OWNER

CLIENT:
Sabz
Engineering
Company

National Iranian Gas Company

IGAT 5 Gas Compressor Stations
DOCUMENT TITLE

DOCUMENT No.

TASHA DOC. NO.

602-106-TSH-VD-015 Rev. 0
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CONSURTIUM:

TASHA Manufacturing Company

SABZ Engineering Company
FBM Hudson Italiana
FBM KNM FZCO.

PWHT PROCEDURE
FOR
SPY-2-1106/2106/3106/4106-EA-101

TASHA DOC. NO.

TOTAL PAGES:

602-106-TSH-VD-015 Rev. 4
8
(EXCLUDING COVER SHEET)

22/02/2006

FOR APPROVAL

N.A

M.S.KH.

M.S.KH.

S.P.Z.

8/1/2006

FOR APPROVAL

N.A

M.S.KH.

M.S.KH.

S.P.Z.

12/11/2005

FOR APPROVAL

N.A

M.S.KH.

M.S.KH.

S.P.Z.

28/09/2005

FOR APPROVAL

H.N.

M.S.KH.

M.S.KH.

S.P.Z.

17/08/2005

FOR APPROVAL

H.N.

M.S.KH.

M.S.KH.

S.P.Z.

REV.

DATE

DESCRIPTION

PREPARED

CHECKED

APPROVED

CONSURTIUM

OWNER

CLIENT:
Sabz
Engineering
Company

National Iranian Gas Company

IGAT 5 Gas Compressor Stations
DOCUMENT TITLE

DOCUMENT No.

TASHA DOC. NO.

602-106-TSH-VD-015 Rev. 0
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Contents
Introduction
1- Scope
2- Reference
3- Heat Treatment Specification
4- Heat Treatment Facilities
5- Heating System
6- Thermo Couple (T/C)
7- Interruption of Heating during P.W.H.T.
8- Operating of Post Weld Heat Treatment
9- Header Boxes
10- Hardness Test
11- Q.C. Form

SH. 1 of 8

OWNER

CLIENT:
Sabz
Engineering
Company

National Iranian Gas Company

IGAT 5 Gas Compressor Stations
DOCUMENT TITLE

DOCUMENT No.

TASHA DOC. NO.

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Introduction:
This procedure covers the minimum requirement for shop post weld heat treatment (SPWHT) of the
headers boxes (SPY--1~4(106)-EA-101) relevant to IGAT-V Air Coolers.

1-

Scope:
This Procedure is contained general requirements of post weld heat treatment, which shall be
applied for Air Cooler headers.

23-

Reference:
ASME Sec.VIII Div.1 Ed.2001 / Welding Spec. (602-000-ME-SP-003-D00)
Heat Treatment Specification:
3-1) The method of applying, checking and controlling preheat and interpass temperature shall be
stated on the WPS.
3-2) the minimum preheat temperature to be applied prior to the commencement of thermal cutting
or welding shall meet requirements of the code, which ever is the highest.
3-3) when welding dissimilar metal welds having different preheat temperature requirements the
more stringent preheat requirement shall normally be applied. This temperature shall be established
during the welding procedure qualification.
3-4) preheat may be applied by any suitable method. Where fuel gas or oil is used, the gas or oil
shall be sulphur free. The fuel/air mixture shall produce a neutral flame to ensure that no carbon
deposit is left on the weld area.
3-5) Preheat shall be applied in a uniform manner and maintained throughout welding. Once preheat
is applied, welding shall not be interrupted or stopped (other than for rest break) until a minimum of
30% of the final weld depth has been completed. On completion of welding, the weld area shall be
cooled slowly under insulation to ambient temperature or, if required by paragraph 3-7 subject to an
intermediate de-hydrogenation heat treatment.
3-6) Preheat and interpass temperatures shall be measured as follows by the use of temperature
indicating crayons, thermocouples or contact pyrometers:
For nominal thickness at the weld preparation less than 50 mm, prheat temperature shall be
maintained for a distance of 4t or 51mm, whichever is less, from the edge of the weld
preparation.
For nominal thickness greater than or equal to 50mm at the weld preparation, preheat
temperature shall be maintained for a distance of 75mm, from the edge of the weld
preparation.
Preheat temperature shall be measured only after sufficient time has elapsed for temperature
equalization (based on two minutes per 25mm thickness)

Interpass temperature shall be measured on the weld metal or the base material immediately
adjacent to the weld.

OWNER

CLIENT:
Sabz
Engineering
Company

National Iranian Gas Company

IGAT 5 Gas Compressor Stations
DOCUMENT TITLE

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Temperature indicating crayons for use on 300 series stainless steel shall be certified free
from injurious contaminants(e.g. sulphur, halides )
3-7) where the specified minimum preheats temperature are 150 C or higher an intermediate
dehydrogenation post weld heat treatment shall be applied in accordance alternatively for
equipment subject to PWHT, preheat shall be maintained without interruption until the start of
PWHT.
Post weld heat treatment
3-8-1) PWHT shall be performed in accordance with code and welding spec.
3-8-2) PWHT in an enclosed furnace is the preferred method, with the electric resistance or
muffle furnace PWHT for local closing welds.
3-8-3) all machined surface shall be protected from scaling during PWHT using a suitable protective
coating.
3-8-4) for equipment subject to PWHT in an enclosed furnace, thermocouples shall be located on
both the inside and outside surfaces at the following locations, as a minimum, to ensure the correct
temperature is attained:
The thickest and thinnest members (including nozzles)
The top and bottom of the equipment (as positioned in the furnace)
3-8-5) for weld subject to a local or partial PWHT, four thermocouples shall be equally spaced
around the weld joint on both the inside and outside surfaces. Where electric resistance elements are
used for local or partial PWHT, a minimum of one control thermocouple shall be used for each
heating circuits.
3-8-6) for local PWHT, the minimum width of the heating band shall be a minimum of 6t or
150mmeithersideof the weld, whichever is greater, or the code requirement if this results in a greater,
or the code requirement if this results in a greater heating band width. Insulation shall extend a
minimum of 250mm beyond the edge of the heating band or the code requirements if this results in
greater insulation width. For flanges weld, the entire flange surface inside and out, shall be insulated.
Whenever practical, the inside surface over the area of the heating band shall be insulated, or if this
is not practical, the ends shall be sealed to prevent draughts and minimize convection currents.
3-8-7) Pressure retaining welds of equipment in sour, amine and caustic services shall be subject to
PWHT after all welding is complete. Attachment welds to pressure retaining components, and any
areas subject to heating for bending, correction of misalignment etc. for equipment in amine and
caustic services shall be subject to PWHT.
3-8-8) Where PWHT is a service requirement in accordance with 3-8-7 welding after PWHT is not
permitted without additional PWHT with the exception of minor, external attachment welds to
equipment in sour service only, providing the PQR complies with the hardness testing requirements.

4-

3-8-9) Where PWHT s a code requirement only welding after PWHT without additional PWHT is
permitted only for the following:
Heat Treatment Facilities:

OWNER

CLIENT:
Sabz
Engineering
Company

National Iranian Gas Company

IGAT 5 Gas Compressor Stations
DOCUMENT TITLE

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The heat treatment operation of this project will carried out by Reactorsaz Co or Artash Co.
Reactorsaz Co. has a heat treatment furnace with the following capacity.
Length
: 18 meter
Width
: 6 meter
Height
: 6 meter
Temperature range : 100-120C
Main fuel
: Natural gas
Control System
: Automatic & monitoring system
Temperature Control
: Automatic Control

5-

Heating System
4-1) for heating of the box to be treated; it shall be place on the bogie and push bogie into the
furnace.
4-2) during the firing, the flame shall not be harmful and not be react with base metal.
4-3) Flames shall not be directly contact with the any part of box or box attachment.

6-

Thermocouple (T/C)
According to furnace category monitoring facilities, control panel and suitable thermocouple (T/C) are
predicted for temperature measurement. T/C location and its contacts type are met the UW-40 design
code. The location of thermocouple connection shell is covered by proper insulation material with
minimum dimension 50 x 50mm.

7-

Interruption of Heating During PWHT:

If heating is interrupted at any stage of the heat cycle, precaution should be taken to minimize the
cooling rate. Subsequent heating shall be in accordance with the relevant heat cycle.
6.1- Interruption in heating period:
Wait until to 600C, and go on reheating.
6.2- Interruption within soak period:
If the temperature drops below the lower limit, it shall be increased to correct range at specified
heating rate for the material and thickness, and then hold period should be restarted.
6.3- Interruption during cooling period:
In this case if the temperature is within cooling rate, then acceptable. But that is beyond, applying
additional insulation shall be taken on furnace gate until the cooling rate reach to acceptable cooling
rate.

8-

Operating of Post Weld Heat Treatment:

The operation of the shop post weld heat treatment should be generally performed in accordance with
the sequence prescribed hereafter.
1- Review the procedure of the heat treatment work and assembly drawing.
2- Check the weld line number, cleaning condition, and other requirement to be performed for post
weld heat treatment.
3- Measure the skin temperature of bare parts.

OWNER

CLIENT:
Sabz
Engineering
Company

National Iranian Gas Company

IGAT 5 Gas Compressor Stations
DOCUMENT TITLE

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4- Determination the burner number and type, thermocouple type, number position and adhesion
condition.
5- Confirm the calibration status (report) of temperature records. The temperature recorder shall be
calibrated in accordance to the fabricator recommendation or laboratory guidance.
6- Thermocouple calibrated record shall be reviewed.
7- Connect the power cables to temperature recorder and controller, respectively.
8- Seal furnace door gap if practical.
9- Check the temporary supports for fill-up distortion due to operation, and check all of the dials
instruments, knobs/ controller and indicators related to the PWHT operation.
10- Heat up unit PWHT temperature is reached at desire of the heat treatment procedure.
11- Monitor the heating rate, holding time and cooling rate during the PWHT operation.
12- Disassemble the thermocouple and temporary attached.
13- Check the time-temperature chart, and make a heat treatment report in accordance with the
time-temperature chart.
14- Submit the report to inspector and client respectively.
15- Surface preparation and painting shall not be undertaken in conditions which are favorable to
surface condensation when temperatures are below 10 C or the relative humidity is above 85%.
16- Paint materials shall not be applied over metal surfaces having temperature less than 3 C
above the dew point or in excess of 38 C.
17- Paint materials shall not be applied to steel when ambient temperatures are expected to fall to
5 C before the paint has dried.
9- Header Boxes:
The following paragraph is applicable to shop post weld heat treatment box that are fabrication by
welding
9.1- Pressure vessel design data:
Design code : API-661
Head material : A516Gr70
9.2- Heat treatment:
Actual heat cycle to be applied to headers is as follows:
1- The rate of heating from ambient temperature up to 300C shall be heat without recording.
2- The rate of heating from 300C to soaking temperature shall be controlled and recorded
automatically and not greater than 222C/hr (according to table 1)
3- Soak temperature: 640 20C
4- Above 426C cooling shall be done in a closed furnace or cooling chamber at a rate not greater
than 278C/hr dived the maximum metal thickness of the shell or head plate in inches, but in no
case more than 278C/hr.
5- During the holding period, there shall not be a greater difference than 50C between the highest
and lowest temperature throughout the portion of the weld line being heated.
6- During performance of heat treatment activity relevant graph for registering of temperature and
time shall be recorded properly.

OWNER

CLIENT:
Sabz
Engineering
Company

National Iranian Gas Company

IGAT 5 Gas Compressor Stations
DOCUMENT TITLE

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10- Hardness Test:

10.1- For verification of correct post weld heat treatment performance at least two welded joint of
each header shall be tested by checked on base hardness test instrument.
10.2- Hardness measurement shall be checked on base metal, H.A.Z and base metal.
10.3- Hardness value shall be recorded on hardness test report.
10.4- The maximum acceptable hardness is 248 H.V. (On PQR)
10.5- For each type of weld, production test requirements of Para. 14.4 of welding spec. will be
considered.

FIG.1) Heat Treatment Cycle for Headers Box

(Not to Scale)
Table 1
Item

Max. Th'k
(mm)

Heating Rate
(C/hr)

SPY-2-(1~4)106-EA-101

22

222

Holding
Time (min)
60

Temperature (C)
640 20

Cooling Rate
(C/hr)

- For any repair after P.W.H.T., it should be heat treated after repair operation locally. (Based on
UCS-56)
- Surface protection for raised face flanges should be considered.

222

OWNER

CLIENT:
Sabz
Engineering
Company

National Iranian Gas Company

IGAT 5 Gas Compressor Stations
DOCUMENT TITLE

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11- Q.C. Form

All information relevant to heat treatment shall be recorded in Q.C. format and relevant graph must be
attached to heat treatment report.

OWNER

CLIENT:
Sabz
Engineering
Company

National Iranian Gas Company

IGAT 5 Gas Compressor Stations
DOCUMENT TITLE

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Project:

Item/ Tag No.:

HEAT - TREATMENT

Owner:

Report No.:
REPORT

Req. No.:

Date:

We Certify That The Under mentioned Item Was Heat-Treated And Found To Be Satisfactory To:

Specification:

Drawing No.

Method of Stress Relieving:

Material:

Required Temperature:

Rate of Heating Up:

Holding Time

Method of Cooling:

Atmosphere Composition

Inspection Authority:
TASHA QC. REPR.:

CLIENT QC. REPR.:

OWNER Q.C REPR.:

DATE:

DATE:

DATE:

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