Training Program

on
PWHT & HYDROTESTING

REAL QMD

1
Program objectives:

• To refresh and update latest developments on Post weld

heat treatment[ PWHT ] & Hydro testing for engineers
joining from other areas.

• To indentify the role and responsibilities of concerned

discipline engineers while handling the PWHT, Heat
treatment & Hydrotesting process.

2
Program contents :

Fundamentals, Process and Monitoring of

• Preheat,
• Post Heating,
• PWHT
• Hydro testing.

3
 INDEX

 CHAPTER 1: PRE HEATING, POST HEATING & PWHT

• References
• Purpose
• Requirement Of Pre & Post Heating
• Methods Of Pre Heating
• Pre Heating In Case Of Interruption In Welding
• Post Heating
• Methods Of PWHT
• Surface Preparation
• Job knowledge of operator
• PWHT (Post Weld Heat Treatment)
• PWHT TEMPERATURE
• Equipments
• Procedure
• Records 4
References
 B31.3 Process Piping

 B31.1 Power Piping

 IBR The Indian Boiler Code

Regulations(1950)

 Iso Drawings For piping class, Material

identification & thickness

 Specifications 3PS GAW 004 & form 167A

 Procedure 2 QM 00 ME 006

5
 Purpose

• Purpose of this procedure is to define the equipments and

methods to be followed for the Preheat, Post heat & PWHT
• PWHT is carried out based on
• Material Composition ( Alloy Steel)
• Thickness of Weldment ( More than 19.05 mm for CS)
• Process Requirement ( Sour Service, Amine, Caustic Service)
• PRE HEATING & POST HEATING are being carried out
• To reduce cooling rates of deposited weld metal & HAZ from
fusion temperature.
• To remove moisture prior to start of welding which produces
hydrogen in presence of electric arc.

6
 Requirement Of Pre & Post Heating

• For Pre heating, the Weld Joint shall be preheated at or above

the min. temperature in all directions from the point of welding
for a distance of 3” or 1.5 times base metal thickness.
• In case of welding of two different P number materials, the
min. Preheat temperature shall be the higher temperature for
the material to be welded
• When welding two different thicknesses, preheat
temperature shall be the greater of the nominal thickness at
the weld.
• Preheating shall cover all types of welds including permanent
welds, tack welds, temporary attachments, repair welds, seal
welds of threaded joints as applicable

7
 Methods Of Pre Heating

• For CS / LTCS, preheating may be carried out either by

flame heating or electrical heating ( induction coil or
flexible ceramic pads)
• For low alloy steel piping materials above 2” NB pre
heating shall be carried out by electrical heating only.

8
 Pre Heating In Case Of Interruption In Welding
• After welding is commenced, preheat shall be maintained till
PWHT is performed on P number 3, 4, 5A, 5B & 6 except all the
following conditions are satisfied

• At least 9.5mm thickness of welding is deposited or 25%

groove is filled.

• For P-3, 4, 5A( Cr < 3% max.) weld is allowed to cool slowly to

room temperature

• For P-5B (Cr > 3%) & P-6, the weld is subjected to an
adequate intermediate heat treatment with a controlled rate of
cooling

9
• After cooling & before welding is resumed, visual
examination of the weld is performed to assure that no
crack have developed
• preheat to be applied, before welding resumes.

10
 Post Heating

• For low alloy steels, post heating shall be carried out at a

temperature specified in applicable WPS.
• For electrical heating, same arrangements as specified in
PWHT shall be followed.
• The method of post heating shall be as follows
• For joints 2” and below size, post heating time shall be
10 minutes( min.) for other cases post heating time
shall be 30 minute( min.)
• For low alloy steel material post heating shall be
carried out by electric heating for joints above 2”
• Preheat temperature shall be continuously maintained
till start of PWHT wherever specified in the codes /
Specifications.
11
Methods Of PWHT

 Furnace heat treatment:

For fabricated equipments, piping
spools in mass.
 Local Heat Treatment:
For local joint of piping spool.
 Flexible ceramic pads/ Induction coil:

 Combustion burner – gas fired:

For fabricated equipments

12
Surface Preparation :

 The area to be covered for preheat, post heat and

PWHT shall be free from paint, grease/ oil, tacks,
spatters to avoid damage due to short-circuiting.

13
Job knowledge of operator

 PWHT technician shall be capable of executing the

activity. This shall be assessed by QMD representative

14
PWHT (Post Weld Heat Treatment)
• This is the process of gradually and uniformly raising the
temperature of the weldment and base metal up to a certain
temperature, holding sufficient time at that temperature and
then gradually and uniformly cooling it to room temperature.
• Post weld heat treatment is required to be carried out on
weldment, as and when called for by Codes / Standard /
Specification. The purpose of PWHT may be either or all the
following reasons..
• To distribute the amount of Residual thermal stresses produced
during welding.
• To increase resistance to stress corrosion.
• To improve dimensional stability and ductility.
• To Temper the hard martensites as and when formed during
welding. 15
PWHT Temperature

 For Heating & Cooling rate, the requirement of WPS

shall be strictly followed.
 Soaking/Holding time & Temperature:- For PWHT
soaking time & temperature requirements the
requirement of WPS shall be strictly followed.

16
Equipment for PWHT

 Control Panels For current Regulation

 Heating Elements For Heating

 Thermocouple For sensing temperature

 Compensating leads For transferring current from

Thermo couple to Recorder

 Temperature recorder For recording temperature

against Time

 Thermal Insulation For avoiding heat loss by

radiation
 Attachment unit

 Earthing cable Green in color to be attached to

ground.. not to spool or
structure
17
Certification of Control Panels

 All equipments are purpose built.

 Electric power sources are 440 V, 3 phase primary supply or
220V single phase with either single phase secondary output
(distribution unit) or step down transformer secondary output
(heat treatment unit) giving low voltage circuits.
 Temperature control equipment is either manually operated
through energy regulators or automated
 All Control panels are duly certified by P & M before utilization
in job to meet the requirements as above and as per
standards.

18
Heating Elements

 Wherever induction heating is followed for PWHT,

the heating element shall be Ni-chrome wire covered
with ceramic beads/heating pads/flexible ceramic
pads.

19
Heating Element position

 Welds shall have a circumferential band of heating coil

around the entire component with the weld located in the
center.
 Heating elements shall be fixed on weldments by means of
black annealed iron wire.
 The width of the heating band shall be as follows,
 For girth welds, the width of the heating band shall be at
least three times the wall thickness at the weld of the
thickest part being joined and shall be maintained on either
side of the joint. (Fig-3.)
 For nozzle and attachment welds, the width of the band
shall extend beyond the nozzle weld or attachment weld on
each side at least two times the header thickness and shall
extend completely around the header. 20
Heating band on Welded Valves

 The width of the heating band shall extend up to 3t

+ weld width. Insulation width shall be 6t+ weld
width on pipe side only.
 Valve body shall be free from insulation & heating
band
 (Valves shall be kept open during the full cycle of
PWHT and bonnet bolts not to be loosened during
PWHT cycle.)

21
PLACING OF HEATING BAND (COILING) & INSULATION

3A- Min. Insulation Band Width

A- Min. Heating Band Width

A A

3T 3T T-Wall
Thickness

Fig-1

22
Thermocouples:

 Material shall be the “K” type i.e. Nickel-Chromium

(Chromel) / Nickel-Aluminum (Alumel) type.
 Compensating coil & thermocouples shall be
calibrated together.
 The distance between two T C wires shall be min
6mm.
 Insulation to be removed from the end of the T C
wire shall not be more than 15mm.
 connect the Positive / Negative side of the TC with
 respective positive/ negative side of compensating
cable.

23
 Thermocouple attachment shall be attached to the work
piece by Direct Wire Capacity Discharge method (Fig.2)
or by nut and bolt connection (Fig.3).
 If the nut and bolt connection method is used (Fig.3),
the materials of nut-bolt shall be of compatible
composition with parent metal.

Tack Weld

6 mm

Direct Wire Capacity

Discharge method
Fig 2
Two tack welds (opposite to each other)
Thermocouple Insertion
Fig.3

24
Number of Thermocouple's:

 Minimum number of thermocouple is one per heating coil.

However in addition to that the following min. numbers of
thermocouples shall be used for pipe welds

 Minimum requirement for number and location of thermocouples

are,
• 1 No up to and inclusive of 6" NPS
• For 2” and below, wherever joints are there within the range
of 100mm distance, one thermocouple is permitted (provided
single coil/pad is used)
• 2 numbers at 180° for above 6" and up to 12" NPS
• inclusive.
• 3 numbers at 120° for above 12" NPS
25
• For socket welds, 1 T C with in 100 mm between two joints
Location of thermocouples

 Thermocouples shall be fixed within the area of heating

band. Additional thermocouples may be fixed as per
requirement to confirm hot zone or gradient limitations,
if necessary.
 Thermocouple (s) and their position (s) shall be
identified on the relevant temperature-recording chart
by number or color/symbol of stamp.
 Thermocouple requirement for branch connection and
pad shall be in line with the requirements as mentioned
in above.
 Thermocouples tack welded with pipe shall be removed
completely after PWHT and the area to be DP tested
26
Calibration of Temperature recorders

 It shall be of the potentiometer, self compensating type

having chart feed recording.
 Recorders shall be calibrated in every six months and
calibration stickers shall be affixed to the recorders.
 In addition, recorders shall be re-calibrated after every
repair and also for the cases where there is reason to
believe that they are in error.
 And also to be verified for chart speed is set at appropriate
speed, Temperature recording system is recording all
thermocouples and providing information on temperature
differences and trends during the heating/cooling cycle.
 Calibration certificates shall be available at site.

27
Thermal Insulation:

 The insulation shall be extended to a minimum distance of

3 times the heating bandwidth. The number of layers and
extent of insulated area depends on:
(1) wall thickness (2) pipe or fitting diameter
(3) gradient requirements & (4) site condition

 But in all cases minimum two (2) layers of insulation with

minimum thickness of 50mm shall be used. Open ends to
pipe and/or fittings shall be blanked to avoid through
draught cooling during cycle.

28
Verification :

 For PWHT, after fixing the heating coils and the

thermocouples with proper connections with the recorder, the
arrangement shall be certified by the Authorized
representative of REAL QMD who shall sign on the graph to
indicate that the arrangements are certified. Then the
insulation shall be applied on the heating coils. Again after
attaining 300°C during heating, the graph shall be re certified
by REAL QMD representatives. This requirement shall be
treated as mandatory for the acceptance of Post heating
(electric heating) as well as for PWHT cycle except for
nitrogen purged/digital recorder.

 During PWHT cycle front door of recorder shall be kept in

closed condition. 29
Interrupted PWHT:

 Due to power loss, equipment failure & due to weather

condition/permit problem, there may be an interruption in
heat treatment cycle.
 If interruption occurs during heating period, the cycle can
be continued from the fallen temperature.
 If interruption occurs during soaking period, then the
soaking temperature shall be re -established from the
fallen temperature at a rate no greater than that specified
in code/established welding procedure and the soaking
cycle shall be repeated.
 If interruption occur during cooling period where
controlled cooling is required, then the complete PWHT
cycle shall be repeated. 30
Records
Prior to starting the electrical heating, the following information
shall be hand written on the recorder chart by the technician.
Date, ISO No’s, Agency’s Name, Weld Joint details, & Chart No
The charts shall be identified with ZXXX XXX / XXXX XXX
1 2 3 4
• Z indicates JERP,
• 1st 3 digits indicate unit number in numeric,
• 2nd 3 digits alphabetic for the name of immediate
contractor.
• 3rd four digits indicate name of the sub contractor
• 4th four digits indicates sequential numbering of the chart
e.g. Z312 RCC / HRIS 0001
Record of PWHT shall be maintained in the format
2 QM 00 FMT ME 138. 31
Checklist for the Stress relieving unit

 Check for condition of power cable

 Check for proper size of the Cable
 Check for glanding for all cables
 Check for lugging for all cables
 Check for tightness of all connection
 Check for sealing of all un used entry/openings
 Check for valid calibration certificate for the unit
 Check for provision against shock material (ELCB/No
openings)
 Megger value of the cables
 Earthing of unit and job
 And Check for Valid Risk assessment sheet availability

32
 CHAPTER-2: HYDRO TESTING

• References
• Purpose
• Equipment
• Pretest requirements
• System test pack
• Preparation of system for testing
• Test medium
• Testing procedure
• On revelation of leak
• Post test procedure
• Test records

33
 References

• 3PS- PL- 007 Specification for Piping Erection & Testing

• B 31.1 Power Piping

• B31.3 Process Piping

• IBR The Indian Boiler Code Regulations (1950)
• Iso Drawings For Field details & Line Identification,
Test limits
• P& ID For routing, continuity, completeness Test
Limits & code requirements
• LDT For Material class, Design pressure, Test
Pressure & type, test medium

34
 Purpose

Prior to initial operation & after completion of

applicable examinations each piping system shall be
tested to ensure leak tightness. The test shall be
hydrostatic leak test in accordance with ASME B31.3
para.345.4
Except,
At the owner’s opinion, a piping system in category D
fluid service may be subjected to service Leak Test
Where the owner considers a hydrostatic test
impracticable, either a pneumatic test or a combined
hydrostatic-pneumatic test may be substituted.

35
 Equipments

• Pressure gauges Ranging 1.5~4 times test pressure

• Filling Pumps
• Pumps for pressurization

36
 Pre Test Requirements

• Upon completion of erection, piping shall be checked for

completeness, supports, valve installation, proper gasketing etc
• System to be tested shall have mechanical & NDT clearance
• Temporary supports to be installed to withstand the test
medium weight if required.
• Spring supports should be locked during flushing & testing
• Pump/ Compressor/ Equipment Piping to be installed till break
point to avoid external loading on equipment connections.
• As Built drawings to be prepared by field Engineer & send to
Design department.
• Before hydrotest of IBR lines As built drgs to be approved by
IBR Authority.
• In case of chemical cleaning, refer specification 22960-3PS PL
37
013
• Spools to be free from dirt, lose foreign material.
• Hydrostatic test diagram showing the block limits
for testing a system as well as the type and test
pressure to be prepared by the field engineer
• Where it is not practical to include a closing weld
[Tie-In] in the pressure test, the weld shall be
tested and examined by RT/UT and DP/MPT
• All reinforcement Pads (RF pad) shall be pneumatic
tested at 1.5 Kg/sq.cm using suitable tapped hole.

38
 System Test Pack

• The contractor shall prepare a system pressure test package

for each test system, including a pressure test diagram based
on P & ID showing the extent of pipe work to be included in
each test.
• The test diagram shall indicate,
- All In Line components which are to be replaced with
temporary spools,
- All internals (applicable) are to be removed for the test, and
- All temporary test blinds and plugs used to isolate the
system being tested.
• The package shall include a sign off sheet with places for the
contractor, QMD and the client signatures and date for each
stage of inspection 39
 Preparation of Systems For Testing

• Temporary blind flanges, Instrument connections shall be

adequately gasketed to prevent damage to flange facings.
• Temporary blind flanges and test blinds used to isolate a test
system shall be of an adequate thickness to withstand the test
pressure, See Standard Drawing P14-RJ000-118.
• Control valves, thermo wells, orifice plates, strainer gaskets,
filter elements, expansion bellows, In Line instruments and all
other In Line components unable to withstand the test
pressure shall be removed and replaced with temporary spools
or spacers.
• PRV & Rupture discs shall not be included in the test.
• If the pressure is to be applied downstream of check valve, the
valves shall have their internals removed. 40
• All valves shall be included in pressure tests, Ball valves half
open & other valves fully open
• All temporary supports, spring support restraints, temporary
spools, blinds and plugs, etc, shall be prominently flagged or
painted bright orange or red to ensure their removal following
testing
• Minimum two test pressure gauge shall be located, one at the
high point of the system and other at the low point of the system
to have cross verification.Pressure gauges shall have current
certification of accuracy. All joints in piping shall be accessible
during test and shall not be insulated, backfilled or otherwise
covered until satisfactory completion of testing in accordance
with this specification, except joints may be primed and painted
prior to leak testing.

41
 Test Medium

• Clean, fresh water free of suspended solids and other

foreign matters shall be used for hydro test of CS piping,
Chloride content shall be less than 300 ppm.
• For testing Low Alloy, austenitic Stainless Steel (300
series) & Nickel alloy steel piping, test fluid shall not
contain more than 30 ppm chlorides.
• Minimum water temperature shall be 10 deg C
• Considering the possibility of brittle failure, Do not test
when metal temperature is below 5 deg C, this can also be
caused by wind chill.

42
 Testing Procedure

• Prior to filling the system with the test medium, the system
shall be inspected for fabrication completeness and
satisfactory test pack documents to be prepared and signed
by concerned QMD lead and disciplined engineer.
• After completion of flushing or purging, the area around the
system under test shall be cleared of unauthorised personnel.
• Liquid testing medium shall be introduced at the system low
point to avoid air pocket formation. Vents at high points shall
be left open and not closed until test medium flow from the
outlet
• Hydro test shall not commence till the test fluid temperature
is in equilibrium with pipe work system. Rate of pressure
increase shall be less than 5 bar/min.
43
• Pressurise the system to the specified test pressure and hold for
10 minutes to allow piping strain to equalise. Once achieved
inspect the complete system. Examinations for leakage shall be of
all joints and connections. The piping system exclusive of possible
localised instances at pump or valve packing shall show no visual
evidence of weeping or leaking. On completion of the check and if
no leaks are detected then leave the system for a further 30
minutes to complete the test.
• Testing at night shall be restricted to small systems only and at
ground level and there must be adequate illumination to detect
even the smallest leakage. There shall be no testing of systems in
pipe racks or elevated structures between sunset and sunrise.
• A system under test pressure shall never be left unattended. If a
test cannot be completed before the end of a work period, the
system shall be depressurised. The contractor shall be responsible
for all safety precautions and procedures during testing. 44
 On Revelation of Leakage

All defects revealed by the test shall, after approval by

the inspector, be repaired and, after inspection, be
retested as specified herein. At the discretion of the
inspector and where permitted by the relevant code
repaired defects may be retested by means other than
pressure testing (for example, 100% radiography and
MPI or ultrasonic examination).

45
Post Test Pressure

• Following the acceptance of a successful test, the system is

to be immediately depressurised and vented & drained in a
gradual and safe manner
• Vent to be opened before opening drain points.
• The system shall then be blown out with dry filtered air
(dew point -40°F) at 150°F (66°C) to 170°F (77°C) at a
velocity of 100 ft/Sec (30 m/Sec) until dry to the
satisfaction of the inspector.
• Replace all items removed for the test and remove all test
blinds, temporary supports, etc. Flange joints opened for
these purposes shall be remade with new gaskets.
• The inspector shall re-inspect the system for mechanical
completeness and sign off the package as complete.
46
 Test Records
• Records shall be made for each system tested which shall
include:-
– Date of test,
– Identification of piping test,[ Loops,spools,system etc ]
– Cross reference to test gauge certificate,
– Test medium,
– Test pressure,
– Test duration,
• Approval by the Inspector
• All test records and authorised Inspectors certifications shall be
retained in the job records.
• Format no- 2QM FMT PP 008
47
Check list for Hydro testing
 Make sure that system identification and test boundaries are
defined early and test packs are signed off
 Perform a pre test inspection by walking down the system for
completeness as per P&ID, tightness of flanged joints, and
checking of joints as applicable
 Establish test medium, test pressure, test boundaries for each
test including blind flange determinations
 Tag test boundaries as per approved procedures & as required
 Sample and test hydrostatic test medium to determine if it is
acceptable or detrimental to the vessel internals and alloy
piping
 Verify that gauges have been calibrated as per project
procedures and that the calibration due date is shown on the
test gauges
 Ensure the max test pressure is within 40% to 80% of gauge
range. Ensure min two gauges are used for pressure testing
 Check that the equipment and temporary piping have been
flushed prior to connection to system
 Verify that required test witness such as the client 48
representative have been notified in advance of scheduled test