105676490-AD-2000-Merkblatt-W5-2009

AD 2000-Merkblatt

Supersedes July 2003 edition; completely revised

AD 2000-Merkblätter are protected by copyright. The rights of use, particularly of any translation, reproduction, extract of figures, transmission byphotomechanical means and storage in data retrieval systems, even of extracts, are reserved to the author. Beuth Verlag has taken all reasonablemeasures to ensure the accuracy of this translation but regrets that no responsibility can be accepted for any error, omission or inaccuracy. In cases ofdoubt or dispute, the latest edition of the German text only is valid.

ICS 23.020.30 March 2009 edition

The AD 2000-Merkblätter are prepared by the seven associations listed below who together form the “Arbeitsgemeinschaft Druckbehälter”(AD). The structure and the application of the AD 2000 Code and the procedural guidelines are covered by AD 2000-Merkblatt G 1.

The AD 2000-Merkblätter contain safety requirements to be met under normal operating conditions. If above-normal loadings are to beexpected 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 ofthis Code has been maintained by other means, e.g. by materials testing, tests, stress analysis, operating experience.

Fachverband Dampfkessel-, Behälter- und Rohrleitungsbau e.V. (FDBR), 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 Maschinenund 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 forthis to the publisher:

Verband der TÜV e.V., Friedrichstraße 136, 10117 Berlin.____________

Materialsfor

pressure vesselsCast steel AD 2000-Merkblatt

W 5

Contents

0 ForewordThe AD 2000 Code can be applied to satisfy the basic safetyrequirements of the Pressure Equipment Directive, princi-pally for the conformity assessment in accordance withmodules “G” and “B + F”.

The AD 2000 Code is structured along the lines of a self-con-tained concept. If other technical rules are used in accordancewith the state of the art to solve related problems, it is assumedthat the overall concept has been taken into account.

The AD 2000 Code can be used as appropriate for othermodules of the Pressure Equipment Directive or for differentsectors of the law. Responsibility for testing is as specifiedin the provisions of the relevant sector of the law.

1 Scope1.1 This AD 2000-Merkblatt is applicable to cast steel usedfor the construction of pressure vessels and pressure vesselcomponents which are operated at working temperatures andambient temperatures down to –10 °C and up to the uppertemperature limits specified in clauses 2 and 3. For working

temperatures below –10 °C, AD 2000-Merkblatt W 10 alsoapplies.

1.2 AD 2000-Merkblatt A 4 applies to accessory housings.

1.3 Basic requirements for materials and material manu-facturer are regulated in AD 2000-Merkblatt W 0.

2 Suitable cast steelThe following cast steel types may be used:

2.1 Ferritic cast steel GE200 (1.0420), GE240 (1.0446)and G20Mn5 (1.6220) to DIN EN 10293 within the applica-tion limits given in Table 3.

2.2 Cast steel for use at room temperature and elevatedtemperatures in accordance with DIN EN 10213, but onlygrades GP240GH (1.0619), G20Mo5 (1.5419), G17CrMo5-5(1.7357), G17CrMo9-10 (1.7379), G17CrMoV5-10 (1.7706),GX8CrNi12 (1.4107) and GX23CrMoV12-1 (1.4931) up tothe wall thicknesses1) specified in this standard.

1) Specified wall thicknesses may be increased upon agreementwith the relevant third party. In its normalized state, however,steel grade GP240GH shall only be used up to a maximum wallthickness of 100 mm.

0 Foreword1 Scope2 Suitable cast steel3 Material requirements4 Heat treatment and welding5 Testing

6 Marking7 Type of test certificate8 Design valuesAppendix 1: Highest admissible indicating

characteristics in the radiographicexamination RT

B55EB1B3C7662F79D1B59483A53B9F2F82C98BEEB793928B7FD56BB682DF1F876DE05A0587F35FDFB3AD73AA414DCADCD06ECDF35CD97C7BA16771E6629A3A886C7995BC6B3C56E44C2F00070DBA226AF1A47B37B4A5A296EE686DDB4D95572BEE0F87

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AD 2000-MerkblattPage 2 AD 2000-Merkblatt W 5, 03.2009 edition

2.3 Cast steel for use at low temperatures to DIN EN10213, but only grades G17Mn5 (1.1131), G20Mn5(1.6220), G9Ni10 (1.5636) and G9Ni14 (1.5638) up to thewall thicknesses1) specified in the standard, and alsoGX3CrNi13-4 (1.6983) in conjunction with VdTÜV-Werk-stoffblatt 452.

2.4 Low-temperature cast steel grades G10Ni6 (1.5621),G26CrMo4 (1.7221)and GX6CrNi18-10 (1.6902) in accord-ance with Stahl-Eisen-Werkstoffblatt (SEW) 685 up to atemperature of 50 °C2).

2.5 Other ferritic or martensitic cast steel upon proof ofqualification by the relevant third party, which shall alsoinclude the application limits, requirements, test and inspec-tion instructions, marking and instructions on furtherprocessing (forming, heat treatment, welding). The caststeel shall exhibit the property values characteristic of thestandard material and shall meet the following minimum re-quirements:

– Elongation at fracture A at room temperature ≥ 15 %,

– Impact energy at lowest working temperature, but notexceeding 20 °C, ≥ 27 J on V-notch test specimens asspecified in DIN EN 10045-1.

A requirement of the above tests is that the fracture behav-iour is ductile. The results of additional brittle fracture tests,obtained in the qualification procedure may justify other min-imum values.

2.6 Austenitic cast steel types to DIN EN 10213, but onlygrades GX5CrNi19-10 (1.4308), GX5CrNiNb19-11 (1.4552),GX5CrNiMo19-11-2 (1.4408) and GX5CrNiMoNb19-11-2(1.4581) to the temperatures stated for the minimum proofstress values indicated in Table 2 of this standard, note beingtaken of the specifications concerning corrosion resistancegiven in Table A.1 of DIN EN 10213. Where a resistance tointercrystalline corrosion is required for cast steel type1.4408, the application temperature shall not exceed300 °C. For centrifugal castings VdTÜV-Werkstoffblatt 286applies, in addition.

2.7 Other austenitic cast steel upon proof of qualificationby the relevant third party, which shall also include the appli-cation limits, requirements, test and inspection instructions,marking and information on further processing (forming,

heat treatment, welding). The cast steel shall exhibit theproperty values characteristic of the standard material andshall meet the following minimum requirements:

– Elongation at fracture A at room temperature ≥ 20 %,

– Impact energy at lowest working temperature, but notexceeding 20 °C, ≤ 35 J on V-notch test specimens asspecified in DIN EN 10045-1.

2.8 For other cast steel specified in 2.5 and 2.7, evidenceof the elevated temperature proof stress and, if applicable,long-term elevated temperature properties shall be providedby the manufacturer, specifying the standard analysis andheat treatment.

3 Material requirements3.1 Regarding the general requirements for cast steelparts, DIN EN 1559-1 and -2 apply in addition to the mate-rial standards.

3.2 Quality levels

Depending on the differing requirements for the internal andexternal surface condition of castings, cast steel shall bedelivered in qualities classified in accordance with Table 1.Table 1 contains the assignment of qualities to the maxi-mum allowable temperature and the maximum allowablepressure unless a higher quality is required due to specialoperating conditions. Where pressure and temperature donot fall under the same quality, the quality with the more ex-acting requirements shall take precedence.

The standards to be applied for non destructive testing aregiven in Table 1.

4 Heat treatment and welding4.1 For heat treatment purposes, the specifications givenin DIN EN 10213 or in the relevant Werkstoffblätter (materialmaterial specifications) apply.

4.2 For welding, the specifications in 6.2 of DIN EN 10213,apply.

1) see page 12) For definition of wall temperature and working temperature, see

Section 5 of AD 2000-Merkblatt B 0.

Table 1. Assignment of quality levels

Quality level

Maximumallowable

temperature

Maximumallowablepressure

Quality levels

permissible indicating characteristics

°C bar PT 2) MT 3) RT 4) UT 5)

11) Welding ends SP1,CP1 SM1 1 1

2 > 450 > 80 SP2,CP2,LP2,AP2 SM2,LM2,AM2 2 2

3 > 400 to ≤ 450 > 32 to ≤ 80 SP3,CP3,LP3,AP3 SM3,LM3,AM3 3 3

4 ≤ 400 ≤ 32 SP4,CP4,LP4,AP4 SM4,LM4,AM4 4 4

1) Linear or aligned indications, when detected by surface testing, are not permitted.2) Liquid penetrant inspection PT in accordance with DIN EN 1371-1 or DIN EN 1371-23) Magnetic particle inspection MT in accordance with DIN EN 13694) Radiographic examination RT in accordance with DIN EN 12681/acceptance criteria in accordance with Appendix 1 to this AD 2000-Merkblatt5) Ultrasonic examination UT in accordance with DIN EN 12680-2


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AD 2000-MerkblattAD 2000-Merkblatt W 5, 03.2009 edition Page 3

The welding procedures shall be approved by the relevantthird party in accordance with DIN EN ISO 11970. All testsgiven in Table 1 of DIN EN ISO 11970 shall be performed.In doing so, the following applies:

– Hardness tests shall not be performed on cast steelgrades of groups F and G.

– Bend tests on two side bend test specimens SBB inaccordance with DIN EN 910. The requirements given inDIN EN ISO 15614-1, 7.4.3, apply.

– Test for resistance to intercrystalline corrosion in accord-ance with DIN EN ISO 3651-2 for cast steel grades ofgroups F and G, if this type of corrosion is required.

– Determination of the ferritic content for cast steel gradesof group G.

– Tensile test and impact V notch test on the parent metal,if no test certificates in accordance with the relevantAD 2000-Merkblätter of the W-series are available forthe parent metal.

The results of the non destructive tests shall fulfil the re-quirements of quality level 1. Cracks and lacks of side fusionare inadmissible. Other defects are admissible within thelimits given in the AD 2000 Merkblatt HP 5/3.

5 Testing5.1 Cast steel components specified in 2.1 to 2.4 and 2.6shall be tested in accordance with the standards and mate-rial specifications contained therein. Testing shall be per-formed on a cast by cast basis so that components havingunder-gone the same heat treatment are covered. The max-imum weight of a test batch for the notched bar impact testand tensile test is 2500 kg. Excess quantities up to 1250 kgshall in each case be added to the preceding test batch.Cast steel components weighing in excess of 1000 kg shallbe tested individually.

For austenitic cast steel components, in addition to the 1,0 %proof stress, the 0,2 % proof stress shall also be deter-mined. The 0,2 % proof stress shall be 25 MPa lower thanthe 1,0 % proof stress.

5.2 For cast steel components specified in 2.5 and 2.7, thetesting requirements shall be laid down in the qualificationtest.

5.3 All castings shall be inspected for their external con-dition. Safety-relevant dimensions shall be checked. Thechemical composition shall be determined by ladle analysis.

5.4 Where quenched and tempered castings are exam-ined cast by cast, they shall be subjected to comparativehardness testing. The result of the hardness tests shallshow a regular quenched and tempered condition (the dif-ference in hardness between the hardest and softest com-ponent tested in the test batch shall not exceed 30 HB).

5.5 Should special operating conditions prevail, leak testsfor checking the tightness of walls and examining the castingfor the presence of defects shall be performed. The type andextent of such tests shall be agreed when placing the order.

5.6 The castings shall be subjected to non-destructivetesting to verify the use of the correct qualities as specifiedin clause 3. The non destructive testing personnel shall becertified in accordance with DIN EN 473 for the test methodsgiven in Table 1.

The extent of testing is defined in Table 2 of this AD 2000-Merkblatt. Castings weighing in excess of 1000 kg shall betested individually.

For weldings, radiographic examination shall be carried outin accordance with DIN EN 1435, Category B.

5.7 For austenitic steel castings to DIN EN 10213, testingfor resistance to intercrystalline corrosion in accordancewith DIN EN ISO 3651-2 shall be performed for each castand heat treatment batch. This test may be waived byagreement with the customer/user.

6 MarkingThe minimum requirement shall be indelibly marked with atleast the following:

– Manufacturer’s symbol

– Designation of material

– Cast number

– Test stamp of relevant third party or authorized inspec-tion representative in cases of deliveries with inspectioncertificates in accordance with DIN EN 10204.

Table 2. Extent of testing to verify the quality level

7 Type of test certificateThe quality shall be certified as follows:

7.1 For cast steel specified in 2.1, by inspection certificate3.1 to DIN EN 10204.

Quality level

Extent of testing in relationto the number of components

1 100 %

2 100 %

3

1. Prototype: 100 %

2. Pilot lot: 100 % on at least 10 components

3. Seriesproduction:

100 % on areas identified as critical on pilot lot components. If no critical areas are identified on pilot lot components, 10 % of the components shall be tested at generally difficult-to-cast locations. All components shall be subjected to surface detection.

4

1. Prototype: 100 %

2. Seriesproduction:

Random testing on areas identified as critical on prototype components or at generally difficult-to-cast locations. All components shall be subjected to surface detection.


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7.2 For cast steel specified in 2.2 to 2.4, inspection certifi-cate 3.2 to DIN EN 10204 is required. For cast steel gradeGP240GH, inspection certificate 3.1 to DIN EN 10204 willsuffice provided the component weight does not exceed500 kg.

7.3 For cast steel specified in 2.6, by inspection certificate3.2 to DIN EN 10204. For unit weights less than 200 kg, in-spection certificate 3.1 to DIN EN 10204 will suffice.

7.4 For cast steel specified in 2.5 and 2.7, in accordancewith the approval testing requirements.

7.5 By means of inspection certificate 3.1 to DIN EN 10204,the manufacturer shall confirm3) that the requirements inthe relevant standards and Table 1 are satisfied with regardto the qualities concerned. If quality is proved by inspectioncertificate 3.2 to DIN EN 10204, the results of the non-destructive tests on welding ends and castings of qualitylevels 1 and 2 shall finally be evaluated by the relevant thirdparty. For radiographic examination, the relevant third partyshall perform the evaluation on 100 % of the castings, forultrasonic examination and surface testing, it shall performa re-evaluation on 10 % of the castings.

7.6 Contents of the inspection certificates to DIN EN 10204

The inspection certificates shall contain the information re-quired by the technical delivery conditions/standards. Fur-thermore, in each inspection certificate the technicaldelivery condition/standard (e. g. DIN EN 10213) and Tech-nical Rule (AD 2000-Merkblatt W 5) forming the basis for thedelivery shall be stated.

8 Design values8.1 For cast steel specified in 2.1, the values in Table 3 apply.

8.2 For cast steel specified in 2.2 and 2.3, with the ex-ception of grade GX3CrNi13 4, the values stipulated inDIN EN 10213 apply. For cast steel GX3CrNi13 4, the val-ues stipulated in VdTÜV Werkstoffblatt 452 apply.

8.3 For cast steel specified in 2.4, the values stipulated inSEW 685 apply.

8.4 For cast steel specified in 2.6, the values stipulatedin DIN EN 10213 are applicable, but they shall be reducedby 25 MPa for calculation purposes (please refer toDIN EN 10213, Table 3, footnote b). For austenitic centrifu-gally cast steel, the values stipulated in the VdTÜV-Werk-stoffblatt 282 apply.

8.5 For cast steel specified in 2.5 and 2.7 the values laiddown in the qualification apply.

8.6 The design strength values laid down for 20 °C by thematerial specifications or qualification apply up to 50 °C andthose specified for 100 °C up to 120 °C. In the remainingtemperature ranges, linear interpolation between the speci-fied values is necessary (e.g. for 80 °C, between 20 °C and100 °C and for 180 °C, between 150 °C and 200 °C), but norounding up is permitted. For individually certified materials(special material appraisal) the interpolation rule only ap-plies if there is a sufficiently close interval4) between thepoints of support.

3) This confirmation may also be included in the certification of therespective higher quality.

4) As a rule, this means a temperature interval of 50 K within therange of elevated temperature proof stress and of 10 K withinthe creep rupture strength range.

Table 3. Application limits and design values for cast steel according to 2.1

Cast steel grade

Wall thicknessDesign value K at design temperature

20 °C 100 °C 150 °C 200 °C 250 °C 3001) °C 3501) °C

mm MPa MPa MPa MPa MPa MPa MPa

GE200 ≤ 100 200 181 167 157 137 118 –

GE240 ≤ 100 230 216 196 176 157 137 –

G20Mn5+N≤ 30 300 216 205 197 193 186 178

> 30 to ≤ 100 260 184 173 166 161 154 146

G20Mn5+QT ≤ 100 300 216 205 197 193 186 178

1) The design temperature shall not exceed 300 °C or 350 °C even for heated parts. AD 2000-Merkblatt B 0, Table 1 shall be takeninto consideration.


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AD 2000-MerkblattAD 2000-Merkblatt W 5, 03.2009 edition Page 5

Tab

le A

1H

ighe

st a

dmis

sibl

e in

dica

ting

char

acte

ristic

s in

the

radi

ogra

phic

exa

min

atio

n R

T

Ap

pen

dix

1 t

o A

D 2

000-

Mer

kbla

tt W

5

Def

cts

Hig

hest

adm

issi

ble

defe

cts

for

qual

ity le

vels

Type

Cod

e le

tter

in

acco

rdan

ce w

ith

AS

TM

1)

With

wal

l th

ickn

esse

sin

mm

Eva

luat

ion

in

acco

rdan

ce w

ith

AS

TM

1)1

2 2)

3 2)

4 2)

Gas

cav

ities

A

up to

51

E44

6A

1A

3A

3A

4

over

51

up

to 1

14E

186

A1

A3

A3

A4

over

114

up

to 3

05E

280

A1

A3

A3

A4

Non

-met

allic

in

clus

ions

B

up to

51

E44

6B

1B

3B

3B

4

over

51

up

to 1

14E

186

B1

B3

B3

B4

over

114

up

to 3

05E

280

B1

B3

B3

B4

Cav

ities

C

up to

51

E44

6C

a1, C

b1,

Ca2

, Cb2

,C

a3, C

b3,

Ca4

, Cb4

,

Cc1

, Cd1

,C

c2, C

d2,

Cc3

, Cd3

,C

c4, C

d4,

over

51

up

to 1

14E

186

Ca1

, Cb1

, Cc1

Ca2

, Cb2

, Cc2

Ca3

, Cb3

, Cc3

Ca4

, Cb4

, Cc4

over

114

up

to 3

05E

280

Ca1

, Cb1

, Cc1

Ca2

, Cb2

, Cc2

Ca3

, Cb3

, Cc3

Ca4

, Cb4

, Cc4

Cra

cks

D +

Ein

adm

issi

ble

inad

mis

sibl

e 3)

inad

mis

sibl

e 3)

inad

mis

sibl

e 3)

Cha

plet

s an

d ch

ills

F

up to

51

E44

6in

adm

issi

ble

inad

mis

sibl

ein

adm

issi

ble

F1

4)

over

51

up

to 1

14E

186

inad

mis

sibl

ein

adm

issi

ble

inad

mis

sibl

eF

1 4)

over

114

up

to 3

05E

280

inad

mis

sibl

ein

adm

issi

ble

inad

mis

sibl

eF

1 4)

1)T

itel:

AS

TM

-E44

6 –

Ref

eren

ce r

adio

grap

hs fo

r st

eel c

astin

gs u

p to

2 in

. (51

mm

) in

thic

knes

s,A

ST

M-E

186

– R

efer

ence

rad

iogr

aphs

for

heav

y w

alle

d (2

to 4

½ in

. (51

to 1

14 m

m))

ste

el c

astin

gs s

owie

AS

TM

-E28

0 –

Ref

eren

ce r

adio

grap

hs fo

r he

avy

wal

led

(4 ½

to 1

2 in

. (11

4 to

305

mm

)) s

teel

cas

tings

.2)

If it

is d

emon

stra

ted

by, e

.g.,

ultr

ason

ic e

xam

inat

ions

that

ther

e ar

e de

fect

s in

the

core

zon

e (s

ee F

igur

e A

.1),

the

info

rmat

ion

give

n fo

r th

e nu

mer

ical

ly h

ighe

r qu

ality

leve

l ap-

plie

s (e

.g. 3

inst

ead

of2)

, unl

ess

othe

rwis

e sp

ecifi

ed in

the

orde

r.3)

Unl

ess

the

inno

cuou

snes

s of

the

crac

ks is

dem

onst

rate

d by

frac

ture

mec

hani

cal e

xam

inat

ions

.4)

Cha

plet

s m

ay b

e pr

esen

t, bu

t sha

ll be

wel

ded

with

a c

rack

-fre

e su

rfac

e.


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Figure A 1: Division of the wall into zones (division refers to thickness d of the finished casting)


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AD 2000-Merkblatt

– Blank page –


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Publisher: Source of supply:

Beuth Verlag GmbH10772 BerlinTel. 030/26 01-22 60Fax 030/26 01-12 [email protected]

Verband der TÜV e.V.

E-Mail: [email protected]://www.vdtuev.de


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Documents

105676490-AD-2000-Merkblatt-W5-2009