105676490-AD-2000-Merkblatt-W5-2009 (2)

AD 2000-Merkblatt ICS 23.020.30

March 2009 edition

Materials for pressure vessels

Cast steel

AD 2000-Merkblatt

W5

The AD 2000-Merkblätter 2000-Merkblätter are prepared by the seven associations listed below who together form the “Arbeitsgemeinschaft Druckbehälter” (AD). The structure and the application of the AD 2000 Code 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 m eeting 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 Code 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 Deutsche Gesetzliche Unfallversicherung (DGUV), Berlin 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 TÜV e.V. (VdTÜV), Berlin 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 TÜV e.V., Friedrichstraße 136, 10117 Berlin. ____________ Contents

6 0 : 4 1 2 2 9 0 9 0 0 2 1 0 0 7 0 9 0 0 6 4 . r N f L 8 0 6 5 8 4 7 . r N d K l . P g n i t s a C t n e m t s e v n I h c e t m A h t u e B d a o l n w o D n e m r o N

0 1 2 3 4 5

Foreword Scope Suit Suitab able le cast cast stee steell Mate Ma teri rial al requ requir irem emen ents ts Heat Heat tre treat atme ment nt and and wel weldi ding ng Testing

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 self-contained concept. If other technical rules are used in accordance with the state of the art to solve related problems, problems, 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 different sectors of the law. Responsibility for testing is as specified in the provisions of the relevant sector of the law. 1

Scope 1.1 This AD 2000-Merkblatt is applicable to cast steel used for the construction of pressure vessels and pressure vessel components which are operated at working temperatures and ambient temperatures down to –10 °C and up to the upper temperature limits specified in clauses 2 and 3. For working

6 Marking 7 Type Type of test test cert certifific icat atee 8 Design va values Append Appendix ix 1: Highes Highestt admiss admissibl iblee indica indicatin tingg characteristics in the radiographic examination RT temperatur temperatures es below below –10 °C, AD AD 2000-Merkb 2000-Merkblatt latt W 10 also also applies. 2000-Merkblatt latt A 4 applies to accessory accessory housings. housings. 1.2 AD 2000-Merkb 1.3 Basic requirements for materials and material manufacturer are regulated in AD 2000-Merkblatt W 0.

2 Suit Suitab able le cast cast steel teel The following cast steel types may be used: 2.1 Ferritic cast steel GE200 (1.0420), GE240 (1.0446) and G20Mn5 (1.6220) to DIN EN 10293 within the application limits given in Table 3. 2.2 Cast steel for use at room temperature and elevated temperatur temperatures es in accordance accordance with DIN DIN EN 10213, but but only grades GP240GH (1.0619), G20Mo5 (1.5419), G17CrMo5-5 (1.7357), G17CrMo9-10 (1.7379), G17CrMoV5-10 (1.7706), GX8CrNi12 (1.4107) and GX23CrMoV12-1 (1.4931) up to the wall thicknesses1) specified in this standard. 1)

Specified wall thicknesses may be increased upon agreement with the relevant third party. In its normalized state, however, steel grade GP240GH shall only be used up to a maximum wall thickness of 100 mm.

Supersedes July 2003 edition; completely revised 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. Beuth Verlag has taken all reasonable 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 5, 03.2009 edition

Cast steel for use at low temperatures to DIN EN 10213, but only grades G17Mn5 (1.1131), G20Mn5 (1.6220), G9Ni10 (1.5636) and G9Ni14 (1.5638) up to the wall thicknesses1) specified in the standard, and also GX3CrNi13-4 (1.6983) in conjunction with VdTÜV-Werkstoffblatt 452. 2.3

Low-temperature cast steel grades G10Ni6 (1.5621), G26CrMo4 (1.7221)and GX6CrNi18-10 (1.6902) in accordance with Stahl-Eisen-Werkstoffblatt (SEW) 685 up to a temperature of 50 °C 2). 2.4

Other ferritic or martensitic cast steel upon proof of qualification by the relevant third party, which shall also include the application limits, requirements, test and inspection instructions, marking and instructions on further processing (forming, heat treatment, welding). The cast steel shall exhibit the property values characteristic of the standard material and shall meet the following minimum requirements: – Elongation at fracture A at room temperature ≥ 15 %, – Impact energy at lowest working temperature, but not exceeding 20 °C, ≥ 27 J on V-notch test specimens as specified in DIN EN 10045-1. A requirement of the above tests is that the fracture behaviour is ductile. The results of additional brittle fracture tests, obtained in the qualification procedure may justify other minimum values. 2.5

Austenitic cast steel types to DIN EN 10213, but only grades GX5CrNi19-10 (1.4308), GX5CrNiNb19-11 (1.4552), GX5CrNiMo19-11-2 (1.4408) and GX5CrNiMoNb19-11-2 (1.4581) to the temperatures stated for the minimum proof stress values indicated in Table 2 of this standard, note being taken of the specifications concerning corrosion resistance given in Table A.1 of DIN EN 10213. Where a resistance to intercrystalline corrosion is required for cast steel type 1.4408, the application temperature shall not exceed 300 °C. For centrifugal castings VdTÜV-Werkstoffblatt 286 applies, in addition. 2.6


Other austenitic cast steel upon proof of qualification by the relevant third party, which shall also include the application limits, requirements, test and inspection instructions, marking and information on further processing (forming,

heat treatment, welding). The cast steel shall exhibit the property values characteristic of the standard material and shall meet the following minimum requirements: – Elongation at fracture A at room temperature ≥ 20 %, – Impact energy at lowest working temperature, but not exceeding 20 °C, ≤ 35 J on V-notch test specimens as specified in DIN EN 10045-1. 2.8 For other cast steel specified in 2.5 and 2.7, evidence of the elevated temperature proof stress and, if applicable, long-term elevated temperature properties shall be provided by the manufacturer, specifying the standard analysis and heat treatment.

3

Material requirements

3.1 Regarding the general requirements for cast steel

parts, DIN EN 1559-1 and -2 apply in addition to the material standards. 3.2 Quality levels Depending on the differing requirements for the internal and external surface condition of castings, cast steel shall be delivered in qualities classified in accordance with Table 1. Table 1 contains the assignment of qualities to the maximum allowable temperature and the maximum allowable pressure unless a higher quality is required due to special operating conditions. Where pressure and temperature do not fall under the same quality, the quality with the more exacting requirements shall take precedence. The standards to be applied for non destructive testing are given in Table 1.

4

Heat treatment and welding 4.1 For heat treatment purposes, the specifications given in DIN EN 10213 or in the relevant Werkstoffblätter (material material specifications) apply. 4.2 For welding, the specifications in 6.2 of DIN EN 10213, apply.

2.7

1) see page 1 2) For definition of wall temperature and working temperature, see

Section 5 of AD 2000-Merkblatt B 0.

Table 1. Assignment of quality levels

Quality level

Maximum allowable temperature

Maximum allowable pressure

°C

bar

11)

permissible indicating characteristics PT 2)

MT 3)

RT 4)

UT 5)

SP1,CP1

SM1

1

1

2

> 450

> 80

SP2,CP2,LP2,AP2

SM2,LM2,AM2

2

2

3

> 400 to ≤ 450

> 32 to ≤ 80

SP3,CP3,LP3,AP3

SM3,LM3,AM3

3

3

SP4,CP4,LP4,AP4

SM4,LM4,AM4

4

4

4 1) 2) 3) 4) 5)

Welding ends

Quality levels

≤

400

≤

32

Linear or aligned indications, when detected by surface testing, are not permitted. Liquid penetrant inspection PT in accordance with DIN EN 1371-1 or DIN EN 1371-2 Magnetic particle inspection MT in accordance with DIN EN 1369 Radiographic examination RT in accordance with DIN EN 12681/acceptance criteria in accordance with Appendix 1 to this AD 2000-Merkblatt Ultrasonic examination UT in accordance with DIN EN 12680-2

AD 2000-Merkblatt AD 2000-Merkblatt W 5, 03.2009 edition Page 3

The welding procedures shall be approved by the relevant third party in accordance with DIN EN ISO 11970. All tests given in Table 1 of DIN EN ISO 11970 shall be performed. In doing so, the following applies: – Hardness tests shall not be performed on cast steel grades of groups F and G. – Bend tests on two side bend test specimens SBB in accordance with DIN EN 910. The requirements given in DIN EN ISO 15614-1, 7.4.3, apply. – Test for resistance to intercrystalline corrosion in accordance with DIN EN ISO 3651-2 for cast steel grades of groups F and G, if this type of corrosion is required. – Determination of the ferritic content for cast steel grades of group G. – Tensile test and impact V notch test on the parent metal, if no test certificates in accordance with the relevant AD 2000-Merkblätter of the W-series are available for the parent metal. The results of the non destructive tests shall fulfil the requirements of quality level 1. Cracks and lacks of side fusion are inadmissible. Other defects are admissible within the limits given in the AD 2000 Merkblatt HP 5/3.

5


Testing 5.1 Cast steel components specified in 2.1 to 2.4 and 2.6 shall be tested in accordance with the standards and material specifications contained therein. Testing shall be performed on a cast by cast basis so that components having under-gone the same heat treatment are covered. The maximum weight of a test batch for the notched bar impact test and tensile test is 2500 kg. Excess quantities up to 1250 kg shall in each case be added to the preceding test batch. Cast steel components weighing in excess of 1000 kg shall be tested individually. For austenitic cast steel components, in addition to the 1,0 % proof stress, the 0,2 % proof stress shall also be determined. The 0,2 % proof stress shall be 25 MPa lower than the 1,0 % proof stress. For cast steel components specified in 2.5 and 2.7, the testing requirements shall be laid down in the qualification test.

The extent of testing is defined in Table 2 of this AD 2000Merkblatt. Castings weighing in excess of 1000 kg shall be tested individually. For weldings, radiographic examination shall be carried out in accordance with DIN EN 1435, Category B. For austenitic steel castings to DIN EN 10213, testing for resistance to intercrystalline corrosion in accordance with DIN EN ISO 3651-2 shall be performed for each cast and heat treatment batch. This test may be waived by agreement with the customer/user. 5.7

6 Marking The minimum requirement shall be indelibly marked with at least the following: – Manufacturer’s symbol – Designation of material – Cast number – Test stamp of relevant third party or authorized inspection representative in cases of deliveries with inspection certificates in accordance with DIN EN 10204. Table 2. Extent of testing to verify the quality level

Quality level

Extent of testing in relation to the number of components

1

100 %

2

100 % 1. Prototype:

100 %

2. Pilot lot:

100 % on at least 10 components

3. Series production:

100 % on areas identified as critical on pilot lot components. If no critical areas are identified on pilot lot components, 10 % of the components shall be tested at generally difficultto-cast locations. All components shall be subjected to surface detection.

1. Prototype:

100 %

2. Series production:

Random testing on areas identified as critical on prototype components or at generally difficult-to-cast locations. All components shall be subjected to surface detection.

3

5.2

All castings shall be inspected for their external condition. Safety-relevant dimensions shall be checked. The chemical composition shall be determined by ladle analysis. 5.3

Where quenched and tempered castings are examined cast by cast, they shall be subjected to comparative hardness testing. The result of the hardness tests shall show a regular quenched and tempered condition (the difference in hardness between the hardest and softest component tested in the test batch shall not exceed 30 HB). 5.4

Should special operating conditions prevail, leak tests for checking the tightness of walls and examining the casting for the presence of defects shall be performed. The type and extent of such tests shall be agreed when placing the order. 5.5

The castings shall be subjected to non-destructive testing to verify the use of the correct qualities as specified in clause 3. The non destructive testing personnel shall be certified in accordance with DIN EN 473 for the test methods given in Table 1. 5.6

4

7 Type of test certificate The quality shall be certified as follows: 7.1 For cast steel specified in 2.1, by inspection certificate 3.1 to DIN EN 10204.


For cast steel specified in 2.2 to 2.4, inspection certificate 3.2 to DIN EN 10204 is required. For cast steel grade GP240GH, inspection certificate 3.1 to DIN EN 10204 will suffice provided the component weight does not exceed 500 kg. 7.2

For cast steel specified in 2.6, by inspection certificate 3.2 to DIN EN 10204. For unit weights less than 200 kg, inspection certificate 3.1 to DIN EN 10204 will suffice. 7.3

For cast steel specified in 2.5 and 2.7, in accordance with the approval testing requirements. 7.4

By means of inspection certificate 3.1 to DIN EN 10204, the manufacturer shall confirm3) that the requirements in the relevant standards and Table 1 are satisfied with regard to the qualities concerned. If quality is proved by inspection certificate 3.2 to DIN EN 10204, the results of the nondestructive tests on welding ends and castings of quality levels 1 and 2 shall finally be evaluated by the relevant third party. For radiographic examination, the relevant third party shall perform the evaluation on 100 % of the castings, for ultrasonic examination and surface testing, it shall perform a re-evaluation on 10 % of the castings. 7.5

7.6

Contents of the inspection certificates to DIN EN 10204

The inspection certificates shall contain the information required by the technical delivery conditions/standards. Furthermore, in each inspection certificate the technical delivery condition/standard (e. g. DIN EN 10213) and Technical Rule (AD 2000-Merkblatt W 5) forming the basis for the delivery shall be stated. 6 0 : 4 1 2 2 9 0 9 0 0 2 1 0 0 7 0 9 0 0 6 4 . r N f L 8 0 6 5 8 4 7 . r N d K l . P g n i t s a C t n e m t s e v n I h c e t m A h t u e B d a o l n w o D n e m r o N

8

Design values 8.1 For cast steel specified in 2.1, the values in Table 3 apply. 8.2 For cast steel specified in 2.2 and 2.3, with the exception of grade GX3CrNi13 4, the values stipulated in DIN EN 10213 apply. For cast steel GX3CrNi13 4, the values stipulated in VdTÜV Werkstoffblatt 452 apply. 8.3 For cast steel specified in 2.4, the values stipulated in SEW 685 apply. 8.4 For cast steel specified in 2.6, the values stipulated in DIN EN 10213 are applicable, but they shall be reduced by 25 MPa for calculation purposes (please refer to DIN EN 10213, Table 3, footnote b). For austenitic centrifugally cast steel, the values stipulated in the VdTÜV-Werkstoffblatt 282 apply. 8.5 For cast steel specified in 2.5 and 2.7 the values laid down in the qualification apply. 8.6 The design strength values laid down for 20 °C by the material specifications or qualification apply up to 50 °C and those specified for 100 °C up to 120 °C. In the remaining temperature ranges, linear interpolation between the specified values is necessary (e.g. for 80 °C, between 20 °C and 100 °C and for 180 °C, between 150 °C and 200 °C), but no rounding up is permitted. For individually certified materials (special material appraisal) the interpolation rule only applies if there is a sufficiently close interval4) between the points of support. 3)

This confirmation may also be included in the certification of the respective higher quality. 4) As a rule, this means a temperature interval of 50 K within the range of elevated temperature proof stress and of 10 K within the creep rupture strength range.

Table 3. Application limits and design values for cast steel according to 2.1

Cast steel grade

Wall thickness mm

Design value K at design temperature 20 °C

100 °C

150 °C

200 °C

250 °C

3001) °C

3501) °C

MPa

MPa

MPa

MPa

MPa

MPa

MPa

GE200

≤

100

200

181

167

157

137

118

–

GE240

≤

100

230

216

196

176

157

137

–

≤

30

300

216

205

197

193

186

178

260

184

173

166

161

154

146

300

216

205

197

193

186

178

G20Mn5+N G20Mn5+QT 1)

> 30 to ≤ 100 ≤

100

The design temperature shall not exceed 300 °C or 350 °C even for heated parts. AD 2000-Merkblatt B 0, Table 1 shall be taken into consideration.

AD 2000-Merkblatt AD 2000-Merkblatt W 5, 03.2009 edition Page 5

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Figure A 1:


Division of the wall into zones (division refers to thickness d of the finished casting)

AD 2000-Merkblatt

– Blank page –



Publisher:

Verband der TÜV e.V.

E-Mail: [email protected] http://www.vdtuev.de

Source of supply:

Beuth Verlag GmbH 10772 Berlin Tel. 030/26 01-22 60 Fax 030/26 01-12 60 [email protected] www.beuth.de

105676490-AD-2000-Merkblatt-W5-2009 (2)

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