9.10 HARDNESS TESTING

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

Hardness Testing

Hardness Testing

Hardness Testing

Hardness Testing

Hardness Testing

Weld Macro

Weld Macro

Hardness Testing

Hardness Testing

Hardness Testing

Portable Hardness Testing

Portable Hardness Testing

Portable Hardness Testing

Portable Hardness Testing

Portable Hardness Testing

Portable Hardness Testing

Portable Hardness Testing

Portable Hardness Testing

Portable Hardness Testing

Portable Hardness Testing

Portable Hardness Testing

Portable Hardness Testing

Portable Hardness Testing

Portable Hardness Testing

Portable Hardness Testing

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

Pressure Testing

Pressure Testing

Pressure Testing

Pressure Testing

Pressure Testing

Pressure Testing

Pressure Testing

Pressure Testing

Pressure Testing

Pressure Testing

Pressure Testing

Pressure Testing

Pressure Testing

Pressure Testing

Pressure Testing

Pressure Testing

Pressure Testing- Incidence

Pressure Testing- Incidence

Pressure Testing- Incidence

Pressure Testing- Incidence

Pressure Testing- Incidence

Pressure Testing- Incidence
http://www.wermac.org/misc/pressuretestingfailure2.html

Pressure Testing- Incidence

Pressure Testing- Incidence

Pressure Testing- Incidence

Pressure Testing- Risk

Pressure Testing- Risk

Pressure Testing- Risk

Pressure Testing- Incidence

Pressure Testing- Risk

Pressure Testing- Incidence

Pressure Testing- Risk

Pressure Testing- Risk

Pressure Testing- Risk

Pressure Testing- Risk

Pressure Testing- Risk

Pressure Testing- Risk

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. Customer or project.
b. Contract number or site.
c. Date of inspection.
d. Component/system.
e. Subassembly/description.
f. Weld identification.
g. Weld type/material/thickness.

9.12.1.2 Inspection Information
a. Date of inspection.
b. Procedure number.
c. Examiner.
d. Examiner certification information.
e. Inspection method.
f. Visual aids and other equipment used.
g. Weld reference datum point.
9.12.1.3 Inspection Results
a. Inspection sheet number.
b. Inspection limitations.
c. Inspection results.
d. 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.