is lesser.
Unequal wall thickness at weld joints shall be provided with independent
control circuits on both side of the welds. In case of pipe-to-flange
welds, the flange OD shall be provided with additional heating elements
so as to avoid heat loss.
Insulation shall extend a minimum of 305mm beyond the edges of the
heating band or the distance determined by the product of bore radius
times the maximum wall thickness, whichever is lesser.
For Pipe to Branch welds, the main pipe member should have a full
circumferential band (for a width of 3 times the main pipe wall
thickness) and the branch shall have a independent circumferential band
(for the same width).

10.0 HARDNESS TEST

Portable Hardness Tester shall be used for carrying out hardness testing.
The equipment shall be calibrated against the standard test block prior
to use.
11.0 INSULATION
11.1
11.2

Insulation shall extend for a minimum distance of 2.5 R x T on each side

of the weld centerline (R bore radius; T maxm wall thickness).
The number of layers may extend and adjusted to meet the variations of
wall thickness, pipe diameter, gradient requirements and site conditions.

12.0 TEMPERATURE CONTROL

An automatic pre-set program control unit will be used to control the
temperature and time automatically throughout the heat treatment
cycle.

13.0 PRECAUTIONS

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GULF SPIC ENGINEERING L. L. C

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PROCEDURE FOR POST WELD HEAT TREATMENT

13.1
13.2
13.3
13.4
13.5
13.6
13.7

13.8

The open ends of the pipes, fittings shall be covered suitably to avoid
draught cooling during heating cycle.
All the welded valves in-line with the heat treated system shall be kept
half open (not full open).
The resistance heater coils situated on the underside of the pipe shall be
examined for bulges indicating loss of contact of the heating elements.
Thermocouples and positions shall be identified on the recorder by
color/symbol.
The chart speed shall be set at 50mm/hr.
The start and end points of heating, holding & cooling cycle shall be
properly recorded in the chart (in a suitable way).
The maximum temperature difference between the thermocouples
during heating and cooling cycle shall not exceed + 50oC. During the
holding period, the maximum temperature difference between the
thermocouples shall be + 20 0C.
Any discrepancies shall be reported to the QC engineer and in
consultation with SIEMENS/ETA & MMD shall decide if any re-heat
treatment will be required.

14.0 DOCUMENTATION & RECORDS

14.1

14.2
14.3
14.4

The heat treatment chart shall have unique identification/sl no. for
reference, parameters of heat treatment, and identification details of
the item & weld heat treated, date, time and signature of the operator
& QC engineer.
The name(s) of the technician(s) shall accompany the chart.
Reference shall be made of the client, project name, and equipment /
piping identity wherever possible.
The final report shall accompany the chart to indicate thermocouple
positions, heating arrangements, and other necessary details. The same
shall be duly signed by the SIEMENS/ETA and MMD.

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