MESAIEED A 2000 CCPP PROJECT

Document Number Document Title Page 1 of 8

Method Statement for Post Weld Heat Rev 00
14T2-00-MA-ONM-SOM-036
Treatment Date

Method Statement For Post Weld Heat Treatment

MESAIEED A 2000 Combined Cycle Power Project

For Review &

00 04.05.08
Approval

DESCRIPTIO PREPARED APPROVED VERIFIED BY

REV DATE VERIFIED BY
N BY SOMI BY SOMI IBERDROLA
INDEX Client
 MESAIEED A 2000 CCPP PROJECT

Document Number Document Title Page 2 of 8

Method Statement for Post Weld Heat Rev 00
14T2-00-MA-ONM-SOM-036
Treatment Date

1. PURPOSE
2. SCOPE
3. REFERENCES
4. RSPONSIBILITIES
5. SPECIAL EQUIPMENTS
6. GENERL REQUIREMENTS
7. HEATING METHOD
8. TIME AND TEMPERATURE REQUIREMENTS
9. HEATING AND COOLING RATES
10. JOINT PREPARARION AND WRAPPING
11. THERMOCOUPLE
12. EXTENSION LEADS
13. TEMPERATURE RECORDING
14. PWHT OF DISSIMILAR P-NUMBER WELDS
15. NON-PRESSURE TO PRESSURE RETAINING PARTS
16. SAFETY
17. INSPECTION
18. DOCUMENTATION

1.0 PURPOSE

The purpose of this procedure is to provide requirements for Post Weld Heat Treatment (PWHT) of weld
joints for the MESAIEED A IPP PROJECT.

2.0 SCOPE

This procedure refers to following documents for performing PWHT of shop & field welded piping system
components in accordance with ASME / ANSI B31.3, B31.1 and Client.
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Method Statement for Post Weld Heat Rev 00
14T2-00-MA-ONM-SOM-036
Treatment Date

3.0 REFERENCES

The following reference documents have been utilized in preparing this procedure and shall be referred to
for additional technical information as necessary. ASME B31.1: Chemical Plant and Refinery Piping.

3.1 ASME B31.1 Power Piping.

3.2 ASME Boiler and Pressure Vessel Code, Section IX, Welding and Brazing Qualifications.

3.3 American Welding Society (AWS) D10.10-75, Local Treatment of Welds in Piping and Tubing.

4.0 RESPONSIBILITIES

4.1 The SOMI Welding Supervisor / Foreman has the responsibility for implementing and ensuring this
procedure

4.2 The SOMI Supervisor / Foreman shall determine the PWHT requirements, based on project
specification and other reference documents.

4.3 The SOMI Welding Supervisor / Foreman shall be responsible for initiating PWHT operations in
accordance with the specification.

5.0 SPECIAL REQUIREMENTS

5.1 Welding Procedure Specifications (WPS) utilized in performing the affected welds shall be qualified
for PWHT when required by the applicable code.

5.2 All temporary attachments within the heat-affected zone shall be removed

6.0 GENERAL REQUIREMENTS

6.1 PWHT shall be in accordance with the applicable WPS, ASME B31.3, and B31.1, or design
drawings and this procedure. Specific requirements of the WPS or this procedure shall govern.

6.2 Prior to the start of work, a detail table-listing of joints or components requiring heat treatment shall
be prepared for review. The table shall include the information for each joint or component, location,
Drawing No., diameter, wall thickness, material, heating rate, cooling rate, soaking temperature &
time, number and location of thermocouple.
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Method Statement for Post Weld Heat Rev 00
14T2-00-MA-ONM-SOM-036
Treatment Date

7.0 HEATING METHOD

The heating shall be done by resistance or induction methods by application of electrical resistance
elements in the form of ceramic heater pads.

8.0 TIME AND TEMPERARURE REQUIREMENTS

8.1 Attachments ‘A’ defines requirements for PWHT applications based on the materials P-numbers
listed in ASME Section IX.

8.2 The minimum holding time shall be in accordance with Attachments ‘A’.

8.3 When members being joined and of unequal thickness, the nominal section thickness at the location
of the Weld heat affected zone in the heavier section shall be the governing thickness for
determining the holding time and heating / cooling rates.

9.0 HEATING AND COOLING RATES

Above 600˚F (316˚C), the rate of heating and cooling shall not exceed 432˚F (222˚C) per hour
divided by the maximum thickness of material in inches at the weld, but in no case the rate shall exceed
432˚F (222˚C) per hour. The welds shall be allowed to cool in still atmosphere to a temperature not
exceeding 800˚F (425˚C). The insulation shall not be removed before the temperature has cooled below
150˚C.

10.0 JOINT PREPARATION AND WRAPPING

10.1 The minimum width of the heated band shall be five times the thickness of the thickest component

10.2 PWHT of welded joints shall require that the entire band be brought up to a uniform temperature
over the circumference of the heated pipe section. A gradual diminishing of temperature outward
from the edges of the heated band shall be maintained.
10.3 Heating elements shall be securely fixed in contact with the work piece by soft iron wire, SS or mild
steel banding to suit the application. Under no circumstances shall galvanized wire or other fixing
material likely to detrimental to the pipe be used.

10.4 Internal drafts or chimney cooling effect during PWHT shall be avoided. Normally, valves will be in
the open or cracked position unless otherwise recommended by the valve supplier. Open-ended
pipe shall be temporarily sealed off upstream and downstream of the welded joint to reduce internal
heat loss by use of the end caps or other acceptable means. When post weld heat treatment is to
be performed on welds between valves and piping system components, the applicable vendor must
be checked or vendor contacted for special requirements.
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Method Statement for Post Weld Heat Rev 00
14T2-00-MA-ONM-SOM-036
Treatment Date

10.5 The weldment shall be clean and free of oil, grease and dirt, prior to PWHT operation. All machined
surfaces such as flange faces, bolt holes, thread etc. shall be protected from oxidation by coating
with deoxaluminite or other suitable material.

10.6 Weather protection against rain and wind exposure shall be provided at all times during periods of
inclement weather.

10.7 Insulation shall be glass wool, or other type provided by IBO. A minimum I” thick layer of ceramic
fiber or a minimum 4” layer of mineral wool shall be required.

10.8 The thermal insulation shall extend a minimum of 12” beyond the heating elements on each side of
the weld joint to avoid harmful temperature gradients, unless otherwise authorized by IBO Inspector.
Code requirement shall however at all times to be complied with.

10.9 Prior to start PWHT the piping / components shall be checked to ensure that all restrains are
removed and pipe is free to expand and contract. Also during PWHT the piping / components shall
be properly supported to prevent sagging and distortion.

10.10 Additional information regarding joint wrapping and preparation shall be in accordance with good
industry practice.

11.0 THERMOCOUPLE

11.1 Type K (Chemical alumel) or type joint J (Iron-Constantan) thermocouples are recommended. All
extension cables, compensating cables and jumper cables in the measurement or control circuit
shall be specified thermocouple wire.

11.2 Thermocouple shall be attached to the work piece by direct wire capacitance discharge method.
The gap between the two wire / work piece junctions shall not exceed 6mm.

11.3 Care shall be taken to ensure that the thermocouple conductor wires do not touch each other, or
metallic components, away from the hot joints.
11.4 Thermocouple hot junctions shall be protected by the application of layer of high temperature putty,
applied locally.

11.5 Wherever possible, thermocouples shall not be located under a heating pad; thermocouples shall
be routed between heating pads or out through the insulations, to avoid close contact with the
heating pad.

11.6 The thermocouple to compensating lead connections shall be minimum of 0.5m from the heated
zone.
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Method Statement for Post Weld Heat Rev 00
14T2-00-MA-ONM-SOM-036
Treatment Date

11.7 Following each heat treatment a minimum 150mm of wire measured from the hot zone, shall be
discarded

11.8 The insulation coloring of the thermocouple / compensating cable core wire shall be RED for
positive and YELLOW for negative to verify that proper wires have been used and are connected in
proper polarity.

11.9 After completion of PWHT, all thermocouples shall be removed and attachment areas ground
smooth to clean sound metal. If specified by the contract, the area shall be examined by MT or PT.

11.10 All temperatures within the heated zone for furnace or localized PWHT shall exceed the specified
minimum holding temperature. The actual temperature range for the soak period as recorded by the
thermocouple shall not have a spread of more than 40˚C.

11.11 Minimum number of thermocouple required shall be as follows:

For Pipe Diameter up to 12” - 1 thermocouple

For Pipe Diameter up to 12” to 24” - 2 thermocouple
For Pipe Diameter up to >”` - 3 thermocouple

One spare thermocouple shall be positioned beside thermocouple specified above, to be utilized in
the event of thermocouple failure to avoid interruption in recording in case of failure of the other
thermocouple.

11.12 The following are Code Requirement for band width distances for thermocouple placement:

The width of the band shall be 3 times the wall thickness of the thickest part being joined. For nozzle
and attachment welds, the width of the band shall extend beyond the nozzle weld on each side at
least 2 times the header thickness.

12.0 EXTENSION LEADS

While in use, extension leads shall positioned off the floor such that they are not damage by being
subjected to direct weight or abuse.

13.0 TEMPERATURE RECORDING

Recorders shall be calibrated every 6 months and current calibration sticker shall be maintained on
the recorder. Frequency of calibration may be extended to 12 months with the approval of Client
Inspection if the documented calibration checks for that particular recorder demonstrate acceptable
Accuracy for a suitable period. Calibration certificate shall be available for review.
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Method Statement for Post Weld Heat Rev 00
14T2-00-MA-ONM-SOM-036
Treatment Date

An automatic temperature recording shall be made of all PWHT operations utilizing a multipoint
recorder. Heating and cooling records shall include all temperatures in excess of 600˚F (326ْC). The
attachment “B” data stamp shall be applied to the back of the chart upon completion of the PWHT
cycle. If a PWHT operation is a second or succeeding PWHT, it shall be indicated as such on the
PWHT record.

Multipoint chart recorder shall clearly differentiate / identify each channel / point by use of different
colored inks or automatic stamping

14.0 PWHT OF DISSIMILAR P_NUMBER WELDS

PWHT of welded joints between dissimilar P-number welds having different post heat requirements
shall be specified for the material requiring higher PWHT temperature.

15.0 NON-PRESSURE TO PRESSURE RETAINING PARTS

When non-pressure retaining materials are welded to pressure retaining materials, the maximum
temperature shall be the temperature specified for the pressure retaining parts as per attachment-A

16.0 SAFETY

All the heating elements shall be thoroughly examined before use in order to ensure that the
element wire is not exposed.
Twist lock connection shall also be examined to ensure that the insulation is sound and that a good
electrical joint is made.
All cable connections shall be properly insulated.
The component surface shall be free of contaminants.
Technicians performing the PWHT shall be experienced in PWHT operation and conversant with
Electrical characteristics in resistance or induction heating. Care should be taken to protect
themselves and others working in the area.

17.0 INSPECTION

17.1 SOMI QC Inspector shall be responsible for inspect5ion of all attributes defined in this section.

17.2 That special instructions / vendor manuals have been complied with.

17.3 That the joint has been properly prepared in accordance with this procedure.

17.4 That thermocouple have been attached in accordance with this procedure.

17.5 The thermocouple placement is in accordance with section 11.0

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Method Statement for Post Weld Heat Rev 00
14T2-00-MA-ONM-SOM-036
Treatment Date

17.6 That the chart recorder is properly calibrated.

17.7 SOMI QC Inspector shall also review the information on the face of the PWHT chart. If the all
information is correct, ha shall sign and date the PWHT chart in the area of the information placed
on the chart.

17.8 Upon completion of the PWHT operation, SOMI QC Inspector shall verify that all temporary
attachments have been removed.

17.9 In process monitoring of all PWHT operations shall be performed by SOMI QC Inspector.
Acceptance by the Welding Inspector of individual PWHT operations shall be sign off on the
Attachment B stamp on the back of each chart.

17.10 After completion of PWHT operation, SOMI QC Welding Inspector shall submit the PWHT Chart
TPSA / SA for their monitoring and approval.

18.0 DOCUMENTATION

Documentation of PWHT shall consist of the PWHT chart, from the recorder.

When the PWHT operation is completed successfully, the PWHT chart along with PWHT Report
shall be submitted for Client for their review ad approval.