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EIED

AMIR KABIR PETROCHEMICAL COMPANY Amir Kabir 6th Olen Plant

NATIONAL PETROCHEMICAL COMPANY

(NPC)

Process Engineering and Contracting Division

Guide Post Weld Heat Treatment


Scope

no.: 01/2004
by: Richard Lothar Teichmann date: July28, 2004 page: 1 of 4

This guide shall dene minimum requirements to carry out a successful post weld heat treatment on prefabricated and eld erected piping within the 6th olen plant of Amir Kabir Petrochemical Company as per design code and project specications. It may used to monitor and control contractors and subcontractors activities and documents. Denitions and Abbreviations AKPC Contractor Subcontractor Design Code WPS PWHT NDT ... Amir Kabir Petrochemical Company ... company erecting piping and/or performing pwht ... company performing post weld heat treatment on behalf of contractor ... ASME B31.3 ... welding procedure specication ... post weld heat treatment, heat treatment carried out after welding in order to decrease residual welding stress and/or change the micro structure ... non destructive testing

Reference Standards and Specications ASME B31.3 ASME IX 00-ESS-PI-3001 Subcontracting Subcontractor should work under the order and responsibility of the contractor and should fully comply with the relevant requirements by design code and/or project specications. Contractor who orders pwht should supply all relevant specications and requirements concerning these work to the subcontractor. Subcontractor should provide records and documentation of his work as specied by the contractor and/or this guide. ... Process Piping ... Qualication Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators ... Welding Specication of Piping Systems

distribution

as per cover letter

Guide Post Weld Heat Treatment


Personnel

no.: 01/2004
by: Richard Lothar Teichmann date: July28, 2004 page: 2 of 4

Contractor and/or subcontractor should appoint a sufcient number of competent personnel for the planning, performing and supervising of pwht according to specied requirements competence should be proofed by experience and certication. Inspection and Testing General Contractor and/or subcontractor should have at his disposal a sufcient number of competent personnel for planning and performing, inspection, testing and assessing of the pwht activities according to specied requirements. Non Destructive Testing Final NDT should be carried out at the stage of PWHT if specied in the design code and/or project specication or otherwise after the nal PWHT. Equipment for Post Weld Heat Treatment Equipment and Measurement All equipment used should be adequate for the application concerned and should match the following minimum requirements: - Thermocouples ... should be from nickel-chromium/nickel-aluminium type BS4937, part 4, type K or equivalent. - Thermocouple extension cable ... copper-constantan compensating cables should be used. The copper lead (+ve) should be connected to the nickel-chromium conductor (non magnetic) and constant lead (-ve) to the nickel-aluminium conductor (magnetic). - Thermal recorder ... should be suitable for the type and number of thermocouples used and should be capable to obtain a continuos graph chart, providing information of temperature differences and trends during the PWHT cycle, the chart speed should be adjusted to 50mm per hour. - Temperature control system ... in case of automatic control, the relevant design code and/or project specication should be programmed into the unit. Once initiated the program shall run until completion. ... manual control requires adjustment of temperature controllers in increments of 10C max. - Electric power supply ... should be controlled by a percentage (time) energy regulator. Facilities - Heating elements ... electrical resistance, multi standard wire, element beads made from high grade sintered aluminium, termination by male camlocks, max. operating temperature 1050C, rating 43amps/63volts. - Insulation ... ceramic bre mesh mats of min. density 96kg/m or Rockwool of min. density 30kg/m.

Guide Post Weld Heat Treatment


Checking of Post Weld Heat Treatment Equipment Calibration of Adjustment and Recording Devices

no.: 01/2004
by: Richard Lothar Teichmann date: July28, 2004 page: 3 of 4

- Temperature control system and thermal recorder should be calibrated at least once per year (12 month cycle). - Thermocouples should be calibrated at least twice per year (6 month cycle). - Records should certify these calibrations. New Equipment New or refurbished equipment should pass a function test prior to use verifying correct function of the equipment. Records should certify these tests. Maintenance Contractor and/or subcontractor should have a maintenance program for PWHT equipment and facilities in place, should be proofed. Post Weld Heat Treatment Activities PWHT Specication Contractor and/or subcontractor should prepare a PWHT specication specic to the project and items to be heat treated, approval required. Work Instruction PWHT specication should be used for instruction purposes, alternatively a work instruction based on an existing PWHT specication should be produced. Work instruction should not be subject to approval. Number of Measuring Points - For piping dia. less or equal 6 one thermocouple should be used. - For piping dia. 6 - 20 three thermocouples should be used symmetrically around the weld. - For piping dia. greater than 20 four thermocouples should be used symmetrically around the weld. Practice - Welds made on SA335 Gr. P91 material must cool down below 100C prior commencing PWHT. - Prior to start PWHT piping should be checked to ensure that all restrains have been removed, so its free to expand and contract. - Piping should be properly supported to avoid sagging and distortion. - If valves are involved in PWHT internals may be removed as per manufactors instructions. - Piping should be protected from impingement of wind and inclement weather, ends should be blinded off to prevent the effect of draughts on the inside of piping. - Thermocouples shall be attached on bright metal using capacitor discharge welding unit as close as possible to the weld and should be covered with high temperature putty after welding. - Heating elements shall cover the area dened by design code and project specication, no gaps allowed around the piping and should be xed with stainless or mild steel banding.

Guide Post Weld Heat Treatment

no.: 01/2004
by: Richard Lothar Teichmann date: July28, 2004 page: 4 of 4

- Insulation shall be extended to min. 200mm distance beyond the outer edges of the heating band, thickness min. two layers of ceramic bres or Rockwool 6 min. and should be xed in a suitable manner. - Perform PWHT cycle as required by design code, project specication and WPS. After starting the cycle the thermal recorder should be securely locked. Heat Treatment Records Records shall include, but not limited to, the following information and should be signed by competent personnel involved: - Clear item identication. - Material (grade, dimension ...). - Equipment used. - Cycle performed. - Thermal recorder chart. - Thermal recorder calibration certicate. - Thermocouple calibration certicate. Non Conformities and Corrective Action If PWHT does not conform to specied requirements the weld or component should not be assessed. AKPC should be informed and a Non Conformance Report should be generated. The satisfactory result of any corrective action should be demonstrated. It should be considered that the corrective action does not have any adverse inuence on the weld or component. If you require any further clarication in these matters, please do not hesitate to contact Linde LE QA/QC site staff.

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