MT Op PWHT 001

PT
T. MULT
TI TERA
AINDO

DOCUMEN
NT NO : MT
T-OP-PWHT -001

TITLE : LO
OCALISED E LECTRICAL
L RESISTANCE POSTWELD
HE
EAT TREATMMENT OF WELD IN CAR
RBON OR
AL
LLOY STEEL
L IN ACCORRDANCE WITTH ANSI / AW
WS
D1.1

18/8/2017 Rev.0 Original Issu
ue Riban H
Hendra Wijayaa
DATE Revision DESCRIPTION B
BY APP.D Clien
nt

No. Procedure : MT-O
OP-PWHT-001
OPE
ERATING PRROCEDUREE LOCALISE
ED Revision : Rev..0
ELE
ECTRICAL RESISTANCE
E POSTWELD
Date : 18/8//2017
ATMENT OF WELD IN
HEAT TREA
CARBON OR ALLOY STEEL
Page : 2 of 15
EXA
AMINATION
N

INDEX

1..0 Applicaation

2..0 Methodd

3..0 Arrangeement of Elements

4..0 Temperature Control

5..0 Thermoocouples

6..0 Thermoocouple Positioons

7..0 Thermoocouple Compeensating Cablee

8..0 Recordders

9..0 Insulatiion

100.0 Proceddure Requiremeents

111.0 Docum
mentation

Appendix I
Appendix II
PT. MUL
LTI TERAINDO

OP-PWHT-001
OPE
ELE
ECTRICAL RESISTANCE
E POSTWELD
Date : 18/8//2017
ATMENT OF WELD IN
HEAT TREA
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EXA
AMINATION
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1.0 APPLICATION
A

Exxternal localiseed PWHT of buutt welds for teemperatures upp to 800°C. Individual tempeerature profiless to be
deetailed prior to commencement.

2.0 METHOD

Electrical resistaance heating using
u modular, flexible ceram
mic pads, of staandard rating aand dimensionns and
Mains
M Heaters housed
h in a staainless steel case

3.0 RRANGEMENT OF ELEMEN
AR NTS

3.1 Hoorizontal Weldss

Pllate Fillet/Butt Welds
W

Foor welds, where the memberss are of equal thickness,
t the hheating elemennts shall be appplied symmetriccally
abbout the weld centreline,
c eitheer as one or moore discrete baands.

Each band will comprise
c pads of equal width,, and the samee nominal heating intensity.

Thhe total width of
o the heated seection of plate shall be a miniimum of 2.5x thhe thickness. Inn this instance
minimum
m heat band shall be 1995mm if allowaable

Where
W more thaan one band of elements is appplied, the gap between bandds shall be limitted to a maximum of
m and below, the
300 mm or the plaate wall thickneess, whicheverr is the lesser. For a wall thickkness of 10 mm
gaap shall be limiited to 10 mm maximum.
m

Loongitudinal gapps between inddividual elemennts shall be lim

mited to 50 mm or the plate w wall thickness,
whichever
w is thee lesser. For a wall thicknesss of 10 mm andd below, the gaap shall be limitted to 10 mm
maximum.
m

Foor a heating syystem, which coomprises more than one circuumferential bannd, the heater ppads in adjacennt
baands shall be rotated
r one quaarter of a pad width
w with respeect to each othher.

Where
W the wall thicknesses off the two plate members diffeer, or for plate tto pipe joints, tthe elements sshall be
arrranged as a minimum
m of twoo circumferentiial bands, suchh as to providee independentlyy controllable hheating
syystems on each side of the weld
w centreline. For pipe to flaange welds, ann additional band of heaters m may be
appplied to the ouutside diameterr of the flange to
t compensatee for heat lossees.

3.2 Innclined and Verrtical Pipeworkk

Pipe to Pipe Buttt Welds

Foor nominal pipee diameters upp to 6" (150 mm
m), and where tthe parent memmbers are of eqqual thickness, the
heeating elementts may be appliied as a single band about thee weld circumfference. The bband shall be biased
doownwards by 252 mm or the wall
w thickness, whichever
w is the lesser.
PT. MUL
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OP-PWHT-001
OPE
ELE
ECTRICAL RESISTANCE
E POSTWELD
Date : 18/8//2017
ATMENT OF WELD IN
HEAT TREA
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EXA
AMINATION
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Foor nominal pipee diameter aboove 6" (150 mmm), the heating elements shalll be applied as two (or more)
discrete bands, arranged symm metrically above and below thhe weld centreline to leave a ccentre gap.

Thhe requirements pertaining too element arranngements detaailed in paragraaphs 3.1.2, 3.1..3, 3.1.4, 3.1.5, 3.1.6
annd 3.1.7 shall also
a apply for innclined and verrtical pipework..

3.3 Pipe to Branch Weld
W (i.e T Branches)

Thhe heating system to be appplied to the main pipe meember shall coomprise a full circumferentiaal zone
exxtending for a minimum distaance of 3x t. on each side off the outermosst branch to pippe weld positioons (t =
thhickness of maiin pipe membeer).

An independent heating system m shall be applied to the brannch member, aand will comprisse a band of heating
elements extendding for a distannce of 3 x t2. along
a the brancch from the edgge of the branch to pipe weld.

Gaps
G shall be limited, insofarr as is practicaal with respectt to pipe attitudde and dimensions as detaiiled in
Sections 3.1 andd 3.2 of this proocedure.

3.4 Weldolets
W

Thhe heat treatment to weldoletts and nippoletss shall in all insstances be carrried out to the full circumferennce of
thhe main carrier pipe as detaileed above.

Trrunions / Reinfforcing pads.
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ELE
ECTRICAL RESISTANCE
E POSTWELD
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ATMENT OF WELD IN
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EXA
AMINATION
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Heat treatment to reinforcing pads and trunions shall be ddone in the fulll circumferencce of the main carrier
pipe. As detailedd within the section on brancches the width of the heated band shall be a minimum of 3 x the
wall
w thickness of the carrier pippe each side ofo the pad extreemity. Thus thee full width of thhe band shall bbe 6 x t
plus the length of
o the attachmeent concerned.

Heat Treatment to piping wherre a shoe type support
s weld eexists

Thhe heat treatm
ment must be carried
c out to thhe full circumfeerence of the main carrier piipe. The lengthh of the
heeated band willl be determinedd by the lengthh of the supporrt longitudinal w
weld added to tthe required 3 x t past
eaach extremity of
o the shoe weld as detailed below.
b

Deetail of heated band requirem
ments for suppoort weld PWHTT

A limited list of elements
e arranggements that will
w satisfy the rrequirements oof paragraphs 33.1, 3.2 and 3.33 is
given for guidance only in Appeendix II. It is reecognised that the listing provvides one soluttion only for a ggiven
weeld geometry; other
o options being
b possible, and may be m made relevant inn the prevailingg circumstancees.
Thhe listing also provided
p data for
f pipe/pipe buutt welds.

3.5 General
G

Elements shall be securely fixxed in contactt with the workkpiece for softt iron wire, staainless steel bbanding
taape, or mild steel banding tapee to suit the appplication.

Heating elements shall be thooroughly examined before usse in order to eensure that thee element wiree is not
exxposed. Exam mination to be made for brokken beads in eeither the pad or the leads. Twistlok connections
shhould also be examined
e to ennsure that the innsulation is souund, and that a good electricaal joint is madee.
PT. MUL
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ELE
ECTRICAL RESISTANCE
E POSTWELD
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ATMENT OF WELD IN
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Where
W elementss are manufactured with cold tails, care shouuld be taken too avoid trappingg the cold tail aand
poower supply caable between thhe workpiece and
a the insulatioon. Element taails should be aadequately
suupported to avooid undue strain at the element/tail junction and at the hot//cold tail junctioon.

4.0 TE
EMPERATURE
E CONTROL

A contactor shall control each circuit of heating elements. In turn this circcuit shall be coontrolled by onee of the
foollowing system
ms:

Semi-automatic control usingg a combinatiion of a set--point controlleer and a perrcentage time//energy
reegulator. The set-point temperature contrroller shall be employed to ensure correctt temperature control
duuring the soaking period.

An automatic pre-set
p program
mme control unit,
u to control automatically the heat treaatment throughhout its
cyycle.

No single controol zone will coomprise more than three heaating elementss. All elementts in any one control
circuit shall havee the same nom
minal power deensity rating (waatts/m²).

5.0 TH
HERMOCOUP
PLES

Thhermocouples shall be made from nickel-chhromium/nickel--aluminium wirre to BSEN60584.2: 1993
toolerance class 2 and BSEN600584.1 Pt4: 19996, or equivalennt. Certification shall be madde available for each
reeel of wire utilissed, and shall inndicate a toleraance of less thaan ±0.75%; thrroughout the teemperature rannge
4000 °C to 800°C C.

Thhermocouples shall be attachhed to the worrkpiece by the direct wire capacitance disccharge method. The
gaap between thee two wire/workkpiece junctions shall not excceed 5 mm.

Care shall be taaken to ensuree that the therm
mocouple condductor wires doo not touch eaach other, or m
metallic
coomponents, aw
way from the hoot junction.

h junctions shall be proteected by the aapplication of a minimum 5 mm layer off high
Thhermocouple hot
teemperature putty, applied locaally.

Wherever
W possibble, thermocouuples shall not be located undder a heating ppad; thermocouuples shall be rrouted
beetween heatingg pads or out thhrough the insuulation, to avoidd close contactt with the heating pad.

Thhe thermocoupple to compenssating lead connnections shall bbe a minimum of 0.5m from the heated zone.
Foollowing each heat

h treatment a minimum of 150mm wire m
measured from the hot zone sshall be discardded.
PT. MUL
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OP-PWHT-001
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ELE
ECTRICAL RESISTANCE
E POSTWELD
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ATMENT OF WELD IN
HEAT TREA
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EXA
AMINATION
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6.0 TH
HERMOCOUP
PLE POSITION
NS

Thhe minimum thermocouple positions
p for pipe/pipe
p weldss shall be as detailed. Addiitional thermoccouples
shhall be fitted as necessary for control puurposes, and to confirm anny other temperature requireements
peeculiar to the ruuling specification.

A minimum of one
o thermocoupple shall, in anny case, be fitteed to correspoond with each iindependent ciircuit of
heeating elements. Thermocouples fitted for f control purrposes may bbe fitted at thee weld centrelline for
syymmetrical heaating systems, and at a disttance of 1½ x t from the w weld centreline for non-symm metrical
heeating systemss. Furthermorre, they shall be
b located at tthe mid positioon of the partiicular element circuit,
circumferentiallyy.

7.0 TH
HERMOCOUP
PLE COMPENS
SATING CABL
LE

Copper/constantan compensating cable shaall be used for extension of tthe thermocouple to the recoording
instrument.

Thhe copper lead (+ve) shall be connected to the nickel- chromium connductor of the thermocouple (non-
magnetic),
m t constantan lead (-ve) shall be connectedd to the nickel--aluminium connductors (magnnetic).
and the

8.0 RECORDERS
R

b of the potenntiometric self compensating type, calibrateed in degrees C
Teemperature reccorders shall be Celsius
with
w respect to a nickel-chromium/nickel-alum minium thermoccouple, Type KK.

Teemperature recorders shall be b calibrated ata intervals nott exceeding 6 months. Thee calibrations sshall be
reecorded and evvidence to thiss effect kept withw the instrum ment. The Calibration Certificate must shoow both
thhe 'as found' annd 'as left' connditions of the instrument.
i Innstruments utilised for a calibbration purposees shall
caarry certificatioon traceable too a National Standard and sshall themselvees be calibrateed at intervalss not to
exxceed 12 montths. Such instrruments shall exhibit
e an accurracy within ±1°°C of the recoggnised standardd.

Inn the event that the calibration check reveals that the instrrument has beeen used with aan error, whichh would
haave led to the measured temperatures
t being outsidee the permitteed tolerances as specified by the
manufacturer,
m or
o pertaining too the contract, then full detaiils of the weldds involved shaall be reportedd to the
inspecting authoority.

Thhe chart speed shall be sett at 25/50 mm m/hour or otheer agreed stanndard and shall be checked during
caalibration. No artificial
a restricttion on pen travvel shall be useed.

9.0 IN
NSULATION

Ceramic fibre blaanket, 25 mm thick,
t shall be provided
p for thee purpose of innsulation.
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OP-PWHT-001
OPE
ELE
ECTRICAL RESISTANCE
E POSTWELD
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ATMENT OF WELD IN
HEAT TREA
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EXA
AMINATION
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Mineral
M wool 500 mm thick, density 90 kg/m
m3 may be utiilised as an aalternative wheere approved bby the
Engineer.

Innsulation shall extend for a minimum distance of 50m
mm beyond thee edge of thee heating elem
ment if
allowable

Thhe number of layers may bee adjusted to meet the variaations of wall tthickness, pipee diameter, gradient
reequirements annd site conditionns.

Wherever
W possiible, pipe endss shall be blaanked off interrnally before hheat treatmentt to limit convection
efffects.

10.0 PROCEDURE REQUIREMEN
R TS

Limitation pertaiining to heating rates, hold time
t and tempperature range, and cooling rates shall be strictly
obbserved and shall be in accoordance with thhe ruling standdard or specificcation. Detailedd procedures sshall be
prrepared prior tot the commencement of work prescribingg the requiredd procedure lim mits and temperature
prrofiles for each material and each
e thickness.

Inn order to makee allowance forr the through thhickness tempeerature gradient at the subjectt weld, during tthe
hoold period, the upper part of the prescribed temperature
t raange shall be aaimed for.

Foor the purposes of this projecct where a Carbbon Steel is beeing utilised, the heating profile maybe as foollows:
However; Client procedure taken from weldinng Procedure (W WPS) Shall takke preference

HEATING RATE
E = Ambieent to 300°C. = unrestrictted.

4000°C. to holding temp = max 600ºC per hour.
Holding temperrature = 550° C ± 10° C.
Holding time = 4hr minimum
m
Cooling rate to 300° C = max 60°C
6
Reference
R = AWS D1.1 2004 Tabble 5.2 and WP
PS # IBAU/83663/006 Rev. 0

11.0 DOCUMENTATION

Thhe temperaturre chart shall be fully identtified and refeerenced with respect to thee thermocouplle/trace
arrrangement. The chart shaall also identiffy the heat treeatment temperature speciffication, chart speed,
daate(s) and timee(s).

Thhe name(s) of the technician((s) shall accom
mpany the chartt.

Reference
R shall be made to thee client, weld iddentity and wheere possible thhe drawing num
mber.
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ECTRICAL RESISTANCE
E POSTWELD
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ATMENT OF WELD IN
HEAT TREA
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EXA
AMINATION
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A sketch shall acccompany the chart to indicatte the thermocoouple positionss and heating aarrangement.
Any discrepancyy shall be reporrted.
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AMINATION
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Page {i}} of {i}
App
pendix 11
Elem
ment X dimensio
on Y d
dimension Volttage Power
Referrence Mm Mm V
V, kW

300
000 75 660 600 2.70

300
001 100 495 600 2.70

300
002 180 330 600 2.70

300
003 205 250 600 2.70

300
004 255 205 600 2.70

300
005 305 165 600 2.70

300
006 380 145 600 2.70

300
007 405 125 600 2.70

300
008 535 100 600 2.70

3009 610 85 600 2.70

300
010 1220 45 600 2.70

300
011 85 255 300 1.35

Note : Thee X‐dimension
n is measured
d across the element tails
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ECTRICAL RESISTANCE
E POSTWELD
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AMINATION
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Page {i} o
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App
pendix III

Typicall Arrangeements for Pipe to Pipe Heaat Treatment
Nomiinal Pipe Pipe
P EElement

Diam
meter & Aliggnment Arrrangement

1” H & V Rope or snnake element, 30V, 80mm wide

1 ½”
1 H & V Rope or snnake element, 30V, 100mm
m wide
Rope or snnake elementt, 30V, 100m

mm wide (Elem
ment
2” H & V
serpentineed symmetriccally, or madee to suit)
1 pad, 3055 x 165mm symmetrical.

3” H & V
(165mm h eated band)
1 pad, 3800 x 145mm symmetrical.
4” H & V
(145mm h eated band)
6”,, up to 1 pad, 5355 x 100mm symmetrical

H
Sche
edule 80 (100mm h eated band)
6”, SSch. 120 2 pads, 5355 x 100mm

H
to
o XXS (100mm b and each sidee of weld)
6” 2 pads, 5355 x 100mm

V
All Scchedules (100mm b and each sidee of weld)
8” up to 2 pads, 3800 x 100mm

H
Sch
h. 120 (145mm w
wide band)
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8”, SSch. 140 3 pads, 255 x 205mm
H
to
o XXS (205mm w
wide band)
Page {ii} o
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Appendixx II – continued

Typical Arrangem
ments for Pipe to Pipe Heaat Treatm
ment
Nominal Pipe Pipe
P Element

Diam
8” 4 pads, 3880 x 145mm

V
All Scchedules (145mm bband each sidee of weld)
10””, up to 3 pads, 3005 x 165mm syymmetrical

H
Sch. 120 (165mm w
wide band)
10”, Sch 140 4 pads, 2005 x 250mm, ssymmetrical

H
to
o XXs (250mm w
wide band)
10” 4 pads, 4665 x 125mm*

V
All SSchedule (125mm bband each sidee of weld)
12”, Sch 10S 2 pads, 535 x 100mm, ssymmetrical

H
to XS
t (100mm w
wide band)
12”,, Sch 80 4 pads, 535 x 100mm, ssymmetrical

H
to
o 140 (100mm w
wide band eacch side of welld)
12” 5 pads, 2005 x 250mm, ssymmetrical

H
Scch 160 (250mm w
wide band)
12
2”, All 4 pads, 535 x100mm
V
Sch
hedules (100mm bband each sidee of weld)
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AMINATION
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12”, 8 pads, 255 x 205mm,
V
Scch 160 (205mm w
14” Sch 10S 3 pads, 3880 x 145mm syymmetrical

H
to XS
t (145mm w
wide band)
Page {iii} o
of {iv}


Typical Arrangem
ment
Nominal Pipe Pipe
P Element

Diam
14” Sch 80 6 pads, 2005 c 250mm syymmetrical

H
to
o 160 (250 mm w
wide band)
14” 6 pads, 3880 x 145mm

V
All Scchedules (145mm w
wide band, each side of weeld)
16”, Sch 10S 5 pads, 255 x 205mm syymmetrical

H
to
o 100 (205mm w
wide band)
16” Sch 120 8 pads, 150 x 330mm syymmetrical

H
to
o 160 (330mm w
wide band)
16” Sch 10S 6 pads, 4665 x 125mm

V
to
o 120 (125mm w
16” Sch 140 8 pads, 3005 x 165mm

V
an
nd 160 (165mm w

H
to XS
t (145mm w
wide band)
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18” Sch 80 8 pads, 3880 x 145mm
H
to
o 160 (145mm w
18” Sch 10S 6 pads, 535 x 100mm

V
to
o 100 (100mm w
18” Sch to 120 8 pads, 3880 x 145

V
to
o 160 (145mm w
wide band, each side of weeld)q
Page {iv} o
of {iv}


Typical Arrangem
ment
Nominal Pipe Pipe
P Element

Diam

H
to
o 100 (250mm w
wide band)
20” Sch 120 10 pads, 150 x 330mm symmetrical

H
to
o 160 (330mm w
wide band)
20” Sch 10S 8 pads, 4005 x 125mm

V
to
o 120 (125mm w
16 pads, 205 x 250mm
20” Sch 1
140 and 160 V
(205mm w
24” Sch 10S 9 pads, 2005 x 250mm

H
to 80
t (250mm w
wide band)
24” Sch 100 18 pads, 205 x 250mm

H
to
o 160 (250mm w
PT. MUL
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AMINATION
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24” Sch 10S 10 pads, 4405 x 125mm
V
to 6
60 & XS (125mm w
24” Sch 80 18 pads, 205 x 250mm

V
to
o 160 (250mm w

* Special
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LTI TERAINDO

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Loongitudinal gapps between inddividual elemennts shall be lim

Foollowing each heat

Any discrepancyy shall be reporrted.

Rope or snnake elementt, 30V, 100m

1 pad, 3055 x 165mm symmetrical.

6”,, up to 1 pad, 5355 x 100mm symmetrical

6”, SSch. 120 2 pads, 5355 x 100mm

6” 2 pads, 5355 x 100mm

8” up to 2 pads, 3800 x 100mm

8” 4 pads, 3880 x 145mm

10””, up to 3 pads, 3005 x 165mm syymmetrical

10”, Sch 140 4 pads, 2005 x 250mm, ssymmetrical

10” 4 pads, 4665 x 125mm*

12”, Sch 10S 2 pads, 535 x 100mm, ssymmetrical

12”,, Sch 80 4 pads, 535 x 100mm, ssymmetrical

12” 5 pads, 2005 x 250mm, ssymmetrical

14” Sch 10S 3 pads, 3880 x 145mm syymmetrical

14” Sch 80 6 pads, 2005 c 250mm syymmetrical

14” 6 pads, 3880 x 145mm

16”, Sch 10S 5 pads, 255 x 205mm syymmetrical

16” Sch 120 8 pads, 150 x 330mm syymmetrical

16” Sch 10S 6 pads, 4665 x 125mm

16” Sch 140 8 pads, 3005 x 165mm

18” Sch 10S 4 pads, 3880 x 145mm syymmetrical

18” Sch 10S 6 pads, 535 x 100mm

18” Sch to 120 8 pads, 3880 x 145

20” Sch 10S 8 pads, 2005 x 250mm syymmetrical

20” Sch 120 10 pads, 150 x 330mm symmetrical

20” Sch 10S 8 pads, 4005 x 125mm

24” Sch 10S 9 pads, 2005 x 250mm

24” Sch 100 18 pads, 205 x 250mm

24” Sch 80 18 pads, 205 x 250mm

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