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HEAT TREATMENT OF
PRESSURE VESSELS
2
HEAT TREATMENT
MECHANICAL PROPERTIES OF METALS &
ALLOYS DEPEND ON
CHEMISTRY (ALLOYING ELEMENTS)
&
HEAT TREATMENT
3
WHAT IS HEAT TREATMENT?
MATERIALS TREATED BY APPLICATION OF
HEAT - NORMALLY DONE IN SOLID STATE
HEATING BY VARIOUS SOURCES
HEATING IN A FURNACE Oil, Gas, Electrical
HEATING OUT SIDE WITH ELECTRIC HEATING
COILS ARROUND THE JOB Local Heat treatment
PASSING HOT AIR INSIDE A CLOSSED VESSEL
Internal firing
4
HEAT TREATMENT
HEAT TEATMENT PARAMETERS
RATE OF HEATING
SOAKING TEMP.
SOAKING TIME
COOLING RATE
COOLING MEDIA
5
WHY HT REQUIRED ?
TO BRING THE PROPERTIES TO THE
DESIRED RANGE
Strength, UTS, YS & Elongation
Toughness
Hardness
CARRIED OUT IN
FABRICATION INDUSTRIES- Fabricated Components
STEEL PLANTS Plates, Pipes, Tubes, Sections
FOUNDRY SHOPS - Castings
FORGING SHOPS Forged Components
6
MATERIALS HEAT TREATED
METALS & ALLOYS
SINGLE PHASE
MULTIPHASE
ALLOYS
Single Phase : Copper Nickel
Multiphase : Steels
METALS (Single phase )
Titanium
7
HEAT TREATEMENT
CRITERIA
COLD WORKED to NORMAL
All materials
UNEQUILIBRIUM PHASES to
EQUILIBRIUM
Stainless Steels ,Maraging Steels
STRESSED to UNSTRESED
All Materials
8
MATERIALS HEAT TREATED
CS
C-Mn , C-Mo , Cr-Mo , Cr-Mo-V, Ni -Steels
Stainless Steels
Non Ferrous Materials
9
TYPES OF HEAT TREATMENT
NORMALIZING
ANNEALING
STRESS RELIEVING
SOLUTION ANNEALING
HARDENING
TEMPERING
AGEING
10
IRON CARBON DIAGRAM
11
NORMALIZING
The steel is heated to 40 C above the upper
critical temperature followed by cooling in the
still air.
To achieve
Uniform structure
Change in Mechanical properties,
UTS, YS & Elongation
Hardness
Impact properties
Refined grains
12
ANNEALING
Steel is heated 10 to 50C above the upper
critical temperature and held for the desired
length of time followed by very slow cooling
within the furnace
To achieve:
Softness & better ductility
Stresses free material Stress generated due to
mechanical working / previous HT
Uniform property through out the material
13
SOLUTION ANNEALING
Austenitic Stainless steels is heated to above
1050C and held for the desired time followed by
fast cooling to room temperature within few
minutes by quenching / blowing the air.
Solution annealing is done on stainless steel and
non ferrous alloys
To soften the material
To remove carbide precipitation formed at grain
boundaries during manufacturing process ( SS )
To improve Corrosion Resistance
14
AGEING
The Material is heated to a certain temperature,
and held for the desired time; followed by
quenching or cooling in air
Ageing is done on materials susceptible for
ageing characteristics : Maraging Steels
Normally increases strength
Improves Toughness
15
AGEING
Maraging Steels
M250
Temperature : 485 C
Normally 3 Hrs 15 mts
Heating Rate : 200 C per hr per inch thick
Cooling Rate : Cool in Air / Quench in water
16
STRESS RELIEVING
The steel is heated to a temperature below close to the
lower critical temperature with a specific rate of
heating. It is held at the temperature for a desired
length of time, followed by cooling with a specific
rate up to certain temperature.
There is no change in grain structure.
Stress relieving is done Fabricated Components of
CS & LAS:
To reduce Internal Stresses
To soften the steel partially
To soften HAZ
17
STRESS RELIEVING
C-Mn , C-Mo , Cr-Mo (< 2% Cr)
C - Mn Steels , C - Mo Steels, Cr-Mo Steels
SA 515Gr 70 , SA204GrA, SA387GR11,CL1
Temperature : 593 C Min
Normally 600 - 640 C, 650-690 C
Time : 15 minutes min ( 1 hr / inch thick)
Heating Rate : 200 C per hr per inch thick
Cooling Rate : 260 C per hr per inch thick
18
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 (1 hr / inch thick)
Heating Rate : 200 C per hr per inch thick
Cooling Rate : 260 C per hr per inch thick
STRESS RELIEVING
19
Ni -Steels
Nickel Steels : 1,2,3% Ni
SA 203 GrA ,D
Temperature : 593 C Min
Normally 600 - 640 C,
Time : 60 mts min (1 hr / inch thick)
Heating Rate : 200 C per hr per inch thick
Cooling Rate : 260 C per hr per inch thick
STRESS RELIEVING
20
Steels enhanced by Heat Treatments
Q&T Steels :
9.5% Ni Steels , SA 517 Gr E
Temperature : 538 C Typ
Normally < 600 C
Time : Min 15 minutes to 2 Hr ( 1 hr / inch thick)
Heating Rate : 200 C per hr per inch thick
Cooling Rate : 260 C per hr per inch thick
STRESS RELIEVING
21
LAYOUT OF A TYPICAL
FURNACE
(Electrical or Gas fired )
RECORDER
P.I.D.
FURNACE
JOB
COMPENSATING
CABLE
THERMOCOUPLE
22
THERMOCOUPLES
PRINCIPLE OF A THERMOCOUPLE
THERMOCOUPLE MATERIAL
TYPES OF THERMOCOUPLE BEING
USED IN HED POWAI / HZW
23
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.
24
THERMOCOUPLE MATERIAL
REQUIREMENT
1. High coefficient of thermal emf.
2. Continuously increasing relation of emf to temperature over
a long range.
3. Freedom from phase changes or other phenomenon giving
rise to discontinuity in temperature emf relationships.
4. Resistance to oxidation, corrosion and contamination.
5. Homogeneity and reproducibility to fit an establish
temperature & emf relationship.
SPEED OF RESPONSE MAY BE IMPROVED AND
RADIATION & CONDUCTION ERRORS MAY BE REDUCED
BY THE USE OF SMALL DIAMETER THERMOCOUPLES.
25
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.
26
TYPES OF THERMOCOUPLE
BEING USED
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
27
recorder
pid
Compensating
cable
Thermocouple
wire
Welded
junction
CONSTRUCTION OF A
K TYPE THERMOCOUPLE
Accuracy : 0.75%
PROPORTIONAL
INTEGRAL
DERIVATIVE
28
S TYPE THERMOCOUPLE
S TYPE THERMOCOUPLE ARE THE STANDARD
THERMOCOUPLES.
IT IS USED FOR CALIBRATING K Type
THERMOCOUPLES.
MATERIAL OF CONSTRUCTION
90% PLATINUM + 10% RHODIUM
PLATINUM
OXIDATION RESISTANCE , SO MORE LIFE .
Accuracy : 0.25 %
29
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 .
30
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)
31
RECORDER
TYPES OF RECORDER
PAPERLESS -- WITH COLOUR DISPLAY SCREEN ,HARD DISC AND FLOPPY
DRIVE. NOT USED IN HED 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)
Y-AXIS IS FOR GRAPH SPEED.
VARIOUS SPEED OF GRAPHS ARE 12.5, 25, 50, 100 MM / HOUR
GENERALLY KEEP 25 MM / HOUR.
32
GRAPH PAPER
GRAPH PAPERS ARE USED FOR PLOTTING THE
FURNACE /JOB TEMPERATURE VIA THERMOCOUPLE.
THEY ARE FITTED ON THE RECORDER.
GRAPH PAPER RECOMMENDED ON RECORDER ONLY
TO BE USED
GRAPH PAPER FOR MFS1 AND HFS1 FURNACE
==> ET 201 CHINO MAKE, JAPAN
GRAPH PAPER FOR PFS FURNACE
==> ET 001 CHINO MAKE, JAPAN
THE LENGTH OF ONE BUNDLE OF GRAPH PAPER IS
GENERALLY 2000 MM.
DOTTING TYPE RECORDER INK (CHINO MAKE, JAPAN)
IS USED IN RECORDER FOR PLOTTING OF GRAPH.
USUALLY , 6 COLOURS ARE FILLED FOR PLOTTING.
33
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 0
0
C to 1000
0
C in steps of 50
0
C is fed
to the indicator / controller.
3. After the millivolt value / temperature reading
displayed is steady, the reading of
indicator/controller shall be noted.
34
PROCEDURE FOR EMPTY FURNACE
CALIBRATION
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.
4. If the error in the indicated readings is more than
the specified accuracy ( +/- 1
0
C ), 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.
35
PROCEDURE FOR EMPTY FURNACE
CALIBRATION
2. The millivolt output for various temperature
ranging from 400 C to 1000
0
C 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.
36
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) +/- 1
0
C
6. Recorder +/- on temperature scale.
+/- minutes on time scale.
37
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.
38
7. Set the temperature of controller to 400
0
C.
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.
PIT FURNACE CALIBRATION PROCEDURE
39
PIT FURNACE CALIBRATION PROCEDURE
12. The temperature is then raised in steps of 50 C up to
1000
0
C. ( I. e. 400
0
C, 450
0
C, .., 950
0
C, 1000
0
C. ) 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 +/- 5
0
C up to 800
0
C and +/- 10
0
C
above 800
0
C.
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.
40
STANDARD OPERATING
PRACTICES FOR LOCAL
STRESS RELIEVING
41
LOCAL STRESS RELIEVING
When