1 Car Heymanne Veriag KG (Gnemaurger Sate 448, D-S0909 Kain AD 2000-Merkblatt Ics 23.020.30 June 2001 edition vessel equi Equipment, installation Pressure vases! enufprment and marking of pressure vessels. AD 2000-Merkblatt Equipment for detecting and limiting ‘A403 pressure and temperature The AD 2000-Merkbtter are prepared by the sovon associations listed below who together form tho “Arbeltsgemeinschat Druckbehaltar” (Ad). The structure and the appicaton of the AD 2000 body of rogulations and the procedural guidelines ere covered by AD 2000-Merkbiat GT. The AD 2000-Merkblater contain safety requiramonts to be met under normal operating conditions, I above-ormal loadings are to be ‘expected during the operation of the pressure vesse) this shall be taken ilo account By meeting special requirements. there are any divergences fom the requirements ofthis AD 2000-Merkblat, it shall be possible to prove thatthe standard of safety of this bod of regulations has boon maintained by other means, e.g. by materials testing, fess, sass analysis, operating experionce. FFachworband Dampfkosse!-, Behélter- und Rofvltungsbau @.V. (FOBR), Disseldort Hauptverband der gewerblchen Berufsgenossenschatten 0.V, Sankt Augustin Verband der Chemischen Industie«.V. (VCD, FrankturtiMain Verbana Beurscher Mascninen- una Anfagenbau e.¥. (VOMA), Facngemeinscnant Vertarenstochnische Maschinen und Apparate, FranktutiMain Verein Deutscher Eisenhittenloute (VDEn), Dassotdort VGB PowerTech eV, Essen Verband der Tectnischen Uberwachungs-Versine @.V. (VATUV), Esson, The above associations continuously update the AD 2000-Merkblate in ine with technical progress. Please address any proposals for this tothe publisher Verband der Technischen Uberwachungs-Vereine e. P.O. Box 103834, D-45038 Essen. Contents 0 Foreword 4 Tomporature measuring dovieoe 1 Scope 5 Safely devices to prevent temperatures 2 Pressure measuring devices 8 Safety devices for provention of excess pressure exceeding upper or lower limits (temperature limiters) 6 Safety prossuira limiters 0 Foreword ‘The AD 2000 body of reguiations can be applied to satisfy the basic safety requirements of the Pressure Equipment Diroctive, 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. I ather technical rules are used in acoordance with the state of the art io 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 ofthe Pressure Equipment Directive or for ierent sectors of the law. Responsiblty for testing 1s as specifiedin the provisions ofthe relevant sector ofthe law. 1 Scope 1.1 This AD 2000-Merkbiatt applies to equipment of pres- ‘sure vessels with devices for detecting and limiting pressure ‘and tomperature') 1.2. Whore other regulations apply to special pressure ves- sels, these are contained in AD 2000-Merkblatt HP 801. 2 i aoossres mses conse pesar vsel ale aocseoes. re ‘rer actors thay shal be miedo asa nny asso ‘Deane nahh aE rn thoy con in extol ‘mochanéal means and storage no 1 doubt or esate the atest eon of the Getman exten vai ‘AO 2000 erate ar pratecod by copyright Tho igh fue, pariodary of ay wanslato,reproaicion, enact of Ages, Wananveuon by pow reireval systems, even of extras, ar recervod the autor Cat Heymann Vatag has taken a easonable ‘measures fo ansure the accuracy ofthis taneain bulrerets thal no resporstally canbe acepled for any ero. cmesion cr accucy. in casesAD 2000-Merkblatt Page 2 AD 2000¥ertit AAC, 06200" eon 2 Pressure measuring devices 2.1 To ensure indication accuracy for operating purposes, pressure vesse's or pressure chambers with a maximum allowable pressure greater than atmospheric pressure shall be fied with suitable measuring devices, e.g. pressure ‘gauge (manometer), remote indicator, recording manome- ter. 24.4 The indicating range of the pressure measuring device shall cover the maximum allowable pressure and test, pressure, but shall nat significantly exceed the test pressure. 24.2 Apressure measuring device shall be such thatitcan- not be rendered inoperative by the charge material (uid) 24.3 The indication given by the pressure measuring {device shall be capable of being checked. The check can be carried out using a 3-way cock for exampie, with facilities for connecting test gauges, or by removing and checking on a test bench, 2.1.4 Tho maximum allowable prossure shall be indicatod by ated warning mark on the face of the pressure gauge, or by relovant details on a special plate. This doos not apply to remote indicating equipment in control rooms or control boards, 241.8. Pressure gauges shall be designed, or arranged in ‘such a way that if leak or fracture of the pressure gauge ‘occurs, operators cannot be injured by the charge material (tid), oF fragments ofthe fracture. If this cannot be achieved by @ suilabie arrangement af the equipment, special safety pressure gauges shall be used. 22. The pressure measuring device shall be fitted: (1) on the pressure vessel, oF (2) with its own connection to the pressure vessel, e.g. via a line or transmitter, or (3) on the pressure generator (pressure supply system) or in the pressure supply pipe of one or more prossure ves: sola 2.2.1. For pressure vessels with two or more pressure ‘supply pipes, the pressure measuring device shall be fitted to each pressure supply pipe where itis nat fitted tothe pres- ‘sure vessel, oF does not have is own connection tothe pres sure vessel 2.2.2 For pressure vessels which are required tobe opened {during operation, the pressure measuring device shall be fit- ted on the pressure vessel itself, and for those where a rise in pressure other than by pressure supply is possibie, e.g. by ‘chemical reaction or for heated pressure vessels, it shall either be on the pressure vessel itself, or be fitted by its own, connection to the pressure vessel 2.3. Ifthe pressure Is clearly determined by the temperature of the charge material (uid), the pressure measuring device may be replaced by a suitable temperature measuring device which measures the temperature of the charge material (fuid) in the pressure vessel. See clause 4 3. Safety devices for prevention of excess pressure 3.1. Prossure vessels or pressure chambers where a pres- ‘sure higher than the maximum allowable pressure can ari shall be fitted with a safely device appropriate to the oper- ating purpose which automatically prevents the maximum allowable pressure rom boing exceeded by more than 10% 3.2 Safety devices for preventing excess pressure are as follows: — pressure relie! devices, or — process instrumentation and contol devices (PCT) which ssafoly provont he causee of possible unaccoptable exooe: 308 of pressure. 3.2.1. Safety devices for the prevention of excess pressure shall be designed and fitted so thatthe charge material (fluid) fs unable to render them inoperative. They shail be easily accessible and be secured against any unintentional change in the response pressure. 3.2.2 In the case of pressure vessels in circuits used for Conveying gases, storage water vessels and steam-heated pre-heaters in thermal power stations, suitable safety shut off valves may also be used, Examples of suitable devices are, for gas piping, safety shut off davices complying with DIN 3381 and, for thermal power plants, safely shutoff devices complying with clause 13 of ‘AD 2000-Merkblatt A 2. 3.2.3 When designing safety devices for the prevention of ‘oxcess prescure, it may be nececeary to tako account of the particular fring system, e.g. selfigntion, fring from below of the relevant pressure vessel, When calculating the discharge capacity of safety devices for the prevention of excess pres: sure in the event of radiated heat (protection against fre Joads) on pressure vessels storing gases, reference shall be ‘made t0 3.2.3.3 of TRB 610. 3.2.4 Pressure reli devices shall not assume the task of regulating the system 3.3. The requirements for process instrumentation and con: trol safety devices as specified in 3.2 are met if. for example, the requirements of AD 2000-Merkblatt A 6 are observed 3.4 Pressure rellet devices as described in 3.2 are spect cally (1) safoty valves as specified in AD 2000-Merkblatt A 2, (2) rupture safety devices as specified in AD 2000-Merkblatt, Ay (8) process instrumentation and contro! safety devices which relieve pressure, in accordance with AD 2000- Merkblatt A 6. 3.4.1 The triggering of the safery cavice for preventing excess pressure shall be avoided where possiblo, 0.9. by ‘maintaining a sulticient tolerance between the working pres sure and maximum allowable pressure. If necessary ~ a pressure regulating device — a pressure limiter shalibe fited upstream eitherindividvally orin combination or, ifthe pressure in the charge chamber is clearly detormi- ned by the temperature of the charge material (uid) ~ a temperature regulating device or — a temporature limiter 3.4.2 When the maximum allowable pressure is exceeded, pressure relief devices shall respond and dischaye the resulting maximum mass flow within a pressure increase of, 10%. If the resulting maximum mass flow is discharged within a lower pressure increase, then the pressure reliefAD 2000-Merkblatt device may respond at a pressure higher than the maximum allowable pressure. In these cases, an adcitional device ~ e.g. a reyulatiny deviow ur pressure finite, shill isu Ural the maximum allowable pressure is not exceeded during ‘continuous operation, 3.4.3 Rupture safety devices may be usedinstead of safety valves if, for example, safety valves are unable to discharge the resulting mass flow because of the formation of gas or steam turbulence, 3.4.4 I a rupture safety device is fited upstream of the ‘safety device, then a device capabie of detecting any oak or {racture in the rupture safoty dovice shall be fitted between the two. This may be in the form of a pressure gauge, for ‘example, which is permanently monitored or which automati- cally riggers an alarm, 3.4.5. It shall not be possible to shut-off the pressure relict device specified in 3.2. 3.4.5.1 If pressure vessels, or pressure chambers are ‘equipped with a second pressure relief device acting as a back-up, a two-way cock, a three-way valve or a blocking device may be filed provided that the necessary discharge area is maintained at al mes, including the changeover. If one of the two pressure rele! devices Is removed, then :moasures shall be taken to ensure thatthe setting on the two- way cock, the three-way valve or the blocking device is not changed, 3.4.5.2 With pressure relief devices as specttied In 3.4 Which discharge into apressurized system—e.g, intothe flare system of a process contol plant, shut-off devices may be present downstream of the pressure relief devices if dange- ‘ous fluids have to be prevented from flowing back during disassembly of the pressure reliel devices. The unimpaired ‘functioning of the pressure relief devices shall also be ensu- red al all imos while pressure vessels protected in this way are sill operating, ‘The requirement is met if, for example, the shut-off devices are secured against unintentional closing, 3.4.6 The pressure relief device shall be fitted as follows: (1) byits own means ofattachmentio the pressure vessel, (2) on the pressure generator (pressure network), oF (3) in the pressure supply line of one or several pressure vessels. 3.4.6.1 Whore pressure vessels have two or more preseure, supply lines, the pressure relief device shall have its own means of attachment to the pressure vessels, or be attached in each pressure supply line. If this device is ‘ocated in the pressure supply line and the pressure in the pressure vessel {cannot Increase because of other factors, such as, for ‘example, chemical reactions or heating, then, by way of devi- ation from sentence 1, it can be shut-off from the pressure vessel by a shut-off device. 3.4.0.2 In ine case ot pressure vessels whore itis possible for the pressure to increase by means other than by the supply of pressure via pressure supply lines -0.g, by chomi- cal reaction or heating, then the pressuro relief devico shall have its own means of attachment fo tho pressure vessol 3.4.7. Discharge lines downstream of pressure relief devi ces shall not impair the operation of those valves and shall be able to discharge the charge material (fuid) safely ia A 499, 08.2001 en Page 3 ‘Atthe design and, it appropriate, also the setting stage of the pressure relief device, account shall be taken of back-pres- ‘sure On the uutlel sie, 3.5 As a deviation from 3.1, an alarm device may be pre- ‘sent instead of the automatically operating safety device for the prevention of excess pressure, if the use of a safely device as specified in 3.1 is either not possible, or inappropr ate ~e.9.ifa corrosive, sticking or sublimating charge mate- tial may impair the operation of safely valves — and if, once {an alarm is given, operational steps can be taken to prevent the pressure rising further. For this, a relief device shall be provided, designed so that a pressure which is more than 10 % in excess of the maximum allowable pressure is avo ded, where such an excess of pressure cannot be avoided safely by other operational measures ~ e.g, by blocking or switching of the pressure generator. ‘The alarm device shall trigger an optical or audible signal in {good time before the maximum allowable pressure of the pressure vessel s exceeded which can be clearly perceived by the operating personnel. The requirements of 3.2.4 and 3.4.1 also apply accordingly 3.5.1 Alarm devices are (1) signal-omiting, pressure-controlled devices with their ‘wn tine connecting to the pressure vessel -6.g. contact pressure gauges, or (2) signal-emitting, temporature-controlled devices ~ e.g contact thermometers, provided the pressure is clearly determined by the tarmperature of the charge material (uid) and if @ thermometer is not already being used instead of the pressure measuring devices. 3.5.2. It shall be possible to check the functioning of the flarm device. 35.3 The requirement of 3.4.5 applies accordingly for alarm devices. 3.8. Pressure vessels In which a negative operating pres: sure may arise for which they are not designed shall be equipped with a pressure relief device to counter an unac- ceptable drop of pressure below the permitted lovel “Those devicas chall bo designod so that they oan onvey th ‘maximum necessary mass flow, usualy in the form of a cu rent of a, without the pressure being able to drop below the allowable negative pressure. 4 Temperature measuring devices 4.4 Pressure vessels, or pressure chambers where the temperatures can go beyond the upper, or lower limits of the ‘minimumimaximum tomperaturee eh bo fitted with a tom perature measuring device suitable for the type of operation, 49. temperature measuring equipment (thermometer), remote indicating equipment or temperature recorders. The ‘equipment shall cover the maximum possible temperature range and shail be such that it cannot be renderea inopera- tive by the charge material (lu). 4.2 It shall be possible to check the indication of the tem- erature measuring device at the point of installation, or on a test bench, 4.3. The minimum/maximum allowable temperature shall be indicated by a red warning mark on the face of the tem-AD 2000-Merkblatt Pogo 4 AD Zo0D‘Menala A 409, 06:2001 econ Perature measuring equipment, or by suitable details on a special plate. Sentence 1 does not apply to temperature meaeuring equip: ent in control rooms or conto! boards. 5 Safety devices to prevent temperatures ‘exceeding upper or lower limits (tempera- ture limiters) 5.1. Pressure vessels, or pressure chambers shall be fitted With a temperature limiter suitable for the type of operation, if unacceptable temperatures of the vessel walls, or of ihe charge material (fluid) can lead to a dangerous situation. The temperature limiter may be replaced by an alarm device com= bined with a temperature reguiator, or temperature measu- ‘ing equipment provided suitable operating measures can be taken to keep the temperature within the allowable limits at, any time when the alarm is operated. The safely device to prevent the temperature going beyond the upper or lower limits shall be secured against being changed unintentio- rally. See DIN 3440. 5.2 The safety device specified in 5.1 shall be fitted so that, itis accessible and cannot be rendered inoperative by the ‘charge material (tluid) of the pressure vessel Publisher: _Nerband der Tecan Ubervchungs ers E-Mail: vdtuey.essen@t-online.de hitpswww.vetuev.de 5.3 It shall bo possible to check the effectiveness of the safety devices in accordance with 5.1 5.4 Where alarm devices are used, iney shall be titted so that the operating personnel can detect when an alarm has been given at all times, 6 Safety pressure li rs Pressure vessels for storing highly toxic or combustible ‘gases which are to be operated without constant supervision and in which the operating pressure can exceed the maxi= ‘mum allowable pressure due to heating devices, or prossure generators shall be equipped with a safety pressure limiter 80 that they meet the requirements of 3.2.4 and 3.4.1 A safety pressure limiter disconnects or shuts off the heating device or the pressure generator respectively when triggered and the resetting function is blocked. Disconnection or shut- ting-off also resutin the event of possible faults in the compo- nents ofthe safety pressure limiter's mechanical or electrical system. The requirements which the safety pressure limiters, shall meet are similar to the requirements specified in DIN, 3440 for safoty tomporature limiter. Provided that the pressure in the charging chambers clearly determined by the temperature of the charge material (fui), a safety temperature limiter in accordance with DIN 3440 can, be used instead of the safety pressure limiter Source of sunny é Car] <2 Heymanns Verlag Luxemburgor StraBe 449, D-5 Telefax: 0221-9 43 73 603 E-Mail: vorkauf@heymanns.com 999 Koln