1

INDEX
1.0

Definitions

2.0

Heat Treatment

3.0

Documentation

4.0

Codes and Standards & Tables

1.0

Definition
1.1 Pre heating :
To reduce rates of cooling from fusion temperature
1.2 Post heating :
To give sufficient time to remove hydrogen & other impurity.
The application of heat to the weld material immediately before or
during a welding
1.3 Post weld heat treatment:
To reduce residual stresses
Temper the marten site which is a hard phase that may have resulted
from welding. This action restores ductility. reduction of residual
thermal stress, which is present in all welds.
This action decreases the likelihood of pre-mature failure. PWHT may
also increase corrosion resistance.
1.4 Methods of heat treatment :
furnace heat treatment
Local heat treatment
. Flexible ceramic pads/ induction coil
combustion burner gas fired

Types of Heat treatment:

1. Annealing: Heating to and holding at a suitable temperature and then cooling
at suitable rate for such purpose as reducing hardness, improving mach
inability, facilitating cold working, producing a desired microstructure or
obtaining desired mechanical, physical, or other properties.
2. Normalizing: a process in which the ferrous metal is heated to a suitable
temperature above the transformation range and is subsequently cooled in still
air in room temperature.
3. Quenching: Rapid cooling of a heated metal
4. Stress relief: Uniform heating of a structure or the major portion there
of to a sufficient temperature to relive the major portion of the residual
stresses , followed by uniform cooling slowly enough to minimize
development of new residual stresses.

heat affected zone: that portion of the base metal which has not been melted
but whose mechanical properties or microstructure has been altered by the
heat of welding, brazing, soldering, forming or cutting.

2. Post weld heat treatment or Stress relieving

Requirement of PWHT: PWHT shall be carried out for the cases as
specified by the applicable engineering specification.
Heating/Cooling Rate:- For Heating & Cooling rate follow the requirement
of Design Code/approved WPS/Specifications.
Soaking/Holding time & Temperature:- For PWHT soaking time &
temperature requirements follow the requirement of applicable Design
Code/approved WPS/Specifications.
Equipment for PWHT: All equipments are purpose built. Electric power
sources are 440 V, 3 phase primary supply or 220V single phase with either
single phase secondary output (distribution unit) or step down transformer
secondary output (heat treatment unit) giving low voltage circuits.
Temperature control equipment is either manually operated through energy
regulators

Automatically operated using modular controls. Recording of

temperature is by means of calibrated chart type temperature recorder.

Heating Elements: PWHT work under this procedure shall be performed by

induction heating using ni-chrome wire covered with ceramic beads/heating
pads/flexible ceramic pads as per parameters specified in applicable Design
Code & approved WPS.

Thermocouples: Material of thermocouples to be used shall be the NickelChromium (cromel) /Nickel, Aluminum (alumel) type. Compensating coil &
thermocouples shall be calibrated. In addition, re-calibration shall be done at
any point of time when there is justified reason to believe that they are in error.
Thermocouple shall be attached to the work piece by Direct Wire Capacity
Discharge method (Fig.1) or by nut and bolt connection (Fig.2). Where
thermocouples are being joined by capacitance discharge method, these are to
be attached with two shots (with attachment unit) as shown in Fig.1. The
distance between two wires shall be min 6mm. Insulation to be removed from
the end of the wire shall not be more than 15mm. Care shall be taken to
connect the positive side of the thermocouple with positive side of
compensating cable. Similarly negative side of the thermocouple shall be
connected with the negative side of the compensating cable. Fig.1 6mm If the
nut and bolt connection method is used (Fig.2), the materials shall be of
compatible composition.

Fig.-1

6 mm
Direct Wire Capacity Discharge method
Fig.-2
Two tack welds (opposite to each other)
Thermocouple insertion

Nut and Bolt connection method

Temperature recorders shall be of the potentiometer self compensating

type having chart feed recording. Recorders shall be calibrated in every
six months and calibration stickers shall be affixed to the recorders. In
addition, recorders shall be re-calibrated after every major repair and
also for the cases where there is reason to believe that they are in error.
PROCEDURE

Surface Preparation : Preparation of surface to the extent to remove

coatings, grease, oil etc. shall be ensured within the area covered for preheat
and post heat (wherever appl icable) and for PWHT to avoid damage due to
short-circuiting of the heating elements.

Job knowledge evaluation of operating personnel: Before starting the job

with induction coil heating (which covers preheating, post heating and
PWHT), technician shall be interviewed by REAL QMD personnel to explain

and/or demonstrate the necessary arrangement and control to the satisfaction

of REAL QMD personnel.

Location and Number of Thermocouple(s): The following guidelines shall

be followed as minimum requirement for number and location of
thermocouples:
i. One thermocouple for pipe diameters up to and inclusive of 6"
NPS. For 2 and below, wherever joints are there within the
range of 100mm distance, one thermocouple is permitted,
provided single coil/pad is used.
ii. Two thermocouples at 180 for pipe diameter above 6" and up
to 12" NPS inclusive.
iii. Three (3) thermocouples at 120 for pipe diameters of above
12" NPS .
Thermocouples shall be fixed within the area of heating band. Additional
thermocouples may be fixed as per requirement to confirm hot zone or
gradient limitations, if necessary. Thermocouple (s) and their position (s) shall
be identified on the relevant temperature-recording chart by number or
color/symbol of stamp.

Thermocouple requirement for branch connection and pad shall be in line

with the requirements as mentioned in above. In all cases, as a minimum
there shall be one thermocouple per coil to control the heat treatment
process.
Heating Element position

Heating band : Welds being locally PWHT treated shall have a

circumferential band around the entire component with the weld located in the
center of the band. The width of the heated band shall be as follows:
A. For girth welds, the width of the heated band shall be at least three
times t he wall thickness at the weld of the thickest part being joined
and shall be maintained on either side of the joint. (Fig-3.)
B. For nozzle and attachment welds, the width of the band heated to the
PWHT temperature shall extend beyond the nozzle weld or attachment
weld on each side at least two times the header thickness and shall
extend completely around the header.

Fig,-3
3A
A

Min. Insulation Band width

A-min. heating band width
3t

3t
t-Wall Thickness

 Assembly Of Welded Valves

For PWHT of Welded Valves, The width of the band heated to the PWHT
temperature shall extend up to 3t + weld width. Insulation width shall be 6t+
weld width both ( heating & insulation bands) on pipe side only as shown
above in fig 4. Valve body shall be free from insulation, Valves shall be kept
open during the full cycle of PWHT and No bonnet bolts to be loosened
during PWHT cycle.

Heating element: Heating elements shall be fixed on weldments by means of

black annealed iron wire.

Insulation: The insulation shall be extended to a minimum distance of 3 times

the heated bandwidth. The number of layers and extent of insulated area
depends on:
i. wall thickness (es)
ii. pipe or fitting diameter
iii. gradient requirements
iv. site condition
But in all cases minimum two (2) layers of insulation with minimum
thickness of 50mm shall be used. Open ends to pipe and/or fittings shall be
blanked to avoid through draught cooling during cycle.

Fig 4
6t + weld
3t + weld
T

3t + weld --- Heating Width

6t + weld --- Insulation Width

FIG. - ASSEMBLY OF WELDED VALVES

Temperature Recording :
The following are required to be verified :
1. chart speed is set at appropriate speed,
2. Temperature recording system is recording all thermocouples and
providing information on temperature differences and trends during
the heating/cooling cycle.

Verification : Preheat temperature shall be verified through the temperature

indicating crayons. Welding shall not commence till the preheat temperature is
attained. This shall be monitored by REAL QMD inspector from time to time.
Post heating temperature (for burner heating) shall be verified through the
temperature indicating crayons. This shall be monitored by REAL QMD
inspector from time to time.
For post heating (electric heating) and PWHT, after fixing the heating
coils and the thermocouples with proper connections with the recorder,
the arrangement shall be certified by the Authorized representative of
REAL QMD who shall sign on the graph to indicate that the
arrangements are certified. Then the insulation shall be applied on the
heating coils. Again after attaining 300C during heating, the graph shall
be re certified by REAL QMD representative. This requirement shall be
treated as mandatory for the acceptance of Post heating (electric heating)
as well as for PWHT cycle except for nitrogen purged/digital recorder.
During PWHT cycle front door of recorder shall be kept in closed
condition.

Interrupted PWHT: Due to power loss, equipment failure etc. due to

weather condition/permit problem, there may be an interruption in heat
treatment cycle.
1. If interruption occurs during heating period, the stress developed shall
get moderated during soaking, so the cycle can be continued.
2. If interruption occurs during soaking period, then the soaking
temperature shall be re -established at a rate no greater than that
specified in code/established welding procedure and the soaking cycle
shall be repeated.

3.0

Documentation
3.1

PWHT Recorder, Thermocouple & Control unit Calibration Certificate

3.2

PWHT Procedure

3.3

PWHT Request

3.4

PWHT chart

3.5

PWHT completion record

3.5 Records
Prior to starting the electrical heating, the following information shall be hand written
on the recorder chart by the technician.1-Date, 2- ISO No.(s), 3- Agencys Name, 4Weld Joint No.(s), 5- Chart No
The charts shall be identified with XXX XXX / XXXX XXXX
1
2
3
4
nd
First 3 digits indicate unit number in numeric,2 3 digits alphabetic for the name of
immediate contractor. 3rd four digits indicate name of the sub contractor and 4 th four digits
indicates sequential numbering of the chart i.e. 312 RCC / HRIS 0001
Record of PWHT shall be maintained in the format 2 QM 00 FMT ME 138.
Thermocouples tack welded with pipe shall be removed after PWHT

4.0

Codes Specification and Standard

ASME SEC VIII: RULES FOR CONSTRUCTION OF PRESSURE VESSELS.

ASME B 31.1: POWER PIPING

ASME B 31.3: PROCESS PIPING

SPECIFICATION 22960 3PS-GAW-004

10

4.1

Code Requirement

PWHT requirement as per ASME Sec VIII Div. -1

Material

Gr.No.
1
2

P NO.-1

3
4
1
2

P NO -3

Holding
Temp.deg.C
593
N.A.
593

PWHT as per Sec. VIII Div. 1

Min. Holding Time For Nominal Thikness at normal Temp.
Up to 2 IN.

Over 2 IN.. to 5 IN.

Over 5 IN.
2hrs+15 minuts
2hrs+15 minuts min.for
1hrs .-15
min.for each
each additional inch
minuts min. additional inch over
over 2inch
2inch
None.
None.
None.
2hrs+15 minuts
2hrs+15 minuts min.for
1hrs .-15
min.for each
each additional inch
minuts min. additional inch over
over 2inch
2inch
5hrs+15 minuts min.for
1hrs .-15
1hrs/in.
each additional inch
minuts min.
over 5inch
5hrs+15 minuts min.for
1hrs .-15
1hrs/in.
each additional inch
minuts min.
over 5inch
5hrs+15 minuts min.for
1hrs .-15
1hrs/in.
each additional inch
minuts min.
over 5inch

P NO -4

1,2

593

P NO -5A,5B,5C

677

P NO -5B

705

P NO -9A

593

$ 1hrs min.+ 15 minuts/in.for thk. Over 1 in.( 25mm)

P NO -9B

593

$ 1hrs min.+ 15 minuts/in.for thk. Over 1 in.( 25mm)

P NO -10A

593

$ 1hrs min.+ 15 minuts/in.for thk. Over 1 in.( 25mm)

P NO -10B

538

1hrs min.+ 15 minuts/in.for thk. Over 1 in.( 25mm)

for all thickness.

P NO -10C

538

$ 1hrs min.+ 15 minuts/in.for thk. Over 1 in.( 25mm)

1hrs min.+ 15 minuts/in.for thk. Over 1 in.( 25mm)

for all thickness.
$ - Refer note of ASME -Sec -VIII Div.-1 UCS - 56 Page no.- 180 -186

P NO -10F

538

11

 PWHT requirement as per ASME b31.1

Material

Carbon Steel

Alloys Steels
Cr<=0.5%

Material

PWHT as per ASME B 31.1

Holding Time based on Nominal Thikness
Holding
Min. wall
Gr.No.
Temp.Rang
thk.mm
deg.C
Up to 2 IN.( 50 mm)
Over 2 IN. ( 50 mm)
1,2,3

<=19

None.

N.A.

N.A.

1,2,3

>19

600 -650

1hr/in(25mm) 15
minuts min.

2hrs+15 minuts min.for each

additional inch over 2inch

<=16

None.

N.A.

N.A.

>16

600 -650

1hr/in(25mm) 15
minuts min.

2hrs+15 minuts min.for each

additional inch over 2inch

<=13

None.

N.A.

N.A.

>13

700 -750

1hr/in(25mm) 15
minuts min.

2hrs+15 minuts min.for each

additional inch over 2inch

<=13

None.

N.A.

N.A.

>13

700-760

1hr/in(25mm) 15
minuts min.

2hrs+15 minuts min.for each

additional inch over 2inch

<=10

None.

N.A.

N.A.

>10

700 -760

1hr/in(25mm) 15
minuts min.

2hrs+15 minuts min.for each

additional inch over 2inch

<=10

None.

N.A.

N.A.

>10

760-800

1hr/in(25mm) 15
minuts min.

2hrs+15 minuts min.for each

additional inch over 2inch

<=10

None.

N.A.

N.A.

>10

730-775

1hr/in(25mm) 15
minuts min.

2hrs+15 minuts min.for each

additional inch over 2inch

all

None.

N.A.

N.A.

<=13

None.

N.A.

N.A.

>13

600-650

1hr/in(25mm) 15
minuts min.

2hrs+15 minuts min.for each

additional inch over 2inch

<=16

None.

N.A.

N.A.

P NO.-1

P NO -3

1,2
1,2

Alloys Steels
0.5<Cr<=2%

P NO -4

Alloys Steels
2.25%<Cr<=10%

P NO -5A

1,2

1
1

Alloys Steels
2.25%<Cr<=10%

P NO -5B

1,2
1,2

410

P NO.-6

1,2
1,2,3

405

P NO.-7

1,2
1,2

Austenitic
Stainless Steel
Ni Alloys steel

P NO.-8

P NO.-9A

1,2,3,4
1
1

Ni Alloys steel

P NO.-9B

5 Ni steel

P NO.-10H

1hr/in(25mm) 15 2hrs+15 minuts min.for each

>16
600 -650
minuts min.
additional inch over 2inch
1
HT is neither required nor prohibited.temp range for Rapid cooling Alloys
1)S31803 -1022-1099 Deg.C,2)

12

 PWHT requirement as per ASME B31.3

PWHT as per ASME B 31.3
Brinnal
Min. Hardness
min/m Hr/I
Time Max.
m
n
Hr.
Holding Time

Material

Material

Min. wall Holding Temp.

A.No.
thk.mm Range. deg.C

Carbon Steel

P NO.-1

Alloys
Cr<=0.5%

Steels

P NO -3

Alloys
Steels
P NO -4
0.5%<Cr<=2%
Alloys
Steels P
2.25%<Cr<=10% -5A,5B,5C
High Alloys Steels
Martensitic

<=19

None.

N.A.

N.A. N.A. N.A.

>19

593- 650

2.4

N.A.

None.
593-718
593-719
None.
704-746
704-746
None.
704-746

N.A.
2.4
2.4
N.A.
2.4
2.4
N.A.
2.4

N.A.
1
1
N.A.
1
1
N.A.
1

N.A.
1
1
N.A.
2
2
N.A.
2

N.A.
225
225
N.A.
225
225
N.A.
241

<=19
2,11 >19
All
<=13
3
>13
All
<=13
>13
NO
4,5
All
(>3%cr)

P NO.-6

704-746

2.4

241

All

732-788

2.4

241

All

621-663

2.4

241

A240 Gr429
High Alloys Steels
Ferritic

P NO.-7

All

None.

None. None. None.

High Alloys Steels

Austenitic

P NO.-8

8,9

All

None.

None. None. None.

Ni alloys steels

P NO.-9A,9B

10

<=19
>19

None.
593-635

N.A.
1.2

Cr-Cu Steel

P NO.-10

nil

All

760-816

1.2

0.5

0.5

Duplex Stainless
Steel

P NO.-10H

nil

All

HT requid as per
material spec.

1.2

0.5

0.5

27 Cr-Steel

P NO.-10 I

nil

All

663-704

2.4

8 Ni ,9 Ni steel

P NO.-11A SG 1

nil

<=51
>51

None.
552-585

N.A.
2.4

5 Ni steel

P NO.-11A SG 2

nil

>51

552-585

2.4

Zr R60705

P NO.-62

nil

All

N.A. N.A.
0.5
1

N.A. N.A.
1
1
1

538-593 HT with
in 14 days after note-1 note-1 note-1
welding

note -1 --Hold time shall be increased by 0.5hr for each 25 mmthk. Cool to 427 deg C at the rate <=278 deg
C/Hr. per 25 mm nominal thk.278 deg C/Hr max. coll in still airfrom 427 deg C.

13