AD 2000-Merkblatt les 23,020.30 July 2003 edition Equipment, installation ‘AD 2000-Merkbiatt and marking of Accessory housings pressure vessels A4 The AD 2000-Merkoitter are prepared by the seven associations fisted below who together fm the “Aubetsgemeinschatt Drache. halter” (AD), The stricture and the apphication of the AD 2000 body of ragulatians and the procedural guelines aro caverod by AD 2000-Kerkbigtt G1 ‘The AD 2000-Aterkbattor contin safety requirements fo be met under nomal operating conditions I above.normal loadings are to be expected aurng the aperatian ofthe pressure vessel, this shal ba taken inte account by meeting special reauivements, there are any dvergences trom the requirements ofthis AD 2000-Merkbla, 1 shal be possibla to prove that tha standarc of safety of this body of reguions has been mainiaines by afer means, e.g. By Malena’ testing, test, stress analysis. operating experience Fachverband Damipthesse, Better- und Rofutelungshst eV, ‘FOBFY, Disseksort ayptvarband der gewerbishen Berulsgenossonschatton @¥., Sankt Augustin Veiband der Chamischen Indust &V. (VCD, Frankfutidain Verband Doutscher Maschinen and Anlaganbay e.V. (YDMA} Fachgemeinschalt Verfabrenstechnische Afaschinen ured Apparat, Frankturtain Staliinstit (DER), Daseliort VGE PonerTech €,, Essen Verano der Tacnnischen Uberwachures-Vereine @V. (VeTEV), Esson The above associations continuously update the AD 2000-Merkbitker inline with technical progress. Please adchess any proposals for this fo he pubister Verband der Technischen Uberwachungs-Vereine e. P. 0, Box 10 38 24, D-45038 Essen Contents. 0 Foreword 5. Genaral principles for design, 1 Scope ‘manufacture and associated tests 2 Definitions 6 Tests prior to putting into service 3. Classification 7 Marking 4. Materials and design 8 Cottificates for the finished 0 Foreword sure vassols and piping with a maximum allowable pres: sure (PS} exceeding 0.5 bar Clauses 4 t0 8 of this AD 2000-Merkblatt, excluding 6.4.1 do not apply to accessory housings in refrigeration and hheat-pumping plant, see AD 2000-Merkblatt HP 801 No. 14 “Druckbehaiter in Kalteaniagen und Warmepum- enanlagen” (Pressure equipment in reingerating and ‘hoat-pumping plant ‘The AD 2000 body of rogulations can be applied to satisfy the basic safety requirements of the Pressure Equipment Directive, principally for the conformity assessment in ‘accordance with medules "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 accoidance with the state of the art to solve ‘elated problems, it is assumed that the overall concept thas been taken into account 2. Definitions ‘The AD 2000 body of requlations can be used as appro- priate for other modules of the Pressure Equipment Ditec- tive or for cifferant sectors of the law. Responsibility for testing is as specified in the provisions of the relevant sector of the law, 1 Scope This AD 2000-Merkblatt applies to pressure-bearing ac- essory Housings and! safety accessory housings for pres- Lenortarger [AD zeoo-tmeotter ave protected by Copnight Te righis of use paeary of any Wandaton, reprodoclen, ewact of Wares, arammasenn by as an stotagein data fevcul Systems, even of extaee, re earned Wo he ahr Cat Heya Vranas falen aaa wanton bk reels tht no respensbiy con be aecepte for sy etc, onsen on siacinec {Sater of doubt ce dist, the net eatin ef the Geman text ony va, a 21 Accessory housings are pressure-bearing housings and have independent chambers, Pressure-bearing hou Sings include the lead-absorting connecting elements that hold the pressure-bearing parts of the housing together 22 Valves include slide gate valves, cocks, gate valves te, 2.3. The nominal size (DN) of an accessory housing is @ numerical size designation, It fs a round number used 2s the nominal size and approximately relates to the manu factured dimensions Suporsedes January 2003 edition; | = Amendments to previous esitionAD 2000-Merkblatt 2.4 The volume V of a valve is the geometrical size of the ‘chamber with an open flow diameter starting at the near- est detachable connection, or at connections used in- stead of detachable connections less the volume of the permanent internal pars, 2.8 “Fluids” are gases, liquids or vapours as a pure phase and their mixtures, Fluids may contain a suspen- sion of solid materia 2.6 Permanent internal parts aro all the parts ~ including pipe assemblies and other hollow bodies ~ installad inside the chamber for the specitied mode of operation by ‘means of a friction or interference fit or which cannot be detached, 2.7 A quality system Is the structural and procedural lofganization introduced mandatorly and documented by the manufacturer for providing quality assurance and the means necessary for this in accordance with the raquice- ‘ments of the Pressure Equipment Directive (quality assur- ance system modules) 3. Classification Accessory housings are classified into the conformity assessment tables on the basis of their maximum alow- able pressure (PS), their nominal size (DN), or volume (V) {88 appropriate and the grcup of fluids for which they are intended. In some cases, both the volume (Vj and the nominal size (DN) are regarded as suitable. In these cases, the accessory shall be classified into a higher category. Far valves. the nominal size (DN) is normally better suited, The tables in the Pressure Equipment Directive are appl cable. Safety accessories that are manufactured for spe- cific pressure equipment may be classified in the same Category as the pressure equipment to be protected. 4 Materials and design ‘The materials and design shall bo solected in accordance: with the intenced application, taking into account factors, such as pressure and temperature stressing and charging ‘material (lluids): dynamic stresses, e.g. pressure surges or pulsating loads shall be noted in particular. 4.1 General principles for manufacturers and materials. ‘The material manufacturer and the materia’s for pressure bearing accessory housings shall meet the requirements of the W series of the AD 2000-Merkblatter, The require ments may be applied as appropriate for category |. 42 Suitable materials ‘The following matetia's may be used for accassory hous- ings within the specified application limits given for each (1) Non-alloy and alloy steel grades as specified in AD. 2000-Merkblatter W 1. W4,W 7, WB, W9, W 12 and wis, @) Austenitic steel grades as specified in AD 2000- Merkbiat: w2, (3) Cast sieel as specified in AD 2000-Merkblatt WW 8, (4). Spheroidat graphite cast iron as specifi in AD 2000. Merkblatt W_ 3/2; matorials specified in AD 2000. Merkbistter W 3/1 and W 3/3 shall not be used for pressure-bearing accessory housings, (5) Aluminium and aluminium aloys, wrought materials as specified in AD 2000-Merkblatt 6/1, (© Copper arc copper alloys, wrought materiale 2 ‘specified in AD 2000-Merkblatt 6/2, (7) Non-metalic materials as specified in the N series of, the AD 2000-Merkbitter. ‘AD 2000-Merkblatt W 10 shall also be obsorvad for work ing temperatures below ~ 10°, ther materials may be used as long as it has been estab- lished that they are suitable for the intended purpose. This can be established on the basis of appraisals, if ap- propriate taking into account operating proots; for acces- sory housings of ~ category | + ll: by the manufacturer, = catagory I+ IV: by the relevent third party. 4.3 Material testing and proof 4.3.1 The scope of the tests and the proaf for materials, {or accessory housings of categories II to IV are specified Jn the requirements of the W series of the AD 2000- Merkblatter, For accessory housings of category |, a test report 2.2 as, specified in EN 10204 is adequate as proof of the quality, characteristics. 4.3.2 As a daviation from clause 6 of AD 2000-Merkblatt W372, spheroidal graphite cast icon with a nominal tensile strength © 400 N/mm? for accessory housings of catego- ries Ito IV with ON < 150 may be supalied with an inspec- tion certificate 9.1.8 if the manufacturer's works has pro- vided the relevant third party with proof of equivalent and fault-tree production, 5 General principles for design, manufacture and associated tests The manufacturer and manufacture of accessory housings shall meet the requirements of the HP series of the AD 2000-Merkbiétter. The requirements may be applied as appropriate for category | 5.1. The design information in AD 2000-Merkblalt HP + is used as appropriate for accessory housings. Accessory housings aro designed in accordance with DIN $849, 5.2 Where the mechanical production of acoessory hous- ings remains uniform through circumferential welds, test- ing of welded coupon plates as specified in AD 2000- Merkblatt HP 5/2 may be dispensed with under the faliow- ing conditions: (1) The accessory housing is made of a material from ‘group 1 or 6 as described in AD 2000-Merkblatt HP 0 and (2) the welding process = manual electric with welding rod, ~ submergedsare or ~ cored wire electrode under inert gas is used. ‘The relevant third party shall carry out random tests to convince itself thet the conditions are adhered to and of the results of the non-destructive test.6 64 AD 2000-Merkblatt Tests prior to putting into service ‘The following tests are raquived for accessory hous- ings: a @ ® ® o @ ” 62 stress evaluation and structural safety test visual exemination of the completed housing for flaws; checking of the completed housing for dimensional accuracy in accardance with the documents in (1); leak tast for cast housings; the leaktightness of the accessory does not need to be tested functionally in this case; the leak test is carried out as described in ‘clause 5 of DIN 3230 Part 3: strength test BT as described in clause § of DIN 3230 Part 3: tho tast prossure is dotermined as described in 4.17 t0-4.19 of AD 2000-Merkbiatt HP 30; non-desiructive tests of the product types for acces sory housings and of the welds in pressure-bearing walls and check to ensura correct materials have been used in the case of all housing parts made of alloy material. In the stress evaluation and the structural safety test as speciliad in 6.1 (1), the following aspects are verified o e @ w tit 61 adequate dimensioning in accordance with DIN 3840 taking note of the characteristic strength values as specilied in the W series of the AD 2000-Merkblatter andl the proof of suitability: perfect design froma safely viewpoint; Use of suitable materials and correct processing of the materials, is not possible to determine the stress as specified in (1) by calculation ~ particularly if other materials are used ~ the deformation shall be measured or a burst test, shall be carried out as a random test, In this test, proof shall be provided that the safety factor to be used in the calculation in accordance with AD 2000-Merkelatt B 0 has been achered to ~ specifically agains! deformation when calculating using the yield strength (R,,, FR.) and against rupture when calculating using the tersile strength. The experimental design’) without calculation shall only be Used if the product of the maximum allowable pressure (PS) and the volume (V) is less than 6000 bar x J, or the pprocuct of the maximum allowable pressure (PS) and the nominal size (DN) is less than 3000 bar. 63 The following requirements shall be noted when camying out the non-destructive tests on the product, types for accessory housings and on the welds of pres- sure-beanng walls as specitied in 6.1 (8). 63. ow 1 Product types Steel grades as specified in 4.2 (1) anc (2) ‘The product types sna be tested as follows: Uitrasonic test 2) plates as specified in AD 2000-Merkblatt W 1, ul ‘vaaonically tested; b) pipes as specified in AD 2000-Merkblatt W 2 or wa; 9) flangos as specified in AD 2000-Merkblatt W 9, 4) seamless hollow bodies as specified in AD 2000: Merkbiait W 12, 2} forgings as specified in AD 2000- Merkblatt W 13, 4) rolled bars and sections 2.30 mm Scope of test: if possible, each volume unit with two axes of ultrasonic scanning at 90° to each other. permissible flaws: s<50mm = EFG 3") s>50mmto 100mm — < EFG4 > 100mmto 150mm — < EFG5 32 150mm = EFG6 1] seamless hollow bodies as specified in AD 2000- Merkbiatt W 12 Surface crack test 2) hot-formed small areas b) crop forgings, excopt those with a gross weight <30 kg, made of nonalloy steels, 16Mo3, 1SCrMo4-8, XECHNITIIE-10, XBCrNIMOTI17-12-2 ‘and X6CrNiNb18-10. The surface crack test can also be dispensed with for material 10CrMo9-10 if ‘agreed with the relevant third party. This suoclause is not applicable to drop-forgad flanges as speci- fied in AD 2000-Merkblatt WV 9. pormissibte flaws: near indications s 3 mm Cast steal grados as spocitied in 4.2 } Accossory housings are tested as described in DIN 1690 Part 10, quaity class B. For accessory housings with = OWS 150 and ~ DN > 180, if the product of the nominal size DN and the maximum allowable pressure in bar does at exceed 20000 quality class 0 10 DIN 1690 Part 10 is adequate. Weld ends to the pipe in category | to IV accessory housings: Quality class A to DIN 1690 Part 1. @) Spheroidal graphite cast iron as specified in 4.2 (4) ‘The test 's carried out following agreement with the purchaser. (4) Materials as specified in 4.2 (6) to (7) shall be tested in accordance with the relevant AD 2000-Merkblalier (ther materiais as specified in 4.2 For accessory housings of = categories 1+ Il: testtype of test in accordance with establishment of suitability by the manufacturer; = categories il + IV:test in accordance’ with estab- lishment of suitability by the rele vant third party 2 63.2 Welds of the pressure-bearing walls (1) The welds of category Io Ill accessory housings shall be tested as described in AD 2000-Merkblatt HP 5/3 ‘With regard to the soope of the test, the requirements of AD 2000-Merkbiait HP 5/3 are applicable, but it shall be at least 10 %. This minimum 10% scope of testing does not apply, however, if itis dealing with non-alloy materials, or Group 6 materials in. accor dance with AD 2000-Merkblatt HP © anc the nominal size of the accessory housing does not exceed DN 100, } Al the swelds of category IV accessory housings shall be subjecied to non-cestructive testing over their ‘whole longth. Hf these are nozzle welds as shown inAD 2000-Merkblatt figure 1, 2 volume tost is required. As a deviation from this, a surface crack testis adequate for nozzles with d,<50mm and 4.<01 ‘The test procedure test class and assessment are specified in AD 2000-Merkblatt HP 5/3. Figure 1. Nozzle welds, example 64 Carrying out the tests 6.4.1 The tests shall be carried out on accessory hous- ings: (1) of catagories | to i: in accordance with the require: ments of the conformity assessment procedures in Annex Ill of the Pressure Equipment Directive, The unit verification (module G) may also be carried out by the relevant third party (2) of category IV by the relevant third party. 6.4.2 The non-destructive tests specified in 6.1 (@) are ‘generally carried out and assessed by the manufacturer of the product type on the product types and/or = manuiscturer of the housing on welds of pressure bearing walls rool shall be provided by an inspaction certificate 3.1.8 8 specified in DIN EN 10204, For product types for eato- gory IV accessory housings, the test results are assessed finally by the relevant third pay. 6.4.8 Verilication that the correct materials have been Used, as specified in 6.1 (7), is camied out by the acces: sory housing manufacturer 6.5 Validation of the tests 6.5.1 The tests on category | to Ill accessory housings shall be validated by an inspection certificate 3.1.8 as specified in DIN EN 19204. Its adequate for a fist of the relevant material validations as specified in the W serias of the AD 2000-Merkblatter to be attached to the inspection cenificate 3.1.8, 6.5.2 As a doviation from 6.5.1, it is adequate for the manufacturer of category | accessory housings of nominal sizes < 80 10 add the mark of the manufacturing works. Publisher: Neand der Technischen Uborwathungs Yering E-Mal: essen@udtuev.de hipyiwwwvdtuer.de 6.5.9. For category IV accessory housings, the tests shall bbe validated by an inspection certificate 3.1.C as specified in DIN EN 10204. The inspection certificate 3.1. shall contain the material validations of the basic materials in accordance with the W series of the AD 2000-Merkblatter (see 4.3). For safety valves with type test as specified in ‘AD 2000-Merkblatt A.2, the tests are validated by an in- spection certificate 9.1.8 unless otherwise specified in the type test. 6.5.4 See 6.4.2 for tho non-destructive testing of product types for accessory housings and of the wolds of pras- ‘sure-beating walls and their validation 7 Marking 7.1 Accessory housings shall be permanently marked wth (1) the mark of the casting manufacturer and of the manufacturer (company processing, assembling and testing the accessories), (2) the material designation, (2) ~ the rated pressure (PM or = the maximum alowable pressure (PS) and the ‘maximunvminimum allowable temperature (TS), (@) the nominal size (ON), ©) the type number of the EC type-examination, {© the year of manutacture 7.2 The completed accessory shall also be marked with (1) the CE marking’, @) the identiication number of the relevant third party’. 8 Certificates for the finished accessories 8.1. Tho required conformity certificates and declarations (of conformity are issued in accordance with the provisions of the selected mociules (1) The centticate of conformity of the relevant third party represents the result of the tests carried out on the item of pressure equipment and its compliance with the relevant requirements of the Pressure Equipment Direotiv. 2) The deciaration of conformity of the manufacturer shall be in accordance with annex Vil of the Pressure Equipment Directive 8.2 The operating instructions shall be issued! in accor- dance with 3.4 of annex |, if required, and sent to the ‘Source of supply Carl “= Heymanns Verlag Luxemburger Strafe 449, D-50989 Kain Teletax: 0221-9 43 73 603 E-Mail: verkauf@heymanns.com