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PRESSURE VESSELS
1
WHAT IS HEAT TREATMENT?
MATERIALS TREATED BY APPLICATION OF
HEAT - NORMALLY DONE IN SOLID STATE
3
MATERIALS HEAT TREATED
5
MATERIALS HEAT TREATED
CS
Stainless Steels
6
TYPES OF HEAT TREATMENT
NORMALIZING
ANNEALING
STRESS RELIEVING
SOLUTION ANNEALING
HARDENING
TEMPERING
AGEING
7
IRON CARBON DIAGRAM
8
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
Hardness
Impact properties
To refine the grains
9
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:
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
13
STRESS RELIEVING
The steel is heated to a temperature below or 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
14
STRESS RELIEVING
C-Mn , C-Mo , Cr-Mo (< 2% Cr)
15
STRESS RELIEVING
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
Time : 1 hr / inch thick
Heating Rate : 200 C per hr per inch thick
Cooling Rate : 260 C per hr per inch thick
16
STRESS RELIEVING
Ni -Steels
Nickel Steels : 1,2,3% Ni
SA 203 GrA ,D
Temperature : 593 C Min
Normally 600 - 640 C,
Time : 60 mts min
Time : 1 hr / inch thick
Heating Rate : 200 C per hr per inch thick
Cooling Rate : 260 C per hr per inch thick
17
STRESS RELIEVING
Steels enhanced by Heat Treatments
Q&T Steels :
9.5% Ni Steels , SA 517 Gr E
Temperature : 538 C Typ
Normally < 600 C
Time : Minimum 15 minutes to 2 Hr
Time : 1 hr / inch thick
Heating Rate : 200 C per hr per inch thick
Cooling Rate : 260 C per hr per inch thick
18
LAYOUT OF A TYPICAL
FURNACE
(Electrical or Gas fired )
FURNACE
THERMOCOUPLE
COMPENSATING
CABLE
JOB
RECORDER P.I.D.
19
THERMOCOUPLES
PRINCIPLE OF A THERMOCOUPLE
THERMOCOUPLE MATERIAL
20
PRINCIPLE OF THERMOCOUPLE
pid
Welded
junction
recorder
Compensating Thermocouple
cable wire
Accuracy : 0.75%
25
S TYPE THERMOCOUPLE
Accuracy : 0.25 %
S TYPE THERMOCOUPLE ARE THE STANDARD
THERMOCOUPLES.
THERMOCOUPLES.
MATERIAL OF CONSTRUCTION
90% PLATINUM + 10% RHODIUM
PLATINUM
26
ISSUE METHODOLOGY
For DISPOSAL TYPE
28
P.I.D.
PID = PROPORTIONAL INTEGRAL DERIVATIVE
29
RECORDER
TYPES OF RECORDER
PAPERLESS -- WITH COLOUR DISPLAY SCREEN ,HARD DISC AND FLOPPY DRIVE.
NOT USED IN HZW.
WITH PAPER -- CURRENTLY BEING USED IN HZW.
32
( ZONE-2 ) ( ZONE-4 ) ( ZONE-6 ) ( ZONE-8 )
BURNER
1640 1650
7900
(BOGIE
WIDTH
)
1650
3575 3575 3575 3575
( ZONE-1 ) ( ZONE-3 ) 14300. ( ZONE-5 ) ( ZONE-7 )
1. PROJECT NO:
2. SECTION NO :
9500
3. CHARGE NO :
4. H. T. REQ. NO :
BURNER
8700
35
STANDARD OPERATING PROCEDURE FOR HFS-1
FURNACE
9. Move the bogie inside the furnace
10. Pass the thermocouples through ports and
connect it with compensating cables
11. Set the program as per heat treatment request.
Secure it and then run it in fast mode as check.
Bring it back to the initial segment and hold.
12. Insert heat treatment chart in recorder and adjust
the speed of the graph.
13. Clear inspection of job and get the signature of
inspector on graph paper for firing the furnace.
14. Check LPG level, pressure and temperature in the
storage tanks and note down in logbook. 36
STANDARD OPERATING PROCEDURE FOR HFS-1
FURNACE
35. Submit the graph and duly filled spot check formats
to inspection for approval of heat treatment.
40
STANDARD OPERATING PROCEDURE FOR HFS-1
FURNACE
39. Unload the job from the bogie and move the bogie
inside the furnace.
40. Close the furnace. Shut off the main power supply.
41
STANDARD OPERATING
PROCEDURE FOR PFS
FURNACE
42
125T Bogie hearth furnace -- PFS
43
PFS FURNACE SKETCH
5600
2650
5500
BURMER
4100
1460
BOGGIE WIDTH
1050
1235
44
STANDARD OPERATING PROCEDURE FOR PFS
FURNACE
1. Receive the job as per HT request.
2. Receive heat treatment request duly approved by
metallurgy engineer.
3. Ensure that Insp. clearance is available prior to
loading for job.
4. Load the job on the bogie as per the heat treatment
furnace request.
5. Ensure the supporting arrangement as per the
attached annexure-I.
6. Ensure the spider arrangement as per annexure- II.
7. Fix the thermocouples at locations shown in furnace
charge.
45
STANDARD OPERATING PROCEDURE FOR PFS
FURNACE
8. Check the entire job as per check list attached as
annexure-III
28. Submit the graph and duly filled spot check formats
to inspection for approval of heat treatment. 49
STANDARD OPERATING PROCEDURE FOR PFS
FURNACE
29. Retrieve the thermocouples from the ports and move
the bogie out of the furnace.
32. Unload the job from bogie and move the bogie
inside the furnace.
51
CERMIC GROUND LEVEL HEATING
BLANKET ELEMENT
CERMIC FIBER
OUTER
SLABER BLOCK BAFFLE
FIRE BRICK SHELL
INSULATING
CASTABLE
ROOF
CERAMIC
BLANKET
4020
125 250
TROLLEY
STRUCTURE
1380
1000
PIT FURNACE SKETCH
4961
52
STANDARD OPERATING PROCEDURE
FOR PIT FURNACE
1. Receive heat treatment request duly authorized
by metallurgy engineer.
2. Receive the job for heat treatment with
inspection clearance.
3. Put the job either on support or on heat
treatment fixture inside the furnace.
4. Ensure that equal clearance is available on all
sides between job and baffle.
5. Ensure that the furnace is calibrated.
6. Connect thermocouples with compensating
cable to PID.
53
STANDARD OPERATING PROCEDURE
FOR PIT FURNACE
7. Set the program in the programmer as per heat
treatment request.
10. Insert the graph inside the recorder and take the
signature of inspector on the graph paper.
54
STANDARD OPERATING PROCEDURE
FOR PIT FURNACE
13. Start recording the time and temperature in the
logbook every 30 minutes.
14. Ensure that the cycle is functioning as per program.
15. After the heat treatment is over, open the furnace
cover.
16. If the job calls for water quenching, lift the job and
dip it in quench tank.
17. It the job calls for air cooling in still air, lift the job
and put it outside on supports in open air.
55
STANDARD OPERATING PROCEDURE
FOR PIT FURNACE
18. It the job doesnt call for anything above, allow the
job to cool down in furnace.
56
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 00C to 10000C in steps of 500C is fed
to the indicator / controller.
3. After the millivolt value / temperature reading
displayed is steady, the reading of
indicator/controller shall be noted. 57
PROCEDURE FOR EMPTY FURNACE
CALIBRATION
4. If the error in the indicated readings is more than
the specified accuracy ( +/- 10C ), 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.
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.
58
PROCEDURE FOR EMPTY FURNACE
CALIBRATION
2. The millivolt output for various temperature
ranging from 400 C to 10000C is fed to the
recorder and is allowed to plot on a graph.
6. Close the furnace lid. Start the furnace and the recorder.
61
PIT FURNACE CALIBRATION PROCEDURE
64
LOCAL STRESS RELIEVING
WHY
Local SR to be done only when furnace SR not feasible
When only certain components to be PWHT
HOW
Can be done by Electrical / Gas / diesel / Induction etc..
Heating band
Inside radius
Insulation band
66
LOCAL STRESS RELIEVING SET UP
SB+HB+IB
LSR of C/S
Spider or
prop
No Welding at top
Multitonne roller
69
SUPPORTING ARRANGEMENTS
70
SUPPORTING ARRANGEMENTS
450mm
burner 600mm
0
90
600mm
300mm(point no:2)
72
SUPPORTING ARRANGEMENTS
Zero gap
Supporting
arrangement
towards bottom
75
GENERAL
Temp. support
Furnace floor
77
THERMOCOUPLES
78
THERMOCOUPLES
ATTACHMENTS
1. Use only TAU-90 capacitor Discharge Welding
machine for thermocouple connection
79
THERMOCOUPLES
ATTACHMENTS
max. 3.0mm
8. Only calibrated thermocouple shall be used.
Calibration shall be by QA.
9. After PWHT, thermocouple area shall be ground
and DP shall be carried out.
80
THERMOCOUPLES
ATTACHMENT UNIT
81
SPECIAL NOTE
DESIGN.
82
CODE EXTRACTS
FURNACE PWHT
LSR
83
REQUIREMENT OF HEAT TREATMENT
AS PER ASME-SEC VIII Div.-1
SERVICE CONDITION (UW-2)
LOW TEMERATURE
OPERATION (UCS-68)
CUSTOMER SPEC.
84
CODE EXTRACT FOR HEAT TREATMENT
( 1 ) The soak band shall contain the weld, heat
affected zone and a portion of base metal adjacent to the
weld being heat treated. The minimum width of this
volume is the widest width of weld plus 1T or 2 inches,
whichever is less, on each side or end of the weld. The
term T is the nominal thickness.
( 2 ) The operation of postweld heat treatment shall
be performed either by heating the vessel as a whole in
an enclosed furnace or heating the vessel in more than
one heat in a furnace, provided the overlap of the heated
sections of the vessel is at least 5 feet ( 1.5m). When this
procedure is used, the portion outside of the furnace
shall be shielded so that the temperature gradient is not
harmful. The cross section where the vessel projects
from the furnace shall not intersect a nozzle or other
structural discontinuity. 85
CODE EXTRACT FOR HEAT TREATMENT
( 3 ) When the vessel is required to be postweld heat
treated, and it is not practicable to postweld heat treat the
completed vessel as a whole or in two or more heats; any
circumferential joints not provisionally heat treated may be
thereafter locally postweld heat treated by heating such
joints by any appropriate means that will assure the
required uniformity.
( 4 ) While carrying out local postweld heat treatment,
the soak band shall extend around the full circumference.
The portion outside the soak band shall be protected so
that the temperature gradient is not harmful.
( 5 ) Heating a circumferential band containing nozzles
or other welded attachments in such a manner that the
entire band shall be brought up uniformly to the required
temperature and held for the specified time. 86
CODE EXTRACT FOR HEAT TREATMENT
( 6 ) Where more than one pressure vessel or more
pressure vessel part are postweld heat treated in one
furnace charge, thermocouples shall be placed on
vessels at the bottom, center, and top of the charge or in
other zones of possible temperature variation so that the
temperature indicated shall be true temperature for all
vessels or parts in those zones.
( 7 ) Postweld heat treatment, When required, shall be
done before the hydrostatic test and after any welded
repairs. A preliminary hydrostatic test to reveal leaks
prior to PWHT is permissible.
( 8 ) For pressure vessels or parts of pressure vessels
being post weld heat treated in a furnace charge, it is the
greatest weld thickness in any vessel or vessel part
which has not previously been postweld heat treated.87
CODE EXTRACT FOR HEAT TREATMENT
( 8 contd...) The nominal thickness is the total depth of
the weld exclusive of any permitted weld
reinforcement.
For groove weld, the nominal thickness is the
depth of the groove.
For fillet welds, the nominal thickness is the
throat dimension.
If a fillet weld is used in conjunction of groove
weld, the nominal thickness is the depth of the
groove or the throat dimension, Whichever is
greater.
For stud welds, the nominal thickness shall be the
diameter of the stud.
( 9 ) For P1 material ( carbon steel), minimum holding
temperature during postweld heat treatment shall
be 1100 Deg. F ( 593 Deg.c). 88
CODE EXTRACT FOR HEAT TREATMENT
89
CODE EXTRACT FOR HEAT TREATMENT
( 10 ) Postweld heat treatment is mandatory in
Following conditions :
For welded joints over 1. 5 nominal thickness.
For welded joints over 1.25 nom. Thickness
through 1.5 nom. Thickness, unless preheat is
applied at a min. Temperature of 200F ( 94c )
during welding.
Vessels or parts of vessels constructed of base
material with corrosion resistant integral or weld
metal overlay cladding or applied corrosion
resistant lining material shall be postweld heat
treated when the base material is required to be
postweld heat treated. In applying this rule, the
determining thickness shall be the total thickness
of base material.
When the PWHT is a service requirement.
90
CODE EXTRACT FOR HEAT TREATMENT
SERVICE CONDITION
91
CODE EXTRACT FOR HEAT TREATMENT
( 11 ) Postweld heat treatment is not mandatory for carbon
steel jobs (P1 material ) in Following conditions
(UG2):
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 P-
NO.1 GROUP NO. 1 AND 2 MATERIALS.
95
96
97
98
99
SELECTION OF SPIDERS AT OPEN ENDS FOR HEAT TREATMENT
SHELL THICKNESS
100
10
20
40
60
70
80
90
30
50
10000
9500
9000
8500
8000
7500
6000
5500
5000
4500
4000
3000
2500
1500
1000
100
10
20
40
60
70
80
90
30
50
SHELL THICKNESS
102
HT CHARGE
103