AD 2000-Merkblatt

ICS 23.020.30 October 2003 edition

Materials AD 2000-Merkblatt
for General principles for materials
pressure vessels W0

The AD 2000-Merkblätter are prepared by the seven associations listed below who together form the “Arbeitsgemeinschaft Druckbe-
hälter” (AD). The structure and the application of the AD 2000 body of regulations and the procedural guidelines are covered by AD
2000-Merkblatt G 1.
The AD 2000-Merkblätter contain safety requirements to be met under normal operating conditions. If above-normal loadings are to be
expected during the operation of the pressure vessel, this shall be taken into account by meeting special requirements.
If there are any divergences from the requirements of this AD 2000-Merkblatt, it shall be possible to prove that the standard of safety of
this body of regulations has been maintained by other means, e.g. by materials testing, tests, stress analysis, operating experience.
Fachverband Dampfkessel-, Behälter- und Rohrleitungsbau e.V. (FDBR), Düsseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sankt Augustin
Verband der Chemischen Industrie e.V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen und
Apparate, Frankfurt/Main
Stahlinstitut VDEh, Düsseldorf
VGB PowerTech e.V., Essen
Verband der Technischen Überwachungs-Vereine e.V. (VdTÜV), Essen
The above associations continuously update the AD 2000-Merkblätter in line with technical progress. Please address any proposals for
this to the publisher:

Verband der Technischen Überwachungs-Vereine e.V., P. O. Box 10 38 34, D-45038 Essen

Contents
0 Foreword 3 Materials for pressure vessels, piping and accessories
1 Scope 4 Filler metals and other consumables
2 General requirements

0 Foreword The W series of AD 2000-Merkblätter regulate the applica-

The AD 2000 body of regulations can be applied to satisfy
the basic safety 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 of a self-contained concept. If other technical rules
are used in accordance with the state of the art to solve
related problems, it is assumed that the overall concept
has been taken into account.
The AD 2000 body of regulations can be used as appro-
priate for other modules of the Pressure Equipment Direc-
tive or for different sectors of the law. Responsibility for
testing is as specified in the provisions of the relevant
sector of the law.
1 Scope
The W series of AD 2000-Merkblätter apply to metals for
Luxemburger Straße 449, D-50939 Köln
tion and the requirements of various product forms, e.g.
plate, strip, tubes.
This AD 2000-Merkblatt does not cover materials for
– gaskets and
– attachment and installation parts.
The N series of the AD 2000-Merkblätter cover non-
metallic materials.
2 General requirements
2.1 The materials shall attain the required mechanical
properties on the finished structural part.
Materials in contact with the vessel content shall suffer
neither serious corrosion attack nor form dangerous com-
pounds with the same.
2.2 The purchaser/user or the manufacturer of the pres-

use in different product forms for the manufacture of
pressure-bearing components of pressure vessels.
The AD 2000-Merkblatt lays down general principles for
the quality of the products, their manufacture and testing.
© Carl Heymanns Verlag KG
sure vessel, piping and accessories shall select only ma-
terials which, when correctly processed, will attain the
properties fully compatible with the service conditions of
the pressure vessels, piping and accessories.

Supersedes October 2000 edition; | = Amendments to previous edition

AD 2000-Merkblätter are protected by Copyright. The rights of use, particularly of any translation, reproduction, extract of figures, transmission by
photomechanical means and storage in data retrieval Systems, even of extracts, are reserved to the author. Carl Heymanns Verlag has taken all reason-
able measures to ensure the accuracy of this translation but regrets that no responsibility can be accepted for any error, omission or inaccuracy. In
cases of doubt or dispute, the latest edition of the German text only is valid.
 AD 2000-Merkblatt
Page 2 AD-2000-Merkblatt W 0, 10. 2003 edition
2.3 The quality characteristics of materials in the delivery
condition, essential for satisfying the conditions of 2.1 and
2.2, and the quality-affecting measures to be adopted
during processing shall be stated in a material specifica-
tion. Preferably this document should refer either wholly or
partially to standards or other technical delivery condi-
tions.
In accordance with 4.2 of Annex I of the Pressure Equip-
ment Directive, only materials shall be used for which
– a harmonized standard,
– a European approval of pressure equipment materials,
or
– a particular material appraisal
is available.
In addition to materials which comply with harmonized
standards, the AD 2000-Merkblätter also list materials for
which there are no harmonized standards, or European
material approvals. These materials, e.g. those which
comply with DIN Standards, Stahl-Eisen-Werkstoffblätter
or VdTÜV-Werkstoffblätter, have proven successful for the
construction of pressure vessels, piping and accessories.
In the application of the AD 2000 Code, they meet the
materials requirements specified in 4.2 of Annex I of the
Pressure Equipment Directive and may be considered to
have undergone a particular material appraisal through the
relevant third party and be employed without additional
test expenditure.
2.4 The products are normally tested in the manufac-
turer's works.
The relevant DIN standards and Stahl-Eisen-Prüfblätter
(Test Sheets) apply to the testing procedures, unless
otherwise stated in the material specification (see 3.4.1).
3 Materials for pressure vessels, piping
and accessories
3.1 Special requirements
3.1.1 The material specification forms the basis for the
assessment of the suitability of the material for pressure
vessels, piping and accessories. For meeting the general
conditions in accordance with clause 2 the minimum re-
quirements laid down in this document are:
– the demands made on the chemical composition and
the mechanical/technological properties,
– the conditions regarding processing and heat treatment
methods and practices,
– the material testing conditions together with the type
and the content of the test certificate,
– the marking requirements,
– the conditions governing the design characteristics.
3.1.2 The manufacturer of the materials shall
– employ equipment ensuring the proper manufacture
and testing of the products,
– employ competent personnel for the manufacture and
testing of the products as well as an inspection author-
ity for non-destructive tests provided such have been
stipulated in the materials specification,
– manufacture the products using a suitable method and
– ensure by means of quality control and suitable re-
cords, the appropriate manufacture and processing of
the products as well as the fulfilment of the conditions
laid down in the material specification.
The same holds for the manufacture of the initial material.
If the manufacturer issues an inspection certificate 3.1.B,
he shall also have available a documented quality man-
agement system.
The works inspector issuing inspection Certificate B for
the manufacturer shall fulfil the conditions of DIN EN 10
204. The name and the test stamp of the works inspector
shall be known to the relevant third party.
3.2 Establishment of the suitability of the material
3.2.1 The suitability of the materials shall be established
by the relevant third party on the basis of the material
specification in accordance with 3.1.1. If the suitability of
the material cannot be established on the basis of the
material specification the relevant third party shall impose
additional essential safety conditions and appropriate
tests for the product.
The relevant third party shall express the result of the
suitability check in writing.
In cases where the suitability check is intended for wider
application, this can be done in the form of a European
material approval (e.g. procedure as specified in VdTÜV-
Merkblätter 1255 to 12641).
If a suitability check for general usage is not available, the
relevant third party may prepare an individual certificate.
3.2.2 The materials listed in the W series of AD 2000-
Merkblätter are suitable for use within the limits quoted in
the relevant AD 2000-Merkblatt. Other application limits
are permissible once suitability in conformity with 3.2.1
has been established.
3.3 Certificate confirming the fulfilment of the condi-
tions laid down for the manufacturer
3.3.1 The manufacturer of the materials shall prove to
the relevant third party that the requirements to 3.1.2 have
been satisfied. Existing QM systems shall be taken into
consideration here. The results of the check shall be con-
firmed by the relevant third party. This generally happens
before the first delivery.
The confirmation is valid for 3 years and is extended with-
out any further test as long as the relevant third party
reassures itself annually that the material-specific re-
quirements are met. This may be done within the context
of continuous material inspections by the relevant third
party.
Manufacturers that meet the requirements specified in
3.1.2 are listed in VdTÜV Merkblatt Werkstoffe 1253/1.
3.3.2 The proof according to 3.3.1 can be replaced in an
individual case by an appropriate enlargement of the
scope of the tests performed on the delivery, e.g. by a
check of the chemical composition on the piece, a heat
treatment check, additional sampling to confirm the uni-
formity of the state. The necessary supplementary tests
shall be imposed by the relevant third party.
3.4 Testing, marking and quality certificates
3.4.1 (1) The conditions governing the suitability check in
accordance with 3.2 are decisive for the testing and mark-
ing of the material as also for the quality certificate; the
marking shall include at least the specifications imposed
for a comparable product in accordance with the corre-
sponding W series of AD 2000-Merkblatt.
1
) Available from: TÜV-Verlag GmbH, P.O.Box 90 30 60, D 51123 Cologne.
 AD 2000-Merkblatt
(2) The quality certificate shall quote the quantitiy deliv-
ered, the typical dimensions and the full wording of the
marking.
(3) If the manufacturer uses, for a given product-form,
materials not refined by him, he shall be in possession of
certificates supplied by the manufacturer of the initial
material stating the chemical composition, the material
designation, the marking, the relevant dimensions and the
quantity delivered.
3.4.2 If a certificate 3.1.C or 3.2 as described in clause 3
of DIN EN 10204 is specified as proof of the quality char-
acteristics, the mechanical/technological tests (e.g. tensile
test, impact test, bending test, flattening test) and the
visual and dimensional examinations shall be carried out
in the presence of the relevant third party. As long as
adequate production reliability has been proven by the
relevant third party, a random visual examination and
dimensional test by the relevant third party is permitted.
Certificates 3.1.C and 3.2 are equivalent in the context of
this clause. Certificates 3.1.A also meet the requirements.
On request, the relevant third party shall indicate the
chemical composition of the cast, the steel making proc-
ess, the manufacturing method and the delivery condition
of the product unless otherwise specified on the basis of
the suitability test described in 3.2.
The relevant third party is entitled to observe the manu-
facturing process. The manufacturing and test procedures
shall not be adversely affected.
In circumstances according to 3.4.1 para (3), the relevant
third party shall be in possession of the certificates from
the manufacturer of the initial material.
3.4.3 The manufacturer shall confirm that the require-
ments of the material specification and the order have
been met, e.g. in the inspection certificate 3.1.B. In cases
where nondestructive tests have been prescribed an in-
spection certificate 3.1.B to DIN EN 10 204 is generally
issued.
3.5 Repairs and repair (final) welds
Material defects may be repaired in conformity with the
conditions laid down in the material specification. If the
AD-2000-Merkblatt W 0, 10. 2003 edition Page 3
question of repair (final) welds is not covered in the mate-
rial specification, repair (final) welding (with the exception
the repair welding of steel castings) may only be carried
out in agreement with the customer and – whenever the
relevant third party is required to test the product – in the
presence of the relevant third party.
In cases of repairs by means of welding, the nature and
the extent of the repairs, as well as the type and the re-
sults of the tests performed on the required area shall be
described in a certificate.
The conditions laid down in DIN 1690, Part 1 apply for
repair welds on steel castings, unless otherwise stated in
the material specification. A process approval test in ac-
cordance with Stahl-Eisen-Werkstoffblatt 110 is required
for repair welds on steel castings.
3.6 Design characteristics
The characteristic values stipulated in the material specifi-
cation are valid for design purposes unless other values
are laid down in the suitability check in 3.2.
4 Filler metals and other consumables
4.1 The filler metals, if required in combination with con-
sumables, shall be suitable for the fabrication of pressure
vessels, piping and accessories, i.e. the weld metal shall
be adapted to the base metals and to the relevant quality
characteristics given in a "filler metal specification".
4.2 The suitability of solder and adhesives can be estab-
lished in a process approval test.
4.3 The suitability shall be established by the report of a
relevant third party on the basis of the filler metal specifi-
cation 2). In cases where a suitability check for general
usage has not been carried out, suitability for a specific,
respectively similar application may be established during
an extended process approval test.
The suitability of the filler metals quoted in VdTÜV-
Kennblatt 1000 shall be established within the scope laid
down in that standard.
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