Lva1 App6892

1
Volume
BASICS OF PWHT
Cameron PWHT Operators Guide
Operators
PWHT Guide
Vol: 1
C A M E R O N P W H T O P E R AT O R S G U I D E
Operators PWHT Guide Vol: 1
2015
Donald K. Robinson
3007 Hwy.182
Bayou Vista, LA 70380
Personal Phone 337-940-1290
Email: Donald.Robinson@c-a-m.com
Table of Contents
Contents
What is a Personal Plan of Action?.....................................2
Filling out the required Paperwork..............................................4
About the required paperwork:..........................................4
Section A, Breakdown of DI-163 Rev. A02:.........................4
Section B, ASME Section IX:..............................................6
Section C, Data & location Maps:.......................................6
Section D, PWHT TC Mapping:...........................................7
Section E, Contact Information:.........................................9
Section F, Quarter Hourly Temperatures:........................10
WS-1684 Rev.01 in a nutshell....................................................11
Interpretation of Specifications:.......................................11
Requirements for Heating Elements:...............................11
Similar or Dissimilar:........................................................13
WS-1991-01in a nutshell............................................................13
The main differences between WS-1684, and WS-1991-01:14
Before starting the layout:..................................................................15
Acquiring the Proper Specs:...............................................................16
Things to consider before setting up:....................................17
Other Considerations:.........................................................17
Laying Out the PWHT:......................................................................19
Laying out for pipe 4.0in. to 16in diameter:.......................19
Similar thickness welds 4.0in to 16in Diameter:....................................19
Dissimilar thickness welds 4.0in to 16in Diameter:................................20
Layout for dissimilar thickness welds type #1:......................20
Layout for dissimilar thickness welds type #2 (ID Heat):.......21
Layout for Pipe with 16in Diameter or greater:......................................22
16in. or greater diameter:..................................................22
Similar Thickness Weldments over 16in Diameter..................................22
Laying out for similar thickness weldments 16in. or greater diameter:
Layout #1 WS-1684 for 16in or greater diameter pipe:........22
22
Layout #2 WS-1991 only, with ID thermocouples for 16in or greater diameter

pipe:...................................................................................23
Layout #3 WS-1991 only, with ID thermocouples for 16in or greater diameter
pipe:...................................................................................24
Dissimilar Thickness Weldments over 16in Diameter:.............................25
Layout #1 WS-1684 & WS-1991-01 for dissimilar thickness weldments 16in. or
greater diameter:................................................................25
Layout #2 WS-1991-01 only, for dissimilar thickness weldments 16in. or
greater diameter:................................................................26
Special Architectures and Non-standard PWHT Layouts:..........................28
Layout #1 WS-1991-01 for Non-Tubular or Non-Standard Architectures:
28
Filling out the required Paperwork.......................................................29
About the required paperwork:............................................29
Items Not Covered in the Previous Sections:............................31
Other Qualified Layouts:...................................................31
Basic rules of thumb:........................................................32
Non-standard PWHT Case in Point:..................................33
Qualification of PWHT:......................................................................33
Qualification Authority:....................................................33
Qualification Requirements (basic):.................................34
What now?....................................................................................40
P R E PAR ATI O N
A N D
C A M E R O N
R E Q U I R E M E N T S
1
Section
Preparing the part for PWHT

Before each PWHT process it is important to make the
sure that the part is properly prepped before laying out
the thermocouple locations. Part preparation is one of the
most important steps of PWHT. This is the first point of
contact you will have with the part. This is also the point
when your personal plan of action will come into play.
he first step in prepping for PWHT is making sure that the part has all
required traceability. Make sure the stencils have been applied per the
routing, with the correct revision number.
I C O N
Valuable information
Procedure review
K E Y
is to insure that the part is prepared as per section 5.0 of WS-001684

Rev.01 as follows:
The next step
5.0
PREPARATION
5.1 The entire area to be heated shall be cleaned of paint, grease, plastic coating
or other carbonaceous material or residue, prior to the heat cycle. Carbonaceous
materials can contaminate the surface of the metal during the heat cycle and
adversely affect the composition of the metal.
5.2 No weldment that has a surface treatment containing lead, cadmium,
tantalum or other poisonous material shall be subjected to a post weld heat
1
P R E PAR ATI O N
A N D
C A M E R O N
treatment. Fumes from such materials are TOXIC! Use the same precautions that
would be used for welding of such materials.
5.3 Contrasting paints made specifically for use with magnetic particle
inspection may be left on during the post weld heat treatment cycle provided they
are shown by testing to be harmless or the manufacturers literature specifically
states that paint can be left on during heat treatment.
Make sure that the part is supported correctly as per section 6.0 of
WS-001684 Rev.01
6.1
PHYSICAL SUPPORT
6.2
All weldments shall be physically supported adjacent to each side of

the heat zone as well as at reasonable intervals along the length of
the structure.
6.3
Support structures shall be able to compensate for linear and

circumferential expansion and contraction of the weldment during
the heating and cooling cycle without causing stress to the
weldment.
6.4
Support structures used shall be able to withstand any temperature

and/or pressure related stress that may be created during the
heating cycle, without degradation.
Personal Plan of Action

Part preparation is one of the most important steps of
PWHT. This is the first point of contact you will have with
the part. This is also the point when your personal plan of
action will come into play.
What is a Personal Plan of Action?
P R E PAR ATI O N
A N D
C A M E R O N
Your personal plan of action is a list of steps that you take in order to insure that
the job is done in an efficient and timely manner.
It is prioritizing and mapping common tasks.
It is personal quality control.
he course of action you take while working through any process greatly
affects the outcome, in speed and quality, of that process.
Knowing what to do, and in what order things should be done gives you an edge
over unskilled labor, and is the proof that you have become proficient in your
prescribed tasks.
In part preparation the basic steps are as follows:
Stencil the part per the routing.

o Verify that the stencil is in the right location on the correct part.
Verify the part numbers against the BOM.

Sign off of the stencil operation, and do the log.
Dope/Protect all seals and threaded holes.
Verify grinding details, and do grinding operation

o Have the grinding verified by a Leaderman.
LP the welds per procedure.

Have Leaderman verify LP
Sign operation and do the log.
Clean grease and paint from all areas to be heated.
Blow grinding dust out of the pipe
P R E PAR ATI O N
A N D
C A M E R O N
Notice that stenciling is always first on the list.
At this point the part should be ready to set up for PWHT.
Make your plan and stick to it.

This applies to every step of every process.
It will make you a more proficient technician.
Filling out the required Paperwork
Before PWHT, departments and vendors

that perform the Post Weld Heat
Treatment process will be required to
document data using the Post Weld Heat
Treatment Form.
About the required paperwork:
Department managers/supervisors, vendor representatives, and Post Weld Heat

Treatment technicians are responsible for communicating and implementing the
requirements of DI-163 Rev. A02 (this is the departmental instruction put in place
for all PWHT performed on parts from the Berwick facility).
Section A, Breakdown of DI-163 Rev. A02:
P R E PAR AT I O N
A N D
C A M E R O N
Form-226 Rev A03: Section A
Procedure
Form-226 Rev A03 Section A must be documented before the

setup and before the heating process is started.
All information pertinent to the process used for section

A shall be completed by the responsible parties involved.
This means that the technician is required to fill out
section A before laying out the PWHT.
The date must reflect the date at the start of the PWHT
process.
Mark the appropriate Process (Local, Oven, Hydrogen

Bake Out, Vendor Local, or Vendor Oven) With an X.
Vendor sections will be filled out by your leadsmen.
Work Order, Part Number, & Serial Number shall be

documented in the appropriate fields.
Weight of the part must be documented in the weight field.
P R E PAR AT I O N
A N D
C A M E R O N
The dimensions of the part (OD X ID & pipe wall thickness

shall be entered into the dimensions field.
The name of the customer and a description of the part

must be placed in the Part Description field.
Weld Map #s are the weld numbers given to weldments

during initial mapping procedures on the attached print of
the weld data information.
The WPS used for welding shall be documented on the

form whether the PWHT is done by a vendor, or completed
locally at our facility. In addition to the WPS, the Local
PWHT specification (the WS) shall be documented for all
PWHT done in-house.
Section B, ASME Section IX:
Form-226 Rev A03: Section B
Post Weld Heat Treat to ASME Section IX
All fields of section B must be documented before the setup and

before the heating process is started, except for; Actual Soak
Temperature, Actual Soak Time, & Chart Speed per Hour
P R E PAR AT I O N
A N D
C A M E R O N
Actual Soak Temperature, Actual Soak Time, & Chart

Speed per Hour shall be documented after the PWHT
process has been completed.
In accordance with the WPS, Minimum, Maximum, and

Target soak temperatures as well as the Soak Period
Range shall be documented before starting PWHT.
The heating and cooling rate of ascent and descent shall

be documented in accordance with the appropriate WPS.
Section C, Data & location Maps:
Form-226 Rev A03: Section C
TC Data map / Location map.
Section C must be documented during the PWHT setup

phase. All TCs must be mapped, and all used TC
connections must be designated in sections C & D by the
technician during the setup process of PWHT.
P R E PAR AT I O N
A N D
C A M E R O N
Thermocouples used must be designated by color or

number, and mapped on the circle maps on section D.
The function of the thermocouples shall be determined as

either a control or monitor and entered into the proper
fields of section C, and also on the chart on section D.
The location of each thermocouple shall be designated in

section C by the weld number in relation to the weld map
made by the welding department during the weld process,
and exact location in relation to the weldment.
Section D, PWHT TC Mapping:
Form-226 Rev A03: Section D
PWHT Mapping.
Section D is designed for the PWHT technician to generate a

detailed PWHT map, and must be documented during
setup, before starting the heating process.
The map outline shall be generated from the proper Cameron
drawing, and imported to the form in section D as shown
below. Leaderman shall provide prints for this section as
needed.
P R E PAR AT I O N
A N D
C A M E R O N
In addition to providing a PWHT Chart, the Operator shall

generate a PWHT Map clearly identifying placement of all
Controlling and Monitoring thermocouples (TCs) both
External and Internal (when internal applies).
o The map shall show (at a minimum) two (2) views:
1) A circumferential placement of TCs around

the part and
2) A "cut away" view that shows the

weld and adjoining parts shape and
dimensions including an accurate
placement of TCs and Pads
Any additional notes or comments concerning the PWHT

performed shall be entered into this section. These
Include:
o Any anomalies which may have occurred, and how
they were fixed.
o Any pertinent information needed in determining the
validity of the PWHT.
P R E PAR AT I O N
A N D
C A M E R O N
o And any dispositions given by the Leaderman

pertaining to information needed by engineering for
explanations of any non-conformance issues.
Additional pages may be needed for full documentation

with notes.
Section E, Contact Information:
Form-226 Rev A03: Section E
Contact Information
Section E is designed for entry of contact information for the

primary Leaderman, Primary technician, and vendor
representative.
The Leaderman in charge of PWHT must be entered into

the primary contact field along with the contacts phone
number and email address.
o This will be the contact for any additional
information needed pertaining to the PWHT process
concerning the part/welds listed in section A of
Form-226 Rev A03
The Cameron representative field must be signed and

dated immediately following the PWHT process and when
all appropriate information has been collected
o This field must be signed by the authority that
supervised the PWHT regardless of whether the
PWHT was In-House or Vended to a third party
company.
P R E PAR AT I O N
A N D
C A M E R O N
A representative signature is required for

any type of PWHT performed, whether it is by
local electrical resistance with ceramic pads,
or by oven. (vendor or in-house).
If the PWHT is done by a vendor, the production planner

field can be filled out, signed, and dated along with the
required Cameron Representative field.
o This field is not mandatory, but rather helps in
tracking the process steps from start to finish.
If vendor supplied labor or equipment is used, the vendor

representative field must be signed and dated by the
attending technician.
o This must only be signed and dated after a
Cameron representative has collected, and
reviewed all of the required vendor supplied
documentation.
Section F, Quarter Hourly Temperatures:
Form-226 Rev A03: Section F
Quarter Hourly Temperatures
Section F is to be documented during the heating

process and cooling process. This section will be
documented by the Post Weld Heat Treatment
technician.
Data must be recorded in increments of fifteen minutes.

o Temperatures must be recorded from the start of
PWHT to the end of the cool down period when the
part cools to below 800F.
o The Post Weld Heat Treatment technician must write
down the time, the minimum thermocouple
temperature, and the maximum thermocouple
P R E PAR AT I O N
A N D
C A M E R O N
temperature in relation to the equipment being

used.
This is MANDATORY for all PWHT procedures
done at the Cameron facilities at Patterson and
Berwick.
WS-1684 Rev.01 in a nutshell

The most common WS used at the Cameron Patterson and
Berwick facilities is 1684 Rev.01.this specification is to be used
by all of Cameron Corporation personnel and their suppliers who
are responsible for the performance and quality control of
localized PWHT.
The specification is written for the use of ceramic heating
elements in the performance of PWHT on Drilling Riser Tubular
Weldments.
Interpretation of Specifications:
Interpretation of PWHT Specifications
Rev.01:of
WS-1684
Interpretation
PWHT 2.0
Section
Processes.
Quarter Hourly
Questions regarding the

intent and/or practice of
this specification shall be brought to your immediate supervisory
authority.
Temperatures
P R E PAR AT I O N
A N D
C A M E R O N
If your immediate supervisor is unable to rectify the query, it is

up to supervisory discretion for course of action up to and
including contacting Cameron welding engineering department
for determination.
Requirements for Heating Elements:
Rev.01:
WS-1684
Requirements
for Heating
Section
7.0
Elements.
Quarter Hourly
The dimensions of the

pads and their placement
are main keys to a successful PWHT process. It is for this reason
that basic rules have been provided to insure proper heating of
the weldment and adjacent material.
Temperatures
7.1 Flexible ceramic heating elements (pads) shall cover

the entire surface area to be heated with no gaps between
heaters over 1 (one inch).
o If a gap is larger than 1 it allows for a greater
gradient heat loss through the unheated material.
It also causes a scenario wherein the material

is heated unevenly allowing welding stresses
to remain in the joined materials.
o Since boosters are normally secondary to the main

area to be heated, allowances are made concerning
gaps, pad sizes, and temperature requirements.
7.2 Heater elements shall extend beyond the center of the

weld cap by no less than five (5) inches on each side.
o The hottest part of the heater element is in the
center of each pad, therefore by extending the width
of the pad you create a larger optimal heating area.
The more pads you use the more even, stable,

and controllable the PWHT will be.
P R E PAR AT I O N
A N D
C A M E R O N
7.3 No overlap or folding of heaters is allowed.

o Overlapping/folding heaters will cause heat to build
up in the areas where the fold or overlap exists. This
will put more stress on the wiring of the pads
resulting in uneven heating, and possibly blowing
the heating elements.
If the pads chosen will overlap or need to be

folded in order to conform to section 7.1, the
technician shall reconfigure (under direction
of the supervisory authority,) the pad sizes,
placements, or numbers to allow for full
conformance to the WS.
7.4 The heating elements cannot exceed 120 In on an 80volt PWHT machine, or 60 In on a 40-volt machine.
o This is the most efficient configuration for a ceramic
heating element.
Qualified
operations
allow
for
other
configurations cleared by welding engineering
as dictated to the technicians by supervisory
authority.
7.5 support heaters (boosters) can be used when required

to better control heat loss through pipe sections, or
flanges, and large diameter or thick wall sections.
o These are also recommended for any section in
which a large heat sink is present.
Placement of boosters can be ascertained by

either consulting a qualified PWHT of similar
architecture, or by the supervisory authority
as needed.
7.6 Each heating element must have its own control

circuit.
o Splitters are disallowed by Cameron Berwick PWHT
supervisory authority, and will not be used.
P R E PAR AT I O N
A N D
C A M E R O N
7.7 Primary heating elements in vicinity of large heat

sinks, or disproportionately dissimilar thicknesses shall be
shifted to provide adequate heat to the thicker side of the
architecture while not overpowering the thinner member.
o Monitoring TCs must be located no less than 2
times the thickness of the weldment area from the
toe of the weld on both sides.
7.8 Heating elements must be secured by tie wire, or

metal banding to prevent shifting during the PWHT
process.
o Use of fiber tape, plastic or rubber strapping, or any
other material that can degrade during the PWHT
process is not allowed for securing of heating
elements.
7.9 A minimum of 2 pads must be used for pipe diameters

4.0 inches or above.
Similar or Dissimilar:
How to tell if a joint is similar or dissimilar.
WHEN FIGURING WHETHER A WELDMENT IS

SIMILAR OR DISSIMILAR USE THIS RULE OF
THUMB.
a. If the change in thickness of the material is less than of
the thinner materials thickness, then the weld is always a
similar thickness joint
b. If the change in thickness is more than of the thinner
materials thickness it is a dissimilar thickness joint, unless
the change in thickness is located 4 times the thickness of
the thinner material or more away from the weld toe.
WS-1991-01in a nutshell
The second most common WS used at the Cameron Patterson
and Berwick facilities is 1991-01.this specification is to be
used by all of Cameron Corporation personnel and their
suppliers who are responsible for the performance and quality
P R E PAR AT I O N
A N D
C A M E R O N
control of localized PWHT, and Here at the Berwick facility for

any pipes from 16 OD and above.
This specification is also used for PWHT of structural repairs
on Pad Eyes, Gussets, and similar structures.
The main differences between WS-1684, and WS-1991-01:
Section 6.1.5 of WS-1991-01 requires that thermocouples

be attached on the opposite side of the main heater
placement whenever possible to verify that the entire
thickness of the weld reaches and holds the soak
temperature. (OD & ID Thermocouples)
6.2.1 part b. If TCs can be placed on the inside of the pipe,

the 2T TCs are not required. In this case, for each heating
element, one TC shall be placed on the OD surface within
inch from the weld, and one TC per element on the ID
near the bead when the joint is of similar thickness.
6.3.2 OD TCs placement will be 1 from the center of the

weld on both sides, and on the ID inch from the bead on
both sides for any dissimilar weld joint.
6.3.3 If ID thermocouples cannot be used on a dissimilar

joint; then in addition to the TCs located near the edge of
the weld, a monitoring TC will be placed 2T of the thicker
material from the edge of the weld on the thicker side.
7.1 Wherever possible, heating elements must be placed

on the OD and ID
2
Section
Before starting the layout:
P R E PAR AT I O N
A N D
C A M E R O N
Before starting any part layout, there are

steps that need to be taken to insure that
the technician has full understanding of
the process to be used.
What you need to begin PWHT
that any technician should take when preparing

to layout for the PWHT process is to consult the
supervisory authority.
he first step
Your immediate supervisor will most certainly have information

concerning the stress operation that is not available through the
routing or WS.
He/she will provide you with valuable information concerning the
architecture of the part to be stressed, as well as information
specifically suited to making a successful PWHT run.
What is supervisory authority?
What it is and
what it effects
Simply Supervisory
put, your Authority
Quarter Hourly
Temperatures
supervisory authority at any Cameron job is the person/people

who are responsible for making sure that the PWHT is run by
Cameron required standards.
This will be the Cameron Primary Contact listed in section E of
the required Form-226 Rev.A03 or the Cameron representative
overseeing PWHT operations at the facility.
Vendor supervisory authority is secondary to the Cameron
Representative authority.
The specifications for PWHT at Cameron

Patterson/Berwick are non-negotiable aspects of our
requirements, and the Cameron Representative is well
versed in the Cameron policies.
o DI-163 Rev. A02 Requires that all vendor work
done for Cameron Patterson/Berwick comply with
P R E PAR AT I O N
A N D
C A M E R O N
the same mandatory standards adhered to by

Cameron technicians.
o Cameron requires a quality of service that is (at a
minimum) equal to the quality offered by our own
PWHT department, including but not limited to
Documentation
Standardization of process
Adherence to departmental instructions
Safety awareness
Attention to details
Reliability
Accountability
The supervisory authority is the individual who holds

the position of accountability between the PWHT
department and Cameron engineering.
Acquiring the Proper Specs:

It is the technicians responsibility to be
sure that the proper specifications are
being used during the PWHT process.
Therefore, the PWHT technician is
required to contact the supervisory
authority to obtain all pertinent
information before starting work on any
production parts.
In the case of a vendor PWHT, the vendor technician
must contact the Cameron Representative in charge of
P R E PAR AT I O N
A N D
C A M E R O N
PWHT. The representative will provide all needed

information before any work begins on production
parts.
Before
Requirements
Layout to
meet before the

layout process.
Quarter Hourly
Temperatures
you will need to obtain Form-226 Rev.A3 from

the supervisory authority and verify the information
contained therein.
efore you start
Form-226 will be partially filled out for you with a cutaway print
of the work-piece for use in mapping your layout. This form is
required by Cameron Patterson/Berwick, and must be filled out
and submitted back to Cameron when the PWHT is completed.
This would be a good time to discuss the requirements for the
layout with the supervisory authority.
Things to consider before setting up:
Many variables must be considered when heat treating tubular

weldments not the least of which are:
Circumference of the inner diameter of the weldment for

pad selection
Circumference of the outer diameter of the weldment for

pad selection
The thickness of the material to be stress relieved
P R E PAR AT I O N
A N D
C A M E R O N
The location of heat sinks, boxes, stabs, flanges, rises, or

thickness changes and their proximities in relation to the
weldments
The ambient temperature
The humidity
etc.
Other Considerations:
What machines will be needed, and how many

o Cameron uses both 12 & 24 bank 80-volt units
o Typical PWHT requirements dictate more heating
elements than typical stress relief operations
used at other facilities.
o All controls and monitors must be charted
What consumables will be required for the job

o Cameron Patterson/Berwick departmental
requirements state that all thermocouple wiring
must be terminated with the proper connectors
(no twisting together, or bunny ears)
These standards are for facility PWHT

crews and all 3rd party vendor technicians
performing PWHT at the Patterson and
Berwick facilities.
o There must be no less than 14 of total heat band

on welds of 1in to 2in thickness, with no less
than 38 inches of insulation cover when heated
from one side
o There must be no less than 7in of total heat band
on welds up to 2in thick, with 24 inches of
insulation cover when heated from both sides
P R E PAR AT I O N
A N D
C A M E R O N
o Fiber tape for insulation attachment
Do you have banding or tie wire for securing heating

elements to the work-piece? (tape cannot be used to
secure pads to the material, nor anything that will
carbonize or degrade during the PWHT process.
Do you have enough heating pads, and pads of proper

sizes for the stress operation? (Cameron will not supply
heating elements to 3rd party vendors)
What WS & WPS will be used
Is there a qualified procedure? (qualified procedures

will be provided by Cameron PWHT supervisory
authority at the time of briefing)
Are there any extra considerations due to architecture

of the part or the position of the areas to be stress
relieved? (Heat sinks, dissimilar thicknesses, etc.)
All of these considerations are important to address before

starting the layout process because you are a
professional, and are expected to be prepared for the job
at hand.
Laying Out the PWHT:
Now that you are ready to

begin, Step back and make
sure the area is safe for work
Do a walk around, and remove any
hazards from the surrounding area. (Step
back 5 X 5.)
You may now start the Layout process.
PWHT
Requirements
layout
for placement of
heating
elements and
thermocouples.
Quarter Hourly
Temperatures
P R E PAR AT I O N
A N D
C A M E R O N
Laying out for pipe 4.0in. to 16in diameter:
Similar thickness welds 4.0in to 16in

Diameter:
The most common architecture

for weld joints are welds joining
material of similar thicknesses
2T=two times the thickness of the weld joint
Pipes of these diameters use WS-1684 requiring one

controlling thermocouple per pad, attached within
inch of the weld toe.
o In addition to the controlling TC, there must also
be a monitoring thermocouple per pad, attached
no less than 2T from the weld toe
The pad must be centered on the

controlling TC
o A minimum of 2 pads must be used per weld (one

on top and one on the bottom) with no gaps
larger than 1, and no overlapping or folding of
the pads
P R E PAR AT I O N
A N D
C A M E R O N
Dissimilar thickness welds 4.0in to 16in

Diameter:
Parts with an architecture where
materials of markedly different
thicknesses are in close proximity to the
weld joint require a more aggressive
monitoring layout than those of a similar
thickness.
Due to the amount of gradient heat loss through the materials,
weldments that are located near heat sinks must be monitored
on both sides of the weld face.
Heating elements must have a separate controlling
thermocouple from the monitors, and all thermocouples (besides
the controlling thermocouple for booster heating elements,) must
reach and hold the soak temperature for the required soak
period as dictated by the WS.
Layout for dissimilar thickness welds type #1:
2T= 2 times the thickness of the material at the weld joint.
Pipes of this type of architecture require one controlling

thermocouple located within inch of the weld toe,
and monitoring TCs located 2T from the toe of the weld
on both sides (as shown above).
P R E PAR AT I O N
A N D
C A M E R O N
o In addition to the controlling and monitoring

TCs, booster heating elements may be required
in order to reduce the gradient heat loss through
the heat Sink/ thicker material, through the
length of the pipe section, or both
Heating elements must be adjusted to allow

for proper heating of the thicker material
without overpowering the thinner side

the pads
Layout for dissimilar thickness welds type #2 (ID Heat):

the (Heat Sink) thicker material, through the
A booster element has been added to the ID

portion of the above part (labeled B) and
P R E PAR AT I O N
A N D
C A M E R O N
a controlling thermocouple has been

attached. This configuration is used
whenever access to the ID allows for the
proper attachment of a controlling
thermocouple to the ID of the heat sink
Heating elements must be adjusted

to allow for proper heating of the
thicker material without
overpowering the thinner side

the pads
Layout for Pipe with 16in Diameter or greater:

16in. or greater diameter:
Laying
Requirements
out large
for pipe tubular

over
diameter
16 Dia.
weldments:
Quarter Hourly
Temperatures
When working with pipes

of larger diameters, changes must be
made in the process to insure the
integrity of the PWHT. That is why the
following layout information has been
provided.
Similar Thickness Weldments over 16in Diameter

Laying out for similar thickness weldments 16in. or greater diameter:
P R E PAR AT I O N
A N D
C A M E R O N
Layout #1 WS-1684 for 16in or greater diameter pipe:
Pipes larger than 16in diameter have many layout

options. When using WS-1684, all welds of similar
thickness must be laid out in the standard format (as
shown above).
One controlling thermocouple must be attached within

in of the weld toe with a monitoring TC located 2T
from the toe of the weld
the length of the pipe section when using this
layout format
Notice that no booster has been added

to this layout
o A minimum of one heating element in each

quadrant of the pipe must be used to insure
proper heating of the entire weldment (as shown
on the circle map)
Please note that adding heating

elements or thermocouples to the ID of
the weld using WS-1684 does not
change the TC requirements
P R E PAR AT I O N
A N D
C A M E R O N
Layout #2 WS-1991 only, with ID thermocouples for 16in or greater diameter pipe:
2T thermocouples are not required.
When using WS-1991-01, on welds of similar thickness,

the above layout is acceptable per section 6.2.1
paragraph B

in of the weld toe with monitoring TCs located 2T
from the toe of the weld on both sides
TCs, booster heating elements are required
(wherever possible) in order to reduce the
gradient heat loss through the length of the pipe
section when using this layout format

to this layout

proper heating of the entire weldment
Please note that wherever possible,

heating elements must be added to the
ID with minimum heat band
requirements from the list in section
7.5
P R E PAR AT I O N
A N D
C A M E R O N
o The addition of heating elements to the ID will

not change the layout for WS-1991-01, but will
guarantee less gradated readings between the
attached TCs
Layout #3 WS-1991, with no ID thermocouples for 16in or greater diameter pipe:
In this case 2T thermocouples are required
When using WS-1991-01, on welds of similar thickness,

the above layout is also acceptable per section 6.2.1
with no ID thermocouples

in of the weld toe with monitoring TCs located 2T
from the toe of the weld
the length of the pipe section when using this
layout format

to this layout

proper heating of the entire weldment
P R E PAR AT I O N
A N D
C A M E R O N
Dissimilar Thickness Weldments over 16in Diameter:

When laying out larger diameter tubular
weldments that join materials of
dissimilar thicknesses, new focus must
be made concerning heat loss and the
displacement of heat through the
materials. For PWHT this means that any
layout used must account for the full soak
temperature throughout the joint and
adjacent material.
Layout #1 WS-1684 & WS-1991-01 for dissimilar thickness weldments 16in. or greater diameter:
In this case 2T thermocouples are required

The heating elements must be adjusted for best control

of material temperatures
P R E PAR AT I O N
A N D
C A M E R O N

TCs, booster heating elements will be required in
order to reduce the gradient heat loss through
the heat Sink, thicker material, through the
A booster element has been added to the

OD portion of the above part (labeled B)
and a controlling thermocouple has been
attached. This configuration is used
whenever access to the ID is not possible
WS-1684 makes no adjustments for PWHT

with added TCs or Heating elements on
the ID of the weldment

o A minimum of 4 pads must be used per weld

(located in each quadrant of the circumference)
with no gaps larger than 1, and no overlapping
or folding of the pads
o TCs can in no case be attached in excess of 24in
from each other, or in excess of of the OD
circumference, whichever is smallest
The controlling and monitoring thermocouples must

reach and hold soak temperature and all range
temperatures must remain in tolerance for the full
duration required by the WPS
1 degree temperature or more above

or below the required soak range is
nonconformance, and must be noted
and addressed immediately
P R E PAR AT I O N
A N D
C A M E R O N
Layout #2 WS-1991-01 only, for dissimilar thickness weldments 16in. or greater diameter:
Booster pads can be added here to help

control gradient heat dispersion.
The addition of heating elements on the

ID is required wherever possible.
In the case where ID TCs can be added, 2T thermocouples are

not required

thermocouple located within 1in of the weld center,
and one monitoring TC located 1in from the center of
the weld on the opposite side of the OD and 2
thermocouples located adjacent from the OD TCs
attached to the ID (as shown above).
The heating elements must be adjusted for best control

of material temperatures
the heat Sink, thicker material, through the
This configuration is used whether or not

adding heating elements to the ID is
possible
WS-1991-01 requires ID heating elements

to be added wherever possible
P R E PAR AT I O N
A N D
C A M E R O N

o A minimum of 4 pads must be used per weld

(located in each quadrant of the circumference)
with no gaps larger than 1, and no overlapping
or folding of the pads
o TCs can in no case be attached in excess of 24in
from each other, or in excess of of the OD
circumference, whichever is smallest
The controlling and monitoring thermocouples must

reach and hold soak temperature and all range
temperatures must remain in tolerance for the full
duration required by the WPS
1 degree temperature or more above

or below the required soak range is
nonconformance, and must be noted
and addressed immediately
Special Architectures and Non-standard PWHT

Layouts:
Layout #1 WS-1991-01 for Non-Tubular or Non-Standard Architectures:
There are many cases when technicians will be

required to layout PWHT on parts that are more
structural in design, or parts that are impossible to
stress using a standard layout.
In these cases, there are some rules that help to insure
the integrity of the post weld heat treating process.
P R E PAR AT I O N
A N D
C A M E R O N
The layout must be configured in such a way as to

insure that the entire weld area has reached and held
soak for the time required by the WPS
o As with all layouts, heating element controls
located at the weld must show the actual
temperature at the weld, and must be within the
range and duration required by the WPS
o Monitoring thermocouples must show that the
entire heat band has reached and held soak
temperature for the full duration required by the
WPS, and must remain within the allowed range
Even 1.0F degrees above the

maximum or below the minimum
required soak temperature is
unacceptable, and must be reported on
the PWHT log with the name of the
operator, time of the occurrence,
nature of the problem, and how it was
fixed
Any time overages or shortages must

be reported on the PWHT log with the
name of the operator, and the reason
for the shortage/overage
The layout must be accepted by the Cameron

Supervisory Authority before the wrapping and heating
processes
When planning the PWHT layout, Cameron Supervisory

Authority overrides all other supervisory input.
You must layout according to the input given by the

Cameron Representative. Failure to do so could forfeit
your ability to work on Cameron production parts.
If there are any logistical conflicts

between any third party vendors
supervisor and the Cameron
Supervisory Authority concerning the
layout of any PWHT, authority goes to
the Cameron Representative
P R E PAR AT I O N
A N D
C A M E R O N
Failure to adhere to Cameron policy or departmental

instructions concerning PWHT will result in an official
query of all technicians/operators, supervisors, charts,
and traceability reporting material by Cameron QA and
Welding Engineering
o If the resulting findings show negligence,
damages may be charged against the purchase
order in the amount required to rectify the issue,
repair the damages, or replace the part
(whichever is required for the best outcome for
the aftermarket customer)
o In any case of negligence, the
technician/operator, and/or supervisor will be reevaluated, and actions will be taken to reduce the
likelihood of such action being repeated including
possible dismissal/banning from the Cameron
facility, and/or a statement of demerit added to
their record of employment
Filling out the required Paperwork
Before PWHT,
departments and vendors
that perform the Post
Weld Heat Treatment
process will be required
to document data using the Post Weld
Heat Treatment Form.
About the required paperwork:
Department managers/supervisors, vendor representatives, and

Post Weld Heat Treatment technicians are responsible for
communicating and implementing the requirements of DI-163
Rev. A02 (this is the departmental instruction put in place for all
PWHT performed on parts from the Berwick facility).
This paperwork is required for every job, every day.
P R E PAR AT I O N
A N D
C A M E R O N
P R E PAR AT I O N
A N D
C A M E R O N
3
Section
Items Not Covered in the Previous Sections:

So far we have covered Pre-PWHT and
Post weld heat treatment basic layouts.
Sometimes parts have an architecture
that will not allow for a standard layout of
pads, insulation, or thermocouples.
In these cases there are a few rules that
must be followed.
Other Qualified Layouts:
The short flange neck of this termination spool looks to be

a standard PWHT layout part. What is not readily apparent
is the rubber flex gasket located at the arrow.
The highest temperature allowed for the rubber is 300F
and the temperature at the weld must reach and hold
a temperature of 1180F. It must also hold that
here are many times when the layout of a particular WS

will be impossible due to factors ranging from
P R E PAR AT I O N
A N D
C A M E R O N
a welded area being too small
a weld joining a vastly dissimilar thickness material
a weld located near to material with a markedly

different tempering temperature
a destructible material within the intended HAZ that

cannot be disassembled or moved
Spot repairs, etc.
Basic rules of thumb:
In these cases, several rules apply:
The entire area of the weld must reach and hold soak
temperature for the full duration of time required by
the WPS used for the welding process (whether using
WS-1684 or WS-1991-01)
TC placements must account for the temperatures of

the weld and adjacent material (whether using WS1684 or WS-1991-01)
Wherever possible TCs must be placed on the opposite

side of the weld to insure full penetration of heat
through the entire weldment and adjacent material.
(whether using WS-1684 or WS-1991-01)
Wherever possible heating elements must be added to

the opposite side of the weldment and correlate with
the pad and TC placement on the weld face (whether
using WS-1684 or WS-1991-01)
Any weldment with less than 2T of face material on

each side of the weldment must have TCs placed at
the farthest limit of the face material, and those TCs
must reach and hold soak temperature for the full
duration time required by the WPS used for the welding
procedure (whether using WS-1684 or WS-1991-01)
P R E PAR AT I O N
A N D
C A M E R O N
o If ID heat can be added, The layout of the

TCs shall, as a minimum, conform to the
WS as written
Insulation placement and amounts must conform to the

WS as written unless qualified by Welding Engineering
o Insulation is not a second thought. It is a qualified
variable written in detail for each WS
Welding Engineering must be contacted for any

architecture that does not fully conform to the required
WS for the PWHT, and Engineering must make any final
decision on the validity of any proposed layout for
which there is no qualified PWHT procedure (whether
using WS-1684 or WS-1991-01)
Please notice that regardless of which WS is used, the same

rules apply. The entire area to be treated must be validated
to insure proper relief of stresses caused by uneven heating
during the welding process.
Non-standard PWHT Case in Point:
In the case of the Flex King weldment (shown at the top of this
section), there is a rubber ring located in close proximity to
the weldment that must be kept at a temperature less than
300F.
Therefore, the PWHT requires that monitoring thermocouples
be attached at the edge of the rubber at no less than 4 points
on the OD and ID. (Equidistance placement and positions
related to the hottest area of each heating element.)
Air circulation must also be added to the process in order to
keep the metal at the rubber under the maximum allowed
temperature of 300F.
Air is added at 4 positions on the OD, blowing in a circular
pattern to remove excess heat from the rubber side of the
material.
P R E PAR AT I O N
A N D
C A M E R O N
An air horn is also added to the ID in order to keep the

adjacent material at the rubber below the maximum
temperature allowed for that material.
The required band of insulation is reduced to keep heat from
gradating toward the rubber flex area.
In addition to the specialized layout, monitoring of the
gradient heat zone must continue through the cool down
phase until the monitors at the rubber do not rise when
the air flow is removed.
As you can see, there are quite a few specialized requirements
for this part.
This illustrates how even a standard layout can require special
considerations in order to insure compliance with the WPS,
especially with uncommon architectures.
Qualification of PWHT:
As stated earlier, there will be times when 2T thermocouples will
be impossible to place on the face of the working material. In
these cases engineering is the failsafe.
Qualification Authority:
The supervisory authority, as required by Cameron Welding

Engineering, WS-1684, and WS-1991-01 may require that a
stress relief procedure be Qualified before performing PWHT
on a production part. Engineering also has the authority to
request a qualification test to be run on any architecture at any
time, with or without any physical appraisal of the item being
questioned.
In those cases it is the responsibility of Welding Engineering to
create a test procedure based on the proper WS, and submit it
(in writing with the appropriate layout mapping) to the
immediate PWHT supervisory authority.
It is then the responsibility of the PWHT department to carry out
the procedure before continuing forward with any layout on the
production part.
P R E PAR AT I O N
A N D
C A M E R O N
Qualification Requirements (basic):
As per section 13.3 of WS-1684, a capability test shall be

conducted to demonstrate the effectiveness of the PWHT
procedure.
13.3.1 requires that a mockup part be made to represent the
diameter, wall thickness, and architecture of the production part
to be qualified, and must provide sufficient mass to simulate the
heat sink of the production part.
An actual weld is not required, but the maximum anticipated
widths of the weldment must be marked on the part (OD and ID
when possible) to simulate the presence of a weld.
13.3.2 Additional TCs are required in the following locations:
Centerline of the OD weld at the same circumferential

locations as the other OD thermocouples.
On the ID pipe surface at least in. from the toe of the

weld at the same circumferential locations as the OD
thermocouples (wherever possible).
13.3.3 Engineering or the supervisory authority may require that

TCs be attached at other locations in order to obtain additional
information.
All TCs must be monitored and charted, and all qualifications

must be verified by no less than 2 full PWHT runs without failure
(to prove conformity to the WS & WPS for the part.)
P R E PAR AT I O N
A N D
C A M E R O N
A qualification test may be performed by PWHT technicians at

the request of Cameron Engineering, and/or the immediate
supervisory authority when a need for such a test is suspected.
Layout for PWHT Qualification:

When laying out a project for Qualification, many variables must
be considered to insure the validity of the proposed process.
Stringent adherence to the guidelines put forth in the WS is
always the baseline for any PWHT operation and must be the
first consideration during the qualification process.
Qualification Layout Requirements (Limiting Factors):
Before beginning the qualification layout, all architectural

aspects of the part must be addressed, TC placements assessed,
heat bands and insulation requirements considered in relation to
the limiting factors, if any.
Limiting factors consist of any existing circumstances that might
disallow adherence to the minimum requirements of the WS.
Elements that may disallow full adherence to a WS include:
Weldments
coupled
to
a
material
that
disproportionately thicker than the joining material
Joints which do not have sufficient adjacent surface

areas to allow for placement of 2T thermocouples.
Parts with architectures that will not allow for heating

elements of the proper width to be used
Weldments or repairs, on or near seal areas
Parts with coatings near the area to be heated that

cannot be harmed during the PWHT process (Xylan
etc.)
is
P R E PAR AT I O N
A N D
C A M E R O N
Parts with rubberized seals or gaskets which cannot be

removed prior to the PWHT process, that are located
within or near the area to be heated
As you can see, there are many factors that may come into
play which could disallow the placement of pads,
thermocouples, or insulation per the specifications of the WS.
In each of these cases, Welding Engineering is the only
department with the authority to adjust the proposed
procedure.
In any case in which the minimum requirements of the WS
cannot be met, the immediate supervisory authority is
required to disclose all pertinent information to Welding
Engineering in person, or in writing with a full explanation of
the factors in question.
It is also required that suggestions for a remedy be submitted
at this time, with a proposed mapping of an alternative PWHT
layout for perusal by the engineering authorities.
Qualification Layout Requirements (Methodology):
For the PWHT technician, the method used in the

qualification process is as follows:
Research and compare procedures performed on

objects of a similar architecture
o Note any similarities and dissimilarities between
those parts
Use a notebook while doing your research
Include details and

procedures researched
maps
of
the
Remember to show TC placements,

pad sizes with their placements, and
ramp speed (include PWHT charts if
available)
P R E PAR AT I O N
A N D
C A M E R O N
Make a supposition/hypothesis about the most viable

means to insure that the proper temperatures will be
reached, and the proper hold times will be met
In the case of a production part:

o Do not guess (this might work.)
o Do not make a decision based on information
alone, or a similar PWHT(this should work)
o Do not use a process that may have worked on
other material, but has not been qualified for your
particular part (this works, can we adjust it to
match our requirements?)
o Do have engineering consider your gathered
information when you submit your layout
proposal
o Do not stress relieve the part
engineering approves the process
until
Design the layout based on your research, and the

proposed viable means made during the suppositional
stage, and map a proposed outcome.
o Mark all required items on your map clearly and
accurately
Submit all proposals and information to Welding

Engineering with a layout map, and a process
deposition (why you believe the process will work)
Engineering will submit a full layout to you based on all

available information, and their expertise.
Setup and run the PWHT according to the designed

viable means
If the layout was successful accept the design

o Run the same layout again to prove the process
P R E PAR AT I O N
A N D
C A M E R O N
If the layout was not successful, report the failure to

Welding Engineering.
Use the information gleaned from the research,

supposition, design, and run stages to adjust any failed
portions of the PWHT toward compliance with the
requirements
o Submit the
Engineering
adjusted
layout
to
Welding
Run again and compare
o If the new layout is successful, run the same

layout again to prove the process.
Turn all maps and information into Welding

Engineering for final acceptance of the process
At this point, the PWHT technician is done with the

qualification process.
All that remains is the disclosure process. It is at this time
that engineering may require more information from the
technician to finalize the details of the PWHT runs
P R E PAR AT I O N
A N D
C A M E R O N
What parts are covered by a qualified procedure?
Welding Engineering may apply the same qualified procedure

across a wide range of part numbers depending on their
similarities, and may also disallow a procedure based on any
dissimilarity between parts within the same genre or
specifications.
Generally speaking, any qualified process is cleared for
application on a part by part basis. The accepted process
must be applied equally across all part numbers for which the
qualified treatment has been assigned.
This means that many parts can be covered by a single
qualified procedure.
The parts that may be covered by a single PWHT procedure
are:
P R E PAR AT I O N
A N D
C A M E R O N
Parts with an architecture that allows for a layout that

exactly mimics the architecture of an existing qualified
procedure
o These will have a thickness that is not more than
10% more or 10% less than the part qualified in
the procedure
o They will use the same number of heating
elements
o They will use the same size heating elements
o The pad arrangement will not be altered
o There will not be an increase in the width of the
weldment of more than .25in. or T of the
thinner member being joined
o There will be no decrease in the distance of the
monitoring thermocouples from the edge of the
weld
o There will be no change in the insulation type
o There will be no change in the thickness or
placement of the insulation
o There will be no change in the output voltage of
the power supply used of more than 10%
o There will be no increase in the qualified
temperature of more than 50F
If all of these requirements are met, the qualified
procedure is acceptable per section 13.4 for Essential
Variables in WS-1684.
(Check with Welding Engineering before proceeding
with PWHT on any production part for which there is
no assigned qualified procedure.)
P R E PAR AT I O N
A N D
C A M E R O N
THE FINAL WORD

The moment you step foot on a Cameron facility, you become
much more than a representative of your own personal work
ethic. You become part of a team.
Everyone at Cameron has made it their goal to be the best of
the best at everything they do, and it shows. They prove it
with their quality of work, with their production, and their
attention to detail.
As part of the team, help will always be available for you
regardless of your status. Whether you are a helper just
starting out as contract labor, a 3rd party vendor, a new hire,
or even just a visitor you are seen as part of a larger picture,
and we want that picture to be a masterpiece.
In PWHT, you are elite. The skills involved in what you do are
not easy to master, and we will make it our goal to help you to
master the processes required by our department.
What now?
Wrap tight, layout accurately, map with attention to detail, and
never neglect to do your job.
Your job requires that all aspects of the PWHT process are
monitored, and validated with detailed traceability. This means
that you are responsible for making sure every PWHT you do is
done according to the Cameron required procedures.
Bottom line is Do your job, Do it well, Ask questions, and
never give any less than your best effort.
Welcome to Cameron.
P R E PAR AT I O N
A N D
C A M E R O N

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1

Cameron PWHT Operators Guide

Operators PWHT Guide Vol: 1

Layout #2 WS-1991 only, with ID thermocouples for 16in or greater diameter

Preparing the part for PWHT

is to insure that the part is prepared as per section 5.0 of WS-001684

All weldments shall be physically supported adjacent to each side of

Support structures shall be able to compensate for linear and

Support structures used shall be able to withstand any temperature

Personal Plan of Action

What is a Personal Plan of Action?

Stencil the part per the routing.

Verify the part numbers against the BOM.

Dope/Protect all seals and threaded holes.

Verify grinding details, and do grinding operation

LP the welds per procedure.

Clean grease and paint from all areas to be heated.

Blow grinding dust out of the pipe

Notice that stenciling is always first on the list.

At this point the part should be ready to set up for PWHT.

Make your plan and stick to it.

Filling out the required Paperwork

Before PWHT, departments and vendors

About the required paperwork:

Department managers/supervisors, vendor representatives, and Post Weld Heat

Section A, Breakdown of DI-163 Rev. A02:

Form-226 Rev A03: Section A

Form-226 Rev A03 Section A must be documented before the

All information pertinent to the process used for section

Mark the appropriate Process (Local, Oven, Hydrogen

Vendor sections will be filled out by your leadsmen.

Work Order, Part Number, & Serial Number shall be

Weight of the part must be documented in the weight field.

The dimensions of the part (OD X ID & pipe wall thickness

The name of the customer and a description of the part

Weld Map #s are the weld numbers given to weldments

The WPS used for welding shall be documented on the

Section B, ASME Section IX:

Form-226 Rev A03: Section B

Post Weld Heat Treat to ASME Section IX

All fields of section B must be documented before the setup and

Actual Soak Temperature, Actual Soak Time, & Chart

In accordance with the WPS, Minimum, Maximum, and

The heating and cooling rate of ascent and descent shall

Section C, Data & location Maps:

Form-226 Rev A03: Section C

TC Data map / Location map.

Section C must be documented during the PWHT setup

Thermocouples used must be designated by color or

The function of the thermocouples shall be determined as

The location of each thermocouple shall be designated in

Section D, PWHT TC Mapping:

Form-226 Rev A03: Section D

Section D is designed for the PWHT technician to generate a

In addition to providing a PWHT Chart, the Operator shall

1) A circumferential placement of TCs around

2) A "cut away" view that shows the

Any additional notes or comments concerning the PWHT

o And any dispositions given by the Leaderman

Additional pages may be needed for full documentation

Section E, Contact Information:

Form-226 Rev A03: Section E

Section E is designed for entry of contact information for the