Method Statement For In-Situ Metallography Test: DCSM Project 2019

METHOD STATEMENT FOR IN-SITU
METALLOGRAPHY TEST
NSRP *DOCUMENT NO :
D-P5-BV-MS-014
DCSM PROJECT
2019
Contractor’s Name : BUREAU VERITAS VIETNAM

Company’s Name : Nghi Son Refinery and Petrochemical LLC.
Plant Location : Nghi Son, Viet Nam
W/ Order No. :
Package No. :5
Scope of Work : METHOD STATEMENT FOR IN-SITU METALLOGRAPHY
TEST
Discipline : DCSM
NSRP DCSM PROJECT 2019

Discipline
Receiving Date
Reviewed By
Review Date
Review Result code
Document Review codes:
1- Rejected (Revise and resubmit), 2- Comments as Noted (Revise and resubmit. Work
may proceed subject to full compliance with comments), 3- Minor Comments
(Acceptable, Works may proceed. Revise & Resubmit as “Certified Final), 4- No
comments (Works may Proceed)
Returned on
Next Submission Due
Date
Reviewed
Rev. Date Description Prepared By Approved By
by
0 Issued For
26/09/2019
Approval
Nguyen Gia Annamalai Annamalai
Dinh Natarajan Natarajan
Project Manager
DESCRIPTION
Page 1 of 5
METALLOGRAPHY TEST
NSRP *DOCUMENT NO :
D-P5-BV-MS-014
DCSM PROJECT
2019
Section Description Page No.
1 Scope of Work 3
2 References 3
3 Site Survey to Do Replica Testing 3
4 Mobilization of Replica Testing Equipment to Be Used at Site 3
5 Replica Testing Inspection at Work Site: 4
6 Results/Conclusion: 5
7 House Keeping 5
1. SCOPE OF WORK:
Page 2 of 5
METALLOGRAPHY TEST
NSRP *DOCUMENT NO :
D-P5-BV-MS-014
DCSM PROJECT
2019
This documented is established to perform the Replica Testing, to reproduce the microstructure of a metal's surface
to examined for degradation that causes micro structural changes and interpret the damage mechanisms, failures if
any and also assess the remaining life of the material/part/component.
2. REFERENCES:
2.1 ASM Hand Book Vol.9: Metallography and Microstructures.
2.2 ASM Hand Book Vol. 17: Nondestructive evaluation and quality control.
2.3 ASTM E1351, Standard Practice for production and Evaluation of Field Metallographic Replicas.
2.4 ASTM E 407, Standard Practice for Micro etching Metals and Alloys.
2.5 ASTM E-03 Standard guide for Preparation of Metallographic Specimen.
2.6 ASTM E 114, Standard Test Methods for Determining Average Grain Size.
2.7 API RP 571, Damage mechanisms affecting fixating equipment in the refining industry.
2.8 API RP 573, Inspection of Fired Boilers and Heaters.
2.9 API RP 576, Inspection of Pressure relieving devices.
2.10 API RP 579, Fitness for Services.
2.11 API RP 580, Risk Based Inspection.
3. SITE SURVEY TO DO REPLICA TESTING

3.1. Ensure the proper planning.
3.2. Ensure the applicable drawing with site layout plan is in place.
3.3. Identification of Replica Location based on client requirement, previous failure history if any, elevated
temperature locations, stress involvement region
4. REPLICA TESTING EQUIPMENT TO BE USED AT SITE

4.1 Portable Metallurgical Microscope.
4.2 Portable Hand Grinding Machine
4.3 Portable Polishing Unit with Diamond Lapping Compound
4.4 Electrolytic Polisher cum Etching Unit
4.5 Etching Chemicals and Reagents as per table.
4.6 Emery grit sizes- Self-adhesive 30mm dia. SIC 120, 220, 300, 500 grits
Page 3 of 5
METALLOGRAPHY TEST
NSRP *DOCUMENT NO :
D-P5-BV-MS-014
DCSM PROJECT
2019
4.7 Replica Kit: Polishing papers, sylvet cloth, polishing media, thermo setting or thermo plastics,
Cellulose acetate replica foils of 0.030 micron size
5. REPLICA TESTING INSPECTION AT WORK SITE:
Specimen Preparation Technique:

Grinding:
 Flatten the specimen with hand grinder to minimum depth to get surface free from pin holes/ scaling/
pitting/surface corrosions and care to be taken not to go too deep nor more than 1.0 mm from surface.
 Grind the surface with emery papers (80- Grit to 1000 Grit Paper) should be done in a particular
direction to that of proceeding paper.
 Once the Grinding steps are completed, the area is ready for Polishing.
Polishing:
 Wash the sample thoroughly and finally polish by the Portable Polisher Using Navigated Aluminum
Oxide Suspension or Magnesium Oxide Suspension (i.e. 6-micron diamond compound followed by
1-micron diamond compound polish).
 Once the polishing steps are completed, the area is ready for Etching.
Etching:
 To etch the reagents in the mirror finished surface of the test required locations as per table-1.
Table-1: Etching Reagents for Micro Examination (For Iron & Steel)
S.NO ETCHING REAGENT METHOD REMARKS

Nital:
Swabbing for few Carbon Steel, Low and
1 Nitric acid (HNO3) = 1-5 ml
seconds to a minute. Medium alloy steel.
Ethyl Alcohol = 95 -100 ml
2 Picral: Picric acid 4 gm alcohol 100 ml do do
Hydraulic acid –5 ml, Picric acid--1 gm, For revealing the austenite grain size in quenched
3 do
Alcohol--100 ml tempered steels.
Ferric chloride –5 gm, Acid - 50 ml, For Hydrochloric microstructure of
4 do
Water-100 ml austenitic nickel & steel
5 Nitric acid –10 ml, Alcohol --90-95 ml do For microstructure of austenitic nickel steel.
Nitric acid --10 ml, Glycerin 1-5ml Warm specimen in For microstructure of Iron Chromium base
6 Hydrochloric acid –20-30 ml water before alloys, high speed steels, austenitic
etching manganese steels, nickel chromium alloys.
Hydrochloric acid 30 ml, Acetic acid 20 For Stainless Steel alloys other alloys high
7 Apply Swabbing
ml in Nickel or Cobalt.
Picric acid –10, Parts (4%), Nitric acid For depth of case and structure of Nitro
8 do
–1 part (4%) alloy.
9 Copper Sulphate –4 gm, Hydrochloric Swabbing For total depth of Nitrided case.
acid-20 ml Water --20 ml
Page 4 of 5
METALLOGRAPHY TEST
NSRP *DOCUMENT NO :
D-P5-BV-MS-014
DCSM PROJECT
2019
(Marbles Reagent)
Replication:
 A small piece of cellulose acetate, 3 to 5mm thick and approximately three times the size of the area to
be replicated, is held by tweezers and softened on one side only.
 Apply acetone with an eyedropper, allow setting for approximately 30 seconds, and then shake to
remove excess acetone.
 The soften side is then pressed firmly against the area with the eraser end of a pencil or tip of the
fingers and helped several seconds.
 Care must be taken that the acetate is not allowed to slip or a smudged replica will be obtained.
 Let the replica remain in this position until it hardens, usually 10 to 15 minutes, depending upon the
size of the replica.
 Once it has hardened it can be stripped with tweezers.
 At this point the stripped replica should be put into a separate container (usually a small Plastic box, or
taped to a glass slide with double-sided tape.
 Several Replicas should be made of each area and should be labeled appropriately.
Labeling of Replica Slits (Identification Marks)
 The Replicated spot marked as XXXX-R-YY, XX is the short name of Client and YY is the replica
number, it will star from 01, 02..., etc. and the same will marked in the replica slit as an Identification of
Replica and also the same will revert all documents and reports for traceability.
6. RESULTS/CONCLUSION:
The examined microstructure of the replica with photographs and quantitative evaluations can be
made and the same submitted as a test/ Investigation report to the Client.
7. HOUSEKEEPING:
7.1. Housekeeping is a must "Before, During & End" of work day.
7.2. Materials must never be left on the ground but stacked neatly on stillage and hard barricaded.
7.3. Work area must be swept clean of all times.
7.4. Used chemicals must have disposed in a safe manner.
Page 5 of 5

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METHOD STATEMENT FOR IN-SITU

Contractor’s Name : BUREAU VERITAS VIETNAM

NSRP DCSM PROJECT 2019

Section Description Page No.

3 Site Survey to Do Replica Testing 3

4 Mobilization of Replica Testing Equipment to Be Used at Site 3

5 Replica Testing Inspection at Work Site: 4

2.5 ASTM E-03 Standard guide for Preparation of Metallographic Specimen.

2.8 API RP 573, Inspection of Fired Boilers and Heaters.

2.9 API RP 576, Inspection of Pressure relieving devices.

2.10 API RP 579, Fitness for Services.

2.11 API RP 580, Risk Based Inspection.

3. SITE SURVEY TO DO REPLICA TESTING

4. REPLICA TESTING EQUIPMENT TO BE USED AT SITE

4.2 Portable Hand Grinding Machine

4.3 Portable Polishing Unit with Diamond Lapping Compound

4.4 Electrolytic Polisher cum Etching Unit

4.5 Etching Chemicals and Reagents as per table.

5. REPLICA TESTING INSPECTION AT WORK SITE:

Specimen Preparation Technique:

S.NO ETCHING REAGENT METHOD REMARKS

7.3. Work area must be swept clean of all times.

7.4. Used chemicals must have disposed in a safe manner.

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