HEAT TREATMENT – PROCEDURE

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ADITHYA HITEC VALVES PVT LTD

HEAT TREATMENT – PROCEDURE

INDEX

1. SCOPE

2. EQUIPMENT

3. PROCESS

4. HEATING

5. HOLDING

6. COOLING

7. TIME TEMPERATURE CHART

8. OTHER GENERAL CONSIDERATION

9. INSPECTION

10. RECORDS

11. RESPONSIBILITY

12.ANNEXURE-F

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1.0 SCOPE

This Procedure describes control and procedure for performing of heat treatment
process to meet the required properties according to the Material Specification / PO
requirements at Adithya Valves.

1.1 APPLICATION:

This procedure is applicable for the heat treatment of Cast carbon Steel, Alloy Steel,
Stainless Steel, Duplex Stainless Steel and High Ni castings manufacture in accordance with
ASTM/EN standards.

2. EQUIPMENT

2.1 FURNACE

Heat treatment operation shall be carried out in electric heat treatment furnace. The
electric furnace is have ceramic fiber lining and equipped with heating element mounted
vertically and horizontally all along sides of the furnace. The furnace is thermal surveyed
for homogeneity once in a year as per

API 6A ,API 6D Annex F,ASTM A991,NORSOK M650 under the witness of third party
(Certification body like TUV,Lloyds,BV, Indian Boiler Regulation etc..)

2.2 TEMPERATURE CONTROLLER & RECORDER

Furnace shall be provided with suitable controller & recorder for the temperature
recording and controlling. The thermocouple, controller & recorder shall be calibrated once
in a three months.

Only calibrated thermocouple, controller & recorder shall be used in the furnace.
The recorder shall be set of ambient temperature at the starting of the furnace.

Heat-treatment equipment calibration shall be performed prior to putting the equipment in

service and shall be recalibrated at a frequency not longer than 12 months from the last
calibration.

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2.3 THERMOCOUPLE:

At least six thermocouples shall be located in the furnace working zones for heat
treatment production process. Thermocouples shall be located at side walls , front, back
and top side of the furnace.

3. PROCESS

3.1 The castings shall be located in the furnace at below 200°C

3.2 No part of the castings shall be in direct contact with the furnace wall and shall raised
and supported by suitable support.

3.3 There shall be a minimum clearance of 6” from side, front and rear walls of facilitate
free flow of heat

3.4 The castings shall be provided with suitable support if necessary to avoid distortion.

4. HEATING:

4.1 The castings shall be heated slowly to the set temperature as per AV specification for
which reference is made from both ASTM and EN specifications. The heating rate shall not
exceed 150°C per hour beyond 200°C

4.2 During heating the temperature at any point in the working zone shall not vary by more
than ±13°C from the furnace set point temperature after the furnace working zone has been
brought up to temperature.

Furnace which used for tempering, stress-relieving shall not vary by more than ± 8°C from
the furnace set point temperature after the furnace working zone has been brought up to
temperature .

5. HOLDING

5.1 The casting shall be held at the set temperature for the whole period of holding time.
Holding time shall be according to the maximum section thickness of casting. One hour per
inch of section thickness shall be given as a holding time to the castings are subjected to the
Heat treatment.

5.2 During the holding period the temperature difference is monitored and.

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controlled within ±20°for water quenching and within ±10°C for tempering

heat treatment.

6. COOLING

6.1 WATER QUENCHING:

Rapid cooling from holding temperature after completion of holding time is in

agitated/circulation water. Hence cooling rate is not controlled. Time Temperature
Diagram should be recorded for entire cycle.

6.2 TEMPERING:
The casting shall be cooled slowly after specified holding time of (1.5 Hrs per inch
of section thickness for tempering cycle).Since the cooling is in still air the rate of control is
not required.Time Temperature Diagram should be recorded for entire cycle.

6.3 POST WELD HEAT TREATMENT

1) Post weld heat treatment shall be performed (PWHT) for all kind of repairs by
welding in line with approved WPS/PQR
2) The ground finished casting shall be subjected to shot blast cleaning on entire surface
and the castings surface shall meet according to MSS SP-55
3) Harness survey shall be performed after PWHT on major weld repair places to ensure
the hardness values are meeting the requirements in accordance with NACE MR-0175

The stress relieving heat treatment process shall be performed as a Post weld heat
treatment for Carbon steel, Carbon Manganese Steel. For Stainless Steel and Duplex
Stainless steel the original heat treatment shall be repeated as per specification.

For carbon steel and carbon manganese steel castings after completion of soaking
hours at set point temperature the castings will be allowed to cool within the furnace
atmosphere till it reaches to 400°C and then the casting shall be allowed to cool in still air.

7. TIME TEMPERATURE CHART

a) Actual Heat treatment temperature and time shall be recorded in charts for the
quenching & tempering cycle performed.
b) The recorder shall continue to record the Time temperature curve till the castings is
taken out the furnace.
c) The Time Temperature chart shall be maintained. The same shall be provided for
review and verification on demand by the customer.
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8. OTHER GENERAL CONSIDERATION:

8.1 Calibrated Heat treatment furnace as per API 6A Annex P, API 6D Annex F ,ASTM
A991,
Norsok M650 shall be used for Heat treatment. For temperature measurement minimum
Six thermocouples shall be used at appropriate location of the furnace walls.

8.2 During quenching time the water in the tank shall be circulated /air agitated.The
castings shall be transferred as fast as possible in to the quenching tank (after completion
of specified holding hrs).Preferably with in 60 Seconds. After Quenching the quenched
water temperature shall be maintained within 55°C

9. INSPECTION

Inspection shall be carried out at the following stages.

BEFORE HTM:

a) Loading of the Job, placement of thermocouples, ensuring calibration status and

functioning of the records and controllers along with thermocouples.
b) Verification of the proposed heat treatment cycle with respect to the standard or PO
requirements.

AFTER HTM:

c) Verification of Heat treatment chart with reference to the cycle followed of this
procedure.
d) Visual Examination of castings after HTM.
e) Mechanical test for Tensile Strength, Yield Strength, Elongation in %, of Reduction
area to confirm heat treated material physical properties as per ASTM /EN standard
requirements.

f) Mechanical test shall be done on keel block in accordance with figure 2 of ASTM
A703 which shall also has been poured in the same melt heat treated along with
castings of its melt.
g) The Carpy Impact test will be done according to ASTM A370.
h) Charpy V Impact test will be performed on a test specimen prepared from the test
coupon and the maximum test temperature shall be as per applicable
specification /PO

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10. RECORDS :

10.1 HEAT TREATMENT LOG :

Records (Heat treatment Log) shall be maintained with the following minimum
details.
a) Item description,
b) specification
c) Heat No
d) Qty
e) HTM Cycle followed
f) Furnace on time
g) Set temperature reach time
h) Set temperature completed time (Soaking Hrs)
i) Water temperature before Quenching
j) Quenching time (From the time which castings exposed to atmosphere
to transfer to Quenching Medium)
k) Set temperature completed time (Soaking Hrs)
l) Rate of Heating/Hr

10.2) TIME TEMPERATURE DIAGRAM:

a) Time temperature diagram should indicate furnace start up temperature

,Soaking
temperature & Soaking hrs and end of cycle for the Quenching & tempering
performed.

11. RESPONSIBILITY:

Heat treatment operation shall be performed by the skilled operator under the
direct control of In charge.

Records related to the Heat treatment process shall be reviewed and approved by
QA/QC

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QA/QC Manager having an authority to assign this work to any Quality person but
the responsibility is remains with him.

For 3.2 Certification also the records shall be reviewed by the Certifying Body.

Recommended heat treatment temperature for the materials are specified in relevant
material data sheets.

12. ANNEXURE-F

Annex F
(normative)

Qualification of Heat-treating Equipment

F.1 General
All heat treatment of parts and TCs shall be performed with equipment meeting the requirements of this annex.

F.2 Temperature Tolerance

The temperature at any point in the working zone shall not vary by more than ±25 °F (±13 °C) from the
furnace setpoint temperature after the furnace working zone has been brought up to temperature. Furnaces
that are used for tempering, aging, and/or stress relieving shall not vary by more than ±15 °F (±8 °C) from
the furnace set-point temperature after the furnace working zone has been brought up to temperature.

F.3 Furnace Calibration

F.3.1 General

The following provided details on the types of furnaces to be surveyed.

F.3.2 Temperature Survey Method for Calibration of Batch-type Furnaces

A temperature survey within the furnace working zone(s) shall be performed on each furnace at the
maximum and minimum temperatures for which each furnace is to be used.

A minimum of nine thermocouple test locations shall be used for all furnaces having a working zone greater
than
10 ft3 (0.3 m3).

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For each 125 ft3 (3.5 m3) of furnace working zone surveyed, at least one thermocouple test location shall be
used, up to a maximum of 40 thermocouples. See Figure F.1 and Figure F.2 for examples of thermocouple
locations

Figure F.1—Thermocouple Location—Rectangular Furnace (Working Zone)

Figure F.2—Thermocouple Locations—Cylindrical Furnace (Working Zone)

For furnaces having a working zone less than 10 ft3 (0.3 m3), the temperature survey may be made with a
minimum
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of three thermocouples located either at the front, center, and rear or at the top, center, and bottom of the
furnace
working zone.

After insertion of the temperature-sensing devices, readings shall be taken at least once every 3 min to
determine
when the temperature of the furnace working zone approaches the bottom of the temperature range being
surveyed.

Once the furnace temperature has reached the set-point temperature, the temperature of all test locations
shall be
recorded at 2-min intervals, maximum, for at least 10 min. Then readings shall be taken at 5-min intervals,
maximum,
for sufficient time (at least 30 min) to determine the recurrent temperature pattern of the furnace working
zone.

Before the furnace set-point temperature is reached, none of the temperature readings shall exceed the set-
point temperature by more than ±25 °F (±13 °C).

After the furnace control set-point temperature is reached, no temperature reading shall vary beyond the
limits
specified. The temperatures within each furnace shall be surveyed within one year prior to use of the furnace
for heat
treatment.

F.3.3 Temperature Survey Method for Recalibration of Batch-type Furnaces

When a furnace is repaired or rebuilt, a new temperature survey shall be carried out before the furnace is
used for heat treatment, subject to the following.
Repairs that return the furnace to the condition it was in at the time of the last furnace survey and calibration or
repairs
that do not affect the temperature tolerance of the furnace shall not require a new temperature survey and
calibration

The SAE AMS 2750 sections on furnace modifications and furnace repairs shall be used to determine whether a
new furnace survey is required. All furnace repairs and modifications shall be documented and the
responsible Quality Assurance organization shall make determination whether an additional furnace survey
and calibration is required based on the repairs or modifications in accordance with AMS 2750.

F.3.4 Continuous-type Furnaces Method

Furnaces used for continuous heat treatment shall be calibrated in accordance with procedures specified
in SAE AMS-H-6875.

F.4 Instruments
F.4.1 General

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Automatic controlling and recording instruments shall be used.

Thermocouples shall be located in the furnace working zone(s) and protected from furnace atmospheres by
means of suitable protective devices.

F.4.2 Accuracy

The controlling and recording instruments used for the heat-treatment processes shall be accurate to ±1 %
of their full-scale range.

F.4.3 Calibration
Temperature-controlling and temperature-recording instruments shall be calibrated at least once every three
months. Equipment used to calibrate the production equipment shall be accurate to ±0.25 % of full-scale range.

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