Professional Documents
Culture Documents
INDEX
Sl.No.
01
02
03
04
05
06
07
08
Description
Cover Sheet
Index
Preface
Foreword
Approval Sheet
Important Note
Status of Amendments
Table of Contents
Page No.
01
02
03
04
05
06
07
08
PREFACE
Construction activities at field are dominated by welding processes for assembly
and building critical products like boiler, boiler auxiliaries, electrostatic precipitator
and piping. Various welding processes are adopted at the field based on the
product requirements and reliability of the welds.
This document has been prepared to provide basic guidelines to all construction
personnel in ensuring effective process management of welding and allied
activities. The various aspects of process control covering the stages of planning &
preparation for welding, controls during welding and post welding requirements are
brought out in the form of specifications, norms and procedures/instructions in this
document. This manual has been updated to reflect the newer materials and
processes developed by BHEL.
The requirements specified in this document are based on the relevant codes/
specifications like IBR, ASME and AWS and also consolidates the experience of
BHEL good welding practices based on more than three decades of manufacturing
and erection. The document also provides DO s and DONT s for the benefit of
users, which would help in better process control and prevention of defects.
I am sure that this Manual would enable the construction activities in a big way to
manage their welding processes effectively to produce defect free quality.
A.V. Krishnan
General Manager (Corporate Quality)
FOREWORD
The present revision of the Heat Treatment Manual has been made with the contribution
from a team of BHEL Engineers having long experience in the areas like Construction Management,
Quality, Welding Technology & Heat treatment of manufacturing units and Power sector.
In this revision, the comments / suggestions offered by Power Sector / Regions, BHEL
HPBP Trichy, Piping Centre, HPEP Hyderabad & HEEP Haridwar and the minimum requirements of
reference codes have been taken care.
This manual deals with, apart from Heat Treatment requirements for BHEL-Trichy complex,
HEEP Haridwar & HPEP Hyderabad packages also. Heat treatment requirements for the new
material P91/T91 are dealt in detail for the benefit of site engineers.
We hope that the present volume will be very much handy and useful for all our site
engineers.
Any further feedback or suggestion is welcome to improve upon the the present
volume in due course.
Place : Chennai
Date : 09.11.2006
(D.Indran)
Executive Director
Power Sector - Southern Region
Page 4
HEAT TREATMENT M A N U A L
FOR
POWER SECTOR
PREPARED BY
NAME
V.KANDHSAMY
UM DESHPANDE
Dr. K.P.DHANDAPANI
P.ELANGOVAN
A.SUKUMARAN
D.DEVASAHAYAM
R.JANARTHANAN
APPROVED BY
A.V.KRISHNAN
DOCUMENT NO.
PSQ-HTM-COM
R01 / 11 06
DESIGNATION / DIVISION
AGM/ PSSR QLY, Chennai
AGM/ CQ, SECUNDRABAD
DGM / WTC-TIRUCHY
DGM / PC- Chennai
Manager/ SAS Cell - TIRUCHY
Manager/ PSSR-QLY, Chennai
Dy. Manager/ PC-Chennai
GENERAL MANAGER
/ CQ, NEW DELHI
ISSUE DATE
13.11.2006
COPY NO.
DATE OF ISSUE
ID No. : 1078
CONTROLLED COPY /
INFORMATION COPY
ISSUED BY
ISSUED TO :
Page 5
IMPORTANT
THIS
HEAT
TREATMENT
MANUAL
PROVIDES
BROAD
BASED
WELDING
PROCEDURE
SPECIFICATIONS,
Page 6
7
STATUS OF AMENDMENTS
Page 7
TABLE OF CONTENTS
Description
Chapter
Page No.
8-22
23-24
General
25
1.
26
2.
27-28
Page 8
CHAPTER-1
HEAT TREATMENT PROCEDURE - BOILER AND AUXILIARIES
Page 9
10
1.0
PURPOSE:
1.1
This procedure provides information, method and control for Pre-Heat (PH) and Post
Weld Heat Treatment (PWHT) of welds at sites.
2.0
DOCUMENT:
2.1
2.1.1
ASME Sec.I
2.1.2
ASME B31.1
2.1.3
2.1.4
AWS D1.1
2.1.5
Welding Manual
2.2
Contract drawings
Erection Welding Schedule or equivalent
2.2.1
Where parameter for preheating and PWHT are not available in the primary documents,
reference may be made to this procedure.
2.2.2
Where such parameters are not contained either in the primary documents or in this
procedure, reference may be made to Manufacturing Units.
3.0
PROCEDURE:
3.1
3.1.1
When parts of two different thicknesses are welded together, the preheating requirements
Page 10
11
3.1.2 When parts of two different P numbers are joined together, the material requiring higher
preheat shall govern (please refer Welding Manual for P numbers).
3.1.3
Preheating shall be checked using thermal chalk (temperature indicating crayons) prior
to start of welding as well as at frequent intervals during welding. It is preferable to
have a thermocouple and a temperature recorder in case of alloy steels of
thickness > 50 mm.
3.1.4
3.1.5
Preheating Methods:
b.
Induction heating
c.
3.2
3.2.1
The method shall be by locally heating a circumferential band including the entire weld
and adjacent area of base metal, by induction or electrical resistance heating.
3.2.2
When heat treating welded joints in components in the boiler proper, width of the
heated circumferential band (W) on either side of the weld, W = 3 times the width
of the widest part of the weld groove but in no case less than twice the width of
weld at reinforcement.
b.
When used in post weld heat treatment in sections - W = 3 times the plate
thickness.
c.
For nozzle and other welded attachments - W must be wider than the nozzle or
attachment or 3 times the wall thickness.
Page 11
12
3.3.1
3.4
3.4.1
Post weld heat treatment temperature shall be measured and monitored by use of
thermocouples with calibrated recorders.
3.4.2
3.4.3
Where the soaking temperature is found to be lesser than specified, the PWHT cycle
shall be repeated.
3.4.4
In case of interruption during PWHT, the following actions are to be taken, depending
on the stage during which interruption occurred.
a.Interruption during heating cycle:
-
The joint can be treated subsequently for the balance left over soaking
period.
3.5.1
Thermocouples shall be used for recording Post Weld Heat Treatment temperatures.
Page 12
3.5.2
3.5.3
13
b.
For other type of t/c: Insert the elements in a SS tube of internal diameter
approximately 6 mm. Apply force on tube and crimp it. Place this t/c and weld
the crimped button to the pipe in area of interest. Do not weld the elements.
c.
Insulate the t/c leads suitably and protect t/c ends from direct radiation from
heating elements.
3.5.3.1 Where a bunch of closely placed tube welds (e.g. Super Heater/Reheater Coils)
require to be Post Weld Heat Treated, the same shall be grouped together as if they
form a single component.
3.5.3.2 In such cases attachment of a minimum of three thermocouples, two at the end tubes
and one at the middle is recommended.
3.6
Soaking Time:
3.6.1
Wherever not specified the soaking time shall be as per Tables I, II and III.
3.6.2
The following guidelines shall be used to determine the thickness and subsequent
selection of the soaking time of PWHT:
a.
For butt welds, the thickness shall be the thickness of the material at the weld.
For bar stock, the thickness shall be the diameter.
b.
c.
For partial penetration branch welds, the thickness shall be the depth of the
groove prior to welding.
d.
For repairs, the thickness shall be the depth of the groove as prepared for repair
welding.
e.
3.6.3
Soaking time is to be reckoned from the time temperature of the joint crosses the
recommended lower temperature of the cycle, to the time it comes down below the
same recommended lower temperature of the cycle.
3.7
3.7.1
Wherever not specified, the heating rate above 300C and cooling rate after soaking
upto 300C shall be as follows: This is applicable for all materials.
Page 13
Thickness of Material
14
Maximum Cooling
Rate Upto 300C
25 mm
220C/hour
220C/hour
> 25 50 mm
110C/hour
110C/hour
> 50 75 mm
75C/hour
75C/hour
> 75mm
55C/hour
55C/hour *
Temperature Records:
3.8.1
All the heat treatment cycles may be controlled within 10C around the
midpoint of the recommended range of temperature for the material.
4.0
4.1
Prior to start of PWHT operations, a job card may be prepared including details of weld
reference, soaking time, soaking temperature, maximum rates of heating and cooling,
temperature recorder details, date of PWHT as per sample format.
4.2
4.3
5.0
5.1
Please refer Welding Manual vide document No. PSQ-WDM-COM for heat treatment of
welds in P-91 materials.
5.2
5.3 Please refer Welding Manual vide document No. PSQ-WDM-COM for heat treatment of
welds in T-91 materials
Page 14
5.4
15
6.0
LIST OF TABLES:
Table-I Weld preheat and PWHT for tubes and pipes outside diameter 102 mm.
Table-II Weld preheat and PWHT for Boiler Header welds.
Table-III Weld preheat and PWHT for pipes outside diameter > 102 mm.
Table-IV P Number and Group Number for Base Materials.
Table-V Pre-heat and PWHT for Non-Pressure Parts including Structurals.
Table-VI Preheat for Flame Cutting.
7.0
RECORDS :
7.1
Page 15
16
Date : ________________________
Package : _____________________
Description :___________________
1. Make : _____________________
2. Type : _____________________
3. Sl.No.: _____________________
Thermocouple Locations :
Minimum 2
d = 1.5 x t from weld centre
Heating Band = 6 x t
Insulation Band = 12 x t
Date of PWHT _________________
Start Time : ___________________
Actual
Contractor
Results : Accepted / Not Accepted
BHEL
Released for further processing
Page 16
17
TABLE - I
WELD PRE HEAT AND PWHT FOR TUBES & PIPES
OUTSIDE DIAMETER 102 mm
(Applicable For Butt Welds And Socket Welds)
P. No. of
Material
Thickness
(mm)
Preheat C
PWHT C
P1 Gr 1& SA 106
Gr C (Note 1)
19
Nil
Nil
Nil
Nil
>9
Nil
620 - 650
13
Nil
Nil
> 13
80 (Note 2)
620 - 650
13
125
Nil (Note 3)
> 13
125
650 - 670
150
Nil (Note 3)
>8
150
700 - 750
P5 B Gr 2
All
220
730 - 760
P8
All
Nil
Nil
12 x 1M
All
200
730 - 760
P1 Gr 2
P3 Gr 1
P4 Gr 1
P5 A Gr 1
Page 17
18
TABLE - II
WELD PREHEAT AND PWHT FOR BOILER HEADER WELDS
(NOTE - 3)
(Applicable For Welding of Header to Header Joints)
P. No. of
Header Material
Thickness
(mm)
Preheat
C
Post Heating
C
PWHT
C
t 19
Nil
Nil
Nil
19 < t 25
Nil
Nil
595 - 625
25 < t 75
100
Nil
595 - 625
t > 75
150
Nil
595 - 625
t < 19
Nil
Nil
620 650
19 < t 25
Nil
150
for 2 hours
620 - 650
19 < t 75
100
150
for 2 hours
620 - 650
t > 75
150
P4 Gr 1
All
P5 A (Note 1)
12 x 1M
P1Gr 1
P1Gr 2
150
150
for 2 hours
Nil
640 - 670
All
150
680 - 710
All
200
Nil
710-740
620 - 650
Note :
1.
All P5A headers shall be inter stage heat treated at 700 - 750C for 30 minutes
soaking prior to any cold straightening operation. In lieu of this, the straightening
can be done after final PWHT. Any P5A Header with weld thickness above
50mm requires inter stage H.T. at 700-750C for 30 minutes soaking minimum
(max. shall be limited to 2.5 minutes/mm of thickness).
2.
Soaking for PWHT shall be at the rate of 1 hour per 25 mm of thickest weld (but
not less than 30 minutes for carbon steel and 1 hour for alloy steel). Soaking
time for 12 x 1 M header material shall be 4 minutes per mm of the applicable
thickness with a minimum of 180 minutes.
3.
Seal welding of Hand Hole Plates, Radiographic plugs and Screws can be
carried out after final PWHT, provided the preheat is carried out as per the
table.
For P number and Group number refer Table - IV.
4.
Page 18
P No. of
Material
P1 Gr 1
&
SA106
Gr C
P1 Gr 2
&
SA 106
Gr C
Thickness
(mm)
TABLE - III
WELD PREHEAT AND PWHT FOR PIPES
OUTSIDE DIAMETER >102 mm
Stub and Attachment welds
Note 1
BUTT WELDS
&2
Throat 19 mm
Throat > 19 mm
Preheat
PWHT
(Note 3)
Preheat
C
PWHT
C
Preheat
C
19
Nil
Nil
Nil
Nil
Nil
>1925
Nil
595 625
Nil
Nil
Nil
595 625
Nil
>2575
150
595 625
150
Nil
150
595 625
Nil
>75
150
595 625
150
600650
150
595 625
Nil
Nil
Nil
Nil
Nil
Nil
620 650
Nil
>919
Nil
620 650
Nil
600650
Nil
620 650
Nil
>19
150
620650
150
600650
150
620 650
150 for
2 hrs
75
125
640670
125
650680
125
640670
Nil
>75
150
640670
150
650680
150
640670
Nil
Pipes
150
680 750
150
700750
150
680750
250 for
2 hrs
Castings &
Forgings
220
680750
250 for
2 hrs
All
220
750770
220
750770
220
750770
280 for
2 hrs
All
220
730760
220
730760
220
730760
280 for
2 hrs
P5 A
P5B Gr2
+
P5 A
Post
heat C
P4 Gr 1
P5B Gr2
+
P5B Gr2,
19
680750
150
700750
150
PWHT
C
595 625
Nil
Note :
1.
Irrespective of the stub or attachment materials, the PWHT cycle shall be governed by the pipe
material.
2.
Throat shall be specified in the drawing. Wherever flanges are welded to pipes combined throat
shall be taken into consideration.
3.
Page 19
4.
20
For butt welds of different P group combinations, PWHT temp. may be as follows:
P1 + P3
620 to 650C
P1 + P4
640 to 670C
P4 + P5A
680 to 720C
a.
For P1 & P3 materials soaking time shall be 1 hour per 25mm up to 50mm
thickness and 2 hours + 15 minutes for each 25mm thickness over 50mm.
b. For P4 & P5 materials, soaking time shall be 1 hour per 25mm up to 125mm
thickness and 5 hours + 15 minutes for each 25mm thickness over 125mm.
Page 20
21
TABLE - IV
P NUMBER AND GROUP NUMBER FOR BASE MATERIALS
P.No Group
No.
Common
Name
Carbon
Steels
Tubes
SA192
Pipes
SA106GRB
SA210GRA1
P1
Plates
SA36
Forgings
Castings
SA266CL1
SA216WCA
SA515GR55
SA352LCA
SA515GR60
SA352LCB
Fittings
SA234WPB
SA515GR65
SA516GR55
SA516GR60
SA516GR65
Carbon
Steels
P1
P3
P4
P5A
P5B
P8
SA106GRC
P3
P8
SA210GRC
Carbon-Moly
Steels
CrMo
Steels
1CrMo/
1CrMo
Steels
2Cr1Mo
Steels
9Cr1MoV
Steels
18Cr-8Ni
Steels
SA515GR70
SA266CL2
SA216WCB
SA105
SA516GR70
SA216WCC
SA234WPC
SA299
SA352LCC
SA209T1
SA335P1
SA217WC1
SA213T2
SA335P2
SA387GR2
SA213T12/
SA335P12
SA387GR12
SA182F12
SA213T11
SA335P11
SA387GR11
SA182F11
SA213T22
SA335P22
SA387GR22
SA182F22
SA213T91
SA335P91
SA387GR91
SA182F91
SA213TP304
SA376TP304
SA240TP304 SA182F304
SA351CF3
SA213TP304H SA376TP304H
SA240TP321 SA182F321
SA351CF8
SA213TP347
SA376TP321
SA240TP347 SA182F347
SA351CF3M
SA213TP347H SA376TP347
SA336F304
SA351CF8M
SA213TP321
SA336F321
SA351CF10
SA336F347
SA351CF10M
SA217WC6
SA234WP12
SA234WP11
SA217WC9
SA234WP22
SA234WP91
SA403
25Cr-20Ni
Steel (Type 310)
SA376TP347H
SA240TP310 SA182F310
SA351CK20
Note : IS1239 & API 5L GR B Pipes, IS2062 Plates may be treated as P No.1 Gr No.1 material.
Page 21
22
TABLE - V
PREHEAT AND PWHT FOR NON PRESSURE PARTS INCLUDING STRUCTURALS
P.No. of
Material /
Material
Specification
Gas Cutting
Welding
Thickness
(mm)
Preheat
C
Thickness
(mm)
Preheat
C
50
Nil
38
Nil
> 38 63
100
> 63
120
150
P1 / IS 2062
> 50
IS 8500
540
Ceiling
Girder
100
PWHT
C
600-650
a)All butt welds > 50
mm thick
b)Any welds to a
tension member
600-650(Soaking time
2.5 Mts. Per mm.
Minimum 120 Mts )
650-700
25
Nil
P4
All
> 25
P5
All
150
150
150
All
150
680-730
All welds
(Note 4)
NOTE :
1.
All gas cut edges may be chipped off, ground or machined to remove the HAZ with
3mm minimum removal.
2.
Clip angles above 10mm, used for beam connections, which are sheared to length,
shall require heat treatment.
3.
All fabricated structural components of P-4 material, with any member above
16mm thickness, the entire assembly shall be post weld heat treated.
4.
All welds of P5 material shall be post heated at 250C for 2 hours or 150C for
4 hours immediately following welding.
5.
Page 22
23
TABLE - VI
PREHEAT FOR FLAME CUTTING
P.No. of Material
Thickness (mm)
Preheat C
P1 Gr 1
< 25
Nil
(Note 1)
25
100
All
150
> 100
150
All
150
All
150
P1 Gr 2
(Note 1)
P3
(Note 1)
P4
(Note 1)
P5
(Note 2)
NOTE :
1. For P1, P3 and P4 materials, when the flame cut edge will be machined
after cutting and when no forming operation is required after cutting, no
preheat is required for flame cutting.
2. P5 materials, except when the part is scheduled for hot forming, shall be
inter stage heat treated at 700-750C for 30 minutes minimum after
flame cutting and prior to any welding. As an alternative to this heat
treatment, a minimum 3 mm of the gas cut edge may be removed by
machining, grinding, chipping, etc.
Page 23
23
HEEP,
CHAPTER -2
HEAT TREATMENT PROCEDURE STEAM TURBINE, TURBO-GENERATOR AND AUXILIARIES
Page 23
24
HEEP,
Page 24
25
CHAPTER - 3
GENERAL
Page 25
26
3. GENERAL
1. TESTING OF TEMPERATURE INDICATING CRAYONS
1.0
SCOPE :
1.1
This procedure details the method of batch testing of Temperature indicating Crayons
(Thermal chalks).
2.0
PROCEDURE :
2.1
Setup:
2.1.1
Rig a test heating arrangement including a test pipe/plate heating arrangements with
controls and a calibrated temperature recorder/thermometer.
2.2
Heat the test pipe / plate (specimen) to a temperature 10 lower than the rated
temperature of the thermal chalk in study, monitoring the temperature through
thermometer/recorder.
2.3
Stroke the thermal chalk as close to the sensing point on the specimen.
2.4
Raise the temperature of the specimen gradually up to 10% higher than the rated
temperature of the thermal chalk in study, stroking the thermal chalk on the specimen
during this period.
2.4.1
When the thermal chalk changes to the specified colour or melts (depending on the
type), within 5 of the rated temperature, the thermal chalk is acceptable.
2.5
Consistent results for 2% of any brand and temperature will qualify the brand for the
rated temperature.
2.6
Where thermal chalks are accepted brand wise, they shall undergo this test at least
once a year.
3.0
RETESTS :
3.1
Any failure in the 2% sample chosen, will call for additional 4% for qualification of the
brand for the rated temperature.
3.2
Where retest results in further non-acceptance, the brand shall stand rejected for the
particular temperature.
4.0
RECORDS :
4.1
Page 26
27
SCOPE :
1.1
This
procedure
provides
for
checking
the
compatibility
and
accuracy
of
HT TEST SYSTEM :
2.1
2.2
2.0
PROCEDURE :
3.1
3.2
Raise the temperature of the test specimen to around 200C and maintain the same.
3.3
Place the sensor of the direct reading thermometer as close to the thermocouple
junction as possible.
3.4
3.5
3.6
Repeat steps 3.2 to 3.5 for test specimen temperatures of 400C and 600C
3.7
Where the temperature read by the temperature recorder is within 10C with respect
to the thermometer, the HT system is compatible.
3.7.1
Where the results are not within the tolerance specified above, further tests are to be
repeated to identify the fault either in thermocouple or compensating cable or both.
3.8
3.9
This compatibility is recommended for each of the thermocouple available for use; this
procedure validates the thermocouple also.
4.0
RECORDS :
Page 27
28
Report No.
Date :
Details
Temperature Recorder
Thermometer
Make:
Model:
Sl. No.:
Range:
Test Results
Temperature Reading C
Sl. No. t/c No. C/C. No.
Recorder Thermometer
Difference C Results*
Witnessed by
Page 28