AD 2000-Merkblatt Ics 23.020.30 October 2000 edition Materials for pressure vessels Cast iron with lamellar graphite (grey cast iron) nor-alloy and low alloy AD 2000-Morkbiatt wait | | J ‘The AO 2000-Morkbfater are prepared bythe seven associations iste Below who together form the “ArDeftsgemenschaft Drucktenaltr (AD). The structure andthe appicaton ofthe AD 2000 body of regulations and the procedural guidelines are covered by AD 2000-Merkat G 1. The AD 2000-Merkblater contain safety requirements to be met under normal operating conditions, If above-normal loadings are to be ‘expected during the operation ofthe pressure vessol, this shall bo taken into account by meeting special requirements. 1 there are any divorgoncos rem the requirements ofthe AD 2000-Morkblt, i shal be possible to prove that the standard of safely of this body of regulations has been mainainod by other means, 0.9, by materials testing, tests, sess analysis, oporatng oxperonce. Fachwerband Damptkesset, Behalter- und Rotveitungsbau e.V. (FDBR), DUsseldor! Hayptverband der gewerblchen Borulsgenossenschaiten @.V., Sankt Augustin Verband der Chemischen Indust 0.V. (VC), FrankfurtiMaln Verband Doutschor Maschinen und Anlagenbau e.V. (VDMA), Fachgemeinschalt Verfehrenstachnische Maschinen lund Apparate, FrankiuriMain Voroin Deutscher Eisenhittenleute (VDEt), Dussoldort GB PoworToch e.V., Essen Verband der Technischen Oberwachungs-Vereine e.¥. (VSTOV), Essen, The above associations continuously update the AD 2000-Merkbiite i ine with technical progress, Pleaso address any proposals for this fo the publisher: Verband der Technischen Oberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen. Contents 3 3 Cera ? é 0 Foreword 1 Scope and general 2 Suitable materials 3 Tests 4 Quality of castings 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 5. F The AD 2000 body of regulations structured along the lines. of a self-contained concept. If oher technical rules are used in accordance 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 or for, different sectors of the law. Responsibility for testing is as specifiedin the provisions of te relevant sector ofine law. 1 Scope and general 1.1. This AD 2000-Merkblatt applies to unalloyed and low- alloyed cast iron with lamellar graphite for the construction (of pressure vessels operating at working temperatures deter- ‘AD 2000-Merblator aro protacted by copyright. The Af doubt or dspte, th aos extn af the German at en val igh of uso, partcuary a ary wast, reproduction exact fires, ranarision by phot mecharial means and sioragoin dala otival str, even af exacts, ae reserved 1 Ie author. Cart Heymann Verag has taken all oasonto measures io onsare the accuracy of his Wanslion Bu roe that no esporslty canbe accoted fr ary ec, omsion or acura. cases 5 Marking 6 Cortitication of quality 7 Dimensioning characteristics Appendix 1: Agreement of the AD-Verbéinde to ‘continue to use the previously valid DIN material standards ‘mined by atmospheric conditions and at ambient temperatu- res of 10°C up tothe limits of temperature given in Clause 2. ‘AD 2000-Merkblatt W 10 also applies where charge working temperatures are below —10°C. See also 2.2 of AD 2000 Morkbiatt WO. 1.2 In the case of castiron with lamellar graphite for the construction of pressure vessels an adequate level of exper- ience on the part of the supplier is assumed. Initial proof shall be provided. 1.3. Castvron with lamellar graphite shall only be used for the construction of pressure vessels i the characteristics of the material offer operational advantages over other types of material. For pressure vessels constructed of cast iran with lamotiar graphite ine following limits to the maximum allow able prossure p, to DIN EN 764, generally apply 25 bar gauge for internal pressure 40 bar gauge for external pressure Inthe case of an internal pressure of more than 6 bar (gauge) and an extemal pressure in excess of 10 bar (gauge), the following products of vessel capacily Vin litres and the maxi-AD 2000-Merkblatt Page 2 AD 20D Menaiah W'9, 10.2000 ain ‘mum allowable pressure PS in bar shall in general not be exceeded: Internal pressure V-PS= 65000 Extemal pressure V- PS = 100000 WW the figures produced are higher than these values, the agreement of the relevant third party and customer'user shall, be obtained. 1.3.1 Additional specifications for drying cylinders In the case of steam drying cylinders, the internal pressure V - PS value of 65000 can be exceeded with the agreement of the relevantthird party under the following preconeitions: (1) The maximum allowable pressure is limited to 15 bar. 2) Themaximum allowable temperature islimited to 300°C. (8) The design shall be selected so that peak stresses are avoided as far as possible. In particular, the toe of cylin- der flanges shall have a radius of atleast D/50 (D = out- side diameter of cylinder). (4) At loast GG-20 shall be used. (8) Generally, stress rele annealing shallbe provided. Slow cooling at a rate of less than 30 K/h in the temperature range 600°C to 150°C shall be equated with subsequent hoat treatment. In both cases proof shall bo supplied 10 the relevant third party through corresponding measure~ ments that the conditions have been mot. (6) The samples shall be taken trom the top and the bottom, of the cylinder. (7) Contrary to what is stated in 4.2 of AD 2000-Merkblatt WA, welding on cylinders is not permitted. 1.4 Due account shall be taken of casting practice when designing pressure vessels made of cast iron with lamellar ‘graphite if blowholes, cracks and peak stresses are to be avoided, 2. Suitable materials The following grades of material may be usedin the construe- tion of pressure vessels: 2.1 Cast iron with lamellar graphite (grey cast iron) to DIN, EN 1561 up to wall temperatures of 300°C: ~ EN-GJL-150, = EN-GJL-200, EN-GIL-250, EN-GiL-300, — EN-GJL-350, Where wall temperatures exceed 300°C, the minimum grade shall be EN-GJL 300 with the wall temperatures generally, being limited to 350°C. In this case, the suitabilly and tensile strength of the cast iron materials at the operating tempera- ture shall he proven initially whan determining suitability Where approriate, heat treatment shall be provided. 22 Other grades of castiron with lamellar graphite are acceptable, i their suitability and quality characteristics have first been confirmed hy the certificate of suitably. 3 Tests 3.1_ Inthe case of those types of materials listed in 2.1, one Of the properties to be tested shall be tensile strength in accordance with DIN EN 1561, Where wall thicknesses exceed 20 mm and if the design so permits, cast-on-speci= ‘mes shall be used. The minimum requirements shall be in ‘accordance with those values for tensile strength given in DIN EN 1561, bearing in mind their retation to wall thicknes- se. For wall temperatures above 300°C the tensile strength at design temperature shall also be tested. 3.2. The number of samples is at least one per 1000 kg of, the same type of castings supplied (test unit AMH as speci- fiedin DINEN 1559-1) orperitem in the case of castings over 500 kg. DIN EN 1559-1 applias with regard to repeat tasting 3.3. Testing of material grades according to 2.2 shall be defined in the suitability certficate according to type and scope, 3.4 Samples of heat-treated castings shall be heat-treated together with the castings and cast-on samples shall not be separated until after heat-treatment has taken place. 3.5. Botore castings subjected to pressure are coated, they shall undergo a hydraulic pressure test of suficiont duration, gonerally at twice the maximum allowable prossuro. It operating conditions are special, an agreement may be reached between the customer/user and the manufacturer to determine the lightness of tne walls and to test for flaws in the casting in addition to the hydraulic pressure test. In such ceases the tests to be applied, either singly or in combination, are as follows: (1) Leak teating with air (test presaure approximately 0.1 times the maximum allowable pressure, but a maximum of 2 bar gauge). A foaming fuid shall be applied betore the hydraulic pressure testis cariedout. In spacial cases a suitable gas shall also be used in conjunction with an Inaicating instrument. (2) Leak testing using petrol or other similar lui, ©.9. water, with low surface tension (test gauge pressure not more than 1,5 times the maximum allowable pressure) betore the hydraulic pressure teat. (3) Radiographic test. (4) Utrasonic testing. If doubts exist, this should be used in, ‘conjunction with another test, in particular the radiogra~ phi toct, 4 Quality of castings 4.1 The external characteristics of the castings shall be Inspected and a check made of those dimensions which are important from the point of view of safety In general, the pro- visions of DIN EN 1559-1 apply in the case of the quality of castings. 4.2. It possible welding on cast-iron parts for pressure ves- sels shall be avoided. In individual cases, following agreement between the rele- vant third party and customeriuser, production welding can be carried out on cast iron prossure vesecls following a procedure qualification test, 5 Marking 5.1 Castings made from those grades of material given in 2.1 shall be marked with the manufacturer's mark, batch numer (sample number) and the material designation in accordance with DIN EN 1561. The tester's mark shall also bo stamped on tho easting 5.2 Castings made from grades of material given in 2.2 shall be marked in accordance with the provisions laid down in the cortiicate of suitabiltyAD 2000-Merkblatt 6 Certification of quality In the case of pressure vessels and parts of pressure vessels subjected to pressure, proof of the quallly characteristics shall be provided in the form of an inspection certificate to DIN EN 10024, 6.1. For pressure vessols parts made of EN-GJL-150, EN- @JL-200 and EN-GJL-250 and for wall. thicknesses, = 50 mm, proof shall be in the form of inspection certificate 3.1.8 as specified in DIN EN 10204, 6.2 For EN-GJL-300 and EN-GJL-950 and wall thicknes- 506!) = 50 mm (all east grados), proof shall bo in the form, of inspection certificate 3.1.A/C as specified In DIN EN 10204. 6.3. In the case of grades of material specified in 2.2 proof shall be in accordance with the provisions of the certificate of suitability, 7 Dimensioning characteristics 7-1 Inthe case of material qrades specified n2.1, the mea- surement characteristics which apply are the values antici pated for tensile strength in he casting which are given in DIN, EN 1561 7AA_Uptoawalltemperature of 300°C the tensile strength at amplent temperature shail be as shown In tabie 1 of OIN, EN 1561 7.1.2. At wall temperatures over 300°C (only EN-GJL-300 and EN-GJL-350 are suitable) the tensile strength at design temperaturo applies, taking into account the cite wall, thickness. The values shall be agreed when formulating the. suitability certificate, 7.2 For material grades according to 2.2 the measurement ‘characteristics shall be specifiedin the suitabilly certificate 7.8. Inthe case of enamelled cast-iron, a strength characte- fisic K of 105 Nimm? can be anticipated. Higher values shall be verified using cast-on and enamelled specimens, With ‘muttiple-onamelied castings lower strength values shall be ‘used according to the number of annealing processes.AD 2000-Merkblatt age 4 AD 20D Mla W 31, 10.2000 econ Appendix 1 to AD 2000-Merkblatt W 3/1 ‘Agreement of the AD-Verband to continue to use the praviously valid DIN material standards Cast iron materials GG-15, GG-20, GG-25, GG-30 and GG-35 as specified in the withdrawn May 1985 edition of Publisher: Neston der Tedinisshen Ubervachungs-Vrsne E-Mail: vdtuey.essen@t-online.de hitp:/wwwvdtuev de DIN 1691 may be used until the EC Directive on Pressure Equipment has been adopted into national legislation and a European Standard has been published on pressure vessels taking into account the specifications of the November 1986 edition of AD-Merkblatt W 3/1 Source of supply: Carl & Heymanns Verlag Luxemburgor StraBe 449, D-50939 Koin Telofax: 0221-9 43 73 603, E-Mail: verkauf@heymanns.com as