QUALITY CONTROL PROCEDURE

DEE DEVELOPMENT
ENGINEERS LTD

POST WELD HEAT TREATMENT

Doc No.

QCP/GEN/007

Rev.
Date
Page

02
08.05.15
Page 1 of 9

PROCEDURE FOR
PREHEAT & POST WELD HEAT TREATMENT
OF JOINTS INVOLVING A Y-PIECE & A PIPE

DOCUMENT NO.
QCP/GEN/007 Rev-02

DEE DEVELOPMENT ENGINEERS LIMITED

02

08.05.15

DDN VERMA

01

26.02.15

Change in Table of
Clause no 9.2

Sunil Kaushik

Ajay Kumar Goel

00

29.11.14

Initial Issue

Sunil Kaushik

Sudeep Singh

REV.

DATE

DESCRIPTION

PREPARED BY
(QC
ENGINEER)

APPROVED BY
(QA/QC HEAD)

DOCUMENT REVISIONS

ACCEPTED
BY

QUALITY CONTROL PROCEDURE

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POST WELD HEAT TREATMENT

INDEX

1.

SCOPE

2.

REFRENCE DOCUMENTS

3.

RESPONSIBILITY

4.

SAFETY

5.

GENERAL REQUIREMENTS

6.

FURNACE HEATING

7.

LOCAL HEATING

8.

INTRUPTION IN PWHT CYCLE

9.

OPERATIONAL REQUIREMENT

10.

SPECIFIC REQUIREMENT

11.

DOCUMENTATION

Doc No.

QCP/GEN/007

Rev.
Date
Page

02
08.05.15
Page 2 of 9

QUALITY CONTROL PROCEDURE

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POST WELD HEAT TREATMENT

Doc No.

QCP/GEN/007

Rev.
Date
Page

02
08.05.15
Page 3 of 9

1.

SCOPE

1.1.

This procedure describes the method for localized PREHEAT & PWHT of joints involving YPiece & power piping using induction heating technique encountered in Power Boilers, Power
Piping or parts thereof. It does not include requirements corresponding to heat treatment
performed inside a heat treatment furnace. Heat treatment shall be in accordance with the
material grouping and thickness in PW-39 of ASME Sec. I and Table 132 (ASME B31.1) except
as otherwise provided in Para 132.2 & 132.3 (ASME B31.1).

2.

REFERENCE DOCUMENTS

2.1.
2.1.1.
2.1.2.
2.1.3.
2.1.4.
2.1.5.

The following referenced documents are indispensable for the application of this document. For
dated references, only the edition cited applies. For undated references, the latest edition of the
referenced document (including any amendments) applies.
ASME B31.1
ASME Section I
Applicable Drawing & Quality Control Plan
ASME Section IX,
ASTM/ANSI E-230

3.

RESPONSIBILITY

3.1.
3.2.

The Head Welding shall be responsible for conducting the PWHT.

The Head (Welding) & Head (QA/QC) shall be responsible for the review, verification &
getting the acceptance of the respective of Authorized Inspector as per QAP.

4.

SAFETY

4.1.

Personnel employed in heat treatment shall be trained and aware of the potential hazards
associated with the employment of equipments.
All personnel shall have the responsibility to themselves and other persons with regard to safety
and shall ensure site facilities are adequate.

4.2.
5.

GENERAL REQUIREMENTS

5.1.
5.2.

Production deptt. sends Preheat/PWHT offer request to Heat Treatment Department

PWHT is applied to all weld joints on Power Boilers, Power Piping and parts thereof except as
indicated in the Para 132.3 (ASME B31.1) for Power Piping and Table PW-39 (ASME Sec. I)
for Power Boiler.
The weld joints that have been post weld heat treated in accordance with the requirements of
this procedure shall again be required to be post weld heat treated, in case of the weld joint
undergoes any repair on account of any reason whatsoever.
This being the case of a local Preheat/PWHT, enough thermal insulation must be provided in
order to ensure absence of any harmful temperature gradient.
The material and welds shall be free of an machining fluids or debris, inspection residues etc.
such as couplant-fluids, magnetic particles and others contaminants which could be detrimental
for the piping material while heating for PWHT.

5.3.
5.4.
5.5.

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5.6.
5.7.

5.9.1
5.9.2
5.9.3
5.9.4

POST WELD HEAT TREATMENT

Doc No.

QCP/GEN/007

Rev.
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02
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Page 4 of 9

The complete piping requiring local Preheat/PWHT must be suitably supported to maintain their
straightness and alignments.
All heating cycles shall be recorded on a recorder having print chart facilities.
5.8. Thermocouple shall be independently recorded and no error exceeding 0.75% in the range
of 275 C to 1250 C shall be permitted as required by ASTM/ANSI E-230.
5.9
This being the case of a Local Heating, each weld shall have
a minimum of two thermocouples
attached for temperature Monitoring purposes. The number of thermocouples for Temperature
Monitoring purposes shall depend on the diameter of pipe [Refer Clause 7.5.1, Table-A].
Once the thermocouple is removed, the locations where the thermocouples were attached shall
be PT or MT tested.
The cycle of PWHT shall be continuously recorded. Each reading shall be identified by a
number or by color of related thermocouple.
All equipments in use shall be purpose built and shall have proven ability in the field.
Temperature control equipment shall be automatic operated by multi-zone programmer with a
thermocouple signal.

HEATING

6.9

Weld is locally PWHT-ed by heating a circumferential band around the entire component with
the weld located in the center of the band. The width the band heated to the PWHT temperature
shall be at least three times the wall thickness at the weld of the thickest part being joint or the
governing code.

6.10

The heating band shall be wrapped considering the heat sink and to get the heating and cooling
rates. The insulation blanket shall remain in place till temperature comes down to the ambient.

6.11

PWHT shall be carried out with the pipe placed in horizontal position.

6.12

Equipments:

6.12.1

Thermocouples

6.12.1.1

The heating/cooling cycles of the heat treatment shall be continuously recorded. Each reading
shall be identified by a specific number or colour of the corresponding thermocouple.
Temperature control equipment shall be automatic operated using multi-zone programmer with
thermocouple signals.
Number of thermocouples attached is a function of diameter of the pipe & uniformly distributed
on to the pipe, as follows:

6.12.1.2
6.12.1.3

Table -A
Pipes diameter(inches)

Number of thermocouples

Up to and including 4"

2 thermocouples

>4" & 10"

3 thermocouples

10"

4 thermocouples

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Doc No.

QCP/GEN/007

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02
08.05.15
Page 5 of 9

POST WELD HEAT TREATMENT

6.13

Induction Heating Equipment:

6.13.1

The induction heating system to be deployed for the job shall be PROHEAT 35 (MILLER
MAKE)./ Equivalent
K type, spot weld thermocouples wires shall be used for sensing & measurement of
temperature. All thermocouples shall be marked with an identification number corresponding
to the recorder channel.

6.13.2

6.13.2

Thermocouples, as mentioned in the above table, shall be attached to the spools using Capacitor
Discharge Welding Technique with approved WPS. Weld energy shall be limited to 125 WSec.

INTERRUPTION IN PWHT CYCLE

7.9

In order to avoid any interruption in input power, a back-up DG set shall be installed. As soon
as the power supply is interrupted, DG set must be switched ON.
To avoid any interruption during recording of temperature-cycle, an UPS of sufficient capacity
shall have been installed.
In case of any remote possibility of power interruption, the following actions shall be taken.
If power goes off during heating in PWHT cycle, continue with the temperature drop. If the
drop is not below 50C, proceed further. If the temperature drop exceeds 50C, the heating shall
be re-started from beginning.
If Power goes off during soaking period and the temperature drops from the soaking
temperature, the duration of lesser temperature shall be extended in the soaking period.
If there is power cut during cooling, but before the unloading temperature, the temperature shall
be raised to the soaking temperature and maintained for the additional period (as per relevant
code e.g. 1hr./inch).
In case of a power cut during cooling, but after the unloading temperature, no action is required.
Let the material be cooled at its normal course.

7.10
7.11
7.12
7.13
7.14
7.15

PREHEAT

8.1

Two different sets of induction coils shall be used for preheating the joint, one
for each side of the joint or weld flank. On pipe side of the joint, the soak band
width shall be a minimum of 3x thickness of the pipe whereas on the Y-Piece
side the minimum width of soak band shall be a minimum of 50 mm [in view of
its increasing thickness]

8.2

No. of thermocouples to be attached shall be resolved in line with Table A,

however, in the present case two nos. thermocouples were attached, one on top
side & the other on bottom side of the joint both for the case of pipe & the Ypiece. In general, thermocouple should be attached at the end of soak band in
each case.

8.3

Preheat temp. shall be set in line with the approved WPS.

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POST WELD HEAT TREATMENT

Doc No.

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Rev.
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02
08.05.15
Page 6 of 9

8.4 Photographs showing the placement & configuration of induction winding in

case of Preheat has been shown in Fig.1 below.

Fig. 1: Photographs showing placement & configuration of induction winding

in case of Preheat

POST WELD HEAT TREATMENT

9.1

A single set of induction coil shall be used for post weld heat treatment.
Winding of the induction coil shall be centrally located on the weld joint. Width
of the soak band shall be determined based on the recommendations in the AWS
D10.10. However, it is recommended that the minimum number of turns of the
induction coil wound over the weld joint should not be less than seven in nos..

9.2

No. of thermocouples to be attached shall be in line with the provisions of Table

A.

9.3

However, specifically in case of joint involving Y-piece & a Pipe, a minimum

of two nos. additional thermocouples shall be attached on the side of Y-Piece
immediately below the terminal turn of the coil, one each located on the
minimum & the maximum thickness of the Y-Piece.

9.4

Photographs showing placement & configuration of induction winding in

case of Post weld heat treatment has been depicted in Fig.2.

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Doc No.

QCP/GEN/007

Rev.
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02
08.05.15
Page 7 of 9

POST WELD HEAT TREATMENT

Fig. 2: Photographs showing placement & configuration of induction winding

in case of Post weld heat treatment.

10

OPERATIONAL REQUIREMENTS

10.9

Rate of Heating and cooling

10.9.1

As recommended by ASME B31.1, Clause 132.5:

10.9.2
10.9.3

Above 315C, the rate of heating and cooling shall not exceed 335C per hr. divided by half the
maximum thickness of material in inches at the weld but in no case shall the rate exceed 335C
per hr..
As recommended by ASME Sec. I:

10.9.4

Above 300C, the heating rate shall be not more than 80C per hr..

10.9.5

Till the temp. reaches 300C, cooling rate shall not exceed 80C/Per hr.. Below 300C, the
piping/component may be cooled in still air.

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QCP/GEN/007

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02
08.05.15
Page 8 of 9

10.9.6

Heating and cooling rate for P91 and Equivalent Material shall be 100 C/hr. maximum and 200
C/hr. for all other material.

10.10

Soaking time & temperature shall be taken from applicable WPS but it shall not less than the
values mentioned in the following table (as per ASME B31.1 of Table 132.1):
Table B

10.11
10.11.1
10.11.1.1
10.11.1.2
10.11.1.3

10.11.2
10.11.2.1
10.11.2.2
10.11.2.3
10.11.2.4

11
11.9

P-Number

Holding
Temperature

625 15 C

675 15 C

5A

730 15 C

P-Number

Holding
Temperature

15E

750 15 C

Soaking Time Based on Nominal Thickness

Up to 2 in(50mm)
Over 2 in(50mm)
2 Hrs. plus 15 min for
1Hr per inch or
each additional inch over
1Hr min.
2 in. (50mm).
2 Hrs. plus 15 min for
1Hr per inch or
each additional inch over
1Hr min.
2 in. (50mm).
2 Hrs. plus 15 min for
1Hr per inch or
each additional inch over
1Hr min.
2 in. (50mm).
Soaking Time Based on Nominal Thickness
Up to 5 in(125mm)
Over 5 in(125mm)
5 Hrs. plus 15 min. for
1hr. per inch or
each additional inch
30 Min. Minimum.
(25mm) over 5 in.
(125mm)

Nominal thickness
As per ASME B31.1, Clause 132.4.1 & 132.2B:
Lesser of:
The thickness of the weld or the thicker of the materials being joined at the weld
When parts of two different P-Numbers are joined by welding, the post weld heat treatment
shall be that specified for the material requiring the higher PWHT temperature. When a non
pressure part is welded to a pressure part and PWHT is required for either part, the maximum
PWHT temperature shall not exceed the maximum temperature acceptable for the pressure
retaining part.
As per ASME Sec. I, Clause PW-39.3:
For full penetration butt welds, the nominal thickness is the thinner of the parts being joined.
For full penetration corner welds, the nominal thickness is the depth of the weld.
For partial penetration groove and material repair welds, the nominal thickness is the depth of
the weld. The total depth of partial or full penetration groove welds made from both sides shall
be taken as the sum of the depth of both sides at a given location.
For fillet weld, the nominal thickness is the weld throat. When a fillet weld is used in
conjunction with a groove weld, the nominal thickness is either the depth of the groove weld or
the fillet throat dimension, whichever is greater.
DOCUMENTATION
The PWHT specification and chart records shall be checked, stamped and approved by Head
(QC) Plant-1 & Plant-2 and shall have the following information:

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POST WELD HEAT TREATMENT

Description
Job No.
Drg. No.
Part/Component ID No.
Weld Joint No
Date of H.T. Request
Rate of Heating
Soaking Time & Temperature
Rate of cooling
Number, location & attachment method
thermocouple
Temperature at the time of loading & unloading
Date of H.T. execution
Graphic scales for both temperature & time
The insulation requirement
Signature

Doc No.

QCP/GEN/007

Rev.
Date
Page

02
08.05.15
Page 9 of 9

H.T Request

of

H.T Charts