9.10 HARDNESS TESTING
9.10 HARDNESS TESTING Hardness testing of the weld and HAZ is often required to assure the welding process and any PWHT resulted in an acceptably “soft� result. Testing production welds and HAZ requires test areas to be ground flat or even flush with the base metal to accommodate the hardness testing instrument in the area of interest. The HAZ can be difficult to locate and is often assumed for testing purposes to be just adjacent to the toe of the weld. Testing coupons for a PQR is easier for the coupon is cross-sectioned and etched to identify the weld, fusion line and HAZ. API RP 582 details hardness test requirements for PQRs and production welds. Hardness testing of production welds often utilizes portable equipment. Field measurements tend to have greater variability and so additional measurements may be required to verify results. However, hardness testing performed as part of the PQR will use laboratory equipment where greater accuracy is possible.
Welding Guidelines for the Chemical, Oil, and Gas Industries API RECOMMENDED PRACTICE 582 SECOND EDITION, DECEMBER 2009
API 582- Vickers Hardness Test Profile
Vickers Hardness
Hardness Testing
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Weld Macro
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Portable Hardness Testing
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9.11 PRESSURE AND LEAK TESTING (LT) Where a hydrostatic or pneumatic pressure test is required, the inspector shall adopt code and specification requirements relevant to vessels or piping. API Standards 510 and 570, API RP 574, and ASME B31.3 provide guidance on the application of pressure tests. Pressure tests should be conducted at temperatures appropriate for the material of construction to avoid brittle fracture. Codes and most specifications do not indicate the duration of pressure tests. The test must be held long enough for a thorough visual inspection to be completed to identify any potential leaks. Typically, a pressure test should be held for at least 30 minutes. The inspector should be aware of the effect of changing temperature of the test medium has in causing either an increase or decrease of pressure during the test period.
Pressure Testing- Safety First
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Pressure Testing- Incidence
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http://www.wermac.org/misc/pressuretestingfailure2.html
Pressure Testing- Incidence
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Pressure Testing- Risk
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Pneumatic pressure tests Pneumatic pressure tests often require special approvals and considerations due to the amount of stored energy in the system. Where pneumatic testing is conducted, the inspector should verify safe pressure-relieving devices, and the cordoning off of test areas to exclude all but essential personnel. The inspector should monitor the pressure at the maximum test level for some time before reducing pressure and performing visual inspection. This safety precaution allows time for a potential failure to occur before the inspector is in the vicinity.
Leak testing Leak testing may be required by code or specification to demonstrate system tightness or integrity, or may be performed during a hydrostatic pressure test to demonstrate containment on a sealed unit such as a pressure vessel. ASME Section V, Article 10, addresses leak testing methods and indicates various test systems to be used for both open and closed units, based upon the desired test sensitivity.
Direct pressure bubble test One of the most common methods used during hydrostatic testing is the direct pressure bubble test. This method employs a liquid bubble solution, which is applied to the areas of a closed system under pressure. A visual test is then performed to note any bubbles that are formed as the leakage gas passes through it. When performing the bubble test, some items of concern include; -
the temperature of surface to be inspected, pre-test and post-test cleaning of the part to be inspected, lighting, visual aids and the hold time at a specific pressure prior to application of the bubble solution.
Typically, the area under test is found to be acceptable when no continuous bubble formation is observed. If the unit under pressure is found to have leakage, it should be depressurized, the leaks repaired as per the governing code, and the test is repeated.
A wide variety of fluids and methods can be used, dependent on the desired result. Considerations for system design limitations may prevent the most common type of leak test using water. Drying, hydrostatic head, and support limitations should be addressed before water is used. The required sensitivity of the results may also lead to a more sensitive leak test media and method.
Bubble Leak Test- Vacuum Box
Bubble Leak Test- Vacuum Box
Leak Testing- Ultrasonic Leak Detection
Leak Testing- Sensitive Leak Test
9.12 WELD INSPECTION DATA RECORDING 9.12.1 Reporting Details Results of the weld inspection should be completely and accurately documented. The inspection report, in many cases will become a permanent record to be maintained and referenced for the life of the weld or part being inspected. Information that might be included in an inspection report is listed in 9.12.1.1 through 9.12.1.3. 9.12.1.1 General Information a. b. c. d. e. f. g.
Customer or project. Contract number or site. Date of inspection. Component/system. Subassembly/description. Weld identification. Weld type/material/thickness.
9.12.1.2 Inspection Information a. b. c. d. e. f. g.
Date of inspection. Procedure number. Examiner. Examiner certification information. Inspection method. Visual aids and other equipment used. Weld reference datum point.
9.12.1.3 Inspection Results a. b. c. d.
Inspection sheet number. Inspection limitations. Inspection results. A description of all recordable and reportable indications.
e. For each indication: I. Indication number. II. Location of indication (from both weld reference datum and centerline). III. Upstream or downstream (clockwise or counterclockwise) from an established reference point. IV. Size and orientation of indication. V. Type of indication (linear or rounded). VI. Acceptable per the acceptance standards of the referencing code. VII. Remarks or notes. VIII.Include a sketch of indication. IX. Reviewer and level of certification. X. Reviewers comments. 9.12.2 Terminology When reporting the results of an inspection it is important to use standard terminology. Examples of standard terminology are shown in Tables 8, 9, and 10.