ICS 23,020.30 July 2006 edition mats siesta | for General principles for materials 7 pressure vessels wo The AD 2000-Merkbatter are prepared by the seven associations Usted below who together form the “Arbeitsgemeinschaft Druck- ‘behaiter" (AD). The structure and the application of the AD 2000 Code and the procedural guidelines are covered by AD 2000-Merk- Diatt G1. ‘Tne AD 2000-Merkolatter contain safety requirements fo be met under normal operating conditions. I above-normal loadings are to be ‘expected during the operation ofthe pressure vessel, this shal be taken into account by meeting special requirements, 1 there are any divergences fram the requirements ofthis AD 2000-Merkblatt, it shall be possible to prove thatthe standard of safety of © Cari Heyman Verlag Goo Lemburger Stabe 49, D-50000 Kan this Code nas been maintained by other means, eg. By materials testing, tests, stress analysis, operating experience Fachworband Damptessel, Bohilter- und Rohrletungsbau e.V. (FDA), Dasseldort ‘Hauptverband der gewerbichen Berufsgenossenschaften e.V, Sankt Augustin Verband der Ghemischen Industrie €.V. (VCD, Frankfurt/Main Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschatt Verfshrenstechnische Maschinen und Apparate, FrankurtiMain ‘Stahinsttut VDEh, Disseldort VGB PowarTech eV, Essen Verband der TOV e.V. VATUM, Berlin Te above associations continuously update the AD 2000-Merkblatter inline with technical progress. Please address any proposals for this tothe publisher: Verband der TOV e.V., FriedrichstraBe 136, 10117 Berlin. Contents. © Foreword 1 Scope 2 General requirements 0 Foreword The AD 2000 Code 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 Code Is structured along the lines of a seit contained concept. If other technical rules are used in accordance with the state of the art to solve related prob- lems, it is assumed that the overall concept has been taken into account. The AD 2000 Code can be used as appropriate for other modules of the Pressure Equipment Directive or for ctfer- tent 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-Merkbiftter apply to metals for use in different product forms for the manufacture of ‘ressure-bearing components of pressure vessels. The AD 2000-Merkblatt lays down general principles for the quality of the products, their manufacture and testing. 3. Materials for pressure vessels 4 Filler metals and other consumables ‘The W series of AD 2000-Merkbitter regulate the applica- tion and the requirements of various product forms, ©.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-Merkblitter cover non- ‘metallic materials. 2. General requirements 2.4 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- ‘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 2004 edition; = Amendments to previous edition "AD 2000-Meribtor are protected by Copyright. The rahis of use, parculary ot any Yanslaon, repoduelen, extract of fours, vararission by Dholomechanea means and storage dat eral Systems, oven oferta rere’ to the ther. Car Meymanns Verlag ha akan lesson fable measures fo ensure the accuracy of fs vansition Out regrets that no responsibly can be accepieg for any erat, omission or nacuracy. asos of doubt or depute atst eatin ofthe Gorman ont onli ada2 ADZono Moro W007 2006 eon 23. 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 | 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-Merkblatter also list materials for, which there are no harmonized standards, or European material approvals. These materials, e.g. those which ‘comply with DIN Standards, Stahi-Eisen-Werkstoffblatter ‘or VaTUV-Werkstoffblatter, 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 | 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. 24 The products are normally tested in the manufac- turer's works. ‘The relevant DIN standards and Stahl-Eisen-Profblatter, (Test Sheets) apply to the testing procedures, unless otherwise stated in the material specification (see 9.4.1), 3 Materials for pressure vessels 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. For meeting the general conditions in accordance with clause 2 the minimum requirements laid down in this document are: = the demands made on the chemical composition and the mechanicaltechnological properties, = the conditions regarding processing and heat treatment methods and practices, = the material testing conditions together with the type land the content of the test certificate, = the marking requirements, = the conditions governing the design characteristics. 8.4.2 The manufacturer of the materials shail = employ equipment ensuring the proper manufacture and testing of the products, = employ competent personnel for the manufacture and ‘esting 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 fulflment of the conditions laid down in the material specification. ‘The same holds for the manufacture of the initial material | ifthe manufacturer issues an inepection certificate 3.1, he shall also have available a documented quality manage- ment system. The works inspector issuing inspection certificates 3.1 for the manufacturer shall fulfil the conditions of DIN EN 10.204. The name and the test stamp of the works inspec- tor shall be known to the relevant third party 3.2 Establishment of the suitability of the material 3.2.1. The suitabilty 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 VaTUV- Merkbiatter 1255 to 1264'). If @ suitability check for general usage is not available, the relevant third party may prepare an individval certificate. 3.2.2 The materials listed in the W series of AD 2000- Merkblatter are suitable for use within the limits quoted in the relevant AD 2000-Merkbiatt. Other application limits, fare permissible once suitability In conformity with 3.2.1 has been established, ‘The W series of AD 2000-Merkblatter are continuously, aligned with currently valid standards. The use of materi- als, which were delivered in accordance with previously valid editions from the AD-, or AD 2000 Codes, Is still permissible. 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 pany. Manufacturers that meet the requirements specified in 3.1.2 are listed in VATUV-Merkblatt Werkstofte 1259/1, for example. 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 pisce, 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 1) atti: TOv- ads Gah Am run Sn, 05118 Cote,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 cocre- sponding W series of AD 2000-Merkblatt. 2) The quality certificate shall quote the quantity deliv- ered, the typical dimensions and the full wording of the marking, @ 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 dimerssions and the ‘quantity delivered. 3.42 (1 The test erates according to DIN EN 10204 for proof of the quality characteristics are spect: fod n the W series of AD 2000-MerKoter as a funtion of the material. If non-destructive tests are specified, they are generally certified in an inspection certificate 3.1 Test certificates according to DIN EN 10204:1998 initially attain their vaicty within the context of the AD 2000 Code if the requirements of 8.1.2 and 3.4.3 are met. {@) If an inspection certificate 3.2 according to 4.2 of DIN EN 10204:2005 is spectiod as proof of the quality charac- teristics, the machanicaltechnological tests (e.g. tensile test, impact test, bending test, flattening test) and the visual examination and dimensional test shall be carried ‘out in the presence of the relevant third party. As long as adequate production reliabilty has been proven to the relevant third party, a random visual examination and dimensional test by the relevant third party is permitted. 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 32 ‘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 ofthe inital material 3.43 If DIN EN 10204:1995 is being applied, the manu- facturer shall confirm that the requirements of the material specication and of the order have been met Test certificates (2.1.4), 3.1.C and 3.2 according to DIN EN 10204:1995 shall be regarded as equivalent with re- spect to inspection certificate 3.2 in the AD 2000 Code The requirements in 3.4.2 @) apply with regard tothe tests being caried out by the relevant third party A0-200-Menicat W 0,7. 2096 ton Page 3 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 question of repair (final) welds is not covered in the mate- ‘al specification, repair final) welding (with the exception the repair welding of steel castings) may only be carried cut 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 wall as the type and the re- sults ofthe 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 Siahi-Eiser-Werkstofiblat 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, ie. 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 relevant third party on the basis of the filler metal specifi- cation’). In cases where a suitability check for general usage has not been carried out, suitability for a spacific, respectively similar application may be established during ‘an extended process approval test. The suitability of the filler metals quoted in VaTUV- | Kennblatt 1000 shall be established within the scope laid down in that standard. 7 tee WaTUVAMaan 189 = tin fe ie Eonrosercing we ShePublisher: Verband der TOV e¥. E-Mail: berlin@vdtuev.de http:/www.vdtuev.de Source of supply: @ Carl Heymanns Verlag Luxemburger StraBe 449, D-50939 Kén Telefax: 0221-9 43 73 603 E-Mail: verkaut@heymanns.com