0 | May 13,08 INITIAL ISSUE, LHKang S.C.Hong REV.| DATE, DESCRIPTION SGN ‘CHKD ‘PPD ASME FOR APPROVAL OWNER MINISTRY OF Syst aya che ELECTRICITY & WATER STATE OF KUWAIT pee ee POWER STATION AND DISTILLATION PLANT PROJECTS SECTOR PRONCT TILE SHUAIBA NORTH COGENERATION (POWERIDISTILLATION) PLANT CONTRACT NO : MEW/C/3656-2007/2008 ae a > mitsuieco.,erp. | A HYUNDAI PWHT Procedure for ASME See.I ‘APPROVED BY | DATE S.CHong | May 13,08 SCALE DOCUMENT NUMBER REV. J/PG/ARSG-HRB-905 0SHUAIBA NORTH COGENERATION (POWER/DISTILLATION) PLANT Heat Treatment Procedure _for ASME Sec.1 Revd Table of Contents 1.0 Scope 20 Responsibilities 3.0 Base Material 40 Preparation of Assemblies For Postweld Heat Treatment 5.0 Methods of Postweld Heat Treatment 60 Postweld Heat Treatment 70 Postweld Heat Treatment of Repair Welds 8.0 Documentation And RecordsSHUA (IBA NORTH COGENERATION (POWER/DISTILLATION) PLANT Heat Treatment Procedure for ASME Sec.l Revd 1.0 20 24 22 3.0 4.0 44 42 43 44 5.0 5.4 5.2 Scope This procedure shall govern the post weld heat treatment of weldments fabricated in accordance with the requirements of section | of ASME Boiler and Pressure Vessel Code. All postweld heat treatment shall be in compliance with PW 39 of SECTION | of the ASME Boiler and Pressure Vessel code. Responsibilities, Production Eng. Dep't is responsible for preparing Heat Treatment Work Instruction based on this procedure. Production department shall perform the operation of postweld heat treatment under Heat Treatment Work Instruction and its details shall be recorded on the Heat Treatment Record Base material ‘The base materials used in the fabrication of weldments to be postweld heat treated in accordance with this procedure shall be listed under P No. of Table QW422 of Section IX Preparation of assemblies for postweld heat treatment Postweld heat treatment shall be done before the hydrostatic test and after repair welding if is done. All areas of the component subject to the postweld heat treatment shall be cleaned of oil, grease, dirt and other foreign materials All welds to be postweld heat treated shall have sufficient thermocouples to ensure correct measurement of temperature and adequate temperature control. (Not less than one of thermocouple is required every 4.6m interval of length.) These thermocouples shall be calibrated regularly to avoid inaccuracy. The thermocouples shall be fixed on the weldments in appropriate methods, such as adhering with high-temperature cement, welding. If welding is used, the welds shall be removed by grinding or other suitable method, and the area shall be ‘examined by MT or PT and met the acceptance criteria of the N.D.E procedure. Methods of postweld heat treatment The weldments shall be postweld heat treated by any of the following methods. 5.1.1 Heating a complete assembly as a unit or parts in the furnace, 5.1.2 Heating sections by electric resistance heaters. (Local Heat Treatment) ‘The operation of postweld heat treatment in the furnace shall be performed using one of the following procedures. 4) Heating the weldments as a whole in an enclosed fumace. 2) Heating the weldments more than one heat in a furnace provided the overlap ofSHUAIBA ‘NORTH COGENERATION (POWER/DISTILLATION) PLANT. Heat Treatment Procedure for ASME Sec.l Rend 5.2.1 5.22 5.23 5.24 53 5.3.1 5.3.2 5.33 the heated sections of weldments is at least 1.5m (5ft). In the case, the portion outside of the furnace shall be wrapped with asbestos for a distance of 1m(3ft) from the furnace door so that the temperature gradient is not harmful. More than one assembly of weldment or part may be postweld heat treated in one heat. If necessary, to control the true temperature of all assemblies and parts, the thermocouples shall be placed on the weldments at the bottom, center and top of the charge or in other zones of possible temperature variation. Weldments of different thickness may be postweld heat treated in the same furnace charge on a basis of the requirements for the thickest of the weldments in the charge. The assemblies of weldment or parts shall be placed inside the furnace with a distance of minimum 0.3m (1ft) from the furnace door. The assemblies of weldment or parts shall be supported by proper means with minimum 0.25m above the furnace hearth to prevent the possible distortion and assure uniform heat flow. The local postweld heat treatment shall be performed by uniformly heating and the portion outside of the heated band shall be protecied so that the temperature gradient is not harmful In the case of heat treatment of longitudinal of circumferential seam, a band shall have @ minimum width of 3 times the wall thickness on tach side of the welded joint. In the case of heat treatment of nozzles or other welded attachments, the circumferential band Around the entire vessel with the welded connection located at the middle of band shall have at least 3 times of wall thickness beyond the welded joint. In the case of heat treatment of welded joints in pipes, tubes and headers, the width of the circumferential band shall be at least 3 times the width of the widest part of welding groove but in no case less than twice the width of the weld reinforcement. 6.0 Postweld heat treatment 64 614 When pressure parts of two different P No. groups are joined by welding, the postweld treat treatment shall be followed the requirements of higher postweld heat treatment temperature, except as noted in para. 6.1.1 When non-pressure parts are welded to pressure parts, the postweld heat treatment temperature of the pressure parts shall control. Partial penetration and fillet welds attaching P-No. SA tubes and pipe to headers of lower P No. material may be postweld heat treated at the temperature specified in Table PW-39 of ASME Sec.I for the lower P No. material provided the tubes or pipe comply with all the following condition 1) Amaximum specified chromium of 3.0% 2) Amaximum nominal outside diameter of 100 am(4") 3) Amaximum thickness of 13m (1/2") 4) Amaximum specified carbon content of not more ‘than 0.15%SHUAIBA NORTH COGENERATION (POWER/DISTILLATION) PLANT Heat Treatment Procedure for ASME Sec. Rev.) 6.2 The minimum holding time at temperature for postweld heat treatment shall be selected from Table PW-39 of ASME Sec.| and shall be based upon the nominal thickness at the weld. The nominal thickness is defined as the thinner of one of the following thickness. 1) The thickness of the weld 2) Pressure retaining materials, or 3) The thinner of the parts being joined. For combination groove and fillet welds, the nominal thickness is the total combined thickness of the deposited weld, groove depth plus fillet weld throat. 6.3 The temperature of the furnace shall not exceed 425'C(600'F) at the time the weld assembly or part is placed in it. 6.4 Heating and cooling The weldments shall be heated slowly to the temperature specified in Table PW-39 of ASME Sec.| and held for the specified time, and shall be allowed to cool slowly in a still atmosphere to a temperature not exceeding 425°C (80°F). Several weldments of varied thickness may be postweld heat treated in a same furnace at the same time. 6.4.1 Heating rate ‘Above 425°C (800'F), the rate of heating shall be not more than 5550°C/h divided by the maximum metal thickness of the shell or head plate in millimeters (‘T’, in. but in no case more than 222°C/h. * 4) During heating period there shall not be a greater variation in temperature throughout the portion of the vessel being heated than 139°C within any 4.6m (16ft) interval of length. 2) During the heating and holding periods, the fumace atmosphere shall be so controlled as to avoid excessive oxidation of the weldments. The furnace shall be of such design as to prevent direct impingement of the flame on the weldments. 64.2 Cooling rate Above 425°C (80°F), cooling shall be done in a closed furnace or cooling chamber at a rate not greater than 6950°C/h divided by the maximum metal thickness of the shell or head plate in millimeters (‘T’, in.), but in no case more than 278°C/h from 425'C(800°F) the components may be cooled in stil air. 6.4.3. The rates of heating and cooling need not be less than 55’C/h (100°F /h). 65 The weld assembly or part shall be held at or above the temperature specified in ‘Table PW-39 of ASME Sec.| for a period of time specified in the Table. Maximum temperature of PWHT shall not exceed lower critical temperature of base material 6.5.1 During the holding period, there shall not be a greater difference than 83°C (150°F) between the highest and lowest temperature indicating by duly calibrate thermocouples throughout the portion being heated. The holding time at temperature specified in the table need not be continuous.SHUAIBA NORTH COGENERATION (POWER/DISTILLATION) PLANT Heat Treatment Procedure for ASME Sec. Rend 6.5.2. When it is impractical to postweld heat treatment at temperature specified Table PW-39 of ASME Sec.l, it is permissible P No. 1 and P No. 3 to carry out the postweld heat treatment at lower temperature for longer periods of time specified in Table Il Table II, Alternative Postweld Heat Treatment ' = Decrease in Temp. Below | Mir Holding Time(tiote 1) as ae Min, Specified Temp "C" | Temp, Hr/25 ma of thickness 28 (50°F) 2Hr 56 (100°F) 4Hr 83 (150°F) 40 Hr “) 414 (20°F) 20 Hr 0 Mark (*) these lower postweld heat treatment temperatures permitted only for P-No. 1 group 1 and 2 materials. Notes: (1) Minimum holding time per inch for thickness up to and including 2 inch add 15 minutes per inch of thickness for thickness greater than 2 inch. (51mm) 7.0 Postweld heat treatment of repair welds The preheating and postweld heat treating rules shall apply to all weld repairs made to pressure parts except as follows. Repair welds may be made to tube-to-header or tube-to-drum welds after postweld heat treatment without requiring an additional postweld heat treatment provided that following conditions are met; 7.1 The depth of any rework welding below the surface shall not exceed the smaller of 10% of the thickness of the drum or header, or 50% of the wall thickness of the tube. 7.2 The area to be rework welded shall be preheated to at least the minimum temperatures as indicated in Table II! for the material; Table Il Material (P-Number) Min. Preheat Temp P-No.4 95% (200°F) P=No.3Gr4,2 95°C (200°F) [RP -Noa | 120% (250°F) | P-No. 5A 150°C (300°F) 7.3 The tubes shall not exceed 100 1m(4") ©.D. except for P No. 1 material, which shall not exceed 170 mn(6-5/8") O.D. 8.0 Documentation and records 8.1 All postweld heat treatment operation shall be recorded on time-temperature charts or temperature logs which reveals the heating rate, holding temperature and time, cooling rate and identification of weld assembly or part.SHUAIBA NORTH COGENERATION (POWER/DISTILLATION) PLANT Heat Treatment Procedure for ASME Sec.l Rend 82 All these records shall be maintained in manufacture's file and shall be furnished to customer at his request. Attachments Attach.#1 :Heat Treatment Work Instruction Altach.#2 : Heat Treatment RecordSHUAIBA NORTH COGENERATION (POWER/DISTILLATION) PLANT Heat Treatment Procedure for ASME Sec.] Rend Attachment #1 : Heat Treatment Work Instruction HEAT TREATMENT WORK INSTRUCTION HIWINO HS ER* we ET Se ameeoitor PROJECT NAME Tekh WORK ORDER NO LA8# ITEM NAMENNO PROCEDURE NO IER * Poi Bi eS * REVNO. {$i7 8 TYPE OF HEAT TREATMENT 3. 70 © POST FORMING/BENDING #8 B2Y/85 #1 CO POST WELD #917 9h.038 © ANNEALING ELA (© QUENCHING PF © NORMALIZING TE © TENPERING Bl HEAT TREATMENT CONDITION 3h it Bie FF HEAT TREATMENT METHOD sh 38773% > O PULL tk © LOCAL Fa COOLING METHOD #20253% > © FURNACE sR #F © ATMOSP 22% WATER AK (© UNDER INSULATION #248 4h Fa" HEATING SOURCE 48 Bi © CAS & — © OTL ith © ELECTRIC RESISTANCE BB ‘THERMOCOUPLE 2418 = © ALUMEL CHROMAL gt 2% © OTHERS 3th MAX. ALLOWABLE VARIATION IN TEMP. DURING HEATING AND COLLING ‘tak A100) BA bia BE fb: HEAT TREATMENT CYCLE. 3 3t #25) MIN. HOLDING TIME i-1>a a ComR MIN.) HEATING RATE Onda a3 COOLING RATE #8085 (MAK. EK T/R) ck (MAK EK T/ HR) nov! sh ABOVE: oak LOCATION OF THERMOCOUPLE 2 t (8f2EE "T" = THERMOCOUPLE MATERIAL 2 WOWINAL THICKNESS BREE 7] PREPARED BY | APPRIVEDBY | REVIEWEDBY | REMARKS 4&7 ir id Sire ne = [ Peoeprencieer | PEDEPTMANAGER | QESECT. MANAGER 0SHUAIBA NORTH COGENERATION (POWER/DISTILLATION) PLANT Heat Treatment Procedure _for ASME Sec. Rev.d Attachments #2 : Heat Treatment Record HEAT TREATMENT RECORD pecs! Ae BR a Poject Name Work Order No. Tee IBY ttem Name Mfr-Ser. No. SiH ue HS Procedure No. Rev. PCD & Step No. a ery sect Drawing No. Rev. Instruction No. Rev. a9 wiry esl 8 1608 Pati No BS SPECIFICATION # cara Heating Rate | Holding Temp Holding Time Cooling Rate AIH FRE CRA Ra (8 RE C/Hr c Hr min CH Prepared by Verified by al Furnace Operator iE QE Sect RULER RE Qe OPERATION _ fF Heating Rate Holding Temp Holding Time: Cooling Rate FR Rie Raa Pd aD ME ‘C/Hr c He min C/A Temp. Measuring Type of Furnace Chart No. Thermocouple No. | Equipment No. af HRS aoe BS Approved by = 00 b Reviewed bt Resp. Sect Manager iar Resp. AC 8 a teak Approved by 7 pevewss ail a ae ad we Customer Be Remarks ‘tt