HEAT

TREATMENT
TRAINING MANUAL
MAY-2001 (REV.-0) 1
 HEAT TREATMENT MANUAL
This Manual is compiled by

Mr K S Rao (QA),
Mr S P Ghiya (Inspection ) and
Mr N M Bodalia (M FS)

Under the guidance of

Mr P D Lohidakshan (Weld Engg & Prod Engg )

2
 INDE
TOPIC
X 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.

4
 HEAT TREATMENT

• WHAT IS HEAT TREATMENT ?

• WHY IS IT REQUIRED ?
• TYPES OF HEAT TREATMENT
• HEAT TREATMENT AT HZW

5
 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
 MATERIALS HEAT TREATED
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
9
 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

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 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 14
 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
15
 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 formed16 at
grain boundaries during manufacturing
 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 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
20
• Heating Rate : 200 C per hr per inch
 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 21
 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
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
• Heating Rate : 200 C per hr per inch 23
• Cooling Rate : 260 C per hr per inch
FURNACE PARTS AND

THEIR ATTACHMENTS

24
 LAYOUT OF A TYPICAL
FURNACE
(Electrical or Gas fired )
FURNAC
E
THERMOCOUPLE
COMPENSATING
CABLE

JO
B

RECORDER P.I.D.

CONTROLLING
BURNER 25
 THERMOCOUPLES
• PRINCIPLE OF A THERMOCOUPLE

• THERMOCOUPLE MATERIALS

• TYPES OF THERMOCOUPLES BEING

USED IN HZW

26
 PRINCIPLE OF THERMOCOUPLE

The basic principle of thermoelectric

thermometry is that a thermocouple develops
an emf which is a function of the difference
in temperature of its measuring junction &
reference junction. If the temperature of
reference junction is known, the temperature
of the measuring junction can be determined
by measuring the emf generated in the circuit.
27
 THERMOCOUPLE MATERIAL
REQUIREMENT
1. High coefficient of thermal emf.
2. Continuously increasing relation of emf to temperature
over a long range.
3. Freedom from phase changes or other phenomenon
giving rise to discontinuity in temperature emf relationships.
4. Resistance to oxidation, corrosion and contamination.
5. Homogeneity and reproducibility to fit an establish
temperature & emf relationship.
SPEED OF RESPONSE MAY BE IMPROVED AND
RADIATION & CONDUCTION ERRORS MAY BE
REDUCED BY THE USE OF SMALL DIAMETER 28
 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.
29
 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
30
 CONSTRUCTION OF A
K TYPE THERMOCOUPLE
White/
White Color
yellow
+Ve
pid
-Ve
Red Color
Blue Color Welde
d
White/
White Color yellow
junctio
n
record +Ve
er -Ve
Color

Color
Blue

Red
Compensati Thermocou
ng ple
cable wire

Accuracy :
0.75% 31
 ‘S’ TYPE THERMOCOUPLE
Accuracy : 0.25
%
• ‘S’ TYPE THERMOCOUPLE ARE THE STANDARD

THERMOCOUPLES.

• IT IS USED FOR CALIBRATING “K” Type

THERMOCOUPLES.

• MATERIAL OF CONSTRUCTION
90% PLATINUM + 10% RHODIUM
PLATINUM

• OXIDATION RESISTANCE , SO MORE LIFE .

32
 For DISPOSAL TYPE

• UsersISSUE METHODOLOGY
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 . 33
• See Annexure-12 for further details
 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 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 36

WE GENERALLY KEEP 25 MM / HOUR.
 GRAPH PAPER
• GRAPH PAPERS ARE USED FOR PLOTTING THE
FURNACE TEMPERATURE VIA THERMOCOUPLE.
THEY ARE FITTED ON THE RECORDER.
• GRAPH PAPER RECOMMENDED ON RECORDER ONLY
TO BE USED
• GRAPH PAPER FOR MFS1 AND HFS1 FURNACE
==> ET 201 CHINO MAKE, JAPAN
GRAPH PAPER FOR PFS FURNACE
==> ET 001 CHINO MAKE, JAPAN
• THE LENGTH OF ONE BUNDLE OF GRAPH PAPER IS
GENERALLY 2000 MM.
• DOTTING TYPE RECORDER INK (CHINO MAKE, JAPAN)

IS USED IN RECORDER FOR PLOTTING OF GRAPH.

USUALLY , 6 COLOURS ARE FILLED FOR PLOTTING.
37
• SEE ANNEXURE-10 FOR FURTHER DETAILS
STANDARD OPERATING
PROCEDURE FOR HFS-1
FURNACE

38
( ZONE-2 ( ZONE-4 ( ZONE-6 ( ZONE-8
) BURNER
) ) )

1640 1650

7900
(BOGIE

WIDTH
)

165
0
357 357 357 357
5
( ZONE-1 5
( ZONE-3 ( 5ZONE-5 5
( ZONE-7
14300
) ) . ) )

HFS-I FURNACE SKETCH 39

 900
0

1. PROJECT NO:
2. SECTION NO :
3. CHARGE NO :
950
0 4. H. T. REQ. NO :

BURNER

1195 7900 BOGGIE WIDTH 105

0

870
0

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
 STANDARD OPERATING PROCEDURE FOR HFS-1
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 adjustthe
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
storage tanks and note down in logbook. 42
 STANDARD OPERATING PROCEDURE FOR HFS-1
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
 STANDARD OPERATING PROCEDURE FOR HFS-1
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
 STANDARD OPERATING PROCEDURE FOR HFS-1
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
and fill the spot check format. 45
 STANDARD OPERATING PROCEDURE FOR HFS-1
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 thermocouplesfrom

compensating cable.

35. Submit the graph and duly filled spot check formats
to inspection for approval of heat treatment.
46
 STANDARD OPERATING PROCEDURE FOR HFS-1
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
560
0
265
0

550
0
BURME
R

410
0
BOGGIE

146
105

0
123

WIDTH
5

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
 STANDARD OPERATING PROCEDURE FOR PFS
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 adjustthe
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. 52
 STANDARD OPERATING PROCEDURE FOR PFS
FURNACE
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 the
pressure by lifting the handle of safety shut off valve.
53
 STANDARD OPERATING PROCEDURE FOR PFS
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
 STANDARD OPERATING PROCEDURE FOR PFS
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
 STANDARD OPERATING PROCEDURE FOR PFS
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
 CERMIC GROUND HEATING
BLANKE LEVEL ELEMEN
OUTER T CERMIC FIBER T
SLABER BAFFL
FIRE BRICK E
BLOCK
SHELL
INSULATING
CASTABLE

ROO
F
CERAMIC
BLANKET

4150 ( REFRACTORY I/S

3700 1/D OF BAFFLE

BLOWER

402
0

)
125 250

TROLLEY
STRUCTURE

138
0 1000
4961 58
PIT FURNACE SKETCH
 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
 STANDARD OPERATING PROCEDURE
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 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’

60
 STANDARD OPERATING PROCEDURE
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
 STANDARD OPERATING PROCEDURE
FOR PIT FURNACE
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.

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 50 0C 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
 PROCEDURE FOR EMPTY FURNACE
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
 PROCEDURE FOR EMPTY FURNACE
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
 PROCEDURE FOR EMPTY FURNACE
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) +/- 10C
6. Recorder +/- 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
 PIT FURNACE CALIBRATION PROCEDURE

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
 PIT FURNACE CALIBRATION PROCEDURE

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 800 0C 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 Weld width ‘X’ +
band lesser of 1T or 2”
X

t
Heating
band
Insulation
band
radius
Inside

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
No Welding at prop

top
Multitonne
roller

200 to 500mm from heating 74

band
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
 SUPPORTING ARRANGEMENTS

600mm
450mm
burn
er 90
0
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
 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

78
 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.
79
 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

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. 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-(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 (UCS-68)

COLD WORKING (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
91
nozzle or other 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. 92
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. 93
 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). 94
CODE EXTRACT FOR HEAT TREATMENT

95
 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.
96
• When the PWHT is a service requirement.
CODE EXTRACT FOR HEAT TREATMENT

SERVICE CONDITION

• LETHAL SERVICE PWHT IS MANDATORY

• EXEMPTIONS ARE FEW

97
 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
98
pressure 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
than 4000F Per hour (200 0C/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
 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 (278 0C/Hour) divided by the
maximum metal thickness of the shell or head plate in inches,
100
but in no case more than 5000F Per hour ( 2780C 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 :

101
102
103
104
105
Annexure-
5

106
107
 HT Annexure-
REQUEST 7

108
 Annexure-
HT CHARGE 8

109
Usage of compansating Annexure-
9
cable
page 1 of 4

110
Usage of compansating Annexure-
9
cable
page 2 of 4

111
Usage of compansating Annexure-
9
cable
page 3 of 4

112
Usage of compansating Annexure-
cable 9
page 4 of 4

113
Information on Graph Paper Annexure-1
Usage 0

114
Mechanical v/s capacitor discharge
Annexure-11
attachments

115
Thermo. Couple Procurement Annexure-1
Procedure 2

116
Thermo. Couple Attachment Annexure-1
Procedure 3
page 1 of 2

117
 Annexure-1
Thermo. Couple Attachment 3
Procedure page 2 of 2

118