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TREATMENT
TRAINING MANUAL
MAY-2001 (REV.-0) 1
HEAT TREATMENT MANUAL
This Manual is compiled by
Mr K S Rao (QA),
Mr S P Ghiya (Inspection ) and
Mr N M Bodalia (M FS)
3
General
• Only qualified supervisors and operators including
LSR operators shall be authorised to operate furnace.
• A list of qualified personnel shall be prepared by QA
and published periodically.
• Thjs manual is prepared on the basis of experience
and feedback, taken from various personnel.
• This manual is for reference only.
4
HEAT TREATMENT
5
WHAT IS HEAT TREATMENT
• MATERIALS TREATED BY
APPLICATION OF HEAT NORMALLY
DONE IN SOLID STATE
• VARIOUS SOURCES OF HEAT
• PARAMETERS ARE HEATING
RATE,SOAKING TEMP,SOAKING
TIME,COOLING RATE AND COOLING
MEDIA
6
WHY IS IT REQUIRED ?
• TO ENHANCE MATERIAL PROPERTIES /
EASE IN FABRICATION BY CHANGING
– Strength,Improve corrosion resistance
– Toughness/Ductility
– Hardness,Dimensional stability etc
– Remove diffusible hydrogen to avoid
hydrogen cracking
• CARRIED OUT IN FABRICATION
INDUSTRIES ,STEEL PLANTS, FOUNDRY, 7
FORGING SHOPS etc..
MATERIALS HEAT TREATED
10
TYPES OF HEAT TREATMENT
• NORMALIZING
• ANNEALING
• STRESS RELIEVING
• SOLUTION ANNEALING-Mainly SS
• HARDENING
• TEMPERING
• AGING
11
IRON CARBON DIAGRAM
12
Iron Carbon Diagram
Portion related to Heat Treatment
13
NORMALIZING
• The steel is heated to 40° C above the upper
critical temperature(910 ºc) followed by cooling
in the still air.
Normalizing is done to achieve the following :
• To get Uniform structure and reduce chemical
gradients
• To change Mechanical properties,
– UTS,YS
– Hardness
– Impact properties
• To refine the grains
14
ANNEALING
• In this process, the steel is heated from 10 to
50°C above the upper critical
temperature(910ºc) and held for the desired
length of time; followed by very slow cooling
in the furnace
Annealing is done to achieve following :
• to soften the steel and improve ductility
• to relieve internal stresses caused by previous
treatment 15
SOLUTION ANNEALING
In Stainless steels , it is heated to 1050°C or
above ,and held for the desired time; followed by
quenching/blowing the air(cooling to room
temperature within few minutes).
Solution annealing is done on stainless steel and
non ferrous alloys to achieve following:
• To soften the material
• To dissolve carbide precipitation formed at grain
boundaries during manufacturing process
• To improve Corrosion Resistance 16
AGING
The Material is heated to a certain temperature,
and held for the desired time; followed by
normally for precipitation hardened alloys or
cooling in air
Aging is done on materials susceptible for
aging characteristics : Maraging Steels
M250
• Temperature : 485 C
• Normally 3 Hrs 15 mts
• Heating Rate : 200 C per hr per inch
• Cooling Rate : Cool in Air / Quench in water
18
STRESS RELIEVING
The steel is heated to a temperature below or
close to the lower critical point, followed by
desired rate of cooling and there is no change
in grain structure.
Stress relieving is done to achieve following :
• To reduce Internal Stresses (residual Stresses)
• To soften the steel partially
THEIR ATTACHMENTS
24
LAYOUT OF A TYPICAL
FURNACE
(Electrical or Gas fired )
FURNACE
THERMOCOUPLE
COMPENSATING
CABLE
JOB
RECORDER P.I.D.
CONTROLLING BURNER 25
THERMOCOUPLES
• PRINCIPLE OF A THERMOCOUPLE
• THERMOCOUPLE MATERIALS
26
PRINCIPLE OF THERMOCOUPLE
Welded
White/yellow junction
White Color
+Ve
recorder
-Ve
Red Color
Compensating Thermocouple
cable wire
Accuracy : 0.75% 31
‘S’ TYPE THERMOCOUPLE
Accuracy : 0.25 %
• MATERIAL OF CONSTRUCTION
90% PLATINUM + 10% RHODIUM
PLATINUM
32
ISSUE METHODOLOGY
For DISPOSAL TYPE
35
RECORDER
TYPES OF RECORDER
PAPERLESS -- WITH COLOUR DISPLAY SCREEN ,HARD DISC AND FLOPPY DRIVE.
NOT USED IN HZW.
•WITH PAPER -- CURRENTLY BEING USED IN HZW.
•24 CHANNEL -- CURRENTLY BEING USED IN PFS( CHINO MAKE-- model no.I003
/Graph ET 001).
•12 CHANNEL -- CURRENTLY BEING USED IN MFS1 AND HFS1
( CHINO MAKE -- model no. EH100 / Graph ET 201).
38
( ZONE-2 ) ( ZONE-4 ) ( ZONE-6 ) ( ZONE-8 )
BURNER
1640 1650
7900
(BOGIE
WIDTH
)
1650
3575 3575 3575 3575
( ZONE-1 ) ( ZONE-3 ) 14300. ( ZONE-5 ) ( ZONE-7 )
1. PROJECT NO:
2. SECTION NO :
3. CHARGE NO :
9500
4. H. T. REQ. NO :
BURNER
8700
41
STANDARD OPERATING PROCEDURE FOR HFS-1
FURNACE
9. Move the bogie inside the furnace
10. Pass the thermocouples through ports and
connect it with compensating cables
11. Set the program as per heat treatment request.
Secure it and then run it in fast mode as check.
Bring it back to the initial segment and hold.
12. Insert heat treatment chart in recorder and adjust
the speed of the graph.
13. Clear inspection of job and get the signature of
inspector on graph paper for firing the furnace.
14. Check LPG level, pressure and temperature in the
storage tanks and note down in logbook. 42
STANDARD OPERATING PROCEDURE FOR HFS-1
FURNACE
15. Switch on the power supply
16. Close the bogie door
17. Follow the procedure for startup of furnace in zone-I
18. Start the blower from the field push button station
provided
19. Give power supply to the ignition panel
20 When the “system healthy” contact comes from the
instrument panel, the lamp for the “system healthy”
signal is on. This indicates that the combustion air
pressure and gas pressure are within the specified
limits
43
21. Now the firing on the cycle can start.
STANDARD OPERATING PROCEDURE FOR HFS-1
FURNACE
22. Open the pilot and main gas valves
23. Press start cycle button on doing so the cycle starts
and purging start indicator lamp is on.
24. After 3 minutes ( time adjusted through timer ) the
purging is completed and ignition start lamp is ON
At the same time the purging start lamp gets OFF.
25. After 10 seconds the ignition start lamp gets OFF
By this time the pilot burner should have been fired
and the pilot flame is established.
26. Flame healthy signal LED gets on which is provided
on the flame sensor relay. This can be viewed through
the glass window provided in the ignition panel.
44
STANDARD OPERATING PROCEDURE FOR HFS-1
FURNACE
27. Due to certain length of pipe between the burner and
solenoid valves, which may contain air, the burner
may not light up in the first attempt. In that case,
repeat the above mentioned procedure.
28. Once the main flame is established, the control is
passed on to the temperature controller.
29. For startup of furnace in other zones, follow the same
steps no 16 to 27 mentioned above.
30. After all zones are started, start recording time and
temperature from recorder every 30 minutes in the
logbook.
31. Conduct spot checks for heat treatment every 4hours
45
and fill the spot check format.
STANDARD OPERATING PROCEDURE FOR HFS-1
FURNACE
35. Submit the graph and duly filled spot check formats
to inspection for approval of heat treatment.
46
STANDARD OPERATING PROCEDURE FOR HFS-1
FURNACE
39. Unload the job from the bogie and move the bogie
inside the furnace.
40. Close the furnace. Shut off the main power supply.
47
STANDARD OPERATING
PROCEDURE FOR PFS
FURNACE
48
125T Bogie hearth furnace -- PFS
49
PFS FURNACE SKETCH
5600
2650
5500
BURMER
4100
1460
BOGGIE WIDTH
1050
1235
50
STANDARD OPERATING PROCEDURE FOR PFS
FURNACE
1. Receive the job as per HT request.
2. Receive heat treatment request duly approved by
metallurgy engineer.
3. Ensure that Insp. clearance is available prior to
loading for job.
4. Load the job on the bogie as per the heat treatment
furnace request.
5. Ensure the supporting arrangement as per the
attached annexure-I.
6. Ensure the spider arrangement as per annexure- II.
7. Fix the thermocouples at locations shown in furnace
charge.
51
STANDARD OPERATING PROCEDURE FOR PFS
FURNACE
8. Check the entire job as per check list attached as
annexure-III
28. Submit the graph and duly filled spot check formats
to inspection for approval of heat treatment. 55
STANDARD OPERATING PROCEDURE FOR PFS
FURNACE
29. Retrieve the thermocouples from the ports and move
the bogie out of the furnace.
32. Unload the job from bogie and move the bogie inside
the furnace.
57
CERMIC GROUND LEVEL HEATING
BLANKET ELEMENT
CERMIC FIBER
OUTER
SLABER BLOCK BAFFLE
FIRE BRICK SHELL
INSULATING
CASTABLE
ROOF
CERAMIC
BLANKET
4020
)
125 250
TROLLEY
STRUCTURE
1380
1000
4961 58
PIT FURNACE SKETCH
STANDARD OPERATING PROCEDURE
FOR PIT FURNACE
10. Insert the graph inside the recorder and take the
signature of inspector on the graph paper.
60
STANDARD OPERATING PROCEDURE
FOR PIT FURNACE
13. Start recording the time and temperature in the
logbook every 30 minutes.
14. Ensure that the cycle is functioning as per program.
15. After the heat treatment is over, open the furnace
cover.
16. If the job calls for water quenching, lift the job and
dip it in quench tank.
17. It the job calls for air cooling in still air, lift the job
and put it outside on supports in open air.
61
STANDARD OPERATING PROCEDURE
FOR PIT FURNACE
18. It the job doesn’t call for anything above, allow the
job to cool down in furnace.
62
PROCEDURE FOR EMPTY FURNACE
CALIBRATION
Calibration of PIDS ( indicator & controller )
1. Connect the millivolt source to the temperature
indicator or controller by a compensating cable.
Care should be taken to clean the wires and
terminals thoroughly before connections are
made.
2. The millivolt output for various temperature
ranging from 00C to 10000C in steps of 500C is fed
to the indicator / controller.
3. After the millivolt value / temperature reading
displayed is steady, the reading of
indicator/controller shall be noted. 63
PROCEDURE FOR EMPTY FURNACE
CALIBRATION
Calibration of recorder
1. Connect the millivolt source to the recorder by a
compensating cable. Care should be taken to
clean the wires and terminals thoroughly before
the connections are made.
64
PROCEDURE FOR EMPTY FURNACE
CALIBRATION
6. Close the furnace lid. Start the furnace and the recorder.
67
PIT FURNACE CALIBRATION PROCEDURE
0
7. Set the temperature of controller to 400 C.
8. After reaching the set temperature, it is allowed to
stabilize for half an hour.
70
LOCAL STRESS RELIEVING
WHY
• Local SR to be done only when furnace SR not feasible
• When only certain components to be PWHT
HOW
• Can be done by Electrical / Gas / diesel / Induction etc..
Heating band
Insulation band
72
LOCAL STRESS RELIEVING SET UP
SB+HB+IB
LSR of C/S
Spider or
prop
No Welding at top
Multitonne roller
74
200 to 500mm from heating band
GOOD ENGG. PRACTICES
FOR FURNACE CHARGES
&LSR
75
SUPPORTING ARRANGEMENTS
1. Heat Treatment request shall be as per Annexure-7
and Annexure-8.
shall be 600mm.
600mm
450mm
burner
900
600mm
300mm(point no:2)
78
SUPPORTING ARRANGEMENTS
Zero gap
Supporting
arrangement
towards bottom
81
GENERAL
Temp. support
Furnace floor
83
THERMOCOUPLES
84
THERMOCOUPLES
ATTACHMENTS
1. Use only TAU-90 capacitor Discharge Welding
machine for thermocouple connection
85
THERMOCOUPLES
ATTACHMENTS
87
SPECIAL NOTE
DESIGN.
88
CODE EXTRACTS
•FURNACE PWHT
•LSR
89
REQUIREMENT OF HEAT TREATMENT
AS PER ASME-SEC VIII Div.-1
• SERVICE CONDITION (UW-2)
• LOW TEMERATURE
OPERATION (UCS-68)
• CUSTOMER SPEC.
90
CODE EXTRACT FOR HEAT TREATMENT
( 1 ) The soak band shall contain the weld, heat
affected zone and a portion of base metal adjacent to the
weld being heat treated. The minimum width of this
volume is the widest width of weld plus 1T or 2 inches,
whichever is less, on each side or end of the weld. The
term ‘T’ is the nominal thickness.
( 2 ) The operation of postweld heat treatment shall be
performed either by heating the vessel as a whole in an
enclosed furnace or heating the vessel in more than one
heat in a furnace, provided the overlap of the heated
sections of the vessel is at least 5 feet ( 1.5m). When this
procedure is used, the portion outside of the furnace
shall be shielded so that the temperature gradient is not
harmful. The cross section where the vessel projects
from the furnace shall not intersect a nozzle or other
91
structural discontinuity.
CODE EXTRACT FOR HEAT TREATMENT
( 3 ) When the vessel is required to be postweld heat
treated, and it is not practicable to postweld heat treat the
completed vessel as a whole or in two or more heats; any
circumferential joints not provisionally heat treated may be
thereafter locally postweld heat treated by heating such
joints by any appropriate means that will assure the
required uniformity.
( 4 ) While carrying out local postweld heat treatment,
the soak band shall extend around the full circumference.
The portion outside the soak band shall be protected so
that the temperature gradient is not harmful.
( 5 ) Heating a circumferential band containing nozzles
or other welded attachments in such a manner that the
entire band shall be brought up uniformly to the required
temperature and held for the specified time. 92
CODE EXTRACT FOR HEAT TREATMENT
( 6 ) Where more than one pressure vessel or more
pressure vessel part are postweld heat treated in one
furnace charge, thermocouples shall be placed on
vessels at the bottom, center, and top of the charge or in
other zones of possible temperature variation so that the
temperature indicated shall be true temperature for all
vessels or parts in those zones.
( 7 ) Postweld heat treatment, When required, shall be
done before the hydrostatic test and after any welded
repairs. A preliminary hydrostatic test to reveal leaks
prior to PWHT is permissible.
( 8 ) For pressure vessels or parts of pressure vessels
being post weld heat treated in a furnace charge, it is the
greatest weld thickness in any vessel or vessel part
which has not previously been postweld heat treated. 93
CODE EXTRACT FOR HEAT TREATMENT
( 8 contd...) The nominal thickness is the total depth of
the weld exclusive of any permitted weld
reinforcement.
For groove weld, the nominal thickness is the
depth of the groove.
For fillet welds, the nominal thickness is the
throat dimension.
If a fillet weld is used in conjunction of groove
weld, the nominal thickness is the depth of the
groove or the throat dimension, Whichever is
greater.
For stud welds, the nominal thickness shall be the
diameter of the stud.
( 9 ) For P–1 material ( carbon steel), minimum holding
temperature during postweld heat treatment shall
be 1100 Deg. F ( 593 Deg.c). 94
CODE EXTRACT FOR HEAT TREATMENT
95
CODE EXTRACT FOR HEAT TREATMENT
( 10 ) Postweld heat treatment is mandatory in
Following conditions :
• For welded joints over 1. 5” nominal thickness.
• For welded joints over 1.25” nom. Thickness
through 1.5” nom. Thickness, unless preheat is
applied at a min. Temperature of 200’F ( 94‘c )
during welding.
• Vessels or parts of vessels constructed of base
material with corrosion resistant integral or weld
metal overlay cladding or applied corrosion
resistant lining material shall be postweld heat
treated when the base material is required to be
postweld heat treated. In applying this rule, the
determining thickness shall be the total thickness
of base material. 96
• When the PWHT is a service requirement.
CODE EXTRACT FOR HEAT TREATMENT
SERVICE CONDITION
97
CODE EXTRACT FOR HEAT TREATMENT
( 11 ) Postweld heat treatment is not mandatory for carbon
steel jobs (P1 material ) in Following conditions (UG2):
NOTES :
1. MINIMUM HOLDING TIME FOR 1” THICKNESS OR LESS ; ADD 15 MINUTES PER INCH OF
THICKNESS FOR THICKNESS GREATER THAN 1”.
2. THESE LOWER POSTWELD HEAT TREATMENT TEMPERATURES PERMITTED ONLY FOR P-
NO.1 GROUP NO. 1 AND 2 MATERIALS. 101
102
103
104
105
SELECTION OF SPIDERS AT OPEN ENDS FOR HEAT TREATMENT
SHELL THICKNESS
Annexure-5
100
10
20
30
40
50
60
70
80
90
10000
9500
9000
8500
8000
7500
6000
5500
5000
4500
4000
3000
2500
1500
1000
100
10
20
30
40
50
60
70
80
90
SHELL THICKNESS
108
Annexure-8
HT CHARGE
109
Annexure-9
Usage of compansating cable
page 1 of 4
110
Annexure-9
Usage of compansating cable
page 2 of 4
111
Annexure-9
Usage of compansating cable
page 3 of 4
112
Usage of compansating cable Annexure-9
page 4 of 4
113
Information on Graph Paper Usage Annexure-10
114
Mechanical v/s capacitor discharge attachments Annexure-11
115
Thermo. Couple Procurement Procedure Annexure-12
116
Thermo. Couple Attachment Procedure Annexure-13
page 1 of 2
117
Annexure-13
Thermo. Couple Attachment Procedure page 2 of 2
118