PWHT

HEAT 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) Under the guidance of Mr P D Lohidakshan (Weld Engg & Prod Engg )
2
INDEX TOPIC
1 . INTRODUCTION ON HEAT TREATMENT
2 . FURNACE PARTS AND ATTACHMENTS 3. STD. OPERATING PROCEDURES(HFS)
PAGE NO.
4- 24
25- 37 38- 47
4 . STD. OPERATING PROCEDURES(PFS)

5 . STD. OPERATING PROCEDURES(MFS) 6 . STANDARD PRACTICES FOR LSR 7 . GOOD ENGINEERING PRACTICE 8 . CODE EXTRACT(REFERENCE ONLY) 89- 101 9 . ANNEXURES
48- 56
57-69 70-74 75-88
102- 118
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.
HEAT TREATMENT
WHAT IS HEAT TREATMENT ? WHY IS IT REQUIRED ? TYPES OF HEAT TREATMENT HEAT TREATMENT AT HZW
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

METALS & ALLOYS
SINGLE PHASE MULTIPHASE
ALLOYS
Single Phase : Copper Nickel Multiphase : Steels-LAS,QT
METALS (Single phase )

Titanium,Al,Ni,Cu etc..
8

CRITERIA COLD WORKED to NORMAL
All materials
UNEQUILIBRIUM PHASES to EQUILIBRIUM:(Stabilise Microstructure & Phases)

Stainless Steels ,Maraging Steels All Materials
STRESSED to UNSTRESED CREATION OF UNEQUILIBRIUM CONDITIONS

Steels
9

MATERIALS CATEGORY C-Mn , C-Mo , Cr-Mo , Ni -Steels, QT Stainless Steels-Austanitic.Martensitic Steels enhanced by Heat Treatments Non Ferrous Materials; Titanium alloys, Aluminum alloys
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 c) 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 50C above the upper critical temperature(910c) 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 1050C 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 16 To improve Corrosion Resistance
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 Normally increase in strength To Improve Toughness/Ductile-brittle transition temp.
17
AGING
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 To improve ductile-brrittle transition temp. and equalize impact values
19
STRESS RELIEVING
C-Mn , C-Mo , Cr-Mo (< 2% Cr)
C - Mn Steels , C - Mo Steels,Cr-Mo Steels
SA 515Gr 70 , SA204GrA, SA387GR11CL1
Temperature : 593 C Min

Normally 600 - 640 C,650-690 C
Time : 15 minutes min

Time : 1 hr / inch
Heating Rate : 200 C per hr per inch Cooling Rate : 260 C per hr per inch
20
STRESS RELIEVING
Cr-Mo Steels
Cr - Mo Steels (Cr >2%)
SA 335P22 ,SA335P5

Normally 680 - 700 C 2.25Cr 704 - 720 C 5 Cr
Time : 15 mts min

Time : 1 hr / inch
21
STRESS RELIEVING
Ni -Steels
Nickel Steels : 1,2,3% Ni
SA 203 GrA ,D

Normally 600 - 640 C,650-690 C
Time : 60 mts min

Time : 1 hr / inch
22
STRESS RELIEVING
Steels enhanced by Heat Treatments
Q&T Steels :
9.5% Ni Steels , SA 517 Gr E
Temperature : 538 C Typ

Normally < 600 C
Time : Minimum 15 minutes to 2 Hr

Time : 1 hr / inch
23
FURNACE PARTS AND 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 TYPES OF THERMOCOUPLES BEING USED IN HZW
26
PRINCIPLE OF THERMOCOUPLE
The basic principle of thermoelectric thermometry is that a thermocouple develops an emf which is a function of the difference in temperature of its measuring junction & reference junction. If the temperature of reference junction is known, the temperature of the measuring junction can be determined by measuring the emf generated in the circuit.
27
THERMOCOUPLE MATERIAL REQUIREMENT

1. High coefficient of thermal emf.
2. Continuously increasing relation of emf to temperature over a long range. 3. Freedom from phase changes or other phenomenon giving rise to discontinuity in temperature emf relationships. 4. Resistance to oxidation, corrosion and contamination. 5. Homogeneity and reproducibility to fit an establish temperature & emf relationship. SPEED OF RESPONSE MAY BE IMPROVED AND RADIATION & CONDUCTION ERRORS MAY BE REDUCED 28 BY THE USE OF SMALL DIAMETER THERMOCOUPLES.
TYPES OF THERMOCOUPLE BEING USED IN HZW

K type :
Material
Nickel based
Chromel
( 10 %Cr )
Alumel
+ ( 2 % Al )
Properties :
Non-Magnetic +
Magnetic
In this type of thermocouple, the wires are joined at one end only to form a point-type temperature sensor. Instrumentation converts the millivolt signal to related temperature. 29
TYPES OF THERMOCOUPLE BEING USED IN HZW contd...

K type : Dia : Insulation coated 2.5 mm Bare(ceramic) 0. 7 mm Refractory
Attachment
Usability
Mech
Reusable
Capacitor
Disposable
Location
Color
PIT F/c
-
except PIT F/c

Red & Yellow
30
CONSTRUCTION OF A
K TYPE THERMOCOUPLE
White Color White/yellow
pid
Blue Color
+Ve
-Ve Red Color
White Color
White/yellow
Welded junction
recorder
+Ve
Red Color
-Ve
Compensating cable
Thermocouple wire
Accuracy : 0.75%
31
S TYPE THERMOCOUPLE
Accuracy : 0.25 %
S TYPE THERMOCOUPLE ARE THE STANDARD THERMOCOUPLES. IT IS USED FOR CALIBRATING K Type THERMOCOUPLES. MATERIAL OF CONSTRUCTION 90% PLATINUM + 10% RHODIUM PLATINUM OXIDATION RESISTANCE , SO MORE LIFE .
32
ISSUE METHODOLOGY For DISPOSAL TYPE

Users will send their requirement of thermocouple
through Consumable slip ( mentioning HTR No ) to QA QA shall issue the same . QA shall issue identification sticker duly attached
Users shall ensure availability of identification sticker on unused wire . See Annexure-12 for further details
33
COMPENSATING CABLE
COMPENSATING CABLE IS DEFINED AS A PAIR OF WIRES HAVING SUCH EMF TEMPERATURE CHARACTERISTICS RELATED TO THE THERMOCOUPLE WITH WHICH THE WIRES ARE INTENDED TO BE USED, THAT WHEN PROPERLY CONNECTED TO THERMOCOUPLE THE EFFECTIVE REFERENCE JUNCTION IS IN EFFECT TRANSFERRED TO THE OTHER END OF THE WIRES.
MATERIAL ==> +ve COPPER ( white ) -ve COPPER NICKEL (blue ) for K TYPE .
See Annexure-9 (Annexure Page 1-4) for further details

34
P.I.D.
PID = PROPORTIONAL INTEGRAL DERIVATIVE
PID FUNCTIONS BOTH AS PROGRAMMER AND CONTROLLER PID CONTROLLER CAN BE ZONE WISE PROGRAMME IS MADE IN SEGMENTS AS PER DIFFERENT STAGES OF HEAT TREATMENT DIGITAL DISPLAY IS AVAILABLE FOR PROGRAMME TEMPERATURE AND FURNACE TEMEPERATURE TYPICAL OR REPETITIVE HEAT TREATMENT CYCLE CAN BE STORED IN PID(PROGRAMMER)
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). COMPENSATING CABLES ARE CONNECTED BEHIND THE RECORDER SCREEN IN CHANNELS. X-AXIS IS FOR TEMPERATURE (RANGE = 0 TO 1200C) THE SCALE ON X-AXIS IS NON-LINEAR. Y-AXIS IS FOR GRAPH SPEED. VARIOUS SPEED OF GRAPHS ARE 12.5, 25, 50, 100 MM / HOUR WE GENERALLY KEEP 25 MM / HOUR.
36
GRAPH PAPER
GRAPH PAPERS ARE USED FOR PLOTTING THE FURNACE TEMPERATURE VIA THERMOCOUPLE. THEY ARE FITTED ON THE RECORDER. GRAPH PAPER RECOMMENDED ON RECORDER ONLY TO BE USED GRAPH PAPER FOR MFS1 AND HFS1 FURNACE ==> ET 201 CHINO MAKE, JAPAN GRAPH PAPER FOR PFS FURNACE ==> ET 001 CHINO MAKE, JAPAN THE LENGTH OF ONE BUNDLE OF GRAPH PAPER IS GENERALLY 2000 MM. DOTTING TYPE RECORDER INK (CHINO MAKE, JAPAN) IS USED IN RECORDER FOR PLOTTING OF GRAPH. USUALLY , 6 COLOURS ARE FILLED FOR PLOTTING. 37 SEE ANNEXURE-10 FOR FURTHER DETAILS
STANDARD OPERATING PROCEDURE FOR HFS-1 FURNACE
38
( ZONE-2 )
( ZONE-4 )
( ZONE-6 )
( ZONE-8 )
BURNER
1640
1650
7900 (BOGIE WIDTH )
1650 3575 ( ZONE-1 )
3575 ( ZONE-3 )
14300.
3575 ( ZONE-5 )
3575 ( ZONE-7 )
HFS-I FURNACE SKETCH
39
9000
1. PROJECT NO: 2. SECTION NO :

9500
3. CHARGE NO : 4. H. T. REQ. NO :
BURNER 1195 7900 BOGGIE WIDTH 8700 1050
HFS-I FURNACE SKETCH
40

1.
2. 3. 4. 5. 6. 7.
Receive the job as per HT request.

Receive heat treatment request duly approved by metallurgy engineer. Ensure that Insp. Clearance is available prior
to loading for job.

Load the supporting arrangement as per the attached annexure -3 Ensure the spider arrangement as per attached annexure - 5 Fix the thermocouples at locations shown in furnace charge. Check the entire job as per check list (annex.-I).
41

9. 10. 11. Move the bogie inside the furnace Pass the thermocouples through ports and connect it with compensating cables 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. Insert heat treatment chart in recorder and adjust the speed of the graph. Clear inspection of job and get the signature of inspector on graph paper for firing the furnace. Check LPG level, pressure and temperature in the 42 storage tanks and note down in logbook.
12. 13. 14.

15. 16. Switch on the power supply Close the bogie door
17.
18.
Follow the procedure for startup of furnace in zone-I

Start the blower from the field push button station provided
19.
20
Give power supply to the ignition panel

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 21. Now the firing on the cycle can start.
43

22. 23. 24. Open the pilot and main gas valves Press start cycle button on doing so the cycle starts and purging start indicator lamp is on. 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

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. Once the main flame is established, the control is passed on to the temperature controller.
28.
29.
30.
For startup of furnace in other zones, follow the same steps no 16 to 27 mentioned above.
After all zones are started, start recording time and temperature from recorder every 30 minutes in the logbook. Conduct spot checks for heat treatment every 4hours 45 and fill the spot check format.
31.

32. Monitor the heat treatment process and graph till the completion to ensure that it is as per program and heat treatment request. 33. After heat treatment cycle is completed, shut off all LPG supply valves and let furnace run with blowers on for 15 minutes. 34. Open the bogie door. Disconnect thermocouples
from compensating cable.

35. Submit the graph and duly filled spot check formats to inspection for approval of heat treatment.
46

36. Retrieve the thermocouples from the ports and the
bogie out of the furnace. 37. 38. Allow the job to reach room temperature. Remove the thermocouples from the job carefully without damaging the junction of thermocouples and without making impression on parent material of job. 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
BURMER
4100 1235 1050
BOGGIE WIDTH
1460
5500
50

1. 2. 3. 4. 5. Receive the job as per HT request. Receive heat treatment request duly approved by metallurgy engineer. Ensure that Insp. clearance is available prior to loading for job. Load the job on the bogie as per the heat treatment furnace request. Ensure the supporting arrangement as per the attached annexure-I.
6.
7.
Ensure the spider arrangement as per annexure- II.

Fix the thermocouples at locations shown in furnace charge.
51

8. Check the entire job as per check list attached as annexure-III Move the bogie inside the furnace. Pass the thermocouples through ports and connect it with compensating cables. Insert heat treatment chart in recorder and adjust the speed of the graph. Clear inspection of job and get the signature of inspector on graph paper for firing the furnace. Check LPG level, pressure and temperature in 52 the storage tanks and note down in logbook.
9. 10.
11.
12.
13.

14. 15. Switch on the power supply. Close the bogie door.
16.
Switch on ID blower first and then the air blower and maintain pressure at about 800mm WG by slowly opening the suction valve.
Ensure that pressure of LPG from yard to inlet of pressure regulator is always less than 20psi (1.5kg/CM2). Open the inlet valve to the regulator and open the outlet valve. If pressure exceeds 1600 mm WG , isolate the pressure by lifting the handle of safety shut off 53 valve.
17.
18. 19.

20. 21. Immediately start lighting the pilot burners and adjust the flame with the air valve . Open the isolating valve for pressure gauge and adjust the pressure regulator by turning the screw provided in the stem so that the pressure is maintained at about 1000mm WG. Light up alternate main burners and adjust the flame lengths uniformly. Lock the doors by pneumatic locking. After all zones start, record time and temperature from recorder every 30 minutes in the logbook.
54
22. 23. 24.

25. Conduct spot checks for heat treatment every 4 hours and fill the spot check format. Monitor the
heat treatment process and graph per heat

treatment request. 26. After the heat treatment cycle is completed, shut off
all LPG valves and let furnace run with blowers on

for 15 minutes. 27. Open the bogie door. Disconnect thermocouples from compensating cables. 28. Submit the graph and duly filled spot check formats to inspection for approval of heat treatment.
55

29. Retrieve the thermocouples from the ports and move
the bogie out of the furnace. 30. 31. Allow the job to reach room temperature. Remove the thermocouples from job carefully and without marking impression on parent material of
job.
32. Unload the job from bogie and move the bogie inside the furnace. 33. Close the furnace. Shut off the power supply.
56
STANDARD OPERATING PROCEDURE FOR PIT FURNACE IN MFS-I
57
FIRE BRICK
CERMIC BLANKET OUTER SHELL
GROUND LEVEL CERMIC FIBER SLABER BLOCK
HEATING ELEMENT BAFFLE
INSULATING CASTABLE
ROOF CERAMIC BLANKET
4150 ( REFRACTORY I/S )
3700 1/D OF BAFFLE
BLOWER
4020
125
250
TROLLEY STRUCTURE 1380
PIT FURNACE SKETCH
4961
1000
58
STANDARD OPERATING PROCEDURE FOR PIT FURNACE

1. 2. 3. 4. Receive heat treatment request duly authorized by metallurgy engineer. Receive the job for heat treatment with inspection clearance. Put the job either on support or on heat treatment fixture inside the furnace. Ensure that equal clearance is available on all sides between job and baffle.
5.
6.
Ensure that the furnace is calibrated.

Connect thermocouples with compensating cable to PID.
59

7. Set the program in the programmer as per heat treatment request. Take a trial run of program to ensure the accuracy. Calibrate all 5 PIDs prior to starting the furnace.
8. 9.
10.
Insert the graph inside the recorder and take the signature of inspector on the graph paper.
Close the furnace door. Start the furnace by giving power supply ON
11. 12.
60

13. 14. 15. 16. 17. Start recording the time and temperature in the logbook every 30 minutes. Ensure that the cycle is functioning as per program. After the heat treatment is over, open the furnace cover. If the job calls for water quenching, lift the job and dip it in quench tank. It the job calls for air cooling in still air, lift the job and put it outside on supports in open air.
61

18. It the job doesnt call for anything above, allow the
job to cool down in furnace. 19. 20. Keep the job outside after removing from furnace. Submit the heat treatment graph to inspection for approval of heat treatment cycle. 21. Close the furnace cover after the furnace is cooled down to room temperature.
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. The millivolt output for various temperature 0 0 0 ranging from 0 C to 1000 C in steps of 50 C is fed to the indicator / controller. After the millivolt value / temperature reading displayed is steady, the reading of indicator/controller shall be noted.
2.
3.
63

4. If the error in the indicated readings is more than the specified accuracy ( +/- 10C ), then correction to be carried out for the indicator / controller and points 1 to 4 shall be repeated till the specified accuracy is obtained is obtained.
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

2. The millivolt output for various temperature ranging from 400 C to 10000C is fed to the recorder and is allowed to plot on a graph.
The graph thus obtained is reviewed for time and temperature values. These values should meet the accuracy requirements. If there is error in the values plotted on the graph, then correction to be carried out for the recorder and points 1 to 4 shall be repeated till the specified accuracy is obtained.
3.
4.
65

EQUIPMENT REQUIRED
1. 2. 3. 4. 5. 20 Nos. big K-type thermocouples 10 Nos. small K-type thermocouples Millivolt source (wahl unit )
ACCURACY
+/- 0.25% +/- 0.25%
( 1 micro volt at 1000 micro volts )

Heat treatment fixture. Temperature indicators (PID) +/- 10C
6.
Recorder
+/- on temperature scale.

+/- minutes on time scale.
66
PIT FURNACE CALIBRATION PROCEDURE

1. 2. Ensure that the PIDs are calibrated as mentioned above. Ensure that the recorder is calibrated as mentioned above.
3.
4.
Ensure that all the thermocouples used are calibrated.

Ensure that the thermocouples are attached to the heat treatment fixture as shown in sketch-I.
5.
Place the heat treatment fixture inside the furnace with thermocouples in position.
6.
Close the furnace lid. Start the furnace and the recorder.
67

7. 8. 9. Set the temperature of controller to 400 C. After reaching the set temperature, it is allowed to stabilize for half an hour. Measure and record the temperature indicated by each of the 20 thermocouples. The temperature is to be read through WAHL UNIT. Three sets of readings are to be taken for each thermocouples at an interval of 10 minutes. Also record the readings indicated by each of the thermocouples at an interval of 10 minutes.
68
10.
11.

12. The temperature is then raised in steps of 50 C up to 1000 C. ( I. e. 400 C, 450 C, .., 950 C, 1000 C. ) The measured temperature is stabilized for 30 minutes. PID reading are also to be recorded along with this. 13. The allowed temperature variation with respect to the set temperature is +/- 50C up to 8000C and +/- 100C above 8000C. 14. This is allowed to plot on the graph and thus obtained for time and temperature values. 15. Calibration of furnace is valid for 1 year.
69
STANDARD OPERATING PRACTICES FOR LOCAL STRESS RELIEVING
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..
DETAILS ON ENSURING PWHT TEMP. IN WELDMENT AREA

Soaking band(SB) = Widest weld width x+ t or 2 inches whichever is less from edge of weld Heating band width (HB) Induction stress level Through thickness criteria SB + 4 rt where r = Inside radius, t = thickness Insulation band width (IB) Axial gradient 71 HB + 4 rt
LSR -BAND WIDTH

Soak band X Weld width X + lesser of 1T or 2
t
Heating band Insulation band
72
LOCAL STRESS RELIEVING SET UP

1. Provide multitonne roller on one end of vessel during LSR of circular seam when job is horizontal. 2. If both ends are open during LSR, provide insulation from inside. If not possible , prevent airflow so that temperature on inside surface do not drop down. 3. Spider/prop shall be provided in such a way that upper portion of spider / prop is not welded with inside surface to allow contraction/expansion of shell surface. 4. Spider/prop shall be between 200- 500mm from heating zone. 5. Temporary attachments, provided for holding insulation, shall be within soak band only. 6. Minimum two thermocouples shall be provided from inside, when accessible.
73
LOCAL STRESS RELIEVING

SB+HB+IB
LSR of C/S
Spider or prop
No Welding at top Multitonne roller
200 to 500mm from heating band
74
GOOD ENGG. PRACTICES FOR FURNACE CHARGES &LSR
75
SUPPORTING ARRANGEMENTS
1. Heat Treatment request shall be as per Annexure-7 and Annexure-8. 2. Minimum distance between floor of the furnace and lower most part of the job shall be 300mm.
3.
The distance between burner flame and saddle

support as well as furnace wall and job shall be 600mm.
4.
Minimum 90 degree saddle to be used, however 120 degree saddle is desirable.

76
burner
900 600mm
600mm
450mm
300mm(point no:2)
5. Saddle shall be arranged in such away that open end of the vessel is maximum 450mm from saddle support. 6. Saddle shall be located as close to spiders (temporarily arranged to control deformation) as possible.
77
7. Spiders shall be provided as per annexure-5
Saddle supports shall be selected as per annexure.-3
9. Spiders or vertical prop shall be provided at open ends, center and below man way/nozzles above 24 10. Avoid gap between saddle support and job surface
78
Zero gap Supporting arrangement
11. Locking/clamping of job, restricting the movement

(axial/lateral) during heat treatment shall be avoided. 12. All long nozzles projecting outside job surface shall be supported.
79
13. Checklist shall be prepared and attached with HT request before furnace is fired as per Ann-1 14. Spot check report shall be filled by supervisor as per Annexure-2 during job is being heat treated. 15. Moonplate support and welding inside surface prior to release for Heat treatment as per Annexure-4 16. General idea about thermocouple locations and its attachments is as per Annexure-6
80
GENERAL
1. Blocking the flame of the burner is not desirable
2. Burner shall have blue flame and not yellow

3. Flame shall not directly impinge on job
4. All burners shall be fired at a time

5. Keep all job nozzles open during heat treatment
6. Above 24 nozzles / manways shall be located

towards bottom
81
GENERAL
Gasket machined surface
Temp. support
Furnace floor
7. Deoxidization agent shall be applied on all machined and gasket faces 8. Gasket / machined face of loose assemblies shall not be touching any object.
82
THERMOCOUPLES
1. All the thermocouples shall be tagged with aluminum sheet and identification hard punched on it. (For PIT furnace only)
2. Minimum two thermocouples to be attached for any charge.
83
THERMOCOUPLES
3. Minimum 8 thermocouples to be used for a charge in HFS- I furnace if the job occupies all 8 zones 4. Maximum distance between two thermocouples for a sample job is as shown in annexure- 6 5. PTC shall have separate thermocouple
84
THERMOCOUPLES ATTACHMENTS
1. Use only TAU-90 capacitor Discharge Welding machine for thermocouple connection
2. Use WPS:999-154 R0 for attachment of thermocouple for cs/alloy steel material

3. Only trained person by welding engineering shall attach thermocouple
4. A list of qualified person shall be by Welding Eng.

85
THERMOCOUPLES ATTACHMENTS
5. Clean surface prior to attachment.
6.
7.
8.
9.
Two wire of thermocouple shall be attached one after another. Gap between two wire of a thermocouple shall be max. 3.0mm Only calibrated thermocouple shall be used.
Calibration shall be by QA. After PWHT, thermocouple area shall be ground
and DP shall be carried out.

10. For further details see Annexure-11 & 13-(page 1&2)
86
THERMOCOUPLES ATTACHMENT UNIT
87
SPECIAL NOTE
IF THE TEMPERATURE OF HEAT TREATMENT
EXCEEEDS
650-DEGREE
CENTIGRADE,
THE
MATERIAL AND SIZE OF SPIDERS AND SUPPORTS TO BE DECIDED BY PLANNING AND APPROVED BY DESIGN.
88
CODE EXTRACTS FURNACE PWHT LSR
89
REQUIREMENT OF HEAT TREATMENT AS PER ASME-SEC VIII Div.-1

SERVICE CONDITION MATERIAL
(UW-2) (UG-85, UW-40,UCS-56,UAT-80,UHA-32,UNF-79)
THICKNESS
LOW TEMERATURE OPERATION COLD WORKING CUSTOMER SPEC.
(UG-85, UW-40,UCS-56,UAT-80,UHA-32,UNF-79)
(UCS-68) (UG-79)
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.

( 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 92 temperature and held for the specified time.

( 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

( 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 P1 material ( carbon steel), minimum holding temperature during postweld heat treatment shall 94 be 1100 Deg. F ( 593 Deg.c).

P. NO. HOLDING TEMP. 1100 DEG. F(593 C) NOM. THICKNE SS UPTO 2 SOAKING PERIOD
1 ( CARBON STEEL) & 3 (LOW ALLOY STEEL)
1 HR. PER INCH. , HOWEVER 15 MINUTES MINIMUM 2 HOURS , PLUS 15 MIN. FOR EACH ADDITIONAL INCH ABOVE 2 2 HOURS , PLUS 15 MIN. FOR EACH ADDITIONAL INCH ABOVE 2
OVER 2 TO 5 OVER 5
* POST WELD HEAT TREATMENT IS MANDATORY ON P-NO.3 GR. NO. 3 MATERIAL IN ALL THICKNESSES.
95

( 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 200F ( 94c ) 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.
SERVICE CONDITION LETHAL SERVICE PWHT IS MANDATORY EXEMPTIONS ARE FEW
97

( 11 ) Postweld heat treatment is not mandatory for carbon steel jobs (P1 material ) in Following conditions (UG2): If groove welds is not over in size or fillet weld with a throat thickness of or less used for attaching non pressure parts to pressure parts provided preheat to a minimum temperature of 200F is applied when the thickness of pressure Part exceeds 1.25. If studs are welded to pressure parts provided preheat to a minimum temperature of 200F is applied when the thickness of the pressure parts exceeds 1.25. for corrosion resistant weld metal overlay cladding or for welds attaching corrosion resistant applied lining provided preheat to a minimum temperature of 200f is maintained during application of the first layer when the thickness of the pressure 98 part exceeds 1.25.

The temperature of furnace shall not exceed 800F
( 4270C) at the time when the vessel or part is placed in it.
Above 800 F( 427 C), the rate of heating shall not be more
than 4000F Per hour (2000C/Hour) divided by the maximum metal thickness of the shell or head plate in inches, but in no
case more than 4000F Per hour( 2220C Per hour ).

During the heating period, There shall not be a greater variation in temperature throughout the portion of the vessel
being heat treated than 2500F( 1390C) within any 15 feet (

4.6m) interval of length.
99

During the holding period, there shall not be a
greater difference than 1500f ( 830c) between the highest and the lowest temperature the portion of the vessel being heated During the heating & holding periods, the furnace atmosphere shall be so controlled as to avoid excessive oxidation of the surface of the vessel. The furnace shall be of such design as to prevent direct heat impingement of the flame on the vessel. Above 800 F ( 427 C), The rate of cooling shall not be
0 0
more than 5000F Per hour (2780C/Hour) divided by the
maximum metal thickness of the shell or head plate in inches,

but in no case more than 500 F Per hour ( 278 C Per hour). 100
0 0

when it is impractical to postweld heat treat at the temperature specified in table mentioned in Sr.. No. 9, It is permissible to carry out the post weld heat treatments at lower temperatures for longer periods of time as shown in table below :
DECREASE IN TEMP. BELOW MIN. SPECIFIED TEMPERATURE IN F 50 (10C) 100(38C) 150(68C) 200(94C) MINIMUM HOLDING TIME AT DECREASED TEMPERATURE (NOTE 1) 2 HOURS 4 HOURS 10 HOURS 20 HOURS NOTES
------2 2
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 PNO.1 GROUP NO. 1 AND 2 MATERIALS. 101
102
103
104
105
SELECTION OF SPIDERS AT OPEN ENDS FOR HEAT TREATMENT

SHELL THICKNESS
10000 9500 9000 8500 8000 7500 7000 ISMB 250 6500 ISMB 250 BOX SEC ISMB 250
SHELL DIAMETER
6000 5500 5000 4500 4000 3500 3000 2500 2000 ISMB 125 1500 1000 500 ISMB 125 ISMB 150 ISMB 150 ISMB 150
SHELL THICKNESS
DATA FOR ABOVE CHANNELS: DESIGNATION WT/ MTR.(KG) WEB HT FLG WD FLG THK WEB THK ISMB 125 13 125 75 7.6 4.4 ISMB 150 14.9 150 80 7.6 4.8 ISMB 250 37.3 250 125 12.5 6.9 ISMC 250 30.4 250 80 14.1 7.1
100
10
20
30
40
50
60
70
80
90
100
10
20
30
40
50
60
70
80
90
Annexure-5
106
107
HT REQUEST
Annexure-7
108
HT CHARGE
Annexure-8
109
Usage of compansating cable
Annexure-9 page 1 of 4
110
111
112
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
117
Thermo. Couple Attachment Procedure
118

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HEAT TREATMENT TRAINING MANUAL

HEAT TREATMENT MANUAL

4 . STD. OPERATING PROCEDURES(PFS)

and published periodically.

This manual is for reference only.

WHAT IS HEAT TREATMENT

MATERIALS HEAT TREATED

METALS (Single phase )

MATERIALS HEAT TREATED

UNEQUILIBRIUM PHASES to EQUILIBRIUM:(Stabilise Microstructure & Phases)

STRESSED to UNSTRESED CREATION OF UNEQUILIBRIUM CONDITIONS

MATERIALS HEAT TREATED

TYPES OF HEAT TREATMENT

IRON CARBON DIAGRAM

Iron Carbon Diagram

To refine the grains

Temperature : 593 C Min

Time : 15 minutes min

Temperature : 676 C Min

Time : 15 mts min

Temperature : 593 C Min

Time : 60 mts min

Temperature : 538 C Typ

Time : Minimum 15 minutes to 2 Hr

FURNACE PARTS AND THEIR ATTACHMENTS

LAYOUT OF A TYPICAL FURNACE (Electrical or Gas fired )

THERMOCOUPLE MATERIAL REQUIREMENT

TYPES OF THERMOCOUPLE BEING USED IN HZW

TYPES OF THERMOCOUPLE BEING USED IN HZW contd...

except PIT F/c

ISSUE METHODOLOGY For DISPOSAL TYPE

See Annexure-9 (Annexure Page 1-4) for further details

12 CHANNEL -- CURRENTLY BEING USED IN MFS1 AND HFS1

STANDARD OPERATING PROCEDURE FOR HFS-1 FURNACE

7900 (BOGIE WIDTH )

1650 3575 ( ZONE-1 )

HFS-I FURNACE SKETCH

1. PROJECT NO: 2. SECTION NO :

BURNER 1195 7900 BOGGIE WIDTH 8700 1050

HFS-I FURNACE SKETCH

STANDARD OPERATING PROCEDURE FOR HFS-1 FURNACE

Receive the job as per HT request.

to loading for job.

STANDARD OPERATING PROCEDURE FOR HFS-1 FURNACE

12. 13. 14.

STANDARD OPERATING PROCEDURE FOR HFS-1 FURNACE

Follow the procedure for startup of furnace in zone-I

Give power supply to the ignition panel

signal is on. This indicates that the combustion air

STANDARD OPERATING PROCEDURE FOR HFS-1 FURNACE

Flame healthy signal LED gets on which is provided

STANDARD OPERATING PROCEDURE FOR HFS-1 FURNACE

STANDARD OPERATING PROCEDURE FOR HFS-1 FURNACE

from compensating cable.

STANDARD OPERATING PROCEDURE FOR HFS-1 FURNACE

Close the furnace. Shut off the main power supply.

STANDARD OPERATING PROCEDURE FOR PFS FURNACE

125T Bogie hearth furnace -- PFS

PFS FURNACE SKETCH

4100 1235 1050

STANDARD OPERATING PROCEDURE FOR PFS FURNACE

Ensure the spider arrangement as per annexure- II.

STANDARD OPERATING PROCEDURE FOR PFS FURNACE

STANDARD OPERATING PROCEDURE FOR PFS FURNACE