AD 2000-Merkblatt Ics 23.020.30 October 2000 edition Pressure vessels ‘made of Pressure vessels made of electro-graphite and hard burned carbon AD 2000-Merkblatt N2 non-metallic materials ‘Te AD 2000-Merkotetr are preparea by he seven assoclavOns NStea Below Who Logetner form the ~Arbetsgemeinschaft Druckbehalter (AD). The stucture and the appleation ofthe AD 2000 body o regulations and the procedural guidelines are covered by AD 2000-MarkbatG 1. The AD 2000-Merkblater contain safety requirements to be met under normal operating candions. If above-normal loadings are to be ‘expected during tho operation af the prossuro vessol, this shall be taken into account by meeting special requirements 1 hero aro any divergences trom the requirements of thie AD 2000-Merkblat, t shal be posse to prove that the standard of ealey of this body of regulatons has been maintained by other means, e.g. by materials testing, fests, stress analysis, operating experience. Fachverband Dampikessel-, Behéiter- und Robrieitungsbau @.V. (FDBR), Disseldor! Hayptverband dor gowerbichon Berufsgenossenschaiten @.V, Sankt Augustin Verband der Chemischen Industrie e.V. (VC), FranklurtiMain Verband Deutscher Maschinen- und Aniagenbau ¢.V. (VOMA), Fachgemeinschait Vorabrenstechnische Maschinen Lund Apparate, FrankturtiMain Verein Deutscher Eisenhdttenlouto (VDER), Dusseldod VGB PowerTech o.V., Essen Verband der Technischen Dberwachungs-Veroine e.¥. (STOV), Essen, The above associations continuously update the AD 2000-Merkbiiter in ine with technical progress, Please address any proposals for this tothe publisher: Verband der Technischen Oberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen. Contents 0 Foreword 8 Design principles 4 Scope 9 Tolorances and surface finish 2 General 10 Pressure testing 3 Materials 11 Literature 4 Testing Annex 1: Specimen of an impaction certiicate 5 Marking ‘Annex 2: Explanatory notes on AD 2000-Merkblatt N 2 6 Certification of quality Annex 3: Test specifications 7 Strength value 0 Foreword The AD 2000 body of regulations can be applied to satisty the basic safety requirements of the Pressure Equipment Directive, principally for the conformity assessment in accordance with Modules “G” and “B ‘The AD 2000 body of regulations is structured along the lines. of a self-contained concept. If other technical rules are used, in acoordance with the state of the art to solve related prob- lems, itis assumed that the overall 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 0° for different sectors of the law. Responsibility fr testing is as ‘pecitiedin the provisions ofthe relevant sector of the law. ‘materials for the manufacture of pressure vessels, parts of pressure vessels and fitings subjected to pressure, which are operated at wall temperatures ranging from ~60°C to +-400°C, the limits for the maximum wall temperatures of he materials being fixed according to the expert opinion of the. relevant third party, 1.2. Tho matorials shall bo selected to correspond to the. purpose, taking into account the mecnanical, thermal and chemical demands made on them. 1.3 Inthe case of pressure vessels made from electro-gra- phite or hard bumed carbon, as a rule the following limits apply to the maximum allowable pressure: 25 bar for exchangers of block construction 16 bar for tubular exchangers g Bt Scope ‘Oar or nalow onder upto NW 200, with nema 9 1.1 This AD 2000-Merkblatt applies to electro-graphite and 6 bar for hollow cylinders over NW 200, with internal & hard bumed carbon, impervious to gases andlor iquids, as pressure "AD 2000 Mordor aro prolcid by copyright The ighs a se, parlor fan arson, eprodactn, exec of ures, ransmission by phot ‘mechanical moans and storage in data reovalsytes, even of exe. ar econo the autor Cav Heymann Varig has ken lesson moasurs o ensure th accuracy of hs Varolaton bu reas tal no reepansby canbe seeped for any evar, amieslon or acourey. ln ease ‘ot doutt repre, the att acon ofthe Gea xt ny valid.AD 2000-Merkblatt Page 2 AD 2000 Mela N 2, 10.200 ein 16 bar for hollow cylinders up to NW 200, with external pressure 10 bar for hollow cylinders ever NW 200, with external pressure, In the case of internal pressures greater than 0,5 bar and external pressures greater than bar, ingeneral the following ‘mathematical products of whe vessel capacity Vin itres and, the maximum allowable pressure PS in bar shall not be exceeded: in the case of intemal pressure: V-PS= 65000 bar - Litre in the case of external pressure’ VPS = 100000 bar + Lite For deviations from these stipulations, the agreement of the relevant thi party shall be obtained, 1.4 Ifthe materials are used for cladding or with armouring which substantially bears the stresses, the above limits do not apply. 2 General 2.1. If electro-graphite or hard burned carbon are used as materials for pressure vessels, parts of pressure vessels or fitings, ther special properties Srl Ue taken into aucouri 2.2. A prerequisite for the manufacture of electro-graphite fand hard burned carbon is that the producing factory is, adequately experienced. Initial po ofthis shall be provided to the relevant third party 23. Vessels under pressure, parts of vessels and fitings made from electro-graphite or hard bumed carbon are used by preference because ofthe high resistance to corrosion of, these materials, They are resistant to almost all organic and inorganic media, provided that these media do not have a. strong oxidising action. 2.4 Tho materials are of abritie nature; they are insensitive to temperature changes. Peak etroaces shall be kept ac low as possible by a suitable design. 2.5 The manufacture of semi-finished articies') is carried ‘out with the procedures usual in the ceramic industry, such, {a6 extrusion proses or block prossos. Parts with compli. cated shapes can be made from semi-finished articles by machining. 2.6 Non-detachable joints in parts are made be cementing, ‘and the strength characteristics ofthe joints shall be guaran. teed to be adequate. Initial proof ofthis shall be provided to the relevant third party 2.7. Detachable joints can be made by means of, among tther things, anchor bolts, or bolts and flanges, 09 made from steel, with, as a rule, soft gaskets?) being used, 3. Materials 3.1. Definitions and characteristics 3.1.4. In the case of hard burned carbon and electro-gra- phite materials, a distinction is drawn between the two kinds Cf material ~ “impregnated” and "non-impregnated” ) 2g, hallow evn tos, clo, patos anos 3 Soe AD 2000 8 7, Take ie (1) Impregnated electro-graphite and impregnated hard ‘bumed carbon exhibit a certain drop in their strength as the temperature increases. The amount of this crop in strength and the limitof the maximum allowable walltem- perature depend on the impregnating medium. (2) Nor-impregnated olectro-graphite and non-impregnated. hard burned carbon exhibit no drop in strength as the temperature increases. 3.4.2 Electro-graphite and hard bumed carbon are divided, into the following strength classes, depending on the average. value of the tensile strength at 20°C: (1) In stops of 2Nimm? in the range of tensile strength between 41Nimm? to 20Nimme, and (2) In steps of 4 Nimme trom a tensile strength of 20Nimm= upwards, The grading into the strength classes is carried out by moans. of the average value obtained in accordance with 4.3 Dovia- tions of individual values from the average value by + 20%2) are permissibie. 3.2. Initial proof of quality characteristics For each kind of material and each impregnating medium, ini- tial proof of the changes in strength with the temperature, the ‘elalionshiy of the bending strength to the tensile strength, land the maximum wall temperature shall be provided by the ‘manufacturer tothe relevant thd party, Forthis, work reports, can be recognised. 3.3 Abbreviated designation of materials and quaiities ‘Abbreviated designations are used for materials. In these the letter K means hard burned carbon and the letter G electro- ‘graphite. The first number following the letter indicates the lower limit of the range of tho etrongth class at 20°C in 'Nimm®; the second number the drop inthis value in por thou- sand per 10°C rise in temperature, and the third number the, ‘maximum permissible wall temperature. Thus, itfor instance {@ non-impregnated hard bummed carbon with a tensile strength of 6 Nimme, having no drop in strength as tno tom: perature rises, and with a maximum permissible wall tor. porature of 400°C is designated as: K6~0~400 fend an impregnated electre-graphite with a tensile strength of 16Nimm?, a drop in strength of 8% and a maximum wall temperature of 200°C is designated as: G 16~8~200 4 Testing 4.1. The test pieces for determining the properties of the ‘material shall be taken from semi-finished articles. I this is injpussible, te lest pieves shall be laken from on compa: rable parts of the charge’). 4.2 For each charge the tensile strength or bending strength and if necessary the compressive strength (for the shape and dimensions of the test specimens see Annex) are to be determined at room temperature. Inthe case of parts of small dimensions or with thin wal thick= nesses, e.g. tubes, the bending strength (bending tensile strength) is determined instead of the tensile strength. Grad- 1 pail cas, s90 49.2. 4} Semtnchod wes whic madre sre mito, ane goto samo ‘raulacng process arcane simensone eval nateAD 2000-Merkblatt ing into the strength classes, as specified in 3.1.2, is cared ‘out on the basis of the bending strength, due account being taken of the relationship between the bending strength and the tensile strength, 43. Obtaining the average value and repeat tests 4.3.1. From each charge 6 tost piooes are taken. Dosisive: for determining the tensile strength is the avorage valuo of the individual results of the tensile test, or rospoctivaly tho, bending tests carried out in ts place. Deviations of individual values from the average value by ++ 20% are pormissibio, 43.2. If anindividual value falls below the average value by ‘more than 20% a replacement test piece shall be tested. If two individual values or the result ofthe replacement test on. the individual test plece do not meet the requirements, 5 fur tmer test pieces are to be tested. Iftnen the requirements, are ‘not met, the products made from this charge may be classi- fied in a lower strength class, or rejected. The decisive value for the lower classification is the new average valu, o, if an Individual value difers from the new average value by more than 20%, the lowest individual value 43.3. For obtaining the new average value, when testing an. Individual replacement test piece or a complete set of test pieces, the test pieces which have been replaced are ‘ignored. 4.3.4 Hone or two individual values come above the aver- ‘age value by more than 20%, these are ignored, and the average value is obtained only from the remaining individual values. 44 Testing the variations in size and the surface finish takes place as a rule during the final test onthe pressure ves- el 5 Marking 5.1. In the caso of somifnished articles, correspondence with the acceptance cartifcate chall be ensured untithey ara incorporated in the pressure vessel. This is done as a rule by marking, 5.2. Parts of the finished pressure vessel which have to withstand proscure shall be provided with tho abbroviated designation of the quality of material and with the manufactu- ror's mark. n the caso of a test by the relevant third party its test stamp shall also be applied. 5.2.1 In the case of small parts it shall be confizmed by tho. ‘manufacturer in a Works Certificate that the required quality, ff material has been used. As a rule, no marking is carried cout on the parts, 6 Certification of quali 6.1 The tests stipulated in clause 4 are carried out and recorded by the manufacturer as production proceeds. The ralavant third party cheeks thatthe tests ara propery carried ‘ou, including the factory records. For that purpose it can be present during manufacture and testing, and satisty itself as 1o the correctness of the works testing by marking random, tests, 6.2 The kind of quality certificate is determinded to the satisfaction ofthe relevant thi party by the inital test of tho material and the impregnating medium in accordance with 2. In the case of sufficiently well-known materials an inspection certificate 3.1. as DIN 500499) is sufficient. In the inspection certificate are statod only the test results ofthe type of test (tensile or bending) which are decisive for the ‘grading of the material into the strength class. 6.3 The manufacturing works have to state in the declara- tion of compliance with the order by means of an abbreviated designation the impregnating medium and the qualily of cement. In addition, in the case of non-detachable joints, adequate strength and temperature resistance for the oper- aling conditions corresponding to the intial proof shall be confirmed by the manufacturing works. 7 Strength value 7.4. The strength value Kat room temperatures the bottom limit of the tensile strength range of each strength class. In the case of materials specified in 3.1.1 (1), the strength value K at temperatures over 20°C is taken as the strength value K at room temperature diminished by the drop in the tensile strength, and the strength values shall be rounded off down: wards to hundredths. At temperatures below +20°C, the strength value K shall be taken as at +20°C. 7.2. The influence of time of a mechanical stress on the. strength values may be ignored. 8 Design p 8.1. For design calculations of pressure vessels or parts of, pressure vessels, the B series of the AD 2000-Merkblatter are to be used, with the following alterations or additions. plos 8.2. Inthe case of electro-graphite and hard burned carbon, the corrosion allowance stipulated in the AD 2000-MerkDlat- ter is dispensed with 8.3. The safety coefficient S as concems the strength value K_ In the case of the maximum allowable pressure and the ‘maximum allowable temperature is S = 9; in the case of the test pressure the safety cootficient S’ = 66. 8.4 Indesign calculations for cylindrical shells under exter- nal overpressure, the calculation to cover elastic buckling as ‘specified in AD 2000-Merkblatt 86 is dispensed with. In the design calculation to prevent plastic deformation, the usual strength value K increased by a factor of 2,5 shall be used in formula (4} of AD 2000-Morkblatt BS. The above also app- lies beyond the scope of AD 2000-Merkblatt B 6 to diameter ratios 1,2 = D/D, = 1,3. 8.5 In design calculations for tubes under extemal over prosaure in accordance with AD 2000 Merkblatt 86, the strength value K can be increased by a factor of 2. 9 Tolerances and surface finish 9.1. Tolerances shall be agreed upon between the manu- facturer and the customer'user; otherwise the Works Stan- dards of the manufacturer apply. 9.2. Permissible deviations where no tolerances are stated In accordance with DIN ISO 2768, “coarse” degree of accu racy, need not be taken into considerationin the calculations. Any otheriowor wall thicknesses shall be taken into consid rationAD 2000-Merkblatt Page 4 AD 200 MestlatN 2. 102000 eon 9.3 Agreement shall be reached between the manufacturer and the customer/user on the surface finish and the amiss pty ot layer ofimpregniating mealum on tne surtace; oiner- wise this is left to the manufacturer. 10 Pressure testing 10.1 The test pressure is 1,3 imes the maximum allowable pressure. In the case of pressures up to 1 bar the test pres sure shall exceed the maximum allowable pressure by not, less than 0,3 bar. 10.2 I itis not possible at the manufacturer's works 10, assemble a pressure vessel for the purpose of carrying out {he pressure test, ne test can be done on ine inalviaual pans. “The requirements of 10.1 apply for the values ofthe test pres- sure. 10.3 Bolore putting the pressure vessel into service it shall ‘be subjected 0 a pressure test in tne assembied conattion, ‘onthe erection site n the presence ofthe relevant third party. 11 Literature Linder, H.: Graphit im Druckbehalterbau Techn. Uberwach. 9 (1968) No. 1, pages 12/14.AD 2000-Merkblatt Annex 1 to AD 2000-Merkblatt N 2 Inspection certificate with reference to DIN EN 10204/3.1.8 Order placed by: Manufacturer: Tost subject Tostconditions: AD 2000-Merkbiatt N 2 Quality of materia corresponding to: Identification mark ‘quality of materia: Manufacturer's mark: tom No. | Number of pieces | Subject Ghargeriaentiicauon No. | Test results Nimm= 1. By our current tosts during manufacture and by the factory supervision of the TOY. itis ensured that the characteristics determined by the specification of the material quality are adhered to. 2. The parts aro impregnated with synthetic resin Type 8. For the comenting of parts to item Nos. coment type has been used. Adequate strength and temperature resistance for the working conditions and the pressure test guaranteed. 4, The small parts have been manufactured from tested semifinished material of material quality Dated, at ‘Works inspectorAD 2000-Merkblatt Poge 6 AD zneo Maiti N 2, 19.2000 aston Annex 2 to AD 2000-Merkblatt N 2 Explanatory notes on AD 2000-Merkblatt N 2 Pressure vessels made from electro-graphite and hard burned carbon Re 2: General Hard burned carbon and electro-graphite are produced as follows: ‘Coke and pitch can be used as the raw materials. They are, first mixed and then brought to the shape required for the semi-finished parts by pressing. These semi-finished parts, known as "green shapings", are then burnt at about 1000°C, for example in a ring furnace. The resulting product after this ‘burning is called "hard bumed carbon’ Electro-graphite is made from hard burned carbon ina further burning processina graphitising furnace at about 000°C: ‘As a tule, the hard burned carbon and electro-graphite thus, obiained are not tight against gases and/or liquids. The necessary gas-tghtness and liquid tightness for pressure vassalsis achieved by impregnation witha synthetic resin, Re 3.3 and 4: Abbreviated designation of materials and tests In the example K 6 ~ 0 ~ 400, the 6 indicates the strength class, in which the average tensile strength covers the range between 6Nimm? and 7,9Nimm?. For the next highest strength class the average tensile strength range lies between 8 Nimm? and 9,9.Nimm?. Exceeding the top limit of the tensile strength ofa relevant strength class is permissible provided that there are no adverse effects as regards the drop in tensile strength with temperature and the top limit of the thermal stresses. Re 8: Design priciples The ratio of the bending strength to the tensile strength (bending factor) in the materials dealt with here is > 1,5: 1, 0 that in itself a higher strength value K could be used in the case of bending strains. As, however, the calculations for, ‘components of electro-graphite or hard burned carbon sub: Jooted to bonding strose aro made, for oxamplo, in accord: ance with AD 2000-Merkblatt B5, the above-mentioned bending factor is ignored, because the corresponding formu: lae contain a support factor of the same amount for ductile materials, Inthe case of eloctro-graphite and hard burned carbon the ratio of the comprossion strength to the tensile strength is at least 3:1 However, for design calculation for extemal overpressure in accordance with AD 2000-Merkblatt 86, the factor 2,5 has, been selected, s0.asto cover any additonal stress effects, Re 9: Tolerances and surface finish AS a nl, in the manufacture af cnmpanents of elactengra- phite and hard bumed carbon the work willbe carried out in accordance with the permissible variations on measure ments where no tolerances are stated, DIN ISO 2768, “coarse” degree of accuracy. In the design calculations any diminution of the wall thickness resulting from this can be ignored, because in comparison withthe wall thickness itis, very small. ‘The machining of workpieces is done as a rule before the impregnating. Ifthe surfanas of workpieces ace not allowed tohave any coating of an impregnating medium, this shall be agreed upon between the manufacturer and the customer! user.AD 2000-Merkblatt ‘AD 000 Mer 2 112000 eon Pape 7 Annex 3 to AD 2000-Merkblatt N 2 | Test specifications (Ghape of teat specimens of olectro-graphito and hard ‘burned carbon, and test procedure). 41. The tensile strength is to be obtained on test specimens in conformity with DIN 81914 (Fig. 1) 2, The bending etrongth shall be dotormined from tost speci ‘mens of dimensions 20 x 20 x 120mm; the distance between supports shall be 100mm, and the test pieces are 10 be loaded centrally. In the case of components of ‘small dimensions or low wall thickness specimens of Tower, square cross-section (e.g. 10 x 19 or 5 x 5mm) ‘may be used; however, a ratio of 1 : 5 is to be observed between the cross-sectional edge length and the length of surface support when testing. In the case of tubes the tubo-soctions may be used to obtain the bending strength (support interval = 5 x external diameter, 3. The compressive strength shall be determined on test specimens of 20 x 20 x 20mm. In the case of compo- rnents with lower dimensions or lower wall thickness samples of stall, syuare cusssectivn (ey. 10. 10 40mm or § x § x 5mm) may be used and in the case Of tubes tube-sections (length = diameter) may be used for determining compressive strength. 4. As olectro-graphite and hard bumed carbon are brite materials suitable measures shall be taken when testing toavoid stress peaks al the points where force is applied, Fig. 1. Test specimenPublisher: <> Verband dr Techn bervchungs Verne E-Mail: vdtuev.essen@t-online.de hitp:/wwwudtuev de Source of supply: Carl Heymanns Verlag Luxemburger Strao 449, D-50939 Kéln Tolofax: 0221-9 43 73 603 E-Mail verkauf@heymanns.com