PREHEATING & PWHT

Carbon
equivalent

Recommended
procedure

Lesser than 0.40%

Any electrode may be used, no problem up

to the combined thickness of 50mm.

Greater than 0.40%

Preheat 100 to 200 0C or switch over to the

basic electrode.

Up to 0.55%

Preheat 200 to 350 0C or switch over to the

basic electrode with reduced temp.

Abov 0.55%

Use only the basic electrode & also preheat

200 - 350 0C or switch over to stainless steel
electrode of high ferrite.

C eq% = C%
+

Mn% (Cr + Mo + V)% (Cu+Ni)%

+
+
5
1
6
5

A Saiferian formula for preheat to prevent cold

cracks;
C = 350

[C]e - 0.25

[C]e= [C]c + [C]t

(Mn + Cr)% Ni%
7Mo%
[C]c = C% +
+
+
9
18
90
[C]t = [C]c X 0.005 t
t = Thickness in mm
Preheat Temp. for C & C-Mn Steel only:
F = 1,000 (C% - 0.11) + 18 t"

Where C% is only up to 0.65%

max.

HEAT TREATMENT
Symbol
(Carbon Steel)

C-1/2 Mo Steel )
C (3.5 Ni)

PREHEAT
THK(mm)
Temp (0C)
< 25
10
> 25
80
<12
10
> 12
100
ALL
95

1 1/4 Cr 1/2Mo)

ALL

150

(5Cr -1/2 Mo & 2

1/4 Cr - 1Mo )

ALL

175

F ( Austenitic )

ALL

10

PWHT
THK(mm)
Temp (0C)
<19
None
> 19
595 -650
< 19
None
>19
595 -720
< 19
None
>19
595 -685
< 12
None
>12
705-745
All
705-760

Duration
1 Hr / 25 Min
min 1 Hr

1/2Hr/25 mm
Min,Min of 1Hr
1Hr /25mm
,Min of 2Hrs
1Hr /25mm
,Min of 2Hrs
-

PWHT BY DIRECT OIL FIRING

METHOD

Salient Features of PWHT by Direct

oil firing method
Principle

Insulate the complete exterior of the vessel / tank and

convert the same into a self contained furnace.

Tank shall be placed on 3 layers of refractory brick laid

on the foundation
Tank is insulated with 1 layer of 75 mm thk, 120 Kg /
m3 density mineral wool insulation on exterior surface
with a meshed wire backing.
Insert high velocity oil burners with angled/straight
cones through certain openings.(The products of
combustion are exhausted through nozzles)

Contd.

 Burners are designed to give a maximum

flame length of approximately 300 mm
Burner rating : 1.5 x 106 Kcal / hour
Combustion air flow 3559 cu.m/hour
Combustion air fan is coupled to each burner
via a flexible hose which can be accurately
controlled to deliver exact quantity of air to
the burner
The burners are inserted through suitable
manways/nozzles.The burners will be fitted
with angled cones to give peripheral firing

Contd.

 K type chromol thermol type or Ni-Cr/Ni A

ltype thermocouples are attached on the
shell roof & bottom of the tank to record the
temperature continuously.
3 phase 380 /415 volt 50 Hz , 60 amp supply
to be provided to combustion air fans & oil
pumping units , adjacent to burners ,to be
individually switched at sources.
Fuel requirement will be approx . 50-55 ltrs
/MT of the tank
Temperature distribution by this teat
treatment method is in line with StandardsAPI
650 ,ASME VIII,BS 5500,DIN,IS 2825 etc

PWHT SPECIFICATION
Unrestricted heating from ambient upto 300 0C
and restricted heating from 3000C at 500C/Hr
with a temperature differential of not more
than 750C between thermocouples.
Soak temperature 5800C.
Soak period of 1 Hour (Minimum)
Restricted cooling from Soaking temperature
at 500 C /Hr
Unrestricted cooling rate from 3000 C
downwards under insulation.

DETAILS OF REVAMP OF REACTOR

FCCU Reactor

Height - 24.8 Mtr

Dia
- 3 Mtr
Thickness
- 19 mm
Material
- P11

Detail of Revamp
Segment of shell replacement (Two segments & 3 circumferential
Seams)
Nozzle replacement ( 10 Nos )
Tray replacement

FEATURES ON PWHT OF REACTOR

PWHT was planned for the Total circumferential band for the

required locations to avoid distortion

Max of 5 Mtrs height was Stress Relieved in a single stretch
and the details are as follows:
Max power requirement 700 Amps ( Provided by 1000 KVA
Hired DG set )
No of heating coils 52
No of thermo couples 30
No of temperature recorders used 5
Total cycle time 14 hrs

FEATURES of PWHT
Thermo couple welding with capacitor
discharge method.
Temperature difference between any two
thermo couple restricted to max of 30
deg C
Simulation heat treatment conducted on
existing material to decide on cycle
parameters
Reactor was held by Crane during PWHT

Sand Blasting & Painting

Use Comparator for right surface

finish.

Use profile Gauge to check proper

profile

Ensure the humidity is less than 85%

during sandblasting / Painting

Ensure primer application is done

within 4 hrs of blasting

Check the paint for min % volume

solid irrespective of data sheet
information.

Sand Blasting & Painting

SSPC SP 10 Specification for

Surface Finish

SSPC VIS SA 2-1/2 Visual

Comparator (Photography)

SSPC PA -2 Dry film Thk

measurement with magnetic
Gages

BS 5493 Protective coating of

iron and steel structures

DFT Measurement Method as per

SSPC PA -2

Make individual three gauge readings

are taken on painted surface and
averaged,which is called Spot
measurement.

Make 5 separate spot measurements

spaced evenly over each 100 sqft.

The average of five spot

measurement shall not be less than
the specified thickness.

No single spot measurement shall be

less than 80% of the specified
thickness.However,individual gauge
reading shall have greater variation.

Area Selection For Paint

Measurement

100 sq ft to be measured for

area upto 300 sqft

300 sqft for area upto 1000 sqft

For area exceeding 1000 sqft ,

first 1000 sqft and 100 sqft for
every additional 1000 sqft

Form at No: L&T/GB/A&PQTR/01

LARSEN & TOUBRO LIMITED : ECC DIVISION

GRIT BLASTING WORKS APPLICATOR / PROCESS QUALIFICATION TEST RECORD
Grit Blaster Name : K.GORAIYA
Ref. Work Procedure : L&T/NPCIL/WP/03 Rev.No: 0
Ref Code / Standards : Technical Specification -Section V; IS 1477 ; IS 4683
Application Process : Compressed air Grit Blasting
Type : MANUALALLY OPERATED
Stamp No. : GB- 01
Date

: 22-08-2003
Variables for each process

Actual Value

Range
Qualified

I . OPERATOR
1. Nozzle used for Grit blasting

6mm

2. Compressor outlet Air Pressure during 6 kg / cm2

blasting
3. Nozzle distance from the job during
300 - 400 mm
blasting
30-35 deg.
4.Nozzle angle of inclination to the job
from the vertical surface during blasting
0.8mm - 1.4mm
5. Grit Size
6. Grit Grade
7. Mixing ratio

NA

6-8mm
5-7 kg / cm2
300 mm minimum
30 deg
0.6mm - 1.6mm
G.C 100 ( 1.00mm) ( As per IS 4683 )
NA

Variables for each process

Actual Value

Range
Qualified

II. PROCESS
1. Rust Grade of Material used
2. Product form used for blasting

Grade B( slightly corroded )

EP's of plate type

3. Infrastructure facility used for the process

Dry covered shed with exhaust fan and halogen lights for proper
illumination

4.Surface profile roughness after blasting

In between segment II / III of profile comparator conforms to ISO /DIS

8503/1

5. Surface preparation by grit blasting

III. CLEANLINESS AFTER BLASTING
1. Copper sulphate CuSO4. 5H2O testing

Sa 21/ 2

Sa 21/ 2
No black spots observed

Applicator & Process test conducted by L&T - ECC - B.SUNDAR

Date of test : 22-8-2003

We certify that the data recorded in this format are correct and that the test has been carried out
as per the requirement of approved work procedure L'&T/WP/03 Rev. 0
L&T QA

CLIENT

Form at No: L&T/A&PQTR/01

LARSEN & TOUBRO LIMITED : ECC DIVISION

PAINTING WORKS APPLICATOR / PROCESS QUALIFICATION TEST RECORD
Painter Name : S.Padmanaban
Ref. Work Procedure : L&T/NPCIL/WP/04

Rev.No: 0

Ref Code / Standards : Technical Specification -Section V; Manufacurers

catologue / recommendations
Application Process : Airless spray painting
Type : MANUALLY OPERATED
Stamp No. : PA - 01
Date

: 22-08-2003
Variables for each process

Actual Value

Range
Qualified

I . OPERATOR
1. Surface used for painting
2. Nozzle used for painting / no

Sa 21/ 2 surface finish

Graco plus 243161

Sa 21/ 2 surface finish

Standard equipment nozzles

3. Compressor outlet Air Pressure during 3.5 kg /cm2

painting
4. Tip size of the nozzle
0.38 to 0.43mm

3 to 4 kg/cm2

5.lapping of spray during paint application 75-100 mm

100mm

6.WFT measured during painting

100 micron

108 to 125 micron as

recommended by the manufacturer

7. D.F.T measured after 24 hours of paint

application

65 to 70 microns

65 to 75 microns

0.38 to 0.43mm

Variables for each process

Actual Value

Range Qualified

II. PROCESS
1. Paint specification / Brand used for
application
2. Mixing ratio of paints

3. Thinner used for application

4. Addition of thinner for application

In organic zinc silicate primer ZINC

ANODE 304 of Berger make.

NPCIL approved paints of zinc

silicate primer and Epoxy finish
coatings
35:65( by weight ) for zinc anode
As per manufacturers
304 & 1:1 for Berger Protectomastic recommendations of NPCIL
approved paints.
Thinner 870 for Zinc anode 304 &
As per manufacturers
Thinner 844 for Berger
recommendations of NPCIL
Protectomastic
approved paints.
3%

5% - 10% ( depending on
temerature conditions various )

5.Pump ratio

30:1 for primer

6. Strainer / mesh size

3. Infrastructure facility used for the
process

80
Dry covered shed with exhaust fan and halogen lights for proper
illumination

III. INSPECTION
1. Visual Inspection during painting
2. Visual Inspection after 24 hrs of drying

No spillage / holidays found .

No mud cracks, sprinkles,pores observed on the surface

Applicator & Process test conducted by L&T - ECC -

B.SUNDAR ( QA)

Date of test : 22-8-2003

We certify that the data recorded in this format are correct and that the test has been carried out
as per the requirement of approved work procedure L&T/WP/04 Rev. 0 & Paint Manufacturers recommendations.
L&T QA

CLIENT