Rev1 General Heat Treatment Procedure PDF

TOTAL 45 PAGES
(Including Cover)
Project Work Instruction(PWI)

PROJECT CODE : A90207
Purpose
PROJECT NAME : CHILCA UNO POWER STATION ADD-ON

PROJECT
For Review
DOCUMENT No. : 0-WD010-CZ731-10047
For Information
TITLE : General Heat Treatment Procedure
For Approval
OWNER : ENERSUR S.A.
For Construction
Reviewed by
QA/QC
posco E&C
03.Jan. 2012
REV.
DATE
PRE.
CHEKD.
APPR.
For Construction
Y.S.Kang
PRE.
J.H. Lim
CHEKD.
DESCRIPTION
POSCO E&C
OWNER:
ENERSUR S.A
Contractor:
POSCO Engineering & Construction

Co., Ltd.
J.H,Yoon
APPR.
GENERAL HEAT TREATMENT

PROCEDURE
Number:
TSG-701
Testing Service Group S.A.C.
GENERAL
HEAT TREATMENT PROCEDURE
JR
29/12/11
AR
29/12/11
RR
29/12/11
JR
11/11/11
AR
11/11/11
RR
11/11/11
Responsible
Date
Responsible
Date
Responsible
VRS
Date
Prepared by
Revised by
Authorized by
WARNING: This document and all its content, drawings, and samples is property of TESTING
SERVICE GROUP S.A.C. (TSG). This document is for the sole purpose of the task described by
the client and TSG.
Total or parcial reproduction of this document without TSGs written consent is prohibited.
TSG-701
REV.1

PROCEDURE
Testing Service Group S.A.C
1. OBJECTIVE
This procedure describes the proper technique for the for the following:
A. Post Weld Heat Treatment.
B. Preheat.
C. Post-heat.
D. Dehydrogenation
E. Heating for interference adjustment.
2. SCOPE
This procedure is applicable in the following cases:
Shop and on-site Pre-fabrication or while already mounted.
Alternative oven method.
All Heat Treatments performed localized by heaters that require temperature control and
temperature uniformity.
On Site Heat local heating on large vessels by internal heat utilizing high speed burners.
3. REFERENCE DOCUMENTS
ASME Boiler and Pressure Vessel Code, Section I: Rules for Construction of Power Boilers
ASME Boiler and Pressure Vessel Code, Section VIII, Division 1: Rules for Construction of
Pressure Vessels
ANSI/ASME B31.1: Power Piping
ANSI/AWS D10.10-90, Recommended Practices for Local Heating of Welds in Piping and
Tubing
ISO 13916, Welding -- Guidance on the measurement of preheating temperature,
interpass temperature and preheat maintenance temperature
BS EN 10052:1994, Vocabulary of heat treatment terms for ferrous products
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PROCEDURE
4. ACRONYMS
ACRONYM.
TYPE
ACRONYM
HEATING METHOD
PWHT
PH
Post Weld Heat Treatment
RE
Heating by electric resistance heaters.
Pre-Heat
HF
Heating by flame
Post H
Posterior Heat
HI
Heating by induction
ACRONYM.
THERMIC CYCLE
Electric Oven
HFT
Heat free temperature (C)
EO
CO
HSB
HR
Heating Rate (C/h)
TC
Thermocouple
H-T
Hold temperature (C)
ACRONYM
DESCRIPTION
Hold Time (minutes)
WT
Weld Thickness
CR
Cooling Rate (C/h)
WM
Weld Material
CFT
Cooling free temperature (C)
BM
Base Material
HAZ
Heat Affected Zone
Combustion oven
High speed burner
5. PERSONNEL
Heat Treatments shall only be performed by personnel with broad experience in Heat
treatment.
6. THERMIC CYCLE AND HEATING BROAD RANGE
The six variables of a thermic cycle are:
A.
B.
C.
D.
E.
F.
Temperature in which the heating rate is free of (HFT).

Heating Rate (HR).
Hold Temperature (H-T).
Hold Time (t).
Cooling Rate (CR).
Temperature in which the cooling rate is free of (CFT).
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REV.1
PROCEDURE
These variables can also be fixated by codes, specifications. Whenever a cooling/heating rate
values are specified it is always assumed that they are maximum values.
Some codes limit the heating and cooling rates with the purpose of avoiding tensions produced
by non-homogeneous contractions or expansions.
The temperature gradient throughout the pipe thickness and length is what causes this tensions.
Eliminating this temperature differences by using local heating is impossible, no matter how slow
the
heating
or
cooling
is
done.
As long as only one side of the thickness is heated, there will be a temperature gradient through it
and the thicker it is the higher the gradient will be for the given thermic input. Experience has
proven that the temperature gradient through the thickness is proportionally inverse to the width
of the heating band aside of the thickness, diameter or energy source.
In general terms, the width of the circumferential band to be heated at any given temperature
specified by a procedure shall be at least five times the highest thickness ( 5 tw ), for welded
joints in any given pipe heat treatment must be performed by a circumferential band that contains
the joints and that the width must be increased by the diameter of the joints to be welded .
This reference values are an example of the following codes:
CODE
ASME B 31.1
ASME B 31.3
ASME VIII
PARRAGRAPH
132.7
331.2.6
U W 40 ( 3 ) y ( 5 )
Mnimum bandwidth for local

PWHT
WELD TOE
JOINT
3 t ( W + 2 t)
D + 4 t
W + 2
D + 2
W+4t
D + 12 t
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PROCEDURE
The objective of these bandwidths is to maintain the radial temperature gradient under
reasonable values. If the bandwidths are respected not only the temperature gradient will be
acceptable, but there wont be an excessive gradient, radial or longitudinal.
With these bandwidths and a proper insulation the radial gradient to the hold temperature
could be detrimental. There is publications which show that for thicknesses of 3 inches or
higher the temperature difference in thickness is approximately 10 C per inch. The heat
treatment procedure must allow these differences as long as the exterior temperature
remains within the maximum range value allowed by the procedure. These will ensure that
the interior temperature in not too low.
It is very important that the circumferential temperature is uniform during the whole thermic
cycle. If there were hotter areas, these will consequently result in permanently deformed,
cracked or altered properties.
6.1 HEATING RATE.
Heating rate affects the temperature difference through the thickness. Radial thermic gradient
produces compression tension on the external fibers and traction in the internal fibers.
Tensions are proportional to the temperature differences within the thickness.
As the heating rate increases, so does the difference in temperature. However as long as no
cracks are produced there wont be no damage since the tensions will be relieved during the
hold time.
It has been proven through experience that the radial thermic gradient will not be excessive as
long as the indicated bandwidth by code is maintained. At any rate, if the difference in
temperature does not exceed 83 C, the tangential tensions will not exceed 14 Kg/mm on
traction or compression. These tensions are acceptable as long as any given heating rate that
does not produce a thermic gradient over 83C is acceptable, unless a code or procedure
specifies the opposite.
2
A guidance value is 200C per hour on thicknesses up to one inch( 1 ).
6. 2 HOLD TIME
Temperature time and Hold Temperature and temperature itself are directly related to the
material en the service requirements. In steels Cr-Mo creep and hydrogen penetration
resistant, hold time to temperature are directly related to final required thickness; since in this
case
PWHT
is
one
of
tempering.
On Carbon Steels the PWHT main objective is one of diminishing residual tensions. This
process depends on time and temperature. There are many procedures that suggest hold
times proportional to the thickness that can result in excessive hold times for thicker parts,
which shall be limited unless the code specifies. A guidance value is one of: one hour (1hr) per
(1) in thickness.
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PROCEDURE
6.3. COOLING RATE

Tensions created during the heating process are usually relieved during the holding time,
while the tensions created during cooling tend to remain in the part. The cooling rate can
also affect properties such as: hardness and toughness. This is the reason why cooling
rates are usually slower than those of heating.
Although insulation is a valid variable to control the cooling rate, this is only used under
CFT with the purpose of obtaining a slow cooling. Due to the utilization of thermic cycle
controllers, the control of CR over the CFT is set by programming the required CR. Since
the CR is higher than high temperatures the program will continue to apply heat during that
part of the cycle.
7.
HEATING METHODS
Heating methods to be applied to specific Heat Treatments:
TABLE 1
METODO DE CALENTAMIENTO
Electric Resistance Heater ( RE)
Heat Induction (HI)
Electric Oven / Combustion Oven(CO / EO)
Heating by flame (HF)
8.
TIPO DE TRATAMIENTO
PWHT PH Post H
PWHT PH Post H
PWHT Post H
PWHT.(see note) - PH
HEAT TREATMENT MACHINES

When using Heat Treatment Machines with thermic cycle program by a computerized
microprocessor, the method RE will be used.
POWER SYSTEM:
Heat Treatment machines are equipped with a Three-Phase Power 70 KVA transformer
with the primary feed circuit of 3 X 380 V.
Current intensity per phase: 115 A. feed cable of 16 mm .
Medium Ground Connection 4 cable section of 16 mm.
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PROCEDURE
COMMAND SYSTEM:
Independent feed transformer 110V, 750W with internal themomagnetic protection and
thermostatic separator.
LOW VOLTAGE SYSTEM:
The secondary transformer delivers 85 V floating with a capacity of 135 A per output.
Outputs: six (6).
Heater per output: three (3).
Total heaters per machine: Eighteen (18).
LOW VOLTAGE CABLES:
50 mm. Rubber insulation.
Power Connectors: Insulated with Micarta. Capacity: 200 A
Compensated Cable TC:
Tipe K 2 X 0,75 mm.
TEMPERATURE MEASUREMENT
The different methods to measure temperature and the relation with the type of heat
treatment Table II.
TEMPERATURE MEASUREMENT METHOD

HEATING METHOD
PWHT. Post H.
PH.
TC
RE TC
TC
Contact Pyrometer
Temp-stick
HI
TC
IDEM
EO CO
TC
N/A
Contact Pyrometer
HF
Temp-stick
Optic Pyrometer
Temp-stick
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PROCEDURE
9.1 THERMOCOUPLES
Only Thermocouple Type K (chromel alumel) conjunction with compensated cables type K
or
KX
with
electrostatic
protection
(Shielded).
Thermocouple Cable shall be double insulated with fiber glass with wire diameter of 0,8 mm
or less See ID color chart. Thermocouple connectors type K with un-even poles will be used
to assure proper connection, Temperature measurement is done exclusively through spot
welded thermocouple to the weld (see Fig.1). The distance between both wires to be welded
shall be greater than 5mm and less than10 mm, in case of a heat treatment is done to a
part without joints to be welded, the TC will be spot welded by the same method to the zone
to be treated. The surface where the TC will be welded shall be prepared by cleaning with
abrasive disk or hand file.
It is absolutely unacceptable to fix the TC with nuts, bands, wires or filler metal in between.
In practice, differences in temperature may be given up to 50 C., whenever this occurs in
materials like Cr-Mo, with a hardness specification, you may be forced to repeat the PWHT.
When the TC does not have proper contact with the zone to be treated may have an
excessive heating.
INTERNATIONAL COLOR CHART FOR THERMOCUPLE CABLES
COMPENSADOS
COND
T
J
EK
K
K
K
S/R
B
TX
JX
EX
WX
KX
VX
SX
BX
BS 1843 / JIS C
602
(+) (-) VAINA
B
Z
Z
Z
A
N
M Z
M
M
B
B
Z
Z
Z
R
R
V
IEC 584 - 3
(+)
M
N
L
(-)
B
B
B
VAINA
M
N
L
Pgina 8 de 17
TSG-701
REV.1
PROCEDURE
8.2
TCSPOT WELDER:
Input: 220 V/ Battery: 12 V

Discharge:
Capacitive 70 V
Mass :
Permanent Magnet.
The welded TC by capacitive discharge do not suffer this inconvenience . the TC wire
HAZ is approximately 1/10 mm and the penetration is minor of 3/10 mm, due to that fact
there wont be any signs of the spot weld.
10
TEMP STICKS.
Temp sticks that change color or melt at a certain temperature can be used as per
TABLE II. These temp sticks generally melt when the temperature to be controlled is
higher than the temperature shown on the stick. This will show that the stick
temperature has been reached, yet we will not know by how far was it exceeded by.
Utilizing a combination of temp sticks a range can determine the real temperature.
11
AMOUNT OF TC PER WELDED JOINT

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REV.1
PROCEDURE
11.1
The spots where the temperature measurement shall be taken are those that have been
subjected to the temperature of the PWHT or Post H.
11.2
When PWHT or Post H is performed on horizontal piping with diameters larger than 254
mm (10) two TC will be set, one on the top and one in the bottom of the weld; for smaller
diameters only one shall be placed on the bottom part of the welded joint.
11.3
Amount of TC shall always be in relation to the length of the welded joint , with at least
one TC per meter of weld or fraction .However there shall be at least one TC per
machines automatic control output/ thermic cycle programmer.
11.4
It is recommended that at least one spare thermocouple per TC is placed in the event the
one them fails. In jobs with small amount of welds is more necessary to use spare TC
since there wont be a chance to repeat the lost PWHT. It is also very important to place a
spare TC in large diameter welded joints (> of 12) in order to avoid repeating PWHT.
The use of TC in relation to the diameter of the welded joint in Esquema I , Table III:
In case of different thicknesses, the measurement shall be done on the thickest part.
1) Measurement Area (
)
2) Number of measurements. See table III
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PROCEDURE
TABLE III. NUMBER OF TC IN RELATION OF DIAMETER AND SCH.
DIAMETER
6
8
10
12
14
16
18
20
24
26
28
30
36
40
1
1
1
2
2
2
2
2
2
2
3
3
4
80
1
1
1
2
2
2
2
2
3
4
4
5
7
SCHEDULE
100
1
1
1
2
2
2
2
3
4
4
5
6
9
120
1
1
1
2
2
2
3
3
4
5
6
7
10
160
1
1
2
2
2
3
3
4
5
7
7
9
12
Thermocouples must be placed in a position determined by the 360 of the circumference by the
number of thermocouples. Eg. : 2 at 180 e/a; 3 at 120 e/a; 4 at 90 e/a. etc.
12
CONTROLLERS AND TEMPERATURE RECORDERS

The signal sent by the TC expressed in en Mv is sent to two types of instruments:
1) Temperature controllers, that have been programmed with the specific thermic cycle
parameters (HFT; HR; HT; t ; CR; CFT)
2) Graphic temperature recorder which record temperature from the TC in relation to the
time of the thermic cycle.
13
HEATERS
Flexible ceramic heaters shall be used similar tol COOPERHEAT. 80 V, / 3600 W, 4,5
W/Cm2 w/ high thermic shock resistant insulated ceramic, different shapes and
configurations depending on the welded joint to be treated. This heaters have a maximum
output of 850C.
For PWHT of temperatures exceeding 850 C (up to 1100 C) RIBBON HEATER type will
be used, this heaters produce radiation heat without having direct contact with the part.
These type of heaters are used for solubilization treatments of stainless steels type AISI
347.
For screen type Heat treatments FOUR-BANK de 12 KVA / 200 V connected in a star
configuration to a three-Phased net of de 480 V.
Pgina 11 de 17
TSG-701
REV.1
PROCEDURE
Models of:
Flexible Ceramic
Heaters
14
THERMAL INSULATION
Ceramic fiber based refractory insulation shall be used, density 8Lb/ft3 (128 Kg./m3).
Working Temperature: 1260 C. Thickness 1.
This insulation shall cover a minimum of 20 times the thickness of each side of the
welded joint.
The use of ASBESTOS (amianto) as insulating material in PWHT is strictly forbidden due
to the health hazards.
The use of mineral wool is only applicable if used only as a second layer on top of the
ceramic fiber in order to minimize costs. This applies in jobs like spheres or large vessels
heated internally by flame.
Mineral wool can be used keeping in mind and making sure it does not contain organic
binder as in fiber glass because of flammability.
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TSG-701
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PROCEDURE
As much as possible the chimney effect shall be avoided by placing end caps on piping
that needs it and removed once the work has finished.
15
WELD IDENTIFICATION AND GRAPHIC RECORDS

Each welded joint must be ID by a number and or letters on the isometrics or welding
map. These numbers will be utilized by TESTING SERVICE GROUP S.A.C to identify the
correspondent PWHT. In case of having an unidentified welded joint in the isometrics,
TESTING SERVICE GROUP S.A.C will identify it by using the closest weld ID and adding
the letter A, B, C, etc.
16
HARDNDESS CONTROL
This will be controlled by the client or supervision who shall perform Hardness Test at each
end every heat treated point of any material, at each side of the weld and HAZ with the
sole purpose of verifying the limits stated on the applying code; The final hardness
depends upon the cycle PHWT.
.
In case that the final temperature supersedes the established limits and that the thermal
cycle recorded during the PWHT was performed properly (Time and Holding
Temperature)will mean that the preheat was not performed correctly.
In this event the PWHT shall be performed once again at the owners risk with the sole
purpose of compensating the failed preheating with an increased holding time.
The hardness control is accomplished with a portable Hardness Tester previously
calibrated
The hardness values allowed in the WM and HAZ shall not exceed 225 HB in both
Carbon Steels and Al Cr-Mo.
Surface preparation shall be accomplished by file or sand paper 50 grade (grinding is not
allowed).
If PWHT is performed by oven, hardness control shall be performed on only 10% of the
heat treated welded joints at the simultaneously.
In order to obtain the hardness value the following must be averaged:
1) In the WM: Three (3) readings (minimum) transverse to the weld bead.
2) In HAZ: Five (5) readings (minimum) performed parallel to the weld bead.
(See Fig. 1.)
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TSG-701
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PROCEDURE
Fig.1
17 GENERAL RECOMMENDTIONS
17.1 Job Description
TC Placement: The temperature sensors are welded by using a capacitive discharge spot
welder after surface preparation by file or grinding. Sensors are secure provisionally with
masking tape . See potential risks.
Heater Placement: This shall be attached to the surface to be treated aided by masking
tape, metal straps 12/30mm wide x 0,5/0,8mm thick, tighten by a gear bender and wire.
The heaters firm hold is most important to keep them from burning.
Refractory Insulation: Shall be applied over the heaters. Fiber shall be strapped with wire
and metal straps. These along with the straps on the heaters will secure the PWHT, until the
thermic cycle is finished.
Heaters and TC connection: The heaters are connected to the heat treatment machine by
way of low voltage cables (85 V) and the high voltage (45 A / heater) cables come with 4
extreme quick connect of a turn.
Equipment Connection to 440 / 380 V: The connection to the client power panel shall be
done by their personnel at the same time the clients personnel shall verify the connection to
avoid false contacts or short. The electric load must be for sought in order to protect power
lines and avoid electrical accident (Cables overheating, short circuits, sparks, personal
accidents and power failure).
Heat Treatment Performance: Although Heat Treatment machine is completely automatic

and is able to complete the thermic cycle without the operators intervention, it is always
imperative that the operator constantly supervises the machine for possible TC and heater
disconnections. Although the PWHT is insulated, the ends of the piping will become hot
enough to cause burns to nearby workers , wood , combustibles, gloves, etc. Prior to
commence work the safety personnel from the plant shall ensure the lack of presence of gas
or combustibles.
PWHT Disassembly: It must be done very carefully avoiding to drop heaters or insulation
from elevations.
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TSG-701
REV.1
PROCEDURE
17.2 Piping / or equipment shall be supported during PWHT to avoid permanent deformations,
whenever metals are exposed to high temperatures their resistance is diminished and if the
weight is not externally supported properly can cause deformations.
17.3 It is advisable to support the pipe or equipment without the use of a weld and that the
distance between hot zone to the support does not exceed 1000 m for horizontal piping.
17.4
In the case of piping or piping sections that must be stressed during erection in order to
compensate for ulterior service expansion, the PHWT effects must be pre-calculated for
the purpose of not relaxing the stressed tensions before mentioned.
17.5
Piping shall not be stressed (torsion) during the thermic cycle in order not to deform the
heated area.
17.6
It is highly recommended not to transport the treated welds until treatment has completely
finished and the temperature does not exceed 80 C.
17.7
Before beginning to apply heat, the pipes or vessels muct be checked to make sure
theyre free of water, flammable liquids, or residual gases as a safety precaution not to
contaminate the weld or the refrigerant effects of chemicals or gases.
18
SAFETY
See below the work equipment related risks and the safety preventive corrective actions
to eliminate or minimize risks.
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PROCEDURE
TSG-701
REV.1
19 HEAT TREATMENT INCIDENTS

Unless otherwise specified, the heat treatment incidents will be managed as follows:
19.1 Recorder Failure
The recorder must be repaired or replaced as soon as possible. Since the automatic
temperature controller can function without the recorder, it is necessary to check the
temperature every five minutes preferably with the installed thermocouples or with a
portable measuring instrument; the measured values shall be recorded.
19.2 Thermocouple Failure
Use another thermocouple
19.3 Automatic Control Failure
Switch to manual control
19.4 PHWT due to power interruption.
In case of a power cut, cover the weld immediately with the thermal insulation blankets in
order to limit the cooling .Providing the cooling range is less than 220 C/h, PHWT shall
resume under the following conditions (see sketch below).
If PHWT is interrupted in the heating up period ( power cut n1): resume PHWT from the
temperature reached.
If PHWT is interrupted during the holding time at temperature (power cut n2):The new
holding time is equal to the difference between the scheduled time lapsed and the
remaining time multiplied by 1.5 (see sketch below)
If PHWT is interrupted in the cooling period (power cut n3): resume PHWT at the
temperature reached.
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PROCEDURE
TSG-701
REV.1
Sketch 1
Pgina 17 de 17

Specific Procedure
TSG-751
Number:
REV 2
POST WELD HEAT TREATMENT

SPECIFIC PROCEDURE
VRS
JR
29/12/2011
AR
29/12/11
RR
29/12/11
Responsible
Date
Responsible
Date
Responsible
Date
Prepared by
Revised by
Authorized by
the client and TSG.
Total or partial reproduction of this document without TSGs written consent is prohibited.
POST WELD HEAT TREATMENT SPECIFIC

PROCEDURE
TSG-751
REV.2
1. Scope
1.1
This procedure is to establish explicitly the minimum requirements of external load of Post
Weld Heat Treatment that will be accomplished by heating mats in welded piping.
1.2
This procedure has been elaborated in order to perform heat treatments for stress relief of
welds in piping of the following material type P91, all thicknesses
1.3
All welds to be heat treated shall be appointed by the client for this purpose.
1.4
This procedure covers equipment description, heating method, placement, type of heating
elements, temperature measurements and thermocouple placement.
Heating and Cooling parameters shall be performed as per ASME B31.1 (see Table 132)
or as specified by the client WPS.
1.5
2. Reference Codes
a) ASME B31.1 - Power Piping ASME code for pressure piping-Edition 2010
c) ASME Section VIII Division 1 - Boiler & Pressure Vessels code
d) E.C.Rollason-Metallurgy for Engineers
e) Sidney H. Avner-Introduction to Physical Metallurgy
f) Sergio G. Laufgang-Weld Heat Treatment
3. PWHT Personnel
3.1 Health and Safety
All personnel working in heat treatment shall be trained and warned of all possible scenarios in
PWHT.
It shall be the employees responsibility to ensure his/her safety by evaluating all risks
associated involved with PWHT as well as the installations such as: enough lighting before
commencing any work.
All cables must be tight carefully to avoid tripping hazards.
3.2 Personnel
The execution of Heat treatments mentioned from point 1 (A to D) from the general procedure
TSG 701, shall be performed with specific experience in HT.P.S.
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PROCEDURE
4. Equipment and Accessories

4.1 Equipment
Equipment must be EHS or similar , shall be able to withstand an input load of (380/440V),
And must be able to produce a secondary monophasic or secondary transformer output load
(Heat Treatment Unit) supplied with a low voltage circuit.
Temperature Controls must be operated manually or though the regulators.
The
card
type
recorder
is
to
be
used
to
record
temperature.
4.2 Accessories
All connection accessories for heat treatment shall be quality made and be defect free.
5. Surface Conditions
All welds to be heat treated shall be free of grease, lubricants, dust or coatings to prevent
damages or short circuit of the accessories.
Prior to commencing PWHT, the component to be heat treated shall be inspected to be sure is
allowed to expand and contract freely within the supports to be used.
Piping open ends must be covered to avoid cooling effects by air flow.
Welds PWHT and repairs must be carried out prior Hydro or any other load test.
Heat elements must be fixated to the parts surface in a band like manner.
Once PWHT is finished thermocouples must be removed and contact and adjacent areas must
be cleaned ,brushed and visually inspected.
6. Method
PWHT method for P91 material listed below.
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PROCEDURE
TSG-751
REV.2
The width of the circumferential band to be heated shall be at least six times the thickness of
the welded material from the edge of weld but no less than 25mm or whatever is greater.
PWHT shall be accomplished in every welded joint prior to final nondestructive examination
NDE
7. Basic Requirements for PWHT

7.1 Thermocouples
Thermocouples Type K (chromel alumel) shall be used in conjunction with compensating

cable type KX with electrostatic protection (shielded).Double fiber glass insulated cable wire
diameter 0,8 mm shall be used.
The distance between both thermocouple wires to be welded must not be > 5mm
Thermocouple Spot welder: Input:
220 V/ Battery 12 V Discharge:
Capacitive 70 V
Mass :
Permanent Magnet
7.2 Insulation
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PROCEDURE
Insulation must be accomplished as follows: Utilizing

Ceramic Fiber of : 8 lb/FT 3(128 Kg /m3) Maximum
working temperature of: 1260C.: 1Thick.
Insulation shall cover at least 20 times the part thickness on each side of the weld.
The number of layers and the length to be covered will depend on:
* Wall Thickness
* Pipe or part diameter
* Ramp
* Atmospheric site conditions
7.3 Temperature Recording
The recorder must be potentiometric auto compensator type. Recording Chart must be
coupled to record all temperatures.
The chart shall be adjusted to record at the speed of 25 mm/h, recording all thermocouple
readings , shall also record all fluctuation between temperatures at all cycles of heating and
cooling.
In the graphic time and temperature chart welds exposed to heat treatment on the same cycle
must be recorded at any given section.
8. Hardness Control
This will be controlled by the client or supervision who shall perform Hardness Test at each end
every heat treated point of any material, at each side of the weld and HAZ with the sole
purpose of verifying the limits stated on the applying code. The final hardness depends upon
the cycle PHWT.
In case that the final temperature supersedes the established limits and that the thermal cycle
recorded during the PWHT was performed properly (Time and Holding Temperature)will mean
that the preheat was not performed correctly.
In this event the PWHT shall be performed once again at the owners risk with the sole purpose
of compensating the failed preheating with an increased holding time.
The hardness control is accomplished with a portable Hardness Tester previously calibrated..
The following guidelines shall be taken into consideration for approximate hardness
magnitudes:
Pgina 5 de 9
TSG-751
REV.2

PROCEDURE
9.
Material
Nominal
Thickness
Tensile Resistance
(Mpa)
Maximum Hardness
P91
All
all
250
(Hb)
General Safety Recommendations

The dangers during Heat Treatment are Voltage and high temperatures which may cause
burns if the insulation is not handled properly or if parts are handled without the use of
insulated gloves.
Keep the following risk analysis into consideration:
MAIN TASKS
POTENTIAL RISKS
Slips/ falls, Bangs
Accessing Work
area
Bangs, Cuts
Smashing
Thermocouple
Welding
Placing the heaters
Sparks, Connection 220 V

Work in elevations, Nearby
heat treatments
Insulation
Airborne Fibers
Connecting low
Burned cables, sparks
voltage heaters 85V)
High Voltage
connections
380/220V)
Heat Treatment
Process
Dismantle
Electric Shock
COUNTERACTIVE MEASURES
The operator must observe a clean area before
beginning work.
The operator must wear full PPE equipment before
and during work.
The shall inspect and evaluate the parts supports
Use Pliers, dielectric gloves and request a hot permit
Operator must wear PPE and safety harness .
Operator must have an altitude work permit if
applies.
Wear respirator and safety glasses
Keep cables away from heat sources, tie cables
steady, cable protection
Place high voltage warning signs to energized
equipment and cables using dielectric gloves,
Protect against wetness, an electric connection
permit
Heat
Barricade the area, permanent watch, wear golves
Airborne Fibers
Wear Respirator, dielectric gloves and safety

glasses
Pgina 6 de 9
TSG-751
REV.2

PROCEDURE
Attachment 1: Thermocouple Number and placement:

SCHEDULE
DIAMETER
40
80
100
120
160
10
12
14
16
18
20
24
26
28
30
36
10
12
Attachment 2: Hardness reading sketch:
Pgina 7 de 9

PROCEDURE
TSG-751
REV.2
WELDING & PHWT Of Grades 91 & 92 material (wall thickness >30t)
Pgina 8 de 9

PROCEDURE
WELDING & PHWT Of Grades 91 & 92 material (wall thickness <30t)
Pgina 9 de 9
TSG-751
REV.2

Specific Procedure
TSG-752
Number:
REV 1

SPECIFIC PROCEDURE
VRS
JR
29/12/2011
AR
29/12/11
RR
29/12/11
Responsible
Date
Responsible
Date
Responsible
Date
Prepared by
Revised by
Authorized by
the client and TSG.

PROCEDURE
TSG-752
REV.1
1. Scope
1.1
1.2
1.3
1.4
1.5
2. Reference Codes
3. PWHT Personnel
PWHT.
3.2 Personnel
Pgina 2 de 9
TSG-752
REV.1

PROCEDURE

4.1 Equipment
The
card
type
recorder
is
to
be
used
to
record
temperature.
4.2 Accessories
6. Method
Pgina 3 de 9

PROCEDURE
TSG-752
REV.1
NDE

7.1 Thermocouples

Capacitive 70 V
Mass :
Permanent Magnet
7.2 Insulation
Pgina 4 de 9
TSG-752
REV.1

PROCEDURE

* Wall Thickness
* Ramp
cooling.
8. Hardness Control
This will be controlled by the client or supervision who will take hardness who shall perform
Hardness Test at each end every heat treated point of any material, readings at each side of
the weld and HAZ with the sole purpose of verifying the limits stated on the applying code. The
final hardness depends upon the cycle PHWT.
magnitudes:
Pgina 5 de 9
TSG-752
REV.1

PROCEDURE
9.
Material
Nominal
Thickness
Tensile Resistance
(Mpa)
Maximum Hardness
P11
all
all
250
(Hb)

insulated gloves.
MAIN TASKS
POTENTIAL RISKS
Slips/ falls, Bangs
Accessing Work
area
Bangs, Cuts
Smashing
Thermocouple
Welding
Placing the heaters

heat treatments
Insulation
Airborne Fibers
Connecting low
High Voltage
connections
380/220V)
Heat Treatment
Process
Dismantle
Electric Shock
beginning work.
and during work.
applies.
permit
Heat
Airborne Fibers

glasses
Pgina 6 de 9
TSG-752
REV.1

PROCEDURE

SCHEDULE
DIAMETER
40
80
100
120
160
10
12
14
16
18
20
24
26
28
30
36
10
12
Pgina 7 de 9

PROCEDURE
Pgina 8 de 9
TSG-752
REV.1

PROCEDURE
pgina 9 de 9
TSG-752
REV.1

Specific Procedure
TSG-753
Number:
REV.1

SPECIFIC PROCEDURE
VRS
JR
29/12/2011
AR
29/12/11
RR
29/12/11
Responsible
Date
Responsible
Date
Responsible
Date
Prepared by
Revised by
Authorized by
the client and TSG.

PROCEDURE
TSG-753
REV.1
1. Scope
1.1
1.2
1.3
1.4
1.5
2. Reference Codes
3. PWHT Personnel
PWHT.
3.2 Personnel
Pgina 2 de 9
TSG-753
REV.1

PROCEDURE

4.1 Equipment
The
card
type
recorder
is
to
be
used
to
record
temperature.
4.2 Accessories
6. Method
Pgina 3 de 9

PROCEDURE
TSG-753
REV.1
NDE

7.1 Thermocouples

Capacitive 70 V
Mass :
Permanent Magnet
7.2 Insulation
Pgina 4 de 9
TSG-753
REV.1

PROCEDURE

* Wall Thickness
* Ramp
cooling.
8. Hardness Control
This will be controlled by the client or supervision who shall perform Hardness Test at each end
every heat treated point of any material, at each side of the weld and HAZ with the sole
purpose of verifying the limits stated on the applying code. The final hardness depends upon
the cycle PHWT.
magnitudes:
Pgina 5 de 9
TSG-753
REV.1

PROCEDURE
9.
Material
Nominal
Thickness
Tensile Resistance
(Mpa)
Maximum Hardness
P22
all
all
250
(Hb)

insulated gloves.
MAIN TASKS
POTENTIAL RISKS
Slips/ falls, Bangs
Accessing Work
area
Bangs, Cuts
Smashing
Thermocouple
Welding
Placing the heaters

heat treatments
Insulation
Airborne Fibers
Connecting low
High Voltage
connections
380/220V)
Heat Treatment
Process
Dismantle
Electric Shock
beginning work.
and during work.
applies.
permit
Heat
Airborne Fibers

glasses
Pgina 6 de 9
TSG-753
REV.1

PROCEDURE

SCHEDULE
DIAMETER
40
80
100
120
160
10
12
14
16
18
20
24
26
28
30
36
10
12
Pgina 7 de 9

PROCEDURE
Pgina 8 de 9
TSG-753
REV.1

PROCEDURE
Pgina 9 de 9
TSG-753
REV.1

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Project Work Instruction(PWI)

PROJECT NAME : CHILCA UNO POWER STATION ADD-ON

DOCUMENT No. : 0-WD010-CZ731-10047

TITLE : General Heat Treatment Procedure

OWNER : ENERSUR S.A.

POSCO Engineering & Construction

GENERAL HEAT TREATMENT

Testing Service Group S.A.C.

GENERAL HEAT TREATMENT

This procedure is applicable in the following cases:

Shop and on-site Pre-fabrication or while already mounted.

Alternative oven method.

GENERAL HEAT TREATMENT

Post Weld Heat Treatment

Heating by electric resistance heaters.

Heat free temperature (C)

Heating Rate (C/h)

Hold temperature (C)

Hold Time (minutes)

Cooling Rate (C/h)

Cooling free temperature (C)

Heat Affected Zone

Temperature in which the heating rate is free of (HFT).

GENERAL HEAT TREATMENT

Mnimum bandwidth for local

GENERAL HEAT TREATMENT

A guidance value is 200C per hour on thicknesses up to one inch( 1 ).

GENERAL HEAT TREATMENT

6.3. COOLING RATE

HEAT TREATMENT MACHINES

GENERAL HEAT TREATMENT

Compensated Cable TC:

Tipe K 2 X 0,75 mm.

TEMPERATURE MEASUREMENT METHOD

GENERAL HEAT TREATMENT

GENERAL HEAT TREATMENT

Input: 220 V/ Battery: 12 V

AMOUNT OF TC PER WELDED JOINT

GENERAL HEAT TREATMENT

GENERAL HEAT TREATMENT

TABLE III. NUMBER OF TC IN RELATION OF DIAMETER AND SCH.

CONTROLLERS AND TEMPERATURE RECORDERS

GENERAL HEAT TREATMENT

GENERAL HEAT TREATMENT

WELD IDENTIFICATION AND GRAPHIC RECORDS

GENERAL HEAT TREATMENT

Heat Treatment Performance: Although Heat Treatment machine is completely automatic

GENERAL HEAT TREATMENT

GENERAL HEAT TREATMENT

Testing Service Group S.A.C.

19 HEAT TREATMENT INCIDENTS

GENERAL HEAT TREATMENT

Testing Service Group S.A.C.

Post Weld Heat Treatment

Testing Service Group S.A.C.

POST WELD HEAT TREATMENT

POST WELD HEAT TREATMENT SPECIFIC

Testing Service Group S.A.C

POST WELD HEAT TREATMENT SPECIFIC

4. Equipment and Accessories

POST WELD HEAT TREATMENT SPECIFIC