SOGEC Hardness Testing Procedure Procedure No:

Rev No: 00 Brinell Hardness Tester ABK-BHN-0002

Date: 04/08/2015

Sogec NDT
Specialized Oil & Gas Engineering Co. Ltd.

Client: ABDULLAH A. AL-BARRAK & SONS CO.

Subject: HARDNESS TESTING PROCEDURE

Project: SAFCO

00 04/08/2015 BT SM
OE OM
REV.NO. COMMENTS DATE PREPARED CHECKED APPROVED
BY BY BY

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SOGEC Hardness Testing Procedure Procedure No:
Rev No: 00 Brinell Hardness Tester ABK-BHN-0002
Date: 04/08/2015

REVISION RECORD

Revision No: Date Description Name

00 04/08/2015 Standard Procedure SM

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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 REPORTS & RECORDS

12.2 Attachments
12.2.1 Hardness Test reports

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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:

ASTM A-833 Standard Practice for Indention Hardness of Metallic

Materials by Comparison Hardness Tester.
ASTM E-10 Standard test Method for Brinell Hardness of Metallic Materials.
ASTM Standard E 110 Standard Test Method for Indention Hardness of
Metallic Materials by Portable Hardness tester.
SAES-W-011 Welding Requirements for On-Plot Piping.
SAES-W-010 Welding Requirements for Pressure Vessels
RP0472 NACE Standard Recommended Practices.
Sogec Safety Policy.
ASME B31.3 Process Piping.
S-PM-G000-1520-0006, Specification for welding procedure approval and
weld status with NDT tracking
S-PM-G000-1520-0005, Non conformity control procedure
S-PM-G000-1520-0010, Welding requirement for pressure vessel
S-PM-G000-1520-0011, Welding Requirements for Piping
SAIC-W-012, welding requirement for pipelines.
SAIC-W-2014

3.0 DEFINITIONS

3.1 Brinell Hardness Test a comparison indention hardness test using

calibrated machine/equipment, into the material under test and measuring
the impression diameter and comparing with a measurement in a known
BHN test bar.

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:-

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SOGEC Hardness Testing Procedure Procedure No:
Rev No: 00 Brinell Hardness Tester ABK-BHN-0002
Date: 04/08/2015

(Diameter of Impression in BHN Test Bar)

( Diameter of Impression in metal )

x (BHN of Test Bar) = BHN of Specimen Metal

3.3 Verification checking or testing to assure conformance with the required

material specification.

3.4 Calibration determination of the values of the significant parameters by

comparison of values indicated by reference instrument or reference
Standards.

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.

5.0 PERSONNEL RESPONSIBILITIES

5.1 The technician shall be responsible for the following:

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

Final review of reports shall be performed by clients inspector.

6.0 EQUIPMENT & MATERIAL

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

6.2 Portable MIC 10

MIC 10 is applied where the telebrinell hardness tester cannot be applied on weld
areas due to lack of proper access & impractical weld geometries as in fillet weld
socket joints, branch connection, O-let welds, 1 and below butt welds.

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SOGEC Hardness Testing Procedure Procedure No:
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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

EQUOTIP is applied for applications in which standard indentation hardness testing

is either not feasible or not economical. The hardness tester EQUOTIP 3 comprises
an indicating device and an impact device. It is based on the rebound hardness
testing method according to Leeb. It is used for testing the hardness of all material
surfaces over a large range of hardness quickly and independently.

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.

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SOGEC Hardness Testing Procedure Procedure No:
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7.0 CALIBRATION

Selection of BHN Test Bar.

The test bar used for calibration shall be of a similar BHN as expected in the
specimen material. For practical purposes of this Procedure, the BHN value of Test
Bar shall be selected based on the maximum BHN permitted by relevant Codes
and Standards as shown in following Table:

Maximum Brinell Hardness

Item Material Services: Wet Sour, Amine, Other
Caustic Services
1 P1 200 225
2 P3, P4 225 225
3 P5 225 235
G1,P6,P7
4 P5 G2 238 238
5 P11 225 225

7.1 For all class items, the hardness shall be carried out according to SAES-W-
011 Para. 14 and reported to client.

7.2 Extent of Testing

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.

7.3 Calibration Reading on Test Bar

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.

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SOGEC Hardness Testing Procedure Procedure No:
Rev No: 00 Brinell Hardness Tester ABK-BHN-0002
Date: 04/08/2015

7.4 Equipment shall be calibrated by the manufacturer at factory prior to

dispatch or whenever repaired by a certified independent laboratory and
approved by CLIENT. As long as the repeatability of the readings on a
Standard hardness test bar is satisfactory, the factory calibration of the
instrument is considered to be valid.

8.0 SURFACE CONDITION

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.

9.0 HARDNESS TESTING PROCEDURE

9.1 TELEBRINELLER Hardness Tester:

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:
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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

9.1.8 Inspection tests of the equipment will be as per the manufactures

instructions
If test instrument used continuously, test at least once a day or after 1000
impacts. The instrument will be tested in the same position as intend for
production testing. If instrument used only periodically, test before and after
conducting test.

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

9.2 MIC 10 Hardness Tester

9.2.1. Accessories
a. PROBES: The probe shall be MIC 205 with test load 50 N (5Kgf).
b. CALIBRATION ACCESSORIES: MIC 10 portable kits 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.

9.2.2. Performance Check

The performance check controls the mechanical and electronic functions of
the impact device and the indicating unit. It is accomplished by measuring
the hardness value of the standard test block applicable to the particular
type of impact device.

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SOGEC Hardness Testing Procedure Procedure No:
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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

9.2.3. Testing Process

a. Operate the equipment as per the instruction given in the manufacturers
operating manual (Attachment-2).
b. Number of impacts per measuring area
Each measuring area shall be tested by at least 3-5 impacts.
Any one point shall not be impacted more than once
If the range within the same measuring area exceeds 10%, then
check whether the surface of the sample has been adequately
ground or whether the sample yields or flexes during the test impact.

9.3 EQUOTIP Hardness Tester:

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.

The performance check of the unit should be carried out as follows:

In the case of continuous operation, at least once a day or at least after

every 1,000 impacts
In the case of infrequent operation, before the beginning and at the end of
a test series

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SOGEC Hardness Testing Procedure Procedure No:
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The performance check is done by measuring the hardness value L on the

test block.
Clean the impact device.
Carry out impacts on a test block at an interval of 3-5 mm (approx. 3-5
impacts).
Read the mean L and compare it with the hardness value as marked on the
test block.

9.3.3. Testing Process

a. Hold the impact device and place it firmly on the test surface.
b. Hold the probe until the beep sound.
c. Then gradually release the probe
d. Hardness value will be displayed on the device screen.
e. Carry out at least 3 to 5 impacts at spaces of at least 3 to 5 mm at each
measuring point and use the average of the individual values.

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)

10.5 Hardness results shall not exceed the following

a. 200 HB for P No1 material for sour service applications or service required
PWHT.
b. 225 HB for P No10(A, B, C, F)
c. 225 HB for P4 and P5 Gr1 material (For 9% Cr material 9 Cr 1Mo, 235 HB
is the maximum limit)
d . 238 HB for P No5 Gr2 material
e . 225 HB for P N11 material
f . 248HB for P5B for 9cr-1Mo-V. Gr. (F61, P91, WP91, Gr.9, & C12A)

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SOGEC Hardness Testing Procedure Procedure No:
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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

a. For vessels requiring PWHT

b. Vessels of P No. 3, 4, 5, 9 or 11 materials.

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 REPORTS & RECORDS

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

12.2.1 Hardness Test Report

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SOGEC Hardness Testing Procedure Procedure No:
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Date: 04/08/2015

ATTACHMENT -I

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