NAQP

Nuclear Quality Assurance
Metal Forgings Private Limited

Procedure
Document No. NQAP/PR/03
Procedure for Heat-Treatment Revision No. 00
Revision Date 29.06.2019
As Per NCA 4253.2 Page Page 1 of 9
Inputs: From_____
1- Heat Treatment Plan PPC/Concern HOD
2- Work order Technology
3- Raw Material Concerned Shop
4- Customer Specification Quality
5- Process Parameters Quality
Resource Needs
1-Heat Treatment Furnace-Calibrated Competence Map
2-Queching tank (water and polymer) Competency matrix and Skill matrix
3- Ancillary & Utilities (E.0.T, Fans etc.)
4-Tools & Fixtures
5- PPE`s (Personal Protective Equipment)
6-Skilled Manpower
7-Calibertaed Thermocouple Process Measures Effectiveness of NC's
8-Electronic supports etc. for proper working. PRODUCTION 1- Production Plan Vs Achieved
9-Refractory Bricks etc. 2-Process Deviation
Heat Efficiency
1- Rework Percentage
Method & System: Treatment 2- Gas consumption cost per ton
1- Heat treatment Procedure.
2- Quenching and Stacking Guide line
3- Check sheet
4- Customer specification
5- Procedure for Identification & Traceability Outputs: - To .
6- Procedure for Control of Nonconforming product 1- Production Report Quality
7-Risk Assessment and Management Sheet 2- Breakdown Slip Maintenance
8-Calibration of Instrument as per procedure. 3- Hardness report Quality
9-Control Plan 4- Preventive Maintenance Schedule Maintenance
10-Validation Report for reference. 5-Operational Check list Production
6-Heat Treatment Chart TPM
Prepared By Reviewed By Approved By

Engineer-QA GM-QA/QC VP-T & M
Procedure
SCOPE:
• This procedure covers the requirement for Heat Treatment of the forgings
manufactured from plain carbon steels, low alloy steels, stainless steels, Duplex steels
and case hardening steels against customers’ orders.
• All forgings shall be Heat Treated in accordance with material specification, Code
Requirement of ASME Sec III Division 1 and customer requirements.
PURPOSE:
• The principal objectives of the heat treatment processes would be to
➢ Refine and homogenize the grain structure.
➢ Achieve the desired mechanical properties.
➢ Improve machinability characteristics of the forging.
➢ Restore ductility after cold working.
RESPONSIBILITY:
• Manager-Heat Treatment & GM – QA/QC
INPUTS:
• Forgings (Forged / Pre-machined Components)
RESOURCES / INFORMATION:
• Calibrated Furnaces for process.
• Product requirements
• Qualified Engineers and Operators
• Engineers &Operator’s Qualification:
➢ Personnel performing heat treatment shall be competent and understand the heat
treatment cycle. They shall have knowledge of furnaces and their operations and of
the temperature monitoring devices installed on the furnaces e.g. thermocouples
and recorders as per their skill matrix.
• Furnaces:
➢ Normalizing ,Annealing, Hardening, Tempering, Iso- Thermal Annealing, Sub

Critical Annealing ,Solution annealing And Post Forging Treatments processes
such as Anti Flaking treatment are carried out in heat treatment furnace which are
defined as below:

Engineer-QA Manager-Heat-Treatment VP-T & M
Procedure
➢ The sizes of the installed furnaces are as follows:
➢ MF/FC/4 Furnace: Length: 5800 mm, Width: 2200mm Height: 1000 mm with
capacity:20 MT-Open Bogie Hearth
➢ All the above furnaces are equipped with thermocouples located per design of the
furnaces to monitor the temperatures within the furnace chamber.
➢ While loading the forgings on the bogie, it shall be ensured that the spacing
between the first layer and the hearth and job to job gap of the furnace is
maintained at 50-100 mm minimum. The purpose behind providing the gap is to
ensure proper circulation of the hot gases within the furnace and maintain
uniformity of temperature within the furnace chamber. and loading is defined as per
the Loading plan annexure No.1.
• Quenching Tank:
➢ All the forgings are quenched in water and polymer during hardening /Solution
Annealing operation depends upon the requirement.
➢ The sizes of the installed quenching tanks are as follows:

➢ Water Quenching Tank: Length: 6000mm, Width: 4000mm , Depth: 5000mm;
Operational Capacity: 1, 20,000 liters.
➢ Polymer Quenching Tank Length:3000mm, Width: 3000mm , Depth: 5000mm;
Operational Capacity: 35,000 liters.
➢ Critical to quality: Polymer Concentration: 12-14%, Maintain PH : 8-10,Proper
agitation to be maintained for uniform hardness, Quenchant temperature before
start of quenching shall be less than or equal to 31 degree C and after quenching
ends it should not be more than 45 degree C as climatic condition are considered.
➢ Quenchant quality(Polymer) quality to be checked on quarterly basis and dame
should be recorded.
• Calibration:
➢ All the thermocouples, controllers, indicators & recorders are calibrated at the
frequency of three months ,accuracy of the same shall meet the API and AMS
standard.
➢ Thermal survey of the heat treatment furnaces to verify temperature uniformity
within the furnace chamber shall be conducted al least once in a year and after
every major repair to the furnaces.

Procedure
• Processing Of Material:
➢ Heat treatment plan: Manager-Heat treatment shall make a group wise/batch
wise, loading plan as per material specification, size, thickness, weight and heat
treatment required by material specification and customers’ requirements.
➢ Heat treatment process: Forgings shall be subjected to one of the heat

treatment processes indicated in table-I as per requirements of the customer’s
PO/TDC.
➢ The time temperature requirements indicated in the table are general guidelines for
the heat treatment processes indicated. In case the customers’ PO or
specifications indicate the time temperature parameters to be followed, the same
shall be used. On completion of the heat treatment process, the time-temperature
charts shall be verified for conformance to the planned requirements.
Tempering cycle to be followed after hardness checked on Quenched material.
➢ Identification: After unloading, the forgings treated in the batch shall be identified
with yellow chalk with Item No, Work Order and Heat No. and material grade
before transferring to the next processing section.
➢ Every Heat-Treatment batch is unique chronological number and job having test
coupon is provided a alphabet A,B,C.. etc. Group wise for Testing’s.
➢ Loading pattern: All the forgings for heat treatment shall be loaded on the bogie
as per the loading pattern. Closed die forgings which are smaller in size shall be
properly stacked in suitable Fixtures while heat treatment process.
➢ Concept of Batch no. & Group no. fot Test Piece Marking and Testings: Every
Heat-Treatment batch is unique chronological number and job having test coupon
is provided a alphabet A, B, C.. Etc. Group wise for Testing.
For Local Orders-Batch No. is a Unique Chronogical number Example 5021, 5022
etc. and will repeat from 0001 after Every 9999 Batch No.

Procedure
For Export Orders-Batch No. is a Unique Chronological number with Prefix EX
Example EX 5021, EX 5022 etc. and will repeat from 0001 after Every 9999 Batch
No.
OUTPUT AND EFFECTIVENESS MONITORING

• Properly heat treated forgings are the output of the process.
• The effectiveness of the process is monitored through mechanical and metallurgical
test results obtained during testing.
•
CROSS REFERENCES
• Heat treatment specifications –TDC/QAP/Check list/Specification(ASTM/EN,ASME,JIS
etc.)
• Quenching Guide line
• Stacking Guide line
• Temperature Parameter & Loading Pattern Table -1
RECORDS:
• Time temperature charts
• Heat treatment Production Report
• Operational Check list
• Hardness Report
Safety Aspects:
• Canvas hand gloves are provided to all workers.

• Crane is operated by trained operators only.
• EOT Crane is provided with manual bell to alarm people while moving inside the shop.
• Safety appliances must be used during operation at all places in Heat Treatment Shop.
AMENDMENT LIST:
S. No. NQAP NO. REV. DATE OF AMENDMENT DETAILS

NO. REV.

Procedure
ANNEXURE-I
1 TIME TEMPERATURE PARAMETERS FOR DIFFERENT HEAT TREATMENT CYCLES
Soaking
time
Heat Treatment Soaking temp
Grade of steel Loading temp Minutes Cooling medium
Process deg C
/inch of
section
A 105, Normalizing N < 400 deg C A 920 – 930 45-60 Air (Forced Air)
A 266
Normalizing &
Tempering NT …do.. N …do.. ..do.. ..do..
T 600-630 45-60 ..do..

LF 2/LF3 Normalizing N < 400 deg C A 920 – 930 45-60 Air (Forced Air)
Normalizing & ..do..

Tempering NT …do.. N …do.. ..do.. Water
Quenched – Q Min.900 Air
Tempered T 600-630 45-60
A182/A336 Normalizing & < 400 deg C N 900-920. 45-60 Air (Forced Air
F11, F12, F22,F1 Quenching Q 960 Water
Tempering (NT &
QT) T 620-730 Air
F-1 Tempering < 400 deg C T 580-630 45-60 Air
F-11,F-12 Tempering < 400 deg C T 620-730 45-60 Air
F-22 Tempering < 400 deg C T 675 Min. 45-60 Air
A182/A336 Normalizing & < 400 deg C N 980-1000. 45-50 Air (Forced Air)
,F 9,F5 Tempering NT T 675 Min. ..do..
Annealing A 955 Min. 45-60
F6a Normalizing & < 400 deg C N 980-1020. 60 Air (Forced Air)
Tempering NT ..do..
CL.1 Second Temp if T 725 Min. 80
CL.2 required T 675 Min 80
CL.3 T 595 Min 80
A 182 Normalizing & < 400 deg C N 1040- 45 Air (Forced Air)
F 91 Tempering NT 1060. ..do..
T 730-800 45-60

Procedure
Soaking
time
Grade of steel Loading temp Minutes Cooling medium
Process deg C
/inch of
section
EN 8/080M40 Normalized & < 400 deg C N 840-860. 45-60 Air (Forced Air)
1045,1035 Tempered NT T 500-650 45-60 ..do..
Normalized- …do… N 840-860 45-60 Air (Forced Air) /

Quenched- Q 840-860 ..do.. Polymer/ water
Tempered NQT T 500-650 45-60 Air
Austenitic Solution annealing < 400 deg C SA 1040-1080 45 Water

St. Steels SA .
304,304L,316,
316L,321, 347 etc
SAE 4140/EN- Normalized – < 400 deg C N 840 – 890 45-60 Air (Forced Air) /
19/42CrMo4, Quenched – …do… Q 850 – 880 ..do.. Polymer/Water
Tempered NQT T 560 – 670 45-60
EN 9 / 070M40 Normalized & < 400 deg C N 840-860. 45-50 Air

Tempered NT T 590-620 45-60 ..do..
Normalized- …do… N 840-860 45-60 Air(Forced Air)

Quenched- Q 830-850 ..do.. Water / oil/Polymer
Tempered NQT T 550-620 45-60 Air
A694 Normalized < 400 deg C N 900-930 45-60 Water

F51/F60/F65/F70 Quenched – Q 900-930 45-60 Air
Tempered QT T 550–660
Water Quenched – < 400 deg C Q 840 – 860 45-60 Polymer / oil
Tempered QT T 550 – 660 45-60 Air
EN 353 / EN 354 Normalized N < 400 deg C 860-870 45-50 Air

Still Air cool down to
Isothermal ..do.. 930 45 650 degree after that
Annealing 650 80 hold the temp as per
given holding cycle
,bring down the temp
at 600 degree C
and(switch off the
furnace) then air cool.

Procedure
Furnace Cool to 400
Degree then air cool.
Annealing 680 60 Air(Forced Air)
Air
Quenching 820 45-60
Tempering 670-680 50-60
Soaking time
Grade of steel Loading temp Minutes/inch of Cooling medium
Process deg C
section
18CrNiMo7-6 Quenched – < 400 Deg C Q 830 – 870 45-50 Water /polymer
Tempered QT T 580 Min 50-60 Air
Isothermal 930 45 Still Air then cool

Annealing 650 80 down to 650
degree after that
hold the temp as
per given holding
cycle ,bring down
the temp at 400
degree C
and(switch off the
furnace) then air
cool.
40NiCrMo7 Quenched – < 400 Deg C Q 830 – 870 45-50 Water /polymer
Tempered QT T 580 Min 45-60 Air
31CrMoV9 Quenched – < 400 Deg C Q 830 – 870 45-50 Polymer

Tempered QT T 590 – 620 45-60 Air
21CrMoV57 Quenched – < 400 Deg C Q 900-950 45-50 Water/Polymer
Tempered QT T 660-720 45-60 Air
28CrNiMoV5-9 Quenched – < 400 Deg C Q 910-930 45-50 Water/Polymer
27CrNiMoV11- Quenched – < 400 Deg C Q 900-930 45-50 Polymer
F51(Duplex) Solution Annealed < 400 Deg C SA 1020-1080 60 Water
F60(Duplex) Solution Annealed < 400 Deg C SA 1050-1125 60 Water
F53(Duplex) Solution Annealed < 400 Deg C SA 1080 60 Water
Remark:- Whenever in case Heat-Treatment details/cycle is provided by Customer in Purchase

Order same Has to be followed

Procedure
LOADING ARRANGEMENT FOR Flanges / Rings


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Nuclear Quality Assurance

Metal Forgings Private Limited

Prepared By Reviewed By Approved By

➢ Normalizing ,Annealing, Hardening, Tempering, Iso- Thermal Annealing, Sub

Prepared By Reviewed By Approved By

➢ The sizes of the installed furnaces are as follows:

➢ The sizes of the installed quenching tanks are as follows:

Prepared By Reviewed By Approved By

➢ Heat treatment process: Forgings shall be subjected to one of the heat

Prepared By Reviewed By Approved By

OUTPUT AND EFFECTIVENESS MONITORING

• Canvas hand gloves are provided to all workers.

S. No. NQAP NO. REV. DATE OF AMENDMENT DETAILS

Prepared By Reviewed By Approved By

T 600-630 45-60 ..do..

Normalizing & ..do..

F-11,F-12 Tempering < 400 deg C T 620-730 45-60 Air

F-22 Tempering < 400 deg C T 675 Min. 45-60 Air

Prepared By Reviewed By Approved By

Normalized- …do… N 840-860 45-60 Air (Forced Air) /

Austenitic Solution annealing < 400 deg C SA 1040-1080 45 Water

EN 9 / 070M40 Normalized & < 400 deg C N 840-860. 45-50 Air

Normalized- …do… N 840-860 45-60 Air(Forced Air)

A694 Normalized < 400 deg C N 900-930 45-60 Water

EN 353 / EN 354 Normalized N < 400 deg C 860-870 45-50 Air

Prepared By Reviewed By Approved By

Annealing 680 60 Air(Forced Air)

Quenching 820 45-60

Tempering 670-680 50-60

Isothermal 930 45 Still Air then cool

31CrMoV9 Quenched – < 400 Deg C Q 830 – 870 45-50 Polymer

F60(Duplex) Solution Annealed < 400 Deg C SA 1050-1125 60 Water

F53(Duplex) Solution Annealed < 400 Deg C SA 1080 60 Water

Remark:- Whenever in case Heat-Treatment details/cycle is provided by Customer in Purchase

Prepared By Reviewed By Approved By

Prepared By Reviewed By Approved By

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