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Shell Petroleum Development Company: (Implemented/Issued For Review/Complete)

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SHELL PETROLEUM DEVELOPMENT COMPANY

[PROJECT NAME]
Classification Status : Restricted

Project Work Instruction


Post Weld Heat Treatment
PWI-2.7

Controlled

Uncontrolle
d

or
If Controlled
Copy Number

Issue Date :
Issued To :
Company :

Proprietary Information: This document contains proprietary information


and may not be partly or wholly reproduced without prior written
permission from Shell Petroleum Development Company.

REVISION STATUS
Rev.

Date

Description

APPROVAL
Focal Point

(Implemented/Issued for
Review/Complete)

IF PRINTED THIS DOCUMENT IS NOT CONTROLLED

Checked

Custodian

Project Name:
Project Work Instruction
Post Weld Heat Treatment

Classification: RESTRICTED
Revision: R1

REVISION DESCRIPTION AND DISTRIBUTION RECORD SHEET


NOTES
1.0

2.0

Revisions
1.1

All revisions for review will be issued at R1, with subsequent R2, R3 etc. if
required.

1.2

All revisions approved for implementation will be issued at A1, with


subsequent A2, A3 etc. if required.

1.3

Narrative sections revised from previous approved issues are to be noted in


the table below and/or highlighted in the RH margin (using the appropriate
revision status) thus : |A2

1.4

Drawings/diagrams revised from previous approved issues are highlighted


by 'clouding' the affected areas and by the use of a triangle containing the
revision status.

1.5

Previous revision highlighting is removed at subsequent issues.

1.6

All revisions to this document must be approved by the position originally


recorded as approving the document and which shall be deemed the
custodian.

Distribution
2.1

Revision notification services for this document will be provided to the


Distribution list below.

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:
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Post Weld Heat Treatment

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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

) Latest editions (example)

3.0 DEFINITIONS / ABBREVIATIONS


Unless specified otherwise, all quality terms in this work instruction will have the meaning
described in ISO 8401 quality vocabulary.
PWHT =

Post weld heat treatment

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

6.0 PWHT REQUIREMENTS


6.1

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

Heating and Cooling Rates


6.2.1 ASME Code, Section I
The weldment shall be heated slowly and uniformly to the specified postweld heat
treatment temperature, held at that temperature for the specified time, and then cooled
slowly under insulation or in still air to a temperature of 425C or below. Below 425C
the weldment may be allowed to cool in still air without insulation. The recommended
heating and cooling rates above 425C should not exceed 315C divided by one-half the
thickness in inches, but should not exceed 315C per hour, nor need not be less than 38C
per hour.
6.2.2 ASME Code, Section III
The heating and cooling rates above 425C shall not exceed 205C per hour divided by
the maximum metal thickness in inches, but in no case shall the rate exceed 205C per
hour. During the heating and cooling period, there shall not be a greater variation in
temperature that 120C within any 15-foot interval of weld length. Regardless of
thickness, the rate need not be less than 38C per hour. Cooling from 425C may be done
in air for any thickness.
6.2.3 ASME Code, Section VIII, Division 1
The heating rate above 425C shall not exceed 205C per hour divided by the maximum
metal thickness in inches, but in no case shall the rate exceed 205C per hour. During the
heating period, there shall not be a greater variation of temperature throughout the portion
of the vessel being heated than 120C within any 15-foot interval of length. Rates of
heating and cooling need not be less than 38C per hour.
The cooling rate above 425C shall not exceed 260C per hour divided by the maximum
metal thickness in inches, but in no case shall the rate exceed 260C per hour. Cooling
from 425C may be done in air for any metal thickness.

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6.2.4 ASME / ANSI Code B31.1


Above 315C, the heating and cooling rates shall be a maximum of 315C per hour
divided by half the maximum thickness in inches but shall not exceed 315C per hour.
6.2.5 ASME / ANSI Code B31.3
The heating and cooling rates shall be unrestricted up to 315C. Above 315C for wall
thickness up to 25mm the heating and cooling rates shall not exceed 250C per hour. For
thicknesses greater than 25mm the heating and cooling rates shall not exceed 5500/tC
(where t is the maximum w.t. in mm) or 55C per hour whichever is the greater. Refer to
the notes in table 3 for special cooling rate requirements.
6.2.6 Cooling
Cooling should be done with the insulation in place, except for the quartz lamp method
and for those ferritic stainless steels that require rapid cooling to avoid embrittlement.
For P-No.6 materials, cooling may be done in air from the PWHT temperature.
For P-No.7 Group Nos.1 and 2 and P-No.10E Group No.5 materials, the cooling rate
above 650C shall be a maximum of 38C per hour, after which the cooling rate shall be
sufficiently rapid to prevent embrittlement. Shut off heat at 650C and remove insulation,
if any, as soon as possible.
For P-No.11A Group Nos.1 and 2, the cooling rate shall be greater than 150C per hour
until 315C is reached.
For the quartz lamp method, cooling from the postweld heat treating temperature shall be
performed by properly down sloping the radiant heat input in still air so as to exceed the
maximum specified cooling rates.
6.3

Minimum Requirements for the Width of the Heated Area


6.3.1 ASME Section I
For vessels postweld heat treated in sections, the minimum width of the heated
circumferential band for butt welded joints shall be at least three times the metal thickness
on each side of the welded joint.
In the case of welded joints in pipes, tubes, and headers, the width of the heated band shall
be at least three times the width of the widest part of the welding groove, but not less than
twice the width of the weld.
Branches, nozzles or other welded attachments shall be postweld heat treated by heating a
circumferential band around the entire vessel with the welded connection located at the
middle of the band. The width of the band shall be wider than the nozzle or other
attachment weld by at least three times the wall thickness of the vessel and shall be located
in such a manner that the entire band will be heated to the required temperature.
6.3.2 ASME Code, Section III
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Project Name:
Project Work Instruction
Post Weld Heat Treatment

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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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6.4

Classification: RESTRICTED
Revision: R1

Heat Treatment Temperature and Time Cycle


6.4.1 Holding Temperatures and Allowable Ranges
Postweld heat treatment holding temperatures and times are specified on the BEJV
Welding Procedure Specification (WPS) and/or the Project Specifications. Additional
limitations are imposed on the holding temperature range as stated below.
The holding temperatures are limited by Code requirements. Table 3 shows the
requirements for P-number materials by Code.
For dissimilar P-numbers, refer to the WPS, Project Specifications and/or the applicable
code. In general, the heat treatment requirements for the higher P-Number material should
be used.
For ASME Section III resistance heating applications, the holding temperature for P-No.1
materials shall be related to the heat source width as shown in Table 1.
For ASME Section III quartz lamp applications, the minimum holding temperature for PNo.1 materials on the edge of the Section III required heat band (2 inches from the fusion
line) shall be based on Table 2.
For Section III applications, when it is impractical to attain the minimum temperatures of
Tables 1 and 2, alternate holding temperatures and times may be utilized. The use of
alternate holding temperatures and times shall be evaluated on a case by case basis.
Internal resistance heaters may be used in conjunction with external heaters. If used, the
internal heater control thermocouples shall be placed on the inside pipe surface. If internal
heaters are placed on the weld root, the external heat source width requirements of Table
1 may be waived. If internal heaters are used, the Code required minimum temperatures
and heat band requirements shall be met.
6.4.2 Time Cycles of Heat Treatment
The postweld heat treating time cycle shall be as specified in Table 4 for ASME Section I,
and for ASME/ANSI B31.1, Table 4.2 for ASME/ANSI B31.3, Table 5 for ASME Section
III, and Table 6 for ASME Section VIII, Division 1, unless specified otherwise in the
BEJV welding procedure specification and/or contractual specifications.
The time-at-temperature for welding procedures may be limited. When applicable, the
maximum time is shown on the WPS.
6.4.3 Interrupted Postweld Heat Treatments
Interrupted postweld heat treatment is defined as decreasing below the minimum specified
holding temperature or exceeding the maximum specified cooling rate and may be caused
by loss of power, equipment malfunction, or operator error.

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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.
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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

Recording Postweld Heat Treatment Cycle


For those cases in which a minimum of four recording thermocouples are required, the
PWHT may be accepted if not more than one recording channel is lost, provided that:
The holding temperature has been achieved and maintained for at least one-half
hour.
The heating equipment and the control system continue to function properly.
The PWHT chart is noted regarding the recording malfunction and proper heating
function and signed by the QC Weld Inspector or his designee.
Multiple-point, temperature-indicating recorders shall be used. Recorders shall be
calibrated in accordance with the manufacturers standard service instructions at least once
every six months or in accordance with jobsite procedures.
A time-temperature recorder chart shall be provided for each postweld heat treatment
operation. Each chart shall show the weld identification numbers, job, unit, system, iso,
etc., location and number of thermocouples (including spares), time and date started, chart
speed (inches per hour), name of operator, and certifying signature of the QC Weld
Inspector.

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.
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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 -

Heat Treatment Report

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Table 1 - RESISTANCE HEATING METHOD


Heat Source Width and Holding Temperature Requirement
Holding Temp. to Obtain 593C on Weld Root(2)
Thickness (1)
Inches
Less than 5T(3)
5T
6T
6.7T
7T
7.3T
8T
9T
10T
11T

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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Table 2 - QUARTZ HALOGEN LAMP HEATING


Thickness and Holding Temperatures

Thickness
Inches

(1)

Holding Temp. to Obtain 593C on Weld Root(2)


Degrees C
Minimum
Recommended

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 Work Instruction


Post Weld Heat Treatment

Table 3 - HOLDING TEMPERATURES, DEGREES C (1)


Holding Temperature Requirement

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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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

1 Hr/inch; 1/4 Hr. Minimum

2 Hrs. + 1/4 Hr. for each


inch over 2 inches

2 Hrs. + 1/4 Hr. for each


inch over 2 inches

4, 5, 6, 7, 9A,
9B and 10A

1 Hr/inch; 1/4 Hr. Minimum

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

1 Hr/inch; 1/4 Hr. Min.

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

TABLE 4.2 - ASME B31.3 MINIMUM TIMES AT PWHT TEMPERATURE


BASE METAL
P. No.
1
3
4
5
6
7
8
9A, 9B
10
10 H
10 I
11 A

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

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Project Work Instruction


Post Weld Heat Treatment

TABLE 5 - ASME SECTION III MINIMUM PWHT TIMES

P-Number

Minimum Holding Time for Weld Thickness (Nominal)


1/2 inch or

1/2 to 2 inches

Over 2 in. to 5

less

Over 5 inches

inches

1, 3

1/2 Hr.

1 Hr/in.

2 Hrs. plus 1/4 Hr. for


each additional inch
over 2 inches

2 Hr. plus 1/4 Hr. each


additional inch over 2
inches

4, 5, 6, 7, 9

1/2 Hr.

1 Hr/in.

1 Hr/in.

5 Hr. plus 1/4 Hr. each


additional inch over 2
inches

11 and 11A

1/2 Hr.

1 Hr/in.

1 Hr/in.

1 Hr/in.

TABLE 6 - ASME SECTION VIII, DIVISION 1 MINIMUM PWHT TIMES

P-Number

Minimum Holding Time for Weld Thickness (Nominal)


Up to 2 inches

Over 2 in. to 5 inches

Over 5 inches

1, 3

1 Hr./in. 15 min. minimum

2 Hrs. plus 1/4 Hr. for each


additional inch over 2 inches

2 Hr. plus 1/4 Hr. each


additional inch over 2 inches

4, 5, 9A, 9B,
10A, 10B, 10F

1 Hr./in. 15 min. minimum

1 Hr/in.

5 Hr. plus 1/4 Hr. each


additional inch over 2 inches

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Project Name:

Classification: RESTRICTED
Revision: R1

Project Work Instruction


Post Weld Heat Treatment

ATTACHMENT 1 HEAT TREATMENT REPORT


FORM NO: PWHT-001
HEAT TREATMENT REPORT
REPORT :
DATE:
RECORDER SERIAL No:

CLIENT:
LINE :
ISO No:
:
PWHT SPECIFICATION:

WELD #

NEXT CALIBRATION DATE:

DIAMETER

THICK.

MATERIAL

UNRESTRICTED RATE OF RISE TO::

WPS

SOAK TIME:

C
2

HOUR

RESTRICTED RATE OF RISE TO ..............

RESTRICTED RATE OF FALL


FROM ....................
C PER HOUR /C

UNRESTRICTED RATE OF FALL FROM

C PER HOUR /C
3

T/C No

SOAK TEMPERATURE:
C

REMARKS:

QC TECHNICIAN

QA / QC INSPECTOR

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Page 17 of 17

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