WI.RMT.01: REPLICA METALLOGRAPHIC TESTING
REVISION NO. 01
DATE: 21.09.2023
SAUDI K-KEM ENGINEERING SERVICE COMPANY
DOCUMENT NAME:
REPLICA METALLOGRAPHIC TESTING
DOCUMENT NO:
WI.RMT.01
DOCUMENT ORIGIN:
OPERATIONS DEPARTMENT
DOCUMENT STATUS:
COPY HOLDER:
REPLICA METALLOGRAPHIC TESTING
PREPARED BY:
AMRUT CHALKE
ASNT NDT LEVEL-III
REVIEWED BY:
YOGESH JADHAV
ASNT NDT LEVEL-III
APPPROVED BY:
KAPILKUMAR BERA
OPERATIONS MANAGER
REVISION NO:
01
DATE:
21.09.2023
Replica Metallographic Testing – Rev. 01
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WI.RMT.01: REPLICA METALLOGRAPHIC TESTING
REVISION NO. 01
DATE: 21.09.2023
SAUDI K-KEM ENGINEERING SERVICE COMPANY
CONTENTS
1.0
PURPOSE
3
2.0
SCOPE
3
3.0
REFERENCE
3
4.0
PERSONNEL QUALIFICATION
3
5.0
GENERAL
3
6.0
RESPONSIBILITIES
5
7.0
EQUIPMENT
5
8.0
PREPARATION
6
9.0
TECHNIQUE
6
10.0
EVALUATION
7
11.0
DOCUMENTATION
7
12.0
FORMS AND RECORDS
7
Replica Metallographic Testing – Rev. 01
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WI.RMT.01: REPLICA METALLOGRAPHIC TESTING
REVISION NO. 01
DATE: 21.09.2023
SAUDI K-KEM ENGINEERING SERVICE COMPANY
1.0 PURPOSE
This procedure describes the method for Replica Metallographic Testing employed by Saudi K-KEM
Engineering Service Company. When requested by the client, the Replica Sampling technique/s
described in this procedure shall be used. Procedure/s developed by the client supersedes the
requirements given in this work instructions and those shall be followed if requested.
2.0 SCOPE
2.1 This practice covers recognized methods for the preparation and evaluation of cellulose
acetate or plastic film replicas which have been obtained from metallographically prepared
surfaces.
2.2 It is designed for the evaluation of replicas to ensure that all significant features of a
metallographically prepared surface have been duplicated and preserved on the replica with
sufficient detail to permit both Light Microscopy (LM) and Scanning Electron Microscopy
(SEM) examination with optimum resolution and sensitivity.
3.0 REFERENCE
The following documents are applicable to meet the general or specific industry requirement.

ASTM E3 (2017) - Standard Guide for Preparation of Metallographic Specimens

ASTM E7 (2022) - Standard Terminology Relating to Metallography

ASTM E407-07(2015) e1 - Standard for Micro etching of Metals and Alloys

ASTM E1351-01(2020) - Standard Practice for Production and Evaluation of Field
Metallographic Replicas
4.0 PERSONNEL QUALIFICATION
4.1 Personnel applying this procedure shall be familiar with this procedure and only trained
personnel are permitted to operate.
4.2 Replica Sampling Inspector must have knowledge of all aspects of Replica Metallographic
Testing methods and the operation of Replica Sampling test equipment used on the job.
4.3 Replica Metallographic Testing inspector must be able to demonstrate working knowledge to
company by operating the approved Replica Sampling chemicals and all related equipment on
a representative samples of alloy materials with one hundred percent accuracy.
5.0 RESPONSIBILITIES
Following are the responsibilities of personnel involved in the scope of the procedure:
5.1
NDT Supervisor / Technician
a. Shall be responsible in job logbook filing.
b. Shall ensure that the logbook is consist of the following: date and time of request,
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WI.RMT.01: REPLICA METALLOGRAPHIC TESTING
REVISION NO. 01
DATE: 21.09.2023
SAUDI K-KEM ENGINEERING SERVICE COMPANY
requester name, receiver name, job description and related details, performing job
personnel and status.
5.2
Operations Manager
a. Shall provide all necessary resources to implement this procedure.
b. Initiate corrective action referred by QA/QC, NDT Supervisor (Conventional/Advanced),
NDT Level III and External Audit team with the operations personnel from time to time.
5.3
QA/QC Personnel
a. Shall be responsible for monitoring overall control of QA/QC activities.
b. Shall be responsible for keeping all records and be able to take part in Internal and
External Audit.
5.4 NDT Supervisor
a. Shall report to Operations Manager.
b. Shall be responsible for day-to-day handling of NDT documents and records.
c. Shall ensure the NDT technician has executed the work and report as per approved NDT
work instructions and quality plan.
d. Implementation of Quality and Inspection Test Plan.
e. Shall be responsible for issuing corrective action reports based on periodical audits carried
out by him (NDT Supervisor) and NDT Level III.
5.5 NDT Level III
a. Shall report to Operations Manager.
b. Responsible for training and necessary certifications of all NDT Technicians.
c. Shall be responsible for keeping all records for training and certification requirement for
NDT technicians.
d. Shall responsible for keeping all records of all calibrated NDT machines/equipment with
close coordination with storekeeper.
e. Shall coordinate closely with storekeeper for maintenance of NDT machines/ equipment
along with necessary actions for repair or replace whenever required.
f. Shall be able to take part in Internal and External Audit.
5.6 Replica (Metallographic) Technician
a. Shall report to Supervisor.
b. Shall execute the work and report as per approved replica procedure and Quality Plan.
c. Implementation of Quality Assurance Plan (QAP) and Inspection Test Plan (ITP).
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WI.RMT.01: REPLICA METALLOGRAPHIC TESTING
REVISION NO. 01
DATE: 21.09.2023
SAUDI K-KEM ENGINEERING SERVICE COMPANY
6.0 EQUIPMENT
Typical equipment selection shall be from the following:
6.1 Suitable mechanical grinding and polishing unit
6.2 Portable microscope
6.3 Acids (etchants), replica foils / films
7.0 PREPARATION
7.1 Cleaning
All grease, oil, paint or the like shall be removed and then the surface prepared by manual,
mechanical and / or electrolytic polishing methods ensuring to observe cleanliness
throughout.
7.2 Method
7.3
7.2.1
Grind to rough flat area of interest, typically 50X50mm.
7.2.2
Grind the same area smooth using successively finer grade abrasive grinding papers.
Normally this would be restricted to actual area of interest, 30x20mm.
7.2.3
Normal sequence of grinding to remove evidence of preceding operation is by use of
grade 120, 240, 400, 600, 800 and 1000 grit grinding papers or similar, but depending
on smoothness obtained with each, some papers may be omitted. Care must be
taken to clean between papers to avoid contamination of subsequent stage with
preceding coarse grit.
7.2.4
During grinding, the direction of the papers shall be rotated 90°. Once previous
scratch evidence is removed, then on completion the surface shall be flat with only
light evidence of scratches appearing in single direction. Surface is to be frequently
cleaned to remove debris.
7.2.5
Final polishing may be undertaken using diamond paste of 9 microns / 6-micron
consistency, again cleaning after use.
7.2.6
Finish shall be achieved by polishing with special cloth and 1micron diamond paste,
again cleaning frequently.
Etching Reagents
7.3.1
Nital
As general etchant, use on carbon steel / low alloy steel and other ferrous alloys.
7.3.2
Aqua Regia / 10% Oxalic acid
As general etchant, on corrosion resistant alloys such as stainless steels, Inconel etc.
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WI.RMT.01: REPLICA METALLOGRAPHIC TESTING
REVISION NO. 01
DATE: 21.09.2023
SAUDI K-KEM ENGINEERING SERVICE COMPANY
7.3.3
Villela’s reagent
As a general etchant for P5, P9 and P91 material
8.0 TECHNIQUE:
8.1 Etching
8.1.1
The optimum etching procedure is not only dependent on the method of preparation
of the specimen, but also upon the exact composition of the material or previous
history or both.
8.1.2
The polished area must be thoroughly cleaned prior to etching.
8.1.3
Suitable etchant shall be prepared to etch the polished area of interest. The area shall
be inspected visually, or with field microscope to check the level of etching. All traces
of etchant shall be cleaned from surface and area dried.
8.1.4
With different alloys and tempers, the etching period may vary from a few seconds to
several minutes, and should be continued until the desired contrast is obtained. For
high temperature or creep range exposed components the technicians shall follow the
alternate polishing-etching-polishing procedure.
8.2 Replication
8.2.1
Normally 30mm x 20mm is acceptable size for replica sample for parent metal. For
cross weld positions grinding and polishing an area of 30mm x 20mm on either side
of the weld is sufficient.
8.2.2
To minimize possible oxidation or contamination of the prepared area, the replica
shall be taken as soon as possible.
8.2.3
After coating one side of the foil with suitable solvent, e.g. methyl acetate or acetone,
the wetted side shall be applied to the clean prepared area on the surface of the
component.
8.2.4
Once film is dry, in approximately 2 to 3 minutes time, remove replica and mount on
glass slide to protect same and mark identity of sample on slide, for reference.
8.2.5
It is recommended to take 2 replicas of the same spot using light and heavy etching
conditions
9.0 EVALUATION
The replicas shall be forwarded to laboratory for preparation, mounting and if necessary for
sputter coating and for further evaluation using metallurgical microscope at appropriate
magnification(s).
9.1
The following shall be observed for the presence in the microstructure of replicas:
9.1.1
Material structure changes / deterioration as compared to original material
specification.
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WI.RMT.01: REPLICA METALLOGRAPHIC TESTING
REVISION NO. 01
DATE: 21.09.2023
SAUDI K-KEM ENGINEERING SERVICE COMPANY
9.2
9.1.2
Material structure damage due to high temperature and service fluid.
9.1.3
The extent of creep damage.
9.1.4
Changes in grain structure of the material or presence of any injurious structure
abnormality viz. Micro Fissures / Cracks, Decarburization, Graphitization,
Spheroidization, Sigma precipitation, Overheated / Burnt structure etc.
9.1.5
No attempt shall be made to predict the remaining life of the tubes / equipment
material for specified works.
Final report shall be issued within four weeks after completing the entire site work. QP to
provide the details of the equipment along with design and operating temperature and
pressure and service history to incorporate in the final report.
10.0 DOCUMENTATION
As a minimum, the report shall include:

Introduction

Scope

Results

Discussion

Conclusions

Recommendations

Appendix

Photographic documentation
11.0 REPORT PREPARATION
Interpretation of the Replica Metallographic Test shall be done by the competent person.
12.0 FORMS AND RECORDS
Records of report generated during the implementation of this procedure are retained and
managed in accordance with the Control of Documented Information Procedure.

Replica Metallographic Testing Report (FM/RMT/10)
Replica Metallographic Testing – Rev. 01
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WI.RMT.01: REPLICA METALLOGRAPHIC TESTING
REVISION NO. 01
DATE: 21.09.2023
SAUDI K-KEM ENGINEERING SERVICE COMPANY
REV #
DATE
CHANGES MADE
00
26.01.2018
First issue
231
01
21.09.2023
Revise and align the work procedure according to
current code requirements and references
409
Replica Metallographic Testing – Rev. 01
DCR #
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