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General Specification: Welding - Materials
General Specification: Welding - Materials
GENERAL SPECIFICATION
Welding - Materials
GS RC WAM 002
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Contents
Foreword ........................................................................................................................ 3
1. Subject ..................................................................................................................... 3
1.1 Introduction ..................................................................................................................... 3
1.2 Purpose .......................................................................................................................... 3
3. Applicability ............................................................................................................. 7
4. Definitions of terms................................................................................................. 7
5. Testing ..................................................................................................................... 8
5.1 Non Destructive Examination (NDE) ............................................................................... 8
5.2 Positive Metal Identification ........................................................................................... 19
5.3 Production hardness testing .......................................................................................... 19
5.4 Vessels Production weld test coupons .......................................................................... 20
Appendix 1 Production hardness testing ............................................................................ 21
Appendix 2 Use of time of flight diffraction (T.O.F.D.) ........................................................ 23
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General Specification Date : 12/2012
Foreword
Engineering Companies and Design Offices that are contractually bound to TOTAL are obliged
to always check that the applicable regulations, in particular regarding SAFETY, QUALITY and
protection of the ENVIRONMENT, do not impose more restrictive measures. If they do,
alternative solutions in accordance with the regulations must be submitted in writing to TOTAL.
Except for when it is used internally, the application of this specification is systematically
covered by a contract.
Caution, for new equipment, this specification supersedes the following specifications:
• GS RC WAM 006 Rev 02 dated 02/2012
• GS RC WAM 007 Rev 00 dated 09/2007
• GS TP WAM 002 Rev 01 dated 10/2010
1. Subject
1.1 Introduction
This Specification defines the examination, and testing requirements for shop and field
fabrication of Pressure Vessels, Shell and Tube Heat Exchangers, and Air Cooled Exchangers.
For licensed units, this specification will have to be applied together with applicable licensor
specifications. The more stringent requirements shall govern.
This specification is not applicable for titanium, aluminium and copper base materials
1.2 Purpose
This Specification supplements the Codes listed in § 2, the project equipment specifications and
the project equipment data sheets/drawings.
For welding and thermal treatment, additional requirements are defined in TOTAL specification
GS RC WAM 001.
For pressure equipments in Wet H2S Services, additional requirements are defined in TOTAL
specification GS RC WAM 011.
For Duplex Stainless steel additional requirements are defined in TOTAL specification
GS RC WAM 010.
For Cr-Mo steel additional requirements are defined in TOTAL specifications GS RC PVE 004
and GS RC PVE 005.
2. Reference documents
The reference documents listed below form an integral part of this General Specification. Unless
otherwise stipulated, the applicable version of these documents, including relevant appendices
and supplements, is the latest revision published at the EFFECTIVE DATE of the CONTRACT.
Standards
Reference Title
ISO 2400 Non-destructive testing Ultrasonic testing Specification for calibration
block No. 1
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Reference Title
ISO 3057 Non-destructive testing — Metallographic replica techniques of surface
examination
ISO 7963 Non-destructive testing - Ultrasonic testing - Specification for calibration
block No. 2
ISO 17636 Non-destructive testing of welds — Radiographic testing of fusion welded joints
ISO 17643 Non-destructive testing of welds — Eddy current testing of welds by
complex-plane analysis
ISO 22825 Non-destructive testing of welds — Ultrasonic testing — Testing of welds
in austenitic steels and nickel-based alloys
EN ISO 9015-1 Destructive tests on welds in metallic materials - Hardness testing -
Part 1: Hardness test on welded joints
EN ISO 9712 Non-destructive testing — Qualification and certification of personnel
EN ISO 9934-1 Magnetic particle testing Part 1: General principles
EN ISO 11666 Non-destructive testing of welds - Ultrasonic testing Acceptance levels
EN ISO 11699-1 Non destructive testing - Industrial radiographic film - Part 1: classification
of film systems for industrial radiography
EN ISO 17635 Non destructive examination of welds - General rules for metallic materials
EN ISO 17637 Non-destructive testing of welds Visual testing of fusion-welded joints
EN ISO 17638 Non-destructive testing of welds Magnetic particle testing
EN ISO 17640 Non-destructive testing of welds Ultrasonic testing Techniques, testing
levels, and assessment
EN ISO 23277 Non-destructive testing of welds Penetrant testing of welds Acceptance levels
EN ISO 23278 Non-destructive testing of welds Magnetic particle testing of welds
Acceptance levels
EN ISO 23279 Non-destructive testing of welds Ultrasonic testing Characterization of
indications in welds
EN ISO 3452-5 Non-destructive testing Penetrant testing Part 5: Penetrant testing at
temperatures higher than 50 °C
EN ISO 3452-6 Non-destructive testing Penetrant testing Part 6: Penetrant testing at
temperatures lower than 10 °C
EN 444 Non-destructive testing General principles for radiographic examination of
metallic materials by X- and gamma rays
EN 462-1 Image Quality Indicators (wire type)
EN 462-2 Non-destructive testing Image quality of radiographs Part 2: image quality
indicators (step/hole type)
EN 473 Qualification and Certification of NDT personnel
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General Specification Date : 12/2012
Reference Title
EN 571-1, Non destructive testing Penetrant testing Part 1 : General principles
EN 1593 Non-destructive testing Leak testing Bubble emission techniques
EN 1711 Non-destructive examination of welds Eddy current examination of welds
by complex plane analysis
EN 1779 Non-destructive testing Leak testing Criteria for method and technique
selection
EN 10204 Metallic Products - Types of Inspection Documents
EN 12517-1 Non-destructive testing of welds Part 1: Evaluation of welded joints in
steel, nickel, titanium and their alloys by radiography — Acceptance levels
Professional documents
Reference Title
American Society of Non destructive Testing
SNT-TC-1A Recommended Practice for Non-destructive Testing Personnel
Qualification and Certification
American Society for Testing and Materials
ASTM A388 / A388M Standard practice for ultrasonic examination of steel forgings
ASTM A578 Specification for straight-beam ultrasonic examination of plain and clad
steel plates for special applications
ASTM A833 Standard practice for indentation hardness of metallic materials by
comparison hardness testers
ASTM A956 Standard test method for leeb hardness testing of steel products
ASTM A1038 Standard practice for portable hardness testing by the ultrasonic contact
impedance method
ASTM E18 Standard test methods for rockwell hardness of metallic materials
ASTM E110 Standard test method for indentation hardness of metallic materials by
portable hardness testers
ASTM E140 Standard hardness conversion tables for metals
ASTM E142 Method for controlling quality of radiographic testing
American Petroleum Institute
API RP 577 Welding inspection and metallurgy
API RP 582 Welding guidelines for the chemical oil gas industries
American Welding Society
AWS A3.0 Standard welding terms and definitions
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General Specification Date : 12/2012
Reference Title
AWS A4.2M Standard procedure for calibrating magnetic instruments to measure the
delta ferrite content of austenitic and duplex austenitic-ferritic stainless
steel weld metal
AWS D18 2 Guide to weld discoloration levels on inside of austenitic stainless steel tube
Regulations
Reference Title
European Directive Directive of the European Parliament and of the Council on the
97/23/EC dated 29 approximation of the laws of the Member States concerning pressure
may 1997 equipment (PED)
Codes
Reference Title
American Society of Mechanical Engineers boiler and pressure vessel code
ASME B46.1 Surface texture (surface roughness, waviness, and lay)
ASME Section II, Welding Rods, Electrodes, and Filler Metals
Part C
ASME Section V Non-destructive Examination
ASME Section VIII, Pressure Vessels
Division 1
ASME Section VIII, Pressure Vessels - Alternative Rules
Division 2
ASME Section IX Welding and Brazing Qualifications
SNCT
CODAP Code de construction Des Appareils à Pression non soumis à la flamme
Reference Title
RG RC PVE 001 Unfired metallic pressure equipment quality class
GS RC PVE 001 Unfired metallic pressure vessels
GS RC PVE 004 General specification for equipment in materials 2¼Cr-1Mo & 2¼Cr-1Mo-¼V
GS RC PVE 005 General specification for equipment in materials 1¼Cr-½Mo
GS RC WAM 001 Welding of pressure vessels and heat exchangers
GS RC WAM 010 Requirements for material supply, welding and fabrication of duplex
stainless steel equipments
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General Specification Date : 12/2012
Reference Title
GS RC WAM 011 Additional Requirements for pressure equipments in Wet H2S Services
Other documents
Reference Title
Not applicable
2.2 Deviations
Any deviation from the requirements of this specification may be suggested by the General
contractor, Engineering company, Manufacturer or Contractor, if he considers such deviation
beneficial for reducing the cost and/or completion time, provided that it does not compromise
the safety of personnel or the regulatory requirements (when such regulations apply).
Deviations must be submitted to TOTAL, as a variant with the necessary justifications, and must
receive the written approval of TOTAL.
3. Applicability
This specification is applicable to all new equipment covered by the § 2.
Full or partial application of this specification for equipment to be repaired or for components of
existing equipment shall by confirmed by TOTAL.
For category D as per RG RC PVE 001, this specification is not applicable to all new equipment
covered by the § 2.
4. Definitions of terms
For the purposes of this Specification, the following definitions shall apply:
• Company / Entity: TOTAL
• Contractor: The party which carries out all or part of the design, engineering, procurement,
construction and commissioning for the project.
• Manufacturer / Vendor / Supplier: The party(s), which manufactures and/or supplies
equipment and services to perform the duties specified by the CONTRACTOR.
• MT Magnetic Particle Testing.
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General Specification Date : 12/2012
• PT Penetrant Testing.
• RT Radiographic Testing.
• UT Ultrasonic Testing.
• VT Visual Testing.
5. Testing
NDE / Hardness / Production test coupons requirements, shall be as specified on the
CONTRACTOR’s equipment drawings, applicable code, project specifications, purchase
requisitions, or purchase orders.
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General Specification Date : 12/2012
5.1.4.1 Material
For 1.25%Cr Mo & 2.25%Cr Mo steels, NDE are described in TOTAL specifications
GS RC PVE 004 and GS RC PVE 005 when applicable.
For 5% cr steel, NDE required are describing in Appendix 4 of GS RC WAM 001.
Some operating conditions can require additional NDE. These supplementary NDE are
described by other specifications or by the CONTRACTOR/COMPANY.
For the other cases and other materials (Carbon steel to 5% of Chromium steel, when
GS RC PVE 004 and GS RC PVE 005 are not applicable), all the following requirement are required.
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General Specification Date : 12/2012
TABLE 10 – NDT TABLE ASME VIII Div1 joint efficiency 1.0 and ASME VIII Div2 and CODAP cat A
Equipment in ASME VIII Div 1 with joint Efficiency 1.0
Before PWHT Final stage after PWHT
and ASME VIII Div 2 and CODAP cat A
Final stage without PWHT (13)
from 0.5%Mo from 0.5%Mo
Type of Joint Carbon steel Carbon steel
to 5% Cr to 5% Cr
Gouged / Ground areas before back-welding
Category A (ASME) & t ≤ 50 mm 100% RT - 100% RT (6) 100% RT
CEA1–1.1 (CODAP) 100% RT (6)
Butt weld t > 50 mm 100% RT
100% MT
Category B (ASME) & t ≤ 50 mm 100% RT (11) - 100% RT (6) 100% RT (11)
CEA1–1.2, CEA1-2, CEA1-3,
(CODAP) 100% RT (6)
t > 50 mm 100% RT -
100% MT
Butt weld (1)
100% RT (3) 100% RT 100%
Butt (1) 10% RT 100% RT 10% RT
Category C (ASME) & 100% MT (3) MT
CEA1–6, CEA1-7, CEA1-8, 100% MT (3)
Corner 100% UT (5) 100% UT (5)
(CODAP) 100% UT (3), (5)
Lap Joint Double fillet 100% MT 100% MT
100% RT 100% RT (8) 100% RT
Butt (1) 10% RT 10% RT
100% MT 100% MT (8) 100% MT
Category D (ASME) &
100% UT(8) 100% UT 100% UT(8) 100% UT
CEA1–4, CEA1-5, (CODAP) Tee full penetrated (Corner) 100% UT (8)
100% MT(8) 100% MT 100% MT(8) 100% MT
Fillet 100% MT - 100% MT
Load bearing attachment (saddle to leg, saddle to chair, lifting lug, 100% MT 100% MT
100% MT
piping support, trunnions…) 100% UT (7) 100% UT (7)
Skirt to shell /head Butt weld between forging or built up
100% RT or UT - 100% RT or UT 100% RT or UT
Category and skirt
CEA1–13, (CODAP) Built up 100% UT, MT or PT (9) - 100% UT, MT or PT (9)
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General Specification Date : 12/2012
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General Specification Date : 12/2012
TABLE 11 – NDT TABLE ASME VIII Div1 joint efficiency 0.85 and CODAP cat B
Equipment in ASME VIII Div 1 with joint Efficiency 0.85 and CODAP cat B
Type of Joint (Note 2 & 7)
Gouged / Ground areas before back-welding 100% MT or PT
Category A and B (ASME) &
Butt weld (1) 10% RT on each long seams + T-cross (3) (4)
CEA1–1, CEA1-2, CEA1-3, (CODAP)
Category C (ASME) &
Butt weld (1) 10% RT
CEA1–6, CEA1-7, CEA1-8, (CODAP)
10% RT
Butt
Category D (ASME) & 10% MT
CEA1–4, CEA1-5, (CODAP) Tee full penetrated (Corner) 10% RT
Fillet 10% MT
Load bearing attachment (saddle to leg, saddle to chair, lifting lug, piping support, trunnions…) 100% MT
Butt weld between forging or built up and skirt 10% RT or UT
Skirt to shell /head Category
Built up 100% UT, MT or PT (5)
CEA1–13, (CODAP)
Fillet 10% MT
Non Load bearing attachment (insulation support, davit, manway support…) 10% MT or PT
Skirt /saddle/chair support 10% MT or PT
Skirt to skirt circumferential and longitudinal butt welds 10% RT
Internal welds 10% MT
Repaired welds 100% MT or PT of excavated areas (6)
Temporary welds See §13.1.4.6
Notes:
1. Butt weld definition according to UW3b for ASME & CEA1 for CODAP
2. For all the welds on non-magnetic materials, including weld deposits, the MT examination shall be substituted by PT.
3. All dissimilar welds shall be subject to 100% RT.
4. At least one exposure shall be taken of each welding process applied to the welded seams
5. After machining
6. Repaired welds have the same extend of NDT after repair than for original weld (included a minimum of 100% of the repair area)
7. For austenitic stainless steel, UT is replaced by RT and MT by PT
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General Specification Date : 12/2012
5.1.4.7 Miscellaneous
When PWHT is required, the Radiographic examination (RT) and the Ultrasonic Examination
(UT) shall be performed as detailed in the table.
Materials Thickness Before PWHT After PWHT
Carbon steel ≤ 50 mm RT
0.5Mo steel ≤ 50 mm RT (1)
CS & 0.5Mo steels > 50 mm RT UT (1)
(1) For thickness between 16 to 50 mm, RT before PWHT followed by UT after PWHT is acceptable with prior
CONTRACTOR/COMPANY approval.
Plates thicker than 50 mm, and non-standards forgings shall be examined by UT, at the mill.
For all the welds on non-magnetic materials, including weld deposits, the MT examination shall
be substituted by P.T.
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General Specification Date : 12/2012
Visual examination procedures shall be in accordance with construction code and this
Specification.
Visual examinations shall be performed on accessible surfaces of all completed welds and shall
include a band of base metal at least 25 mm wide on each side if the welds.
The surface under examination shall be viewed under white light of at least 1000 Lux intensity
on the surface. Glare and reflections shall be avoided.
Acceptance criteria for visual inspection shall be as required in construction code.
Magnetic particle examination procedures shall be in accordance with the requirements and
methods specified in the construction code.
Magnetic particle examination of welds shall include a band of base metal at least 25 mm wide
on each side of the weld.
The evaluation of indications and the acceptance criteria shall be in accordance with the
construction code.
The surface shall be examined in at least two approximately perpendicular directions to detect
defects lying in any orientation.
The surface under examination shall be viewed under white light of at least 1000 Lux intensity
on the surface. Glare and reflections shall be avoided.
Only magnetic yoke method with wet or fluorescent particles shall be used. Permanent
magnetic probes shall not be permitted as well as magnetization accomplished by passing
current through the part to be examined.
For the wet particles method the surface to be inspected shall be coated with a white
background paint of a fine consistency.
Fluorescent particles shall be used to examine internal surfaces with black light. The surface
under examination shall be viewed under UV-A (Black light) of at least 10W/m2 intensity on the
surface. The background white light intensity shall not exceed 20 Lux. The black light intensity
shall be measured with a black light meter.
Adequacy of magnetic field strength shall be verified by Magnetic particle field indicator.
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General Specification Date : 12/2012
As a minimum the following shall be included in the MT procedure : scope, surface preparation,
areas to be examined; stage(s) at which examined (i.e. after welding, after heat treatment, after
hydrotest, etc.); magnetizing technique (e.g. AC Yoke), equipment used, magnetic ink trade
name; frequency of calibration of equipment and test of bath strength; coverage and direction of
magnetic field, measurement of field strength; application of examination media; acceptance
level; reporting format; operator qualifications.
5.1.10.2 General
Radiographic examination procedures shall be in accordance with the requirements and
methods specified in the construction code.
Interpretation and acceptance criteria of radiographs shall be in accordance with the
construction code.
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General Specification Date : 12/2012
For base metal thickness > 12.5 mm radiographic examination shall be performed by X-Ray
whenever possible and practicable however Gamma radiation may be used with Se 75, Ir192
(Co60 may also be used for thickness above 50 mm) provided the required radiographic
sensitivity is obtained, and with CONTRACTOR/COMPANY prior agreement.
5.1.10.4 Examination
The double films technique may be used to reduce shooting time.
Film overlap shall be 50 mm minimum.
Radiography of welds on nozzles and communicating chambers etc. having a nominal diameter
of 3’’ or less may be performed by elliptical projection technique. At least two separate
exposures are required at locations 90° apart.
Where there is no internal access, radiographs of welds in pipe shall be double wall technique
with a minimum of 3 shots up to 4’’ in diameter and 4 shots over 4’’ diameter and only that portion
of the weld on the film side of the pipe (opposite to the radiation-source side) shall be interpreted.
Because of the variation in pipe diameters, wall thicknesses and source-to-film distances, it may
be necessary to take more than the minimum number of radiographs to properly examine the
entire circumference of a weld.
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Note: For composite viewing of multiple film exposures, each film of the composite set shall
have a minimum density of 1.3.
The density of the radiograph anywhere through the area of interest varies by more than minus
15% or plus 30% from the density through the body of the hole IQI or adjacent to the designated
wire of a wire IQI, within the minimum/maximum allowable density ranges specified in T-282.1.
5.1.10.9 Film marking
Following information shall be marked on the films:
• the job number,
• the item number,
• the weld number,
• welder’s symbol,
• examination stage,
• date of examination.
Markings shall clear the outer edges of the weld and shall not interact with IQI designation.
5.1.10.10 Report
In addition to code requirements, report shall include the following information as a minimum:
• date of examination,
• job number/ item number,
• source of radiation used together with power,
• codification of defects used for interpretation,
• for each weld joint: shooting technique / geometrical unsharpness or calculating parameters,
• for each film: density / film use / IQI seen versus IQI required,
• for each film: all imperfection/indication (defined according to ISO 6520-1) detected has to be
noted with precise localization. For non acceptable defects, reference of report after repair have
to be noted on initial report.
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General Specification Date : 12/2012
Ultrasonic examination procedures shall be in accordance with the requirements and methods
specified in the construction code.
The acceptance criteria shall be in accordance with the construction code.
The frequency of the transducers shall be 2 or 4 MHz and the angle shall be in the range of 45°
to 70°. For thicknesses above 20 mm, at least two different probe angles shall be used.
Inspection reports shall include as a minimum all information specified in the construction code.
As a minimum the following shall be included in the UT procedure: scope; equipment; probe type
and details; surface preparation; cleaning and couplant; technique sheet for each technique
specified (number of techniques to be sufficient to cover all type of joints to be covered by the
procedures scope); material; weld material (if different); sketch showing joint configuration, beam
coverage; extent of scan; scanning pattern; material thickness and curvature; calibrations and
frequency; means of setting and scanning sensitivity levels and DAC curves, flaw location and
size evaluation; acceptance criteria; reporting format; operator qualifications.
For each weld joints, all imperfection/indication (defined according to ISO 6520-1) detected has
to be noted with precise localization on final report. For non acceptable imperfection, references
of report after repair have to be noted on initial report
5.1.12 Time Of Flight Diffraction (TOFD)
Use of TOFD in substitution of radiographic examination when permitted by Code and Code
case shall require prior COMPANY/COMPANY approval.
TOFD shall be in accordance with TOTAL Appendix 2 of this specification (e.g. base material
thickness: TOFD can be used above 20 mm) and described in the construction code.
Any TOFD proposal by VENDOR shall be issued at bid stage including at least the following:
• VENDOR references with TOFD (list and type of equipment with project name,
engineering contractor, client, design code, service, material, thickness, diameter, length
and type of joint checked),
• TOFD third party references (same as above),
• typical TOFD procedure,
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Personnel performing hardness testing shall be familiar with all hardness testing procedures
and test methods.
Procedures and test methods used for portable hardness testing shall be in accordance with
ASTM E110 and requirements described in Appendix 8.
Following portable hardness testers (or equivalent) are allowed:
• poldi tester for comparaison method according to ASTM A833,
• computest tester for Indentation Hardness method according to ASTM E18
• Mic10/20 tester for Ultrasonic Contact Impedance method according to ASTM A1038.08
Rebound method (Equotip type) according to ASTM A956 is forbidden.
Hardness test measurements shall also be performed on production weld test coupon (see
§ 5.4) in order to compare results with the vessel’s welds.
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Appendix 1
2. Surface preparation
The requirements for surface preparation are described below:
• the diameter of the surface depend on the technique but is at least 10 mm,
• the area has to be flat,
• the surface has to be ground AND smooth polished (grade 120) with a ''flap disc'' in order
to obtain roughness 1 µm,
• with SAW process, smooth polishing alone can be efficient in order to obtain the good
area for the hardness measurement,
• with manual processes (GTAW, SMAW), the grinding and smooth polishing are required
in order to obtain the good area or the hardness measurement.
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Appendix 1
4. Indentation Hardness method according to ASTM E18, DIN 50157, « ASTM B724 »
(eg Computest tester)
Indentation Hardness method technology can be used:
• for Thickness more than 5 mm,
• for Base Metal, Weld and ‘’HAZ’’( with etching),
• for HR results ( ≈ possible to convert to Hv or HB),
• with a surface preparation as per §1 of this appendix,
• with a Reference coupon,
• with an area for the measurement: mini 40 mm width,
Requirements for hardness measurements:
• in addition to the mandatory procedures of manufacturer,
• hardness measurement shall consist at least of one set of 3 individual measurements
(average of the 3 individual measurements),
• one set of measurements shall be rejected if the difference between the maximum an
minimum value exceed: 30Hv for manual process (GTAW, SMAW) and 20Hv for
automatic process (SAW) and base material.
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Appendix 2
Next revision.
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