In this chart,
X-axis represents temperature and Y-axis represents Time.
In X-axis each line to line distance represents 10Deg C (See it is written as X 100C, that
means in X axis, 2 means 2 X 100C= 200C, 3 means 3 X 100C= 300C etc.)
In Y-axis each line to line distance represents half an hour. That means the time between 2
and 3 represents one hour.
These are the basics.
How to read the graph?
The letter designation applies only to the temperature voltage relationship and not to the
material. For ease of understanding it is to be noted that the negative side in all cases is of red
colour.
Thermocouples are available in various sizes. Faster response is obtained from thinner wires
but there are chances that the thinner wires are easily get damaged.
1. Control panel and Proportional Integral Derivative (PID) controller: Control panel receives
the power input from the mains. ELCB/Fuse, over current protection system etc will be in the
control panel.
PID controller need power for working the same which will be taken from control panel. The
PID controller contains PID's which can be programmed as per the requirement of PWHT
cycle.
Then PID controller takes the input's as follows:
Temperature up to soaking temperature.
Time for reaching up to soaking temperature (rate of heating)
Soaking temperature
Time for soaking.
Temperature up to controlled cooling
Time to reach that temperature (Rate of cooling)
2. Temperature recorder:
Temperature recorder records the temperature against time. This will be recorded against
each thermocouple and each graph corresponding to be each thermocouple will be of
different colour. The temperature recorder is working on the principle of potentiometer
3. Thermocouples:
Thermocouples detects the temperature as voltages based on the seebeck effect or
thermoelectric effect. These voltages are used by PID controller to control the temperature
and temperature recorder for recording it.
4. Thermocouple extension wires:
Thermocouple extension wires are used to connect the thermocouple to the PID controller
and temperature recorder.
5. Coils:
Coils heat the joints by resistance heating method.
6. Power cables:
Power cables are used for connection between PID controller &Control Panel to the coils for
power transmission.
Refer the connection diagram.
The coils are heated thereby temperature is developed through resistance heating. The current
required to the coils are given by control panel through PID controller. The PID controller
detects the temperature of the Job through the thermocouple connected to the PID controller
and decides whether the current to be allowed to flow through the coils or not. This on and
off of current flow through the coil by the feedback of thermocouple helps the process to
generate a controlled temperature cycle.
One coil can be used to connect more than one joint depends in the length of the coil (the
length of the coil is decided by the current load.)
Suppose 2 joints are connected by a coil. One thermocouple from any one joint will be used
to control the temperature and is called controlling thermocouple. This thermocouple will be
taken from the joint and will be connected to the PID controller and from PID controller it is
connected to the temperature recorder.
All other thermocouples from both the joints (on the assumption that two joints are connected
using a coil) are directly connected to the temperature recorder.
One temperature recorder can detect temperature from 6 points in a 6 point recorder (most
common) and temperature 12 points in a 12 point recorder.
A PID controller contains 3 PID's (most common design) which will control 3 different coils
connected from the PID controller.
POINTS TO BE NOTED
General points to be noted in the Job selection for PWHT (Examples based on PWHT
of pipe joints.)
1. Using a coil, pipes of different schedules should not be connected to PWHT.
2. Using a coil, pipes of different materials should not be heated even though the PWHT
cycle is same.
3. The controlling and detecting temperature thermocouple should be taken only from joints
only. The thickness of pipe elbow flange etc will slightly different and tacking thermocouple
on the parent material (adjacent to the joint) will cause error in temperature detection as more
thickness requires more temperature for heating and in the meantime the less thickness
portion will be overheated.
4. Thermocouple tacking shall be done by capacitance discharge method to the possible
extend.
5. After the removal of thermocouple the thermocouple tacked area shall be visually
inspected to see whether cracks or any defects are present.
Poldi hardness tester is having a standard test bar and a test facility on which hammering is
done for indentations. The diameter of indentations in the bar and the parent material are
taken and the hardness value HB can be read from the standard chart available with poldi
tester. Poldi uses impact method of indentation.