7

Postweld Heat Treatment

1 GENERAL

Postweld heat treatment (PWHT) of the vessel is decided

based on the material of construction, fabrication methods,
thickness of shell sections, etc., as contained in clause UW 40
(see Chapter 21, Section 17). Usually, vessels of 11/2 in. (38
mm) and over in thickness have to undergo PWHT. Those in
the range of 11/4 to 11/2 in. (32 to 38 mm) need not go for PWHT,
provided preheat at a minimum temperature of 200°F (93.3°C)
is given during welding. Further, vessels that are subjected
to low temperatures shall also undergo PWHT irrespective of
thickness. As this is a design criterion, it is not elaborated
here. However, as this requirement is indicated in the draw-
ings, we try to carry out the PWHT according to the provisions
of the code.

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 154 Chapter 7

2 PROCEDURE

In any procedure for PWHT, the following aspects shall be ad-

dressed.

2.1 Method of PWHT

Depending on the size of the vessel and capacity of the furnace
(size and maximum temperature), a full or partial PWHT is
performed. In full PWHT, there are two types of firing meth-
ods. The most common one is the furnace PWHT wherein the
vessel is loaded inside the furnace and heated to the required
level in a single firing as per the previously laid down proce-
dure. This is the most desirable type of PWHT because all pa-
rameters in the heating, soaking, and cooling cycle can be con-
trolled well. However, the availability of such furnaces are the
only constraint. Both oil firing as well as electrical heating
could be used for this. If PWHT in one go is not possible due
to the size of the vessel, UW 40 permits the use of part-by-
part PWHT with sufficient overlap of the heated zones.
In the second method, the vessel itself is made the fur-
nace by providing burners at appropriate points and by giving
insulation all around the vessel. The method is called internal
firing and is very much dependent on the skill of those that
perform this feat. The method of heating adopted is generally
oil firing with an additional electrical- or oil-fired heating sys-
tem at anticipated cold spots.
The third method is to do the PWHT of welds alone when
the design permits, using electrical resistance heating. Here
again proper overlap between two PWHT zones shall be given
as envisaged in UW 40.

2.2 Heating Rate

The heating rates to be followed are given in UCS 56 for car-
bon steel vessels and UHT 56 for steels whose properties en-
hanced by heat treatment. The rate specified in UCS 56 is
above 800°F (427°C), which is the maximum permitted fur-

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 Postweld Heat Treatment 155

nace temperature at the time of loading the vessel. The heat-

ing rates recommended are based on the thickness of the
shells. As thickness increases, the rate falls. As per UCS 56,
the rate suggested is 400°F/hr per inch (204.4°C/hr per 25
mm) thickness of the vessel, but in no case more than 400°F/
hr (204.4°C/hr). The manufacturer can always go for a lower
heating rate. However, too low a heating rate may be too ex-
pensive.

2.3 Soaking Temperature and Time

For carbon steel vessels, the soaking time and temperature
are specified in UCS 56. Soaking temperature is related to the
material specification, whereas the time is based on the thick-
ness of the shell of the vessel. For P. No. 1 materials, the soak-
ing time specified is 1 hr per inch (1 hr per 25 mm) of vessel
thickness with a minimum of 15 min. Similarly the soaking
temperature specified is 1100°F (593.3°C). Soaking at temper-
atures lower than that specified calls for extended soaking
time, as specified in UCS 56.1. However, it is recommended
to carry out the PWHT at the specified temperature and time
frame so that detrimental effects due to spheroidization can
be avoided.

2.4 Cooling Rate

After soaking, the cooling starts. As per UCS 56, the recom-
mended maximum cooling rate is 500°F/hr per inch (260°C/
hr per 25 mm) thickness of the vessel but in no case greater
than 500°F/hr (260°C/hr). Slower cooling rates are always
preferred, the only consideration being cost. The cooling rate
specified is only up to 800°F (427°C), below which it may be
cooled in still air.

3 HEAT TREATMENT CYCLE

The chart indicating the heating rate, soaking temperature/

time, and cooling rate is the heat treatment cycle and shall

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 156 Chapter 7

form a part of the procedure previously approved as per the

provisions of the code. All the other details elaborated are the
ones that are normally followed by the operator of the furnace.

4 PLACEMENT OF THERMOCOUPLES

The number of thermocouples to be used for monitoring the

temperature is calculated based on the diameter, length, and
position of other welded attachments on the vessel as per the
code. Once the number of thermocouples is finalized based on
the code and client specification, the location of the same is
fixed based on the configuration of the vessel as well as the
heating method proposed and the location of the heat source.
By looking at the position of the heat source and the configu-
ration of the vessel, one can easily locate the probable cold and
hot spots. Even though the very purpose of the thermocouple
is to monitor the temperature, it should also indicate the dif-
ference in temperature at the hot and cold spots. Because of
this reason, thermocouples shall be randomly provided at the
hot and cold spots evenly as far as possible. In case the differ-
ence in temperature between thermocouples is found to be in
excess of that stipulated in the codes [i.e., 250°F (121°C) while
heating and 150°F (65.6°C) during soaking], the same shall
be brought within the acceptable limits by either bringing
down the heating rate or by providing additional heat sources
at the cold spots.

5 CALIBRATION OF RECORDERS
AND THERMOCOUPLES

The recorders to be used shall have valid calibration certifi-

cates on the date of performance of the PWHT. Further the
thermocouples shall also have valid certification as to the
chemical composition of the element as this is the only possible
calibration for the same.

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 Postweld Heat Treatment 157

Figure 7.1 Postweld heat treatment confirmation report.

Copyright © 2002 Marcel Dekker, Inc.

 158 Chapter 7

6 VERIFICATION OF POSTWELD HEAT

TREATMENT AND RECORDS

A certificate indicating the loading temperature, heating rate,

soaking temperature, soaking time, cooling rate, unloading
temperature, etc., is prepared as in Figure 7.1 for every heat
treatment. In addition to this information, the actual heat
treatment chart will have the speed of the chart and will ac-
company this certificate. A sample procedure for PWHT is en-
closed in Chapter 15 in which a PWHT cycle is proposed. The
actual time/temperature chart obtained from the multipoint
recorder connected to thermocouples will reveal the deviation
from the proposed cycle. The following aspects shall be verified
from the chart:

1. The loading temperature shall be below 800°F

(427°C).
2. The heating and cooling rates shall be either equal
to or lesser than that specified in the procedure
drawn out as per code. For calculating this the chart
speed has also to be noted down.
3. Soaking temperature and time shall be marginally
above that specified.
4. The unloading temperature shall be less than 900°F
(482°C), that specified in the code.
5. All recorders and thermocouples shall have a valid
calibration certificate.

Copyright © 2002 Marcel Dekker, Inc.