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Sogec NDT
Specialized Oil & Gas Engineering Co. Ltd.
Project: SAFCO
00 04/08/2015 BT SM
OE OM
REV.NO. COMMENTS DATE PREPARED CHECKED APPROVED
BY BY BY
Sogec Page 1 of 13
SOGEC Hardness Testing Procedure Procedure No:
Rev No: 00 Brinell Hardness Tester ABK-BHN-0002
Date: 04/08/2015
REVISION RECORD
Sogec Page 2 of 13
SOGEC Hardness Testing Procedure Procedure No:
Rev No: 00 Brinell Hardness Tester ABK-BHN-0002
Date: 04/08/2015
INDEX
1 PURPOSE
2 SCOPE
3 REFERENCES
4 DEFINITIONS
5 PERSONNEL
6 PERSONNEL RESPONSIBILITIES
7 EQUIPMENT
8 CALIBRATION
9 SURFACE CONDITION
10 HARDNESS TESTING PROCEDURE
11 ACCEPTANCE CRITERIA
12.2 Attachments
12.2.1 Hardness Test reports
Sogec Page 3 of 13
SOGEC Hardness Testing Procedure Procedure No:
Rev No: 00 Brinell Hardness Tester ABK-BHN-0002
Date: 04/08/2015
1.0 PURPOSE
To describe the requirements for hardness testing of materials and welded joints to
verify their acceptability to meet client specification
2.0 SCOPE
This procedure shall be implemented which defines test methods and extent of
Brinell hardness examination to be carried out on metallic materials, parent metal
weldments and weldments using a portable hardness tester before or after PWHT.
2.0 REFERENCES
The following Codes and Standards shall be referred to in conjunction with this
procedure:
3.0 DEFINITIONS
3.2 Brinell Hardness Number, HB a number related to the load applied to the
material and the surface area of the permanent impression made by the ball
indenter in the material and the known hardness test bar. A special
calculator designed to calculate the Brinell Hardness (BHN) of the specimen
material using the following mathematical equation:-
Sogec Page 4 of 13
SOGEC Hardness Testing Procedure Procedure No:
Rev No: 00 Brinell Hardness Tester ABK-BHN-0002
Date: 04/08/2015
4.0 PERSONNEL
Personnel undertaking hardness test will be conversant with the equipment in use
and the limitations if any. No formal qualification is required except the training and
practice for accurate notations and calculations as necessary. Personnel will be
trained by SOGEC and approved by Clients witnessing the application of this
procedure prior to beginning the testing.
1. Selecting Equipment.
2. Selection of BHN Test Bar
3. Calibration
4. Surface preparation
5. Hardness testing
6. Calculating the hardness of specimen
7. Recording results and preparing reports
6.1 TELEBRINELLER
Hardness Tester of make: Mannings, UK Model and TELEWELD
If TELEBRINELL hardness tester cannot be applied due to weld geometry, then
alternative hardness tester can be used subject to approval by the COMPANY
complying with ASTM A 833
Sogec Page 5 of 13
SOGEC Hardness Testing Procedure Procedure No:
Rev No: 00 Brinell Hardness Tester ABK-BHN-0002
Date: 04/08/2015
Principle of Operation:
The MIC 10 works to the UCI (Ultrasonic Contact Impedance) method of
measurement. In the case of the Ultrasonic Contact Impedance (UCI) method, the
hardness of a material is determined on the basis of the size of the test indentation
left behind in the material by a vickers diamond after applying a defined load,
similar to that of hardness testing according to Vickers. Unlike the stationary
instruments, the diagonals of the indentation are not optically evaluated but in UCI
method, its surface area is indirectly electronically detected by determining the shift
of an ultrasonic frequency. A UCI probe mainly consists of a Vickers diamond fixed
to the end of a metal rod. This oscillating rod is excited by piezoelectric crystals to a
longitudinal oscillation at a resonant frequency of about 70 KHz. If the defined test
load of the UCI probe used, applied via a metal spring, acts on the test material,
there is a shift in the frequency of resonance. UCI hardness testing is based on the
relationship between the frequency shift and the hardness of the material under
test.
The frequency shift determined by means of the UCI probe is proportional to the
contact surface of the Vickers diamond with the test material and consequently to
the size of the test indentation created by the diamond under test load. The softer
the test material, the deeper the diamond penetrates. On the other hand, a large
contact surface leads to a high frequency shift. Different to the conventional Vickers
test, the diagonals of the test indentation are not optically determined for the
hardness value after removing the load, but its surface area is electronically
detected in a matter of seconds.
Velocity measurements are achieved through a permanent magnet in the impact
body that generates an induction volt in the coil of the impact device. The signal
voltage is proportional to the velocity of the impact body. Signal processing
provides the hardness reading for display and storage.
6.3 EQUOTIP
Principle of Operation:
When measurement is done with EQUOTIP 3, an impact body with a hard tip is
impacted by spring energy against the sample to be measured and then rebounds.
During the impact, a permanent magnet integrated in the impact body passes
through a coil in which voltage is induced by the forwards and backwards
movement. This voltage is proportional to the velocities. The ratio of the rebound
velocity vr to the impact velocity vi multiplied by 1,000 yields the hardness value HL
(Leeb hardness). HL is a direct measure of the hardness.
The impact and rebound velocity is measured when the impact body tip is approx. 1
mm (0.04 inches) away from the sample to be measured. The measuring signal is
converted to the hardness value by the unit electronics, shown in the display and
stored in the unit memory.
Sogec Page 6 of 13
SOGEC Hardness Testing Procedure Procedure No:
Rev No: 00 Brinell Hardness Tester ABK-BHN-0002
Date: 04/08/2015
7.0 CALIBRATION
7.1 For all class items, the hardness shall be carried out according to SAES-W-
011 Para. 14 and reported to client.
With reference to NACE RP0472, clauses 3.5, 3.6 & 3.7 as follows:
Vessel or tank butt welds a minimum of one test per weld seam. Unless
otherwise specified by client, one test should be made for each 3M (10ft) of
weld seam. In addition, one test shall be made on each nozzle flange to
neck and nozzle neck to shell/head weld. Each welding procedure used shall
be tested. When dissimilar metals are joined by welding, the hardness limits
specified for the base and welding material are met for each material.
Testing of fillet weld deposits should be done when feasible, the number of
tests and locations shall be approved by client.
The selected BHN reference test bar initial selected shall be within + 12.5%
of the maximum hardness of the specimen material. After the first test the
difference in hardness should be -10 to +50 BHN if not discard and redo with
new test bar. New test bar should have an hardness closer to material being
tested for improved accuracy.
Sogec Page 7 of 13
SOGEC Hardness Testing Procedure Procedure No:
Rev No: 00 Brinell Hardness Tester ABK-BHN-0002
Date: 04/08/2015
8.1 The specimen material or weld surface, HAZ shall be prepared for testing by
the following methods, filing, grinding, sanding or polished with abrasive
materials. To remove scale, rust or decarburised metal giving a flat smooth
surface so that the edge of the indented impressions are clearly seen for
measurement with the microscope.
8.2 Care must be taken to avoid excessive heating or cold working of the
surface, which will change the hardness of the test surface and lead to
erroneous readings.
8.3 Test shall be performed after PWHT when PWHT is applicable, unless
specified otherwise.
9.1.1 Select BHN test bar as describe in Sect. 7 and insert the bar into the bar
holder. Hardness impressions can be made on only two adjacent sides of
the test bars. Guidelines in Appendix A of NACE RP0472 are Mandatory.
9.1.2 Position bar holder on or near the centre (1) of weld deposit or (2) HAZ as
specified in ASME B31.3 para. 331.1.1.7. Note the specimen material shall
be a minimum of 12mm thick and adequately supported to stop any
deflection or movement during the hammer blow. All tests shall be a
minimum of 7mm from the material edge. No two reading should be within
7mm of the adjacent one.
(1) Weldment
Base Metal
(2) HAZ
9.1.3 Hold the test bar holder firmly and flat on the test surface so the anvil and
ball indenter are central and using a 3-5 pound hammer strike a sharp blow
squarely on the anvil. This will leave an impression from the 10mm diameter
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SOGEC Hardness Testing Procedure Procedure No:
Rev No: 00 Brinell Hardness Tester ABK-BHN-0002
Date: 04/08/2015
ball in the specimen material and the BHN test bar. The diameter of
impression in test bar and material surface should be between 3.0mm and
4.0mm if they do not discard and re-test in new area.
9.1.4 Using Brinell microscope read the size of the impression in test specimen
and BHN test bar, position the scale on edge of impression and observe the
scale on opposite side. Take two readings at right angles to each other on
each impression and this will give the mean value of the impression. Note
the scale is graduated in 0.1mm increments, measurements may be
estimated to the nearest 0.05mm.
9.1.5 By using the supplied calculator or the mathematical equation the specimen
material hardness can be determined as described in section 3.2
9.1.6 If using computer turn movable scale to the reading from the microscope of
impression in material on scale No. 2 is opposite reading of impression in
test bar on scale No. 1.
9.1.7 Opposite the Brinell Hardness number of test bar on scale No. 3 the Brinell
Hardness number of material will be found on scale No. 4
9.1.9 Test areas are prepared as detailed in paragraph 8.0., Five hardness
readings constitute one hardness test. The five and there average reading
shall be reported, if the results are in excess of the required material
specification re-testing will take place again. If still in excess the client
inspection department will be informed
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SOGEC Hardness Testing Procedure Procedure No:
Rev No: 00 Brinell Hardness Tester ABK-BHN-0002
Date: 04/08/2015
The frequency of conducting performance check is once per day and after
every 1000 impacts if the instrument is being used continuously.
If the instrument is not being used continuously then before and after
conducting the test the calibration should be performed.
a. Clean the impact device
b. Perform impact test on the standard test block. As a rule 3 or 5 test
impacts are sufficient. The distance between impact location and outer edge
of the standard test block should measure at least 5 mm.
c. Read off mean value and compare with reference value. The instrument
operates properly if the indicates mean value falls within the reference
range.
If the deviation from the reference value exceeds + 10%, the instrument
should not be used and shall be recalibrated by authorized calibration
agency or by the manufacturer
9.3.1. Accessories
a. PROBES: The probe shall be Impact device
b. CALIBRATION ACCESSORIES: Equotip kit shall have calibration
standards of known hardness value with instructions and certificate of
calibration of the standard piece for cross reference or to demonstrate
calibration accuracy during testing.
9.3.2. Performance Check
The performance check accomplished by measuring the hardness value of
the standard test block applicable to the particular type of impact device.
Sogec Page 10 of 13
SOGEC Hardness Testing Procedure Procedure No:
Rev No: 00 Brinell Hardness Tester ABK-BHN-0002
Date: 04/08/2015
10 ACCEPTANCE CRITERIA
10.1 Any reading that exceeds the specified material limit by 10 BHN shall be
retested; three tests shall be done in the same location as the initial tests. If
all three retests are below the specified limits then the joint is acceptable but
if one is still in excess of the specified limit then the weld joint is considered
unacceptable. If any welds are found to be unacceptable, then two additional
welds from the same lot shall be tested. If more than one weld in a lot is
found to be unacceptable, then all welds in that lot shall be tested.
10.2 Hardness testing shall be in accordance with NACE RP0472 and the listed
requirements below. All welding processes and consumables, including
SMAW and GTAW shall be tested. Reading in HAZ shall be conducted if
specified by the applicable code or standard.
10.3 For any line or joint repaired, Hardness Test shall be witnessed by client
Inspection team as well.
10.4 All dissimilar welds are Hardness tested (Welds & HAZ)
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SOGEC Hardness Testing Procedure Procedure No:
Rev No: 00 Brinell Hardness Tester ABK-BHN-0002
Date: 04/08/2015
11 EXTENT OF VERIFICATION
Hardness testing is required on production welds for the following applications for
all materials in sour services
Hardness test shall consist of at least on hardness measurement in weld metal and
HAZ which shall be taken on each longitudinal and circumferential weld seam and
each diameter of branch connection nozzle.
12.1 The test report results shall be prepared in the Hardness Test Report and
shall include the following information:
Client identity.
Part number or pipe spool number.
Weld identification.
Name of operator.
Type of equipment used.
Date of testing.
Status as to prior or after heat treatment.
12.2 Attachment
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SOGEC Hardness Testing Procedure Procedure No:
Rev No: 00 Brinell Hardness Tester ABK-BHN-0002
Date: 04/08/2015
ATTACHMENT -I
Sogec Page 13 of 13