Heat Treatment Training Manual

HEAT
TREATMENT
TRAINING MANUAL
MAY-2001
(REV.-0)
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
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
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, FORGING SHOPS etc..
7
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
STRESSED to UNSTRESED
All Materials
CREATION OF UNEQUILIBRIUM
CONDITIONS
Steels

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

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
CONTROLLING BURNER
P.I.D.
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
Properties :
Chromel
( 10 %Cr )
Alumel
+ ( 2 % Al )
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
Mech
Capacitor
Usability
Reusable
Disposable
Location
PIT F/c
except PIT F/c
Color
30
Red & Yellow
CONSTRUCTION OF A
K TYPE THERMOCOUPLE
pid
Blue Color
White Color
Blue Color
recorder
+Ve
-Ve
Red Color
White/yellow
Welded
junction
+Ve
-Ve
Compensating
cable
Accuracy : 0.75%
White/yellow
Red Color
White Color
Thermocouple
wire
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 )
1640
( ZONE-4 )
( ZONE-6 )
( ZONE-8 )
BURNER
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
1050
8700
HFS-I FURNACE SKETCH
40
STANDARD OPERATING PROCEDURE FOR HFS-1

FURNACE
1.
Receive the job as per HT request.
2.
Receive heat treatment request duly approved by

metallurgy engineer.
3.
Ensure that Insp. Clearance is available prior

to loading for job.
4.
Load the supporting arrangement as per the attached

annexure -3
5.
Ensure the spider arrangement as per attached

annexure - 5
6.
Fix the thermocouples at locations shown in furnace

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

41

FURNACE
9.
Move the bogie inside the furnace
10.
Pass the thermocouples through ports and

connect it with compensating cables
11.
Set the program as per heat treatment request.

Secure it and then run it in fast mode as check.
Bring it back to the initial segment and hold.
12.
Insert heat treatment chart in recorder and adjust

the speed of the graph.
13.
Clear inspection of job and get the signature of

inspector on graph paper for firing the furnace.
14.
Check LPG level, pressure and temperature in the

42
storage tanks and note down in logbook.

FURNACE
15.
Switch on the power supply
16.
Close the bogie door
17.
Follow the procedure for startup of furnace in zone-I
18.
Start the blower from the field push button station

provided
19.
Give power supply to the ignition panel
20
When the system healthy contact comes from the

instrument panel, the lamp for the system healthy
signal is on. This indicates that the combustion air
pressure and gas pressure are within the specified
limits
21.
Now the firing on the cycle can start.
43

FURNACE
22.
Open the pilot and main gas valves
23.
Press start cycle button on doing so the cycle starts

and purging start indicator lamp is on.
24.
After 3 minutes ( time adjusted through timer ) the

purging is completed and ignition start lamp is ON
At the same time the purging start lamp gets OFF.
25.
After 10 seconds the ignition start lamp gets OFF

By this time the pilot burner should have been fired
and the pilot flame is established.
26.
Flame healthy signal LED gets on which is provided

on the flame sensor relay. This can be viewed through
the glass window provided in the ignition panel.
44

FURNACE
27.
Due to certain length of pipe between the burner and

solenoid valves, which may contain air, the burner
may not light up in the first attempt. In that case,
repeat the above mentioned procedure.
28.
Once the main flame is established, the control is

passed on to the temperature controller.
29.
For startup of furnace in other zones, follow the
same steps no 16 to 27 mentioned above.
30.
After all zones are started, start recording time and

temperature from recorder every 30 minutes in the
logbook.
31.
Conduct spot checks for heat treatment every 4hours

45
and fill the spot check format.

FURNACE
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

FURNACE
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.
47
STANDARD OPERATING
PROCEDURE FOR PFS
FURNACE
48
125T Bogie hearth furnace -- PFS
49
PFS FURNACE SKETCH

5600
5500
2650
BURMER
BOGGIE WIDTH
1460
1050
1235
4100
50
STANDARD OPERATING PROCEDURE FOR PFS

FURNACE
1.
Receive the job as per HT request.
2.
Receive heat treatment request duly approved by

metallurgy engineer.
3.
Ensure that Insp. clearance is available prior to

loading for job.
4.
Load the job on the bogie as per the heat treatment

furnace request.
5.
Ensure the supporting arrangement as per the

attached annexure-I.
6.
Ensure the spider arrangement as per annexure- II.
7.
Fix the thermocouples at locations shown in furnace

charge.
51

FURNACE
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

52
the storage tanks and note down in logbook.

FURNACE
14.
Switch on the power supply.
15.
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.
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 the

pressure by lifting the handle of safety shut off
53
valve.

FURNACE
20.
Immediately start lighting the pilot burners and adjust

the flame with the air valve .
21.
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.
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 temperature

from recorder every 30 minutes in the logbook.
54

FURNACE
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

FURNACE
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.
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
3700 1/D OF BAFFLE
4150 ( REFRACTORY I/S )
BLOWER
4020
125
250
TROLLEY
STRUCTURE
1380
PIT FURNACE SKETCH
4961
1000
58
STANDARD OPERATING PROCEDURE

FOR PIT FURNACE
1.
Receive heat treatment request duly authorized

by metallurgy engineer.
2.
Receive the job for heat treatment with

inspection clearance.
3.
Put the job either on support or on heat

treatment fixture inside the furnace.
4.
Ensure that equal clearance is available on all

sides between job and baffle.
5.
Ensure that the furnace is calibrated.
6.
Connect thermocouples with compensating

cable to PID.
59

FOR PIT FURNACE
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 PIDs 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

60

FOR PIT FURNACE
13.
Start recording the time and temperature in the

logbook every 30 minutes.
14.
Ensure that the cycle is functioning as per program.
15.
After the heat treatment is over, open the furnace

cover.
16.
If the job calls for water quenching, lift the job and
dip it in quench tank.
17.
It the job calls for air cooling in still air, lift the job
and put it outside on supports in open air.
61

FOR PIT FURNACE
18.
It the job doesnt 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.
62
PROCEDURE FOR EMPTY FURNACE

CALIBRATION
Calibration of PIDS ( indicator & controller )
1.
Connect the millivolt source to the temperature

indicator or controller by a compensating
cable. Care should be taken to clean the wires and
terminals thoroughly before connections are
made.
2.
The millivolt output for various temperature

ranging from 00C to 10000C in steps of 500C is fed
to the indicator / controller.
3.
After the millivolt value / temperature reading

displayed is steady, the reading of
indicator/controller shall be noted.
63

CALIBRATION
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

CALIBRATION
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.
65

CALIBRATION
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)
6.
Recorder
+/- 10C
+/- on temperature scale.

+/- minutes on time scale.
66
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.
67

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.
68

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.
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
Inside radius
Heating band
Insulation band
72
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.
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
600mm
90
450mm
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.
77
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
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.
Two wire of thermocouple shall be attached one

after another.
Gap between two wire of a thermocouple shall be
8.
max. 3.0mm
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-(page861&2)
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
(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
COLD WORKING
(UCS-68)
(UG-79)
CUSTOMER SPEC.
90
CODE EXTRACT FOR HEAT TREATMENT

( 1 ) The soak band shall contain the weld, heat
affected zone and a portion of base metal adjacent to the
weld being heat treated. The minimum width of this
volume is the widest width of weld plus 1T or 2 inches,
whichever is less, on each side or end of the weld. The
term T is the nominal thickness.
( 2 )
The operation of postweld heat treatment shall
be performed either by heating the vessel as a whole in
an enclosed furnace or heating the vessel in more than
one heat in a furnace, provided the overlap of the heated
sections of the vessel is at least 5 feet ( 1.5m). When this
procedure is used, the portion outside of the furnace
shall be shielded so that the temperature gradient is not
harmful. The cross section where the vessel projects
from the furnace shall not intersect a nozzle or other
91
structural discontinuity.

( 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.
1 ( CARBON
STEEL) & 3
(LOW ALLOY
STEEL)
1100 DEG. F(593

C)
NOM.
THICKNE
SS
UPTO 2
SOAKING PERIOD
OVER 2
TO 5
2 HOURS , PLUS 15 MIN.

FOR EACH ADDITIONAL
INCH ABOVE 2
2 HOURS , PLUS 15 MIN.
FOR EACH ADDITIONAL
INCH ABOVE 2
OVER 5
1 HR. PER INCH. ,

HOWEVER 15 MINUTES
MINIMUM
* 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
98
of the first layer when the thickness of the pressure
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 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.
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 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,
0
100
but in no case more than 500 F Per hour ( 278 C Per hour).

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)
MINIMUM HOLDING
TIME AT DECREASED
TEMPERATURE (NOTE 1)
2 HOURS
NOTES
100(38C)
4 HOURS
----
150(68C)
10 HOURS
200(94C)
20 HOURS
----
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
100
90
80
70
60
50
40
30
20
10000
10
SHELL THICKNESS
Annexure-5
9500
9000
8500
8000
7500
7000 ISMB 250
ISMB 250 BOX SEC
ISMB 250
6000
5500
5000
4500
4000
3500
ISMB 150
3000
2500
2000 ISMB 125
ISMB 150
1500
1000
100
90
80
70
60
ISMB 150
50
40
30
ISMB 125
20
500
10
SHELL DIAMETER
6500
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
106
107
HT REQUEST
Annexure-7
108
HT CHARGE
Annexure-8
109
Usage of compansating cable
Annexure-9
page 1 of 4
110
Annexure-9
page 2 of 4
111
Annexure-9
page 3 of 4
112
Annexure-9
page 4 of 4
113
Information on Graph Paper Usage
Annexure-10
114
Mechanical v/s capacitor discharge attachments Annexure-11
115
Thermo. Couple Procurement Procedure
Annexure12
116
Thermo. Couple Attachment Procedure
Annexure13
page 1 of 2
117
Thermo. Couple Attachment Procedure
Annexure13
page 2 of 2
118

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Heat Treatment Training Manual

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HEAT

HEAT TREATMENT MANUAL

1 . INTRODUCTION ON HEAT TREATMENT

2 . FURNACE PARTS AND ATTACHMENTS

3. STD. OPERATING PROCEDURES(HFS)

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

WHAT IS HEAT TREATMENT ?

WHAT IS HEAT TREATMENT

MATERIALS HEAT TREATED

METALS (Single phase )

MATERIALS HEAT TREATED

MATERIALS HEAT TREATED

C-Mn , C-Mo , Cr-Mo , Ni -Steels, QT

TYPES OF HEAT TREATMENT

IRON CARBON DIAGRAM

Iron Carbon Diagram

To refine the grains

to soften the steel and improve ductility

Temperature : 593 C Min

Time : 15 minutes min

Heating Rate : 200 C per hr per inch

Temperature : 676 C Min

Time : 15 mts min

Heating Rate : 200 C per hr per inch

Temperature : 593 C Min

Time : 60 mts min

Heating Rate : 200 C per hr per inch

Temperature : 538 C Typ

Time : Minimum 15 minutes to 2 Hr

Heating Rate : 200 C per hr per inch

FURNACE PARTS AND

In this type of thermocouple, the wires are

except PIT F/c

Red & Yellow

IT IS USED FOR CALIBRATING K Type

OXIDATION RESISTANCE , SO MORE LIFE .

For DISPOSAL TYPE

Users will send their requirement of thermocouple

through Consumable slip ( mentioning HTR No ) to

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

PID FUNCTIONS BOTH AS PROGRAMMER AND

WITH COLOUR DISPLAY SCREEN ,HARD DISC AND FLOPPY DRIVE.

WITH PAPER -- CURRENTLY BEING USED IN HZW.

12 CHANNEL -- CURRENTLY BEING USED IN MFS1 AND HFS1

HFS-I FURNACE SKETCH

7900 BOGGIE WIDTH

HFS-I FURNACE SKETCH

STANDARD OPERATING PROCEDURE FOR HFS-1

Receive the job as per HT request.

Receive heat treatment request duly approved by

Ensure that Insp. Clearance is available prior

Load the supporting arrangement as per the attached

Ensure the spider arrangement as per attached

Fix the thermocouples at locations shown in furnace

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

STANDARD OPERATING PROCEDURE FOR HFS-1

Move the bogie inside the furnace

Pass the thermocouples through ports and

Set the program as per heat treatment request.