ATMOSPHERE SAFETY

Why atmosphere?
• Protection from scaling
• To diffuse carbon into steel surface to
develop strength and wear resistance
What does the atmospere contain?
• Carbon Monoxide
• Hydrogen
• LPG

All these are highly inflammable, highly toxic

and form explosive mixtures rapidly.
Knowlegde and training is necessary to so
that they can be handled safely.
 Carbon Monoxide

Carbon monoxide is a colorless and odorless gas

that cannot be detected through sense of smell
or taste. Exposure to carbon monoxide may
cause you to experience any or all of these
symptoms:
• Headaches, tightness across the forehead and
temples
• Weariness, weakness, dizziness and vomiting
• Loss of muscular control
• Watering and smarting of the eyes
 Propane
• When produced, propane is colorless and
odorless. For safety and detection purposes, a
chemical odorant (ethyl mercaptan) is added to
propane. The presence of the odorant alerts you
of a potential propane gas leak.
• Propane vapor is heavier than air. As such, in
the event of an unintended release of propane
vapor, the vapor will migrate to the lowest point.
For example-furnace pits.
Properties of Hydrogen…
 Areas being covered
1. Difference between inert and combustible
gases
2. Hazards involved
3. Procedure for gassing the furnace
4. Procedure for removing the atmosphere
5. Procedure for purging chambers and
vestibules
6. What to do when power fails
7. Precautions in handling various gases and
liquids
 Fire triangle
combustion engine

Fue( petrol)l
oxygen

Source of ignition.
(Spark) > 600 deg.C

Absence of any one of them combustion cannot occur and they must be
within combustible limits. For petrol it is 1.3 -6.0%.If engine is flooded with
Petrol engine will not start.
 Furnace atmosphere

Fuel-CO, H2, LPG AIR ( Oxygen <0.002)

Ignition – auto ignition

flamability falamability
HEAT ABOVE FUEL MIN OXYGEN LIMIT limit,LCL limit,UCL
>530 deg C Natural gas CH4 18.1 5.5 13.6
>580 deg C Hydrogen 6.59 9 68.6

>650 deg C Carbon Monoxide 4.7 13 77.6

Petrol 1.3 6.0
 Oxygen is the problem
1. To avoid explosion from occuring we
should prevent oxygen from entering the
furnace.
2. This is done by flame curtains, pilots ,
exlosion hatches.
3. Atmosphere is allowed to enter the
furnace only its temperature is above
815 deg C
Safe handling of gases points to remember
• Inert gases do not burn and are safe.Combustible gases are unsafe
and they burn/explode
• Endothermic gas contains 20% CO, 40 %H2 and 40%N2. this is
much higher than the their lower combustible limit
• Minimum ignition temperature for hydrogen and hydrogen is close to
595 deg C.
• Introduction of endothermic atmosphere into furnace below 760
degree C constitues explosion hazard.
• It is safe to introduce atmophere above 815degree C
• To purge furnaces require ata least 5 times its volume is required.
• Before entering any furnace for repairs ,disconnect gas lines,freshly
purge the furnace with air and blow air continuously.
• Carbon monoxide is extreemly toxic , unburnt furnace atmosphere
should not be exhausted into a room
• If power or gas fails feed bottled nitrogen at the rate no more than
the flow rate of endothermic gas and light the gas curtains at all
doors till emergency power is restored.
 Procedure for gassing the furnace
1. Heat furnace uniformaly to above 815 degree C
2. Open the vestibule door/s
3. Place a lit flare in the vestibule/s close to the furnace door
4. Start feeding endo thermic gas
5. When flame appears at the furnace door/s the oxygen inside the
furnace is completely purged from the furnace.
6. Lower the vestibule door partially, take out the lit flare and keep at
the bottom of the vestibule door to ignite the gases escaping from
the door
7. Shut the vestibule door/s.
8. Make sure that door pilots and purge stack pilots are lit and
endogas is burning at the purge stack
 Procedure for removing the
atmosphere
• Make sure that furnace temperature is above 815 degree C.
• Open vestibule door/s and keep a lit flare in the vestibule close to
the inner furnace door/s.
• Open the furnace doors and allow the atmosphere to burn at the
furnace door/s
• Turn off endothermic gas.
• When the endothermic gas stops burning at the furnace door/s
,furnace is purged.
• Keep furnace door/s open for a minimum of 30 minutes after the gas
stops burning at the door/s to ensure that any accumulation
combustible gases in the brick work alsos gets burnt.
• Close the furnace door and drop the temperature.
Safety Instructions Do’s and Dont’s
Safety Instructions
 BOMBAY HIGH SR
SL NO. PARTICULARS GRADE ( URAN)
1 Liquid Density @15deg, gms/cc 0.553
2 apecific gravity ( Air=1.0) approx 1.8
3 vapour pressure @100deg F, lbs/sq inch gauge 120
4 chemical composition %vol  
  Propane 38.7
  Propylene 0.0
  Butylene 0.0
  N-Butane 37.1
  Iso -Butane 24.2
  Total C5 and higher 0.0
5 Caloriefic Value  
  Gross K.Cal/kg 12500
  Nett K.cals/kg 10950
6 Air needed for complete combustion(Vols.Air/One vol.gas) 27.5
7 Sulphur, wt % <0.004
8 Exlosive limits,(% gas in air/gas ixture)  
  Lower 1.5
  Upper 9.0
9 Liquid /gas Ratio 1/120
10 Flame Temp.  
  In Air Deg.C 2000
  In Oxygen,deg.C 2850
     
 RESULT,Straight
run RESULT,
LPG,HPCL Mangal
USSAR,MUM ore
SR. NO. CHARACTERISTICS UNIT REQUIREMENT BAI LPG
1 Vapour Pressure @ 40° C K Pa 1050 (max) 938.18 700
2 Volatility for 95% by volume evaporation °C 2.0 (max) 1.61 2

Not worse than

3 Copper Strip Corrosion for 1 Hr at 38° C   ASTM No. 1 ASTM No. 1 a 1
4 H2S   Pass Pass Pass
5 Free Water Content   None None Nil
Not in the
6 Mercaptan ppm 20(min) More than 20 report
7 C2 Hydrocarbons (Ethane) Mole(%) Report 2.23 3.52
8 C3 Hydrocarbons (Propane) Mole(%) Report 53.45 23.83
9 i-C4 Hydrocarbons (Iso-Butane) Mole(%) Report 18.74 20.3
10 n-C4 Hydrocarbons (N-Butane) Mole(%) Report 23.75 51.4
11 i-C5 Hydrocarbons Mole(%) 1.61
} 2.5 (Max)
12 n-C5 Hydrocarbons Mole(%) 0.22 0.95
13 Density @ 15 ° C gms/cc Report 0.5384 0.5537
14 Total Volatile Sulphur PPM, max 150 NIL 20
 Endothermic gas
It is a mixture of 20% carbon monoxide,
40%hydrogen and 40% nitrogen.
It is highly inflammable and highly toxic.
But it is a friend of heat treaters, because
it supplies the carbon monoxide required
for gas carburising .
 Principal components
Principal components of an endo gas generator are:
1. a heating chamber to supply heat by combustion or
electric heating elements,
2. one or more cylindrical retorts (usually vertical) in the
heating chamber with
3. numerous small, porous ceramic pieces, impregnated
with nickel as a catalyst for the reaction.
4. a cooling heat exchanger to rapidly cool the reaction
products to a temperature that will not allow the reaction
to proceed further.
5. the control system that maintains the reaction
temperature and adjusts the gas/air ratio to provide
desired dew point.
Endoe generator at AAL
Endo generator-line diagram
Air –gas ratio
Carbon content vs dew point
Dew point vs air gas ratio
 reactions
1. C3H8+3O2 6CO+8H2
2. C3H8 3C+4H2
3. 2CO CO2 +C
4. C3H8+5O2 3CO2 +4H2O
5. C3H8 +3CO2 6CO +4H2
6. 2H2O 2H2 +O2
Reaction 1 and 5 to be encouraged and 2 to 4 to be discouraged.This is
done by the
Nickel oxide catalyst and temperature of 1050degC
 LPG quality
• Sulphur in LPG poisons the catalyst.
Therefore LPG must be free from sulphur.
• Straight run gas (from Uran) contains less
than 3 ppm sulphur, where as catalyst
craked LPG from Mangalore contains
more than 20ppm
• Uran LPG only is procured in AAL.
 Properties of LPG
RESULT,Straight RESULT,
run LPG,HPCL Mangalore
SR. NO. CHARACTERISTICS UNIT REQUIREMENT USSAR,MUMBAI LPG
1 Vapour Pressure @ 40° C K Pa 1050 (max) 938.18 700
2 Volatility for 95% by volume evaporation °C 2.0 (max) 1.61 2
Not worse than
3 Copper Strip Corrosion for 1 Hr at 38° C   ASTM No. 1 ASTM No. 1 a 1
4 H2S   Pass Pass Pass
5 Free Water Content   None None Nil
Not in the
6 Mercaptan ppm 20(min) More than 20 report
7 C2 Hydrocarbons (Ethane) Mole(%) Report 2.23 3.52
8 C3 Hydrocarbons (Propane) Mole(%) Report 53.45 23.83
9 i-C4 Hydrocarbons (Iso-Butane) Mole(%) Report 18.74 20.3
10 n-C4 Hydrocarbons (N-Butane) Mole(%) Report 23.75 51.4
11 i-C5 Hydrocarbons Mole(%) 1.61
} 2.5 (Max)
12 n-C5 Hydrocarbons Mole(%) 0.22 0.95
13 Density @ 15 ° C gms/cc Report 0.5384 0.5537
14 Total Volatile Sulphur PPM, max 150 NIL 20
 BOMBAY HIGH SR GRADE
SL NO. PARTICULARS ( URAN)
1 Liquid Density @15deg, gms/cc 0.553
2 apecific gravity ( Air=1.0) approx 1.8
3 vapour pressure @100deg F, lbs/sq inch gauge 120
4 chemical composition %vol  
  Propane 38.7
  Propylene 0.0
  Butylene 0.0
  N-Butane 37.1
  Iso -Butane 24.2
  Total C5 and higher 0.0
5 Caloriefic Value  
  Gross K.Cal/kg 12500
  Nett K.cals/kg 10950

6 Air needed for complete combustion(Vols.Air/One vol.gas) 27.5

7 Sulphur, wt % <0.004
8 Exlosive limits,(% gas in air/gas ixture)  
  Lower 1.5
  Upper 9.0
9 Liquid /gas Ratio 1/120
10 Flame Temp.  
  In Air Deg.C 2000
  In Oxygen,deg.C 2850
     
 Maintenace.
Daily:
1. Visually examine all instrumentation to
assure that operation is normal.....without
incident. Determine that control outputs
are within the expected range of
operation.
2. Check temperature of water discharged
from heat exchanger.
Weekly:
1. Regenerate ( burn out ) carbon in
generator using air
2. After regeneration and readjustment of
generator to proper condition, check the
carbon potential.
3. Clean the air filter
• Monthly:
1. Clean air-gas mixing valve (carburetor )
thoroughly.
2.Check carbon potential by shim stock
analysis.
3. Inspect thermocouples and protection
tubes and replace every 3 to 4 months.
4. Check LPG pressure after the regulator to
maintain balance to the carburetor.
5. Verify correct operation of over
temperature controls.
Semi- annually:
1. Replace heat exchanger with standby, clean and
refurbish them for next service.
2. Inspect catalyst in retort and fill to proper level or
replace.
3. Inspect and clean all burners.
4. Clean endo delivery lines to furnaces.
5. Inspect cooling water thermostats, solenoids.
6. Perform complete instrument calibration and service,
including safety controls.
7. Have oxygen probe ( carbon sensor ) refurbished,
inspected and certified.
Annually:
• 1. Check compressor blades.
• 2. Check motor and compressor bearings.
 Carbon potential control
• Due point control
• Carbon di-oxide control
• Oxygen potential control
 Oxygen probe control
• More reliable.
• Insitu probe.
• Very quick ,real time data gets captured
• Zirconium oxide sheath acts as an
electolyte(solid)
• Reference is air
• Measures the potential difference between
atmosphere and reference air.
Electroplating cell
Schematic Diagram Carbon Sensor
 Formula
• E=0.0496Tlog pO2/pO2ref.
T- Temp in deg K,
E-Emf imillivolts
 Heat resistance alloy castings
• Contain more than 12% Chromium
• Capable of performing satisfactorily above
650 deg C
• Have good surface film stability in various
atmopsheres and the temperatures they
are subjected
• Have sufficient mecahnical strength and
ductility to meet high temerature survice
conditions.
 Role of Nickel
• Designated as HA, HC,…..HT,HU etc.
• First letter denotes “ heat resistance alloy”
• Second letter indicates nominal nickel content,
increasing from A to X.
• Nickel is present in cast alloys in amounts up to 70%
• Function of Nickel is to strengthen and toughen the
matrix,increase resistance to oxidation,carbusrisation
,nitriding and thermal fatigue.
• Nickel promotes formation of Austenite which is stronger
and more stable at elevated temperatures than ferrite
 Role of Chromium
• Chromium content varies from 10- 30%
• It imparts resistance to oxidation(scaling)
at elevated temperature and to sulphur
containing atmospheres.
• Chromium carbides precipitatein the
matrix and contibute to high temperature
creep and rupture strength.
• It also increases resistance to
carburisation.
 Role of Carbon and Silicon
• Carbon content ranges from 0.20 to 0.75%.
• Increasing the carbon improves the high
temperature strenth and creep resistance at the
expence of ductility.
• Silicon has beneficial effect on the high
temerature corrosion resistance and on
resistance to carburisation.
• Silicon in amounts >2%,lowers the high
temperature creep . Therfore it is limited to 1.5%
in castings intended for service higher than 815
deg C.
Grouping of Heat resistance alloys
• Chromium- Iron Alloys : HA, HC, HD
• Cromium - Nickel –Iron Alloys : HE, HF,
HH,HI,HK,HL
• Nickel-Chromium – Iron Alloys :
HN,HP,HT,HU,HW,HX
 Properties of 3 groups
TYPE OF ALLOY PROPERTIES.
Chromium up to 30%, Nickel up to 7%.They are
ferritic and poor hot strength. Not used in critical
HA,HC,HD load bearing application beyond 760 deg.c
Contain 18-24% Chromium , 8-22% nickel. Either
partial of completely austenitic. Good high
temperature strength, hot and cold ductility and
resistance to oxidising and reducing conditions.
They are useful in deducing atmospheres high in
HE,HF,HH,HI,HK,HL sulphur
Contain 25-70% nickel, 10-26% chromium. Fully
austenitic. Good weldability,Can be used
satisfactorily up to 1150 deg.C.Good hot
strength,resistanmce to carbusrisation and
thermal fatigue. Can be used for load bearing
applications and cyclic heating and large
HN,HP,HT,HU,HW,HX temperature differentials.
Properites of HT and HU
Contains 35% nickel, 17% chromium.About 1/7th of total
production of HR ALLOYS is HT grade because of its value
insesisting thermal shock, resistance to oxidation and
carburisation at high temperatures.Except in high sulphur
gases,it performs satisfactorily up to 1150 deg C in oxidising
atmopsheres and up to 1100 deg C in reducing
atmospheres.It is used for load bearing membersin furance
applications such as retorts, radient tubes,cyanide and salt
HT pots,hearth plates and trays quenched with work.

Contains 39% nickel,18% chromium. Has exceptionally high

combination of creep strength and ductility up to 110 deg C.
Used where high hot strength is required. It is used in
applications involving high stress and rapid thermal cycling.It
hsd good resistance to corrosion by either oxidising or
reducing hot gases containing moderate amounts of
sulphur.Typical uses are salt pots, Quenching trays, fixtures
HU and gas dissociation equipment.
Fan casting
Base Tray –all case furnace
CCF base tray
Top tray-allcase Furnace
Gear spacer
Pinion top tray
PEG