SAUDI ARAMCO ID/PIEU-15-July-2018-REV. 2018.05.00(Standards Cutoff - May 31,2018) Rev.2018.05.

00 31-May-18
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Hardness Testing Procedure - All Applications
SAIC-W-2012 15-Jul-18 WELD-
(Plant Piping, Pipelines, Vessels & Tanks)
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.

LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.

SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

A GENERAL PROCEDURE REQUIREMENTS

Production Hardness Testing Info (Weld reporting/tracking) shall be

reported in an e-format (Excel, Access, PDF or similar). Data
Management & Tracking System (Database) that must be SA approved
SAEP-1160,
A1 prior to start of work.
Para. 5.1
Note: For fewer than 500 groove/butt weld joints, contractor may use
hardcopy tracking system with approval of SA Insp Dept.using applicable
SATR for Hardness Test & SATR-W-2008 Weld Summary Report.

Database for Welding (& Hardness Testing) covers two types of welds for
either pressure piping (Plant, Pipelines) or field-erected pressure vessels
and API storage tanks:
SAEP-1160,
A2 A) Full penetration groove & butt weld hardness tests are
Para. 6.1
tracked
B) Socket & Fillet welds (Includes "other" weld or components specified
for Hardness Testing).

Procedure details criteria for weld identification & selection of welds to be

Hardness Tested & responsibilities (per design):
SAEP-1160,
A) HT Random Sampling reqmts for
Table
A3 specific production welds. B) HT
under Para 6.1,
of PWHT welds (both Service and thickness considerations)
Design information must reflect actual data and
changes can occur during evolution of the project.

Procedure covers HT or repairs. Repair welds in cast, forged, or plate

components shall be hardness tested, as specified in paragraph 2.2.7.7, NACE SP0472,
A4
Para 2.2.7.7

Procedure addresses:
1) Hardness testing using Portable TeleBrinell Hardness Tester in
accordance with ASTM E 10 NACE SP0472
A5 2) Hardness testing using comparison hardness tester in accordance with Para 2.2.7.3
ASTM A 833

Procedure specifies
Portable Telebrinell Hardness Tester (Method) primary equipment for
hardness test for full penetration groove and butt welds accessible by NACE SP0472,
equipment. Para 2.2.7.3
A6
NOTE: SAES-W-011
If telebrinell hardness tester can not be applied due to the weld geometry Para 14.5
then alternative hardness tester may be used after approval by CSD
welding engineer

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SAUDI ARAMCO ID/PIEU-15-July-2018-REV. 2018.05.00(Standards Cutoff - May 31,2018) Rev.2018.05.00 31-May-18
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Hardness Testing Procedure - All Applications
SAIC-W-2012 15-Jul-18 WELD-
(Plant Piping, Pipelines, Vessels & Tanks)
Attachment 1

ASME B31.3 Section 331.1.7 Hardness Tests (Mandatory). Hardness tests of production welds and of hot bent and hot formed piping are intended to
verify satisfactory heat treatment. The hardness limit applies to the weld & the heat affected zone (HAZ) tested as close as practicable to the edge of
the weld. (a) Where a hardness limit is specified in Table 331.1.1, at least 10% of welds, hot bends, and hot formed components in each furnace heat
treated batch and 100% of those locally heat treated shall be tested. (b) When dissimilar metals are joined by welding, hardness limits specified for the
base and welding materials in Table 331.1.1 shall be met for each material.

Saudi Aramco: Company General Use

ASME B31.3 Section 331.1.7 Hardness Tests (Mandatory). Hardness tests of production welds and of hot bent and hot formed piping are intended to
verify satisfactory
SAUDI ARAMCO heat treatment. The
ID/PIEU-15-July-2018-REV. hardness limitCutoff
2018.05.00(Standards applies to31,2018)
- May the weld & the heat affected zone (HAZ) tested as close
Rev.2018.05.00 as practicable to the edge of
31-May-18
the weld. (a) Where a hardness limit is specified in Table 331.1.1, at least 10% of welds, hot bends, and hot
SAIC NUMBER formed
DATE components
APPROVED in each furnace heat
QR NUMBER
SAUDI
treated batchARAMCO
and 100% of those INSPECTION
locally heat treatedCHECKLIST
shall be tested. (b) When dissimilar metals are joined by welding, hardness limits specified for the
base and welding materials in Table 331.1.1 shall be met for each material.
Review Hardness Testing Procedure - All Applications
SAIC-W-2012 15-Jul-18 WELD-
(Plant Piping, Pipelines, Vessels & Tanks)

Attachment 2 - ASTM A 833 – 08a

Portable Brinell Hardness Testing (BHT) of Welds
1. Finish—When necessary, the surface on which the impression is to be made shall be filed, ground, machined, or polished
with abrasive material so that the edge of the impression shall be defined clearly enough to permit the measurement of the diameter
to the specified accuracy. Take care to avoid overheating or cold working the surface. Sufficient metal shall be removed to eliminate
decarburized metal.

2.Assemble the comparative test bar into the apparatus making sure a minimum distance of no less than 5 mm will exist
between diameter of the impression to be made and any other indentations on the face. Minimum distance of the indentation
diameter from the edge of the part tested shall be 12.5 mm.
3. If the apparatus is equipped with a presetting bar stop, ensure the fixture is properly in place.
4. Ensure that the hardness test block is flat on the test surface.

5.Apply the impact load using a 1 to 21⁄4kg (2 to 5 lb) hammer. It is essential to apply a well guided, short blow in order to avoid a rebound and thus a
double blow that may produce an erroneous result by damaging the sharp edge of the ball impression.

6.Impression Diameter—The diameter of the impression produced on the comparative test bar should not exceed 4.2 mm. If
a larger impression is produced, the comparative bar may give way laterally and the test result may be in error. In this case the
use of the 1500-kg load should be considered (see ASTM A 833-08, para6.2).

7. Measurements— Two diameters of each impression at right angles to each other shall be measured to within 0.05 mm and
their mean value used as the basis for subsequent calculations.
If the two diameter measurements differ by more than 0.1 mm, the readings shall be discarded in accordance with Test
Methods and Definitions A 370, and the test repeated.

8. Determination of Part Hardness—Employing the calibration device or mathematical equation supplied by the manufacturer
for the apparatus, determine the hardness of the part by using both (test bar and part) impression diameters and the hardness of the comparative bar in
accordance with the equipment manufacturer’s instructions.
9. Report: The report shall include the following information. 9.1. Indentation hardness number of the part or component as calculated in 8 with the
designation HBC and the Brinell hardness number of the comparative test bar,
9.1.1. The result shall be written as shown in the following example: 232HBC/240 where 232 is the hardness determined as defined in 8 and 240 is the
Brinell hardness of the comparative test bar.
9.2 Identification of the manufacturer’s equipment, and
9.3 Diameters of the impressions in the part or component and comparative test bar. comparative test bar.

10.Repair welds in cast, forged, or plate components shall be hardness tested, when required, in accordance with the NACE SP 0472 Para 2.2.7.7:

11. All hardness impressions at one test location should have at least 6.4 mm (0.25 in.) between their nearest edges.
12. Replace indenter ball when it is out-of-round. (Inspect & rotate ball regularly, disassemble to rotate & inspect for flat spots)
REFERENCE TEST BAR REQUIREMENTS
Note: Brinell Hardness Testing (BHT) is a self-calibrating method based on hardness impression comparison. Reference bars are M&TE, simply
Calibration standards of "Known" Material Composition & Hardness Values. (SAEP-355, Sect 6)

BHT Reference (Test) Bars are M&TE and shall:

1. Be from a Certified source (QC Record, CMTRs) to attest to their quality & HT Value per their applicable ASTM mfg requirements.
2. Have their hardness value clearly marked at the ends of each bar by the manufacturer.
3. Test Bar Selection (Material type & Hardness value) shall be selected to be "SIMILAR" to the test piece. (SAEP-355, Section 6)
3a. Test Bar Material shall be the same P-No as the Test Piece, unless CSD specifies otherwise.
3b. Test Bar Hardness Value shall be within +/- 10% of Maximum Specified Hardness (either 200 BHN, 225, 235, 248) allowed by SA.

NOTE: SELECT CORRECT "RANGE" OF TEST BARS: A range of test bars (100 - 400 BHN are sold) is required for BHT Test bars for production
work must be within +/- 10% of maximum specified Hardness (200 for Sour Service, ALL PLANT PIPING), 200 for vessel work or as specified in NACE
MR 0175 at 225, 235, 248 for alloy steels). Check job specs for Matls to be PWHT (Piping Line Class, Data Sheets) as applicable. Before work
begins, ensure an available range/adequate supply of test bars is based on “KNOWN” material specs (CMTRs).

3c. RETESTING PRACTICE & INVESTIGATION OF UNACCEPTABLE RESULTS (PER STEP # 9) FOLLOW EXAMPLES BELOW

Example 1: A 188 BHN value test bar is used for HT of welds (200 BHN Sour Service line, test bar is P-No-1, within +/- 10% of max BHN). Test results
show 159 BHN value. Per Step # 9 of procedure, the result is invalid & retesting is required & should be performed with a bar of a hardness value closer
to 159 BHN value to obtain a valid result, even if it is below 200. Retests with same bar will result in retesting (over & over again). Per CSD, this general
retest policy is waived and is unnecessary as the final result will be under 200 & acceptable.

Example 2: Same 188 BHN value test bar is used for testing (235 BHN P-No 5 Heater Tubes ASTM A335, bar is the wrong P-No mat'l & not within +/-
10% of Max BHN value). Test bar must be selected per Example # 1 & P-No 5 Test bars of higher HT value are needed.

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SAUDI ARAMCO ID/PIEU-15-July-2018-REV. 2018.05.00(Standards Cutoff - May 31,2018) Rev.2018.05.00 31-May-18
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Review Hardness Testing Procedure - All Applications
SAIC-W-2012 15-Jul-18 WELD-
(Plant Piping, Pipelines, Vessels & Tanks)

Example 3: A 225 BHN value test bar is obtained for testing Example # 2 Heater Tubes (P-5 mat'l within +/- 10% of Max BHN value). Weld readings
(U-bends) show 351 BHN value. Metallurgical Investigation of U-bends & welds finds all sampled readings (300+) using correct range of test bars.
Investigation follows. CSD rejects the welds & requires PWHT & RT (disposition). Further investigation revealed that the Heater Tubes (over 3,000
total) were never PWHT'd, yet all had been accepted by HT reports using Equotip method. See Checklist Item D7.

Alternative Hardness Testing Equipment (2 Approved by CSD) for Branch Connection & Fillet welds, etc
1. Krautkramer Microdur 10 (MIC-10) is one of two equipment types allowed. Rebound type or Leeb portable testers that use spring-loaded probes
(specifically Proceq Equotip and others) are prohibited for use in SA. (See SAEP-355, Para. 6.2.1). Krautkramer Microdur MIC 10 portable hardness
testers require a careful selection of interchangeable probes to obtain Hardness readings from welds with geometries inaccessible to BHT (branch
connections, fillets, curved/convex surfaces, etc). Provide/document/demonstrate operator training. Careful test surface prep (fine grind/finish, 400 grit
per CSD for reliable result) is required. Verify 10% of MIC-10 readings by BHT comparison. (Once daily with testing/minimum). Take BHT
readings as close as possible to MIC-10 readings, accuracy to be within 10% with acceptable BHT results. (NACE MR0175, , owner/user option
for alternative equip).
2. MIC-20 & later generations of Krautkramer Microdur technology
can be applied (pending CSD approval).

1a. Krautkramer Microdur 10 (MIC-10) Manual Probes req'd for tight convex geometries are: Article (Model) MIC 201/ 205 with Test Load 10 N
(1 kgf) / 50N (5 kgf). Portable kits must have calibration standards of known Rockwell Hardness, Hardness Conversion Tables, instructions &
laminated cards for calibration (Keep these on site with equipment to demonstrate calibration accuracy)

2. MiniBrineller (a miniature version of the Telebrinell) is also acceptable per CSD. Information on these unit complete kits can be obtained @
http://www.ndtech.net/products/minibrineller.html Verify 5-10% of Minibrineller readings by BHT (Telebrinell), same as MIC-10.

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