Hardness Testing

Reliance

Procedure for Hardness Testing

EPCMD-2-QM00-JEP-ME-005

00

17.12.2011

Issued for Implementation

PPP / PKD

PKS / EMK / KSS

SNS

Rev

Date

Revision

Prepared By

Checked By

Approved By

Reliance Contents 1. Purpose ………………………………………………………………………………………………………..3 2. Scope ………………………………………………………………………………………………...……....3 3. References …………………………………………………………………………………………………..3 4. Abbreviations and Terms ……………………………………………………………………………3 5. Responsibilities ……………………………………………………………………………………………4 6. Methodology ………………………………………………………………………………………………..4

EPCMD-2-QM00-JEP-ME-005 00 Confidential © Reliance. All rights reserved

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Reliance 1.

Purpose The purpose of this procedure is to define the methods to be followed for hardness testing of materials / welds.

2.

Scope This procedure covers the approved methods and equipment to be used for hardness testing during fabrication and erection of steel piping, equipment or any other product. This is applicable for all working at Reliance projects.

3.

References ASTM A956 - Standard test method for Leeb Hardness testing of Steel Products. ASTM A833 -

Standard practice for indentation hardness of metallic materials by comparison hardness testers

ASTM E10

4.

-

Test method for Brinell hardness of metallic materials

User Manual -

Integrated Hardness Tester TH-130, Time group

User Manual -

Digital Hardness Tester HLN 11A, Time group

User Manual -

Digital Hardness tester Dyna MIC, Krautkramer

User Manual -

Digital Hardness tester Equotip 3, Proceq

Abbreviations and Terms BHN

-

Brinell Hardness Number

CS

-

Carbon Steel

DCC

-

HAZ

-

Heat Affected Zone

HOD

-

Head of the Department

PWHT

-

Post Weld Heat Treatment

QMD

-

Quality Management Department

Document Control Center

EPCMD-2-QM00-JEP-ME-005 00 Confidential © Reliance. All rights reserved

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Reliance 5.

Responsibilities Construction Managers / Engineer in Charge are responsible for implementing this procedure in their area. HOD, QMD is responsible for maintaining this procedure. DCC is the custodian of this document

6.

Methodology Contractor’s Quality Control personnel shall be responsible for the execution of hardness testing in presence of Reliance QMD persons. Any one of the following testing methods described in clauses 6.1 or 6.2 may be adopted to check hardness.

6.1

Brinell Hardness Testing by Poldi Hardness Tester

6.1.1 Prior to testing, the area shall be ground / filed flat. Grinding shall be carried out without using excessive force. No overheating or burning shall be permitted. 6.1.2 Select the Poldi standard test bar having a BHN closest to the expected BHN of the piece. 6.1.3 Place the standard test bar between the ball and plunger. 6.1.4 With standard test bar inserted, place the Poldi tester vertically over the area to be checked, so that ball touches the ground surface. 6.1.5 Hit the plunger with a medium weight (4lb/2kg) hammer. The blow should be neither excessive nor too light and should be as vertical as possible. The blow will have two indentations – one on the standard test bar and the other on the test specimen. To minimize error, diameter of the indentation on the standard test bar should be max. 4.2 mm dia. 6.1.6 Using the microscope provided in the Poldi kit, measure the diameters of the indentations, both on the area under test and on the standard test bar. The diameters taken shall be the average of any elliptical indentations. 6.1.7 Refer the booklet provided with the Poldi kit to select the suitable table for material and its heat treatment condition. In the table, look up the column “Dia. of indentation on standard test bar” for the dia. of indentation actually obtained on the test bar. Then look up the row “Dia. of indentation on specimen” for the actual dia. of indentation obtained on the specimen / test surface. Where this column and row intersects, the Brinell Hardness Numbers

EPCMD-2-QM00-JEP-ME-005 00 Confidential © Reliance. All rights reserved

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Reliance can be read (lower reading). To get exact hardness of the test specimen, multiply the number with multiplying factor inscribed on the standard test bar. 6.1.8 All hardness impressions at one test location should have at least 6.4mm between their nearest edges. For practical consideration, we may include 10mm. 6.1.9 Hardness impressions to be made on only two adjacent sides of standard test bar. Replace indenter ball when it is out of round. 6.1.10 All results shall be recorded on Hardness Testing Inspection Report No. EPCMD-2-QM00-FMT-ME-015.

6.2

Digital hardness testing by rebound velocity method

6.2.1 The surfaces to be tested shall be smooth and desired area shall be prepared either by grinding or hand filing. Also, paint, scales, pits or other surface coatings if any shall be completely removed. 6.2.2 The test specimen shall have 5.0 mm minimum thickness and 5 Kg weight. At the time of taking hardness the specimen shall be rigid. 6.2.3 For thicknesses lower than 10 mm and pipe dia. up to 6”, the test surface shall be either directly supported or with in 300 mm from the support. For thickness above 10 mm and or pipe dia. above 6”, the hardness can be measured irrespective of its position/ support location. 6.2.4 Standard flat support ring shall be replaced with special support rings for convex or concave in case the test specimen radius is less than 30 mm (10mm, the above condition does not apply. b) On all AS, for thickness less than 10 mm, whenever result exceeds 210 HB, it shall be cross checked with Poldi tester and the greater of the two results shall be considered for further action/ disposition as per governing requirements. For thickness >10mm, the above condition does not apply.

6.3

No point shall be impacted more than once. The difference between two impacts shall not be less than 3 mm edge to edge.

6.4

Acceptance Criteria, Frequency of Tests & Reporting Acceptance criteria and frequency of tests shall be as per applicable Codes/ Standard/ Specifications / ITP’s. Reporting of all test results and acceptance / rejection shall be on Hardness Test Inspection Report Form no: EPCMD-2-QM00-FMT-ME-015.

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