'© Carl Hoymanns Verlag KE (ember Sra 44, 0 5099 Kaln AD 2000-Merkblatt Ics 23.020.30 October 2000 edition Equipment, installation and marking of pressure vessels Openings, closures and closure elements ‘AD 2000-Merkblatt AS Tho AD 2000-Merkbltter aro propared by the seven azcociatons listed below wh togothor frm tho “Arbeitegemeineohait Oruckbohaltr' (AD). The structure and the apptston of te AD 2000 body of regulations and dhe procedural guidelines are covered by AD 2000-MerkDlat G 1. The AD 2000-Merkblatter contain sally requirements to be met under normal operating conditions. I above-normel loadings are to be {expected during the operation of the pressure vessel, his shall be taken into account by meeting special requirements. tere are any divergences from tho requirements ofthis AD 2000-Morkblat,t shal be possible o prove that the standard of safety of this body of regulations has been maintained by ather means, e.g. By materials testing, tests, stress analysis, operating experince. Fachwerband Damptkessel, Bahiiter- und Rotletungsbau e.V. (FDBR), Dussoldor! Hauptverband der gewerblchen Berufsgenossenschalton eV, Sankt Augustin Verband dor Chemischon Industrie e.V. (VCH), Frank Vorband Doutscher Maschinen: und Aniagenbau e.V. Lund Apparate, FrankturtiMain Voroin Deutsche, Eisanhittonlouto (VDER), Disseldort VGB PowerTech e.V, Essen Verband der Technischen Uberwachungs-Vereine eV. risfain (WOMA), Fachgemeinschat Verlaronstechnische Maschinen WTO, Essen. The above associations continuously update the AD 2000-Merkblatter inline with tochnical progress. Please address any proposals for {nis tothe publisher: Verband der Technischen Uberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen. Contents 0 Foreword 1 Scope 2 Openings 3 Closures: 0 Foreword The AD 2000 body of regulations can be applied to satisfy the basic safely 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 structured along the lines of a self-contained concept. If other technical rules are used in accordance with the stato 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 or for, ifferent sectors of the law. Responsibility for tosting is as ‘specified in the provisions of the relevant sector of the law. 1 Scope 1.1 This AD 2000-Merkblatt applies to openings, closures ‘and closure elements of pressure vessels. It contains re- ‘quirements for the nature and dimensions of openings to ‘enable inspections to be carried out. Requirements regard ing the number and siting of openings are presented in ‘Appendix 1 to this AD 2000-Merkblat. “AD 2000 Morkbtor are protected by copyright The rights of vse, particulary ‘mechanical rears and storage in data retrieval systems, even of eto. a ‘measures tone ‘tout rapt, he ata eon the German ent ony a cus of is ransaton tigre that no reepersbty can bo accpted fr any ere, amasion or nacturacy. aoe 4 Closure elements 5 Materials, calculations and manufacture of closures and closure elements Requirements for closures and closure elements are also given, 4.2 Where other rogulations apply to particular presaure vessels, these are given in AD 2000-Merkblatt A 801) 2 Openings 24. General requirements 24.1 Pressure vessels shall be proved with openings ~ the nature, dimensions, number and siting of which shall enable inspections to be cared out. These are manholes {easy-eccess and resricted-acoess openings) ana inspec: tion pots (head holes, hand Roles and peep holes) 2.1.2 Manholes and inspection ports are not necessary it the tests can be carried out in some other manner, e.g. via nozzles, pipe adaptors or other detachable parts, 2.1.3 Manholes and inspection ports are not necessary it they are unviable or unsuitable due to the type of construction, of the pressure vessel (e.g, tube apparatus, plate heat * Inpreparaton king secourtha PED (97 23EC) by coporatog he neces San acre vues om teen TFS, of ay warcaon repcdcton, exact of fques, varemiaion by pha rresrved othe ater. atl Heyman Verlag has atone roasonaeAD 2000-Merkblatt Page 2 AD ZmOD etal A 5, 10.2000 ston exchangers, heating and cooling jackets, pipe arrange- ‘ments), the method of operation or charge material 2.1.4 Where necessary, attention is drawn to Annex V No, 1.2.1.3 of the Hazardous Substances Ordor (GetStoffV) ‘as well as the Guidelines for Working in Containors and Con- fined Spaces (Order Number ZH 1/77 obtainable from Carl Hoymanne Verlag, Cologne). 2.2. Nature and dimensions of openings ‘The minimum dimensions specified in the following Table 1 for the effective size of openings may be reduced by 20 mm _at most on account of the presence of coatings or linings only in the case of easy-access and restricted-access openings. ‘The nozzle height o ing height species for oponingsrepre- sents the maximum distance to be negotiated and maximum hhoight rositicting the view of the inside of the vesael 2.3. Siting and accessibility of openings 2.3.4 The positioning of the openings in the vessel shall be ‘governed by practical considerations and shall allow the ‘openings to serve their intended purpose; itis also neces sary forthe space required inside vessels to be available to permit a person to climb inside, tomove about within the ves Sl, Or 10 enable inspections to be carried out, or, when necessary. lo enable persons to be rescued from the vessel. Inthe case of an oval opening in a largely perpendicular wall, the major axis should generally be horizontal Table 1. Overview of requirements and dimensions of openings Type Inside diameter’ — | Nozzle or Definitions and of nominal width) =| ing requirements, ‘opening DN minimum |__ height Round Oval Maximum (mm) (eam) (nm) Easy-aocess ‘Access into the vessel shall be possible with the ‘opening | help of aids and personal protection gear. normal | DN 600 - | - minimum | DN 500 250 ‘Only when indispensable for design reasons Restricted- 450 | 350 x 450 150 2.9, aco. to Annex V No. 1 of the Hazardous acoess | ‘Substances Order and Guidelines for Working ‘openings in | in Containers and Confined Spaces (Order special cases | No. ZH 1/77 obtainable trom Carl Heymanns ‘Veriag, Cologne) for containers up to 10 m= | capacity and when at least one additional vent DN 100 is present Restricted- It shall be possible to move about within the access openings vessel without personal protective gear or aids: normal) 420/820 x 420 | 150 straight | conical designs shall not be allowed to impair 420 | 320 x 420 | 175 tapered accessibility, ‘minimum | 400 | 800 x 400 | 150 straight | Only when indispensable for design reasons; 400 | 300 x 400 | 175 tapered restrictions due to coatings or linings are not permissible Head hole 320 | 220 x 920 120 Opening though which a head, an arm and a light source can be introduced into the vesse! imultaneously. Hand hole 120 | 100 x 150 | 65 straight | Opening through which a hand-held lamp and 120 | 100 150 | 100 tapered | hand can be introduced into the vessel | simultaneously. If the maximum dimension of | the nozzle or ring heights exceeded for design | reasons, the opening shall be enlarged in such ‘a manner that the field of view afforded is, | preserved, Peep nole 50 = ou. ‘Opening through which the inside of the vessel ‘can be inspected with the aid of special lighting ‘equipment. Smaller diameters or greater nozzle ‘heights are only permissible if they are indispensable for design reasons and the field of view afforded is preserved andlor the inspec- tion is made possible by additional means (provision of suitable inspection equipment).AD 2000-Merkblatt 2.3.2 If special aids (e.g. ladders, platforms, hand-holds) are requited for climbing into the vessel, moving about inside, Xt, oF carrying out inspections through the openings, 1 Is, nocessary elther for provision to be made in the design for such aids, or itis for the operator to make them available at tho time of the ingpection. This also applies for the removal of closure covers which are dificult to manipulate, 3 Closures 3.1. Definitions 3.14 Closures are, for example, blanking flanges, covers Which are located on the inside, covers with special closure elements, yoke closures and quick-acting closures. They form a direct closure between the pressure vessel and the surrounding atmosphere, 3.1.2 The term quick-acting closure describes all forms of, ‘closure, with the exception of yoke closures, which ~ com- pared with closures where the closure elements have to be ‘operated individually — have shorter opening and closing times. 3.1.2.1. Interlocked quick-acting closures are those where the opening process andlor the pressure application is inter looked in such away that unwanted functional proccases are not possible, 3.4.2.2 Non-interlocked quick-acting closures are those which do not meet the requirements for interlocked quick-act- Ing eloource. 3.1.3 The term yoke closure describes an externally app- lied cover mounted on the prossure vessel at one side and ‘closed by means of aclosure oloment,o.g. clamping bolt 3.1.4 Covers with special closure elements have at least, {wo closure elements to be operated individually without the Use of a tool. 3.2 Gonoral requirements: 3.2.1 Closures shall be designed so that they are suitable {or their intended purpose and cannot fail under operating stress, @. automatic opening under pressure Is not possible. 3.2.2 Pants of closures in accoraance with 3.1.1 which are ‘subject to pressure form part of the test as specified in AD 2000-Merkbiatt HP 511 and HP 512. 3.2.3. If there is a danger due to delay in bolling of the ‘charge material, e.g, when steniizing iqu-tied containers inpressure vessels, it shall be ensured thatthe pressure ves- ‘sei cannot be opened until the temperature of the liquid has ‘dropped sufficiently below the boiling point at atmospheric, pressure. A thermal safety device, for instance, meets this, roquirement 3.2.4 Covers located on the inside shall not be used on pressure vessels with a dangerous charge material, e.g. sub- stances in accordance with the Hazardous Substances, Order. 3.2.5. In the case of covers which are located on the inside ‘and which are secured by means of a yoke and a central bolt- ing arrangement, the clearance relative to the edae of the hole — uniformly’ Gistributed all the way round ~ may not, ‘exceed 3 mmin the case of vessels with operating pressures Lup to and including 32 bar, and may not exceed 2 mm in the case of those with operating pressures in excess of 32 ber. AD Ato aka 5, 10.2000 eon Page The seal shall be prevented from being forced out. This Fequirement is regarded as having been satisfied if metal ‘seals or metal braided seals are used, or if covers of the type in question have a bead, a shoulder, or are of convex form on the low-pressure side. In the case of pressed plate ‘components with a bead or a convex profile, the latter shall, be at least 5 mm higher than the thickness of the seal 3.9 Additional requirements for yoke closures, quick- acting closures and covers with special closure elements 3.3.1. Yoke closures shal be designed so that the cover is, positively ventilated before the closure element releases the Cover. This requirement is, for instance, fulfilled by yoke clo- sures in accordance DIN 28 126. Yoke closures for openings. whose maximum aperture dimension exceeds 600 mm shall, meet the requirements for quick-acting closures. 3.3.2 Quick-acting closures shall be designed sothatopen- ing under pressure is not possible. ‘An interlocking device is necessary for closures which due, to the geometry can exert a force from the internal pressure, (on the closure in the opening direction. This shall be design- 1d so that opening is securely prevented even without a selt- locking device. In the case of non-interlocked quick-acting closures the preseure warning dovico in accordance with 3.3.4 shall be connected to the locking device. For non-inter- locked quick-acting closures the locking device in accord: ance with 3.3.7 shall be included in the lock. 3.3.3 The suitability and reliability of quick-aeting closures shall be verified. In the case ofinterlocked quick-acting closu: res on pressure vessels, the interiock shall be tested by an individual test or type test. The functional testing of quick-act ing closures shall be carried out as part of the acceptance test in accordance with AD 2000-Merkblatt HP 513%), 3.8.4 Non-interlocked quick-acting closures shall have a pressure waming system which is connected to the closure system in such amanner that the quick-acting closure cannot, ‘open until the prossure warning deviee ie open. It shall not be possible for the pressure warning device to close until after the quick-acting device has closed comple- tely The closure of the cover oF of the closure elements with the pressure waming device closed shall be precluded. The pressure warning device shall have an intemal diameter of at least 8 mm. If there is a danger of obstruction, special measures are required. It shall be possible for a clearing device to be pushed through the pressure warning device and any discharge shall not constitute a hazard. Where adis- ‘charge pipe is connected this shall nt incorporate any shut off device or have the effect of constricting the cross section The route adopted for the discharge pipe shall not incorpo- rate any bends which appreciably impede the flow. The outlet ‘of the pipe shall bein the field of view of the operating person: nel, oritshalle possible to see the flow through the pipe. 3.3.5 Norintetlocked quick-acting closures shall_ be designed so that a gap is formed on opening through which the pressure in the pressure vessel can be safely discharged bore the cover is opened further. Where the charge material has a tendency to adhere, aposi- twve gap shall necessarily be formed on opening. ‘When designing the restraining device which limits the gap. ‘dynamic forces such as those produced when the cover is, ‘opened shall be allowed for.AD 2000-Merkblatt Page 4 AD 2000.Merk.t AS, 12000 eon 3.3.6 Where non-interlocked quick-acting closures are used, manual means only shall be employed for opening and applying pressure 3.3.7 Inthe case ofinterlocked quick-acting closures itshall bbe ensured that the closure cannot be opened until the pres- sure is equalized with atmosphere, During closing i shall be ensured that the vessel can be pres: surized only after the closure is fully sealed, Inthe case of electrical components of interlocks, the require- ents are considered to be complied with, for example, ifthe specifications of DIN VDE 0116 are met. This also applies 2S appropriate to non-electrical components, 3.3.8 Covers with special closure eloments shall be design- ‘0d 60 that a gap is formed on opening through which the pres- ‘sure in the vessel can be safely released before the cover, is oponed further. Where the charge materialhas a tendency toachere this gap, shalt be produced in a positive manner. 3.3.9. It shall be possible to detect whether all the closure elements have reached their terminal positions, 3.3.10 Inthe case of quick-acting closures fitted to pressure vessels, where the charge material is of a caustic, extremely, toxic or combustible nature, leakiightness shall be ensured through the adoption of special design measures such as the application of proceure from an oxtornal aouree to the cal When pressure from an external source is used to effect a seal, there shall be no possibilty ofthe charge space being pressurized until after the extomal pressure has been applied To the seal 3.3.11 All safety devices on quick-acting closures shall be designed and fitted so that: (1) they cannot be rendered ineffective by the charge mate- tial (2) the functional safety is not impaired by environmental influences; (@) functional inspections and maintenance work can be carried oUt at suitable intarvala, Publisher: eu de Technischen eran Verne E-Mail: vdtuey.essen@t-oniine.de hitp:/twwwvdtuev.de 4° Closure elements 44° Clamp-boits Clamp-bolts which clamp the closure cover to the mating flange shall be design-tested or subject to individual tests, (Guidelines for component testing of clamp-bolts, see ‘Appendix 2). They shall be secured to prevent them from slipping off, and shall be attached to the vessel in such ‘manner that when they are swung away they cannot drop of 42 Hinged bolts Hingod bolts which aro lt into the closure cover slots, ©.9 eye bolts according to DIN 444, shall be secured against Unintentional sipping. Nuts and washers shallbe fully seated outside the slots 5 Materials, calculations and manufacture of, closures and closure elements 5.1 The requirements for closure covers, flanges, bolts and ‘other closure components subjected to pressure, in respect ‘of materials, calculations and manufacture, are satisfied it the relevant AD 2000-Merkblatter are employed 5.2. The permissible surface pressure K,, e.g. at the projec- tione of bayonet type elooures made from rolled steel, ean be assumed to be 1,0. In the case of unmachined surfaces or surfaces which have not at least been finished to give a ‘smooth fit, it shall be assumed that the surfaces are load- bearing to the extent of no more than 75%, 5.3. Allowance shall be made for any weakening ofthe clo- ‘sure components due to wear of corrosion by increasing tho calculated dimensions through the addition of appropriate margins 5.4_In the case of closures with several locking elements, the closure components shall be designed and machined so that the individual components are subjected to uniform load= ing during service. 5.5. Inthe case of closures with more than three locking ele- ‘ments, the theoretical load on a locking element determined, (on the basis of the prevailing conditions in the case in point, shall be increased by at least 20% when carrying out cal- ulations. Source of supply Carl Heymanns Verlag Luxemburger Stra8e 449, D-50939 Koln Telefax: 0221-9 43 73 603 E-Mail: verkaul@heymanns.com