2621B. 2023

Address: 8th Riad Shams – Eight Area -Nasr City-Cairo-Egypt.
KIT FOR ENGINEERING INNOVATION Website: www.kit-egy.com

INSPECTION REPORT SYSTEM Phone: (02) 01012000780
(02) 01012000760
ABSTRACT
The microstructures of steels are
altered when exposed to high
working temperatures for long
periods, which results in varied
physical and chemical proprieties.
This study evaluates the behavior
of ASTM A106 steel of Burner No.
F-2621 B after it is exposed to
REPLICA various temperatures for long
durations.
MICROSTRUCTURE
NDT
SUCO
(02) 01012000760
Report
Replica Microstructure Non Destructive Testing
of Heaters (burners) tubes at Gabl Elzeit Field, SUCO
Content:
1- Introduction
2- Equipment & Working procedures
3- Microstructure Evolution
4- Hardness measurements
5- Conclusion
NDT INSPECTOR APPROVED BY
Name Eng. Mohammed Gharieb Dr.Eng. Consultant:- Wael Hoziefa
Signature
Date 12/04/2023 12/04/2023

(02) 01012000760
Replica Microstructure Non Destructive Testing

of Heaters (burners) tubes at Gabl zeit field, SUCO
References:
ASTM A 106: Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service1
ASME SA 106: SPECIFICATION FOR SEAMLESS CARBON STEEL PIPEFOR HIGH-TEMPERATURE SERVICE
ASTM E1351 :- the replica microstructure is produced according to the standard practice.
1- Introduction
Replication metallography is a non-destructive sampling procedure which records and
preserves the topography of a metallographic specimen as a negative relief on
a plastic film. The microstructural replica can be examined using a light microscope
for subsequent analysis like grain size alteration or change in its shapes especially
when grains subjected to heat to detect the grain transformation which will be
accomplished with hardness values that could give the right decision for any future
maintenance of such parts.
‫يعد اختبار البصمة الميتالورجيه من االختبارات الغير اتالفية والذي يعتمد علي تسجيل البنية المجهرية للمعدن علي شرائح‬
‫ فئة ب والتي تتغير طبقا لتغير‬106 ‫بالستيكية وحيث ان المعدن محل الدراسة هو مواسير الصلب الكربوني من النوع‬
‫ ولذلك تم رفع البصمات لدراستها باستخدام الميكروسكوب الضوئي لفهم ورصد التغير المجهري في‬، ‫درجات الحرارة‬
. ‫شكل وحجم الحبيبات وربطها بقيم الصالدة لتحديد القرار الصحيح في اجراء تغيير او صيانة للمواسير محل الدراسة‬
-:‫طبقا لما سبق فان التقرير ينقسم الي جزئين وهما‬
.‫ التجهيز واخذ البصمات الميكروسكوبية ووضع الصور المرصودة‬-: ‫ الجزء األول‬-
‫ قياس الصالدة واجراء خريطة مفصلة لها‬-: ‫ الجزء الثاني‬-
.‫وبناءا علي ما سبق يتم وضع الجزء الثالث واألخير وهو التوصيات الالزمة للحفاظ علي المواسير محل الدراسة‬
(02) 01012000760
PART ONE: - REPLICATION METALLOGRAPHY

REPLICATION PROCEDURE
In Replica Metallography steps followed are like that of common methods used in laboratory
metallography with the exception that the part to be viewed is not required to be brought to
the laboratory
1. Surface Preparation
Surface preparation holds key in revealing the microstructure to be studied. It involves steps
like grinding, polishing, and etching. Components in service usually have a well-developed
corrosion or oxidation product or a decarburized layer on the surface that must be removed
before replication using emery papers which are arranged gradually (80 – 120 -240 – 300 –
400 – 600 – 800 and 1000 mesh) followed by polishing cloths which are of (6 – 3 – 1
Microns) . In Situ, Replication Metallography utilizes portable grinding and polishing unit
to serve this purpose. as shown in figure 1
2. Preparation of Replica
During work these steps were omitted because the equipment was not in working condition.
Instead already prepared specimens were used for preparation of replicas. Replication of a
surface can involve either direct or indirect methods. In the direct, or single stage, method,
a replica is made of the specimen surface and subsequently examined in the microscope,
while in the indirect method; the final replica is taken from an earlier primary replica of the
specimen surface. Only the direct method will be considered in this effort because it lends
itself more favorably to on-site preparation. Replication of surface was performed by using
Replica-Kit. Replica of the sample was prepared as:
(02) 01012000760
i. Two drops of replication fluid were applied to the replica foil.

ii. Replica strip was pressed firmly against the prepared sample surface for at least 30
seconds so that clear impression of the specimen can be obtained for observation
under microscope.
iii. Prepared replica was fixed on a glass slide by removing its back cover tape.
3. Microstructural Analysis and Interpretation of Results
Prepared replicas were viewed by using portable microscope and were compared with actual
microstructure
of the specimens as shown in Figure 2. Basic technique of utilizing the equipment for
preparation and observation of replicas has been practiced whereas interpretation of results
will require the team to be trained at advanced level to interpret the results.
The samples were obtained as two groups which were for;
Gas heater (6 samples; for 1st , 2nd , 3th , 5th tubes and for 2fitting )
(02) 01012000760
Fig. 1: Grinding, polishing, and etching of the tubes under investigation.
Fig. 2: Replica and microstructure Evaluation and hardness testing of the obtained samples
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MICROSTRUCTURAL ANALYSIS.
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1- MICROSTRUCTURAL ANALYSIS.
Visual examination using portable microscopy was carried out for the selected tubes which indicate variation
in the macrostructure as the surface have a noticed pitting which look like previous observation.
(02) 01012000760
The first group of samples were as following
1st Tube Microstructure 2nd Tube Microstructure

Previous Structure Previous Structure
This location at the first raw of the tubes, the structure This location at the second tube of the tubes, the
is partially coarser than standard. The average hardness structure was more coarser than that of standard, The
at this replica spot was 100.8 HB average hardness at this replica spot was 99.3 HB
Current Structure Current Structure
This location at the second tube of the tubes,

- This location at the first raw of the tubes, the
the structure was coarser than previous structure and
structure is coarse carbides at the grain
associated with intergranular cavity chains (tiny
boundaries. There are intergranular oriented microcracks) to standard, The average hardness at this
cavity chains (tiny microcracks) which were replica spot was 92.1 HB
observed earlier in the previous report, and it was
increased as size that will need to more
observations during operations associated with
care and control.
The difference in the HB while the structure is likely
- The average hardness at this tube was 94.2 HB the same is due to that previously just 5 points were
The difference in the HB while the structure is likely recorded while currently a grid (map) with huge
the same is due to that previously just 5 points amount were recorded that also shown in the
were recorded while currently a grid (map) with values which are convergent.
huge amount were recorded that also shown in the
values which are convergent.
(02) 01012000760
3rd Tube Microstructure 5th Tube Microstructure

Previous Structure Previous Structure
Was not obtained previously
This location at the fifth raw of the tubes, the

structure was coarser than standard which could be
hard and tend to be more brittleness, the average
hardness at this replica spot was 100.1 HB
Current Structure Current Structure
This location at the 3rd raw of the tubes, the This location at the 5th raw of the tubes,
structure was coarser than standard which the structure was coarser than standard
could be hard and tend to be more which could be hard and tend to be more
brittleness, observation of small amounts of brittleness, there are intergranular cavity
isolated cavities, the average hardness at chains (very tiny microcracks), the
this replica spot was 94.5 HB average hardness at this replica spot was
83 HB
The difference in the HB while the structure is

likely the same is due to that previously just 5
points were recorded while currently a grid
(map) with huge amount were recorded that
also shown in the values which are convergent.
(02) 01012000760
Fitting Microstructure Fitting Microstructure

Previous structure Previous structure
Was not obtained previously
This location at the fitting, the structure is coarser

which is usually normal for such fittings, The average
hardness at this replica spot was 106.3 HB
This location at the fitting, the structure is coarser which This location at the fitting, the structure is coarser
is usually normal for such fittings, The average hardness which is usually normal for such fittings, The average
at this replica spot was 92.6 HB hardness at this replica spot was 93.5 HB
The difference in the HB while the structure is

likely the same is due to that previously just 5
points were recorded while currently a grid
(map) with huge amount were recorded that
also shown in the values which are convergent.
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HARDNESS RESULTS
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INTERNAL TUBES HARDNESS MEASURMENTS

Names Read 1 Read2 Read3 Read4 Read5 AVG(HL) AVG(HB)
T1A1 357 349 344 363 332 349 95.5
T1A2 328 333 339 342 324 333 92
T1A3 290 349 331 317 314 320 84
T1A4 316 329 342 329 340 331 91
T1A5 348 315 343 280 245 306 80
T5A6 257 281 292 311 308 290 75
T5A7 323 328 328 306 331 323 85.5
T5A8 337 336 335 345 350 241 95
T5A9 299 310 326 338 337 322 85
T5A10 322 321 314 307 291 311 81
T2A1 335 296 299 348 330 322 85
T2A2 325 306 325 304 319 316 83
T2A3 314 328 308 330 334 323 85.5
T2A4 358 326 322 332 325 333 92
T2A5 328 345 332 304 291 320 84
T2A6 344 348 335 355 353 347 95.5
T2A7 354 326 323 342 305 330 91
T2A8 372 319 371 336 313 322 85
T2A9 320 321 329 310 284 313 82
T2A10 316 323 331 362 348 336 93
T3A1 327 313 323 318 343 325 90
T3A2 329 305 294 311 315 311 82
T3A3 309 333 315 310 296 313 84
T3A4 323 310 335 311 345 325 90
T3A5 329 293 348 312 345 325 90
T3A6 292 265 313 305 341 303 79
T3A7 342 325 323 312 300 320 84
T3A8 319 333 323 316 311 320 84
T3A9 330 351` 274 301 344 320 84
T3A10 303 260 321 286 279 290 75
T4A1 330 322 335 317 339 329 91
T4A2 341 337 294 314 309 319 84
T4A3 308 297 308 189 277 276 72
T4A4 332 335 305 302 306 316 83
T4A5 299 297 315 314 293 304 80
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T6A1 323 288 325 282 315 307 81

T6A2 341 319 373 329 313 335 92.5
T6A3 304 314 230 297 361 301 79
T6A4 331 298 317 312 336 319 83
T6A5 338 316 310 281 279 305 80.5
T8A1 342 341 354 282 353 334 92.5
T8A2 343 309 307 292 322 315 83
T8A3 320 298 274 296 355 309 81
T8A4 323 350 344 274 331 324 90
T8A5 333 343 349 323 333 336 93
T10A1 238 340 338 305 344 313 82
T10A2 314 330 288 327 302 312 81.5
T10A3 375 303 347 355 359 348 95.5
T10A4 280 341 331 331 318 320 84
T10A5 318 322 320 273 338 314 80
FITTING
Names Read 1 Read2 Read3 Read4 Read5 AVG(HL) AVG(HB)
f(1) 342 349 375 356 334 351 97
f(2) 345 320 332 295 340 326 90.5
f(3) 333 295 336 352 318 327 90.5
f(4) 326 343 344 314 342 334 92
f(5) 309 349 356 411 322 349 95.5
f(6) 329 331 314 363 355 338 93

(02) 01012000760
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Recommendation
1- Microstructural analysis show alteration in microstructure which usually observed in

such application due to variation of operating temperature which could make heat
treatment of tubes, this variation could make a failure if care and periodic maintenance
were recorded.
2- The hardness map was carried out to check variation of microstructure, the map
shows a variation in the values which was range (83 – 94.5 HB), this variation is from
the bottom moving upward. However such variation is identical with operation
condition as operation temperature is about 300 degree Celsius and heat is maintain
down for long time that mean the T1, T2 , T3 and T4 considered to be in annealing
heat treatment statues that make them more ductile which identical with their
hardness values.
3- The fitting was in good condition and normal reading was recorded either as replica or
hardness value (92-97 HB).
4- The behind tubes record high hardness values as they are heated then cooled due to
air, so they show a high hardness value.
The periodic inspection using replica and hardness testing shall be carried out annually
and must be supported with thickness measurement of the tubes, especially the four
lower tubes to record variation in thickness with relation to structure and hardness.
Heater No. 2621B was observed using replica nondestructive testing and the values
were recorded at the time of inspection, any alteration or change due to operation or
other conditions is due to reasonability of owner.
NDT INSPECTOR APPROVED BY
Name Eng. Mohammed Gharieb Dr.Eng. Consultant: - Wael Hoziefa
Signature
Date 06/06/2023 06/06/2023

2621B. 2023

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Address: 8th Riad Shams – Eight Area -Nasr City-Cairo-Egypt.

KIT FOR ENGINEERING INNOVATION Website: www.kit-egy.com

Replica Microstructure Non Destructive Testing

of Heaters (burners) tubes at Gabl Elzeit Field, SUCO

NDT INSPECTOR APPROVED BY

Name Eng. Mohammed Gharieb Dr.Eng. Consultant:- Wael Hoziefa

Date 12/04/2023 12/04/2023

Replica Microstructure Non Destructive Testing

-:‫طبقا لما سبق فان التقرير ينقسم الي جزئين وهما‬

.‫ التجهيز واخذ البصمات الميكروسكوبية ووضع الصور المرصودة‬-: ‫ الجزء األول‬-

‫ قياس الصالدة واجراء خريطة مفصلة لها‬-: ‫ الجزء الثاني‬-

PART ONE: - REPLICATION METALLOGRAPHY

i. Two drops of replication fluid were applied to the replica foil.

3. Microstructural Analysis and Interpretation of Results

The samples were obtained as two groups which were for;

Fig. 1: Grinding, polishing, and etching of the tubes under investigation.

The first group of samples were as following

1st Tube Microstructure 2nd Tube Microstructure

This location at the second tube of the tubes,

3rd Tube Microstructure 5th Tube Microstructure

Was not obtained previously

This location at the fifth raw of the tubes, the

The difference in the HB while the structure is

Fitting Microstructure Fitting Microstructure

Was not obtained previously

This location at the fitting, the structure is coarser

The difference in the HB while the structure is

INTERNAL TUBES HARDNESS MEASURMENTS

T6A1 323 288 325 282 315 307 81

f(1) 342 349 375 356 334 351 97

f(2) 345 320 332 295 340 326 90.5

f(3) 333 295 336 352 318 327 90.5

f(4) 326 343 344 314 342 334 92

f(5) 309 349 356 411 322 349 95.5

f(6) 329 331 314 363 355 338 93

1- Microstructural analysis show alteration in microstructure which usually observed in

NDT INSPECTOR APPROVED BY

Name Eng. Mohammed Gharieb Dr.Eng. Consultant: - Wael Hoziefa

Date 06/06/2023 06/06/2023

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