AD 2000-Merkblatt Ics 23.020.30 ‘October 2000 edition Manufacture and testing of pressure vessels General principles of design, manufacture and associated tests AD 2000-Merkblatt HPO ‘The AD 2000-Merkblatter are prepared by the seven associations sted below who together form the “Arbottagemeinschaft Druckbehiter” (AD). The structure and te application of the AD 2000 body of requlabons and the procedural guidlines are covered by AD 2000-Markbat G1. ‘The AD 2000-Merkbisttor contain safety requirements to be met under normal operating condions. f above-norma loadings are fo bo “expected during the operation ofthe pressure vessel, this shal be taken into account by moeting special requirements. there are any divergences fom the requirements ofthis AD 2000-Merkbla, It shal be possible to prove that the standard of safty of itis body of regulations has been maintained by other means, e.g. by materials testng, tess, stress analysis, opereting experience. Fachverband Dampikesser-, Behiter- und Rohrietungsbau e.V. (FDBR), Ddsseldort Fauptverband der gewerblchen Berutsgonossenschafen e.V., Sankt Augustin Verband der Chemischan Industrie o.V. (VCD, FrankfurtIMain ‘Verband Deutscher Maschinen- und Anlagenbau ¢.V. (VDMA), Fachgemeinschaft Vertahrenstechnische Maschinen lund Apparat, FrankdurtiMain Verein Deutscher ElsenhUttenleute (VDER), Dasseldod —* VaB PowerTech ev. Essen Verband der Technischen Uberwachungs-Vereine e.V. (VaTOV), Essen. ‘The above associations continuously update the AD 2000-Merkblater in ine wth technical progress. Please address any proposals for this to the publisher: Verband der Technischen Oberwachungs-Vereine @.V., P.0. Box 103834, D-45038 Essen. Contents 0 Foreword 4 Marking 1 Scope 5 Testing 2 Principles 6 Modification and repair work 4 Prerequisites 7 Supplement 1 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 is structured along the lines ot predominantly under static load!) and their joining with ‘non-pressure parts, e.g. by welding. These Merkblatter fol- tow up AD 2000-Merkblatter in the W Series and specify the tests to be performed before, during and after manufacture either by a relevant third party, or by the manufacturer. 1.2. 11AD 2000-Merkblatter in the HP Series contain no pro- i Cf a sel-contained concept. If other technical rules are used in accordance with the state of the art to solve related prob- lems, itis assumed thatthe 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 diferent sectors of the law. Responsibility for testing is as ‘specifiedin the provisions ofthe relevant sector of the law. 1 Scope Visions forthe fabrication and testing of individual materials, agreement shall be reached between the manufacturer, ‘customeriuser and the relevant third party. For non-metalic materials, AD 2000-Merkblatter in the 'N Series shall also be observed. 4.3 Where a vesselis composed of a numberof chambers, it shall be classified in the highest category applicable to the individual chambers. If a chamber contais several fuids, ‘classification shall be on the basis ofthe fuid which requires, the highest category. Se ee een apes i "7 AD 20a 8 + dnases varus peso ng om each ter ‘vessels and pressure vessel components which are wholly” denon ve ‘Spatong on dean and menace "AO 2000 Meriter ar tote by copyigh. The sights our, pare of any Wansaton, reproduction, exact of fares, ansmisson by polo ‘mechanic means and storage cla raoval systems, oven fea are eran the du. Cal Heymann Vag Mes ake al reasonable ‘sees rr aay fe anon bP prs cnb ne 7 Oran rey Nese ‘tout or depo, th sot eaton othe German eet ony val © Cail Heymanne Vag KO Conemburger Sade 849,AD 2000-Merkblatt Page 2 AD 2000s HP 0, 102000 eon 1.4 AD 2000-Merkblatter in the HP Series include the folowing HPO — General principles of design, manufacture and associated tests Supplement: Synoplic Tables: Conditions Under which no postweld heat treatments required, ype and ‘scope of production tests and nondestructive testing H+ ~ Design and construction HP2 _— Procedure quaifation testing for Joining pro- cess 1: Procedure quatfication testing for welded joints HP3 = Welding supervisors, welders HP4 —— Test supervisors and testers in non-destruc- tive testing HPS Manufacture and testing of joints 1: Principles of welding practice (2; Production testing of welds, Testing of ‘base metal alter postweidheat treatment 18: Nor-destructve testing of wolded joints Appendix 1: Minimum requirements for non-dostucve testing methods HP7 —— Heattreatment 1: General principles Ferric stools ‘Austenite steels 1: Aluminium and aluminium alloys HPe Testing [1 Testing of pressings made rom steel, ai- rmiium and aluminium alloys 12 Testing of stool sections HP-20 ' = Performance of pressure tests HP 100R®) ~ Construction reguations ~ metal piping HP 110) - Construction regulations - piping made of glass reinforced thermosetting plastics (grp), wh and without finer HP 511 — Design examination HP 512 — Final testing and pressure testing HP 5122) — Examination of technical documentation and. acceptance of piping HP 513R) - Conformity evaluation of assemblies HP 120R2) ~ Construction regulations — thermoplastic pip- ing 2 Principles 2.1 Manufacture of the pressure vessels shall be based on the pertinent drawings and relevant documents, 2.2 The manutacturer of pressure vessole or pressure ves- ‘sel components shall arange forall the necessary jobs to be carried out properly, making sure that this is done in accord- ance with good engineering practice, particulary in accord- ‘ance with AD 2000-Merkbiatter. 5 pepsin angio acount he PED (87/21 rerpra ences {tecnica reqatemont wom te relat TROTEA * In pparatan aking mo acer he PED (72M) 2.3 If any requirements due to the operating conditions of the pressure vessels have to be met which go beyond the specifications in AD 2000-Merkblatter, e.g. dynamic load, corrosion allowance, additional tests and their scope, reduced tolerances, use of certain materials, joining proces- ‘ses and filer metals, addtional heat treatment, these shall be made known by the customer/user in good time so that ‘they may be taken into account in the design and manufac ture of the prassure vessels, 3. Prerequisites 3,1. Manufacturers shall meet the welding requirements of DIN EN 729-3. ‘3:2 Manufacturers shall have available the necessary faci ties*) to ensure that the materials are properly processed and the necessary tests can be performed. 3.3 Manufacturers shall have their own supervisory staff and trained workers for production purposes. The requ ‘ments for welding supervisors and welders are laid down in ‘AD 2000-Merkbiatt HP 3 and those for test supervisors and testers are laid down in AD 2000-Merkblatt HP 4. 3.4 Manufacturers of pressure vessels which are welded or joined by moans of other mathods (e.g. brazed or bonded) shall provide the relevant third party with evidence, inthe form of a procedure qualification test adapted to the manu- facturing process, that they are fully conversant with the \wolding procedures or other joining procosses used. Supple- mentary tests are necessary ifthe materials, dimensions or joining processes, for example, are changed beyond the ‘scope and validity ofthe procedure qualification test. 3.5. Itmanufacturing obs such as forming orheat treatment ‘are contracted out fo other manufacturers, the latter shall ‘Also be qualied todo these jobs according io the conditions spoctid in 3:1 t0 34. 36. The rolovant thi party shal satsy tse, within the framework of is inspection duties, that the prorequstes ‘specified in 3.1 to 3.5 are being met. The production sequonce shal not be adversly affected in so doing. 4 Marking 4.1. The marking of materials shall be maintained through- out the process of manufacture. If orginal markings are dis ‘carded or parts without markings could be created by dividing ‘up parts during the course of manufacture, markings shall be transferred, as a rule, before fabrication. This shall be done 's0.as to allow the material specifications tobe correlated with the components just as easily as with the original marking; this may be achieved by means of a certificate to be issued for the purpose. Appropriate measures shall be taken 10 ensure that there is no possibilty of confusion inthe transfer of markings. For non-pressure weld-on parts, markings shall only be transferred if the correlation of materials is not unambi- ‘guously evident from the drawing or parts lst. 4.2 Markings shall be transferred observing 4.1 in accord- ance with 4.2.1 10 42.3, 5) Paces aaewhore ic have te requtes aches may be usedAD 2000-Merkblatt 4.2.1. In the case of materials for which a certiicate 3.1.A, (0F3.1.C to DIN EN 10204 is required, the markings shall be ‘transferred by the relevant third party. This does not apply {o'small parts®) made from tested products such as stay bars, slay tubes, stay bolts, nipples, nozzles, flanges, compensat- ing rings and covers. The transfer of markings can be done by the works employee in charge. “The provisions in AD 2000-Merkblatt W7 apply to marking {or screws and nuts made from tested products. 42.2 In the case of materials which may be delivered with certificates 2.2 oF 3.1.B to DIN EN 10204, markings may be transterred by the manufacturer or supplier afior having reached writen agreement with the relevant third paty In this agreement, the name of the works employee in charge and the works mark used by him shall be stated in writing. Clause 4.2.1, second sentence, apples to small pats. 4.2.3. Inthe case of parts which are to undergo further pro- ‘cessing at the construction site, where markings are trans- ferred by the employee in charge at the manufacturer's ‘works, the said parts shall be accompanied, on request, by papers certifying the transfer. These papers shall state that the markings have been transferred by agreement with the relevant third party. Alternatively, anote to this effect may bbe included in the material test certificate according to DIN EN 10204. 5 Testing ‘As a rule, testing of pressure vessols and pressure vessel ‘components, which must be n a condition suitable fortesting, 's performed at the place of manufacture. 6 Modification and repair work 6.1 The relevant third party shall be informed of modifica- lions and repairs during manufacture, 6.2 _ The relevant thd party's consent shall be obtained in {he following cases for modifications and repair work on @ finished component after non-destructive testing: Material Groups FRelovant thie pary’s| ace. to Table 1 concent required: 1 [12.61.5267 for dopth of repair > 20 mm and, atthe same tim, lengtn ‘of repair > 300 rom 43,54,A1 (or wall thicknesses >20mm 9,42,53, 8, A12,A13, | always required NtNi2, TI 9 Dxpaning on ne inptance ot te component concede ane of ‘arang ty berate or operand wit ‘AD 200Manblat HP 0, 10.2000 eon Page 3 ‘Material Groups ‘ace. to Table t Relovant third party's consent required: Welding n particulary atic fixed postion, eg. where space is rested or whore igh degrees of distorion are 2 | Regards of the srateral Fepair depth of 2 or less 3 1 subsequent heat treatment |s sponsed with for technical reason even though heat ‘weatmnt would be required according to stipulations in ‘AD 2000 Morkoatior 63 In the case of repeated modifications and rep: including those during manufacture, the consent of the rele vant third party shall be obtained in advance. 6.4 The relevant third party's permission can also be ‘obtained in the form of a general approval of repair instruc- tions. 6.5 The relevant third party's permission shall be obtained ‘before the start of modification and repair work after the final inspection or stage inspection. 7 Supplement ‘The Supplement consists of a chart which, according to the Classification into Material Groups and wall thicknesses (nominal thicknesses), states the conditions under which no postweld heat treatment is necessary, the type and scope ot production tests and non-destructive testing of welded pres- ‘Sure vessels or pressure vessel components. For details, see ‘AD 2000-Merkblattor HP 7 and HP 5.AD 2000-Merkblatt Page AD 2000Aanta HP 0, 1.2000 eon Footnotes for Synoptic Table 1 +) Other materials to be assigned to comparable Material Groups according to material speciiatons as stated in tho assessment of ‘suitabiliy. Where components made from diferent Material Groups are welded logether the Group having the greater scope of testing is applicable, 2) U = unannealed, W = heat treated 2) Apples respective of stress categories according to AD 2000-Merkblalt W 10. 4) Notch postion at right angles to surtace. f 5) Notch postin, as far as possible, parallel tothe surface: for specimens < 10 mm tick, at ight angles tothe surface 5) Hot tensile test accorcng to DIN 60145 on longitudinal specimens taken from the wold metal i the working temperature > 360°C; for fine-grained structural steels, hot tensile test as stated above ifthe working temperature = 200°C. 2) LN = Longitudinal wolds and butt wlds under ful stress [AN = Crcumferontal welds (but wolds and flap-wolded Milt wolds as speciod In AD 2000-Merkblatt HP 1, Section 2.4; for wekiod ‘nde, see AD 2000-Merkblat HP 5/2, Secion 5 ‘St_ = Joints between LN ongitusnal welds) and RN (circumferential welds) or between LN and LN *) KN = The filet welds tobe tested are welds connecting wold-on parts, including assembly aids, 1o the pressure-hoaring wall SIN = Nozzle wold. *) Scope of testing to be extended accordingly i caustic crack resistance is required *) If condtions under which no postweld heat treatment is requirod aro met. . 1) G = as for base meta. "Hf experience has boon proved as stated in AD 2000-Merkblatt HP 5:3, Section 22.1, the scape of testing is reduced to 10%. +9) If experience has been proved as stated in AD 2000-Merkblatt HP $13, Section 2.2.1, the scope o testing is reduced to 2%. Generally Is sufcont to include tho circumferential wolds by testing the jolts when making random tests on the longitudinal wolds. 4) Tobe tested on weld length, not necessary on certain objecs. The places tobe tested shall be agroed withthe olavant thd party. ') General tis sufficient to include the joints and circumferential welds by testing te ots when making random tests onthe longitudinal wold. ‘™) experince has been proved as sated in AD 2000-Merkblat HP 5/3, Section 22.1, for Material Groups 1, 5.1 and 6the scope of testing |s reduced tothe same extent aa fr wall thicknosses == 15 mm. ") Should vieual examination as stated in AD 2000-Merkbiatt HP 83, Section 2.1 give rise to doubts, @ non-destructive test shall be per- formed. "It more than 10 nozzles are welded to a pressure vessol which are similar in terms of dimension and welding procedure, the scope of testing can be reduced to 5% of the nozzle welds but al least 2 nozzle welds shal be tesled, *) experience has been proved as stated in AD 2000-Merkblatt HP 57, Section 22.1, non-destructive test shallonlyhavetobe performed if Vigual examination as stated In AD 2000-Merkblatt HP 5/3, Section 2.1 has given rise to doubts. %) In the case of stoel X 20 CrMoV 12 1, toting of impact strength shall be caried out regardiess of the wall thickness, Le. including ‘5 15 mm to 2 5 mm. n addition, the hardness of each wold shal b test. ') Testing of impact strength shall be carried out regardless of the wall thickness, a9. including = 15 mm to = § mm, The technological ben est shall be performed for wall thicknesses <8 mm, *) Heat treatment does not aways signity an improvement in properties. The possiie benefits of dispensing with heat treatment should ‘Aso be considered in the case of wal thicknesses > 60 mm. Special agreements shall be made, 2) used in the temperature range below - 10°C according to AD 2000-Merkblat W 10. 1) As far as ths is required by he purchaser. 2) ston Mata! Groups 5.154 ar used at lowest operating emperatures = 10°C andthe requemens in AD 2000-Maniat 'W 10 are mot, the sare provisions apply as for Material Groups 1 10 3 =) The MP method shall be used in preference, if an adequate relate parmesbily 4, Is gen. 4 ©a ed = (en) Binet Supe os pm sat wreaN oe pn el pera: A Rm eX Pana GION PN RAT) “1 RL Soul (0002'01 uomipe ‘(penunued) Leiaes ‘oan HeKDHON-o002 GYate +] ae | om [om om | 0 [nveennoenet ys (Cod arn SAPO po TO oe) GA pa BU RR Pama LOR OTR weal (0008-01, uonipe ‘(penunuoD) beraeL ‘OaH HEI HOR-oOG GY(Se ens Ro ar Bb BRIA Ho Ban LRSIGO fA wpa el RO nO PRN GRD cn DAT EARL TT (0007'01 uompe ‘ZeraeL, ‘oan HEIqHeN-oOG GYSE Ra RN ae RE eB GaN RT pa A HRN Re Sa ooo HR aS Sama =y ¥ 000201 Uonpe ‘EeraeL aH NMEDLON a