AD 2000-MerkblattICS 23.020.30 June 2014 edition Materials Seamless hollow components made AD 2000-Merkblatt for from non-alloyed and alloy pressure vessels steels for pressure vessel shells W 12 The AD 2000-Merkblätter are prepared by the seven associations listed below who together form the “Arbeitsgemeinschaft Druck- behälter” (AD). The structure and the application of the AD 2000 Code and the procedural guidelines are covered by AD 2000-Merk- blatt G 1. The AD 2000-Merkblätter contain safety requirements to be met under normal operating conditions. If above-normal loadings are to be expected during the operation of the pressure vessel, this shall be taken into account by meeting special requirements. If there are any divergences from the requirements of this AD 2000-Merkblatt, it shall be possible to prove that the standard of safety of this Code has been maintained by other means, e.g. by materials testing, tests, stress analysis, operating experience. FDBR e. V. Fachverband Anlagenbau, Düsseldorf Deutsche Gesetzliche Unfallversicherung (DGUV), Berlin Verband der Chemischen Industrie e. V. (VCI), Frankfurt/Main Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen und Apparate, Frankfurt/Main Stahlinstitut VDEh, Düsseldorf VGB PowerTech e. V., Essen Verband der TÜV e. V. (VdTÜV), Berlin The above associations continuously update the AD 2000-Merkblätter in line with technical progress. Please address any proposals for this to the publisher: Verband der TÜV e. V., Friedrichstraße 136, 10117 Berlin. Contents Page 0 Foreword.................................................................................................... 2 1 Scope......................................................................................................... 2 2 Suitable materials ...................................................................................... 2 3 Manufacture and heat treatment ................................................................ 3 4 Testing ....................................................................................................... 3 5 Marking ...................................................................................................... 5 6 Certification of quality................................................................................. 5 7 Design values ............................................................................................ 5 supersedes July 2003 edition; | amendments to previous edition AD 2000-Merkblätter are protected by copyright. The rights of use, particularly of any translation, reproduction, extract of figures, transmission by photomechanical means and storage in data retrieval systems, even of extracts, are reserved to the author. Beuth Verlag has taken all reasonable measures to ensure the accuracy of this translation but regrets that no responsibility can be accepted for any error, omission or inaccuracy. In cases of doubt or dispute, the latest edition of the German text only is valid. AD 2000-Merkblatt Page 2 AD 2000-Merkblatt W 12, 06.2014 edition 0 Foreword The AD 2000 Code can be applied to satisfy the basic safety requirements of the Pressure Equipment Directive, principally for the conformity assessment in accordance with modules “G” and “B F”. The AD 2000 Code is structured along the lines of a self-contained concept. If other technical rules are used in accordance with the state of the art to solve related problems, it is assumed that the overall concept has been taken into account. The AD 2000 Code can be used as appropriate for other modules of the Pressure Equipment Directive or for different sectors of the law. Responsibility for testing is as specified in the provisions of the relevant sector of the law. 1 Scope 1.1 This AD 2000-Merkblatt is applicable to seamless hollow components, hollow parts and part-shells – hereafter referred to simply as hollow components – made from non-alloyed and alloy steels for pressure vessel shells which are operated at working temperatures and at ambient temperatures down to 10 °C. Hollow components can be manufactured by forging, pressing, rolling and drawing or by machining1). Depending on the manufacturing processes, they are produced with open ends, with ends closed on one or both sides by flanging or drawing in and with pressed or forged-on ends. Clause 7 of AD 2000-Merkblatt W 4 applies to pressure vessel shells made of tubes with ends which are not formed. For working temperatures below 10 °C, AD 2000-Merkblatt W 10 also applies. 1.2 The basic requirements for the materials and the material manufacturer are governed in AD 2000-Merkblatt W 0. 2 Suitable materials In the case of internal or external overpressure, the steel grades as specified in 2.1 to 2.3 may be used within the application limits according to Tables 1 and 2 or according to the stipulation in the verification of suitability. 2.1 Hollow components manufactured by drawing in or flanging may be manufactured from seamless tubes as specified in 2.1.1 to 2.1.4. Use is governed by the application limits in Table 1. 2.1.1 Tubes of quality TR2 according to DIN EN 10216-1 “Non-alloy steel tubes with specified room temperature properties”. 2.1.2 Seamless tubes according to DIN EN 10216-2 “Non-alloy and alloy steel tubes with specified elevated temperature properties”, made from the steel grades listed in Table 1 of the Merkblatt. Additionally, VdTÜV- Werkstoffblätter 377/2, 533/2, 007/2, 109, 511/2, 552/2 and 522/2 apply for steel grades 15NiCuMoNb5-6-4, 7CrMoVTiB10-10, X11CrMo5, X11CrMo9-1, X10CrMoVNb9-1, X10CrWMoVNb9-2 and X11CrMoWVNb9-1-1. 2.1.3 Seamless tubes according to DIN EN 10216-4 “Non-alloy and alloy steel tubes with specified low temperature properties”. 2.1.4 Seamless tubes according to DIN EN 10216-3 “Alloy fine grain steel tubes” in conjunction with VdTÜV- Werkstoffblätter 352/2, 354/2 and 357/2 with the exception of P620 and P690. 2.2 Hollow forgings may be manufactured from steel grades as specified in 2.2.1 to 2.2.3. Use is governed by the application limits in Table 2. 2.2.1 Steel grades 16Mo3, 13CrMo4-5, 14MoV6-3, 11CrMo9-10, X10CrMoVNb9-1 and X20CrMoV11-1 according to DIN EN 10222-2 “Steel forgings for pressure purposes – Part 2”, including steel grades P250GH according to DIN EN 10222-2, Part 2 (National Annex NB). Additionally, VdTÜV-Werkstoffblätter 184, 511/3 and 110 apply for steel grades 14MoV6-3, X10CrMoVNb9-1 and X20CrMoV11-1. 2.2.2 Nickel steels with high impact strength at low temperature 13MnNi6-3, 12Ni14, X12Ni5 and X8Ni9 according to DIN EN 10222-3 “Steel forgings for pressure purposes – Part 3” up to 50 °C. AD 2000-Merkblatt W 10, Table 3a applies for short-term service at higher temperatures. 2.2.3 Steel grades according to DIN EN 10222-4 “Steel forgings for pressure purposes – Part 4” in conjunction with VdTÜV-Werkstoffblätter 352/3, 354/3 and 356/3. 2.3 Hollow components made from other steel grades according to verification of suitability by the relevant third party; in this case, the application limits shall be stated. 1) In the case of hollow components cut from a solid blank, it may be necessary, depending on the material and dimensions, to carry out heat treatment after boring. AD 2000-Merkblatt AD 2000-Merkblatt W 12, 06.2014 edition Page 3 The steels shall satisfy the following requirements: (1) Elongation at failure A in the transverse direction (tr) shall be at least 14 %. When testing in a longitudinal direction (l) this value shall be two units higher. (2) The impact energy on the V-notch test specimen shall correspond to the values which characterize the material. The mean value from three V-notch test specimens in the transverse direction (tr) shall be at least 27 J at the lowest working temperature, but not exceeding 20 °C. This value shall be at least 43 J when testing in the longitudinal direction (l). 3 Manufacture and heat treatment The hollow components are manufactured by hot or cold forming, possibly in conjunction with machining. After forming or, in the case of parts cut from a solid blank, the entire component shall be subjected to heat treatment appropriate for the material, noting footnote 1. 4 Testing With respect to the requirements for the testing of hollow components, the DIN EN standards and the VdTÜV- Werkstoffblätter noted in 2.1 and 2.2 are decisive. The requirements of the verification of suitability apply for hollow components made from other steel grades. 4.1 to 4.10 apply for the testing of the hollow components. Tables 3 and 4 provide an overview. Testing of the impact energy is performed with wall thicknesses not less than 5 mm for steel grades as specified in 2.1.3, 2.1.4 and 2.2.2, and with wall thicknesses not less than 10 mm for steel grades as specified in 2.1.1, 2.1.2, 2.2.1 and 2.2.3, provided nothing else is specified. For other steel grades as specified in 2.3 as well as steel grades for which the VdTÜV-Werkstoffblätter apply, the impact energy is tested in accordance with the verification of suitability. The hollow components shall be tested after the final heat treatment. If no provision is made for individual testing, testing is performed in batches. A batch includes hollow components produced from one cast having the same diameter and wall thickness and originating from one heat treatment batch. 4.1 Mechanical testing of hollow components made from seamless tubes 4.1.1 For hollow components having an outside diameter less than 660 mm as specified in 2.1, tensile tests and, if necessary, impact tests shall be performed on specimens from 2 % of the hollow components in a batch or from at least two hollow components. For batch sizes less than 10, testing on one hollow component is sufficient. An impact test is required for nominal wall thicknesses not less than 20 mm for steel grade 16Mo3 and for nominal wall thicknesses not less than 30 mm for steel grades P195GH, P235GH and P265GH. Provisions to the contrary are stipulated in 4.1.1.1. 4.1.1.1 For hollow components having an outside diameter not less than 325 mm and less than 660 mm made from steel grades 14MoV6-3, 12Ni14 and X12Ni5, including steel grades having a minimum tensile strength exceeding 520 MPa, tensile tests and, if necessary, impact tests shall be performed on specimens from 10 % of the hollow components in a batch or from at least two hollow components. 4.1.2 For hollow components having an outside diameter exceeding 660 mm as specified in 2.1, tensile tests and impact tests shall be performed on specimens from 10 % of the hollow components in a batch or from at least two hollow components. Provisions to the contrary are stipulated in 4.1.2.1. 4.1.2.1 For hollow components made from steel grades 14MoV6-3, 12Ni14 and X12Ni5, including steel grades having a minimum tensile strength exceeding 520 MPa, tensile tests and impact tests shall be performed on specimens from one end of each hollow component. For hollow components made from steel grades 14MoV6-3, including steel grades having a minimum tensile strength exceeding 520 MPa (with the exception of P460), testing shall be performed at both ends at points offset by 180 °C in the case of lengths exceeding 4 m. 4.2 Mechanical testing of hollow forgings 4.2.1 For hollow components as specified in 2.2 having an inside diameter less than 600 mm, tensile tests and, if necessary, impact tests shall be performed on specimens from 2 % of the hollow components in a batch or from at least two hollow components. For batch sizes less than 10, testing on one hollow component is sufficient. Provisions to the contrary are stipulated in 4.2.1.1. 4.2.1.1 For hollow components having an inside diameter not less than 300 mm and less than 600 mm made from steel grades 14MoV6-3, 12Ni14 and X12Ni5, including steel grades having a minimum tensile strength exceeding 520 MPa, tensile tests and, if necessary, impact tests shall be performed on test specimens from 10 % of the hollow components in a batch or from at least two hollow components. AD 2000-Merkblatt Page 4 AD 2000-Merkblatt W 12, 06.2014 edition 4.2.2 For hollow components having an inside diameter not less than 600 mm as specified in 2.2, tensile tests and impact tests shall be performed on specimens from 10 % of the components in a batch or from at least two hollow components. Provisions to the contrary are stipulated in 4.2.2.1. 4.2.2.1 For hollow components made from steel grades 14MoV6-3, 12Ni14 and X12Ni5, including steel grades having a minimum tensile strength exceeding 520 MPa, tensile tests and impact tests shall be performed on specimens from one end of each hollow component. For hollow components made from steel grades 14MoV6-3, X10CrMoVNb9-1, X20CrMoV11-1 and X8Ni9, testing shall be performed at both ends at points offset by 180° in the case of lengths exceeding 4 m. 4.3 Mechanical testing of hollow components made from other steel grades Hollow components made from other steel grades as specified in 2.3 shall be tested by the relevant third party in accordance with the verification of suitability. The scope of testing shall correspond to that for comparable steel grades. 4.4 Removal of specimens 4.4.1 The specimens shall generally be taken in a transverse or tangential direction (tr/l), provided that specimens which conform to standards can be produced without dressing. In the case of inside diameters less than approximately 200 mm or in the case of low wall thicknesses, longitudinal specimens may be taken. 4.4.2 The testing of hollow components is performed on ring sections which shall be removed from the cylindrical part after the final heat treatment. For this purpose, excess lengths shall be left on all hollow components or further test pieces shall be made available for testing depending on the required number of specimens. 4.4.3 If the ends of the hollow components are reduced or closed by hot forming, sufficiently wide ring sections2) shall be cut off after having been marked appropriately before further processing and then subjected to the same heat treatment as the hollow components. In the case of hardened and tempered steels, account shall be taken of special heat treatment conditions. The specimens shall be assembled in a suitable way3) to produce a test block which undergoes the same heat treatment as the hollow component. 4.4.4 If testing on ring sections cannot be carried out on ring sections or is not practicable, particularly in the case of large hollow components (inside diameter exceeding approximately 800 mm), special agreements shall be made. 4.5 Dimensional inspection The dimensions of the hollow components which are important in terms of safety shall be inspected. Where the specifications contain no tolerances, the following permissible deviations from the nominal dimensions apply: Inside or outside diameter: 1% Wall thickness: 0 %/25 % Different tolerances can be agreed. 4.6 Visual examination Hollow components which are descaled on the inside and outside shall be visually examined. They shall have a smooth external and internal surface equivalent to the as-manufactured condition so that significant surface defects can be detected. 4.7 Hardness test A hardness test shall be performed for hollow components made from steels in the delivery condition NT or QT. The following stipulations apply: Hollow components having an outside diameter less than 325 mm shall be tested at one end. Hollow components having an outside diameter not less than 325 mm and not more than 2 m long shall be tested at both ends around their circumference at points offset by 180°. Hollow components having an outside diameter not less than 325 mm and longer than 2 m shall be tested to a suitable extent over their entire length. The ring sections cut off according to 4.4.3 shall also be subjected to a hardness test. 4.8 Non-destructive testing All seamless hollow components for working pressures exceeding 80 bar shall be subjected to ultrasonic examination over their entire length. 2) Width 2 wall thickness, minimum 150 mm. 3) In the case of liquid quenching and tempering, by a circumferential weld (seal welding). AD 2000-Merkblatt AD 2000-Merkblatt W 12, 06.2014 edition Page 5 Before forming of the ends, hollow components shall be subjected to ultrasonic examination for longitudinal flaws and, in the case of outside diameters exceeding 200 mm, to additional ultrasonic examination for transverse flaws. Testing and assessment of hollow components made from steel as specified in 2.1 are carried out in accordance with the conditions in DIN EN ISO 10893-10, acceptance level U2C. For hollow components made from steel as specified in 2.2, testing of the internal quality is carried out as 100 % scanning coverage in accordance with DIN EN 10228-3. The following quality classes shall be used in conjunction with the wall thickness s: s 50 mm Quality class 4 s 50 mm 100 mm Quality class 3 s 100 mm Quality class 2 Defect size assessment is carried out according to the 6 dB decay technique and the sensitivity setting according to the DGS method. The shaped areas of hollow components for working pressures exceeding 80 bar shall be subjected to a surface crack test. Testing is carried out by the manufacturer using suitable methods in agreement with the relevant third party. 4.9 Testing to ascertain that correct materials have been used Hollow components made from alloy steels shall be subjected to testing to ensure that the correct materials have been used. 5 Marking The finished hollow components shall be marked as follows: steel grade, cast number or abbreviation for the cast, manufacturer’s brand mark, designation number of the hollow component (factory No., serial No., etc.), mark for the ultrasonic examination performed, stamp of the relevant third party. 6 Certification of quality 6.1 Certification of quality shall be provided in accordance with Tables 1 and 2. 6.2 In addition, the manufacturer shall certify that: the material corresponds to the steel grade and, if applicable, the quality level or test class in the relevant standard or verification of suitability taking into account the special stipulations in this AD 2000-Merkblatt, the hollow components are in a proper heat-treated condition appropriate to the steel grade (e.g. normalized or hardened and tempered), the non-destructive testing with inspection certificate 3.1 according to DIN EN 10204, the result of the ladle analysis, the results of further tests to be performed by the manufacturer, the result of the test to ensure that the correct materials have been used in the case of alloy steels. 6.3 The acceptance test certificate shall include the information given in the Technical Delivery Conditions/Standards. Additionally, the Technical Delivery Condition/Standard (e.g. DIN EN 10216-2) and the Technical Rule (AD 2000-Merkblatt W 12) fundamental to the delivery shall be given in every acceptance test certificate. 7 Design values The stipulations in AD 2000-Merkblätter W 4 and W 13 are applicable for the design values. AD 2000-Merkblatt Page 6 AD 2000-Merkblatt W 12, 06.2014 edition Table 1 — Application limits and certification of quality for hollow components made from seamless tubes Application limits Max. allowable Certification of quality Design Standards Clause Steel grades working according to temperature1) pressure DIN EN 10204 PS [bar] °C 80 P195TR2 with NDT for DIN EN 10216-1 2.1.1 P235TR2 longitudinal 300 3.1 P265TR2 imperfections without limit P195GH P235GH 80 450 P265GH P195GH, test category 1 P235GH, P195GH P265GH: P235GH 3.1 P265GH test category 2 16Mo3 14MoV6-3 10CrMo5-5 13CrMo4-5 DIN EN 10216-2 2.1.2 10CrMo9-10 up to the 11CrMo9-10 temperature 25CrMo4 without limit other steel grades: limits given in 15NiCuMoNb5-6-4 3.2 the standard 7CrMoVTiB10-10 X11CrMo5 X11CrMo9-1 X10CrMoVNb9-1 X10CrWMoVNb9-2 X11CrMoWVNb9-1-1 X20CrMoV11-1 alloy steels always test category 2 P355N 300 P460N P355NH 400 P460NH P275NL1 + L2, test category 1 300 P355N + NH: 80; 3.1 DIN EN 10216-32) 2.1.4 400, if test category 2 P275NL1 + NL2 without limit certification of other steel grades: P355NL1 + NL2 the 0,2 % proof 3.2 P460NL1 + NL2 stress at raised temperature is agreed when ordering P215NL P255QL 3.1 P265NL test category 1 26CrMo4-2 refer to 80; DIN EN 10216-4 2.1.3 11MnNi5-3 AD 2000- test category 2 13MnNi6-3 Merkblatt W 10 without limit 3.2 12Ni14 X12Ni5 X10Ni9 1) Refer to AD 2000-Merkblatt B 0 Clause 5. 2) In conjunction with VdTÜV-Werkstoffblätter 352/2, 354/2 and 357/2. AD 2000-Merkblatt AD 2000-Merkblatt W 12, 06.2014 edition Page 7 Table 2 — Application limits and certification of quality for hollow forgings Application limits Certification of quality Max. allowable Design by material test Standards Clause Steel grades working temperature1) certificate according pressure to DIN EN 10204 PS [bar] °C P250GH 3.1 16Mo3 up to the 13CrMo4-5 temperatures DIN EN 10222-2 2.2.1 14MoV6-32) given in the 3.2 11CrMo9-10 standard X10CrMoVNb9-12) X20CrMoV11-12) 13MnNi6-3 80 12Ni14 with non- refer to AD 2000- DIN EN 10222-3 2.2.2 3.2 X12Ni9 destructive Merkblatt W 10 X8Ni9 testing: without limit 300 P285NH 400, if certi- P285NH, P285QH fication of the P285QH: P355NH 0,2 % proof 3.1 DIN EN 10222-43) 2.2.3 P355QH1 stress at raised P420NH other steel grades: temperature is P420QH 3.2 agreed when ordering 2.3 other according to the stipulations in the verification of suitability 1) Refer to AD 2000-Merkblatt B 0 Clause 5. 2) In conjunction with VdTÜV-Werkstoffblätter 184, 511/3 or 110. 3) In conjunction with VdTÜV-Werkstoffblätter 352/3, 354/3 and 356/3. AD 2000-Merkblatt Page 8 AD 2000-Merkblatt W 12, 06.2014 edition Table 3 — Overview of scope of testing for hollow components made from seamless tubes Outside Scope of testing1) Standards Clause Steel grades diameter 2 %, 10 %, 100 %, mm at least 22) at least 2 one end 4.1.1 P195TR2 660 X DIN EN 10216-1 P235TR2 4.1.2 P265TR2 660 X P195GH P235GH 4.1.1 P265GH 660 X 16Mo3 10CrMo5-5 DIN EN 10216-2 13CrMo4-5 10CrMo9-10 4.1.2 X11CrMo5+I 660 X X11CrMo5+NT1 X11CrMo9-1+I 4.1.1 14MoV6-3 325 X 11CrMo9-10 4.1.1.1 325 to 660 X 25CrMo4 15NiCuMoNb5-6-4 7CrMoVTiB10-10 DIN EN 10216-2 X11CrMo5+NT2 X11CrMo9-1+NT 4.1.2.1 660 X3) X10CrMoVNb9-1 X10CrWMoVNb9-2 X11CrMoWVNb9-1-1 X20CrMoV11-1 4.1.1 all qualities 660 X 4.1.2 P275 and P355 660 X DIN EN 10216-3 4.1.1 325 X all qualities 4.1.1.1 325 to 660 X P460 4.1.2.1 660 X P215NL 4.1.1 P255QL 660 X DIN EN 10216-4 P265NL 11MnNi5-3 4.1.2 660 X 13MnNi6-3 4.1.1 325 X 12Ni14 4.1.1.1 325 to 660 X X12Ni5 4.1.2.1 660 X DIN EN 10216-4 4.1.1 325 X 26CrMo4-2 4.1.1.1 325 to 660 X X10Ni9 4.1.2.1 660 X3) X Designates the test scope to be complied with. 1) See 4.7 with regard to the hardness test. 2) 1 is sufficient for batches of less than 10. 3) For lengths exceeding 4 m, test at both ends offset by 180°. AD 2000-Merkblatt AD 2000-Merkblatt W 12, 06.2014 edition Page 9 Table 4 — Overview of scope of testing for hollow forgings Outside Scope of testing1) diameter 2 % at least 2; Standards Clause Steel grades up to 10 10 %, 100 %, mm components 1 at least 2 one end is sufficient DIN EN 10222-2 4.2.1 P250GH 600 X (including 16Mo3 National 4.2.2 13CrMo4-5 600 X Annex NB) 11CrMo9-10 4.2.1 300 X 14MoV6-3 DIN EN 10222-2 4.2.1.1 X10CrMoVNb9-1 300 to 600 X X20CrMoV11-1 4.2.2.1 600 X2) 4.2.1 600 X 13MnNi6-3 4.2.2 600 X 4.2.1 300 X 12Ni14 4.2.1.1 300 to 600 X DIN EN 10222-3 X12Ni5 4.2.2.1 600 X 4.2.1 300 X 4.2.1.1 X8Ni9 300 to 600 X 4.2.2.1 600 X2) 4.2.1 P285NH 600 X P285QH 4.2.2 P355NH 600 X P355QH1 DIN EN 10222-4 4.2.1 300 X P420NH 4.2.1.1 300 to 600 X P420QH 4.2.2.1 600 X 4.3 other according to the stipulations in the verification of suitability X Designates the test scope to be complied with. 1) See 4.7 with regard to the hardness test. 2) For lengths exceeding 4 m, test at both ends offset by 180°. AD 2000-Merkblatt Page 10 AD 2000-Merkblatt W 12, 06.2014 edition AD 2000-Merkblatt AD 2000-Merkblatt W 12, 06.2014 edition Page 11 AD 2000-Merkblatt Page 12 AD 2000-Merkblatt W 12, 06.2014 edition Publisher: Source of supply: Beuth Verlag GmbH D-10772 Berlin Verband der TÜV e.V. Tel. +49 30 / 26 01-22 60 Fax +49 30 / 26 01-12 60 E-Mail:
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