AD 2000-Merkblatt HP 8-1 Ed

8/2/2019 AD 2000-Merkblatt HP 8-1 Ed

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res 23.020.30 September 2001 editionManufacture and Testing of pressings made from AD 2000-Merkblatttesting ofpressure vessels steel, aluminium and aluminium alloys HP 8/1

The AD 2000-Merkblat ter are prepared by the seven associations listed below who together form the "Arbeitsgemeinschaft Druckbehelter"(AD). The structure and the application of the AD 2000 body of regulations and the procedural guidelines are covered by AD 2000-Merkblatt G 1.The AD 2000-Merkbratter contain safety requirements to be met under normal operating conditions. If above-normar loadings are to beexpected during the operation of the pressure vessel, this shall be taken into account by meeting speciar requirements.rf there are any divergences from the requirements of this AD 2000-Merkbratt, It shall be posslble to prove that the standard of safety ofthis body of regulations has been maintained by other means, e.g. by materials testing, tests, stress analysis, operating experience.

Fachverband Dampfkessel-, BeMlter- und Rohrleltungsbau e. V. (FDBR), DiissekiortHauptverband der gewerblichen Berufsgenossenschaften e. V., Sankt AugustinVerband der Chemischen Industrie e.V. (Vel), Frankfurt/MainVerband Deutscher Maschinen- und Anlagenbau e . V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinenund Apparate, Frankfurt/MainVerein Deutscher EisenhOttenleute (VDEh), DOsseldorfVGB Power Tech e.V., EssenVerband der Technischen Oberwachungs-Vereine e.V. (VdTOV), Essen.

The above associations continuously update the AD 20aO-Merkblatter in line with technical progress. Please address any proposals forthis to the publisher:

Verband der Technischen Oberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

c 1;0~'";a'?~ c : : .~O>g~;::'",,,,,> r!~ U 5~ m~ ~ r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~~ ~ AD 2000-Merkblii.tter are protected by copyright. The rights of use, particularly of any translation, reproduction, extract of figures, transmission by photo-

'" mechanical means and storage in data retrieval systems, even of extracts, are reserved to the author. Car l Heymanns Verlag has taken all reasonable; 3 . 3 measures to ensure the accuracy of th is translation but regrets that no responsibility can be accepted for any error, omission or inaccuracy. In casesof doubt or dispute. the latest edition of the German text only is valid.

o Foreword1 Scope2 Material tests3 Scope of material test and removalof specimens

4 Requirements

o ForewordThe AD 2000 body of regulations can be applied to satisfythe basic safety requirements of the Pressure EquipmentDirective, principally for the conformity assessment inaccordance with Modules "G" and "8 + F".The AD 2000 body of regulations is structured along the l inesof a self-contained concept. If other technical rules are usedin accordance with the state of the art to solve related prob-lems, it is assumed that the overall concept has been takeninto account.The AD 2000 body of regulations can be used as appropriatefor other modules of the Pressure Equipment Directive or fordifferent sectors of the law. Responsibility for testing is asspecified in the provisions ofthe relevant sector ofthe law.

Scope1. 1 This AD 2000Merkblatt deals with the testing of thestrength and toughness properties of pressings made fromflat products, regardless of the manufacturing process, aswell as visual examination and dimensional checks. Pres-

Contents5 Repeat tests6 Visual examination and dimensional check7 Marking8 Test certificatesAppendices 1 to 3: Examples of certificates

sings include ends, segments and other preformed compo-nents.1.2 This AD 2000-Merkblatt is also applicable to pressingsmanufactured from individual components by welding andsubsequent forming. AD 2000-Merkblatter HP 2/1, HP 5/ 2and HP 5/3 deal with the testing of such welded joints beforeand after forming.

2 Material testsThis AD 2000-Merkblatt is applicable on condition that theforming process and the equipment have been verifiedaccording to AD 2000-Merkblatt HP 0 or W O. A procedurequalification test according to AD 2000-Merkblatt HP 2/ 1which also covers the formed welded joint is required in thecase of pressings as specified in 1.2.2.1 Material tests on pressings as defined in Table 1 takeplace after the heat treatment which follows forming. Testingis required even if heat treatment may be omitted accordingto AD 2000-Merkblatter HP 7/2, HP 7/3 or HP 7/4; testing isthen performed after forming. Notwithstanding this, testing of


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Page 2 AD 2000-Merkb latt HP 8/1, 09.2001 edition

the starting products is suffic ient in the case of torisphericalends for which, according to 2.5 of AD 2000-MerkblattHP 7/2, heat treatment is not required and is not carried out.If the heat treatment of the pressing consists of stress reliev-ing, the specimen sections may be removed beforehand andmay be heat treated in the same manner (see 2.6 of AD 2000-Merkblatt HP 7/1).2.2 The scope of the material testing of pressings isdefinedin 3. This is on condition that the starting flat products meetthe requirements in Series W AD 2000-Merkblatter. Whenpressings are tested individually by the relevant third party,notwithstanding Series WAD 2000-Merkblatler, the startingflat products may be tested by the works authorised inspectorof the material manufacturer.For pressings which are manufactured by cold forming with-out subsequent heat treatment, flat products tested accord-ing to Series W AD 2000-Merkblatter shall be used.2.3 In the case of pressings made from clad flat products,3 applies analogously as far as the scope of material testingis concerned. The basic material is decisive when assigningmaterials to the Material Groups in Table 1. Special agree-ments may be necessary if a different heat treatment has tobe used for the basic material because of the cladding mate-rial.2.4 For hardened-and-tempered steels where batch testingis carried out, a hardness test performed by the manufactureron 10% of the pressings, but on at least three pressings, isrequired in order to demonstrate the uniformity of hardeningand tempering.2.5 The testing of pressings made from materials accordingto other material specifications takes places according to theassignment to a Material Group as defined in AD 2000-Merkblatt HP 0, Synoptic Tables 1 and 2 as stated in theassessment of suitability, unless the assessment of suitabi-lity stipulates individual testing.

3 Scope of material test and removal ofspecimens

3.1 For pressings having a length or diameter = . : : 4 m, thescope of the material test is defined in Table 1. A productionbatch shall only comprise pressings made from flat productsfrom the same cast and, in the case of steels in MaterialGroups 2 to 4.1, 5.1 to 5.4 (excluding X 8 Ni 9) and 7, fromthe same cast and with the same subsequent heat treatment.The wall thickness of pressings in a production batch shallnot differ from the average wall thickness by more than 20 %.One specimen section shall be removed in each case.3.2 For pressings having a length or diameter> 4 m, thematerial test shall be performed on each pressing (individualtesting). This applies to pressings which are heated andformed as a whole or heat treated as a whole as well as topressings which are manufactured from individual compo-nents by welding and subsequent forming. These specif ica-tions do not apply to pressings made of materials of Mater ialGroup 1 (1) regardless of thickness and Material Group 6 forthicknesses = . : : 30 mm for material 1.4541 and 1.4571 and= . : : 20 mm for other materials.3.2.1 A specimen section shall be removed from eachpressing having a length or diameter> 4 m and = . : : 6 m. If apressing contains single components from more than onecast, a specimen section shall be removed for each cast.

3.2.2 A specimen section shall be removed from two oppo-site sides in the case of pressings having a length or diameter> 6 m. If the pressing consists of two or more single compo-nents from the same cast, the two specimen sections shallbe removed from two single components. If a pressing con-tains single components from more than one cast, a speci-men section shall be removed for each cast.3.3 Excess lengths shall be providedforthe removal of spe-cimen sections. If this is not possible, the removal of speci-men sections shall be agreed, with the relevant third party ifapplicable. For materials in Material Groups 1 and 5.1 , speci-men sections which were subjected to a heat-treatment pro-cess identical that for the pressings themselves may betested.3.3.1 If it is possible to remove pieces from pressings hav-ing a length or diameter = . : : 6 m, such pieces may replace thespecimen sections taken from excess lengths.3.3.2 Where batch testing is carried out, it is not necessaryto provide excess length for the removal of specimen sec-tions on all the pressings in a batch.3_4 One set of specimens consisting of a tensile test speci-men and three notch impact specimens shall be cut in eachcase from the test sections. If starting flat products are usedwhich were not tested according to Series W AD 2000-Merkblatter, the tests to be performed are governed by therequirements in Series WAD 2000-Merkblatter. The speci-mens shal l be removed at r ight anqlest) to the roil ing-direc-tion. In the case of pressings made from steels as specifiedin DIN EN 10025, the notch impact specimens shall be cutparallel to the roiling-direction.

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4 RequirementsThe requirements stipulated for the starting products inSeries WAD 2000-Merkblatter are applicable, depending onthe nominal wall thickness of the pressings, unless AD 2000-Merkblatter HP 7/2, HP 7/3 or HP 7/4 stipulate other provisi-ons. The provisions in 8 of AD 2000-Merkblatt HP 5/2 shallbe observed.For pressings which were hot-formed or heat treated, theupper l imit of the tensi le strength range may be exceeded byapproximately 5 % provided that the other properties of thefinished component meet the requirements.

5 Repeat tests5.1 If the results do not meet the requirements, the proce-dure to be adopted is as follows:5.1.1 If the unsatisfactory results of a test are self-evidentlyattributable to deficiencies in the testing techniques emplo-yed orto a defect of very l imited size in a specimen, the nega-tive results shall be disregarded in deciding whether therequirements have been met and the relevant test shall berepeated.5.1.2 If the unsatisfactory results of a test are attributableto improper heat treatment, the pressings in the relevant testlot can be subjected again to the heat treatment process,whereupon the entire test shall be repeated.

1) A deviation of up to 20 degrees from this direction is permissible.


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Page 4 AD 2000-MerkblattHP 8/1, 09.2001 editionTable 1. Scope of material testing on pressings having a length or diameter :-:-::; mMaterial Material qradess) Scope of testing Scope of testing with relaxationGroup') without relaxation Prereq uisites Scope of testing

1 2 3 4 51 (1) Plain steels with a lower ten- Testing of initial plate with - -

sile strength limit specimens from specimen:::;440 N /mm2 excluding fine- sections which were separa-grained structural steels. tely heat treated or removed

from the finished heat-treatedplate3)

1 (2) Alloy steels and fine-grained 1. Testing of initial plate with 30 production batches must 1. Test ing of in it ial p late withstructural steels with mini- specimens from specimen initially be tested without specimens from specimenmum yield point sections which were sspara- rejection (proof of correct pro- sections which were separa-< 355 N /mm2 as well as tely heat treated or removed duction) excluding "other tely heat treated or removedP295GH and P355GH to DIN from the finished heal - treated materials" for which individual from the finished heat-treatedEN 10028-2 and S355J2G3 plate3) testi ng is stipulated in the plate'') andto DIN EN 10025 excluding 2. Testing of pressinqs per relevant third party's certifi- 2. Test one pressing for eachsteels with high impact production batch; production cate of conformity 100 pressings made from thestrength at low temperature. batches same material with the sameSee Footnote2) for up to 10 units 1 pressing subsequent heat treatmenttorispherical ends up to 25 units 2 pressings

up to 100 units 3 pressings1 pressing for each additional100 units

1 (3) Fine-grained structural steelswith minimum yield point2355 N /mm2 to< 370 N /mm2 excludingsteels with high impactstrength at low temperature

2 Fine-grained structural steelswith minimum yield point2370 to < 430 N/mm2excluding steels with highimpact strength at lowtemperature 1. Testing of in itial p late with

3 Fine-grained structural steels Testing of each pressing 30 pressings must initially be specimens from specimenwith a minimum yield point (individual testing) tested without rejection (proof sections which were separa-2430 N /mm2 excluding of correct production) exolud- tely heat treated or removedsteels with a high impact ing "other materials" for from the finished heat -treatedstrength at low temperature. which individual testing is sti- plate3)Hardened-and-tempered pulated in the relevant third 2. Testing of pressings perhigh-temperatu re structural party's certificate of confer- production batch; productionsteels mity batches11 NiMoV 5 3 up to 10 units 1 pressing17 MnMoV 6 4 up to 25 units 2 pressings15 NiCuMoNb 5 up to 100 units 3 pressings12 MnNiMo 55 1 pressing for each additional13 MnNiMo 54 100 units20 MnMoNi 5522 NiMoCr 3 720 MnMoNi 4 5

4.1 High-temperature steels:13 CrMo 4 410 CrMo 9 1012 CrMo 195X 10 erMo 9 1

4.2 High-temperature steels: Testi ng of each pressing - -14 MoV 6 3 and (individual testing)X 20 CrMoV 121


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AD 2000-Merkblat t HP 811,09,2001 edi tion Page 5

Table 1. Scope of material testing on pressings having a length or diameter zs 4 m (continued)Material Material grades6) Scope of testing Scope of testing with relaxationGroup') without relaxation Prerequ isites Scope of testing

1 2 3 4 55.1 Fine-grained structural steels Testing of each pressing 30 presslngs must initiaUy be 1. Testing of init ia l plate wi th

to DIN EN 10028-3 of the (individual testing) tested without rejection (proof specimens from specimenlow-temperature series and of of correct production) excJud- sections which were separa-the low-temperature special ing "other materials" for tely heat t reated or removedseries with a minimum yield which individual testing is sti- from the finished heat-treatedpoint < 370 N/mm2. Fine- pulated in the relevant thi rd plateS)grained structural steels to party's certi ficate of confor- 2. Testing of pressings perDIN EN 10028-3 of the basic mity production batch; productionand high-temperature series batcheswith a minimum yield point up to 10 uni ts 1 pressing


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Page6 AD 2000-Merkblatt HP 8/1, 09.2001 edition

Table 1. Scope of material testing on pressings having a length or diameter :'S 4 m (continued)Material Material grades6) Scope of testi ng Scope of testing with relaxationGroup'] without relaxation Prerequisites Scope of testing

1 2 3 4 56 X 6 CrNiTi 1810 Testing of initial plate with - -:s : 30 mm, specimens from specimenf; X 6 CrNiMoTi sections which were separa-5: 17122:S:30mm, tely heat treated or removed

'@ Other grades from the finished heat-treated:0~ :s : 20 mm plate::2:6 X 6 CrNiTi 18 10 1. Testing of initial plate with 30 production batches must 1. Testing of initial plate withco0 > 30 mm, specimens from specimen initiaJly be tested without specimens from specimenv0 X 6 CrNiMoTi sections which were separa- rejection (proof of correct pro- sections which were separa- 30 mm, tely heat treated or removed duction) excluding "other tely heat treated or removed< .S Other grades from the f inished heat-treated mater ials" for which individual from the f inished heat-treated'-'ill > 20 mm plate5) testing is stipulated in the plates)'"i3 2. Testing of pressings per relevant third party's certifi- 2. Test one pressing for each.ill'" production batch; production cate of conformity 100 pressings made from theE batches same material and with thecr"-' up to 10 units 1 pressing same subsequent heat treat-;=> up to 25 units 2 pressings mentl:

up to 100 units 3 pressings1 pressing for each additional100 units

7 Ferrite-free austenitic steels, Testing of each pressing 30 pressings must initially be 1. Testing of ini tial p late withbut if appropriate, with ferrite (individual testing) tested without rejection (proof specimens from specimencomponents in the weld metal of correct production) exclud- sections which were separa-and austenitic steels of Mate- ing "other materials" for tely heat treated or removedrial Group 6 as long as they which individual testing is sti- from the finished heat-treatedare welded with fil ler metal pulated in the relevant third platewith :s : 3 % delta ferrite in the party's certificate of confor- 2. Testing of pressings perweld metal, e.q, mity production batch; productionX 8 CrNiNb 1613, batchesX 8 CrNiNb 16 16, up to 10 units 1 pressingX 8 CrNiMoVNb 16 13. up to 25 units 2 pressingsup to 100 units 3 pressings

1 pressing for each additional100 units

All A199,98R Testing of initial plate with - -A199,8 specimens from specimenAI99,7; A199,5 sections which were separa-teiy heat treated or removedAI2 (1) AIMn1; AIMnCu from the finished heat-treated

plateAI2 (2) AIMg3 :s : 30 mm 1. Test ing of ini tial plate with 30 production batches must 1. Test ing of ini tial p late with

AIMg2MnO,8 :s : 30 mm specimens from specimen initially be tested without specimens from specimenAIMg4,5Mn 515 mm sections which were separa- rejection (proof of correct pro- sections which were separa-

tely heal treated or removed duction) excluding "other (ely heat treated or removedfrom the finished heat- treated materials" for which individual from the finlshed heat-treatedplate testing is stipulated in the plate2. Testing of pressings per relevant third party's certifi- 2, Test one pressing for eachproduction batch; product ion cate of conformity 100 pressings made from thebatches same mater ial and with theup to IOu nits 1 pressing same subsequent heat treat-up to 25 units 2 pressings mentup to 100 units 3 pressings1 pressing for each additional100 units

AI2 (3) AIMg3 > 30 mm Testing of each pressing 30 pressings must initially be 1. Test ing of ini tial plate withAIMg2MnO,8 > 30-mm (individual testing) tested without rejection (proof specimens from specimenAIMg4,5Mn > 15 mm of correct production) exclud- sections which were separa-

ing "other materials" for tely heat treated or removedwhich individual testing is st i- f rom the f inished heat-treatedpulated in the relevant third plateparty's certificate of confer- 2. Testing of pressing permity production batch; production

batchesup to 10 units 1 pressingup to 25 units 2 pressingsup to 100 units 3 pressings1 pressing for each additional100 units


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AD 2000-Merkbfatt HP 8/1, 09.2001 edi lion Page 7

Table 2. Markinq') of small pressings with an outside diameter or nominal width up to 220 mmOutside Materia! Group Marking Test certificate Test certificate

diameter or ace. to tor the starting materialnominal Appendixwidth2)

:::; 50 1 (1) steel grades ace. to None 1, 2 or 3 Kept by manufacturer ofDIN EN 10025 pressings

AI1> 50 Material symbol and 1,2or3 Kept by manufacturer ofto:::; 220 manufacturer's pressings

brandmark:::;220 1 (1) except steel grades ace. to Material symbol and 1, 2 or 3 Kept by manufacturer of

DIN EN 10025 manufacturer's brand- pressings1 (2) mark67AI2(1)AI2 (2)

:::;88,9 Other Material Groups Material symbol and 1, 2 or 3 Test certificate is enclosedmanufacturer's brand-mark as well as therelevant third party'stest mark

> 88,9 ace. to clause 7 1,2 or 3') With thickness greater lhan 3 mm for s teel and 5 rnrnfor aluminium, marking is obtained by stamping or impress ion. Ink marking or engraving is used for srnal-ler thicknesses Smal l axis of nominal width inthe case of oval components


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Page 8 AD 2000-Merkblat t HP 8/1.09.2001 edi tion

Appendix 1 to AD 2000-Merkblatt HP 8/1Inspection certificate 3.1.B1)

Test report")Certificate of compliance with the order")

for hot-formed pressings made from ferrit ic steels

Purchaser: Order No.:Manufacturer: Job No.:Basis of testing: AD 2000-Merkblatt HP 8/1Delivery date:Item No. Quantity Object/dimensions Material Melt Specimen No.

Plate Pressing(

We hereby confirm that the forming process was performed ace. to AD 2000-Merkblatt HP 7/2, Section 3.2_Heat treatment after forming: (state holding temperature, holding time and cooling conditions)The hot-pressing process was monitored by (Technical Supervisory Body). Evidence was provided of suitability of the equip-ment used for heat treatment in accordance with AD 2000-Merkblatt HP 7/1 Section 3.1_Plate/supplied by yourselves*)/according to enclosed*)1 in our possession*)/test certificate(s) to DIN EN 10204 were used:(state type, test No., date, issuer)The plate used was restamped where necessary. The pressings are also marked with the following details:- Pressing manufacturer 's brandmark- Specimen number- Batch number and identification of product which provided the specimen jf applicable- Mark of testerTesting of the pressings1. Visual examination and dimensional check2. Material test3. For welded ends:3.1 The requirements in AD 2000-Merkblatt HP 5/2 were met3.2 Non-destructive testing according to AD 2000-Merkblatt HP 5/3

Surface crack testRadiographic examinationUltrasonic examination

satisfied in accordance with Enclosure

Date Signed

Enclosures

') In accordance with DIN EN 10204.) Delete inappropriate items


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AD 2000-Merkblat t HP 8/1, 09.2001 edi tion Page 9

Appendix 2 to AD 2000-Merkblatt HP 8/1Inspection certi ficate 3.1.8')

Test report')Certificate of compliance with the order')

for hot-formed pressings made from austenitic steels

Purchaser: Order No.:Manufacturer: Job No.:Basis of testing: AD 2000-Merkblatt HP 8/1Delivery date:Item No. Quantity Object/dimensions Material Melt Specimen No.

Plate Pressing

We hereby confirm that the conditions in AD 2000-Merkblatt HP 7/3, Table 1, column 3*)/4*) were adhered to for the formingprocess.Heat treatment after forming: (state solution annealing and quenching or stabilising)The hot-pressing process was monitored by (Technical Supervisory Body). Evidence was provided of suitability of the equip-ment used for heat treatment in accordance with AD 2000-Merkblatt HP 7/1 Section 3.1.Plate/supplied by yourselves*)/according to enclosed')/ in our possession*)/test certificate(s) to DIN EN 10204 were used:(state type, test No., date, issuer)The plate used was restamped where necessary. The pressings are also marked with the following details:- Pressing manufacturer 's brandmark- Specimen number- Batch number and identification of product which provided the specimen if applicable- Mark of testerTesting of the pressings1. Visual examination and dimensional check2. Material test3. For welded ends:3.1 The requirements in AD 2000-Merkblatt HP 5/2 were met3.2 Non-destructive testing according to AD 2000-Merkblatt HP 5/3



Date Signed

Enclosures

1) In accordance wi th DIN EN 10204*) Delete inappropriate items


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Page 10 AD 2000Merkblatt HP 8/1, 09.2001 edition

Appendix 3 to AD 2000-Merkblatt HP 8 /1Inspection certificate 3.1.81)

Test report")Certificate of compliance with the order")

relating to cold-formed pressings

Purchaser: Order No.:Manufacturer: Job No.:Basis of testing: AD 2000-Merkblatt HP 8/ 1Delivery date:Item No. Quantity Object/dimensions Material Melt Specimen No.

Plate Pressing(

We hereby confirm that normalising*)/solution annealinq"] at ... C with a holding time of ... min with subsequent cooling inIwith ... Ina heat treatment*) was performed. The heat treatment meets the stipulations in AD 2000-Merkblatter HP 7/2 orHP 7/3.Further heat treatment ...The forming process was monitored by (Technical Supervisory Body). Evidence was provided of suitability of the equipmentused for heat treatment in accordance with AD 2000-Merkblatt HP 7/1 Section 3.1.Plate/supplied by yourselves*)/according to enolosed'j/ in our possession'j/test certificate(s) to DIN EN 10204 were used:(state type, test No., date, issuer)The plate used was restamped where necessary. The pressings are also marked with the following details:- Pressing manufacturer's brand mark- Specimen number- Batch number and identification of product which provided the specimen if applicable- Mark of tester

(

Testing of the pressings1. Visual examination and dimensional check2. Material test3. For welded ends:3.1 The requirements in AD 2000-Merkblatt HP 5/2 were met3.2 Non-destructive testing according to AD 2000-Merkblatt HP 5/ 3



Date Signed

Enclosures1) In accordance wi th DIN EN 10204") Delete inappropriate items


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