BASIC HEAT

TREATMENT
TRAINING
(REV.-0)

1
 HEAT TREATMENT

• WHAT IS HEAT TREATMENT ?

• WHY IS IT REQUIRED ?

• TYPES OF HEAT TREATMENT

2
 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
3
 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, FORGING SHOPS etc..

4
TYPES OF HEAT TREATMENT
• NORMALIZING
• ANNEALING
• STRESS RELIEVING
• SOLUTION ANNEALING-Mainly SS
• HARDENING
• TEMPERING

5
 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 6
 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 7
 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 8
 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-brittle transition temp. and equalize

impact values

9
 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
10
 STRESS RELIEVING
Cr-Mo Steels
Cr - Mo Steels (Cr >2%)
– SA 335P22 ,SA335P5
• Temperature : 676 C Min
– Normally 680 - 700 C 2.25Cr
– 704 - 720 C 5 Cr
• Time : 15 mts min
– Time : 1 hr / inch
• Heating Rate : 200 C per hr per inch
• Cooling Rate : 260 C per hr per inch 11
 STRESS RELIEVING
Ni -Steels
• Nickel Steels : 1,2,3% Ni
– SA 203 GrA ,D
• Temperature : 593 C Min
– Normally 600 - 640 C,650-690 C
• Time : 60 mts min
– Time : 1 hr / inch
• Heating Rate : 200 C per hr per inch
• Cooling Rate : 260 C per hr per inch
12
 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
• Heating Rate : 200 C per hr per inch
• Cooling Rate : 260 C per hr per inch
13
FURNACE PARTS AND

THEIR ATTACHMENTS

14
 LAYOUT OF A TYPICAL
FURNACE
(Electrical or Gas fired )
FURNACE

THERMOCOUPLE
COMPENSATING
CABLE

JOB

RECORDER P.I.D.

CONTROLLING BURNER 15
 THERMOCOUPLES
• PRINCIPLE OF A THERMOCOUPLE

• THERMOCOUPLE MATERIALS

16
 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.
17
 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
18
BY THE USE OF SMALL DIAMETER THERMOCOUPLES.
 TYPES OF THERMOCOUPLE
K type :
Material : Chromel + Alumel
Nickel based ( 10 %Cr ) + ( 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. 19
 TYPES OF THERMOCOUPLE
contd...
K type :
Dia : 2.5 mm 0. 7 mm
Insulation Bare(ceramic) Refractory
coated
Attachment Mech Capacitor
Usability Reusable Disposable
Location PIT F/c except PIT F/c
20
Color - Red & Yellow
 CONSTRUCTION OF A
K TYPE THERMOCOUPLE
White Color White/yellow
+Ve
pid
-Ve
Blue Color Red Color

Welded
White/yellow junction
White Color
+Ve
recorder
-Ve
Blue Color

Red Color
Compensating Thermocouple
cable wire

Accuracy : 0.75% 21
 ‘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 .

22
 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 .

23
 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)

24
 RECORDER
TYPES OF RECORDER
PAPERLESS -- WITH COLOUR DISPLAY SCREEN ,HARD DISC AND FLOPPY DRIVE.

•WITH PAPER – GENERALLY USED IN HT.

•24 CHANNEL –

•12 CHANNEL –
COMPENSATING CABLES ARE CONNECTED BEHIND THE RECORDER SCREEN IN
CHANNELS.

•X-AXIS IS FOR TEMPERATURE (RANGE = 0 TO 1200’C)

•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 25

 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
==> ET 201 CHINO MAKE, JAPAN

==> 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.
26
TYPICAL FURNACE

27
( 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 )

FURNACE SKETCH 28
 9000

1. PROJECT NO:
2. SECTION NO :

9500
3. CHARGE NO :
4. H. T. REQ. NO :

BURNER

1195 7900 BOGGIE WIDTH 1050

8700

FURNACE SKETCH 29
 CERMIC GROUND LEVEL HEATING
BLANKET ELEMENT
CERMIC FIBER
OUTER
SLABER BLOCK BAFFLE
FIRE BRICK SHELL

INSULATING
CASTABLE

ROOF

CERAMIC
BLANKET

4150 ( REFRACTORY

3700 1/D OF BAFFLE

BLOWER

4020

I/S )
125 250

TROLLEY
STRUCTURE

1380
1000
4961 30
PIT FURNACE SKETCH
LOCAL STRESS RELIEVING
( LSR )

31
 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 32
• HB + 4√ rt
 LSR -BAND WIDTH

Soak band Weld width ‘X’ +

lesser of 1T or 2”
X

Heating band
Inside radius

Insulation band

33
 LOCAL STRESS RELIEVING SET UP

1. Provide multitonne roller on one end of vessel during

LSR ofcircular 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.
34
 LOCAL STRESS RELIEVING

SB+HB+IB

LSR of C/S

Spider or
prop
No Welding at top

Multitonne roller

35
200 to 500mm from heating band
GOOD ENGG. PRACTICES
FOR FURNACE CHARGES
&LSR

36
 SUPPORTING ARRANGEMENTS

1. Heat Treatment request shall be as per Annexure

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.

37
 SUPPORTING ARRANGEMENTS

600mm
450mm
burner
0
90
600mm

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.
38
 SUPPORTING ARRANGEMENTS

7. Spiders shall be provided as per annexure

8 Saddle supports shall be selected as per annexure.

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

39
 SUPPORTING ARRANGEMENTS

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. 40
 SUPPORTING ARRANGEMENTS
13. Checklist shall be prepared and attached with HT

request before furnace is fired.

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

16. General idea about thermocouple locations and its

attachments is as per Annexure 41

 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 42
 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.
43
 THERMOCOUPLES
ATTACHMENT UNIT

44
 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.

45
 CODE EXTRACTS

• FURNACE PWHT
•LSR

46
 REQUIREMENT OF HEAT TREATMENT
AS PER ASME-SEC VIII Div.-1
• SERVICE CONDITION (UW-2)

• MATERIAL (UG-85, UW-40,UCS-56,UAT-80,UHA-32,UNF-79)

• THICKNESS (UG-85, UW-40,UCS-56,UAT-80,UHA-32,UNF-79)

• LOW TEMERATURE
OPERATION (UCS-68)

• COLD WORKING (UG-79)

• CUSTOMER SPEC.

47
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
48
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. 49
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. 50
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). 51
CODE EXTRACT FOR HEAT TREATMENT

P. NO. HOLDING TEMP. NOM. SOAKING PERIOD

THICKNE
SS
1 ( CARBON 1100 DEG. F(593’ UPTO 2” 1 HR. PER INCH. ,
STEEL) & 3 C) HOWEVER 15 MINUTES
(LOW ALLOY MINIMUM
STEEL)
OVER 2” 2 HOURS , PLUS 15 MIN.
TO 5” FOR EACH ADDITIONAL
INCH ABOVE 2”
OVER 5 ” 2 HOURS , PLUS 15 MIN.
FOR EACH ADDITIONAL
INCH ABOVE 2”

* POST WELD HEAT TREATMENT IS MANDATORY ON P-NO.3 GR. NO. 3

MATERIAL IN ALL THICKNESSES.

52
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. 53
• When the PWHT is a service requirement.
 CODE EXTRACT FOR HEAT TREATMENT
( 11 ) Postweld heat treatment is not mandatory for carbon
steel jobs (P1 material ) in Following conditions
(UG2):

• If groove welds is not over ½” in size or fillet weld

with a throat thickness of ½” or less used for attaching
non pressure parts to pressure parts provided preheat
to a minimum temperature of 200’F 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 200’F 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 200’f is maintained during application
of the first layer when the thickness of the pressure54
part exceeds 1.25”.
 CODE EXTRACT FOR HEAT TREATMENT

• The temperature of furnace shall not exceed 800’F

( 4270C) at the time when the vessel or part is placed in it.
• Above 8000F( 4270C), the rate of heating shall not be more
0 0
than 400 F Per hour (200 C/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. 55
 CODE EXTRACT FOR HEAT TREATMENT
• 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 8000F ( 4270C), The rate of cooling shall not be
0 0
more than 500 F Per hour (278 C/Hour) divided by the
maximum metal thickness of the shell or head plate in inches,
56
0 0
but in no case more than 500 F Per hour ( 278 C Per hour).
CODE EXTRACT FOR HEAT TREATMENT
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 MINIMUM HOLDING NOTES
MIN. SPECIFIED TIME AT DECREASED
TEMPERATURE IN ‘F TEMPERATURE (NOTE 1)
50 (10’C) 2 HOURS ----
100(38’C) 4 HOURS ----
150(68’C) 10 HOURS 2
200(94’C) 20 HOURS 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 P-
NO.1 GROUP NO. 1 AND 2 MATERIALS. 57
 AS PER B31.3 ( Table 331.1.1 )
BASE METAL WALL THICK ( Nom ) MIN TENSILE TEMP RANGE HOLDING TIME
HR/IN Min

Carbon Steel < 19mm ALL None …… ……

> 19mm ALL 593-649’c 1 1

Alloy Steel < 19mm < 490 Mpa None ….... ……

( Cr < ½% )
> 19mm ALL 593-718’c 1 1

ALL > 490 Mpa 593-718’c 1 1

Alloy Steel < 13mm < 490 Mpa None ….... ……

( ½% Cr < 2% )
> 13mm ALL 704-746’c 1 2

ALL > 490 Mpa 704-746’c 1 2

58
59
 SELECTION OF SPIDERS AT OPEN ENDS FOR HEAT TREATMENT

SHELL THICKNESS
Annexure-5

100
10

20

30

50

60

90
40

70

80
10000

9500

9000

8500

8000

7500

7000 ISMB 250

6500 ISMB 250 BOX SEC ISMB 250

SHELL DIAMETER

6000

5500

5000

4500

4000

3500 ISMB 150

3000

2500

2000 ISMB 125 ISMB 150

1500

1000

500 ISMB 125 ISMB 150

100
10

20

30

50

60

90
40

70

80
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 60
61
HT REQUEST Annexure-7

62
 Annexure-8
HT CHARGE

63
THANK YOU

64