TCM Division

THERMAL PROCESS PROCEDURE 032309-01, Rev. 0

BULL’S EYE POST WELD HEAT TREATMENT (PWHT)

Per
ASME BPVC SECTION VIII DIV. 1
NBIC RD-1100

VESSEL V-4
NOZZLE K3A ATTACHMENT WELD
SA-285-C & SA-106-B (ASME P-No. 1) CARBON STEELS

For
PETROLEOS DE VENEZUELA S.A. (PDVSA)
Cardon, Venezuela

By
TEAM INDUSTRIAL SERVICES, INC.
Estado Falcon, Venezuela

March 23, 2009

PDVSA Approval: ______________________ ____________________ _______

Signature Title Date

Team Approval: ______________________ ____________________ _______

Signature Title Date
 Written By:
BULL’S EYE PWHT STRESS RELIEF
TCM ASME BPVC SEC. VIII & NBIC RD-1100
Thompson/Martin
Approved By:
DIVISION Nozzle K3A Attachment Weld on Vessel V-4 M. Goita
Rev.: Date:
PAGE 1 of 11 Field Procedure 032309-01 0 3/23/09

1.0 OVERVIEW

The following table summarizes the specifications for this thermal processing procedure.

PARAMETER SPECIFICATION
Client Petroleos De Venezuela S. A. (PDVSA)
Location Cardon, Venezuela
Work Piece Identification Vessel V-4
Weld Identification Nozzle K3A attachment weld
Head & Nozzle Material SA-285-C & SA-106-B (ASME P-No. 1) CS
Head Thickness & Inner Diameter 1-1/8-inch (28.5 mm) & 4-ft (1219 mm)
Nozzle Dimensions 2-inch NPS, 2-3/8-inch (60 mm) O. D.
Governing Codes Section VIII, ASME BPVC, and NBIC
Heating Method Electric Resistance Heat Treating System
PWHT Soak Temperature 1150 °F (795 oC) ± 25 °F (14 oC)
PWHT Soak Time 2 hours, minimum
Max. Heating Rate above 800 °F 240 °F/hr (133 °C/hr)
Max. Cooling Rate above 800 °F 300 °F/hr (167 °C/hr)

2.0 SCOPE

2.1 Background

Welding produces high temperatures, severe temperature gradients, and rapid cooling and
solidification which increase residual stresses, grain size, and brittleness in the weld and its
adjoining base material, which in turn can reduce fatigue life, corrosion resistance, and
dimensional stability of the weldment assembly. Post weld heat treatment (PWHT) can
relieve these ill effects by reducing residual stress and hydrogen content, and by restoring
ductility and corrosion resistance.

2.2 Purpose

The purpose of this procedure is to define specifications for a Bull’s Eye PWHT of nozzle
K3A attachment weld on vessel V-4 in compliance with ASME BPVC Section VIII Div. 1
and NBIC requirements. This procedure identifies the locations and attachment methods for
thermocouples, electric resistance heaters, and thermal insulation, to ensure that client and
code requirements for heating, soak, cooling, and gradient control are achieved.
 Team PWHT Procedure 032309-01, Rev. 0 Page 2 of 11

2.3 Governing Documents

• The 2007 edition of Section VIII, Division 1 of the American Society of Mechanical
Engineers (ASME) Boiler and Pressure Vessel Code (BPVC)
• Paragraph UW-40 for soak band width requirements
• Table UCS-56.1 for PWHT soak temperature and time
• Article UCS-56 for heating and cooling rates
• The 2004-06 edition of the National Board Inspection Code (NBIC) RD-1100
• An as yet unidentified PDVSA welding procedure specification (WPS)

2.4 Technical Approach

Electronically controlled electric resistance heaters, in conjunction with thermocouples and

thermal insulation will be utilized to create a bull’s eye heated band (HB) concentric to the
nozzle neck attachment weld, of sufficient size to ensure that the soak band (SB) achieves
PWHT soak temperature. The HB and insulation assisted gradient control band (GCB) are
utilized to avoid exceeding NBIC maximum allowable temperature gradients.

2.5 Procedural Tasks

The majority of the tasks described in this procedure are within Team's scope of activity.
However, the purpose of this document is to describe those tasks or activities, and not to
assign responsibility for them. The Team supervising technician will coordinate with the
client to assign these duties, and is empowered to make minor alterations to this procedure,
such as heater selection, in order to improve the quality of the PWHT by accommodating
variations in available equipment and space. Major revisions must be approved by the
client and Team’s Technical Support Group (TSG), to ensure that the PWHT is not
compromised in any way.

3.0 VESSEL AND NOZZLE DETAILS

Vessel V-4 and nozzle K3A are illustrated in PDVSA 3-sheet design drawing RCN-523.864, Rev.
5, of December 11, 2008. Primary details are summarized below.

• Vessel Configuration: Horizontal cylindrical bullet on 2 saddle supports

• Shell & Head Material: SA-285-C (ASME P-No. 1) carbon steel
• Shell & Head Thickness: 1-1/8-inch (28.5-mm)
• Shell Inner Diameter: 4-ft (1.219-m)
• Nozzle Material: SA-106-B (ASME P-No. 1) carbon steel
• Nozzle Size & Position: 2-inch NPS on right-side head, near top of shell centerline
• Nozzle Location: 16-15/16-inches (430 mm) above central axis
• Nozzle Thickness: Schedule 160, 0.344-inch (8.7 mm) wall thickness
• Nozzle Weld Size: 0.55-inch (14-mm) fillet
• Total Weld Thickness: Head + fillet = 1-11/16-inch (43-mm)
 Team PWHT Procedure 032309-01, Rev. 0 Page 3 of 11

4.0 UW-40 REQUIREMENT FOR ATTACHMENT WELD SOAK BAND (SB) WIDTH

Paragraph UW-40 (a) (7) requires that the local PWHT of a nozzle attachment weld employ a soak
band that shall extend beyond the weld in all directions a minimum distance of the wall thickness
or 2 inches, whichever is less, as illustrated in Figure 1, below.

The Lesser The Lesser

of t or 2" of t or 2"

t
The Lesser of t or 2" The Lesser of t or 2"

Figure 1 – Nozzle Attachment Weld Soak Band Width

Therefore, for a shell thickness of 1-1/8-inch (28.5-mm), the PWHT soak band (SB) must extend
beyond the edges of the attachment weld a distance of at least 1-1/8-inch (28.5-mm). For a 0.55-
inch (14-mm) fillet weld, the SB diameter should be at least 5-3/4 inches (145 mm)

5.0 TEMPERATURE GRADIENT CONTROL

NBIC RD-1100 requires that the radial gradient from the SB not exceed 250 °F/ft (455 °C/m).
Therefore, at a distance of 1-ft (0.3-m) from the edge of the SB, the temperature in the HB must
not be below 900 oF (656 oC), for a PWHT soak temperature set-point of 1150 oF (795 oC).

6.0 HEATER ARRANGEMENT

Figures 2 and 3 on the following pages illustrate the bull’s eye PWHT heater and thermocouple
arrangement for the nozzle and repad attachment welds, incorporating code-mandated SB
requirements as defined above.

6.1 FCP Heaters

Each FCP heater has a surface area of 120 in². When powered by 80-VAC from a standard
Team 6-zone power and control (6-PAC) console, it will develop a thermal power capacity
of 3.6 kW, which is a uniform area power density of 30 W/in². Heaters are identified by
their flexible width dimension. For example, a CP12 heater is has a flexible 12-inch width,
and a rigid 10-inch length. Up to three heaters can be powered in parallel in a single
temperature control zone, in accordance with Team Standard Practice SP-08. All heaters
are to be attached to the shell by means of capacitor discharge welded stud pins and friction
washers, in compliance with Team Standard Practices SP-01 and SP-08.
 Team PWHT Procedure 032309-01, Rev. 0 Page 4 of 11

A B
CP10
CP12

A
B
A A
CP12 CP10
CP24 CP24
B
CP21

Figure 2 – End View of Bull’s Eye Thermocouple & Heater Arrangement on Head for Nozzle K3A
 Team PWHT Procedure 032309-01, Rev. 0 Page 5 of 11

Figure 3 – Section View of Bull’s Eye Thermocouple & Heater Arrangement along Head Centerline
 Team PWHT Procedure 032309-01, Rev. 0 Page 6 of 11

6.2 Bull’s Eye HB Heater & Thermocouple Pattern

The bull’s eye HB heater and thermocouple pattern is illustrated in Figures 2 and 3 on the
previous page. It consists of three heater bands, as described below.

6.2.1 HB around Neck of Nozzle K3A

A 5-inch wide band of a single CP24 heater is to be banded to the neck of nozzle
K3A, with approximately 15 inches of length allowed to extend through the
insulation.

6.2.2 Head HB

Surrounding the nozzle on the head will be a nominal 23-1/2-inch (597-mm) square
band, consisting of 2 CP10 heaters and 2 CP12 heaters, arranged into two 2-heater
temperature control zones, with a nominal 1-inch space between heaters.

6.2.3 Head GCB

Surrounding the head HB will be a GCB with outer dimensions of a nominal 36-
inch (914-mm) square, consisting of 2 CP21 heaters and 2 CP24 heaters, arranged
into two 2-heater zones.

7.0 TEMPERATURE MEASUREMENT

7.1 Thermocouple Type and Quantity

Each of the 5 temperature control zones is to be instrumented with a Type K control

thermocouple, attached to the head or nozzle neck surface by means of capacitor discharge
welding, to ensure accurate temperature measurement, in compliance with Team Standard
Practice SP-02. A spare thermocouple is to be located within 1/2-inch of each control
thermocouple.

7.2 Thermocouple Locations

The precise thermocouple locations are illustrated in Figures 2 and 3 on the previous pages,
and described in Sub-section 6.2. Basically, each thermocouple is to be as close to the
geographic center of its 1-heater or 2-heater zone as possible, while remaining on the SB
and GCB constant-diameter rings.

7.3 Thermocouple Set-Point Temperatures

7.3.1 HB on K3A Neck

The thermocouple on the nozzle neck is to have a PWHT soak temperature set-
point.
 Team PWHT Procedure 032309-01, Rev. 0 Page 7 of 11

7.3.2 Head HB

The 2 thermocouples in the shell HB, which are on the edge of the 7-inch diameter
SB, are to have PWHT soak temperature set-points.

7.3.3 Head GCB

The 2 thermocouples in the shell GCB are all on a 31-inch diameter circle, placing
them 12 inches (24.5 mm) from the SB edge. Consequently, their temperature set-
point is to be 250 oF (139 °C) below the PHWT soak temperature, for a value of
900 oF (656 °C).

8.0 THERMAL INSULATION

The entire bull’s eye is to be covered with a layer of 1-inch thick 6-lb/ft3-density non refractory
ceramic fiber (Non-RCF) thermal insulation, which is to extend 2-ft. beyond the edges of all
heaters. It is to be secured to the shell with the same type of capacitor discharge welded stud pins
and friction washers that hold the heaters in place.

9.0 EQUIPMENT INSTALLATION

9.1 Safety

Team site personnel will work with the client’s safety personnel, to ensure that the on-site
safety steps described on the following page are taken:

9.1.1 Permit Requirements

All necessary hot-work permits are to be acquired by Team’s supervising

technician, and all Team site personnel shall be familiar with permit requirements.

9.1.2 Personnel Protective Equipment (PPE)

All Team personnel shall wear protective clothing and equipment, as described in
the Team Safety Manual, and shall satisfy all site-specific safety requirements.

9.1.3 Fire Extinguisher

A type ABC fire extinguisher shall be available to Team personnel within ready
access to the PWHT location.
 Team PWHT Procedure 032309-01, Rev. 0 Page 8 of 11

9.2 Equipment Access

Scaffolding or man-lifts are to be provided as needed for personnel to install

thermocouples, heaters, and insulation. The 6-PAC (6-zone power and control) console is
to be placed within 50 ft from the weld, with secondary cables positioned out of harms
way. All zone cabling is to be clearly identified, and supported to prevent any pulling on
heater tails. The 6-PAC console requires a 100-Amp, 480-VAC, 3-phase electric power
supply.

10.0 RELEVANT TEAM STANDARD PRACTICES

Equipment specifications and preparation instructions relevant to this field procedure are provided
in the Team Standard Practices listed on the following page.

SP-01: Attachment of Stud Pins by Means of Capacitor Discharge Welding

SP-02: Attachment of Thermocouples by Means of Capacitor Discharge Welding
SP-05: Thermal Insulation – Specifications and Usage Guidelines
SP-06: Temperature Measurement and Recording Equipment - Specifications & Usage
SP-08: Low Voltage Electric Resistance Heating – Specifications, Usage, and Safety Guidelines

11.0 PWHT TEMPERATURE REQUIREMENTS

The heating, soak, and cooling specifications on the following page are in accordance with the
requirements of article UCS-56 and Table UCS-56.1 for P-No. 1 carbon steel welds with total
thicknesses of 1-11/16-inches (43-mm).

11.1 Heating

11.1.1 Below and at 800 °F (600 oC)

From ambient to 800 °F (600 oC), Team recommends that the heating rates not
exceed 400 °F/hr (222 oC/hr), in an effort to minimize temperature differences within
concentric heater bands.

11.1.2 Above 800 °F (600 oC)

Above 800 °F (600 oC), heating rates shall not exceed 240 °F/hr (133 oC/hr).

11.1.3 Temperature Differential

While heating above 800 °F (600 oC), there shall not be a greater variation in
temperature than 150 ºF (83 oC) among thermocouples within any given concentric
heater band. The heating rate may be reduced to ensure that these differentials are
not exceeded.
Team PWHT Procedure 032309-01, Rev. 0 Page 9 of 11

11.1.4 Maximum Temperature

During the heating period, no temperature shall exceed 1175 ºF (809 oC).

11.1.5 Thermocouple Failure

If a thermocouple fails during the controlled portion of the heating cycle, the cycle
may be held at that point until the transfer to a spare thermocouple is completed.

11.2 Soak

11.2.1 Temperature

Soak temperature shall be between 1125 ºF (781 oC) and 1175 ºF (809 oC). The soak
period is to begin when the core HB soak temperatures reach 1125 ºF (781 oC). At
no time shall the temperature of these thermocouples either exceed 1175 ºF (809 oC),
or fall below 1125 ºF (781 oC).

11.2.2 Time

The minimum soak time shall be 2 hours.

11.2.3 Thermocouple Failure

In the event of a thermocouple failure during soak, the transfer to the spare
thermocouple is to be done immediately. If the temperature of the soak
thermocouple falls below 1125 ºF (781 oC) at any time during the transfer, the soak
period is to be resumed when it reaches 1125 ºF (781 oC). The total accumulated
time above 1125 ºF (781 oC) is to be the soak time.

11.2.4 GCB Control Thermocouple Set-Point Temperatures

The set-point temperature for shell GCB thermocouples cannot be less than 900 oF
(656 °C), as defined in Subsection 7.3, in compliance with the NBIC mandated
maximum allowable temperature gradient.

11.3 Cooling

11.3.1 800 °F (600 oC)

Above 800 °F (600 oC), the maximum cooling rate shall not exceed 300 °F/hr (167
o
C/hr).
 Team PWHT Procedure 032309-01, Rev. 0 Page 10 of 11

11.3.2 Temperature Differential

While cooling above 800 °F (600 oC), there shall not be a greater variation in
temperature than 150 ºF (83 oC) among thermocouples in any given concentric heater
band. Cooling rates may be reduced to ensure that these differentials are not
exceeded.

11.3.3 At and Below 800 °F (600 oC)

At and below 800 °F (600 oC), the cooling rate need not be restricted, and cooling
can be completed in still air. Thermal insulation can be removed whenever it is
deemed safe to do so.

11.3.4 Thermocouple Failure

In the event of a thermocouple failure during the controlled portion cooling, the
cycle may be held at that point until the transfer to the spare thermocouple is made.

12.0 DOCUMENTATION

A Team Job Folder is to be submitted to the client, containing the following documents:

12.1 Temperature-Time Record

Each thermocouple is to have its temperature/time history recorded on a dedicated channel

of a strip chart recorder. The strip chart label is to identify the correlation of thermocouple
numbers and strip chart recorder channels, and is to contain the following information:

• Date
• Identification of work piece
• Thermocouple type
• Stress relieving company
• Stress relieving operator and signature
• Chart recorder serial number and date of latest calibration

12.2 Recorder Calibration

Each recorder is to be accompanied by its certificate of calibration.

12.3 Job Report Log

In the event of a non-conformance, a manual log is to be maintained by Team technicians

to document pertinent details, and the Team supervising technician and the PDVSA quality
control manager are to be notified as soon as possible to help define corrective action.
Team PWHT Procedure 032309-01, Rev. 0 Page 11 of 11

12.4 Heat Treatment Record (HTR)

A daily HTR shall be submitted to document personnel, time, material, and equipment.

12.5 Approvals

This procedure requires approval signatures by an authorized representative of the client

and by the Team supervising technician before any Team site work can begin.