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9, 050809 Ko Uocorburger Sal © Gar Heymanns Veg KO. ~ AD 2000-Merkblatt - Ics 23.020.30 ‘May 2002 edition Manutacture and testing of pressure vessels Manufacture and testing of joints Production testing of welds, Testing of base metal after postweld heat treatment | ‘AD 2000-Merkblatt HP 5/2 ‘The AD 2000-Morkoatter ara prepared by the sven assoctations listed below who together form ia “Arbetsgemoinschatt Druckbehaiter” (AD), Te sisctre and tne appscaton ofthe AD 2000 body cf regulations ard ihe procedural guidelines ere covered by AD 2000-Morkblat G1. The AD 2000.Merkbttor contain safety requitenronts to be mot under normal operating conditions. I above-nomal loadings are to be expected during the operation ofthe proseure vecce, this shal be taken into eccount by meeting special requirements, 1 thar are any divergences trom the requirements ofthis AD 2000-Merkblat, It shall be possible to preve tha the stander of safety of thie body ofregulatons has been maintained by other means, e.g. by materials lesting, less, tess analysis, erating experience, Fachvorband Dampikessel, Behaiter- und Rotrletungsbau e.V. (FOBR), Dtsseldort Hauptverband der gewerbichon Berutsgenossanschaiton o.V, Sankt Augustin Verband dor Chemischen industi o.¥. (VOD, Frankfurtifain Verband Deutscher Maschinen- und Anlagonbau @.V. (VOMA), Fachgemelnschatt Vertehrenstechnische Maschinen und Apparate, Frankurislan Verein Deutscher Eisenhitenloute (VDEN), Dasseort VGB PowerTech eV, Essen Vesbend der Technischen Uberwachungs-Voreine 0. (VETOV), Essen. Tha above associations continueusly Upcate the ADD 2000-Merkbitter inne with technical progress, Please address eny proposals for {mis to te publisher: Verband der Technischen Uberwachungs-Vereine 6.V., P.O. Box 103834, D-45038 Essen. Contents 0 Foreword 5 Number of test pieces with welded ends 1 Scope 6 Selecting and dimensioning the test pieces: 7 Testing the welded joints 8 Welded joint requirements, 9 Testing of the base material following post-weld heat treatment 2 Type ol test pieces 8 Number of test pieces with longitudinal seams 4 Number of test piaces with ‘circumferential seams (test pieces welded separately) 0 Foreword ‘The AD 2000 body of regulations can be applied to satisy 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 body of regulations is structured along the ines materials following post-weld troatmont in the case of pros- ‘sure vessels and pressure vessel components (productions tests) made of stee! or aluminium alloys. In the case of othar non-ferrous metals, the following regulations should be ap- plied as appropriate. of a self-contained concept. If other technical rules are used in accordance with the state of the art to solve related prob- lome, itis assumed thatthe ovorall concept has been taken into account, ‘The AD 2000 body of regulations can be used as appropriate for other modules of the Pressure Equipment Directive or for different sectors of the law. Responsibity for testing is as specttiedinthe provisionsof the relevant sectorof thelaw. 1 Scope This AD 2000-Merkblatt covers the testing of the quality characteristics of welded joints and the tesiing of the base Supersedes September 2001 estan; | 2 Type of test pieces In the case of pressure vessels or parts thereof with longitud- inal soams') or of longitudinal and crcumterential seams fabricated by the same weiging method, the test pieces required under 3shall be welded in olongation of thelongitud- inal seam. If only circumferential wolds are made, or if ci ‘cunnferential seams are welied by other methods, the test Plates and rings required according to section 4 shall be welded separately, ) Lengiudaly weles nz rte as excl ps ‘Amendments to previous edition "AD 2006 Meriter ar protacod by copyright. Tho igs use, prbealay oany waren, opodvaton eax of gree Terarissonty ahto- ‘mechanical means ad storago in daa ative jets, von ef exacts, are coord oe saber. Car HoymanneVeriag ha een a reeonabla ‘essures tensa te seesrary of fs Wansaton but regrets hat 0 reponsibicy can be scooped fr any rr, omen or inaoeuracy. noe tout cr ass he es ton oY Geen ot ony vat penne “© AD 2000-Merkblatt Page 2 AD E000 ert HP i, 05.208 ton 3 Number of test pieces with longitudinal seams ‘Tho number of test pioces depends on tho matorials usod, the number of cylindrical paris and the design stress level of the welded joint which may be 85% or 100% of the design stress (KIS) in eecordance with Tables 1, 20r3. Thefollowing test pieces are required: 3.1 Design stress levels equal to 100% of the permis- sible design stress 3444 Materials of Groups 1, 4.1,5.1,6,7.and Al, Nit One test piece par vessel, respective ofthe number of casts and two test pieces ifthere are more than fivecylindricalparts per vessel In the case of heat-treated pressure vessols there shall be ‘one test pioce per heat treatment batch. In tho caso of X 10, CrMo 8 1 steel from Material Group 4.1, 3.1.2 applies. In the caso of shelis(cylintical parts, heads, sections) mace of df. ferent materials, athe materials used shallbe included, Two grades of materiel may be included in one test piece. 34.2 Materials of Groups 2, 3, 4.2, 5.2, 5.3, 5.4, 8 and AL2,Ni2,Ti1 (One test piece per cast and vessel and two test pieces in he ‘case of pressure vessels with more than five cytindrical parts ‘of the same cast. Two casts may be included on one test piece. 3.1.1 applies in the case of Group 2 and 5.2 materials requlr- ing ne heat treatment, Groups 3 and 5.9 where wall thicknes- ‘Ses are under 20 mm or according to the wall thickness limit, and for which the assessment of suitability permits the waiv- ing of heat-lreatment, and Group 5.4if no heat-reatmenthas, been cared out, 3.1.3 Relaxation of the regulations The number of test pieces may be reduced to 10% subject to the folloning concittons: (1) From the oth vessel in series manufacture or within the scope of one procedure qualification in the case of mate fais in Groups 4, 2, 6, Al 1 and Al 2 after 25 production tests and after 50 production tests in the case of mater- als from Groups 3, 4, § and 7. 2) The results of the previous production tests shall have ‘mot the requirements in Table 4 or Table 5. Where welding supervisors have changed, or in the case of lengthy breaks in production, a relaxation ofthe regulations may only be contemplated if knowledge and experience gained has been retained. ‘The rules cannot be relaxed for stee! where special condi- tions have to be observed, @.9. X 20 CrMoV 12 1, 14 MoV 6 8, fuid-tempered fino-grain structural stools. 3.2 Design stress level equal to 85% of the permissible design stress In as far as design stress level of 85% of the permissible design stress is applied as stated in Tables 1, 203, one test piece shall be requited on 2% of the cylindrical parte. The ‘minimum number of test pieces, however, is one per year for each material group and each welding method. 4 Number of test pieces with circumferential seams (test pieces welded separately) Whore prossure vessel sholls are joined with circumferential ‘seams or where the welding procedures forthe circumferen= tia! and longituginal joints are different, one test place por year for each material group and welding procedure are required. 5 Number of test pieces with welded ends 5.1 Ends manufactured from welded blank dises In the case of welds on ends fabricated from welded blank ‘discs {not including hemispherical ends}, proceed according to section 4 If the weld or Its extension intersecis the crown areacf0,6D, (see also AD 2000-MerkblattB3, Figs. 5 and6 [left-hand sido of drawing) 52 Ends welded from pressings In the case of welds on ends welded trom pressings (aot in- cluding hemispherical ends), procsed according to section 4 if the weld or its extension intersects the crown area of 0,6 -D, (see also AD 2000-Merkbiait 8 3, Figs.8 and 9 flet- hand side of the drawing) 6 Selecting and dimensioning the test pieces 6.1 In the caso of tosts which do not depend on the cast, the test pieces may be taken from parts of similar thickness (deviations of + 20% are permissible). In tests which are dependent on cast, the test pieces shall correspond to the ‘manufactured prossure vessel in thickness and cast. Where relaxed rules apply as set out in'3.1 3, test pieces from casts of comparable composition may be used. ‘With thicknesses fess than 10 mm the total tolerance may be shifted to one side, 6.2 Selection ofthe test pieces shall be such that the spec ‘mens required in accordance with Tables 1, 2 or3 and those which may be needed in accordance with 9 can be cut from them; selection shall also allow for the possiblity of spare ‘specimens being obtained. The length of the weld shall not exceed 300 mm, Where test pieces are wolded separately, the dimensions and the welding conditions shall conform to the component tee 7 Testing the welded joints Test pieces shall be in the heat-treated state corresponding ‘exactly with that of the last heat-treatment of the vessel. In the case of ends fabricated from welded blank discs or ‘welded irom pressings, the testpieces shall bein the identical heat-realment state as thal of the last heat treatment of the fends. Where, in the case of torispherical ends, the require- ‘ment to heat treat after cold-forming may be waived, the test pieces shall be in the same heat-treated state asthe original plates. The specimens shal then be removed and tested. The tost shall be carried out in the presence of the relevant third party. The scope of the test depends on the material, the wall thickness and the heet treatment, and can be found In Tables 1, 2 or 8. In special cases agreement may be reached to use supple- mentary or non-standard specimens. AD: 2000-Merkblatt - Specimens are sectioned and tested as appropriate in accordance with AD 2000-Morkblatt HP 2/1 Where the lowest operating temperature is below ~200°C, the notched bar impact test at ~ 196°C is carried out subject to the following conditions: (1) that in the procedure qualification and the final produc: tion test the notch impact strength is tested at — 196°C and at the lowest operating temperature and that the reaults of the testa carried out at the lowest operating temperature are not substantially lower than those obtained at ~ 196°C; (2) that in the further production tests the results obtained from the notched bar tests do not differ significantly from those determined in the procedure qualification or in the first production test. 8 Welded joint requirements ‘See Table 4 or 5. 9 Testing of the base material following post- weld heat treatment 9.1 Testing of the base materials folowing post-weld heat treatment is carried out using the test pieces stipulated in 3.4.1 and 3.1.2 9.2 Inthecase of Material Groups 1, 4.1 and 5.1, the tensile strength and yield point of the base material are tested only s0280 | ~ any 3] o 1 mse iene coors! oe tlh ee other a os 3 - = | tmacto | 3.2 0r 4 moe soa sos [YS] ou2a0 | - | oy | os le 7 [regres errr san Seat coe Sareea eco greece eee eee ame ateee Bie [2] oo [sfalilt See Secon ltanrtoe a ee eee eee corer eect a >a = @) 3 3 1 1 7 7 [frogs or sone Ceaanmmac |v fal 20 2] on fale fs |e | rm See Late aw ea eee ce tee ie Sry oe ose eee Sa EEE gee aE ‘steals ft A 250 - 3 3 {i 1 peer ramen, yeni Eran ~ AD 2000-Merkblatt Table 1. Type and scope of production tests; ‘extract trom Synoptic Table 1 in AD 2000-Merkélatt HP 0 (Continued) we ‘St gate “yp ee peo pe es oo Posicion . aaa z 3 lel sents apecrnens Pla, af weer |g ; £ Bo lee) stg soroeanre iy rplel) ays ls] £2 | $o2 silgs 3a e oe bhaa| Gb 3 Le g | E23 iF et Rege pig ule ui He ilee| 28 i ailbe3] & ESE HL Z| 2 | #2 |es2| 22 | 282 | om ° Secon 1 2 ef7 {|e [ef] « [mlmleful ws | iw Benstesewcwess | w fmol 28 72) SF Ls) 5 | tft | smn | store 42 | onesie soos tnove8 +X 20 Oro 121 Ww | 100 a 2 en) wm] 8 1 1 | tmecro | 3.104 31 | Preganed acira soe me BN tion 8 an ‘rion sores wo nah impact eng tn par a2) =) wy} an] - | - ture and soscial Series with high | U | 100 | >20=38m) | — se) ey fod macro invpact strength at tow tempore > 88= 80") | — ay yp) ot v {ie hevng nanan spot “Sfrol Foca Sn! sie ae so ‘basic and high-tempereturs rere Soto ats yt pl xa aes oes so sopitoioar wine S22, | | omemes | 99 | oe» | ~ | frees eatagoyibamwrtore. | w | 100 | ~aoeeo | — [memes |S) | Sy | = 1 = | mace Sroieven eons Ferree eer] meme creed tae Pee oe ta 17i7¢ 00S goo Wows, tans 9 ana me 9 Ud tt ‘rive alone epmtng on enn tus down -60°0) cet —— Column. IF uw] os] 3% | 2 fier” (221271 = | = | amaso | szore >isteo |= sisa} 2 | t tiger on tone ope ing te fertrfor 32 | Frege scura tl ey tng Se epn ioe ead ais [a [reverent | an fam | a | = |, ‘iro nero wt tah uf sco | 518, | 2 [poremesa tan sm | | = | mace impact renga np: ee tte and spat Sane gh comet impenatengh aw erp out szore ‘Cetavng atveus a po Seon w= Nie ee) wets | - Fregerelemeua sone | wo) S23 | 2 so) T | 2 | moe See DN 7100, 7478 nd Tri bane a penne Gates Foden 970 Non © ban fuse neo Ao somnioat wi fee egy bo 10°C Seat gare Sao arto Oi ts a 117 west peraingtnpereures bow Sees. Page 6 AO Z0004erkat HP 82, 08.2002 eston Table 1. Type and scope of production tests; ‘extract from Synoptic Table 1 in AD 2000-Merkblatt HP 0 (Continued) ioe einem ee oy =e a ox nga pens 3 Ha pote i s let 33| bay oe be Be) gil: | ba | Gf | bee Hf TD lee ae i Te a} aud Re aii geese G2 /2 Bil see ul E]E)EEGE gb | gE Hite < — Fest espnmesnenc acest] Tastes TTC at emer TTT TT Sownne ieee oe iene oon ieee = Spt oa Bee ee 7 fccreerece et age ae eee aye] roel =e ise tte saarecmmenms | fe] =e fam im, fay | a wove | are paras mas faeeatcareas = jeanne a ieee Seu cemec one ue mares. oo ee a ree. Serene ee aoe ee oma wlttee ehiees ee ee | Reteme e ne-e a wy) spe oremee ps3 fa] rs a = 6 | Austeniic storis aco, to DIN: | macro twmmtrooneeseos | lie | se [2] om ||) -|1 |: lace vie rates 5 w) so [2] om fs] -]s ts fame wim] Se Pf] aus fa fly e |e | seem =15 2 - - - - eum ole]. [2] a |e] = wos | ore 7D rrmtos same oat Sears a ppt Heoulacas ott ‘ae welded using Mer matenais | y | all 2 3 1 fa | ame syricamemememe | uf] ow |e 3 yo | eet | see as os; LEER eee Preerrtn uff a fe] on fad oe] - | sme | ares aw) a fel] ov fsfs fa] - | rm | arene Table 2, Type and scope of production tests; AD 2000-Merkblatt extract from Synoptic Table 2 in AD 2000-Merkblatt HP 0 ‘AD 2p Mettsah HP 92 052002 eton Page? Se | oe Se a oe : Sim il sexta oS a ul ET | alii sf 5 & able u ey rls LAB GH i PE alts) a: | aie Hi Ce e|E VERE) HH oe oe a] EB) E [ez|Foz| ae agree” [ow] mw] a ABER ASHER a vw | ae | en geo ay wwf ae] con fan] = P27] 4] Jvc [seer Abigé-5Nn wa7, wee, | UW | 85% | 802) ind en) oe 1 | tmacro | 82 0r4 e uw] am | oe sonar wrote ww| me] =e set sta Footnotes? to, see Synoptic Tabet. 2) Testing of pact strong sony peromed in caso pressure vesbls whore posit ot shock loading must be arises £7) Reativoly ite welding and asin tecicel exparence is curaty avlabl for wal icknoenoeoxccoding 90 me. ©) For hchnosses 16 mim, de bend ts! specren according fe DIN 60121, ©) Val or Ati 5Mn only expedence has baen proved ab sated in 31.9 f AD 2000-Morblet HP 52, AD '2000-Merkblatt Page @ AD 2000Medtiet HP 52, 05.202 aston Table 3. Type and scope of production tests; ‘extract from Synoptic Table 3 in AD 2000-Merkblatt HP 0 eon era ce T ‘Production test ile aca 8 : ee a Be lag ef tamportie € ba Hl au | 4 i|, (Alte) fe | de ai /27) 260) |e: 8 laa ibay aie BEL SUE P/E)HGH EB pele 7 | ons 7 i 16 cr) ar a} at 2} on [os |- | - | - | 1mao | szore Nz | Mita toss uw] ao | 2 {ay |e fos] + | | amo | arore © (i toss Nig 20 Fe tance) Noise Nilo 6 Cr 15 To 46.67 xia nier am 3220 Tit | Ten uw] too | an 2{ oe [a f- | + | - | smo | sroe src other metals Fostnoes to), 866 Table 1, Foobcts 0), 690 Table 2 5) Onin sae of Mo 16 Cr 16, Mo 16 C1, No 28 "AD 2000-Merkblatt ~ ‘0 atcostetian He 32, 05.2002 eaten Paxeo ‘Table 4. Requirements for testing welded stoe! joints (for testing the parent metal following post-weld heat treatment, see ‘Section 9). Type of test Requirements “Tensio teat aright angles to “Tensile strength as required forthe paront metal or as specie for the weld filer metal by the the weld assossment af suitably Tensile test on @ spevimen of weld | Elastic limit or 0.2% proof stress, tensile strength and elongation at break as required for the metal Parent metal or as specified forthe weld filer metal by the assessment of sultablly Notched bar impact bending test) | At charging tomporatures As epeciied for parent metal Inthe transverse dlrecton ‘om the contre of the weld on the | of - 10°C and above: ‘Test temperature as when testing the parent meal, But not 180-V-notch specimen lower then ~10°C. When using feric-austontc, austenitic and ickel-based alloy wed filers = 40 J. ‘At charging iomperstures As lowest operating temperature below ~10°C: = 274) when using fertic weld filer metals; = 8242}9) when using feriie-austanilic,austonic andnickel- based alloy weld filers Notched bar impact bonding test’) in | At charging temperatures = 27,87) on the ISO-V-notch specimen. Test temperature es the region of he weld ranstiononte | of ~10°Cand above: ‘when tasting the parent metal but not lower tan —10°C 180-V-notch specimen ‘Atcheraing temperatures = 27) at lowest operating temperature below ~ 10°C: Technological bending test Bencingangle | Strength group) Diameter of Degrees mandrel 1805) Fotis stosis with «| ‘minimum tanlle strength «< 430 Nim? 2-8 ‘minimum tense strength = 430 to < 460 Nim! 25-8 1809) Stainoss and low-temporatwe austenfic els, Be High-tempereture austeniicsieets, a8 Fentte steels wth aminimum tnste strength = 460 Nim? | 3-2 if bonding angle of 180" s not achieved, the llloning apps: =90 ‘Econgaton (Ly = width of weld + wall thickness, symmarcal to weld) ‘= Minimum elongation at break Ay of te parent metal o Etongaion over the with ofthe weld > 305%) and dotec-roo fracture i appearance Metatograptic section In the macro-section the woldes jint must manifest pertect layer structure and weld penetration assessment In tho case ot miro-sections an examination must be cacied aut for cracks. Only cinks ar ‘acceptable and thon only if thoy are shown to eccur oxcaslonaly. AAgreomont must also have boen obtained from the relevant thd paty that they are aocaptable inthe ight of the material and the fleld of application, Hardness testing In tno heat etectea areas he harcnoss rating musi net @xcead350 HV 10, Peakhardnass values ‘ove this imitin narrow transion zones may be daregarded ithe result ofthe technological tests meets the requirements 1 Inte cate of gainons nat standard 1 em wih, re eg uroment regaréng input srength nin a prepsion oe ees aecton of space, 5 nly ona sg value may la bon tha mines aa was, ough by it ma 29% 9) Tovale song ete 1 he smal! area a kno 4 Tho 6 rua re cova ile bona tests bee criti ONOT21 andthe specimen as sn eed HC ha spt tut Ectnp. 9 Inne oe of als wich have bon alee dMrnty, az XN, ret vss mayb aed wth he revatio pncure vessel on whlch hte reaufed ca ou turtles 9 Yes th west peatng lenge nde 200°C to nga ba ng es ard out 195°C pola tat. Mine powder tet proccien eth moan song rtenoa st 198- and tha el aprsg tgs, The reas oth tess shal haw fo atresia opt th loess sprang ear ns compared wy ett 155 tho harpoon ns Be resus the ole at pct argh chat hot ety selicanly tom ose asia te proces rine ret. oncton ie 1 For wold ee co 20 Ca 12 1 vie my fal ew Ns vate by 10% AD 2000-Merkblatt = = Fogo 19 AD 2000 Mex 2, 06.208 eon Table 5. Requirements for testing welded joints (aluminium and aluminium alloys) Type of test Requrements| “Tensile test tight angles to he wold “Tensile Seng as forbase materialoras speciied forthe wed ler Inthe assessment oFsultad- ity “Tensle test on a specimen of the weld metal 0.2% proof stress, tensile strength and elongation at bresk as forthe base metal or as spectiod for tha wold lr in the assessment of suitaily Notched bar impact fending test) from the centre af the weld metal ‘AL room temperature = 184, butno value under 12.4 ‘At charging temperatures = 144, but no value under 12 J when > 15 mm t6 DIN 60121, part 1, section 5.23, lass than 50°C: Technological bending test, Bondingangle | Materal and material condtion| Diamar of Degrees rmandret When s 15 mm to DIN 0121, | 180 ‘Ag9,98 A Wa and Fa aa part), seoton 62.1 ‘99,8 8 and FB (99,7 WW6 and FE (809.5 WT, FY, F8 ‘inn 9, W10, F10 180 ‘lMncu Wid ae Jigs Wie, Wi, F18 AIMGENNO,8 WIE, WI9, F18, F19, F20 | Anga.siin w27, 28, F27 Ira bending angle of 180° isnot achieved, the folowing applies < 18090 | Elongation (Ly ~ width of wold + wall thickness syrmmetical fo the weld) Minimum stongation at break As ofthe parent msial orc Elongation aver the width ofthe weld > 20% and delec-tee fracture anpea- Motallographical assessment (maeroisection) Inthemaero-eacton the welded ointmustmanifestpertectiayer stucureand weld penetration (Cay for sluminum alloys ster Grog A 2 ¥e AD 2000 Mose 6, Table 2 fr pewure veszels aly 9 be autocad ope ar Publisher Verband der Techishen Uberwochungs Vein E-Mall: vituey.essen@tonline.ce psiwonn vetuev de Source of supply: a. ( eS Carl Heymanns Verlag Luxomburger StraGe 449, 0-50939 Kdln Telefax: 0221-9 43.73 603 E-Mail: verkaut@heymanns.com