RAJASTHAN NORTHERN AREA DEVELOPMENT PROJECT BHAGYAM FIELD DEVELOPMENT MECHANICAL WORKS FOR WELL PAD WORK PROCEDURE

FOR PREHEATING & POST WELD HEAT TREATMENT (PWHT) BD1253AA-BHAG-Q-PRO-0012

A2 A1 Rev

21-07-11 07-06-11 Date

Issued For Review Issued For Review Purpose of Issue

SS Perumal SS Perumal Prepared By

Anwar Baig Anwar Baig Checked By

Nitin Makwana Nitin Makwana Approved By

BD1253AA-BHAG-Q-PRO-0012

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WORK PROCEDURE FOR PRE-HEATING & POST WELD HEAT TREATMENT (PWHT)

TABLE OF CONTENTS DESCRIPTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Purpose Scope Reference Document Definitions Health and Safety Method Heat Treatment Cycle Thermocouple Position Arrangement Heating Element Thermocouple Thermocouple Extension Cable Thermal Insulation Temperature Recorder Temperature Control System Hardness Testing Documentation Job Safety Analysis PAGE NO 3 3 3 3 4 4 5 6 6 7 7 8 9 10 10 11 12

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1.

Purpose
This procedure intends to give guidelines for carrying out localized post weld heat treatment of circumferential welds of process / pressure piping.

2.

Scope
This procedure in general, conforms to recommendations of code

ANSI-B-31.3 for piping. This procedure is limited to the Heat Treatment performed with Electric Power only. (I.e. Resistance Heaters: - either in form of coils or "finger" elements.)

3.

Reference Documents
ASME B31.3 Process Piping Drawing References. Project Quality Control Plan. Specification for piping fabrication & erecton.

4.

Definitions
AEL CEIL HSE P&ID PWHT NDT Artson Engineering Ltd. Cairn Energy India Pvt. Ltd. Health Safety and Environment Piping & Instrument Drawing Post Weld Heat Treatment Non Destructive Test

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5.

Health and Safety

As per HSE plan, the following systems to be followed; All relevant elements of HSE Plan BD1253AA-BHAG-R-PLN-0001 shall be followed Emergency and response Plan BD1253AA-BHAG-R-PLN-0003 shall be followed in case of any emergency Project Security Plan BD1253AA-BHAG-R-PLN-0004 Daily pep talk shall be conducted prior to proceed for the work.

6.

Method
Pre-heat shall be atleast sufficient to dry surface to be welded, but

not less than 10C. The minimum Pre-heat temperature shall be specified as in WPS. The Pre-heat temperature shall be as per the ASME B31.3. Table

330.1.1. If any loss or intterruptions of continuous Pre-heat then liquid

penetrtrent examination shall be done for incomplete weld joint. Temperature indicating thermocouples or calibrated pyrometer shall

be used to measure Pre-heat and interpass temperature. Heating Elements, of Ni-Cr (80% + 20%) wire of suitable gauge

(Ranging from 8 G to 20 G), insulated with porcelain beads, having various outputs (in kw) depending on the requirement, either in the from of coils or finger, shall be arranged around and on the weld portion and

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heated electrically at 240 Volt supply. In case of high thickness & big diameter vessels, the heating

elements shall have to be provided also from the inside to achieve uniform heating. Heating element are covered initially with mineral wool and finally

wrapped with ceramic pad/blanket to shield the heat. The electric power is to be supplied from 3 phase 4 wire system i.e.

3 x 240 V. with Neutral. Each control panel is having maximum current carrying capacity of 63 Amp. per phase. The power to the heating elements is controlled by timer as well as by on/off switch, manually. The work piece is to be firmly supported and adequately earthed

electrically, before commencing the "HEATING" operation

7.

Heat Treatment Cycle

The typical details of HT cycle for carbon steel & Aloy steel in general is as under. Heating from Ambient to 300C: unrestricted Heating from 300C to 650C for carbon steel: 1500C (1500C/Hour Max.) Or to 7200C for Alloy steel: Wall thickness in inches

Soaking Period: One hour per inch of Wall thickness (one hour

minimum Rate of cooling to 300C: 170C (170C/Hour)

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Wall thickness in inches 300C to Ambient: To Cool in still Air.

8.

Arrangement of Heating Elements

Normally three sets of heating elements shall be wound round

the joint. One on each side of the weld and the third at the center of the weld. Similar configuration to be adopted, if Heating elements are required to be placed from inside. string. The Heating element are to be arranged in nos. of zones to The Heating element shall be held in position by Asbestos

effect even heating of the entire desired portion. The width of the Heating Elements, on either side of the weld,

shall be minimum distance.

9.

Thermocouples
All Thermocouples type, shall to be of the 4937, nickel-chromium/nickelpart 4. Type K All

aluminum

con-forming

BS

Thermocouples/Thermocouple wire shall be supplied with a valid certificate of conformance. Thermocouples shall be attached by means of the direct wire

discharge method in order to avoid errors introduced by direct heating sources. The conductor wires shall be fixed to the work piece no further than 5 mm. apart. To enhance the mechanical strength of the Thermocouple hotREVA2 Page 6 of 15

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Junction, chloride-free high temperature cement shall be applied to the hot junction. The Thermocouple to thermocouple extension cable junction shall

be kept clear from the heated zone

10.

Thermocouple Position
All thermo couples positions and numbers/colour, shall be

distinguished on temperature recording chart. The following Thermo couple location shall be considered as

guide only

Sl.No 1 2 3

Size Up to & including 50 mm Above 50mm to 300mm Above 300mm to 500mm

No of Thermocouples one two three

Thermocouple Position 360(top) 60/360 120/240/360

NOTE: The specific requirements of Heat Treatment Cycle as well as Thermocouple placement for a particular job, however, are to be obtained from the inspection Authorities concerned, prior to commencement of job.

11.

Thermocouple Extension Cable

Copper-Constantan compensating cables shall be used. The Copper Lead (+Ve) shall be connected to the nickel
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chromium conductor (non-magnetic), and the Constantan lead (-Ve) to the nickel aluminum conductor (magnetic). Care shall be taken to ensure that the compensating cable is not

subject to a. direct or indirect heating b. Electrical interference c. Mechanical damage.

12.

Thermal Insulation
The insulation consists of mineral wool wrapped around Heating

Element and then covered with a layer of ceramic blanket on entire length of heating zone. The insulation shall extend a minimum distance of 300 mm

beyond the outer-most edges of the heated band wall The number of layers applied and extent is dependent on thickness, pipe diameter, gradient requirements and site

conditions , in all cases , a minimum of two layers shall be applied. The overall width of insulation shall be minimum 10 times JRT(R=radius & T=Thickness) Where ever possible, pipes/vessels open ends shall be blanked

off before heat treatment commences. The insulation shall be bound with black annealed iron wire The total insulation covering will be such to provide minimum

heat loss.
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Temperature

crayons

shall

be

used

to

ensure

that

the

temperature do not exceed 300C at any nearest point beyond insulation covering.

13.

Temperature Recorders
The records shall be of six point type, suitable for 0 1000

C/1200 C having continuous recording chart and chopper bar with colour dots, with scanning period of 20 seconds/dot. Accuracy 1%. only 1 no. Chart to be used for each weld joint preferably. Position of Thermocouples to be shown on a sketch and identified on chart recording.

With these recorders, a continuous graph chart of all the

thermocouples is obtained, providing information of temperature differences and trends during the heat treatment cycle. The charts also provide proof of the heat treatment cycle on completion. The chart speed shall be adjusted to 20 mm. per hour, and

the time interval between cycles for any particular thermocouple will be approximately 2 minutes. Each recording instrument will give information and immediate

indication of a thermocouple open circuit condition. Each temperature recording instrument shall be checked,

calibrated before commencement of a heat treatment contract and thereafter at intervals not exceeding one month. Calibration certificates shall be available for review and such
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calibrations can be witnessed by client if required. During a heat treatment cycle, the recorder shall be securely

locked.

14.

Temperature Control System

The temperature control system shall guarantee a post weld

heat treatment within the limits of the specification. The manual mode of operation shall require adjustment of

temperature controllers for heated zones within the heated band to ensure temperature uniformity. Adjustments shall be made in increments of 100 C or as

specifically required. The heat shall be controlled by Timer or by 'ON/OFF' switch

manually. Ultimate control is achieved by using Timer & manual control of

energy and by continuous inspection of Temperature Recorder chart. Throughout the heat treatment cycle (restricted range) the differential between thermocouples registering peak

temperature

temperatures shall be within the limits 20C.

15. Hardness Testing

After PWHT, hardness of the weld joints and heat effected zone shall be checked by hardness tests. The hardness value shall be within 225.
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16.

Documentation
This procedure, any amendments and the heat treatment

specification are sanctioned by the customer prior to commencement of the heat treatment. The heat treatment chart shall have the following information: Technicians name. Starting and Completion time with date. Specification details. Thermocouple locations. Recorder identification number. ISO, line and weld numbers as applicable.

The soak (hold) period shall clearly mark on the heat treatment

chart. The thickness to be used in applying the heat treatment requirements shall be that of the thicker component measured at the joint. Charts shall be reviewed and approved by Q.C. Department, prior

to submission to authorities concerned. For OC purpose. Chart shall be signed by QC Supervisor with

time and date at the commencement and completion of heat treatment in order to provide valid proof of chart recording.

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NAME OF THE PROJECT ACTIVITY/IDENTITY OF TASK AREA AND LOCATION PLANT & MACHINERY, EQUIPMENT INVOLVED PPEs REQUIRED

: RAJASTHAN NORTHERN AREA DEVELOPMENT PROJECT : Job Safety Analysis for PWHT : All Well Pads. : Thermocouples, Current regulators, Insulation materials etc. : Safety Helmet, Safety Glasses, Safety Shoes, Rubber Hand Gloves, Coverall.

Sl. No. 1 2. 3. Approved By Checked By Prepared By

Name

Position

Signature

Date

Mr. Mukeshwar Tiwary Mr. Nitin Makwana Mr. Shohab Kardar

Sr. RCM RCM HSE Manager

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S.No
1

Activity
Preparation for Post Weld Heat Treatment.

Hazards
1. Unauthorized Entry 2. Electricity Leakage.

Control Measures
1. Permit to work system shall be followed. 2. Barricade the testing area with proper sign boards to restrict unauthorized entry. 3. Ensure isolation of the testing equipment or line has been done. 4. Ensure all tools used for PWHT are having calibration and test certificates. 5. Test piece is isolated and properly earthed. 6.Only 3 core double insulated cable shall be used . No domestic wire shall be used 7. All cables shall be connected with proper connector. No insulation tape shall be used. 8. Use separate earthing from pipe

Action Taken
Site Engineers/ Site Supervisor

2.

Post Weld Heat Treatment.

1. Electrocution. 2. Injury (burn) to workers. 3. Insufficient Insulation. 4.No Asbestos shall be used, use other insulation matetial 1. Test piece shall be properly marked and kept clear from other workers. 2. Ensure ELCB is used and shall be checked before starting the test. REVA2

Site Engineers/ Site Supervisor

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Example: Rockwool

3. Insulation shall be checked before starting the job. 4. Ensure the workers are wearing proper PPEs. 5. Use dust mask & Hand Gloveswhile handling insulation material. 6. Communicate burn hazard from hot surface to employees in the tool box talk.

3.

Wind up and housekeeping.

1. Scattered material. 2. Slipping or tripping.

1. Ensure proper windup and housekeeping is done at site. Area need to be free of scrap insulation material. 2. All accessories (insulation materials used) must being collected and kept separately if not in use. 3. Barricading and other signage shall be removed.

Site Engineers/ Site Supervisor

4.

Heat Stress due to adverse weather conditions

1.Heat stroke unconsciousness. 2. Heat Rashes 3. Heat Exhaustion

or 1. Wear Full Sleeves cotton coveralls. 2. Always wear Hard Hat and face covers.

Site Engineers/ Site Supervisor

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3. Drink plenty of water and more frequently. 4. Make Schedule for rotation of workers if possible and work in groups.

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