1

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR - CORPORATE QUALITY

INDEX
Sl.No.
01
02
03
04
05
06
07
08

Description
Cover Sheet
Index
Preface
Foreword
Approval Sheet
Important Note
Status of Amendments
Table of Contents

Page No.
01
02
03
04
05
06
07
08

PREFACE
Construction activities at field are dominated by welding processes for assembly
and building critical products like boiler, boiler auxiliaries, electrostatic precipitator
and piping. Various welding processes are adopted at the field based on the
product requirements and reliability of the welds.

This document has been prepared to provide basic guidelines to all construction
personnel in ensuring effective process management of welding and allied
activities. The various aspects of process control covering the stages of planning &
preparation for welding, controls during welding and post welding requirements are
brought out in the form of specifications, norms and procedures/instructions in this
document. This manual has been updated to reflect the newer materials and
processes developed by BHEL.

The requirements specified in this document are based on the relevant codes/
specifications like IBR, ASME and AWS and also consolidates the experience of
BHEL good welding practices based on more than three decades of manufacturing
and erection. The document also provides DO s and DONT s for the benefit of
users, which would help in better process control and prevention of defects.

I am sure that this Manual would enable the construction activities in a big way to
manage their welding processes effectively to produce defect free quality.

A.V. Krishnan
General Manager (Corporate Quality)

FOREWORD
The present revision of the Heat Treatment Manual has been made with the contribution
from a team of BHEL Engineers having long experience in the areas like Construction Management,
Quality, Welding Technology & Heat treatment of manufacturing units and Power sector.

In this revision, the comments / suggestions offered by Power Sector / Regions, BHEL
HPBP Trichy, Piping Centre, HPEP Hyderabad & HEEP Haridwar and the minimum requirements of
reference codes have been taken care.

This manual deals with, apart from Heat Treatment requirements for BHEL-Trichy complex,
HEEP Haridwar & HPEP Hyderabad packages also. Heat treatment requirements for the new
material P91/T91 are dealt in detail for the benefit of site engineers.

We hope that the present volume will be very much handy and useful for all our site
engineers.

Any further feedback or suggestion is welcome to improve upon the the present
volume in due course.

Place : Chennai
Date : 09.11.2006

(D.Indran)
Executive Director
Power Sector - Southern Region

Page 4

HEAT TREATMENT M A N U A L
FOR
POWER SECTOR

PREPARED BY

NAME
V.KANDHSAMY
UM DESHPANDE
Dr. K.P.DHANDAPANI
P.ELANGOVAN
A.SUKUMARAN
D.DEVASAHAYAM
R.JANARTHANAN

APPROVED BY
A.V.KRISHNAN
DOCUMENT NO.

PSQ-HTM-COM
R01 / 11 06

DESIGNATION / DIVISION
AGM/ PSSR QLY, Chennai
AGM/ CQ, SECUNDRABAD
DGM / WTC-TIRUCHY
DGM / PC- Chennai
Manager/ SAS Cell - TIRUCHY
Manager/ PSSR-QLY, Chennai
Dy. Manager/ PC-Chennai

GENERAL MANAGER
/ CQ, NEW DELHI
ISSUE DATE

13.11.2006

COPY NO.
DATE OF ISSUE

ID No. : 1078
CONTROLLED COPY /
INFORMATION COPY

ISSUED BY
ISSUED TO :

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR / CORPORATE QUALITY

Page 5

IMPORTANT
THIS

HEAT

TREATMENT

MANUAL

PROVIDES

BROAD

BASED

GUIDELINES FOR HEAT TREATMENT WORK AT SITES. HOWEVER,

SITES MUST ENSURE ADHERENCE TO THE PRIMARY DOCUMENTS
LIKE CONTRACT DRAWINGS, ERECTION WELDING SCHEDULE, PLANT
/ CORPORATE STANDARDS, WHEREVER SUPPLIED, STATUTORY
DOCUMENTS,

WELDING

PROCEDURE

SPECIFICATIONS,

CONTRACTUAL OBLIGATIONS, IF ANY AND SPECIAL INSTRUCTIONS

ISSUED BY MANUFACTURING UNITS SPECIFIC TO THE PROJECT.

Page 6

7
STATUS OF AMENDMENTS

Page 7

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER - 1

TABLE OF CONTENTS
Description

Chapter

Page No.

Heat Treatment Procedure - Boiler and Auxiliaries

8-22

Heat Treatment Procedure - Steam Turbine, TurboGenerator and Auxiliaries

23-24

General

25

1.

Testing of Temperature Indicating Crayons

26

2.

Compatibility Test for Heat Treatment System

27-28

Page 8

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER - 1

CHAPTER-1
HEAT TREATMENT PROCEDURE - BOILER AND AUXILIARIES

Page 9

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER - 1

10

1. HEAT TREATMENT PROCEDURE - BOILER AND AUXILIARIES

1.0

PURPOSE:

1.1

This procedure provides information, method and control for Pre-Heat (PH) and Post
Weld Heat Treatment (PWHT) of welds at sites.

2.0

DOCUMENT:

2.1

The following documents are referred in preparation of this procedure:

2.1.1

ASME Sec.I

2.1.2

ASME B31.1

2.1.3

Indian Boiler Regulations

2.1.4

AWS D1.1

2.1.5

Welding Manual

2.2

The following are to be referred as Primary Documents:

-

Contract drawings
Erection Welding Schedule or equivalent

Plant / Corporate standards, where supplied

Welding procedure specification, where supplied

Contractual obligations, if any.

2.2.1

Where parameter for preheating and PWHT are not available in the primary documents,
reference may be made to this procedure.

2.2.2

Where such parameters are not contained either in the primary documents or in this
procedure, reference may be made to Manufacturing Units.

3.0

PROCEDURE:

3.1

Pre Heating (PH):

3.1.1

When parts of two different thicknesses are welded together, the preheating requirements

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HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER - 1

11

3.1.2 When parts of two different P numbers are joined together, the material requiring higher
preheat shall govern (please refer Welding Manual for P numbers).
3.1.3

Preheating shall be checked using thermal chalk (temperature indicating crayons) prior
to start of welding as well as at frequent intervals during welding. It is preferable to
have a thermocouple and a temperature recorder in case of alloy steels of
thickness > 50 mm.

3.1.4

In case of any interruption during welding, preheating temperature shall be maintained

at joint by wrapping dry thermal insulating blankets to ensure slow and uniform cooling.

3.1.5

Preheating Methods:

3.1.5.1 Preheating shall be applied by any of the methods given below:

a.

Electrical resistance heating

b.

Induction heating

c.

Oxy-acetylene or other gas torches

3.2

Post Weld Heat Treatment (PWHT):

3.2.1

The method shall be by locally heating a circumferential band including the entire weld
and adjacent area of base metal, by induction or electrical resistance heating.

3.2.2

Heat band for PWHT.

3.2.2.1 For Boilers:

a.

When heat treating welded joints in components in the boiler proper, width of the
heated circumferential band (W) on either side of the weld, W = 3 times the width
of the widest part of the weld groove but in no case less than twice the width of
weld at reinforcement.

b.

When used in post weld heat treatment in sections - W = 3 times the plate
thickness.

c.

For nozzle and other welded attachments - W must be wider than the nozzle or
attachment or 3 times the wall thickness.

3.2.2.2 For Piping:

W = 3 times the wall thickness of thickest part. In case of nozzles and attachment
welds, the width of the heat band shall extend beyond the nozzle or the attachment wall
on each side by at least twice the higher thickness and shall extend completely around
the header.

Page 11

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER - 1

12

3.2.2.3 Other Pressure Vessels:

Heat bandwidth, placement of thermocouple, preheat and PWHT information shall be
obtained from the supplier.
3.3

Condition of Welded Joints:

3.3.1

The weldment shall be free of grease, oil etc. prior to PH/PWHT.

3.4

Temperature Measurement for PWHT:

3.4.1

Post weld heat treatment temperature shall be measured and monitored by use of
thermocouples with calibrated recorders.

3.4.2

The periodicity of calibration of the equipment shall be as per calibration procedure.

3.4.3

Where the soaking temperature is found to be lesser than specified, the PWHT cycle
shall be repeated.

3.4.4

In case of interruption during PWHT, the following actions are to be taken, depending
on the stage during which interruption occurred.
a.Interruption during heating cycle:
-

The whole operation to be repeated from the beginning.

b.Interruption during soaking:

-

The joint can be treated subsequently for the balance left over soaking
period.

c.Interruption during cooling:

- Ensure slow cooling by covering with insulation to a minimum width of 1.5 times
the outer diameter applied equally about the centre line of weld, till the
temperature reaches around 300C.
3.5

Thermocouple (t/c) Fixing:

3.5.1

Thermocouples shall be used for recording Post Weld Heat Treatment temperatures.

3.5.1.1 Following are guidelines regarding number and placement of thermocouples:

3.5.1.2 Minimum of two thermocouples per weld.
3.5.1.3 Thermocouples located 180 apart.
3.5.1.4 Thermocouples located at top and bottom of weld.
3.5.1.5 Thermocouples located at a distance of approximately 1.5 times of the wall thickness
about the centre line of weld.
3.5.1.6 One point of the 6/12 points recorder shall be used for recording ambient temperature.

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HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER - 1

3.5.2

3.5.3

13

The following guidelines may be used for attaching thermocouples to job:

a.

For capacitor discharge method: Thermocouple elements should be attached

within 6 mm of each other.

b.

For other type of t/c: Insert the elements in a SS tube of internal diameter
approximately 6 mm. Apply force on tube and crimp it. Place this t/c and weld
the crimped button to the pipe in area of interest. Do not weld the elements.

c.

Insulate the t/c leads suitably and protect t/c ends from direct radiation from
heating elements.

For Bunched Tubes:

3.5.3.1 Where a bunch of closely placed tube welds (e.g. Super Heater/Reheater Coils)
require to be Post Weld Heat Treated, the same shall be grouped together as if they
form a single component.
3.5.3.2 In such cases attachment of a minimum of three thermocouples, two at the end tubes
and one at the middle is recommended.
3.6

Soaking Time:

3.6.1

Wherever not specified the soaking time shall be as per Tables I, II and III.

3.6.2

The following guidelines shall be used to determine the thickness and subsequent
selection of the soaking time of PWHT:
a.

For butt welds, the thickness shall be the thickness of the material at the weld.
For bar stock, the thickness shall be the diameter.

b.

For fillet welds, the thickness shall be the throat thickness.

c.

For partial penetration branch welds, the thickness shall be the depth of the
groove prior to welding.

d.

For repairs, the thickness shall be the depth of the groove as prepared for repair
welding.

e.

For combination of different welds in a component, the maximum thickness in

the definitions given above shall govern.

3.6.3

Soaking time is to be reckoned from the time temperature of the joint crosses the
recommended lower temperature of the cycle, to the time it comes down below the
same recommended lower temperature of the cycle.

3.7

Heating and Cooling Rates:

3.7.1

Wherever not specified, the heating rate above 300C and cooling rate after soaking
upto 300C shall be as follows: This is applicable for all materials.

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HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER - 1

Thickness of Material

Maximum Heating Rate Above

300C

14

Maximum Cooling
Rate Upto 300C

25 mm

220C/hour

220C/hour

> 25 50 mm

110C/hour

110C/hour

> 50 75 mm

75C/hour

75C/hour

> 75mm

55C/hour

55C/hour *

* For structural - 65C/ hour (Max.)

3.8

Temperature Records:

3.8.1

All the heat treatment cycles may be controlled within 10C around the
midpoint of the recommended range of temperature for the material.

4.0

POST WELD HEAT TREATMENT (PWHT) JOB CARD:

4.1

Prior to start of PWHT operations, a job card may be prepared including details of weld
reference, soaking time, soaking temperature, maximum rates of heating and cooling,
temperature recorder details, date of PWHT as per sample format.

4.2

On completion of PWHT the actuals may be recorded on the job card.

4.3

A chart number shall be given to each chart.

5.0

HEAT TREATMENT OF P-91 WELDS :

5.1

Please refer Welding Manual vide document No. PSQ-WDM-COM for heat treatment of
welds in P-91 materials.

5.2

HEAT TREATMENT OF T-91 WELDS:

5.3 Please refer Welding Manual vide document No. PSQ-WDM-COM for heat treatment of
welds in T-91 materials

Page 14

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER - 1

5.4

15

HEAT TREATMENT OPERATOR REQUIREMENTS:

The operator for the Heat Treatment shall be a qualified Electrician and should be
conversant in the operation & maintenance of heat treatment machines & Process. He
should be trained properly by the concerned Welding / Electrical Engineer in order to
handle/ maintain the machines / process without any trouble / problem.

6.0

LIST OF TABLES:
Table-I Weld preheat and PWHT for tubes and pipes outside diameter 102 mm.
Table-II Weld preheat and PWHT for Boiler Header welds.
Table-III Weld preheat and PWHT for pipes outside diameter > 102 mm.
Table-IV P Number and Group Number for Base Materials.
Table-V Pre-heat and PWHT for Non-Pressure Parts including Structurals.
Table-VI Preheat for Flame Cutting.

7.0

RECORDS :

7.1

Pertinent Records like Job card, PWHT Charts, shall be maintained.

Page 15

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER - 1

16

POST WELD HEAT TREATMENT (PWHT) JOB CARD

Project : ____________________
Card No. : ____________________

Date : ________________________

Unit No. : _____________________

Package : _____________________

Description :___________________

Temp. Recorder Details :

Weld Reference : _______________

1. Make : _____________________

Material Spec. : ________________

2. Type : _____________________

Size : Dia __________________ mm

3. Sl.No.: _____________________

Thick (t) ______________ mm

NDE Cleared on :_______________
Report No. :
_______________

4. Chart speed: ________ mm / hour

5. Calibration Due on : __________

Thermocouple Locations :
Minimum 2
d = 1.5 x t from weld centre
Heating Band = 6 x t
Insulation Band = 12 x t
Date of PWHT _________________
Start Time : ___________________

Chart No. : _____________________

End Time :_____________________
Required

Actual

Rate of Heating (Max) C/h

Soaking Temperature C
Soaking Time (Minutes)
Rate of cooling (Max) C

Ambient temperature recorded on the PWHT Chart: ____________

Contractor
Results : Accepted / Not Accepted

BHEL
Released for further processing

Page 16

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER - 1

17

TABLE - I
WELD PRE HEAT AND PWHT FOR TUBES & PIPES
OUTSIDE DIAMETER 102 mm
(Applicable For Butt Welds And Socket Welds)
P. No. of
Material

Thickness
(mm)

Preheat C

PWHT C

P1 Gr 1& SA 106
Gr C (Note 1)

19

Nil

Nil

Nil

Nil

>9

Nil

620 - 650

13

Nil

Nil

> 13

80 (Note 2)

620 - 650

13

125

Nil (Note 3)

> 13

125

650 - 670

150

Nil (Note 3)

>8

150

700 - 750

P5 B Gr 2

All

220

730 - 760

P8

All

Nil

Nil

12 x 1M

All

200

730 - 760

P1 Gr 2

P3 Gr 1

P4 Gr 1

P5 A Gr 1

Note 1 : For SA 106 Gr .C with less than 0.25 % carbon content .

Note 2 : Pre-heating is necessary for t>16mm.
Note 3 : Less than 0.15 % carbon content .

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HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER - 1

18

TABLE - II
WELD PREHEAT AND PWHT FOR BOILER HEADER WELDS
(NOTE - 3)
(Applicable For Welding of Header to Header Joints)
P. No. of
Header Material

Thickness
(mm)

Preheat
C

Post Heating
C

PWHT
C

t 19

Nil

Nil

Nil

19 < t 25

Nil

Nil

595 - 625

25 < t 75

100

Nil

595 - 625

t > 75

150

Nil

595 - 625

t < 19

Nil

Nil

620 650

19 < t 25

Nil

150
for 2 hours

620 - 650

19 < t 75

100

150
for 2 hours

620 - 650

t > 75

150

P4 Gr 1

All

P5 A (Note 1)
12 x 1M

P1Gr 1

P1Gr 2

150

150
for 2 hours
Nil

640 - 670

All

150

250 for 2 hours

680 - 710

All

200

Nil

710-740

620 - 650

Note :
1.

All P5A headers shall be inter stage heat treated at 700 - 750C for 30 minutes
soaking prior to any cold straightening operation. In lieu of this, the straightening
can be done after final PWHT. Any P5A Header with weld thickness above
50mm requires inter stage H.T. at 700-750C for 30 minutes soaking minimum
(max. shall be limited to 2.5 minutes/mm of thickness).

2.

Soaking for PWHT shall be at the rate of 1 hour per 25 mm of thickest weld (but
not less than 30 minutes for carbon steel and 1 hour for alloy steel). Soaking
time for 12 x 1 M header material shall be 4 minutes per mm of the applicable
thickness with a minimum of 180 minutes.

3.

Seal welding of Hand Hole Plates, Radiographic plugs and Screws can be
carried out after final PWHT, provided the preheat is carried out as per the
table.
For P number and Group number refer Table - IV.

4.

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HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER - 1

P No. of
Material

P1 Gr 1
&
SA106
Gr C

P1 Gr 2
&
SA 106
Gr C

Thickness
(mm)

TABLE - III
WELD PREHEAT AND PWHT FOR PIPES
OUTSIDE DIAMETER >102 mm
Stub and Attachment welds
Note 1
BUTT WELDS
&2
Throat 19 mm
Throat > 19 mm
Preheat
PWHT

(Note 3)

Preheat
C

PWHT
C

Preheat
C

19

Nil

Nil

Nil

Nil

Nil

>1925

Nil

595 625

Nil

Nil

Nil

595 625

Nil

>2575

150

595 625

150

Nil

150

595 625

Nil

>75

150

595 625

150

600650

150

595 625

Nil

Nil

Nil

Nil

Nil

Nil

620 650

Nil

>919

Nil

620 650

Nil

600650

Nil

620 650

Nil

>19

150

620650

150

600650

150

620 650

150 for
2 hrs

75

125

640670

125

650680

125

640670

Nil

>75

150

640670

150

650680

150

640670

Nil

Pipes

150

680 750

150

700750

150

680750

250 for
2 hrs

Castings &
Forgings

220

680750

250 for
2 hrs

All

220

750770

220

750770

220

750770

280 for
2 hrs

All

220

730760

220

730760

220

730760

280 for
2 hrs

P5 A

P5B Gr2
+
P5 A

Post
heat C

P4 Gr 1

P5B Gr2
+
P5B Gr2,

19

680750

150

700750

150

PWHT
C
595 625

Nil

Note :
1.

Irrespective of the stub or attachment materials, the PWHT cycle shall be governed by the pipe
material.

2.

Throat shall be specified in the drawing. Wherever flanges are welded to pipes combined throat
shall be taken into consideration.

3.

Post heating shall be done immediately after welding.

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HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER - 1

4.

20

For butt welds of different P group combinations, PWHT temp. may be as follows:
P1 + P3

620 to 650C

P1 + P4

640 to 670C

P4 + P5A

680 to 720C

(For other P Group combinations, refer to Engineering)

5.

a.

For P1 & P3 materials soaking time shall be 1 hour per 25mm up to 50mm
thickness and 2 hours + 15 minutes for each 25mm thickness over 50mm.

b. For P4 & P5 materials, soaking time shall be 1 hour per 25mm up to 125mm
thickness and 5 hours + 15 minutes for each 25mm thickness over 125mm.

6. For P number and Group number refer Table IV.

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HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER - 1

21

TABLE - IV
P NUMBER AND GROUP NUMBER FOR BASE MATERIALS
P.No Group
No.

Common
Name
Carbon
Steels

Tubes
SA192

Pipes
SA106GRB

SA210GRA1

P1

Plates
SA36

Forgings

Castings

SA266CL1

SA216WCA

SA515GR55

SA352LCA

SA515GR60

SA352LCB

Fittings
SA234WPB

SA515GR65
SA516GR55
SA516GR60
SA516GR65
Carbon
Steels

P1

P3

P4

P5A

P5B

P8

SA106GRC

P3

P8

SA210GRC

Carbon-Moly
Steels
CrMo
Steels
1CrMo/
1CrMo
Steels
2Cr1Mo
Steels
9Cr1MoV
Steels
18Cr-8Ni
Steels

SA515GR70

SA266CL2

SA216WCB

SA105

SA516GR70

SA216WCC

SA234WPC

SA299

SA352LCC

SA209T1

SA335P1

SA217WC1

SA213T2

SA335P2

SA387GR2

SA213T12/

SA335P12

SA387GR12

SA182F12

SA213T11

SA335P11

SA387GR11

SA182F11

SA213T22

SA335P22

SA387GR22

SA182F22

SA213T91

SA335P91

SA387GR91

SA182F91

SA213TP304

SA376TP304

SA240TP304 SA182F304

SA351CF3

SA213TP304H SA376TP304H

SA240TP321 SA182F321

SA351CF8

SA213TP347

SA376TP321

SA240TP347 SA182F347

SA351CF3M

SA213TP347H SA376TP347

SA336F304

SA351CF8M

SA213TP321

SA336F321

SA351CF10

SA336F347

SA351CF10M

SA217WC6

SA234WP12
SA234WP11

SA217WC9

SA234WP22
SA234WP91
SA403

25Cr-20Ni
Steel (Type 310)

SA376TP347H

SA240TP310 SA182F310

SA351CK20

Note : IS1239 & API 5L GR B Pipes, IS2062 Plates may be treated as P No.1 Gr No.1 material.

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HEAT TREATMENT MANUAL FOR POWER SECTOR

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22

TABLE - V
PREHEAT AND PWHT FOR NON PRESSURE PARTS INCLUDING STRUCTURALS
P.No. of
Material /
Material
Specification

Gas Cutting

Welding

Thickness
(mm)

Preheat
C

Thickness
(mm)

Preheat
C

50

Nil

38

Nil

> 38 63

100

> 63

120

10< < 200

150

P1 / IS 2062
> 50
IS 8500
540
Ceiling
Girder

100

PWHT
C
600-650
a)All butt welds > 50
mm thick
b)Any welds to a
tension member
600-650(Soaking time
2.5 Mts. Per mm.
Minimum 120 Mts )
650-700

25

Nil

P4

All
> 25

P5

All

150

b)All fabricated components > 16mm

thick (Note 3)

150

150

a)All butt welds in

tension member

All

150

680-730
All welds
(Note 4)

NOTE :
1.

All gas cut edges may be chipped off, ground or machined to remove the HAZ with
3mm minimum removal.

2.

Clip angles above 10mm, used for beam connections, which are sheared to length,
shall require heat treatment.

3.

All fabricated structural components of P-4 material, with any member above
16mm thickness, the entire assembly shall be post weld heat treated.

4.

All welds of P5 material shall be post heated at 250C for 2 hours or 150C for
4 hours immediately following welding.

5.

Soaking time shall be as below :

a. P1 and P3 materials one hour per 25mm up to 50mm thickness and
2 hours + 15 minutes for each 25mm thickness over 50mm.
b. P4 and P5 materials one hour per 25mm up to 125mm thickness and
5 hours + 15 minutes for each 25mm thickness over 125mm.

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HEAT TREATMENT MANUAL FOR POWER SECTOR

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23

TABLE - VI
PREHEAT FOR FLAME CUTTING
P.No. of Material

Thickness (mm)

Preheat C

P1 Gr 1

< 25

Nil

(Note 1)

25

100

All

150

> 100

150

All

150

All

150

P1 Gr 2
(Note 1)
P3
(Note 1)
P4
(Note 1)

P5
(Note 2)
NOTE :

1. For P1, P3 and P4 materials, when the flame cut edge will be machined
after cutting and when no forming operation is required after cutting, no
preheat is required for flame cutting.
2. P5 materials, except when the part is scheduled for hot forming, shall be
inter stage heat treated at 700-750C for 30 minutes minimum after
flame cutting and prior to any welding. As an alternative to this heat
treatment, a minimum 3 mm of the gas cut edge may be removed by
machining, grinding, chipping, etc.

Page 23

HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -2

23

2. HEAT TREATMENT PROCEDURE STEAM TURBINE, TURBO-GENERATOR AND AUXILIARIES

Procedure for Post Weld Heat Please refer Plant Standard,

treatment of Pressure Vessel as Haridwar - HW 0980814
per ASME code Section VIII,
Div.I

For other Components

HEEP,

Please refer Heat treatment ProcedureBoiler and Auxiliaries of Chapter-I

CHAPTER -2
HEAT TREATMENT PROCEDURE STEAM TURBINE, TURBO-GENERATOR AND AUXILIARIES

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2. HEAT TREATMENT PROCEDURE STEAM TURBINE, TURBO-GENERATOR AND AUXILIARIES

Procedure for Post Weld Heat Please refer Plant Standard,

treatment of Pressure Vessel as Haridwar - HW 0980814
per ASME code Section VIII,
Div.I

For other Components

HEEP,

Please refer Heat treatment ProcedureBoiler and Auxiliaries of Chapter-I

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HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -3

25

CHAPTER - 3
GENERAL

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HEAT TREATMENT MANUAL FOR POWER SECTOR

CHAPTER -3

26

3. GENERAL
1. TESTING OF TEMPERATURE INDICATING CRAYONS
1.0

SCOPE :

1.1

This procedure details the method of batch testing of Temperature indicating Crayons
(Thermal chalks).

2.0

PROCEDURE :

2.1

Setup:

2.1.1

Rig a test heating arrangement including a test pipe/plate heating arrangements with
controls and a calibrated temperature recorder/thermometer.

2.2

Heat the test pipe / plate (specimen) to a temperature 10 lower than the rated
temperature of the thermal chalk in study, monitoring the temperature through
thermometer/recorder.

2.3

Stroke the thermal chalk as close to the sensing point on the specimen.

2.4

Raise the temperature of the specimen gradually up to 10% higher than the rated
temperature of the thermal chalk in study, stroking the thermal chalk on the specimen
during this period.

2.4.1

When the thermal chalk changes to the specified colour or melts (depending on the
type), within 5 of the rated temperature, the thermal chalk is acceptable.

2.5

Consistent results for 2% of any brand and temperature will qualify the brand for the
rated temperature.

2.6

Where thermal chalks are accepted brand wise, they shall undergo this test at least
once a year.

3.0

RETESTS :

3.1

Any failure in the 2% sample chosen, will call for additional 4% for qualification of the
brand for the rated temperature.

3.2

Where retest results in further non-acceptance, the brand shall stand rejected for the
particular temperature.

4.0

RECORDS :

4.1

Records of testing and brands accepted/rejected including details of calibrated

devices used in the setup shall be maintained.

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2. COMPATIBILITY TEST FOR HEAT TREATMENT SYSTEM

1.0

SCOPE :

1.1

This

procedure

provides

for

checking

the

compatibility

and

accuracy

of

thermocouples, compensating cables, temperature recorder, connected in Heat

Treatment (HT) operations at sites.
2.0

HT TEST SYSTEM :

2.1

The thermocouple (type k-chromal-Alumel is generally used at sites) attached to a test

specimen with heating arrangements and controls, compensating cables, a calibrated
temperature recorder rigged together for the test HT system.

2.2

A calibrated (accuracy 0.5%) direct-reading thermometer (like a digital thermometer

with sensor) is used for verification.

2.0

PROCEDURE :

3.1

Attach the thermocouple as detailed in Chapter I of this manual.

3.2

Raise the temperature of the test specimen to around 200C and maintain the same.

3.3

Place the sensor of the direct reading thermometer as close to the thermocouple
junction as possible.

3.4

Wait till the temperature stabilises.

3.5

Note reading of the thermometer and that of the temperature recorder.

3.6

Repeat steps 3.2 to 3.5 for test specimen temperatures of 400C and 600C

3.7

Where the temperature read by the temperature recorder is within 10C with respect
to the thermometer, the HT system is compatible.

3.7.1

Where the results are not within the tolerance specified above, further tests are to be
repeated to identify the fault either in thermocouple or compensating cable or both.

3.8

Adequate insulation of thermocouple, sensor from direct radiation of heat elements

shall be ensured as a precaution throughout the test.

3.9

This compatibility is recommended for each of the thermocouple available for use; this
procedure validates the thermocouple also.

4.0

RECORDS :

4.1Records pertaining to the test, shall be prepared and maintained.

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28

Compatibility Test for HT System

Site :

Report No.
Date :

Details

Temperature Recorder

Thermometer

Make:
Model:
Sl. No.:
Range:

Test Results
Temperature Reading C
Sl. No. t/c No. C/C. No.

Recorder Thermometer

Difference C Results*

Record results (Accepted/Rejected) where rejected, record the faulty component as

required by 3.7.1

Witnessed by

(Name & Signature)

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