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Quality Control Procedure

Hardness Testing Author:

Date:

Abani Bar Sr. NDT Tech

October 20, 2007

Responsible Management Approval: Nilesh Pathare Sr. NDT and CSWIP Inspection Head

Oct 20, 2007

Quality Approval: Sridhar Manja QAM, TCR Engineering Services, India

SOP Nr: Version (if not part of document or SOP number):

N/A QCP/TCR/HT/1.0 Rev. 0

Issue Date of this document:

March 6, 2013

Effective Date of this document:

March 6, 2013

Supercedes: Type:

Oct 20, 2007

New Controlled Copy

Signature:

Doc. Classification: Hardness Testing Version: 1.0 Rev. 0 Location: Middle-East, India

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Title: Hardness Testing

TABLE OF CONTENTS 1.

SCOPE

3

2.

DEFINITIONS

3

3.

REFERENCES

3

4.

RESPONSIBILITIES

3

5.

PERSONNEL QUALIFICATIONS

4

6.

EQUIPMENT

4

7.

PROCEDURE

4

8.

ACCEPTANCE CRITERIA

6

9.

SAFETY

6

10.

DOCUMENTATION AND REPORTING OF TEST RESULTS

6

Hardness Testing PROCEDURE

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Title: Hardness Testing

1.

SCOPE This procedure specifies the requirements for hardness testing of production welds. The purpose of this Quality Control Procedure is to address clause 4.9 “Process Control” of ISO 9002: 1994, to define the equipment and methods to be followed for hardness testing of materials / weldments.

2. DEFINITIONS HT: Hardness Testing PWHT: Post Weld Heat Treatment BHN: Brinell hardness number BHV: Brinell hardness Value HAZ: Heat Affected Zone NDT: Non Destructive Testing QAM: Quality Assurance Manager

3.

REFERENCES Latest revisions of the following documents shall be referred to in conjunction with this procedure: Codes and Standards ASME B313 Chemical Plant and Petroleum Refinery Piping, latest edition. AWS D1.1 Structural Welding Code ASME Boiler and Pressure Vessel Code, Section V, Nondestructive Examination ASNT Recommended Practice No. SNT-TC-1A, Personnel Qualification and Certification in Nondestructive Testing ANSI / ASNT CP 189, Standard for Qualification and Certification of Nondestructive Testing Personnel TCR Internal Documentation TCR-QMS: Quality Assurance Systems Manual TCR-HSE: TCR Safety Manual TCR Written Practice for training, qualification, and certification of NDT personnel

4. RESPONSIBILITIES TCR site in charge shall be responsible for the control, coordination and numbering of all items tested for HT as per the schedule received from client. TCR site in charge will ensure effective communication is maintained with the client with respect to the assigned HT Testing project. The NDT Controller delegated for the control and coordination of NDT activities shall issue the HT Inspector with a daily written list of welds ready for inspection. The HT Inspector shall be responsible for conducting and reporting the results of inspection is accordance with this present Procedure.

Hardness Testing PROCEDURE

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Title: Hardness Testing

5. PERSONNEL QUALIFICATIONS Only trained personnel shall undertake the operation and interpretation of recorded results to ensure that both the procedure and the work are implemented correctly in order to identify / verify the nominal material compositions. The following guidelines shall be used for the efficient and safe HT operations:  TCR Personnel: Selected on the basis of previous work experience.  Crew composition is normally composed of a Site-in-charge, and one or more HT technicians.  The customer will be provided opportunity to review the experience details of HT technicians.

6. EQUIPMENT Testing shall be carried out by using a TIME Inc. portable hardness tester, Model TH-130. The TIME Inc’s portable hardness tester’s method of operation is by measuring the impact and rebound velocities of an impact device, under spring loading, against the test piece. Hardness is measured in hardness number L and must be converted to Brinell Hardness Value (BHV). Due to the “pin-point” measurement made by the TIME Inc. precautions necessary to enable accurate testing are:  The test piece must be adequately supported.  For each hardness measurement 3 impact measurements are to be made and the results averaged.  Correction is required for impact angle.  For all testing detailed referenced should be made to the operating instructions for the equipment. Key parameters to be used are:  Impact device D  Set impact direction.  Set conversion to H.B.  Charge TIME Inc’s portable hardness tester by depressing charging tube.  Place impact device on test surface.  Trigger impact device.

7. PROCEDURE A. SURFACE REQUIREMENTS Prior to testing the area to be tested shall be prepared by grinding flush (in the case of butt welds enough area (spots) shall be ground to enable full hardness survey to be performed). Grinding shall be carried out without excessive use of force; no overheating or burning shall be permitted. Upon completion of grinding a further preparation shall be made using a rotary grit paper grinding wheel. No sharp edges shall be left on the area ground for Hardness testing. Grit standard shall be in accordance with the Manufacturer’s recommendation. Model

Degree of Smoothness RA Hardness Testing PROCEDURE

Abrasive Grain Size RT Doc. Ref. QCP-TCR-02 Issue 1 Revision 0 Confidential, Page 4 of 7

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Title: Hardness Testing

Time Inc D (TH-130)

2

10

280

Preparation by this method shall be made as close as possible to 90° (perpendicular) of the previous grinding as practicable.

B. EQUIPMENT PERFORMANCE CHECK Performance checks shall be carried out in accordance with the manufacturers instructions supplied with the equipment. Calibration: Time hardness Tester TH 130 shall be calibrated on the test block supplied with the instrument. The reading on calibration block is in “HLD” scale. While calibrating the equipment HLD measuring scale shall be selected. And during measuring Hardness of test objects the measuring scale shall be change to required scale like “HB, HRB, or HRC”. For test pieces less than 5Kg. they shall be supported or coupled with calibration block or object having weight more than 5Kg. Frequency of performance checks shall be: Test instrument used continuously At least once a day and the latest after 1000 impacts. Test instrument used periodically Before conducting the test

C. BRINELL HARDNESS TESTING METHOD Brinell hardness number shall be the required hardness value for all field testing. Testing shall be carried out on shop or field welds. Tests shall be performed after PWHT unless specified otherwise. Location of all tests shall be in the C.L. of weld metal and both side of Heat affected zones. Reporting of all test results and acceptance/ rejection shall be on Hardness Test Inspection Report. Only that portion of the Form which corresponds to the test method used needs to be filled out, the other test method shall be marked "N/A. Prior to test, the test area (work piece) shall, if required, be additionally supported. Tests areas shall be prepared. For each test area three impacts shall be carried out and the average of these shall be recorded. All results and averages shall be recorded on Hardness test Inspection Report. For each group of readings the difference in value shall not exceed 30. If it exceeds, surface has been adequately prepared to the required surface finish.

Hardness Testing PROCEDURE

check whether the

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Title: Hardness Testing Conversion from the measure hardness value to H.B is made automatically within the equipment. This converted value is then recorded as the measured hardness.

8. ACCEPTANCE CRITERIA Acceptance criteria of HT on weld joints will be as follows, with the Brinell Hardness Value Restrictions not exceed the following: Material Group P1 P3-P4 P5-P6

Maximum Brinell Hardness Value 235 BHN 225 BHN 241 BHN

Nonferrous materials and austenitic stainless steel welds will not require hardness testing. For P-No.3 through P-No.6 materials, hardness testing shall be conducted on 10% welds in each furnace heat treated batch and 100% of those which are locally heat treated. Hardness results shall not exceed the above mentioned values.

9. SAFETY Only trained personnel shall use this instrument.

10.

DOCUMENTATION AND REPORTING OF TEST RESULTS

Each inspection shall be reported together with the BHN and will contacting the following information  Client Name  PO / request no.  TCR job no.  Component and / or joint identification  Specification  Reference code or acceptance criteria  Test procedure  Dimensions and / or area of test  Material type and condition  BHN  Test technique  Test system  Test or access restrictions or remarks  Interpretation and test results  Technician name, qualification level and signature  Date of test Hardness Testing PROCEDURE

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Title: Hardness Testing

Encl: TCR-HT Form

Hardness Testing PROCEDURE

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