2011

PERSONAL PROTECTIVE
EQUIPMENTS,WELDING,NDT&PWHT

SHIVENDRA PRATAP SINGH

SGIL
5/2/2011
 Personal protective equipment

• Supervisers are responsible to ensure personal

protectiveequipment is worn to protect
workers from potential hazards

• MORE THAN ONE-FOURTH OF THESE INJURIES

WILL INVOLVE THE HEAD, EYES, HANDS, OR
FEET

• Clothing that protects the body & extremities

will be worn

• Loose clothing will not be worn where it can

contact or catch on energised conductors
 ,moving parts,equipment,or other hazards of
this type

• UNDER THE REQUIREMENTS OF 29 CFR

1910.132, ENGINEERING CONTROLS SHALL BE
THE PRIMARY METHOD USED TO ELIMINATE
HAZARD EXPOSURE IN THE WORK PLACE.
• TYPES OF EYE AND FACE PROTECTION
INCLUDE:
-SAFETY GLASSES

- GOGGLES

- FACE SHIELDS
- WELDING HELMETS

HEAD PROTECTION:

l HELMETS AND HATS FOR THE PROTECTION OF

DOC EMPLOYEES FROM THE IMPACT OF
FALLING AND FLYING OBJECTS AND FROM
LIMITED ELECTRICAL SHOCK AND BURN SHALL
MEET THE SPECIFICATIONS OF ANSI Z89.1
HEAD PROTECTION

• SHELL IS DESIGNED TO ABSORB SOME IMPACT

• SUSPENSION MUST BE ADJUSTED SO SHELL IS

1.5 INCHES ABOVE THE HEAD
• HARD HATS ARE TESTED TO WITHSTAND
IMPACT OF 8 LB WEIGHT DROPPED FROM 5 FT

• HARD HATS MUST ALSO MEET WEIGHT,

FLAMMABILITY AND ELECTRICAL INSULATION
STANDARDS

(HARD HAT)

FOOT PROTECTION

l FOOT INJURIES ARE MOST LIKELY TO OCCUR

WITH:

• HEAVY OBJECTS FALLING ON YOUR FEET

• ROLLING OF HEAVY OBJECTS

• PIERCING OF OBJECTS THROUGH SOLES OF

YOUR SHOE
FEW POINTS REMEMBERED FOR
PREVENTING FOOT INJURIES
• IF WORKING AROUND ELECTRICAL WIRES,
BOOTS/SHOES MUST BE METAL FREE AND
NON-CONDUCTIVE

• STATIC FREE ENVIRONMENTS REQUIRE

CONDUCTIVE SHOES

• RUBBER OR SYNTHETIC FOOTWEAR MAY BE

REQUIRED AROUND CHEMICALS

• AVOID LEATHER SHOES/BOOTS AROUND

CORROSIVES

• FOOT GUARDS AND HEEL AND ANKLE

SHIELDS MAY BE REQUIRED FOR
PARTICULAR WORK

(SAFETY BOOTS)

HAND PROTECTION
• FINGERS, HANDS AND ARMS ARE INJURED
MORE THAN OTHER PARTS OF THE BODY

• GLOVES ARE THE MOST COMMON PROTECTORS

FOR THE HANDS

• BARRIER CREMES MAY BE USED AS HAND

PROTECTION OR, IN CONJUCTION WITH OTHER
HAND PROTECTION

HAND GLOVES (RUBBER)

HEARING PROTECTION
REQUIRED WHEN NOISE MEETS OR EXCEEDS
85DBA.IF YOU HAVE TO YELL TO BE HEARD
,WEAR EARPLUGS

(EAR PLUGS)
SAFETY GLASSES-
To be worn at all times when in constructional
area.Additional eye/face protection should be
wornwhen there’s a possibility of flying debris
for work being performed by either the
employee or others in the area-

• Working with crushing equipment

• Hammering,chipping,drilling

• Cutting with disc or power-driven saw and

other cutting under tension

• Any grinding work

• Use of compressed air ,water or other

liquid/solutions with shot,injection or
other abrasive cleaning

• Use and handling cartridge-operated tools.

• Working with chemical solid-liquid

substances

• Concrete(spraying&vibration) pouring.

• Coiling rebar/cable and related

operations,such as cable straightening.

• Strapping and unstrapping under tension.

• Handling of glass either whole or broken.

Approved dark/tinted safety glasses should be worn when
working in the bright sunlight.However ,clear glasses
should be worn at night and when inside buildings or in
covered areas with limited lightingsPerforming abrasive
blasting work.

Face shields-
Face shields must be worn in addition to safety
glasses when
performing,cutting,grinding,hammering,chippi
ng,handling hazardous liquids,abrasive
blasting,cartridge operated tools and concrete
work.
 Welding

a localized coalescence of metals or non metals

produced either-

• By heating the materials to the welding

temperature ,with or without the application of
pressure or

• By the application of pressure alone and with

or without the use of filler metal.
 Common welding process
• Shielded metal arc welding(SMAW)

• Gas tungsten arc welding(GTAW)

• Gas metal arc welding(GMAW)

• Flux cored arc welding(FCAW)

• Submerged arc welding(SAW)

GMAW PROCESS
• Popularly known as MIG process.
• It is a semi-automatic process.
• Uses gases(co2,argon or mix)for
shielding.
• Uses continuous solid metal wire
feed.
• No deposition of slag.
• High productivity 3kg/hr or more

GMAW EQUIPMENTS
• Welding power source

• Wire feeder mechanism

• Gun with gas supply & trigger switch

-manual(semi automatic)guns
-automatic torches available

Flux core arc welding

• Similar to GMAW process except that the
electrode is tubular containing a granular
flux.
 • Shielding gas may or may not be used
depending on the type of electrode
used(eg. Self-shielded flux cored wires do
not require gas shielding).

• Solidified weld metal is covered by a layer

of slag.

• Equipment used is identical to gmaw

except high current capacity guns and
power sources.

Equipment set up
FCAW

• Torch

• Electric power source

• Shielded gas source

• Wire spool with wire drive control

 Torch gas mixture
• Inert gas (MIG)
-Argon or helium or mixture of these
• Active gases(MAG&FCAW)
-Carbon dioxide
-argon plus oxygen and/or carbon dioxide
-nitrogen,hydrogen

“ELECTRODE/ROD CLASSIFICATION AS PER

AWS”

EXXT-X
WHERE-
E-electrode rod
X-minimum tensile strength in ten thousand
psi
X-position (‘0’- F&H,’1’-ALL Positions)
T-tubular electrode
X-chemical composition/operation
characterstics
 ADVANTAGES-
• High efficiency due to increased deposition
rate.

• Good performance on contaminated surfaces.

• Baking process of electrodes eliminated.

• Can be used for field applications.

• Deep penetrating arc reduces the possibility of

fusion problems.

• Frequent changing of electrode is eliminated.

• Metal conversion factor is upto 95%.

LIMITATION-
• Presence of a layer of solidified slag

• Smoke generated is more than in

GMAW&SMAW.

• Equipment required is more complex.

• Slag inclusion due to trapping slag within

the weld deposit.

• Not advisable for pipe thickness less than

12.5mm.

• Requires proper wind shielding.

• High travel speed is required.

 SMAW FCAW
-Slower process -faster
process
-example- -for the
same joint
For a 30”*12.7mm joint, it takes
only 1.5hrs
It takes 4.5hrs

-for a weldo’let of 16”*10” -for the

same weld it
It takes 7 hrs takes only
2.15 hours

“FCAW IS THREE(3) TIMES FASTER THAN SMAW”

Welding position
 WELD FINISH
BUTT WELD-

(BUTT WELD)
Butt welding is a metal welding process in which round or profile
stock is welded end to end.

Butt welding can be used to run a processing machine continuously,

as opposed to having to restart such machine with a new supply of
metals.

Usually, the seams (or abutment sections) are cleaned and

prepared, and set on an automated piece of equipment which then
welds the two materials together. Afterward, the material is
usually ground down to a smooth finish and either sent on its way
to the processing machine, or sold as a completed product.

WELD FINISH-WELDO’LET
Weldolet are basically self reinforced fittings.

Weldolet is used for Butt weld branch connection where standard tee
is not

available due to size restrictions and the piping is of critical / high

pressure service.

Weld finish-trunion
Weld finish-branch with RF pad
MACHINES USED AT PFS-
 • Lincoln make DC600 power source with LN25
wire feeder and magnum 200/400amps welding
torches.

• Fronius make synergic 5000cc with VR400S

wire feeder and torch assembly.

• 1.2mm flux cored wire is used in both wire

feeders for better control of weld metal.

• Piped CO2 gas facility available in all four

shops.

LIMITATIONS AT SITE WELDING-

• Additional protection for shielding gas from
heavy windows.

• Transportation of additional CO2 cylinders.

• Scaffolding arrangement for wire feeder at

elevations.
• Not suitable for thickness less than 12.7mm
and pipe size less than 10 inch dia.

• Spacing of joint with adjacent pipe at rack.

“FUNDAMENTALS OF NDT”
Nondestructive testing (NDT) is a wide group of
analysis techniques used in science and industry
to evaluate the properties of a material,
component or system without causing damage.
The terms Nondestructive examination (NDE),
Nondestructive inspection (NDI), and
Nondestructive evaluation (NDE) are also
commonly used to describe this technology.
Because NDT does not permanently alter the
article being inspected, it is a highly-valuable
technique that can save both money and time in
product evaluation, troubleshooting, and research.
Common NDT methods include ultrasonic,
magnetic-particle, liquid penetrant, radiographic,
remote visual inspection (RVI), eddy-current
testing, and low coherence interferometry . NDT is
a commonly-used tool in forensic engineering,
mechanical engineering, electrical engineering,
civil engineering, systems engineering,
aeronautical engineering, medicine, and art.

Scope-
• NDT method are used to detect
surface,subsurfaces and internal
discontinuities in the materials and give
quality control checks in various stages of
manufacturing
• ASME sec-V IS the relevant code for the
variouss NDT methods used in industries.

PROGRAM OBJECTIVE-
 • To bring the awareness of various NDT
methods ,their applications ,advantages and
limitations.
• To share our field experience and discuss case
studies to high light the importance of NDT.

BRIEF DESCRIPTION OF NDT-

• Various NDT methods are used in the
industries for the various purpose at different
stages.
• The mechanism of each method varies and is
based on the scientific principles,they are
based on the application of sound energy
,electrical energy,mechanical energy,magnetic
energy etc.photo graphic principle of light
energy is also used.
• Each method has its own advantage and
limitation.
• They are used in various fields like medical
field ,ENGG. INDUSTRIES and also in day to day
life.
• Sonography is used to check the sex of unborn
child.
• X-ray are use in the airport to check the
luggage of the passenger.
• MT,UT&PT ARE USED IN INDUSTRIES.

APPLICATION-
• DEFECT DETECTION-type,size&location of
defects
 • CHECKING OF VARIOUS PROPERTIES-
density,chemical composition,electrical and
thermal conductivity.
• Sorting out mix up of material-
composition,grain size,chemical
composition&heat treatment cond.
• DIMENSIONAL GAUGING-material
thickness&coating/plating thickness check.

IN SGIL we use NDT methods mostly for defect

detection and thickness checking of the
pipes,plates,forgings castings and welding.

SELECTION OF NDT METHOD

Selection of NDT method to check the quality of
product is based on the following information-

• Type & location of the defect.

• Nature of the defect.
• Expected orientation of the defect.
• Surface condition.
• Applicable codes&standards.(ASME,BS,IS,DIN
etc.)
• Quantity of materials and facilities of NDT
method.
• Inspection at site or at workshop.
• Accessibility for the site inspection.
• Environmental condition.
• NDT instrumental availability.
• Cost&time reqd.
VISUAL TESTING-
Visual testing is the oldest and simple NDT
method and most commonly used
everywhere.it is used to detect surface defects
like laps,cracks,blow holes and many other
defects which are visible to naked
eyes.nowadays sophisticated instruments like
boroscope,fibroscope,magnifying lenses
etc,are used.

REQUIREMENT FOR TESTING-

• Natural light/light source
• Safe scaffolding
• Personal safety equipments
• Surface temperature with in 10 to 300c
• The surface for visual testing shall be free from
loose scale,paint and discontinuities such as pits
or gauges,weld spatter,dirt or other foreign
matter which affect examination results.

MAGNETIC PARTICLE TESTING-

• The magnetism is induced in the part by
electricity or by using permanent magnet
resulting the flow of lines of magnetic flux
in the part.
• The magnetic lines of forces which pas
through the component are breaking due
to discontinuity in the material.
• These broken lines are checked by using
iron powder forming the defectbindications
on the surface at the area where
discontinuities are present.
 • MT is applicable to ferromagnetic material
only.
• It is applicable for the detection of
surfaces and sub surface discontinuities
only.

MAGNETIC PARTICLE TEST-

MAGNETIC PARTICLE TEST KIT WITH MAGNETIC FIELD INDICATOR

MAGNETIC PARTICLE TESTING-

ABOVE FIGURE MENTIONED MAGNETIC PARTICLE TESTING

LIQUID PENETRANT TESTING-

PROCEDURE-
• Clean the surface area to be tested.

• Apply penetrant by brushing or spraying;wait for 7 to

15 mins.

• Remove excess penetrant by wiping with lint free

cloth.

• Apply developer &wait for 15 minutes

• Inspection and evaluation of the defects.

• Cleaning to be done with free cloth only.

LIMITATION-
 • Surface temperature with in 10 to 52c.

• Smooth surface is required.

• Porous material can not be tested.

REQUIREMENT FOR TESTING-

• Natural light/light source.

• Safe scaffolding.

• Personal safety equipments.

• Surface temperature with in 10 to 52c.

• The surface for liquid penetrant testing shall be free from

loose scale ,paint and discontinuities such as pits or
gouges,weld spatter,dirt or other foreign matter which
affect examination results.

• The surface preparation can be carried out by grinding.

• The purpose of surface preparation is-

-to avoid masking indication on te job surface

-to remove excess penetrant by wiping facilitate on

job surface

figure mentioned liquid penetrant testing.

THE FIGURE MENTIONED BELOW IS LIQUID
PENETRATION TESTING KIT WITH
CLEANER,PENETRANT&DEVELOPER-

ULTRA SONIC TESTING-

Ultrasonic sound waves are generated by using
electrical transducer.these waves are transmitted in the
material by using couplant.the sound waves are flowing
inside the material and are distributed by the presence
of discontinuities in the material.The path of sound
waves and its disturbance is monitored on the CRT
screen.the loss of sound energy is indicated on the
screen which gives the idea about the defects ,its
size&location.

REQUIREMENT –
• NATURAL LIGHT/LIGHT SOURCE

• SAFE SCAFFOLDING

• PERSONAL SAFETY EQUIPMENTS

• SURFACE TEMP. WITH 10 TO 52C

• SURFACE FOR UT SHALL BE UNIFORM AND FREE

FROM LOOSE SCALE,PAINT AND AND
DISCONTINUITIES SUCH AS PITS,WELD
SPATTER,DIRT OR OTHER FOREIGN MATTER WHICH
AFFECT EXAMINATION RESULTS

• SURFACE PREPARATION CAN BE CARRIED OUT BY

GRINDING.

• PURPOSE OF SURFACE PREPARATION-

-TO HAVE BETTER CONTACT AND TO FACILITATE

BETTER CONTACT OF
PROBE ON JOB SURFACE

SURFACE PREPARATION FOR

TESTING-
• DIFFERENT TYPES OF SURFACE PREPARATIONS
ARE REQUIRED FOR PIPING
,NOZZLE&STRUCTURAL JOBS AS UNDER.

• PIPE TO PIPE JOINT.

• IN THIS TYPE OF JOINT,SURFACE TO BE

PREPARED FOR LONGITUDINAL SCANNING ON
THE PIPE SURFACE.TE SCANNING ZONE OR
SKIP DISTANCE REQUIRED IS 250MM ON BOTH
SIDES OF THE JOINT.SCANNING ZONE SHALL BE
FREE FROM WELD SPATTER,CLEAT MARK ETC.

• ALSO SURFACE NEEDS TO BE PREPARED FOR

CIRCUMFERENTIAL SCANNING.HERE SCANNING
IS CARRIED OUT FROM TOP OF THE JOINT.SO
RIPPLES OF THE WELD JOINT SHALL BE
 GROUND FLAT TO HAVE A PROPER SEATING OF
THE MINIATURE PROBE MOUNTED ON SHOE ON
THE WELD JOINT.AFTER GRINDING,THE
GRINDING MARKS SHALL BE SMOOTHEN BY
LIGHT FILLING WITH ROUND FILE.

ULTRA SONIC TESTING

ULTRASONIC TESTING TRANSDUCER
(PHASED ARRAY ULTRASONIC TESTING)

TOFD CONFIGURATION-

RADIOGRAPHY TESTING-
Radiography testing depends upon the ability of x-rays or
gamma rays to penetrate the test material.during
penetration the rays are partially absorbed by the
material.The amount of absorption depends upon the
density and thickness of the material.Defective areas do
not absorb the radiation energy.

Difference in radiation energy due to the presence of

discontinuity is recorded on a photographic film.

REQUIREMENT OF TESTING-
• Safe scaffolding.
• Safe work permit.

• Surface temp. with in 10to52c

• Thickness and diameter

• Material

• The surface for testing shall be free from loose scale

and ,discontinuous such as pits or gouges,weld
spatter,other foreign matter which affect examination
results.

• The surface preparation can be carried out by

grinding.the purpose of the surface preparation is to
avoid masking indication.

RADIOGRAPHY TESTING INSTRUMENT

LEAK TESTING-
• The ability to find out the leakages using air/gas
medium at pressure or at vaccum.

• The air or gas is filled in the vessel/tank at the

required pressure and temperature.the leakage
is detected by the loss of pressure checked by
pressure gauge.

• Some times soaps solution is also used which

forms air bubbles at the area of leakage.
 • The surface for testing shall be free from loose
scale,paint and discontinuities such as pits or
gouges,weld spatter,dirt or other foreign matter
which affect examination results.

• The surface preparation can be carried out by

grinding

EDDY CURRENT TESTING

• This method is used for various applications such
as mixed metal sorting,dimensions
gauging,detection of defect ,measuring electrical
conductivity etc.

• Principle of eddy currents is based on the

generation of induced current in the material and
monitoring on the screen.
 PWHT

PROGRAM OBJECTIVE-
• To refresh and update latest developments on
the post weld heat treatment(PWHT) &hydro
testing for engineers joining from other areas.

• To identify the role and responsibilities of

concerned discipline engineers while handling
the PWHT ,heat treatment&hydrotesting process.
Program contents-
Fundamentals,process and monitoring of-

• Preheat

• Post heating

• PWHT

• Hydro testing

Purpose-
Purpose of this procedure is to define the equipments
and methods to be followed for the preheat,postheat
&PWHT.

PWHT is carried out based on

• Material composition

• Thickness of weldment

• Process requirement

PRE HEATING AND POST HEATING ARE 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.

REQUIREMENT OF PRE&POST HEATING-

• For preheating,the weld joint shall be preheated

at or above the min. temperature in all direction
 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 no.

materials,the min. preheat temperature shall be
higher temperature for the materials to be
welded

• When welding two different thickness,oreheat

temperature shall be the higher temperature for
the material to be welded

• When welding two different thickness,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.

METHODS OF PRE-HEATING-
• For CS/LTCS ,preheating may be carried out by
flame heating or electrical heating.

• For low alloy steel ,piping materials above 2”NB

pre heating shall be carried out by electrical
heating only.

PREHEATING 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 9.5mkm 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

• 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.

POST HEATING-
• For low alloy steels,post heating shall be carried
out a temperature specified in applicable WPS

• For elec. Heating,same arrangements are

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 min. for
other cases post heating time shall be 30minutes

-for low alloy steel material post heating shall be carried out by electric
heating for joints above2”

-preheat temperature shall be continuously maintained till start of

PWHT wherever specified in the codes/specifications.

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 fabrication

equipments

SURFACE PREPARATION-
The area to be covered for preheat ,post heat and PWHT
shall be free from paint,grease,tacks,spatters to avoid
damage due to short circuiting.

JOB KNOWLEDGR OF OPERATOR-

PWHT technician shall be capable of executing the
activity.this shall be assessed by QMD REPRESENTATIVE

PWHT(POST WELD HEAT TREATMENT)-

• THIS IS THE PROCESS OF GRADUALLY AND UNIFORMLY
RAISING THE TEMPERATURE OF THE WELDMEENT 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 ALONG 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 MATENSITIES AS AND WHEN FORM

DURING WELDING.

PWHT TEMPERATURE-
• For heating and cooling rate,the requirement
of WPS shall be strictly followed.

• Soaking/holding time &temperature-for PWHT

soaking time&temperature requirement of
WPS shall be strictly followed.

Equipment for PWHT

• Control panels

• Heating elements

• Thermocouple

• Compensating leads

• Temperature recorder

• Thermal insulation

• Attachment unit

• Earthing cable

CERTIFICATION OF CONTROL
PANELS-
• All equipments are purpose built.

• Electric power sources are 440v,3phase primary

supply or 220v single phase with either single
phase secondary output or step down
 transformer secondary output 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 requirement
as above and as per standards.

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.

Heating element position-

• Welds shall have a circumferential band of
heating coil around the entire component
with the weld located in 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.

• 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.

(ABOVE IMAGE SHOWING PWHT

PROCESSES)
THERMOCOUPLES-
• Material shall be the “k”type i.e. Nickel –Chromium
/Nickel-Aluminium type

• Compensating coil&thermocouple shall be caliberated

together.

• The distance between two T C wires shall be min

6mm.

• Insulation shall be removed from the end of the TC

WIRE shall not be more than 15mm.

• Connect the positive/negative side of the TC with

respective positive/negative side of compensation
cable.

• Thermocouple attachment shall be attached to the

work piece by direct wire capacity discharge method
or by nut and bolt connection.

• If the nut and bolt connection method Is used,the

materials of nut-bolt shall be of compatible
composition with parent metal.
 capacity discharge method

tack welds

Number of thermocouples-
1. Minimum no. of thermocouple is one one per
heating coil.However in addition to that the
following min. no. of thermocouples shall be used
for pipe welds.
 2. Minimum requirement for number and location of
thermocouples are-

• 1 no. upto and inclusive of 6’’NPS

• For 2”and below,wherever joints are there within

the range of 100mm distance,one thermocouple
is permitted

• 2 numbers at 180degree for above 6” and up to

12” NPS inclusive.

• 3 numbers at 120degree for above 12”NPS

• For socket welds,I T C with in 100MM between

two joints.

But in all case minimum two layers of insulation with

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

Verification-
• For PWHT,after fixing the heating coils and the
thermocouples with proper connections with
recorder,the arrangement shall be certified by the
authorized representative of REAL QMD who shall
sign on the graph to indicate that the arrangement
are certified.Then the insulation shall be applied on
the heating coils.Again after attaining 300degree
Celsius during heating,the graph shall be recertified
by REAL QMD representatives.This requirement
shall be treated as mandatory for the acceptance of
post 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
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-estabilished from the fallen
temperature at a rate no greater than that
specified in code/estabilished 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.

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 and their position shall

be identified on the relevant
temperature recording chart by number
or color/symbol of stamp.
 • Thermocouples requirement for branch
connection and pad shall be in line with
the requirement as mentioned in above

• Thermocouples tack welded with pipe

shall be removed completely after
PWHT and area to be DP tested

CALIBERATION OF
TEMPERATURE RECORDERS-
• It shall be of the potentiometer ,
self compensating type having
chart feed recording.

• Recorders shall be caliberated in

every 6months and caliberation
stickers shall be affixed to the
recorders

• In addition, recorders shall be re-

caliberated 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 to appropriate
speed,temperature recording
system is recording all
thermocouples and providing
information on temperature
differences and trends during the
heating/cooling cycle
 • Caliberation certificates shall be
available at site.

THERMAL INSULATION-
The insulation shall be extended to a
minimum distance of 3 times the
heating bandwidth.The no. of layers and
extent of insulated area depends on-

1. Wall thickness

2. Pipe or fitting diameter

3. Gradient requirements&

4. Site condition

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 chart shall be
identified with ZXXX XXX /XXXX XXX

• Z indicates JERP

• 1st 3 digits indicate unit no. 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

CHECKLIST FOR THE

STRESS RELIEVING UNIT-
• Check for the condition of power
cable

• Check for the proper size of the

cable

• Check for glanding for all cables

• Check for lugging for all cables

• Check for tightness for all

connection

• Check for sealing of all un used

entry
 • Check for valid caliberation
certificate for the unit

• Check for provision against shock

material

• Megger value of al the cables

• Earthing of unit and job

• And check for valid risk assessment

sheet availability.

FINISH