PWHT
PWHT
PWHT
PRESSURE VESSELS
HEAT TREATMENT
MECHANICAL PROPERTIES OF METALS &
ALLOYS DEPEND ON
HEAT TREATMENT
HEAT TEATMENT PARAMETERS
RATE OF HEATING
SOAKING TEMP.
SOAKING TIME
COOLING RATE
COOLING MEDIA
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
5
ALLOYS
Single Phase : Copper Nickel
Multiphase : Steels
HEAT TREATEMENT
CRITERIA
COLD WORKED to NORMAL
All materials
UNEQUILIBRIUM PHASES to
EQUILIBRIUM
Stainless Steels ,Maraging Steels
STRESSED to UNSTRESED
All Materials
NORMALIZING
ANNEALING
STRESS RELIEVING
SOLUTION ANNEALING
HARDENING
TEMPERING
AGEING
9
10
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
11
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:
12
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 )
13
To improve Corrosion Resistance
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
14
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
15
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
16
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
STRESS RELIEVING
Cr-Mo Steels
Cr - Mo Steels (Cr >2%)
SA 335P22 ,SA335P5
704 - 720 C 5 Cr
STRESS RELIEVING
Ni -Steels
Nickel Steels : 1,2,3% Ni
SA 203 GrA ,D
19
STRESS RELIEVING
Steels enhanced by Heat Treatments
Q&T Steels :
9.5% Ni Steels , SA 517 Gr E
LAYOUT OF A TYPICAL
FURNACE
(Electrical or Gas fired )
FURNACE
THERMOCOUPLE
COMPENSATING
CABLE
JOB
RECORDER
P.I.D.
21
THERMOCOUPLES
PRINCIPLE OF A THERMOCOUPLE
THERMOCOUPLE MATERIAL
TYPES OF THERMOCOUPLE BEING
USED IN HED POWAI / HZW
22
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.
23
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
24
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
TYPES OF THERMOCOUPLE
BEING USED IN HZW .
K type :
Dia :
Insulation
coated
2.5 mm
Bare(ceramic)
0. 7 mm
Refractory
Attachment
Mech
Capacitor
Usability
Reusable
Disposable
Location
PIT F/c
Color
26
CONSTRUCTION OF A
K TYPE THERMOCOUPLE
pid
PROPORTIONAL
INTEGRAL
DERIVATIVE
Welded
junction
recorder
Compensating
cable
Accuracy : 0.75%
Thermocouple
wire
27
S TYPE THERMOCOUPLE
Accuracy : 0.25 %
S TYPE THERMOCOUPLE ARE THE STANDARD
THERMOCOUPLES.
MATERIAL OF CONSTRUCTION
90% PLATINUM + 10% RHODIUM
PLATINUM
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 .
29
P.I.D.
PID = PROPORTIONAL INTEGRAL DERIVATIVE
30
RECORDER
TYPES OF RECORDER
PAPERLESS -- WITH COLOUR DISPLAY SCREEN ,HARD DISC AND FLOPPY
DRIVE. NOT USED IN HED HZW.
12 CHANNEL --
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. 32
3.
33
Calibration of recorder
1.
3.
4.
35
ACCURACY
1.
+/- 0.25%
2.
+/- 0.25%
3.
4.
5.
6.
Recorder
+/- 10C
2.
3.
4.
5.
6.
Close the furnace lid. Start the furnace and the recorder.
37
8.
9.
10.
11.
13.
14.
15.
39
STANDARD OPERATING
PRACTICES FOR LOCAL
STRESS RELIEVING
40
When
Local SR to be done only when
HOW
Lesser of 1T or 2
Inside radius
Heating band
Insulation band
42
LSR of C/S
Spider or
prop
No Welding at top
Multitonne roller
44
45
SUPPORTING ARRANGEMENTS
1.
2.
3.
4.
SUPPORTING ARRANGEMENTS
burner
600mm
90
450mm
600mm
300mm(point no:2)
SUPPORTING ARRANGEMENTS
48
SUPPORTING ARRANGEMENTS
Zero gap
Supporting
arrangement
49
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
50
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
51
GENERAL
Temp. support
Furnace floor
THERMOCOUPLES
1. All the thermocouples shall be
tagged with aluminum
sheet
and identification hard punched
on it.
(For PIT furnace only)
53
THERMOCOUPLES
54
THERMOCOUPLES
ATTACHMENTS
1. Use only TAU-90 capacitor Discharge Welding
machine for thermocouple connection
2.
3.
4.
THERMOCOUPLES
ATTACHMENTS
5.
6.
7.
8.
max. 3.0mm
Only calibrated thermocouple shall be used.
Calibration shall be by QA.
9.
56
THERMOCOUPLES
ATTACHMENT UNIT
57
SPECIAL NOTE
IF THE TEMPERATURE OF HEAT TREATMENT
EXCEEEDS
650-DEGREE
CENTIGRADE,
THE
58
CODE EXTRACTS
FURNACE PWHT
LSR
59
(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.
60
HOLDING TEMP.
1 ( CARBON
STEEL) & 3
(LOW ALLOY
STEEL)
NOM.
THICKNE
SS
UPTO 2
SOAKING PERIOD
OVER 2
TO 5
OVER 5
65
SERVICE CONDITION
LETHAL SERVICE PWHT IS MANDATORY
EXEMPTIONS ARE FEW
67
69
70
but in no case more than 500 F Per hour ( 278 C Per hour).
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.
71
72
73
74
75
100
90
80
70
60
50
40
30
20
10000
10
SHELL THICKNESS
9500
9000
8500
8000
7500
7000 ISMB 250
SHELL DIAMETER
6500
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
20
ISMB 125
10
500
SHELL THICKNESS
Annexure-5
76
77
HT REQUEST
78
HT CHARGE
79