Reliance

Preheating Procedure Qualification

For
Equipment Nozzle Modification
(CS and LTCS)
EPCMD-2-QM00-JEP-ME-032

00

05.07.2012

Issued for Implementation

PPP / ALJ

KSS / EMK

SNS

Rev

Date

Revision

Prepared
By

Checked
By

Approved
By

Reliance
Contents
1. Purpose ...3
2. Scope ....3
3. References ...3
4. Abbreviations and Terms ..3
5. Responsibilities ....4
6. Methodology ...4
7. Attachments ...5

EPCMD-2-QM00-JEP-ME-032, Rev:00
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1.

Purpose
The purpose of this document is to provide step by step methodology for preheat
procedure qualification used for carbon steel and LTCS materials during equipment
modification. It is necessary to develop the procedure to ensure uniform heating using
oxy-acetylene torch and with precautionary measurements, have adequate confidence
to avoid any local hot spot /puncturing.
Studies were made on the issue and following points were observed:

2.

i)

In ordinary oxyacetylene cutting torch, the lever system is added to trigger the
cutting action. In case the oxyacetylene heating torch is designed without any
lever system, the likely hood of accidental cutting of base material is drastically
reduced.

ii)

Using oxyacetylene gas, the flame generated is having two distinct regions. The
primary combustion takes place due to inner blue cone region generating
highest temperature, i.e. as high as 3092 C which is much above the melting
point of iron (1539C). The secondary combustion takes place in the outer
portion of the flame whose temperature is below the melting point of iron and
this can be utilized only for preheating. Hence during preheating, care needs to
be exercised so that the blue cone region does not come in direct contact with
the base material.

Scope
The scope of this procedure is limited to the carbon steel and LTCS materials and
applicable to equipment modifications for project of Reliance.

3.

4.

5.

Reference

AWS Handbook

Modern Arc Welding Technology S.V. Nadkarni

Abbreviations and Terms

CS

Carbon steel

HOD

Head of the department

LTCS

Low temperature carbon steel

PWHT -

Post Weld Heat Treatment

QMD

Quality Management Department

Responsibilities

Construction Managers/Engineer in Charges is responsible for implementing this

procedure in their area.

EPCMD-2-QM00-JEP-ME-032, Rev:00
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Reliance

HOD, QMD is responsible for maintaining this procedure.

DCC is the custodian of this document.

6.

Methodology

6.1

Variables:
Following are the essential variables and change in any of these variables shall require
re-qualification of the procedure:

The heating torch must be designed without any lever arrangement for cutting
actions. In addition, the heating torch design and manufacturer of torch shall be
treated as essential variable.

The distance between torch tip and job surface shall be maintained 6 inch
(minimum) and blue cone flame length shall be 3 inch (max). Any change will
require re-qualification.

6.2

Preparation of joint:
Under present scope of work for nozzle modification job, the material is required to be
preheated for thickness > 25mm. The maximum thickness of vessel is 88mm.
Instances will arise (during nozzle to shell joining) that though the nozzle thickness
does not ask for preheating, but preheating is required due to the heavy thickness of
shell. The preheating temperature on job shall be as follows:

Sr.
No.

6.3

Thickness of base material (In case of dissimilar thickness, preheating temperature shall
be decided by the higher thickness material)

Preheat
temperature (min)

01

Thickness>25 to 32mm

79C

02

Thickness >32 to 60mm

95C

03

Thickness >60 to 88mm

125C

Test coupon dimension and preheat temperature

In order to have adequate confidence, the test coupon is chosen with thickness
10.97mm or lower (one set of plate, groove joint, length 300mm minimum). The
criteria for deciding 10.97mm coupon thickness is that this is the lowest thickness of
nozzle within available scope. Coupon shall be preheated at a minimum preheat
temperature of 125 C.

EPCMD-2-QM00-JEP-ME-032, Rev:00
Confidential Reliance. All rights reserved

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6.4

Observation and verification:

6.4.1

Time taken to reach the preheat temperature on the groove shall be noted. Preheating
temperature shall be checked with temple stick.

6.4.2

After reaching the preheating temperature on the groove, same shall be verified on
either plate at a distance of 25mm (minimum) from the edge of the groove to assess
the uniformity of heating.

6.4.3

The length up to which the same preheat temperature is maintained shall be noted to
understand and assess the capacity of the torch.

6.4.4

Preheat temperature shall be continued on the joint for a further period of 30 minutes
and then observed through visual inspection for any puncture/damage on the coupon.

6.5

Acceptance:

6.5.1

In case the same preheat temperature is achieved on groove as well as on either side
of the joint at a time and there is no physical damage observed on base material
during preheating, the procedure shall be treated as qualified within the limits of
variables.

6.5.2

The minimum thickness qualified shall be the thickness of the test coupon.

7.

Attachment:
Annexure-1 (Preheating Procedure Qualification Record Format)

EPCMD-2-QM00-JEP-ME-032, Rev:00
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Annexure-1
Pre-heating Procedure Qualification Record Format
Sr.

Check points

No.
01

02

03

Remarks

Whether oxyacetylene heating torch is

designed without lever arrangement.
Detail design of torch (attach sketch and
extra sheets if necessary)
Approximate distance between torch tip and
job surface during preheating

04

Approximate length of blue cone

05

Base metal thickness and specification

06

Observation

Whether preheating temperature of 125C is

reached on groove
Measure preheat temperature on groove and

07

on both plates at a distance of 25mm from

groove edge to understand uniformity of
heating

08
09

Time taken to reach preheat temperature

Length of coupon up to which 125C preheat
temperature is maintained
Observation: Puncture or damage of base

10

material, if any (after holding the preheat

temperature 125C for 30 minutes
minimum)
Conclusion:

11

EPCMD-2-QM00-JEP-ME-032, Rev:00
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