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HEAT TREATMENT
MECHANICAL PROPERTIES OF METALS & ALLOYS DEPEND ON CHEMISTRY (ALLOYING ELEMENTS) & HEAT TREATMENT
HEAT TREATMENT
HEAT TEATMENT PARAMETERS
RATE OF HEATING SOAKING TEMP. SOAKING TIME COOLING RATE COOLING MEDIA
WHY HT REQUIRED ?
TO BRING THE PROPERTIES TO THE DESIRED RANGE Strength, UTS, YS & Elongation Toughness Hardness CARRIED OUT IN
FABRICATION INDUSTRIES- Fabricated Components STEEL PLANTS Plates, Pipes, Tubes, Sections FOUNDRY SHOPS - Castings FORGING SHOPS Forged Components
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ALLOYS
Single Phase : Copper Nickel Multiphase : Steels
HEAT TREATEMENT
CRITERIA COLD WORKED to NORMAL
All materials
STRESSED to UNSTRESED
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NORMALIZING
The steel is heated to 40 C above the upper critical temperature followed by cooling in the still air. To achieve Uniform structure Change in Mechanical properties,
UTS, YS & Elongation Hardness Impact properties
Refined grains
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ANNEALING
Steel is heated 10 to 50C above the upper critical temperature and held for the desired length of time followed by very slow cooling within the furnace
To achieve:
Softness & better ductility Stresses free material Stress generated due to
mechanical working / previous HT
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SOLUTION ANNEALING
Austenitic Stainless steels is heated to above 1050C and held for the desired time followed by fast cooling to room temperature within few minutes by quenching / blowing the air. Solution annealing is done on stainless steel and non ferrous alloys To soften the material To remove carbide precipitation formed at grain boundaries during manufacturing process ( SS ) 13 To improve Corrosion Resistance
AGEING
The Material is heated to a certain temperature, and held for the desired time; followed by quenching or cooling in air Ageing is done on materials susceptible for ageing characteristics : Maraging Steels Normally increases strength Improves Toughness
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AGEING
Maraging Steels
M250 Temperature : 485 C Normally 3 Hrs 15 mts Heating Rate : 200 C per hr per inch thick Cooling Rate : Cool in Air / Quench in water
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STRESS RELIEVING
The steel is heated to a temperature below close to the lower critical temperature with a specific rate of heating. It is held at the temperature for a desired length of time, followed by cooling with a specific rate up to certain temperature. There is no change in grain structure. Stress relieving is done Fabricated Components of CS & LAS: To reduce Internal Stresses To soften the steel partially To soften HAZ 16
STRESS RELIEVING
C-Mn , C-Mo , Cr-Mo (< 2% Cr)
C - Mn Steels , C - Mo Steels, Cr-Mo Steels
SA 515Gr 70 , SA204GrA, SA387GR11,CL1
Time : 15 minutes min ( 1 hr / inch thick) Heating Rate : 200 C per hr per inch thick Cooling Rate : 260 C per hr per inch thick
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STRESS RELIEVING
Cr-Mo Steels
Cr - Mo Steels (Cr >2%) Temperature : 676 C Min
SA 335P22 ,SA335P5 Normally 680 - 700 C 2.25Cr 704 - 720 C 5 Cr
Time : 15 mts min (1 hr / inch thick) Heating Rate : 200 C per hr per inch thick Cooling Rate : 260 C per hr per inch thick
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STRESS RELIEVING
Ni -Steels
Nickel Steels : 1,2,3% Ni
SA 203 GrA ,D
Time : 60 mts min (1 hr / inch thick) Heating Rate : 200 C per hr per inch thick Cooling Rate : 260 C per hr per inch thick
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STRESS RELIEVING
Steels enhanced by Heat Treatments
Q&T Steels :
9.5% Ni Steels , SA 517 Gr E
Time : Min 15 minutes to 2 Hr ( 1 hr / inch thick) Heating Rate : 200 C per hr per inch thick Cooling Rate : 260 C per hr per inch thick
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FURNACE
JOB
RECORDER
P.I.D.
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THERMOCOUPLES
PRINCIPLE OF A THERMOCOUPLE THERMOCOUPLE MATERIAL TYPES OF THERMOCOUPLE BEING USED IN HED POWAI / HZW
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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.
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Non-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. 25
K type : Dia :
Welded junction
recorder
Compensating cable
Thermocouple wire
Accuracy : 0.75%
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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 .
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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 .
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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)
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RECORDER
TYPES OF RECORDER PAPERLESS -- WITH COLOUR DISPLAY SCREEN ,HARD DISC AND FLOPPY WITH PAPER -- CURRENTLY BEING USED IN HZW. 24 CHANNEL -- CURRENTLY BEING USED IN PFS( CHINO MAKE-- model no.I003 12 CHANNEL -/Graph ET 001). 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. DRIVE. NOT USED IN HED HZW.
X-AXIS IS FOR TEMPERATURE (RANGE = 0 TO 1200C) Y-AXIS IS FOR GRAPH SPEED. VARIOUS SPEED OF GRAPHS ARE 12.5, 25, 50, 100 MM / HOUR GENERALLY KEEP 25 MM / HOUR.
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GRAPH PAPER
GRAPH PAPERS ARE USED FOR PLOTTING THE FURNACE /JOB 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. 32
2.
3.
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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.
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3.
4.
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ACCURACY
+/- 0.25% +/- 0.25%
10. 11.
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When
Local SR to be done only when furnace SR not feasible Only when certain weld joints on components to be heat treated
HOW
Done by Electrical heating coil 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) 41 Axial gradient HB + 4 rt
T
Heating band Insulation band
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LSR of C/S
Spider or prop
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SUPPORTING ARRANGEMENTS
1. Minimum distance between wall of furnace and the job shall be 600mm. 2. Minimum distance between floor of the furnace and lower most part of the job shall be 300mm. 3. The distance between the flame of burner and saddle support shall be 600mm. 4. Minimum 90 degree saddle to be used, however 120 degree saddle is desirable.
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SUPPORTING ARRANGEMENTS
450mm
burner
600mm 900
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.
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SUPPORTING ARRANGEMENTS
7. 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
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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.
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SUPPORTING ARRANGEMENTS
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
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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
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GENERAL
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.
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THERMOCOUPLES
1. All the thermocouples shall be tagged with aluminum sheet and identification hard punched on it. (For PIT furnace only)
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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
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THERMOCOUPLES ATTACHMENTS
1. Use only TAU-90 capacitor Discharge Welding machine for thermocouple connection 2. Use specified WPS for attachment of thermocouple for cs/alloy steel material 3. Only trained person by welding engineering shall attach thermocouple.
THERMOCOUPLES ATTACHMENTS
5. 6. 7. 8. 9. Clean surface prior to attachment. 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.
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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.
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OVER 2 TO 5 OVER 5
* POST WELD HEAT TREATMENT IS MANDATORY ON P-NO.3 GR. NO. 3 MATERIAL IN ALL THICKNESSES.
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( 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. 66 When the PWHT is a service requirement.
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( 4270C) at the time when the vessel or part is placed in it. 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 400 F Per hour( 222 C 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 250 F( 139 C) within any 15 feet ( 4.6m) interval of length.
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greater difference than 150 f ( 83 c) 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 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, but in no case more than 500 F Per hour ( 278 C Per hour). 70
0 0
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. 71