Aic HT 100 Hardness - Testing

AXIS INSPECTION LTD. No.
: AIC-HT-100
OPERATING PROCEDURE Issue : 1

(WORK INSTRUCTION)
HARDNESS TESTING PROCEDURE Rev. : 0
AXIS INSPECTION LTD.
OPERATING PROCEDURE
HARDNESS TESTING PROCEDURE
This document is the property of Axis Inspection Ltd. and must not be copied, loaned or information it contains be disclosed Page 1 of 17
to a third party without the written consent of Axis Inspection Ltd.
AXIS INSPECTION LTD. No. : AIC-HT-100

(WORK INSTRUCTION)
TABLE OF CONTENTS
Page
1 Scope 4
2 References 4
3 Application and extent of inspection 5
4 Equipment 6
5 Personnel Qualification 6
6 Surface preparation 7
7 Procedure 7
8 Acceptance Standard 10
9 Retest 12
10 Report 12
11 Attachment -1 Report format 13

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1.0 SCOPE
1.1 This procedure covers the minimum requirements of Hardness testing of welds, base
metal and other metallic materials in various product forms viz. forgings, castings, rolle
d products, machined components etc.
1.2 For the requirements not specified in this procedure, codes and standards or/and spec
ifications as shown in paragraph 2.0 shall be applied.
2.0 REFERENCES
2.1 ASME B 31.3, 2008 Edition Process Piping
2.2 NACE Standard RP -0472-2000 Methods and controls to prevent in service enviro
nmental cracking of carbon steel weldments in
Corrosive petroleum refining environments
2.3 NACE standard MR0175 Sulfide stress cracking resistant metallic materials
for oilfield equipments
2.4 NACE Standard MR0103 materials resistant to sulfide stress cracking in

corrosive petroleum refining environments
2.5 ASTM E-10 Standard test method for brinnel hardness of

metallic materials
2.6 JERES-W-010 Jubail Export Refinery Engineering Standard ,

Welding requirements for pressure vessels
2.7 JERES-W-011 Jubail Export Refinery Engineering Standard,

Welding requirements for on plot piping
2.8 ASTM E- 140 Standard Hardness conversion tables for metals
2.9 ASTM E-92 Standard test method for Vickers hardness of


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Metallic materials
2.10 ASTM E-110 Standard test method for indentation hardness of

metallic materials by portable hardness testers
2.11 ASTM E-833 Standard practice for indentation hardness of

metallic materials by comparison hardness testers
2.12 Instruction manual Telebrinnel potable hardness tester
2.13 Instruction Manual Krautkramer MIC 10 , Hardness tester
3.0 APPLICATION AND EXTENT OF INSPECTION
3.1 If hardness test is performed on completed welds it shall be made after final heat treat
ment unless otherwise specified by client.
3.2 Only weld deposits and Heat Affected Zone require testing unless otherwise specified
by the client. The hardness test of the HAZ shall be made at a point as near as practica
ble to edge of the weld.
3.3 Hardness test shall consist of at least one hardness measurements in weld metal and
HAZ which shall be taken on each longitudinal and circumferential weld seam and
each diameter of branch connection nozzle.
3.4 Weld deposits shall be tested on the side contacted by the process whenever
possible. If access to the process side is impractical, such as on piping or small-
diameter vessels, testing shall be done on the opposite side.
3.5 For vessel or tank butt welds, a minimum of one location per weld seam shall be
tested. Unless otherwise specified by the client, one test should be made for each 3m
(10 ft) 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.
3.6 Testing of fillet weld deposits should be done when feasible. The number of tests and

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locations required shall be approved by the client with paragraph 3.4 as a guide.
3.7 For piping welds, a percentage of butt welds shall be tested. A suggested minimum of
10% should be tested except the following case, unless otherwise specified by the
client.
3.7 100% of Hardness testing of the welds in the following service is required.
Sour water service (Defined as 690Kpa hydrogen partial pressure in the process
stream.), Wet H2S service (Defined as any process stream containing liquid water and
more than 50 ppm pl H2S or H2 S plus CN – also called “wet H2S service”.) and welds
after local PWHT.
4.0 EQUIPMENT
4.1 This procedure identifies the below equipments for the hardness testing
4.1.1 Brinnel Hardness Testing – Telebrinneller portable hardness tester or

equivalent
4.1.2 Vickers Hardness Testing – Krautkramer MIC -10 or equivalent (UCI method)
4.2 The area of hardness test shall not be destructed by the impact of the hardness tester.
4.3 The Telebrineller equipment shall not be used where the weld geometry is not suitable
to conduct the test.
5.0 PERSONNEL QUALIFICATION

5.1 Personnel performing hardness testing shall have received adequate training in
hardness testing principles ,test equipments and test requirements.
6.0 SURFACE PREPARATION
6.1 The weld reinforcement shall be ground flat and smooth for an area large enough to
conduct the test, but in no circumstance shall the thickness of the weld be reduced to
less than that of the thickness of the base metal.
6.2 The HAZ (heat affected zone) surface shall be prepared by grinding or brushing as app
ropriate. Care is required in the use of power tools to avoid overheating the test surface

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during its preparation. Do not take readings on scaled or discolored areas.

6.3 The section to be tested recommended to be at least 1/4 inch thick and adequately sup
ported to prevent any movement or deflection during the hammer blow. All tests should
be made at least 1/4 inch from the nearest edge.
6.4 The surface finish must be such that the edges of an impression are adequately
defined when viewed through the Brinell microscope.
6.5 On curved surfaces, grind a flat spot large enough to contain the test impression.
7.0 PROCEDURE
7.1 Test procedure for Telebrinneller Equipment
7.1.1 Select the Telebrineller Test Bar in such a way that the Brinell hardness number
(BHN) of the Test Bar is no more than 15% harder or softer than the BHN of the
tested part. The BHN of a Test Bar shall be etched on both ends. If the
approximate BHN of the part is completely unknown, you may use any Test Bar
to determine an approximate BHN. Then, if necessary, the accuracy may be
refined by retesting with a Bar within the + or - 15% range.
7.1.2 Inserting the Test Bar: Depress the button on the spacer block Assembly (7) of
the Bar Holder and slide it forward to the end of the slot nearest the Anvil (2).
Release the Button so it locks into the first detent. Insert a Test Bar (1) into the
Bar Holder until it butts against the Spacer Block and proceed with making a
test as described in the next three sections. After completing the first test, index
the Spacer Block Assembly back one notch and reinsert the Test Bar in the
same orientation. Continue testing and indexing until 10 impressions have been
made then return the Spacer Block Assembly to the front detent. Insert the
opposite end of the Bar into the Bar Holder and repeat the process for 10 more
tests. Follow the same procedure for the other face of the Test Bar.

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7.1.3 Making the Impressions: Place the Bar Holder on the surface to be tested with
the anvil (2) above the test location. If the Rubber Rear Piece (4) cannot rest
on the same surface, it must be supported by hand so the Bar Holder remains
parallel to the test surface. Using a hammer weighing 1.4- to 2.3-kg (3.0- to 5.0-
lb) strike a sharp blow squarely on the Anvil. Pull the hammer back on the
rebound so it does not bounce on the Anvil which can cause secondary
Impressions. To keep the blow square on the Anvil, so the Bar Holder does not
move laterally and produce smeared impressions, grip the hammer handle
close to the head and use a perpendicular lunching motion rather than an arced
swing. The force of the blow is not a critical factor but it is advisable that it be
regulated to make impressions in the 3 mm to 4 mm range. On harder materials
above 450 BHN) smaller impressions will be satisfactory.
7.1.4 Measuring the impressions: Place the Brinell Microscope over the impression in
the test specimen (6). If ambient light is insufficient, use the penlight on the
scope to illuminate the impression. If necessary, screw the top, move up or
down until, when looking through the scope, the measuring scale and the
impression are both in sharp focus. Rotate the upper part of the scope until the
scale is crosswise to any surface; striations and position the scope so the 1 mm
graduation is over one edge of the impression. Observe 1e scale at the
opposite side of the impression to measure the diameter. Note that the scale is
graduated in .1 mm increments and measurements may be estimated to the
nearest .05 mm. After recording the diameter of the impression in the test
specimen, pull the Telebrineller Test Bar far enough from the Bar Holder to
expose the corresponding impression and repeat the above process to
determine its diameter.

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7.1.5 Determine the Brinell Hardness number by using the slide calculator supplied
by the manufacturer or by using Equation:
H w = H b × (Db / Dw)²
Where:
Hw = Hardness of Weld;
Hb = Hardness stamped on the test bar;
Db = Diameter of impression in the test bar; and
Dw = Diameter of impression in weld.
7.1.6 Substract the determined weld hardness from the test bar hardness. The
difference should be -10 to +50; if not, discard the reading and do a retest with
a new test bar. The new test bar should have hardness closer to the weld
hardness to improve the reading accuracy.
7.2 Test procedure for MIC-10

7.2.1 Select the probe model based on guidelines given in below table
Test Load Probe Model Applications

98 N(10Kgf) MIC 2010 Forgings, welds& HAZ
MIC 205 Induction or Carburized mechanical parts
MIC 205 L Measurement in grooves, gear tooth flanks
50 N (5 Kgf) and roots
MIC 205 S Turbine blades , inside tubes with dia > 90
mm
MIC 201 Ion Nitrided stamping dies and

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molds,forms,presses,thin walled parts

10 N( 1 Kgf) MIC 201L Bearings, Tooth flanks
MIC 201 S Turbine blades , inside tubes wth dia > 90
mm
7.2.2 Hardness values shall be made in short time measurement mode using the
conical probe attachment when handheld probes are used for measurements.
When the equipment has to be used with defined dwell time a cylindrical probe
attachment shall be used with a test support.
7.2.3 Connect the appropriate probe and turn on the instrument .Select the
appropriate hardness display scale. If measurements are made on low alloy
steels the equipment is preprogrammed with the calibration value for such
steels.
7.2.4 If measurement has to be made in any other material (other than low alloy
steels) calibration has to be performed on a sample of the material to be tested
with known hardness value. Carry out a measurement set of 5 single
measurements on the sample material and the displayed reading is adjusted
until it matches with the known hardness reading .The instrument automatically
calculates the calibration value and displays it. Once calibrated the equipment
can be proceeded for inspection.
7.2.5 For measurements position the probe tip vertically on to the surface of the test
material and once the equipment display indicates probe contact, it shall be
pressed down to the limit for about 1 second. An acoustic signal will indicate the
end of measurement and the instrument displays the measured value.
7.2.6 Make at least 5 readings on adjutants areas and the average shall be accepted
as the hardness value.
7.2.7 Pipe fixed-vertical up-progression(5G/PF & 6G/H-LO45): Weld zone(Weld
Metal/HAZs) hardness test location shall performed be at 0o (overhead welding
position); as per the here below mentioned sketch.
7.2.8 Ferrite –austenitic Stainless steel (duplex and super duplex) weld zone ( weld
metal/hazs) hardness test location shall be performed at 270 deg. Or 90 deg.
And 0 deg.(overhead welding position); as per here below mentioned sketch.

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Sketch-1
7.2.9 Pipe fixed - vertical down progression (5G/Pg & 6G/J-LO45) : weld zone (Weld
Metal/HAZs) hardness test location shall be performed at 180deg. ( flat
position) and 0 deg. ( overhead welding position); as per the here below
mentioned sketch.
7.2.10 Ferritic –Austenitic stainess steel (Duplex and Super-Duplex) weld zone(
Weld metal/HAZs) hardness test location shall be performed at 180 deg.(
position) and 0 deg.( overhead welding position); as per the below mentioned
sketch.

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7.2.11 Rotating pipe –flat position welds (1G/PA):hardness test shall be performed at
two location, the welding start/stop location and at a location 180 deg. Away
from the start/stop locations.
7.2.12 Weld metal hardness indentation shall be done on a surface, as stated in para
7.1, in the centre of the weld.
7.2.13 Weld metal hardness indentation shall be done on a surface prepared, as

stated in 7.1 & etched using suitable solution to bring out the microstructure,
identifying the HAZz side and Fusion line. Indentation shall be located, as
much as possible ,in both HAZa-CGZ ( Heat affected zones-Coarse
Grain Zone) side, as per the here below sketch;

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7.3. Additional production hardness Test requirements for Grade 91 steel.

Production hardness test shall be performed, after PWHT, on parent metal, Weld Metal
and heat affected Zone.
7.3.1 Weld metal hardness indentation shall be done on a surface, as stated in para
7.1, in the centre of the weld.
7.3.2 Weld metal hardness indentation shall be done on a surface prepared, as

stated in 7.1 & etched using suitable solution to bring out the microstructure,
identifying the HAZz side and Fusion line. Indentation shall be located, as much

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as possible ,in both HAZa-CGZ ( Heat affected zones-Coarse Grain Zone) side,
as per the here below sketch;
7.3.1. Brinnel Hardness Testing – Telebrinneller portable hardness tester or

equivalent.
8.0 ACCEPTANCE STANDARD
8.1 Hardness tested components shall be evaluated as per the client/ contract
specification.
8.2 If no acceptance criteria is specified by the customer, then table 1 and Table 2 below
may be used as guidelines for reporting test results on welds. Weld deposits and HAZ
areas found to exceed the maximum hardness criteria given in Table 1 or Table 2
below are unacceptable and shall be reported to the client. The hardness limits shall
be:
8.3 For Hardness testing for SATORP – JERP, acceptance criteria specified in Table 3
shall be followed for production welds.

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Table 1 Hardness limits for Production weld Hardness tests( as per JERES- W -011)
Material Maximum
Group Hardness
P- 1 200 BHN
P-3 225 BHN
P- 4 225 BHN
P-5A, B, C 241 BHN
P-6 241BHN
8.4 Table 2 Hardness limits as per NACE MR 0103 -2003

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8.5 Table 3 : Hardness limits as per JERES-W-011
Material Group Max hardness limit

P-1 200 BHN
P-3 225 BHN
P-4 225 BHN
P-5 Gr-1** 225 BHN
P -5 Gr 2 238 BHN
** For 9% Cr material -9Cr-1Mo 235 BHN is the maximum limit
8.6 For austenitic stainless steel, hardness testing values for welds, HAZ and base
material shall be below 237 BHN (22 HRC) for sour services.
9.0 RETEST
9.1 If any hardness reading exceeds the specified limit by no more than 10 BHN, then
minimum of 3 additional tests on the adjacent areas shall be made near the original
high reading. If all three (3) retests are below the specified limits, then the joint is
acceptable. If any of the three additional test results are not in the permitted range,
then the weld/ HAZ shall be considered unacceptable.
9.2 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.
10.0 REPORT
10.1 Report all hardness readings in the attached format AXIS-HT-139 Rev.00 and
distribute the copies to the client as required.

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APPENDIX – I
Sample Report Format

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AXIS INSPECTION LTD. No.

OPERATING PROCEDURE Issue : 1

HARDNESS TESTING PROCEDURE Rev. : 0

AXIS INSPECTION LTD.

HARDNESS TESTING PROCEDURE

OPERATING PROCEDURE Issue : 1

HARDNESS TESTING PROCEDURE Rev. : 0

3 Application and extent of inspection 5

11 Attachment -1 Report format 13

OPERATING PROCEDURE Issue : 1

HARDNESS TESTING PROCEDURE Rev. : 0

2.1 ASME B 31.3, 2008 Edition Process Piping

2.4 NACE Standard MR0103 materials resistant to sulfide stress cracking in

2.5 ASTM E-10 Standard test method for brinnel hardness of

2.6 JERES-W-010 Jubail Export Refinery Engineering Standard ,

2.7 JERES-W-011 Jubail Export Refinery Engineering Standard,

2.8 ASTM E- 140 Standard Hardness conversion tables for metals

2.9 ASTM E-92 Standard test method for Vickers hardness of

OPERATING PROCEDURE Issue : 1

HARDNESS TESTING PROCEDURE Rev. : 0

2.10 ASTM E-110 Standard test method for indentation hardness of

2.11 ASTM E-833 Standard practice for indentation hardness of

2.12 Instruction manual Telebrinnel potable hardness tester

2.13 Instruction Manual Krautkramer MIC 10 , Hardness tester

3.0 APPLICATION AND EXTENT OF INSPECTION

OPERATING PROCEDURE Issue : 1

HARDNESS TESTING PROCEDURE Rev. : 0

4.1.1 Brinnel Hardness Testing – Telebrinneller portable hardness tester or

5.0 PERSONNEL QUALIFICATION

6.0 SURFACE PREPARATION

OPERATING PROCEDURE Issue : 1

HARDNESS TESTING PROCEDURE Rev. : 0

during its preparation. Do not take readings on scaled or discolored areas.

7.1 Test procedure for Telebrinneller Equipment

OPERATING PROCEDURE Issue : 1

HARDNESS TESTING PROCEDURE Rev. : 0

OPERATING PROCEDURE Issue : 1

HARDNESS TESTING PROCEDURE Rev. : 0

Hb = Hardness stamped on the test bar;

Db = Diameter of impression in the test bar; and

Dw = Diameter of impression in weld.

7.2 Test procedure for MIC-10

Test Load Probe Model Applications

OPERATING PROCEDURE Issue : 1

HARDNESS TESTING PROCEDURE Rev. : 0

molds,forms,presses,thin walled parts

OPERATING PROCEDURE Issue : 1

HARDNESS TESTING PROCEDURE Rev. : 0

OPERATING PROCEDURE Issue : 1

HARDNESS TESTING PROCEDURE Rev. : 0

7.2.13 Weld metal hardness indentation shall be done on a surface prepared, as

OPERATING PROCEDURE Issue : 1

HARDNESS TESTING PROCEDURE Rev. : 0

7.3. Additional production hardness Test requirements for Grade 91 steel.

7.3.2 Weld metal hardness indentation shall be done on a surface prepared, as

OPERATING PROCEDURE Issue : 1

HARDNESS TESTING PROCEDURE Rev. : 0

7.3.1. Brinnel Hardness Testing – Telebrinneller portable hardness tester or

8.0 ACCEPTANCE STANDARD

OPERATING PROCEDURE Issue : 1

HARDNESS TESTING PROCEDURE Rev. : 0

8.4 Table 2 Hardness limits as per NACE MR 0103 -2003

OPERATING PROCEDURE Issue : 1