The Worlds Most Innovative and Responsive Heat Treatment Service Provider

THERMAL POWER WELDING SEMINAR

CLEVELAND, OH
2729 SEPTEMBER 2016

Gary Lewis Global Director Business Development

Superheat FGH
BISyE Georgia Tech
glewis@superheatfgh.com
SIGNIFICANCE OF HEAT TREATMENT
LIFE ASSESSMENT (HARDNESS)
EPRI LIFE REDUCTION TABLES
 WHY WE HEAT TREAT
Preheat and Interpass Control
Prevent H cracking (Drive off moisture, reduce cooling rate,
increase H diffusion)
Redistribute solidification stresses
Minimize brittleness (cooling)

Hydrogen Bake-Out
Remove Hydrogen, H2O
Solidification crack
Prevent cracking and facilitate diffusion

Post Weld Heat Treatment (PWHT)

Achieve specific microstructure
Relax residual stress
Hydrogen removal
Avoid Cracking
Dimensional Stability
Improved Ductility & Corrosion Resistance
Toughness
 HEAT TREATMENTS IMPACT
MATERIAL QUALITY

PROJECT SUCCESS
Safety & Security
Labor & Productivity
Planning & Schedule

COST CONTROL
Estimating / Budgeting
FINAL COST

LIFE MANAGEMENT
Operations & Repair
Record Keeping
IMPROVING AN INDUSTRY SINCE 2006

Program 63 AWS WELD CRACK CONFERENCE 2008

CREATIVE LICENSE
 MATERIAL QUALITY
Advanced Alloys CSEF Steel (P91)
These materials are relatively new additions to the ASME
Construction Codes.
The only materials recognized by Code, that have their mechanical
properties enhanced by heat treatment.
 TECHNICAL RESOURCES

LIMITATIONS
Codes of Construction

While most Codes do have technical requirements for soak temperature,

hold time, and sometimes even heating and cooling rates, they generally
dont address temperature control, temperature monitoring,
temperature gradients, heated band widths, control zone placement.

ALL of these are necessary for a good heat treatment.

 THREATS TO UNIFORMITY AND ACCURACY

OVERLAPPING HEATERS HEATER FAILURE

WALL THICKNESS

GAPS BETWEEN HEATERS

 APPLICATION RESOURCES
FAMILIARITY WITH CODES AND STANDARDS

RECOMMENDED ASME Piping Fabrication

Codes
PRACTICES
B31.1 Power Piping
B31.3 Process Piping
Section 1: Boiler and
Pressure Vessels
Repair Codes
NBIC and API
Standards regarding Service
Environment
NACE and ANSI
AMERICAN WELDING SOCIETY
AWS D10.10

Soak Band A band the containing the weld and a certain amount of material
on either side of it, that must be heated to the PWHT temperature.
Heated Band A band encompassing the soak band that must be heated by the
heaters in order to get the soak band and the ID of the weld to temperature.
Gradient Control Band A band encompassing the heated band that must be
either heated or insulated to ensure that harmful gradients are not generated
at the edges of the heated band.
 PROCEDURES
PREHEAT
Preheat and Interpass Control
Prevent H cracking (Drive off moisture, reduce cooling
rate, increase H diffusion)
Slow the cooling process
Redistribute solidification stresses
Minimize brittleness (cooling)

Solidification crack

WHEN IN DOUBT, GIVE IT MORE PREHEATTOM MYERS

TEMPERATURE MANAGEMENT
PREHEATING
TEMPERATURE CONTROL
FLAME PREHEAT

2 Tube Section
6 x External Thermocouples
2 x Internal Thermocouples
350F Preheat
 TEMPERATURE CONTROL
FLAME PREHEAT

FINDINGS:
Heating Times 2 - Minutes

Overshoot 750F In 2m 30sec

Maintaining Uniformity 50F To 350F

Through Wall Temperature Achieved

Heat Retention Cooled Below 200F

In 8 Minutes
 PROCEDURES
POST WELD HEAT TREATMENT (PWHT)

Purpose for applying PWHT in Grade 91 for Power

TEMPER THE MICROSTRUCTURE

REDUCE WELDING RESIDUAL STRESS

INCREASE FRACTURE TOUGHNESS

(PER EPRI WELL ENGINEERED APPROACH MAY 2015)

RESISTANCE ZONE CONTROL
INDUCTION CONTROL
 TRANSPARENCY
DIFFICULT AUDIT AND INSPECTION
ETHICS IN HEAT TREATMENT
CHARTS AND DATA RECORDERS
COMPLEX GEOMETRIES
HEAT TREAT CONTROL
IMPLICATIONS OF AWS D10.10
Standard Practice 2 Tee PWHT

D10.10 Recommends 10 Thermocouples

 RECENT CODE ACTIVITY
CSEF STEEL (P91)

AWS D10.10 (All Materials)

RECOMMENDED PRACTICES
ADDRESSES ALL FIELD HT
MORE BACKGROUND AND INSIGHT
CORNERSTONE OF MANY NEW PROCEDURES

AWS D10.22 (CSEF Steel)

RIGID SPECIFICATION
ONLY PERTAINS TO CSEF STEEL
ELECTRIC RESISTANCE ONLY
ADOPTED ASME Section 1 (Boilers) as a Non-Mandatory Appendix
UNDER REVIEW ASME B31.1 and B31.3
THERMODYNAMICS & HEAT TRANSFER MODELING
EPRI STRUCTURAL INTEGRITY
 PROJECT MANAGEMENT
PLANNING
Job Walks & Field Coordination

Weld Count / Material Specs

Logistics

Assets

Administration

Billing The #1 reason organizations blow their budget has been

identified as inadequate planning or lack of preparation
Reporting
 MANAGEMENT OF WELDING
WELDING DESIGN AND PRODUCTIVITY

DONT OVERLOOK HEAT

TREATMENT!
INSUFFICIENT WELD RELATED KNOWLEDGE AT ALL LEVELS
MATT YARMUCH

CORPORATE and PROJECT MANAGEMENT OWNERS

ENGINEERING & DESIGN

PROCUREMENT TECHNICIANS
 PROCESS QUALITY MANAGEMENT
TOOLS - TECHNOLOGY - PLANNING

SmartPak
WRAPPING SPECS

M12 / M24

Smart Shack

Off Site Quality Management Center

SmartLog
 ENERGY OWNERS DRIVING QUALITY
NEW CONSTRUCTION OUTAGES - MAINTENANCE

Driving compliance and best practices

Speaking out and Investing in Planning
Engaging Points of Interest and Influence
Owner Maryland
12 in Pipe Sockolet
Designer Kansas City
Contractor - Texas
Fabricator Mississippi
Project Site Texas
Driving R & D
 EXECUTION FLEXIBILITY
LABOR OPTIMIZATION
Southern Company Vogtle Nuclear
Jamnagar Refinery - India

Chevron Gorgon LNG

Australia
RECORD KEEPING

Comprehensive Turnover Packages

MOCKUPS - DEMOS - TRIALS
ExxonMobil Baton Rouge
COLLABORATIVE INITIATIVES

Foster Wheeler T23 Waterwall EPRI / Fluor / Maverick PQRs

 FUTURE TESTING INITIATIVES
COMPLEX GEOMETRIES
VALVES, HEADERS AND INDUCTION CONTROL
HEAT TREAT QUALIFICATION PROGRAM
AWS D10.23
Qualification Designations
Introduction to Heat Treat
Materials
Heat Treatment Processes
Basic Heat Transfer
Technologies / Equipment
Areas of the Work Piece
Control and Charting
Understanding Codes
Ethics and Accountability
Safety
Site Operation Protocols
Heat Treat Components
Hardness Testing / NDE
Data Acquisition
Installation Drawings
Documentation
Turnover Documents
 REFERENCE MATERIAL
EPRI CONTRIBUTIONS

Checking hardness at each stage of fabrication and installation is

considered essential good practice..
 EPRI HT VIDEO SERIES
Video 1 Significance of Heat Treatment: Risks and Rewards

Video 2 Best Practices: Dos and Don'ts

Video 3 - Application Specific

 ORBITAL PREHEAT DEMO
WELD PROCEDURE QUALIFICATIONS
PREHEAT for PROCEDURE QUALIFICATIONS 2016
 THANK YOU!
Strive not to be a success, but rather to be of value
Albert Einstein

Gary Lewis
Director Business Development
glewis@superheatfgh.com