Al-Zour Refinery Project

(Contract No.: ZOR/EPC-0055-A –

Main Process Units)

AL ZOUR REFINERY PROJECT

PROJECT NO: 10031 UNIT: 04

PURCHASE ORDER NUMBER (RFP): 1003304060 EQUIPMENT: ALL

REVIEW RESPONSE BY PURCHASER:

Purchaser review and comments do not indicate either responsibility or liability for accuracy and completeness of this document
or alter any contractual terms and conditions:

DATE:
VENDOR IDENTIFICATION: TEMA INDIA LIMITED

DOCUMENT TITLE: PWHT PROCEDURE

VENDOR DOCUMENT No.: V-04-E-0003A-0015 REV: A CODE: PRC-0011

CONTRACTOR DOCUMENT No.: REV: A DOCUMENT SIZE: A4

V-04-E-0003A-0015

COMPANY DOCUMENT No.: REV: A PAGES: 13

V-P055AZOR-04-21-4-V73015

COMPANY CATEGORY: IFI

 COMMENT SHEET
Contractor Document No: V-04-E-0003A-0015 Rev No.: O

Document Title: PWHT PROCEDURE

SR PAGE
CLIENT COMMENT TEMA RESPONSE CLIENT RESPONSE
NO. NO.

Noted, as per attached Annexure- I of

PWHT @ 610°C minimum as per P4049N-0000-DE10-VAR-0087 & DEP PWHT Procedure 620±10° C mention and
1 3
30.10.02.17 § 2.3.6 ensure to maintain 610° C minimum as
per requirement.

Noted, Hardness test shall be conducted

on the weld, HAZ of the part/assembly
2 3 Welding & hardness requirement as per DEP 30.10.02.17 § 2.3.4
after heat Treatment.

3 3 Incorporate applicable specification. Noted, incorporated in PWHT procedure.

Page 1 of 1
 PROCEDURE FOR POST WELD Procedure No. HT/16-050/01
HEAT TREATMENT OF CARBON & Page 2 of 3
Revision 1
ALLOY STEEL COMPONENTS
Date 14/01/2017
1 SCOPE
1.1 This procedure is applicable for post weld heat treatment of carbon and alloy steel pressure
vessel assemblies in single heat or multiple heats in TEMA INDIA LIMITED.

1.2 The procedure is applicable for post weld heat treatment of pressure vessel assemblies in oil
fired or electrically heated enclosed furnace method in TEMA INDIA LIMITED.

2 OBJECTIVE
2.1 The objective of this procedure is to provide a uniform method for post weld heat treatment of
assemblies for equipment no. mentioned in cover page.

3 REFERENCE STANDARD AND DOCUMENTS

3.1 Following Standard and Documents shall be referred.
ASME Section VIII Div. 1, 2015
Welding and Testing Plan and Fabrication Drawing
Client Specification No: DEP 31.22.20.31-Gen.,DEP 31.21.01.30: P4049N-0000-DE10-VAR-0003,
DEP 30.10.02.15- Gen,p055azor-00.10.10.001,P4049N-0000-DE10-VAR-0087,DEP 30.10.02.17
P4049N-0000-DE10-VAR-0009, DEP 30.10.60.18

4 PROCEDURE
4.1 All activities required to be completed before post weld heat treatment including non destructive
examination as applicable shall be completed on the components, which are to be heat treated.

4.2 The components shall be properly supported in such a way to avoid undue attachment restraints.
4.3 The components shall be loaded on appropriate saddle support and one end of the component
shall be sliding to accommodate thermal expansion in the part.

4.4 K-type chromium/Aluminum thermocouples shall be used for measuring temperature during heat
treatment.
4.5 The hot junction of calibrated thermocouples shall be attached directly to the wall of components
by capacitor discharge method using WPS No. TC-CDW-1. The extension wire of thermocouples
shall be attached to calibrated temperature recorder(s).
4.6 A diagram showing thermocouple locations as per Annexure - I shall be prepared and
components shall be heat treated as per the heating cycle. Heating cycle containing loading
temperature, heating rate, holding temperature and time, cooling rate and unloading temperature
as per Welding and Testing Plan & as per attached Annexure - I.
4.7 If more than one assembly, having variation in heating cycle, are to be post weld heat treated in
one charge the heat treatment cycle to be followed shall be approved by Head QA & C.

4.8 There shall not be a greater variation in temperature throughout the vessel than 250°F (120˚C)
within any 15 ft. (4.6mtr) interval during heating period. There shall not be a difference between
highest and lowest temperature through the vessel greater than 150°F (83˚C) during holding
period.

QA/48-2 Rev 0
 PROCEDURE FOR POST WELD Procedure No. HT/16-050/01
HEAT TREATMENT OF CARBON & Page 3 of 3
Revision 1
ALLOY STEEL COMPONENTS
Date 14/01/2017

4.9 A component longer than furnace can be heat treated in more than one furnace charge provided
the overlap of the heated section of the component is at least 5 ft. (1.5 m). When this procedure
is used, the portion outside of the furnace shall be shielded so that the temperature gradient is
not harmful. The cross-section where the component projects from the furnace shall not intersect
a nozzle or other structural discontinuity.

4.10 When parts of two different P-numbers are joined by welding, the post weld heat treatment
temperature shall be that specified for the material requiring the higher post weld heat treatment
temperature.

4.11 Time temperature graph shall be obtained along with the details of thermocouples / temperature
recorder(s), thermocouple location diagram, status of calibration and shall be kept in record for
review.

4.12 After PWHT, when the job is cooled to atmospheric temp., thermocouples shall be removed from
the job surface by smooth grinding.

4.13 Hardness test shall be conducted on the weld, HAZ of the part/assembly after heat Treatment.

5 PRECAUTIONS
5.1 There shall be adequate distance between furnace wall and component for free movement of
flue gas to all parts of the vessel.

5.2 There shall not be direct impingement of burner flame on the component. Baffle shall be used to
avoid direct impingement of burner flame on the components.

5.3 In case of oil fired furnace oxidizing flame shall not be used.

5.4 Thread holes, tapped holes and flange facing shall be protected to avoid oxidation.

5.5 Only calibrated thermocouples and temperature recorder(s) shall be used.

QA/48-2 Rev 0
 PROCEDURE FOR LOCAL POST Procedure No. HT/16-050/02
WELD HEAT TREATMENT OF TUBE Page 2 of 3
Revision 1
TO TUBESHEET JOINT Date 14/01/2017

1 SCOPE
1.1 This procedure is applicable for local post weld heat treatment of tube to tube sheet joint by
electrical heating method in TEMA INDIA LIMITED.
2 OBJECTIVE
2.1 The objective of this procedure is to provide a uniform method for local post weld heat treatment
of tube to tube sheet joint for equipment no. mentioned in cover page

3 REFERENCE STANDARD AND DOCUMENTS

3.1 Following Standard and Documents shall be referred.
ASME Section VIII Div. 1, 2015
Welding and Testing Plan and Fabrication Drawing
Client Specification No: DEP 31.22.20.31-Gen.,DEP 31.21.01.30: P4049N-0000-DE10-VAR-0003,
DEP 30.10.02.15- Gen,p055azor-00.10.10.001,P4049N-0000-DE10-VAR-0087,DEP 30.10.02.17
P4049N-0000-DE10-VAR-0009, DEP 30.10.60.18

4 PROCEDURE
4.1 All activities required to be completed before post weld heat treatment including non destructive
examination as applicable shall be completed.
4.2 The components shall be properly supported in such a way to avoid undue attachment
restraints.

4.3 The machined surfaces shall be suitably covered by ceramic blankets in order to protect it from
corrosion.
4.4 K-type chromium/Aluminum thermocouples shall be used for measuring temperature during heat
treatment.
4.5 The hot junction of calibrated thermocouples shall be attached directly to the wall of components
by capacitor discharge method using WPS No. TC-CDW-1. The thermocouples shall be
attached to calibrated temperature recorder(s) through extension wires. The thermocouple to
extension wire connection shall be minimum 0.5m outside the heated zone. The speed of
temperature recorder(s) shall be selected according to chart in use.
4.6 A diagram showing thermocouple locations as per Annexure - I shall be prepared and
components shall be heat treated as per the heating cycle. Heating cycle containing loading
temperature, heating rate, holding temperature and time, cooling rate and unloading temperature
shall be provided in Welding and Testing Plan & as per attached Annexure - I. However the
Heating cycle provided thus shall satisfy the Para 4.7 through 4.9 of this procedure.
4.7 If not otherwise specified, the rate of heating above 800°F ( 425°C) shall not be more than
400°F/hr (220°C/hr) divided by maximum thickness of weld in shell or head in inches, but in no
case more than 400°F/hr (220°C/hr) and less than 100°F/hr (55°C/hr).

QA/48-2 Rev 0
 PROCEDURE FOR LOCAL POST Procedure No. HT/16-050/02
WELD HEAT TREATMENT OF TUBE Page 3 of 3
Revision 1
TO TUBESHEET JOINT Date 14/01/2017

4.8 There shall not be a greater variation in temperature throughout the soak band than 250˚F
(120˚C) within any 15 ft. (4.6mtr) interval during heating period. There shall not be a difference
between highest and lowest temperature through soak band greater than 70°F (40˚C) during
holding time except where the range is further limited by Code or Drawing or Welding and
Testing Plan
4.9 If not otherwise specified, the rate of cooling above 800°F (425°C) shall not be more than
500°F/hr (280°C/hr) divided by maximum thickness of weld in shell or head in inches, but in no
case more than 500°F/hr (280°C/hr) and less than 100°F/hr (55°C/hr). From 800°F (425°C) the
power could be turned off and from 270°F (150°C) the vessel welds can be cooled in still air.
4.10 As a minimum the soak band shall contain the weld, HAZ, and a portion of base metal adjacent
to the weld being heat treated of tube sheet. The soak band shall include at circle or line that
extends beyond outer tube ligament by nominal thickness of tube sheet or 2 in. (50mm)
whichever is less.
4.11 Adequate insulation coverage over and above the soak band shall be made as required by the
code while performing local post weld heat treatment tube to tube sheet joint.
4.12 Use minimum of 50mm thk ceramic insulation material.
4.13 When material of two different P-numbers are joined by welding, the post weld heat treatment
temperature shall be that specified for the material requiring the higher post weld heat treatment
temperature.
4.14 Time temperature graph shall be obtained along with the details of thermocouples/ temperature
recorder(s), thermocouple location diagram, status of calibration and shall be kept in record for
review.
4.15 After PWHT, when the job is cooled to atmospheric temp., thermocouples shall be removed from
the job surface by smooth grinding.

5 PRECAUTIONS

5.1 Thread holes, tapped holes and flange facing shall be protected to avoid oxidation.

5.2 Prior to heat treatment, all oil, grease, paint etc. shall be removed from the job surface.

5.3 Only calibrated thermocouples and temperature recorder(s) shall be used.

QA/48-2 Rev 0
 Procedure No. HT/16-050/02
PROCEDURES FOR LOCAL POST Page 1 OF 1
WELD HEAT TREATMENT Revision 01
Date 14.01.2017

ANNEXURE – 1

EQUIPMENT NO: - 04-E-0009, 14-E-0009, 04-E-0003 A/B/C, 14-E-0003 A/B/C, 04-E-0006, 14-E-0006

TUBE TO TUBE SHEET WELD JOINT

RATE OF RATE OF
ITEM TYPE OF HEAT HEATING LOADING HOLDING HOLDING UNLOADING
HEATING COOLING
DISCRIPTION TREATMENT METHOD TEMP (˚C) TEMP. (˚C) TIME TEMP (˚C)
(˚C/HOUR) (˚C/HOUR)
TUBE TO
60
TUBE SHEET PWHT LOCAL 300 Max. 100 620±10 100 300
MINUTE
JOINT

Note: Thermocouples shall be attached to the component wall as shown.

QA/48-2 Rev 0