heat treatment training manual.ppt

1

HEAT

TREATMENT

TRAINING MANUAL

MAY-2001 (REV.-0)

2

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 )

HEAT TREATMENT MANUAL

3

INDEX

TOPIC PAGE NO.

1 . INTRODUCTION ON HEAT TREATMENT 4- 24

2 . FURNACE PARTS AND ATTACHMENTS 25- 37

3. STD. OPERATING PROCEDURES(HFS) 38- 47

4 . STD. OPERATING PROCEDURES(PFS) 48- 56

5 . STD. OPERATING PROCEDURES(MFS) 57-69

6 . STANDARD PRACTICES FOR LSR 70-74

7 . GOOD ENGINEERING PRACTICE 75-88

8 . CODE EXTRACT(REFERENCE ONLY) 89- 101

9 . ANNEXURES 102- 118

4

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.

5

HEAT TREATMENT

• WHAT IS HEAT TREATMENT ?

• WHY IS IT REQUIRED ?

• TYPES OF HEAT TREATMENT

• HEAT TREATMENT AT HZW

6

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

7

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..

8

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..

9

MATERIALS HEAT TREATEDCRITERIA• COLD WORKED to NORMAL

– All materials• UNEQUILIBRIUM PHASES to

EQUILIBRIUM:(Stabilise Microstructure & Phases)– Stainless Steels ,Maraging Steels

• STRESSED to UNSTRESED– All Materials

• CREATION OF UNEQUILIBRIUM CONDITIONS– Steels

10

MATERIALS HEAT TREATED

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

11

TYPES OF HEAT TREATMENT

• NORMALIZING

• ANNEALING

• STRESS RELIEVING

• SOLUTION ANNEALING-Mainly SS

• HARDENING

• TEMPERING

• AGING

12

IRON CARBON DIAGRAM

13

Iron Carbon DiagramPortion related to Heat Treatment

14

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

15

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

16

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

17

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.

18

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

19

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

20

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


• Cooling Rate : 260 C per hr per inch

21

Cr-Mo SteelsCr - 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



STRESS RELIEVING

22

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



STRESS RELIEVING

23

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



STRESS RELIEVING

24

FURNACE PARTS AND

THEIR ATTACHMENTS

25

LAYOUT OF A TYPICAL FURNACE

(Electrical or Gas fired )

RECORDER P.I.D.

FURNACE

JOB

COMPENSATING CABLE

THERMOCOUPLE

CONTROLLING BURNER

26

THERMOCOUPLES

• PRINCIPLE OF A THERMOCOUPLE

• THERMOCOUPLE MATERIALS

• TYPES OF THERMOCOUPLES BEING USED IN HZW

27

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.

28

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 BY THE USE OF SMALL DIAMETER THERMOCOUPLES.

29

TYPES OF THERMOCOUPLE BEING USED IN HZW

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.

30

TYPES OF THERMOCOUPLE BEING USED IN HZW 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

Color - Red & Yellow

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recorder

pid

Compensating cable

Thermocouple wire

Welded junction

CONSTRUCTION OF A

K TYPE THERMOCOUPLE

Accuracy : 0.75%

Red

Col

or

Blu

e C

olor

White ColorWhite/yellow

+Ve

-Ve

-Ve

+Ve

White Color White/yellow

Blue Color Red Color

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‘S’ TYPE THERMOCOUPLE

• ‘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 .

Accuracy : 0.25 %

33

ISSUE METHODOLOGYFor 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

34

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

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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)

36

RECORDER TYPES OF RECORDERPAPERLESS -- 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 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•WE GENERALLY KEEP 25 MM / HOUR.

37

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.• SEE ANNEXURE-10 FOR FURTHER DETAILS

38

STANDARD OPERATING PROCEDURE FOR HFS-1

FURNACE

39

1650

3575

14300.

3575 3575 3575( ZONE-1 ) ( ZONE-3 ) ( ZONE-5 ) ( ZONE-7 )

( ZONE-2 ) ( ZONE-4 ) ( ZONE-6 ) ( ZONE-8 )

1640 1650

7900 (BOGIE WIDTH )

BURNER

HFS-I FURNACE SKETCH

40

7900 BOGGIE WIDTH

8700

1050

9500

9000

1195

1. PROJECT NO:

2. SECTION NO :

3. CHARGE NO :

4. H. T. REQ. NO :

BURNER

HFS-I FURNACE SKETCH

41

STANDARD OPERATING PROCEDURE FOR HFS-1 FURNACE

1. Receive the job as per HT request.

2. Receive heat treatment request duly approved bymetallurgy engineer.

3. Ensure that Insp. Clearance is available prior

to loading for job.

4. Load the supporting arrangement as per the attachedannexure -3

5. Ensure the spider arrangement as per attachedannexure - 5

6. Fix the thermocouples at locations shown in furnacecharge.

7. Check the entire job as per check list (annex.-I).

42


9. Move the bogie inside the furnace

10. Pass the thermocouples through ports andconnect 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 adjustthe speed of the graph.

13. Clear inspection of job and get the signature ofinspector on graph paper for firing the furnace.

14. Check LPG level, pressure and temperature in thestorage tanks and note down in logbook.

43


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

21. Now the firing on the cycle can start.

44


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.

45


27. Due to certain length of pipe between the burner andsolenoid valves, which may contain air, the burnermay not light up in the first attempt. In that case,repeat the above mentioned procedure.

28. Once the main flame is established, the control ispassed 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 andtemperature from recorder every 30 minutes in thelogbook.

31. Conduct spot checks for heat treatment every 4hoursand fill the spot check format.

46


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.

47

36. Retrieve the thermocouples from the ports and the

bogie out of the furnace.

37. Allow the job to reach room temperature.

38. 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.


48

STANDARD OPERATING PROCEDURE FOR PFS

FURNACE

49

125T Bogie hearth furnace -- PFS

50

BOGGIE WIDTH

4100

2650

5600

10

50

12

35

14

60

55

00

BURMER

PFS FURNACE SKETCH

51

STANDARD OPERATING PROCEDURE FOR PFS FURNACE

1. Receive the job as per HT request.

2. Receive heat treatment request duly approved bymetallurgy engineer.

3. Ensure that Insp. clearance is available prior toloading for job.

4. Load the job on the bogie as per the heat treatmentfurnace request.

5. Ensure the supporting arrangement as per theattached annexure-I.

6. Ensure the spider arrangement as per annexure- II.

7. Fix the thermocouples at locations shown in furnacecharge.

52


8. Check the entire job as per check list attached as

annexure-III

9. Move the bogie inside the furnace.

10. Pass the thermocouples through ports and

connect it with compensating cables.

11. Insert heat treatment chart in recorder and adjust

the speed of the graph.

12. Clear inspection of job and get the signature

of inspector on graph paper for firing the furnace.

13. Check LPG level, pressure and temperature in

the storage tanks and note down in logbook.

53


14. Switch on the power supply.

15. Close the bogie door.

16. Switch on ID blower first and then the air blowerand maintain pressure at about 800mm WG by slowly opening the suction valve.

17. Ensure that pressure of LPG from yard to inlet of pressure regulator is always less than 20psi (1.5kg/CM2).

18. Open the inlet valve to the regulator and open the outlet valve.

19. If pressure exceeds 1600 mm WG , isolate thepressure by lifting the handle of safety shut off valve.

54


20. Immediately start lighting the pilot burners and adjust the flame with the air valve .

21. Open the isolating valve for pressure gauge andadjust the pressure regulator by turning the screwprovided in the stem so that the pressure is maintained at about 1000mm WG.

22. Light up alternate main burners and adjust the flame lengths uniformly.

23. Lock the doors by pneumatic locking.

24. After all zones start, record time and temperaturefrom recorder every 30 minutes in the logbook.

55


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.

56

29. Retrieve the thermocouples from the ports and move

the bogie out of the furnace.

30. Allow the job to reach room temperature.

31. 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.


57

STANDARD OPERATING PROCEDURE FOR PIT

FURNACE IN MFS-I

58B

LO

WE

R

3700 1/D O

F B

AF

FL

E

4150 ( RE

FR

AC

TO

RY

I/S

)

49611000

250125

1380

4020

TROLLEY STRUCTURE

CERAMIC BLANKET

ROOF

BAFFLE

HEATING ELEMENT

CERMIC FIBER SLABER BLOCK

INSULATINGCASTABLE

FIRE BRICK OUTER SHELL

CERMIC BLANKET

GROUND LEVEL

PIT FURNACE SKETCH

59

STANDARD OPERATING PROCEDURE

FOR PIT FURNACE

1. Receive heat treatment request duly authorizedby metallurgy engineer.

2. Receive the job for heat treatment withinspection clearance.

3. Put the job either on support or on heattreatment fixture inside the furnace.

4. Ensure that equal clearance is available on allsides between job and baffle.

5. Ensure that the furnace is calibrated.

6. Connect thermocouples with compensatingcable to PID.

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7. Set the program in the programmer as per heat

treatment request.

8. Take a trial run of program to ensure the accuracy.

9. Calibrate all 5 PID’s prior to starting the furnace.

10. Insert the graph inside the recorder and take the

signature of inspector on the graph paper.

11. Close the furnace door.

12. Start the furnace by giving power supply ‘ON’


FOR PIT FURNACE

61

13. Start recording the time and temperature in thelogbook every 30 minutes.

14. Ensure that the cycle is functioning as per program.

15. After the heat treatment is over, open the furnacecover.

16. If the job calls for water quenching, lift the job anddip it in quench tank.

17. It the job calls for air cooling in still air, lift the joband put it outside on supports in open air.


FOR PIT FURNACE

62

18. It the job doesn’t call for anything above, allow the

job to cool down in furnace.

19. Keep the job outside after removing from furnace.

20. 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.


FOR PIT FURNACE

63

PROCEDURE FOR EMPTY FURNACE CALIBRATION

Calibration of PIDS ( indicator & controller )

1. Connect the millivolt source to the temperatureindicator or controller by a compensating

cable. Care should be taken to clean the wires andterminals thoroughly before connections aremade.

2. The millivolt output for various temperature

ranging from 00C to 10000C in steps of 500C is fedto the indicator / controller.

3. After the millivolt value / temperature readingdisplayed is steady, the reading ofindicator/controller shall be noted.

64


Calibration of recorder

1. Connect the millivolt source to the recorder by acompensating cable. Care should be taken toclean the wires and terminals thoroughly beforethe connections are made.

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.

65


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.

3. The graph thus obtained is reviewed for time

and temperature values. These values should

meet the accuracy requirements.

4. 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.

66


EQUIPMENT REQUIRED ACCURACY

1. 20 Nos. big K-type thermocouples +/- 0.25%

2. 10 Nos. small K-type thermocouples +/- 0.25%

3. Millivolt source (wahl unit )

( 1 micro volt at 1000 micro volts )

4. Heat treatment fixture.

5. Temperature indicators (PID) +/- 10C

6. Recorder +/- on temperature scale.

+/- minutes on time scale.

67

PIT FURNACE CALIBRATION PROCEDURE

1. Ensure that the PIDs are calibrated as mentioned above.

2. Ensure that the recorder is calibrated as mentioned

above.

3. Ensure that all the thermocouples used are calibrated.

4. 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.

68

7. Set the temperature of controller to 4000C.

8. After reaching the set temperature, it is allowed to stabilize for half an hour.

9. Measure and record the temperature indicated by

each of the 20 thermocouples. The temperature is to

be read through WAHL UNIT.

10. Three sets of readings are to be taken for each

thermocouples at an interval of 10 minutes.

11. Also record the readings indicated by each of the

thermocouples at an interval of 10 minutes.


69


12. The temperature is then raised in steps of 50 C up to

10000C. ( I. e. 4000C, 4500C, …….., 9500C, 10000C. ) 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.

70

STANDARD OPERATING PRACTICES FOR LOCAL

STRESS RELIEVING

71

LOCAL STRESS RELIEVINGWHY • 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• HB + 4 rt

72

LSR -BAND WIDTH

Weld width ‘X’ + lesser of 1T or 2”

X

t

Soak band

Insulation band

Heating band

Insi

de

rad

ius

73

LOCAL STRESS RELIEVING SET UP1. 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.

74

LOCAL STRESS RELIEVING

No Welding at top

Multitonne roller

200 to 500mm from heating band

LSR of C/S

SB+HB+IB

Spider orprop

75

GOOD ENGG. PRACTICES FOR FURNACE CHARGES

& L S R

76

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.

77

600mm

900

600mm


450mm

5. Saddle shall be arranged in such away that openend 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.

burner

300mm(point no:2)

78

SUPPORTING ARRANGEMENTS7. Spiders shall be provided as per annexure-5

8 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

79

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.

80

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


81

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

82

GENERAL

Temp. support

Furnace floor

Gasket machined surface

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.

83

THERMOCOUPLES1. 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.

84

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

THERMOCOUPLES

85

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.

THERMOCOUPLES ATTACHMENTS

86

5. Clean surface prior to attachment.

6. Two wire of thermocouple shall be attached one after another.

7. Gap between two wire of a thermocouple shall be

max. 3.0mm 8. Only calibrated thermocouple shall be used.

Calibration shall be by QA.

9. After PWHT, thermocouple area shall be ground

and DP shall be carried out.

10. For further details see Annexure-11 & 13-(page 1&2)

THERMOCOUPLES ATTACHMENTS

87

THERMOCOUPLES ATTACHMENT UNIT

88

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.

89

CODE EXTRACTS •FURNACE PWHT• L S R

90

REQUIREMENT OF HEAT TREATMENTAS 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.

91

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 structural discontinuity.

92

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.

93

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.

94

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).

95


P. NO. HOLDING TEMP. NOM.THICKNESS

SOAKING PERIOD

1 ( CARBONSTEEL) & 3(LOW ALLOYSTEEL)

1100 DEG. F(593’C)

UPTO 2” 1 HR. PER INCH. ,HOWEVER 15 MINUTESMINIMUM

OVER 2”TO 5”

2 HOURS , PLUS 15 MIN.FOR EACH ADDITIONALINCH ABOVE 2”

OVER 5 ” 2 HOURS , PLUS 15 MIN.FOR EACH ADDITIONALINCH ABOVE 2”

* POST WELD HEAT TREATMENT IS MANDATORY ON P-NO.3 GR. NO. 3MATERIAL IN ALL THICKNESSES.

96

( 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.

• When the PWHT is a service requirement.


97

SERVICE CONDITION

• LETHAL SERVICE PWHT IS MANDATORY

• EXEMPTIONS ARE FEW


98

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 pressure part exceeds 1.25”.

99


• 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

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.

100

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

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 5000F Per hour ( 2780C Per hour).

101

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. BELOWMIN. SPECIFIED

TEMPERATURE IN ‘F

MINIMUM HOLDINGTIME AT DECREASED

TEMPERATURE (NOTE 1)

NOTES

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.

106

SELECTION OF SPIDERS AT OPEN ENDS FOR HEAT TREATMENT

10000 10 20 30 40 50 60 70 80 90 100

9500

9000

8500

8000

7500

7000 ISMB 250

6500 ISMB 250 BOX SEC ISMB 250

6000

5500

5000

4500

4000

3500 ISMB 150

3000

2500

2000 ISMB 125 ISMB 150

1500

1000

500 ISMB 125 ISMB 150

10 20 30 40 50 60 70 80 90 100

DATA FOR ABOVE CHANNELS:WEB HT FLG WD FLG THK WEB THK

SH

EL

L D

IAM

ET

ER

WT/ MTR.(KG)13

SHELL THICKNESS

ISMB 125 75

ISMB 25014.937.3

SHELL THICKNESS

ISMC 250

DESIGNATION

30.4

125150250250

ISMB 150 8012580

7.67.6

12.514.1

4.44.86.97.1

Annexure-5

108

HT REQUEST Annexure-7

109

HT CHARGEAnnexure-8

110

Usage of compansating cable Annexure-9page 1 of 4

111


112


113


114

Information on Graph Paper Usage Annexure-10

115

Mechanical v/s capacitor discharge attachmentsAnnexure-

11

116

Thermo. Couple Procurement ProcedureAnnexure-

12

117

Thermo. Couple Attachment ProcedureAnnexure-

13page 1 of 2

118

Thermo. Couple Attachment Procedure

Annexure-13

page 2 of 2

heat treatment training manual.ppt

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