HEAT TREATMENT M A N U A L FOR POWER SECTOR

PREPARED BY

NAME V.KANDHSAMY UM DESHPANDE Dr. K.P.DHANDAPANI P.ELANGOVAN A.SUKUMARAN D.DEVASAHAYAM R.JANARTHANAN

DESIGNATION / DIVISION AGM/ PSSR QLY, Chennai AGM/ CQ, SECUNDRABAD DGM / WTC-TIRUCHY DGM / PC- Chennai Manager/ SAS Cell - TIRUCHY Manager/ PSSR-QLY, Chennai Dy. Manager/ PC-Chennai

APPROVED BY DOCUMENT NO. COPY NO. DATE OF ISSUE ISSUED BY ISSUED TO :

A.V.KRISHNAN PSQ-HTM-COM R01 / 11 06

GENERAL MANAGER / CQ, NEW DELHI ISSUE DATE 13.11.2006

ID No. : CONTROLLED COPY / INFORMATION COPY

BHARAT HEAVY ELECTRICALS LIMITED POWER SECTOR / CORPORATE QUALITY

IMPORTANT
THIS HEAT TREATMENT MANUAL PROVIDES BROAD BASED GUIDELINES FOR HEAT TREATMENT WORK AT SITES. HOWEVER, SITES MUST ENSURE ADHERENCE TO THE PRIMARY DOCUMENTS LIKE CONTRACT DRAWINGS, ERECTION WELDING SCHEDULE, PLANT / CORPORATE STANDARDS, WHEREVER SUPPLIED, STATUTORY DOCUMENTS, WELDING PROCEDURE SPECIFICATIONS, CONTRACTUAL OBLIGATIONS, IF ANY AND SPECIAL INSTRUCTIONS ISSUED BY MANUFACTURING UNITS SPECIFIC TO THE PROJECT.

Sl.No.

STATUS OF AMENDMENTS Reference of Sheet(s) Amendment No. & Date Amended

Remarks

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER - 1

TABLE OF CONTENTS
Chapter 1 2 3 Description Page No.

Heat Treatment Procedure - Boiler and Auxiliaries Heat Treatment Procedure - Steam Turbine, TurboGenerator and Auxiliaries General 1. 2. Testing of Temperature Indicating Crayons Compatibility Test for Heat Treatment System

8-22 23-24 25 26 27-28

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER - 1

CHAPTER-1 HEAT TREATMENT PROCEDURE - BOILER AND AUXILIARIES

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER - 1

1. HEAT TREATMENT PROCEDURE - BOILER AND AUXILIARIES

1.0 1.1 PURPOSE: This procedure provides information, method and control for Pre-Heat (PH) and Post Weld Heat Treatment (PWHT) of welds at sites. DOCUMENT: The following documents are referred in preparation of this procedure: ASME Sec.I ASME B31.1 Indian Boiler Regulations AWS D1.1 Welding Manual The following are to be referred as Primary Documents: 2.2.1 Contract drawings Erection Welding Schedule or equivalent Plant / Corporate standards, where supplied Welding procedure specification, where supplied Contractual obligations, if any.

2.0 2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.2

Where parameter for preheating and PWHT are not available in the primary documents, reference may be made to this procedure. Where such parameters are not contained either in the primary documents or in this procedure, reference may be made to Manufacturing Units. PROCEDURE: Pre Heating (PH): When parts of two different thicknesses are welded together, the preheating requirements of the thicker shall rule

2.2.2

3.0 3.1 3.1.1

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER - 1

3.1.2 When parts of two different P numbers are joined together, the material requiring higher preheat shall govern (please refer Welding Manual for P numbers). 3.1.3 Preheating shall be checked using thermal chalk (temperature indicating crayons) prior to start of welding as well as at frequent intervals during welding. It is preferable to have a thermocouple and a temperature recorder in case of alloy steels of thickness > 50 mm. 3.1.4 3.1.5 In case of any interruption during welding, preheating temperature shall be maintained at joint by wrapping dry thermal insulating blankets to ensure slow and uniform cooling. Preheating Methods:

3.1.5.1 Preheating shall be applied by any of the methods given below: a. b. c. 3.2 3.2.1 3.2.2 Electrical resistance heating Induction heating Oxy-acetylene or other gas torches

Post Weld Heat Treatment (PWHT): The method shall be by locally heating a circumferential band including the entire weld and adjacent area of base metal, by induction or electrical resistance heating. Heat band for PWHT.

3.2.2.1 For Boilers: a. When heat treating welded joints in components in the boiler proper, width of the heated circumferential band (W) on either side of the weld, W = 3 times the width of the widest part of the weld groove but in no case less than twice the width of weld at reinforcement. When used in post weld heat treatment in sections - W = 3 times the plate thickness. For nozzle and other welded attachments - W must be wider than the nozzle or attachment or 3 times the wall thickness.

b. c.

3.2.2.2 For Piping: W = 3 times the wall thickness of thickest part. In case of nozzles and attachment welds, the width of the heat band shall extend beyond the nozzle or the attachment wall on each side by at least twice the higher thickness and shall extend completely around the header.

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER - 1

3.2.2.3 Other Pressure Vessels: Heat bandwidth, placement of thermocouple, preheat and PWHT information shall be obtained from the supplier. 3.3 3.3.1 3.4 3.4.1 3.4.2 3.4.3 3.4.4 Condition of Welded Joints: The weldment shall be free of grease, oil etc. prior to PH/PWHT. Temperature Measurement for PWHT: Post weld heat treatment temperature shall be measured and monitored by use of thermocouples with calibrated recorders. The periodicity of calibration of the equipment shall be as per calibration procedure. Where the soaking temperature is found to be lesser than specified, the PWHT cycle shall be repeated. In case of interruption during PWHT, the following actions are to be taken, depending on the stage during which interruption occurred. a.Interruption during heating cycle: The whole operation to be repeated from the beginning. The joint can be treated subsequently for the balance left over soaking period. c.Interruption during cooling: - Ensure slow cooling by covering with insulation to a minimum width of 1.5 times the outer diameter applied equally about the centre line of weld, till the temperature reaches around 300 C. 3.5 3.5.1 Thermocouple (t/c) Fixing: Thermocouples shall be used for recording Post Weld Heat Treatment temperatures. b.Interruption during soaking:

3.5.1.1 Following are guidelines regarding number and placement of thermocouples: 3.5.1.2 Minimum of two thermocouples per weld. 3.5.1.3 Thermocouples located 180 apart. 3.5.1.4 Thermocouples located at top and bottom of weld. 3.5.1.5 Thermocouples located at a distance of approximately 1.5 times of the wall thickness about the centre line of weld. 3.5.1.6 One point of the 6/12 points recorder shall be used for recording ambient temperature.

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER - 1

3.5.2

The following guidelines may be used for attaching thermocouples to job: a. b. For capacitor discharge method: Thermocouple elements should be attached within 6 mm of each other. For other type of t/c: Insert the elements in a SS tube of internal diameter approximately 6 mm. Apply force on tube and crimp it. Place this t/c and weld the crimped button to the pipe in area of interest. Do not weld the elements. Insulate the t/c leads suitably and protect t/c ends from direct radiation from heating elements.

c. 3.5.3

For Bunched Tubes:

3.5.3.1 Where a bunch of closely placed tube welds (e.g. Super Heater/Reheater Coils) require to be Post Weld Heat Treated, the same shall be grouped together as if they form a single component. 3.5.3.2 In such cases attachment of a minimum of three thermocouples, two at the end tubes and one at the middle is recommended. 3.6 3.6.1 3.6.2 Soaking Time: Wherever not specified the soaking time shall be as per Tables I, II and III. The following guidelines shall be used to determine the thickness and subsequent selection of the soaking time of PWHT: a. b. c. d. e. For butt welds, the thickness shall be the thickness of the material at the weld. For bar stock, the thickness shall be the diameter. For fillet welds, the thickness shall be the throat thickness. For partial penetration branch welds, the thickness shall be the depth of the groove prior to welding. For repairs, the thickness shall be the depth of the groove as prepared for repair welding. For combination of different welds in a component, the maximum thickness in the definitions given above shall govern.

3.6.3

Soaking time is to be reckoned from the time temperature of the joint crosses the recommended lower temperature of the cycle, to the time it comes down below the same recommended lower temperature of the cycle. Heating and Cooling Rates: Wherever not specified, the heating rate above 300 C and cooling rate after soaking upto 300 C shall be as follows: This is applicable for all materials.

3.7 3.7.1

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER - 1

Thickness of Material 25 mm > 25 50 mm > 50 75 mm > 75mm

Maximum Heating Rate Above 300 C 220 C/hour 110 C/hour 75 C/hour 55 C/hour

Maximum Cooling Rate Upto 300 C 220 C/hour 110 C/hour 75 C/hour 55 C/hour *

* For structural - 65 C/ hour (Max.) 3.8 Temperature Records:

3.8.1
4.0 4.1

All the heat treatment cycles may be controlled within 10 C around the midpoint of the recommended range of temperature for the material.
POST WELD HEAT TREATMENT (PWHT) JOB CARD: Prior to start of PWHT operations, a job card may be prepared including details of weld reference, soaking time, soaking temperature, maximum rates of heating and cooling, temperature recorder details, date of PWHT as per sample format. On completion of PWHT the actuals may be recorded on the job card. A chart number shall be given to each chart. HEAT TREATMENT OF P-91 WELDS : Please refer Welding Manual vide document No. PSQ-WDM-COM for heat treatment of welds in P-91 materials. HEAT TREATMENT OF T-91 WELDS:

4.2 4.3 5.0 5.1

5.2

5.3 Please refer Welding Manual vide document No. PSQ-WDM-COM for heat treatment of welds in T-91 materials

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER - 1

5.4

HEAT TREATMENT OPERATOR REQUIREMENTS: The operator for the Heat Treatment shall be a qualified Electrician and should be conversant in the operation & maintenance of heat treatment machines & Process. He should be trained properly by the concerned Welding / Electrical Engineer in order to handle/ maintain the machines / process without any trouble / problem.

6.0

LIST OF TABLES: Table-I Weld preheat and PWHT for tubes and pipes outside diameter 102 mm. Table-II Weld preheat and PWHT for Boiler Header welds. Table-III Weld preheat and PWHT for pipes outside diameter > 102 mm. Table-IV P Number and Group Number for Base Materials. Table-V Pre-heat and PWHT for Non-Pressure Parts including Structurals. Table-VI Preheat for Flame Cutting.

7.0 7.1

RECORDS : Pertinent Records like Job card, PWHT Charts, shall be maintained.

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER - 1

POST WELD HEAT TREATMENT (PWHT) JOB CARD Project : ____________________

Card No. : ____________________ Unit No. : _____________________ Description :___________________ Weld Reference : _______________ Material Spec. : ________________ Size : Dia __________________ mm Thick (t) ______________ mm NDE Cleared on :_______________ Report No. : _______________ Date : ________________________ Package : _____________________ Temp. Recorder Details : 1. Make : _____________________ 2. Type : _____________________ 3. Sl.No.: _____________________ 4. Chart speed: ________ mm / hour 5. Calibration Due on : __________

Thermocouple Locations : Minimum 2 d = 1.5 x t from weld centre Heating Band = 6 x t Insulation Band = 12 x t Date of PWHT _________________ Start Time : ___________________ Chart No. : _____________________ End Time :_____________________ Required Rate of Heating (Max) C/h Soaking Temperature C Soaking Time (Minutes) Rate of cooling (Max) C Actual

Ambient temperature recorded on the PWHT Chart: ____________

Contractor Results : Accepted / Not Accepted

BHEL Released for further processing

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER - 1

TABLE - I WELD PRE HEAT AND PWHT FOR TUBES & PIPES OUTSIDE DIAMETER 102 mm (Applicable For Butt Welds And Socket Welds)
P. No. of Material P1 Gr 1& SA 106 Gr C (Note 1) P1 Gr 2 Thickness (mm) 19 9 >9 13 > 13 13 > 13 8 >8 All All All Preheat C Nil Nil Nil Nil 80 (Note 2) 125 125 150 150 220 Nil 200 PWHT C Nil Nil 620 - 650 Nil 620 - 650 Nil (Note 3) 650 - 670 Nil (Note 3) 700 - 750 730 - 760 Nil 730 - 760

P3 Gr 1

P4 Gr 1

P5 A Gr 1 P5 B Gr 2 P8 12 x 1M

Note 1 : For SA 106 Gr .C with less than 0.25 % carbon content . Note 2 : Pre-heating is necessary for t>16mm. Note 3 : Less than 0.15 % carbon content .

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER - 1

TABLE - II WELD PREHEAT AND PWHT FOR BOILER HEADER WELDS (NOTE - 3) (Applicable For Welding of Header to Header Joints)
P. No. of Header Material P1Gr 1 Thickness (mm) t 19 19 < t 25 25 < t 75 t > 75 t < 19 P1Gr 2 19 < t 25 19 < t 75 t > 75 P4 Gr 1 P5 A (Note 1) 12 x 1M Note : 1. All P5A headers shall be inter stage heat treated at 700 - 750 C for 30 minutes soaking prior to any cold straightening operation. In lieu of this, the straightening can be done after final PWHT. Any P5A Header with weld thickness above 50mm requires inter stage H.T. at 700-750 C for 30 minutes soaking minimum (max. shall be limited to 2.5 minutes/mm of thickness). Soaking for PWHT shall be at the rate of 1 hour per 25 mm of thickest weld (but not less than 30 minutes for carbon steel and 1 hour for alloy steel). Soaking time for 12 x 1 M header material shall be 4 minutes per mm of the applicable thickness with a minimum of 180 minutes. Seal welding of Hand Hole Plates, Radiographic plugs and Screws can be carried out after final PWHT, provided the preheat is carried out as per the table. For P number and Group number refer Table - IV. All All All Preheat C Nil Nil 100 150 Nil Nil 100 150 150 150 200 Post Heating C Nil Nil Nil Nil Nil 150 for 2 hours 150 for 2 hours 150 for 2 hours Nil 250 for 2 hours Nil PWHT C Nil 595 - 625 595 - 625 595 - 625 620 650 620 - 650 620 - 650 620 - 650 640 - 670 680 - 710 710-740

2.

3.

4.

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER - 1

P No. of Material

Thickness (mm)

TABLE - III WELD PREHEAT AND PWHT FOR PIPES OUTSIDE DIAMETER >102 mm Stub and Attachment welds Note 1 BUTT WELDS &2 Throat 19 mm Throat > 19 mm Preheat PWHT C C Preheat PWHT Preheat PWHT C C C Nil Nil 150 150 Nil Nil 150 125 150 150 220 Nil 595 625 595 625 595 625 Nil 620 650 620650 640670 640670 680 750 680750 750770 Nil Nil 150 150 Nil Nil 150 125 150 150 150 Nil Nil Nil 600650 Nil 600650 600650 650680 650680 700750 700750 750770 Nil Nil 150 150 Nil Nil 150 125 150 150 150 C 595 625

Post heat C (Note 3) Nil Nil Nil Nil Nil Nil 150 for 2 hrs Nil Nil 250 for 2 hrs 250 for 2 hrs 280 for 2 hrs

19 P1 Gr 1 & SA106 Gr C >1925 >2575 >75 P1 Gr 2 & SA 106 Gr C 9 >919 >19 75 P4 Gr 1 >75 Pipes Castings & Forgings All

595 625 595 625 595 625 620 650 620 650 620 650 640670 640670 680750 680750 750770

P5 A

P5B Gr2 + P5B Gr2, P5B Gr2 + P5 A Note : 1.

220

220

220

All

220

730760

220

730760

220

730760

280 for 2 hrs

Irrespective of the stub or attachment materials, the PWHT cycle shall be governed by the pipe material.

2.

Throat shall be specified in the drawing. Wherever flanges are welded to pipes combined throat shall be taken into consideration.

3.

Post heating shall be done immediately after welding.

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER - 1

4.

For butt welds of different P group combinations, PWHT temp. may be as follows: P1 + P3 P1 + P4 P4 + P5A 620 to 650 C 640 to 670 C 680 to 720 C

(For other P Group combinations, refer to Engineering) 5. a. For P1 & P3 materials soaking time shall be 1 hour per 25mm up to 50mm thickness and 2 hours + 15 minutes for each 25mm thickness over 50mm.

b. For P4 & P5 materials, soaking time shall be 1 hour per 25mm up to 125mm thickness and 5 hours + 15 minutes for each 25mm thickness over 125mm. 6. For P number and Group number refer Table IV.

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER - 1

TABLE - IV P NUMBER AND GROUP NUMBER FOR BASE MATERIALS

P.No Group No. Common Name Carbon Steels Tubes SA192 SA210GRA1 Pipes SA106GRB Plates SA36 SA515GR55 SA515GR60 P1 1 SA515GR65 SA516GR55 SA516GR60 SA516GR65 Carbon Steels P1 2 SA210GRC SA106GRC SA515GR70 SA516GR70 SA299 P3 1 Carbon-Moly Steels CrMo Steels 1CrMo/ 1CrMo Steels 2Cr1Mo Steels 9Cr1MoV Steels 18Cr-8Ni Steels SA209T1 SA335P1 SA266CL2 SA216WCB SA216WCC SA352LCC SA217WC1 SA105 SA234WPC Forgings SA266CL1 Castings SA216WCA SA352LCA SA352LCB Fittings SA234WPB

P3 P4

1 1

SA213T2 SA213T12/ SA213T11 SA213T22 SA213T91 SA213TP304

SA335P2 SA335P12 SA335P11 SA335P22 SA335P91 SA376TP304

SA387GR2 SA387GR12 SA387GR11 SA387GR22 SA387GR91 SA182F12 SA182F11 SA182F22 SA182F91 SA351CF3 SA351CF8 SA351CF3M SA351CF8M SA351CF10 SA351CF10M SA351CK20 SA217WC9 SA217WC6 SA234WP12 SA234WP11 SA234WP22 SA234WP91 SA403

P5A P5B

1 2

SA240TP304 SA182F304 SA240TP321 SA182F321 SA240TP347 SA182F347 SA336F304 SA336F321 SA336F347

SA213TP304H SA376TP304H P8 1 SA213TP347 SA376TP321

SA213TP347H SA376TP347 SA213TP321 SA376TP347H

P8

25Cr-20Ni Steel (Type 310)

SA240TP310 SA182F310

Note : IS1239 & API 5L GR B Pipes, IS2062 Plates may be treated as P No.1 Gr No.1 material.

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER - 1

TABLE - V PREHEAT AND PWHT FOR NON PRESSURE PARTS INCLUDING STRUCTURALS
P.No. of Material / Material Specification Gas Cutting Thickness (mm) 50 P1 / IS 2062 > 50 IS 8500 540 Ceiling Girder 100 Preheat C Nil Thickness (mm) 38 > 38 63 > 63 Welding Preheat C Nil 100 120 PWHT C 600-650 a)All butt welds > 50 mm thick b)Any welds to a tension member 600-650(Soaking time 2.5 Mts. Per mm. Minimum 120 Mts ) 650-700 All > 25 150 150 a)All butt welds in tension member b)All fabricated components > 16mm thick (Note 3) 680-730 All welds (Note 4)

10< < 200

150

25 P4

Nil

P5

All

150

All

150

NOTE : 1. 2. 3. 4. 5. All gas cut edges may be chipped off, ground or machined to remove the HAZ with 3mm minimum removal. Clip angles above 10mm, used for beam connections, which are sheared to length, shall require heat treatment. All fabricated structural components of P-4 material, with any member above 16mm thickness, the entire assembly shall be post weld heat treated. All welds of P5 material shall be post heated at 250 C for 2 hours or 150 C for 4 hours immediately following welding. Soaking time shall be as below : a. P1 and P3 materials one hour per 25mm up to 50mm thickness and 2 hours + 15 minutes for each 25mm thickness over 50mm. b. P4 and P5 materials one hour per 25mm up to 125mm thickness and 5 hours + 15 minutes for each 25mm thickness over 125mm.

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER - 1

TABLE - VI PREHEAT FOR FLAME CUTTING

P.No. of Material P1 Gr 1 (Note 1) P1 Gr 2 (Note 1) P3 (Note 1) P4 (Note 1) Thickness (mm) < 25 25 All > 100 All Preheat C Nil 100 150 150 150

P5 (Note 2) NOTE :

All

150

1. For P1, P3 and P4 materials, when the flame cut edge will be machined after cutting and when no forming operation is required after cutting, no preheat is required for flame cutting. 2. P5 materials, except when the part is scheduled for hot forming, shall be inter stage heat treated at 700-750 C for 30 minutes minimum after flame cutting and prior to any welding. As an alternative to this heat treatment, a minimum 3 mm of the gas cut edge may be removed by machining, grinding, chipping, etc.

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER -2

23

2. HEAT TREATMENT PROCEDURE STEAM TURBINE, TURBO-GENERATOR AND AUXILIARIES

Procedure for Post Weld Heat Please refer Plant Standard, treatment of Pressure Vessel as Haridwar - HW 0980814 per ASME code Section VIII, Div.I For other Components

HEEP,

Please refer Heat treatment ProcedureBoiler and Auxiliaries of Chapter-I

CHAPTER -2 HEAT TREATMENT PROCEDURE STEAM TURBINE, TURBO-GENERATOR AND AUXILIARIES

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER -2

24

2. HEAT TREATMENT PROCEDURE STEAM TURBINE, TURBO-GENERATOR AND AUXILIARIES

Procedure for Post Weld Heat Please refer Plant Standard, treatment of Pressure Vessel as Haridwar - HW 0980814 per ASME code Section VIII, Div.I For other Components

HEEP,

Please refer Heat treatment ProcedureBoiler and Auxiliaries of Chapter-I

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER -3

25

CHAPTER - 3 GENERAL

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER -3

26

3. GENERAL 1. TESTING OF TEMPERATURE INDICATING CRAYONS

1.0 1.1 SCOPE : This procedure details the method of batch testing of Temperature indicating Crayons (Thermal chalks). 2.0 2.1 2.1.1 2.2 PROCEDURE : Setup: Rig a test heating arrangement including a test pipe/plate heating arrangements with controls and a calibrated temperature recorder/thermometer. Heat the test pipe / plate (specimen) to a temperature 10 lower than the rated temperature of the thermal chalk in study, monitoring the temperature through thermometer/recorder. 2.3 2.4 Stroke the thermal chalk as close to the sensing point on the specimen. Raise the temperature of the specimen gradually up to 10% higher than the rated temperature of the thermal chalk in study, stroking the thermal chalk on the specimen during this period. 2.4.1 2.5 2.6 When the thermal chalk changes to the specified colour or melts (depending on the type), within 5 of the rated temperature, the thermal chalk is acceptable. Consistent results for 2% of any brand and temperature will qualify the brand for the rated temperature. Where thermal chalks are accepted brand wise, they shall undergo this test at least once a year. 3.0 3.1 3.2 RETESTS : Any failure in the 2% sample chosen, will call for additional 4% for qualification of the brand for the rated temperature. Where retest results in further non-acceptance, the brand shall stand rejected for the particular temperature. 4.0 4.1 RECORDS : Records of testing and brands accepted/rejected including details of calibrated devices used in the setup shall be maintained.

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER -3

27

2. COMPATIBILITY TEST FOR HEAT TREATMENT SYSTEM

1.0 1.1 SCOPE : This procedure provides for checking the compatibility and accuracy of

thermocouples, compensating cables, temperature recorder, connected in Heat Treatment (HT) operations at sites. 2.0 2.1 HT TEST SYSTEM : The thermocouple (type k-chromal-Alumel is generally used at sites) attached to a test specimen with heating arrangements and controls, compensating cables, a calibrated temperature recorder rigged together for the test HT system. 2.2 A calibrated (accuracy 0.5%) direct-reading thermometer (like a digital thermometer with sensor) is used for verification. 2.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.7.1 3.8 3.9 PROCEDURE : Attach the thermocouple as detailed in Chapter I of this manual. Raise the temperature of the test specimen to around 200 C and maintain the same. Place the sensor of the direct reading thermometer as close to the thermocouple junction as possible. Wait till the temperature stabilises. Note reading of the thermometer and that of the temperature recorder. Repeat steps 3.2 to 3.5 for test specimen temperatures of 400 C and 600 C Where the temperature read by the temperature recorder is within 10 C with respect to the thermometer, the HT system is compatible. Where the results are not within the tolerance specified above, further tests are to be repeated to identify the fault either in thermocouple or compensating cable or both. Adequate insulation of thermocouple, sensor from direct radiation of heat elements shall be ensured as a precaution throughout the test. This compatibility is recommended for each of the thermocouple available for use; this procedure validates the thermocouple also. 4.0 RECORDS :

4.1Records pertaining to the test, shall be prepared and maintained.

HEAT TREATMENT MANUAL FOR POWER SECTOR CHAPTER -3

28

Compatibility Test for HT System

Site : Report No. Date :

Details Make: Model: Sl. No.: Range:

Temperature Recorder

Thermometer

Test Results
Sl. No. t/c No. C/C. No. Temperature Reading C Recorder Thermometer Difference C Results*

Record results (Accepted/Rejected) where rejected, record the faulty component as required by 3.7.1

Witnessed by

(Name & Signature)