PROCEDURE FOR PWHT OF B.F.

TOP CONE

General requirement of PWHT:

1. The top cone shall be heat treated in vertical position.

2. Before starting the insulation operation all the surfaces involved with PWHT to be performed
shall be free from oil, grease and other foreign materials.
3. The heating of each area shall be performed by electrical resistance (Nichrome
Coil wire wound in the form of snake shape) and placed in contact with external surface of the
top cone.
4. Calibrated thermo couple (type-K) shall be used. The thermo couple can be as a pilot and/or
reordering thermo couples. The thermo couples shall be directly fixed to the surface by electrical
discharging equipment. The temperature measured by the thermo couple can be recorded on
multi channel temperature recorder. The number of thermo couple shall be equal to the number
of channels of the temperature recorder.
5. The electrical resistance shall be fixed on the areas to be heat-treated by mechanical fastening
(with the use of temporary fixing elements). The insulation shall be done by mineral wool cloth
(ceramic blanket) to be placed on the electrical resistance coils ( external surface) and on the
inner surface also to cover the area to be heat-treated. The minimum thickness required for
insulation shall be 80 mm for external surface and 50 mm for internal surface.

NDT before PWHT:

1. The constitutional weld joints shall be submitted to radiography (only 60mm thk. Plate joints) to
20% as per QCP.

PWHT process:

1. The PWHT shall be done for total cone in two intervals for each half of total vertical cross
section. I.e. PWHT of CJ-18 & ring 18 VJ (4 nos.) shall be carried out at a stretch, except above
shall be in another stretch (Off take nozzle CJs will be excluded).
2. The electrical resistance shall cover each constitutional weld joints and also the circular and
rectangular nozzles. The insulation shall cover the 100% inner and outer side of the shell top
cone ring (including each nozzle).

Positioning of Thermo couples:

1. The thermo couple on the shell shall be placed in five different concentric sections of top cone
ring. The pilot thermo couples shall be placed on the external side and recording thermo couple
on internal side. The number of thermo couples will be fixed as per the code specification.
2. Where as for each circular nozzle shall have three nos. of equi-distant pilot thermo couples on
external side of the soak band and three nos. of recording thermo couples on the internal side of
the relevant soak band.
3. The main rectangular nozzle shall have six nos. of pilot thermo couples and four nos. of
recording thermo couples. Other nozzles shall have one no. each pilot and recording thermo
couples.

PWHT Parameters:

1. Heating up to 100*- free.

2. Above 100*C, heating rate- 100*C/Hr.
3. Holding temperature- 600*C 20*C.
 4. Holding time 3 Hrs & 20 Mins. (For Mean 70mm thk.)
5. Cooling rate (Up to 250*C)- 100*C/Hr.
6. Cooling from 250*C to room temperature free (with insulation intact).
7. PWHT temperature recording.

PWHT Documentation:

1. Identification of items submitted to heat-treatment.

2. Type and no. of PWHT machine/ unit.
3. Type of electrical resistance.
4. Type and position of thermo couples.
5. Time and temperature graph.
6. Maximum heating rate.
7. Holding time and temperature.
8. Maximum cooling rate.
9. Date of execution.

NDT after PWHT:

1. The constitutional weld joints shall be subjected to NDE(100% UT )

2. 100% UT for each nozzle to shell welding
3. Dimensional check of Top cone according to applicable dimensional requirement.

L&T PWIT DCO

UT FOR 12MM Thk. PLATE ON DUST CATCHER MAIN STRUCTURE

Ultrasonic testing on Dust catcher (Ring 31 to 36) is not effectual to reveal volumetric defect
because of the following reasons.

1. Thickness of shell plate is 12 mm.

2. Curved surface.
3.