Shell Petroleum Development Company: (Implemented/Issued For Review/Complete)
Shell Petroleum Development Company: (Implemented/Issued For Review/Complete)
Shell Petroleum Development Company: (Implemented/Issued For Review/Complete)
[PROJECT NAME]
Classification Status : Restricted
Controlled
Uncontrolle
d
or
If Controlled
Copy Number
Issue Date :
Issued To :
Company :
REVISION STATUS
Rev.
Date
Description
APPROVAL
Focal Point
(Implemented/Issued for
Review/Complete)
Checked
Custodian
Project Name:
Project Work Instruction
Post Weld Heat Treatment
Classification: RESTRICTED
Revision: R1
2.0
Revisions
1.1
All revisions for review will be issued at R1, with subsequent R2, R3 etc. if
required.
1.2
1.3
1.4
1.5
1.6
Distribution
2.1
2.2
Other copy holders are responsible to verify with the DCC that their copy
is current before use.
2.3
Parties not included on the distribution list below and requiring revision
services shall notify the custodian department for inclusion at the next
issue.
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Project Name:
Project Work Instruction
Post Weld Heat Treatment
Classification: RESTRICTED
Revision: R1
Contents
1.0
SCOPE..................................................................................................................................4
2.0
REFERENCES.....................................................................................................................4
3.0
DEFINITIONS / ABBREVIATIONS.................................................................................4
4.0
RESPONSIBILITIES..........................................................................................................4
5.0
QUALIFICATIONS............................................................................................................4
6.0
PWHT REQUIREMENTS.................................................................................................5
7.0
DOCUMENTATION / RECORDS...................................................................................11
ATTACHMENT 1 HEAT TREATMENT REPORT....................................................17
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Project Name:
Project Work Instruction
Post Weld Heat Treatment
Classification: RESTRICTED
Revision: R1
1.0 SCOPE
The scope of this project work instruction includes the post weld heat treatment of pipe
and equipment weldments, including whole items of equipment either by local methods or
in an enclosed furnace.
This procedure is applicable to all post weld heat treatment carried out on the and Offplot
Project.
2.0 REFERENCES
I) ASME Code Section I
)
II) ASME Code Section III
)
III)
ASME Code Section VIII div.1
IV)
ASME B31-1
)
V) ASME B31-3
)
DEP 61.40.20.30 GEN Section 4.11
4.0 RESPONSIBILITIES
The Quality Assurance Manager is responsible for monitoring/auditing compliance with
the requirements of this work instruction.
The QC department are responsible for ensuring that the requirements of this work
instruction are implemented.
The appointed PWHT technicians are responsible for carrying out PWHT, as directed by
the Contractor QC department, in accordance with this work instruction.
5.0 QUALIFICATIONS
The personnel responsible for the implementation of this work instruction shall be suitably
qualified by one or all of the following means
1) Formal education / Qualification
2) Training / Recognised approval
3) Experience
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Project Name:
Project Work Instruction
Post Weld Heat Treatment
Classification: RESTRICTED
Revision: R1
Heating Methods
Postweld heat treating under this work instruction shall be accomplished by electric
resistance heating, induction heating, quartz halogen lamp heating, gas-fired muffle
furnaces, or as otherwise specified in the project specifications. Induction heating and gasfired muffle furnaces are not permitted for ASME Section III unless there are qualification
data showing that uniform temperatures are achieved and that the internal temperatures
are also acceptable. Exothermic heating is prohibited.
6.2
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Project Name:
Project Work Instruction
Post Weld Heat Treatment
Classification: RESTRICTED
Revision: R1
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Project Name:
Project Work Instruction
Post Weld Heat Treatment
Classification: RESTRICTED
Revision: R1
For postweld heat treating of circumferenctial joints, the width of the heated band
measured from each side of the greatest width of the finished weld shall be the thickness
of the weld or two inches, whichever is less.
The resistance method heat source width shall be a multiple of the thickness and shall be
related to the PWHT holding temperature as shown in Table 1. For quartz lamp method
PWHT, the heat source width shall be either a single band, double band or greater in
accordance with Table 2.
6.3.3 ASME Section VIII, Division 1
For local postweld heat treating of circumferential joints on vessels, the width of the
heated band measured from each side of the greatest width of the finished weld shall be
not less than two times the shell thickness. The portion outside the heating device shall be
protected so that the temperature gradient is not harmful.
For local postweld heat treating of circumferential joints of pipe or tubing, the width on
each side of the center line of circumferential joints in piping or tubing to be heated to the
postweld heat treatment temperature, shall be protected so that the temperature gradient is
not harmful.
Nozzles or other welded attachments shall be postweld heat treated by heating a
circumferential band around the entire vessel or header. The heated band shall extend at
least six times the wall thickness beyond the weld that connects the nozzle or other
attachment. The portion outside the heating device shall be protected so that the
temperature gradient is not harmful.
6.3.4 ASME / ANSI Code B31.1
For local postweld heat treatment of butt weld joints, the minimum width of the heated
band at the specified temperature, centered on the weld, shall be at least three times the
wall thickness of the thicker part.
Branches and other welded attachments shall be postweld heat treated by heating a
circumferential band around the pipe or header to which the attachment is welded. The
width of the heated band shall extend at least two times the header thickness beyond the
nozzle or attachment weld and shall extend completely around the header.
6.3.5 ASME / ANSI B31.3
As for ASME / ANSI B31.1
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Project Name:
Project Work Instruction
Post Weld Heat Treatment
6.4
Classification: RESTRICTED
Revision: R1
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Project Name:
Project Work Instruction
Post Weld Heat Treatment
Classification: RESTRICTED
Revision: R1
For welds in which the postweld heat treatment temperature has dropped below the
minimum holding temperature without exceeding the specified cooling rate, actions should
be initiated to restart the heat treatment as soon as possible.
The weldment shall be reheated as a rate not to exceed that specified by the applicable
Code, and the holding temperature shall be re-established. The additional required holding
time shall be calculated by finding time remaining to complete the postweld heat treatment
from the first holding period. The weld shall be held at temperature for this time period or
for one-half hour, whichever is greater.
For welds in which the maximum Code cooling rate was exceeded, the postweld heat
treatment shall be redone for both the entire holding period and cool-down rate, providing
the total time-at-temperature will not exceed that qualified by the welding procedure for
ASME Section III applications. If an interrupted heat treatment occurs, actions should be
initiated to restart the heat treatment as soon as possible.
The weldment shall be reheated at a rate not to exceed that specified by the applicable
Code, and the holding temperature shall be re-established. The required holding time shall
be that originally determined for the particular weld. Upon completion of the holding
period, cool down shall be conducted within specified applicable Code limits.
Where quartz lamp heating failures lead to cool down rates that exceed applicable Code
requirements, it is recommended that as a minimum, visual inspection of the heated
surface be conducted after final postweld heat treatment.
Interrupted postweld heat treatments shall be noted and explained on the charts and
records.
6.5
Temperature Control
Postweld heat treatment temperatures shall be checked by the use of chromel-alumel
thermocouples, chromel-alumel lead wire, and multiple-point temperature-indicating
recorders.
Thermocouples, and thermocouple wires, shall be purchased to standard limits of error of
not more than 0.75 percent in the range of 277C to 1260C. This requirement shall be so
stated in the purchase requisition. Thermocouple wire for capacitor discharge applications
shall be covered with high temperature insulation. Thermocouple wire less than three feet
in length shall not be used.
The thermocouples should be attached by the capacitor discharge method. Placement of
the thermocouples shall be as required in the job specifications. In cases where
circumstances require deviations from the recommended thermocouple placement, the
locations shall be determined by BEJV Welding Engineer.
If thermocouples are used inside pipe joints, these shall be recorded. The requirements of
Tables 1 and 2 for holding temperatures and heat source width may be waived.
IF PRINTED THIS DOCUMENT IS NOT CONTROLLED
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Project Name:
Project Work Instruction
Post Weld Heat Treatment
Classification: RESTRICTED
Revision: R1
All heat control zones that include a portion of the Code required heated band shall be
programmed or manually controlled to be within the Code required temperature range,
including any material limitations on the upper temperature. The heat zones on dissimilar
thickness generally should be controlled separately. If a heat zone covers the weld and the
HAZ on each thickness, it shall be controlled separately from the other heat zones. Heat
zones that do not include portions of the Code required heated band width may be
programmed to control at lesser temperatures. Dissimilar thickness means a change of at
least 1/4 inch. The thickness determination may be made from drawings without actual
measurement.
For dissimilar thickness welds, the resistance method heat source width should be
increased to approximately 11T where possible. The heat source may be offset to
counteract the increased heat dissipation in the thicker component. Separate heat bands
may be placed on the thicker component and may be separated from those on the weld to
counteract the heat sink effect. This is commonly called a choker heat. Resistance
heating bands should cover the weld. Flexible ceramic fiber-insulated heating elements
may be placed two layers thick to counteract the heat dissipation to greater thickness. This
technique should be used only when the heat source width cannot be increased on the
thicker component.
6.6
6.7
Thermal Insulation
Thermal insulation such as nonflamable paper, nonflamable blankets, mineral wool blocks,
or ceramic fiber blankets shall be wrapped around the outside of the heated area. When
using the quartz halogen lamp heating method insulation is not required. Reflective foil
may be used to supplement insulation.
IF PRINTED THIS DOCUMENT IS NOT CONTROLLED
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Project Name:
Project Work Instruction
Post Weld Heat Treatment
Classification: RESTRICTED
Revision: R1
The inside of the area being postweld heat treated should be sealed to prevent internal air
currents from creating excessively high thermal gradients through the thickness of the
piping. When possible, the pipe should be blocked on both ends. When it is impossible to
block the pipe (e.g., direct connections between heat exchangers), the QC Weld Inspector
shall waive this requirement.
7.0 DOCUMENTATION / RECORDS
The PWHT record sheet and PWHT chart shall be checked for correctness by the QC
Weld Inspector or his designee and endorsed immediately prior to and after the PWHT
cycle. The original record sheet and PWHT chart shall be retained by QC Department and
filed in the quality records until final handover.
See Attachment 1 -
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Project Name:
Project Work Instruction
Post Weld Heat Treatment
Classification: RESTRICTED
Revision: R1
Degrees C
Minimum
(4)
621
618
613
610
608
600
595
595
593
Recommended
(4)
635
632
626
623
621
615
610
610
608
NOTES:
1. The heat source is to be centered on the weld. For dissimilar thicknesses, the heat source may
be off center. The heat source shall have a minimum power capability of 28 watts/sq.inch.
2. The holding temperature is measured approximately 2 to 2-1/4 inches from the external fusion
line of single welded joints and joints with a few layers of back welding. For double Vee joints
in which one-third thickness or more is welded from the second side, monitor the temperatures
on both sides; do not use this table.
3. T is the nominal weld thickness, the lesser of throat dimension, depth of groove or thinner
material being joined.
4. Heat sources less than 5T require objective evidence of acceptability prior to use.
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Project Name:
Project Work Instruction
Post Weld Heat Treatment
Classification: RESTRICTED
Revision: R1
Thickness
Inches
(1)
1-1/2(3)
2(3)
2-1/2(3)
3
3-1/4
3-1/2
3-3/4
4
593
593
593
604
608
608
610
613
608
608
608
615
618
618
621
621
4-1/4
615
621
NOTES:
1. The throat thickness of the weld should be used.
2. For double Vee joints in which the one-third thickness or more is welded from the second side,
monitor the temperatures on both sides; do not use this table.
3. This table is based on using double bands of four lamp heating modules around the weld.
Thickness 2-1/2 inches and less may utilize a single band of heating modules.
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Project Name:
Classification: RESTRICTED
Revision: R1
ASME/
ANSI
ASME
I
Code
ASME
VIII
ASME
III
ASME/
ANSI
P No
1
B 31.1
593-649 (2)
(2)
593
(2)
593
(3)
593-677 (2)
B 31.3
593-649
3
4
5
593-649 (2)
705-745
705-760
593
593
677
593
593
677
593-677 (2)
593-677
677-760
593-718
705-745
705-760
760-800
760
677
677-760
733-788
6 (G4)
593-621
7
8
9A
733-773
(4)
593-649
733
(4)
593
733
(4)
593
705-760
(4)
593-677
(4)
593-635
9B
10 A, B, C & F
10 E
10 G, H
10 I
677-705
-
593
677
-
593-635
593
677
(4)
733
593-635
-
593-635
760-816 (5)
663-704 (6)
538-566
552-585 (7)
11 A
NOTES:
1. The temperatures shown are minimums, unless a range is shown.
2. Lower holding temperatures are permitted with materials engineering approval only.
3. For ASME Section III, additional restrictions are imposed; see Tables 2, 3, 5 and paragraph
7.1.
4. PWHT is neither required nor prohibited.
5. Cool as rapidly as possible after the hold period.
6. Cooling rate to 649C shall be less than 56C/Hr, therafter, the cooling rate shall be fast
enough to prevent embrittlement.
7. Cooling rate shall be >167C/Hr to 316C.
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Project Name:
Project Work Instruction
Post Weld Heat Treatment
Classification: RESTRICTED
Revision: R1
TABLE 4.1 - ASME SECTION I & ASME/ANSI B31.1 MINIMUM TIMES AT PWHT
TEMPERATURE
P-No.
Up to 2 inches
Over to 5 inches
Over to 5 inches
1 Hr/inch; 1/4
Hr. Minimum
4, 5, 6, 7, 9A,
9B and 10A
ASME/ANSi B31.1
2 Hrs. + 1/4 Hr. for each
inch over 2 inches
ASME Section I
1 Hr./inch
ASME/ANSi B31.1
2 Hrs. + 1/4 Hr. for each
inch over 2 inches
ASME Section I
5 Hrs. plus 1/4 Hr. for each
inch over 5 inches
None
10E
None
ASME/ANSi B31.1
2 Hrs. + 1/4 Hr. for each
inch over 2 inches
ASME Section I
1 Hr./inch
None
ASME/ANSi B31.1
2 Hrs. + 1/4 Hr. for each
inch over 2 inches
ASME Section I
1 Hr./inch minimum
HOLDING TIME
Nominal Wall
Minutes / mm
Min. Time (Hrs)
2. 4
2. 4
2. 4
2. 4
2. 4
1. 2
1. 2
1. 2
2. 4
2. 4
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1
1
2
2
2
1
1/2
1/2
1
1
Project Name:
Classification: RESTRICTED
Revision: R1
P-Number
1/2 to 2 inches
Over 2 in. to 5
less
Over 5 inches
inches
1, 3
1/2 Hr.
1 Hr/in.
4, 5, 6, 7, 9
1/2 Hr.
1 Hr/in.
1 Hr/in.
11 and 11A
1/2 Hr.
1 Hr/in.
1 Hr/in.
1 Hr/in.
P-Number
Over 5 inches
1, 3
4, 5, 9A, 9B,
10A, 10B, 10F
1 Hr/in.
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Project Name:
Classification: RESTRICTED
Revision: R1
CLIENT:
LINE :
ISO No:
:
PWHT SPECIFICATION:
WELD #
DIAMETER
THICK.
MATERIAL
WPS
SOAK TIME:
C
2
HOUR
C PER HOUR /C
3
T/C No
SOAK TEMPERATURE:
C
REMARKS:
QC TECHNICIAN
QA / QC INSPECTOR
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