ICS 23.020.30 January 2003 edition Materials Cast iron materials ‘AD 2000-Merkblatt for Austenitic cast iron with pressure vessels w33 lamellar graphite The AD 2000-Merkotter are prepared by the aoven aasociations fisted below who together frm the “Arbeitagenreinschatt Druckbohiter”™ (AD). Te stucture and the appicaton of tre AD 2000 body of regulations and the procedural guidelines are covered by AD 2000-Morkbat G1. The AD 2000-Merkbatter contain salty requirements to be met under normal operating conalions. If above-nermal oadings are to be expected during the operation of the pressure vessel his shall be taken into account by meeting special requirements. I tere are any divergences fram the requirements ofthis AD 2000-Merkblat, shall be possible to prove that th standard of salty of this body of regulations has been maintained by other means, e.g. by materials testing, tests, stress analysis, operating experience. Fachverband Damptkesse, Behiiter- und Robrieitungsbau @.V. (FDR), Dasseldor! Hauptverband der gewerblchen Borufsgenossenschaften eV, Sankt Augustin Verband der Chemischen Industrie e.V. (VC), FrankfurtiMain Verband Deutscher Maschinen- und Aniagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen Lund Apparate, FrankfurtiMain 1 Stahlinsttut (VOEH), Dsseldort VGB PoworTech o.V., Essen Verband der Technischon Oborwachungs-Vereine 0.V. (VSTOV), Essen. Tho above associations continuously update the AD 2000-Morkblte in ine with technical progress. Please address any proposals for this tothe publisher: Verband der Technischen Oberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen. Contents 0 Foreword 1 Scope and general 2 Permissible grades of materials 8 Tests 0 Foreword ‘The AD 2000 body of regulations can be applied to satisfy the basic safely requlremonts of the Pressure Equipment Directive, principally for the conformity assessment in accordance with Modules "G" and "B + F”. ‘The AD 2000 body of regulations s structured along the lines. (of a self-contained concopt. If othor tochnioal rules aro used in accordance with the state of the art to solve related prob- lems, itis assumed that the overall concopt has been taken into account, “The AD 2000 body of ragulations can be used as appropriate for other modules of the Pressure Equipment Directive or for, ifferent sectors of the law, Responsibility for testing is as -specifiedin the provisions ofthe relevant sector of the law. 1 Scope and general § 1.1 This AD 2000-Merkblatt applies to austenitic cast iron With lameliar graphite for the construction of pressure vessels {see also AD-2000-Merkolatt A 4) operating at working tem- 3 peratures and at ambient temperatures from — 10°C uptothe } limits of temperature given in clause 2. For temperatures. 4 Quality of castings 5 Marking 6 Certification of quality 7 Design strength values bolow ~10°C, AD 2000-Merkblatt W 10 shall also be taken into consideration. The grades shall be selected in accord- ance with the planned application taking into account the mechanical, thermal and chemical stresses and the physical properties (see DIN 1694). See also 2.2 of AD 2000-Merk- blatt Wo, 1.2. The production of austanitic cast iron with lamellar gra- phite presupposes an adequate level of experience on the part of the suppliers. inital proof shall be provided tothe rele- vant third party 1.3 Auctonitic cast iron with lamellar graphite shall be used {or the construction of pressure vessels ifthe characteristics, ‘of the material offer operational advantages over other typos. ‘of material. For pressure vessels constructed of austenitic, cast iron with lamellar graphite, the following limits to the /maximum allowable pressing p, apply (see DIN EN 764): 25 bar internal gauge pressure 40 bar extemal gauge pressure. In the case of an internal gauge pressure of more than 6 bar and an extemal gauge pressure exceeding 10 bar, tne follow ing products of vessels capacity Vin litres and maximum allo- | wable pressure p in bar shall in general not be excocded: ‘rate 49, ‘Supersedes October 2000 ealton; | = Amendments to previous edition "AD 2000-Narkter are pototd by copyright. Te ighis of usp, parla of any Wansaon, oped extract of igures, ransmision by pho ‘mechanical means and stoago in data retival este, oven a extcts, a resrvodto the shor. Cart Heymann Verlag has taken al oseonab ‘measures to ensure the accuracy of his ransiaon but eyes Pat no responsi ean be accopod fr any exe, omsion Or nnocuacy. In eas05 {St coust or spur, he ata etn a ho Gorman toe omy ai. Caen © Cat Hoymanne Verag KGPage 2. AD 2000 Monat W 3:9, 0.209 eon Internal gauge pressure V - PS = 65000 External gauge pressure V- PS = 100000. If the figures produced are higher than these values, the agreement of the relevant third party shall be obtained 1.4 Due account shall be taken of casting practice when designing pressure vessels made of austenitic cast ron with, lamellar graphite if lowholes, cracks and peak stresses are tobe avoided. The designer shall agree the types of pressure vessel with the foundry. 2. Permissible grades of materials ‘The following grades may be used for the walls of pressure vessels: 24. Austenitic grades of cast iron with lamellar graphite 10 DIN 1694 up to wall temperatures of 350°C. In addition, in ‘special cases a working temperature of up to 450°C maxi ‘mum can be allowed. I the wall temperatures are over 350°C. the suitabilty and the characteristics ofthe lamellar graphitic, austenitic cast iron at the working temperature shall be inti- ally certified by the expert opinion of the relevant third party. 2.2 Other austenitic cast iron materials with lamellar gra- phite, provided that their suitability and characteristics have ‘been iniialy certified by the expert opinion of the relevant third party 3 Tests 3.1_In the case of austenitic cast iron grades with lamellar {graphite as specified in 2.1, the tensile strength and the che- ‘mical composition are tobe determined. DIN 1684 covers the, ‘minimum requirements, and Table2 applies to the tensile strengll i velation ly te wall hickres. In auaiion, the up tute elongation shall be determined; minimum requirements, are not laid down. Besides this, for wall temperatures over ‘350°C to 450°C the tensile strength and the elongation atthe ‘maximum allowable temperature shall be determined. The following applies to the selection and manufacture of test pie- ces and test procedure: 3.1.1. From the test pieces, which should, if possible, be in the form of flange-tke strips with a thickness corresponding to the crtical wall hickness, ang cast as an Integral part of the casting, in suticient number and size, that the specified ‘specimens and if necessary specimens for repeat test, can be taken from them, 3.4.2 Incastings with wall thioknosses up to 60mm the epe- ‘cimens for the tensile tests can be taken from separately cast test pieces, in which case the cooling conditions shall corre- ‘spond to those of the casting itself. DIN 1694 and Table 1 ‘cover the dimensions. It shall be ensured thatthe test pieces. ‘correspond to ine casting, Table 1. Relationship between wall thickness and separa- toly cast test piece atical wall thickness of casting, | Test specimens o DIN 1604 41010 v1 101030 2, “U° specimen and simpliied *U" specimen 30 to 50 ya AD 2000-Merkblatt 3.1.3. Furthermore, the following are to be complied wit, ‘where they apply DIN 50125 — Testing of metalic materials; tensile test pieces; directives for manufacture; DIN EN 10002-1 ~ Metalic materials ~ Tensile testing — Part 1: Method of testing at ambiont temperature; DIN EN 10002-5 — Metalic materials ~ Tensile testing — Part 6: Method of testing at elevated temperature. 3.2. The number of test pices is atleast ohne tet piece for the tensile test per 1000kg of castings ofthe same kind, or ‘one test piece per casting if the casting inthe rough weighs mare than 500kg. DIN 1694 applies to repeat tests 3.3. Tho type and eoope ofthe testing fr eactiron materials a spectiod in 2.2 are to be determined by the relevant third party. 3.4. Test pieces from heat treated castings shall be in the ‘same heat treated condition as the castings. and be heat re- ated together wth them. Cast-on test pieces shall not be cut off until ater the heat treatment 3.5 Before any coating is apple, all castings which have to withstand pressure shall be subjected toa hydraulic pres: ‘sure test of adequate duration and, as a rue, at twice the | working gauge pressure. For deviations in the case of valve housings, see AD 2000-Merkblatt Aa 3.6. If special stress conaitions are present, the following tests for establishing that the walls are leak proof and for testing for faults the material can be agreed upon between the customeriuser an the manufacturer, the tests being con- ducted separately or in combination: (1) Leak testing with air (eat pressure about 0,1 times the |. working gauge pressure, maximum bar gauge) by pain- ting with a foam-producing liquid after conducting the waler pressure test; in special cases also by using @ sui- table gas and indicating equipment. (2) Leak testing wit pretroleum or another liquid which has the same effect, e.g. water containing a wetting agent {maximum test pressure equal to 1,5 times the working gauge pressure), before the hydraulic pressure test (8) Leakage test with satured or superheated steam (maxi- | mum test pressure equal tothe working gauge working pressure), after the water pressure test. (4) Radiographic examination (6) Utrasonic testing, i necessary in combination with ano- ther test, in particular radiographic examination. 4 Quality of castings 4.1 The extemal characteristics of castings shall be inspec- ted and a check made of those dimensions important fram. the point of view of safety. In general the requirements of DIN. 1694 apply to the quality of castings. The cast iron shall not show any cracks nor fairy large biow holes, and shall be tree from highh internal stresses. f necessary, the folowing heat treatments shall be given: (1) Annealing at 930 to 980°C and quenching, e.g. in air, ol, ‘water and/or (2) Stress relieving at 600 to 700°C. 4.2 As far as possible, welding shall be avoided on cast parts from austenitic cast on with lamellar graphite for presAD 2000-Merkblatt ‘sure vessels. In exceptional cases welding!) and repair wel ding’) may be cartied out on pressure vessels made from ‘austenitic cast iron with lamellar graphite, with the agreement of the relevant third party and customerluser, after a proce- dure qualification test has been carried out Table 2. Guaranteed strengh characteristics and desian strength values Grate rong vane torval | Tonto ousanaon | Mate! | hecnoas | chert im |e aacnwnia? | ose | aw | 100 owe | te soso | 20 bo 8 GaLnicue i662] 0655 | sw 10 inert 09 ea ss ours caLweucises| ose | swi0 | am (Ni-Resist 1b)°) 101030 | 180 gos | ico ore) | a0 eancraee [ase [a1 | 170 troneaet ay) wow | tao goose | is overs. | i Gaunicraee | asset —sie10 | 200 (nist 259) ‘o je 1 GGL-NISICr 20 0.6867 200 ‘0 is i cawwersoa | aear | awe | a0 test oh ox | i goose | iso owrso | 30 @aLnsie-s08s | 06600 [aw | v0 (teres) wow | ks wows | j30 owes | 10 ) Wtng cari cuty tho anfacrr ofthe casings he couse ol menu the wie eet anaring he cua meses oe gutted ae teres ana lw aurpoce force cst Ov ube Ropar wats re card for hepa ol casts whch hve been damaged ‘tng oe by wich moans easing etre ara pons to) ‘orate ae Usatuogs by Be clot Sing rored 9) Th tos rackets ae ede naman and re an froma, AD Boop W 39.01.20 exton Page 2 5 Marking Castings as specified in 2.1 are to be marked with the manu- facturer's mark, the batch number or melt number (test piece number), and the grade in accordance with DIN 1694, Castings as specified in 2.2 are to be marked according tO the expert opinion of relevant third party. In addition, the exa- miner's mark shall be stamped on. AD 2000-Merkblatt A4 applies to valve bodies. 6 Certification of quality For pressure vessels and parts of pressure vessels under pressure, the certification of characteristics and of the hydraulic pressure test shall be provided by an inspection | certificate 3.1,C/inspection report 3.2 to DIN EN 10204. In ‘addition, chemical composition (ladle analysis) and heat treatment are to be certified by the manufacturers. 7 Design strength values 7.4. The following applies as the design strength valve: 7.1.4 Upto wall temperature of 350°C, the tensile strenath at room temperature, taking into consideration the wall thick- ness civen in Table2. 7.1.2. Ata wall temperature over 350°C up to 450°C max., the tensile strength at the design temperature, taking into ‘account the wall thickness. The values are to be agreed upon between the manufacturer and the relevant third party 7.2. For austenitic cast iron materials wth lamellar graphite a8 specified in 2.2, the strongth values are to be laid down according to the expert opinion of the relevant third party 7.3. When designing pressure vessels made rom austenitic cast iron wit lamellar graphite, the safety factors!) given in Table aro to be taken into consideration for the tensile strength, Table 3. Safety factors Material grades as DIN 1694 Salely faciors S rot annealed 8 anneaios 6 Te aly ator ae gen he prvonaly, risuch nea hey etch Ao 2ato Mercian boPublisher Verband der Technischen Uerwachungs Verene eX E-Mall: vdtuev.essen@t-oniine.de bttp:twww.vdtuev.de Source ot suppy: Carl Heymanns Verlag Luxemburger StraBe 449, D-50939 Koln Telefax: 0221-9 43 73.603 E-Mail: verkauf@heymanns.com