AD-MerkbBtter Edition Juli 2000

Technical Rules for Pressure Vessels

English Edition
Contents and Order Form
We order from Carl Heymanns Verlag KG, Luxemburger StraBe 449, D-50939 K6ln

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............... DruckbehV 1.97 Order on Pressure Vessels, Gas Pressure Vessels and Filling Plants
(Pressure Vessel Order)

Fundamentals
............... Gl 8. 88 AD-Regulations; Structure, Application and Method Guidelines

Materials
............... w 0 6.86 General principles for materials
............... w 1 2. 98 Flat products of unalloyed and alloy steels
............... w 2 1.00 Austenitic steels 22,-
............... w 3/l 1 . 0 0 Cast iron with lamellar graphite (grey cast iron), non-alloy and low alloy 14,-
............... W 312 1.00 Cast iron materials; Spheroidal-graphite cast iron, non-alloy and low alloy 14,-
............... w 313 4. 70 Cast iron materials; Austenitic cast iron with lamellar graphite 8.-
............... w 4 5.92 Tubes made from non-alloyed and alloy steels 18,-
4 .h, ............... w 5 2. 98 Cast steel 16,-
t ............... w 611 1.00 Aluminium and aluminium alloys; Wrought materials 23.-
............... W 612 5.88 Copper and copper alloys 30,-
............... w 7 1.00 Bolts and nuts made from ferritic steels 18,-
............... W8 7. 87 Clad steels 9,-
............... w9 7.95 Steel flanges 16,-
............... WlO 5. 00 Materials for low temperatures; Ferrous materials 20,-
............... w12 8.88 Seamless hollow components made from non-alloyed and alloy steels for pressure
vessel shells
............... w13 2. 98 Forgings and rolled components made of non-alloyed and alloy steels

Manufacture and Testing

............... HP 0 12.98 General principles of design, manufacture and associated tests 38,- .....
............... HP 1 1.95 Design and construction 16,-
............... HP2ll 1.00 Procedure qualification testing for joining processes:
Procedure qualification testing for welded joints 17,-
Welding supervisors; welders s
............... HP 3 4. 96 8,-
............... HP 4 7.89 Test supervisors and testers in non-destructive testing 5,-
............... HP 5/l 1.00 Manufacture and testing of joints;
Principles of welding practice 7,- .I J
./ .,
............... HP 512 7. 89 Manufacture and testing of joints;
Production testing of welds, Testing of base metal after postweld heat treatment 18,-
............... HP 513 1.00 Manufacture and testing of joints;
Non-destructive testing of welded joints 32,-
............... H P 513 A p p e n d i x 1 1.00 -, M i n i m u m r e q u i r e m e n t s f o r n o n - d e s t r u c t i v e t e s t i n g m e t h o d s 19,-
............... HP 711 7. 89 Heat treatment; General principles 6,-
............... HP 712 7. 89 Heat treatment; Ferritic steels 13,-
............... HP 713 7. 89 Heat treatment; Austenitic steels 9,-
............... HP 714 7. 89 Heat treatment; Aluminium and aluminium alloys ‘3,-
............... HP 8/l 9. 98 Testing of pressings made from steel, aluminium and aluminium alloys 27,-
............... HP 812 7.89 Testing of steel part-shells %-

............... HP 30 2. 98 Performance of pressure tests lO,-

Non-metallic materials
............... N 1 7. 87 Pressure vessels in glass fibre reinforced thermosetting plastics 1 7 -
............... N 2 6. 71 Pressure vessels made of electro-graphite and hard burned carbon 9:-
............... N 2 Appendix 1 11.71 Appendix 1 to AD-Merkblatt N 2, June 1971 edition 4,-
............... N4 9. 83 Pressure vessels made of glass 16,-
............... N 4 Appendix 1 6.85 Assessment of defects in walls of pressure vessels made of glass 6,-
Design
............... BO 1.95 Design of pressure vessels 12,-
............... B1 8. 86 Cylindrical and spherical shells subjected to internal overpressure 26,-
8,- j
............... B 2 1.95 Conical shells design subject to internal and external pressure
............... B3 10.90 Domed ends subject to internal or external pressure 15,- /
............... B4 5. 91 Dished heads 15,-
............... B5 5.99 Unstayed and stayed flat ends and plates 40,- I
............... B6 1.95 Cylindrical shells subjected to external overpressure 20,-
............... B7 6. 86 Boltings 9,-
............... 08 2.98 Flanges 19,-
............... 89 7. 95 Openings in cylindrical, conical and spherical shells 27,-
I
............... BlO 6. 88 Thick walled cylindrical shells subject to internal pressure 55:- 6-
............... 013 5. 99 Single-Ply Bellows Expansion Joints
 -. ox ,.-.,. .- . . . . . . . . . . . ..^.
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&an- No Title
Edition Price/DM
titv

Special cases

............... s 1 :‘ 5 . 9 8 Simplified analysis for cyclic loading 56,-

............... s 2 5. 98 Analysis for cyclic loading 98,-
General verification of stability for pressure vessels
............... s 318 5. 99 -; Basic principles 18.-
............... s 311 5. 99 -; Vessels on skirt supports 18,-
............... S 312 ’ 2. 98 Verification of load-carrying capacity for horizontal vessels on saddle supports 26,-
General verification of stability for pressure vessels
............... s 313 5. 99 -; Vessels with domed ends on feet 16,-
............... s 314 5. 99 -; Vessels with support brackets 30,-
............... s 315 2. 95 -; Vessels with ring supports 20,-
............... s 316 2. 98 -; V e s s e l s w i t h n o z z l e s s u b j e c t t o a d d i t i o n a l l o a d i n g s 14,-
............... s 3l7 4. 96 -; Allowing for thermal stresses in heat exchangers with solid headers 5,- ‘.‘,
............... s 4 2. 98 Evaluation of stresses determined by way of calculation and experimental stress analysis 22,-

Equipment
............... A1 1.95 Safety devices against excess pressure; Bursting safety devices 21,-
............... A2 5. 00 Safety devices against excess pressure: Safety valves 30,-
............... A 5 7. 95 Openings, closures and closure elements 12,-
............... A 5 Appendix 1 12.83 Directives for the arrangement of manholes and inspection ports &-
............... A 5 Appendix 2 7. 95 Guidelines for component testing of clamp-bolts 6,-
............... A 6 6. 86 Safety devices against excess pressure; MCR-safety devices 6,-
. . . 31. Supplement 6. 86 31. Amendment and Supplement to AD-Merkblatter I , -
!
_.............. 33. and
34. Supplement 11.8715.80 33. and 34. Amendment and Supplement to AD-Merkblatter z-
. AD-MerkblBtter completly with plastic ring binder 860,-

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 KS: 23.020.30 Edition January 1997

Order on Pressure Vessels, Gas Pressure Vessels and Filling Plants

(Pressure Vessel Order - DruckbehV)
and General Administrative Regulation

Order
on Pressure Vessels, Gas Pressure Vessels and Filling Plants
(Pressure Vessel Order - DruckbehV)
of 27 February 1980 (Federal Gazette I p. 173) amended by the First Order amending the Pressure Vessel Order of 21 April 1989
( F e d e r a l G a z e t t e I p. 830), b y A n n e x I C h a p t e r VIII T e c h n i c a l F i e l d B C l a u s e I I N o . 5 o f t h e U n i f i c a t i o n A g r e e m e n t o f 3 1 A u g u s t 1 9 9 0
i n c o n j u n c t i o n w i t h A r t i c l e 1 ,of t h e L a w o f 2 3 S e p t e m b e r 1 9 9 0 ( F e d e r a l G a z e t t e I I p. 8 8 5 . 1 0 2 5 ) a n d a l s o b y A r t i c l e s 1 a n d 2 o f t h e
Order on the Equipment Safety Law and amending the Pressure Vessel Order of 25 June 1992 (Federal Gazette I p. 1171), l a s t a m e n d e d
b y t h e S e c o n d L a w a m e n d i n g t h e E q u i p m e n t S a f e t y L a w o f 2 6 A u g u s t 1 9 9 2 ( F e d e r a l G a z e t t e I p. 1564’), b y A r t i c l e 5 5 o f t h e L a w a m e n d -
ing the agreement of 2 May 1992 on the European Economic Area (EEA Implementation Law) of 27 April 1993 (Federal Gazette I
p . 512) b y A r t i c l e s 1 a n d 2 o f t h e O r d e r o n t h e E q u i p m e n t S a f e t y L a w a n d a m e n d i n g t h e O r d e r o f 1 2 M a y 1 9 9 3 ( F e d e r a l G a z e t t e I
p . 704) b y A r t i c l e 6 o f t h e L a w f o r t h e R e o r g a n i z a t i o n o f t h e R a i l w a y s o f 2 7 D e c e m b e r 1 9 9 3 ( F e d e r a l G a z e t t e I p. 2378) b y A r t i c l e 1 2
para. 51 of the Law for the Reorganization of the Posts and Telecommunrcation Service of 14 September 1994 (Federal Gazette I
p . 2 3 2 5 ) a n d b y A r t i c l e 2 o f t h e O r d e r a m e n d i n g t h e O r d e r s tn a c c o r d a n c e w i t h S e c t i o n 1 1 o f t h e E q u i p m e n t S a f e t y L a w o f 2 2 J u n e
1 9 9 5 ( F e d e r a l G a z e t t e I p . 836) b y A r t i c l e 1 4 para. 1 2 o f t h e G e n e r a l Magnetrc S u s p e n s i o n Rarlway L a w o f 1 9 J u l y 1 9 9 6 ( F e d e r a l G a z e t t e I
p. 1014) and by Article 4 of the Second Order on the Equipment Safety Law and on the amendment of the Orders on the Equipment
Safety Law of 12 December 1996 (Federal Gazette I p. 1914).

Contents

Part I Part IV
General regulations Filling plants
0 1 Field of application 9 2 6 Licence
0 2 Exclusion from application 9 27 Major modification
0 3 Definitions g 28 Tests
0 4 General requirements, authorization for the issue of 5 2 9 Non-appkation of Sections 26 to 28
technical regulations 5 30 Operatron of filling plants
Q 5 Further requirements
Part V
5 6 Exceptions
Pipelines
5 7 Federal Government pressure vessels, gas pressure
vessels, filling plants and pipelines 5 30a Pre-commissroning tests
5 30b Recurrent tests
9 3Oc Testing in specific cases
Part II Part VI
Pressure vessels Further general regulations,
9 8 Classification in test groups transitional and definitive regulations
9 9 Testing before entry into service 5 31
Authorized inspectors
0 10 Recurrent tests Ej 32
Experts
8 1 1 Testing in specific cases 5 33
Notification of defects, test certificates
4 12 Testing of specific pressure vessels 5 34
Notification of accidents and injury
$13 Operation of pressure vessels 5 35
Supervisory authorities for Federal Government
8 1 4 Test certificates and inventory of pressure vessels installations and for power plants
5 36 German Pressure Vessels Committee
$37 Transitional regulations for pressure vessels
5 3 8 Transitional regulations for gas pressure vessels
Part Ill
$39 T r a n s i t i o n a l r e g u l a t i o n s f o r f i l l i n g p l a n t s
Gas pressure vessels
9 39a Transitional regulations for pipelines
0 15 Filling
1p 39b (deleted)
5 16 Tests
5 40 Contravention of regulations
5 17 Modification and repair
9 41 (deleted)
5 18 Special construction
1 9 42 (deleted)
5 19 Gas pressure vessels not subject to testing by
p 43 (Cessation of validity)
authorized inspectors
6 2 0 Non-application of Sections 15 to 19 Appendix I (to Section 4 para. 1)
9 21 Immediate emptying Appendix II ( t o S e c t i o n 1 2 )
8 22 Type approval
3 23 Intervals between tests Sixth Order on the Equipment Safety Law
5 24 N o t i f i c a t i o n o f d i s t r i b u t i o n d e p o t s (Order for the Entry into Service of Simple Pressure Vessels
9 25 Orders by supervisory authorities - 6th GSGV)

‘) Am& 9 no. 3 has been incorporated -see textual markings.

Supersedes Edition April 1996; 1 = Amendments to previous Edition

Carl Heymanns Verlag KG

Luxemburger SiraBe 449, 50939 K6ln

-. “--
^_.-..-,.A
 Page 2 Pressure Vessel Order, Edition 01.97’
Part I
General regulations
Section 1
l
Field of application
(1) This Order applies to the setting up and operation of
pressure vessels, gas pressure vessels, filling plants and
pipelines and to the fittings of pressure vessels, gas pres-
sure vessels and pipelines.
I (2) This Order does not apply to pressure vessels, gas
pressure vessels, filling plants and pipelines:
1. of rolling stock of railway companies and magnetic sus-
I pension railway vehicles, other than cargo containers,
insofar as such equipment is subject to the provisions
of the Federal and Regional Governments’ (Lander)
construction and operating regulations and also insofar
as power installations are involved,
2. on ocean-going vessels under foreign flags or on oce-
an-going vessels for which the Federal Ministry of
I Transport has authorized the flying of the Federal flag,
purely for an initial voyage of transfer to another port,
in accordance with Section 10 of the Flags Act in the
amended version published in Federal Gazette Part Ill,
classification No. 9514-1,
3. on board watercraft, the home port of which does not
come within the scope of this Order,
4. of the Bundeswehr (Federal Armed Forces), whencivili-
ans are not, or are only temporarily, employed instead
of military personnel in operating the vessels, plants or
pipelines,
5. in mining companies, with the exception of open-cast
mines.
I (3) This Order, with the exception of No. 5 of Appendix I
to this Order, does not apply to pressure vessels, gas pres-
sure vessels, filling plants and pipelines which are being
developed, manufactured for export or tested at the manu-
facturer’s works. Number 5 of Appendix I to this Order
. applies in respect of operation of such vessels plants and
pipelines while being tested.
1(4) This Order does not apply to working chambers, equip-
ment used in their operation and hospital compressed-air
chambers, insofar as these are subject to the Compressed
Air Order (Druckluftverordnung) of 4 October 1972 (Fed-
eral Gazette 1, p. 1909) amended by Section 69 para. 3 of
the Law of 12 April 1976 (Federal Gazette I p. 965).
I (5) If a pressure vessel, gas pressure vessel, filling plant
or pipeline includes a component which, as an installation
subject to supervision under Section 2 para. 2a of the
Equipment Safety Law, must also comply with another
Order covering the erection and operation of such an
installation, then the regulations contained in the other
Order shall be applied to that component also.
1 (6) Where nuclear regulations impose or permit wider or
other requirements they shall apply to pressure vessels,
gas pressure vessels, filling plants and pipelines which are
subject to this Order and to the nuclear regulations at the
same time.
I 21.
Section 2
Exclusion from application ’ Acetylene
(1) This Order shall not apply to the following pressure
vessels :
1. Pressure vessels on ocean-going ships,
2. Pressure vessels intended solely for the equipping or
operation of aircraft or of road or rail vehicles used on
public routes,
3. Pressure vessels permanently connected to water
craft or aircraft and air navigation equipment,
4. Pressure vessels used for the purposes of marine
engineering,
5. Vessels subjected only to the pressure of a column of
liquid constituted by the material being charged, pro-
vided no additional pressure in excess of 0,l bars can
be built up,
6. Heating elements in space heating installations,
7. Casks and canisters for liquids which comply with the
statutory transport regulations and which are emptied
at a gauge pressure not exceeding 0,5 bars or a nega-
tive gauge pressure, provided an unduly high pressure
is prevented,
8. Cylinders and housings of engines, turbines, com-
pressors, pumps;
actuators, regulators and attenuators;
annular combustion chambers and tubular ring com-
bustion chambers in gas turbines,
9. Mechanical parts that are subject to internal pressure
and are overdimensioned in relation to the internal
pressure to which they are subjected for reasons of
power transmission, structural rigidity or manufacture,
10. Blast furnaces including their furnace cooling equip-
ment, blast heaters, dust separators and crude-gas
cleaning plants;
direct reduction shaft furnaces including their furnace
.!
cooling equipment, gas converters and dust separa-
tors;
furnaces and ladles for melting, remelting, degassing
and casting molten steel and non-ferrous metals
under vacuum,
i,
11. Exhaust silencers,
12. Pressure-tight encapsulated electrical apparatus, oil
filled cables, oilostatic cables, transformers, charge-
able accumulators, turbogenerators, choke coils,
capacitors, incandescent filament lamps, gas dis-
charge lamps and electronic valves,
13. Pressure vessels installed in rockets,
14. Variable-volume gas vessels,
15. Pressure cookers with a cubic capacity not exceeding
10 litres and a permissible working pressure not
exceeding 2 bars,
16. Vacuum die-casting machines,
17. Vehicle tyres,
18. Storage containers that come within the scope of the
Order on beverage-dispensing equipment,
19. Tank containers used for conveying foodstuffs or
beverages,
20. Vessels for combustible liquids that come within the
scope of the Order on combustible liquids,
Acetylene generators, coolers, dryers, cleaners and
storage containers coming within the scope of the
Order, c
22,. Steam boilers that come within the scope of the Steam
f
Boilers Order,
 . : , . . I . . _ s . _ . . , . _ , ^ . . . _ , ” - .
_ ^
23. Pressure vessels for pipeline operation in the meaning
of Section 2 para. 2 of the Order on Gas High Pressure
Pipelines and
a) come within the scope of the Order on Gas High
Pressure Pipelines or
b) are operated at a gauge pressure not exceeding
16 bars in the context of the public gas supply,
24. Pressure vessels
a) with a cubic capacity not exceeding 0.1 litres,
b) with a product of pressure and cubic capacity not
exceeding 20,
c) according to Section 8 para. 1 No. 2 with a permis-
sible operating pressure not exceeding 500 bars
and a product of pressure and cubic capacity not
exceeding 10000,
25. Centrifugal machines in which there is an internal
pressure.
(2) This Order shall not be applied to the following gas
pressure vessels:
1. Gas pressure containers permanently connected to
watercraft or aircraft.
2. Beverage and basic materials containers in the mean-
ing of the Beverage Dispensing Equipment Order.
3. Gas pressure vessels with a maximum cubic capacity
of 10 cm3.
4. Gas pressure vessels with a maximum cubic capacity
of 50 cm3, when they are only intended to be filled once.
5. Gas pressure vessels for compressed gases in which
a gauge pressure exceeding 1 bar cannot be generated
at 15°C.
. (3) This Order is not applicable to filling plants which are
intended
1. only for taking samples of gases under pressure,
2. for filling vessels according to para. 2 No. 2,
3. for filling non-combustible, non-toxic gases under pres-
sure in gas pressure vessels with a cubic capacity not
exceeding 50 cm3,
4. for filling gas pressure vessels according to Section 3
para. 5 which are equated with pressure vessels in the
meaning of Section 3 para. 1,
5. for acetylene
and to filling plants which
a) are power plants within the meaning of Section 2,
para. 1 of the Energy Industry Law,
b ) are erected and operated on company land by public
gas supply companies and
c) are intended for filling pressure vessels, which as
required components for the operation of vehicles
are permanently connected to them, with natural
gas used as propellant.
(4) This Order shall not be applied to the following pipe-
lines:
1. Pipelines that come within the scope of the Steam
Boilers Order, the Order on Combustible Liquids, the
Acetylene Order or the Order on Gas High Pressure
Pipelines,
2. Pipelines that are operated with a maximum gauge
pressure of 16 bars in the context of the public gas
supply,
e
Page 3 Pressure Vessel Order, Edition 01.97
3. Pipelines that are component parts of blast furnaces
and other installations according to para. 1 No. 10,
4. Pipelines that are component parts of machines,
hydraulic installations or air-conditioning and ventilation
installations,
5. Pipelines in connection with natural gas, crude oil and
other borings, insofar as they are subject to Board of
Mines inspection,
6. Pipelines that are permanently and rigidly connected
with watercraft.
Section 3
Definitions
(1) Pressure vessels within the meaning of this Order are
vessels or pipe assemblies which are not gas pressure
vessels and in which an operating pressure that exceeds
0,l bar exists or can arise by reason of the mode of oper-
ation. Sentence 1 applies to the pressurized chambers of
vessels with a number of chambers. Notwithstanding sen-
tences 1 and 2, vessels for low temperature liquid gases
are also pressure vessels within the meaning of this Order
if a working pressure in excess of 0,Ol bars exists or can
arise in them. Pressure vessels within the meaning of sen-
tence 1 do not include pipelines and pipeline extensions
used for conveying materials, even if they include second-
ary heating to keep the material in a suitable condition for
conveying. Pressure vessels within the meaning of sen-
tence 1 also do not include installations, appliances and
equipment, including fittings, which carry out or take over
measuring, regulating, flow technology or flow interruption
functions under working pressure.
(2) Items of equipment of pressure vessels within the
meaning of this Order are items of equipment that are
necessary for safety purposes and other instruments and
measuring and regulating equipment used in the operation
of the pressure vessels, insofar as they are able to
influence the safety of the pressure vessel or the function
of the items of equipment that are necessary for safety pur-
poses, and also the connecting lines between the pressure
vessels and the items of equipment. Combustion accesso-
ries and other heating devices are equivalent to items of
equipment.
(3) Gas pressure vessels within the meaning of this Order
are portable vessels which are filled with compressed
gases and are taken to another place for the gases to be
drawn off after being filled. Gas pressure vessels include
the items of equipment that can affect their safety.
(4) Compressed gases within the meaning of this Order
are substances whose critical temperature is below 50 “C
or whose vapour pressure is more than 3 bars at 50 “C.
Hydrogen cyanide is equivalent to these compressed
gases.
(5) The gas pressure vessels listed below are the equiva-
lent of pressure vessels within the meaning of para. 1 :
1. Gas pressure vessels for non-combustible, non-toxic
compressed gases if the vessels are open between fill-
ing and emptying or suitable devices intended to pre-
vent the ingress of air prevent a gauge pressure in
excess of 0,2 bars from arising in the vessel,
2. Gas pressure vessels which are filled with liquids or
solids which are superposed with a compressed gas in
the gaseous state as a protection against explosion or
whilst mixing or conveying, other than containers of fire
 P a g e 4 Pressure Vessel Order, Edition 01.97
extinguishers that are permanently pressurised by a
compressed gas and gas pressure vessels that are
intended to be filled only once,
3. Gas pressure vessels which are permanently con-
nected to vehicles or mobile operating plants as compo-
nents that are necessary to their operation, other than
gas pressure vessels for compressed gases used as
propellants or fuels,
4. Gas pressure vessels of portable equipment for filling
vehicle tyres, ventilating brakes and clutches, for filling
oil with the aid of compressed air and for spraying, inso-
far as the containers are filled via a connection to the
works’ own compressed air supply with no more than
1 16 bars working pressure.
(6) Filling plants within the meaning of the Order are:
1. Equipment for putting compressed gases from gas
pressure vessels into pressure vessels according to
para. 1 which are intended for the storage of com-
pressed gases,
2. Plants for filling gas pressure vessels. These filling
plants include the equipment used to operate them.
Pressure vessels from which the compressed gas used
for filling is taken, and their fittings, do not form part of which are at least equally as safe, in particular also those
the filling plant.
(7) The permissible working pressure within the meaning
of this Order is the maximum working pressure specified
for reasons of safety.
(8) The cubic capacity of a pressure vessel or pressure
chamber within the meaning of this Order is the geometric
size of the cavity less the volume of fixed internal fittings.
(9) Pipelines within the meaning of this Order are pipelines
with more than 0,l bars working pressure for conveying
combustible, corrosive or toxic gases, vapours or liquids.
Pipelines also include those pipelines that connect pres-
sure vessels with one another or with other parts of the
installation that generate pressure. Pipelines also include
their items of equipment.
(10) Gases, vapours or liquids are combustible, corrosive
or toxic when they are highly flammable, slightly flam-
mable, flammable, corrosive, very toxic or toxic substan-
ces or preparations in the meaning of Section 3 No. 3 of
the Chemicals Act (Chemikaliengesetz).
(11) Items of equipment of pipelines in the meaning of this 1(4) Authorization in accordance with Section 11 para. 1
Order are those items of equipment required for safety pur-
poses and those other fittings and items of measuring or
regulating equipment that serve to operate the pipeline,
insofar as they can affect the safety of the pipeline or the 1 Federal Ministry for Labour and Social Order insofar as it
function of the items of equipment that are required for
safety purposes.
Section 4
General requirements, authorization
for the issue of technical regulations
(1) Pressure vessels, gas pressure vessels, filling plants
and pipelines shall be constructed and operated in accord-
ance with the regulations in Appendix I to this Order, a sta-
tutory order issued on the basis of Section 11 para. 1 no. 3
of the Equipment Safety Law in conjunction with sub-
1 clause 4, and otherwise in accordance with the state of the
art.
(2) When pressure vessels, gas pressure vessels, filling
plants and pipelines are subject also to Orders as specified
in Section 4, para. 1 of the Equipment Safety Law, the
requirements of these Orders apply with regard to their
I characteristics; compliance with these requirements shall
be established and verified in accordance with the
methods laid down in these Orders. To this extent, a test I.
for compliance with these characteristic requirements is
dispensed with from the pre-commissioning test as speci-
fied in Section 9, 28 and 30a and from the tests as speci-
fied in Section 16 within the framework of issuing the
licence in accordance with Section 26.
1 (3) For pressure vessels, gas pressure vessels, filling
plants and pipelines which are correctly manufactured and
brought into service in accordance with regulations or
requirements valid in another Member State of the Euro-
pean Communities or another Contracting State of the
Agreement on the European Economic Area and guaran-
tee the same safety, it shall be assumed that the require-
ments of para. 1 regarding safe construction are complied
with. Where there are reasons in individual cases, it shall
be verified at the request of the relevant authority that the
requirements of sentence 1 are complied with. Standards
of the German Standards Institute (DIN) or other technical
regulations listed in the Technical Regulations for pressure
vessels, gas pressure vessels, filling plants or pipelines I
also apply for example and do not preclude other solutions f
j.
which are contained in standards or other technical regula- !
tions or requirements of other Member States of the Euro-
pean Communities or Contracting States of the Agreement
on the European Economic Area. Where the submission
of expert opinions, or test certification of German bodies
is envisaged in this Order or in an associated technical
regulation, in order to verify that the relevant requirements
regarding safe construction have been met within the
meaning of para. 1, test reports from bodies approved in
other Member States of the European Communities, or in
other Contracting States of the Agreement on the Euro-
pean Economic Area shall also be taken into account. The
technical requirements, tests and test procedures on which
the test reports of these bodies are based should be as
equally stringent as those of the German bodies. These
bodies are those which specifically meet the relevant requi-
rements, particularly those laid down in the harmonized
1 European standards publicized by the Federal Ministry for
Labour and Social Affairs in the Federal Gazette. Regula-
tions of this Order to convert Legal Instruments of the
Council European Union or the Commission of the Euro-
pean Communities remain unaffected.
no. 3 of the Equipment Safety Law relating to the issuing
of technical regulations for pressure vessels, gas pressure
vessels, filling plants and pipelines is transferred to the
relates to the issuing of technical regulations for the con-
struction and operation of pressure vessels, gas pressure
vessels, filling plants and pipelines not used for the public
supply services. The transfer of authorization is restricted
to the issuing of technical regulations which supplement
the appendix to this Order.
j (5) The requirements according to para. 1 shall be
regarded as met in respect of pressure vessels and gas
pressure vessels if they comply with the statutory transport
regulations for the conveyance of dangerous materials.
I Para. 2 remains unaffected.
Section 5
Further requirements
Pressure vessels, gas pressure vessels, filling plants and
pipelines shall also meet any requirements that go beyond

those of Section 4 para. 1 which are set out by the compe-
tent authority in individual cases for the purpose of prevent-
ing specific hazards to employees or third parties. Sec-
tion 26 para. 4 sentences 2 and 3 remain unaffected.
Section 6
Exceptions
(1) The competent authority may permit exceptions to
Section 4 para. 1 for special reasons in individual cases,
if safety can be ensured by other means.
(2) On application from the manufacturer, the competent
authority may permit exceptions to Section 4 para. 1 if this
is in conformity with technical progress and safety can be
ensured by other means. Section 22 shall apply as appro-
priate.
Section 7
Federal Government pressure vessels, gas pressure
vessels, filling plants and pipelines
(1) The powers according to Sections 5 and 6 shall be
1 delegated to the competent Federal Ministry or the author-
ity nominated by him in respect of pressure vessels, gas
pressure vessels, filling plants and pipelines belonging to
the Federal Government’s Water and Shipping Depart-
ment, the Bundeswehr (Federal Armed Forces) and the
Bundesgrenzschutz (Federal Border Police). Section 14
para. 2 of the Equipment Safety Law applies as appropriate
for plants in accordance with sentence 1 for companies
deriving from the special fund of the Deutsche Bundespost
(Federal Post Off ice).
I (2) The Federal Ministry of Defence can permit exceptions
to the regulations of this Order in respect of Federal Armed
Forces pressure vessels, gas pressure vessels, filling
plants and pipelines which come under this Order if this
becomes necessary by compelling reasons of defence or
for the fulfilment of the Federal Republic’s international
obligations, and safety can be ensured by other means.
Part II
Pressure vessels
Section 6
Classification in test groups
(1) Pressure vessels are classified in the following groups
according to the permissible working pressure p in bars,
the cubic capacity of the pressure chamber I in litres and
the product p . I of the pressure and the cubic capacity
(where there is more than one separate pressure chamber
the product is determined separately for each chamber):
1. Pressure vessels in which the pressure is exerted by
gases or vapours, liquids or solids with a gas or vapour
cushion or by liquids, the temperature of which exceeds
the boiling temperature at atmospheric pressure:
Group I: Pressure vessels for low-temperature,
liquid gases with a permissible working
pressure p between 0,Ol and 0,l bars;
Pressure vessels with a permissible work-
ing pressure p not exceeding 25 bars and a
product of pressure and cubic capacity p . I
not exceeding 200;
Pressure vessels in the form of pipe layouts
that consist entirely of pipes with an inside
cross-section not exceeding 100 cm*, when
the product of the permissible working pres-
sure in bars and the inside diameter D in mil-
limetres does not exceed 2000.
. . . . . . . . ^
P a g e 5 Pressure Vessel Order, Edition 01.97
Group II: Pressure vessels with a permissible work-
ing pressure p of more than 25 bars and a .
product p . I of pressure and cubic capacity
not exceeding 200;
Pressure vessels with a permissible work-
ing pressure p not exceeding 1 bar and a
permissible product p . I of pressure and
cubic capacity greater than 200;
Group III: Pressure vessels with a permissible work-
ing pressure p of more than 1 bar, in which
the product p + I of pressure and cubic capa-
city is between 200 and 1000 (p > 1 bar and
200 < p . I ZZ 1000);
Group IV: Pressure vessels with a permissible work-
ing pressure p of more than 1 bar, in which
the product p . I of pressure and cubic capa-
city exceeds 1000 (p >l bar and p I >
1000).
2. Pressure vessels in which the pressure is exerted only
by liquids, the temperature of which does not exceed
the boiling temperature at atmospheric pressure:
Group V: Pressure vessels with a permissible work-
ing pressure p not exceeding 500 bars
(p 5 500 bars) and pressure vessels with a
permissible working pressure exceeding
500 bars, in which the product p . I of pres-
sure and cubic capacity does not exceed
1000 (p > 500 bars and p . I 5 1000);
Group VI: Pressure vessels with a permissible work-
ing pressure p of more than 500 bars, in
which the product p. I of pressure and cubic
capacity is between 1000 and 10000
(p> 500barsandlOOO c.p.1~ 10000);
Group VII: Pressure vessels with a permissible work-
ing pressure p of more than 500 bars, in
which the product p. I of pressure and cubic
capacity is more than 10000 (p > 500 bars
and p. I > 10000).
(2) For the initial test and the acceptance test as a whole,
pressure vessels with a number of pressure chambers,
excluding those in process engineering installations, are
assigned to the group in para. 1 with the highest test requi-
rements applicable to any one of the pressure chambers.
In respect of recurrent tests, the pressure chambers shall
be assigned separately to the groups that apply to them
according to para. 1.
(3) Notwithstanding para. 1 the types of pressure vessel
mentioned below shall be assigned to Group II regardless
of the permissible working pressure and cubic capacity:
1. Tube furnaces in process engineering installations if
they are pipe layouts,
2. Pressure vessels in refrigerating plants and heat pump
installations that consist entirely of pipe layouts, pro-
vided they do not belong to Group 1,
3. Pressure vessels that consist entirely of pipe layouts
and are used for the vaporisation of non-corrosive
gases,
4. Steam traps and separators for gas bubbles, if the
capacity of the gas chamber of separators is limited to
not more than 10% of the capacity of the vessel,
5. Steam-heated cylinder presses and presses for mecha-
nical ironing, steaming, sealing, setting and methods of
processing articles of clothing, laundry or other textiles
and leather products that are similar to setting,
 ..- >. . . . . . ..(. _ .” , . . . . ._t. . . . . . . .,..- . I . _ .” . ‘.~_ . _ .._ ^ __
- :
. . . I .

Page 6 Pressure Vessel Order, Edition 01.97

6 . Compressed gas condensers, The acceptance test according to para. 1, apart from a
necessary installation test, may also be dispensed with if
7 . indirectly heated heat generators and expansion tanks
in water heating installations with working temperatures the registered type test according to sentence 1 also
not exceeding 120 “C as long as the expansion tanks covers the acceptance test.
do not belong to Group I. (6) Para. 5 does not apply to pressure vessels which are
constructed on site and in which the product p x I of pres-
Section 9 sure and cubic capacity exceeds 5000.
Testing before entry into service
(7) Should the authorized inspector or expert determine
(1) A pressure vessel of Groups III, IV, VI and VII may not that the pressure vessel is not in serviceable condition a
be put into service until the authorized inspector has sub- decision shall be taken by the competent authority on appli-
jected it to an initial test and an acceptance test and has cation.
certified that he has found it to be in serviceable condition.
(8) If a pressure vessel has been tested as a gas pressure
(2) Pressure vessels of Group 1, where they are used for vessel by an authorized inspector according to para. 16
combustible, corrosive or toxic gases, vapours or liquids, and furnished with the test mark and test date and the inter-
and of Group II may not be put into service until: val between tests indicated on the gas pressure vessel has
1. the manufacturer has subjected the pressure vessel to not yet expired, then notwithstanding paras. 1 and 2 the
a pressure test and has issued a certificate to the effect gas pressure vessel may be put into service as a pressure
that the pressure vessel has been properly manufac- vessel after it has undergone an acceptance test by an
tured and authorized inspector or expert, according to the relevant
test group, has complied with the requirements of this test
2. that the results of the pressure test show that it complies and this has been certified by the authorized inspector or
with the relevant requirements and an expert has sub-
expert.
jected the pressure vessel to an acceptance test and
certified that it complies with the requirements relevant (9) Paras. 1 and 2 do not apply to pressure vessels that
to such tests. are permanently connected to vehicles and which are regi-
stered and tested according to traffic regulations.
(3) The initial test consists of a preliminary test, a structu-
ral test and a pressure test. The acceptance test consists j (10) Section 4, para. 2 remains unaffected.
of a service test, an equipment test and an installation test.
(4) In the case of a pressure vessel which has been sub- Section 10
jected to an acceptance test - not including the installation Recurrent tests
test - elsewhere and for which there is a certificate in
respect of such an acceptance test it is sufficient if a test (1) An authorized inspector shall subject a pressure ves-
of proper installation has been carried out by an expert at sel of Groups IV and VII to recurrent tests within the periods
the place of operation and a certificate is available in specified in paras. 4 to 9.
respect of this. Sentence 1 applies by analogy to pressure (2) An authorized inspector shall subject a pressure ves-
vessels according to para. 1 for which a type approval test sel of Group I, where it is used for combustible, corrosive
according to para. 5 sentence 1 has been registered which or toxic gases, vapours or liquids, and of Groups II, III and
also covers the acceptance test. VI to recurrent tests to be determined by the operator on
(5) The initial test by an authorized inspector according to the basis of experience of the method of operation and the
para. 1 can be dispensed with if charge material.
1. there is a registration with the Hauptverband der (3) Recurrent tests shall consist of internal tests and pres-
gewerblichen Berufsgenossenschaften (Federation of sure tests. In the case of pressure vessels heated by fire,
Industrial Employers’ Liability Insurance Associations) waste gas or electricity the recurrent tests shall additionally
to the effect that: consist of external tests, normally on pressure vessels
4 the authorized inspectors of a technical supervision which are in operation. Internal tests according to senten-
association appropriate to the manufacturer or, if the ce 1 shall be supplemented or replaced by pressure tests
pressure vessel involved is made of non-metallic or other suitable tests if internal tests cannot be carried out
materials, the Bundesanstalt fiir Materialforschung to the necessary extent. Pressure tests according to sen-
und -prijfung (Federal Materials Research and Test tence 1 shall be replaced by non-destructive tests if pres-
Institute), sure testing is not possible because of the design of the
pressure vessel or is not expedient because of the method
W a test centre nominated by a Member State or other of operation.
Contracting State of the Agreement on the Euro-
pean Economic Area in accordance with Article 13 (4) Internal tests on pressure vessels of Groups IV and VII
of Council Directive No. 76/767/EEC of 27 July 1976 shall be carried out every five years, pressure tests every
on the harmonisation of the statutory regulations of ten years, and external tests every two years. In individual
Member States by means of joint regulations for cases the supervisory authority may:
pressure vessels and methods of testing them (EC 1. extend these periods, provided safety is ensured by
Official Journal No. L 262 p. 153), have certified other means, or
that a type test has been carried out and the type
sample complies with the requirements of this Order 2. shorten them, where this is necessary for the protection
and of employees or third parties.
2. the manufacturer certifies that the pressure vessel cor- (5) Where intervals between tests are specified for pres-
responds to the type sample tested and has been sub- sure vessels in the statutory transport regulations for traffic
jected to a pressure test and complies with the relevant which does not cross frontiers, these shall apply in place
requirements according to the results of that test. of the intervals between tests given in para. 4 sentence 1.

(6) The intervals between internal tests and pressure tests
shall commence on the date of the first acceptance test and
from the new acceptance test in the case of a change in
the place of installation. The tests shall have been carried
out six months at the latest after the month in which they
fall due has expired. Notwithstanding sentence I the peri-
ods shall run
1. from the date of the structural test, if the date of the first
acceptance test is more than two years after the structu-
ral test, and
2. from the date of the last internal test, if the date of the
new acceptance test is more than two years after the
last internal test.
(7) The interval between external tests shall be regarded
as having been adhered to if the test is carried out during
the calendar year in which the period expires.
(8) If the pressure vessel is not in operation when the test
falls due the recurrent tests shall be carried out before it
is put into service again.
(9) If an extraordinary test has been carried out the period
between recurrent tests shall commence with the comple-
tion of the extraordinary test provided this corresponds to
the recurrent test.
(10) A pressure vessel of Group IV or VII may only be
operated again after the period applicable to recurrent
tests has expired if the tests have been carried out in good
time and the authorized inspector has certified that accord-
ing to the results of the test the pressure vessel has comp-
lied with the requirements applicable to such tests.
(11) If the authorized inspector finds that the pressureves-
sel is not in serviceable condition a decision shall be given
by the competent authority on application.
. per manner, carry out necessary repair work without delay
(12) Section 9 para. 9 shall apply as appropriate.
. Section 11
Testing in specific cases
(1) If a pressure vessel has been substantially modified as
regards its design or method of operation then Section 9
shall be applied as appropriate. A modification shall be
regarded as a substantial one if it can adversely affect the
safety of the pressure vessel.
(2) If a pressure vessel has been substantially repaired or
major parts of a pressure vessel have been replaced the
pressure vessel may be returned to service only after it has
been tested for serviceability to the extent determined by
the repair or replacement by an authorized inspector in the
case of pressure vessels of Groups III, IV, VI and VII and
by an expert in the case of Group II pressure vessels, and
a test certificate has been issued. Para. 1 sentence 2 shall
apply as appropriate.
(3) Pressure vessels which have already been in service
elsewhere may only be returned to service after they have
undergone a new acceptance test by an authorized inspec-
tor in the case of Group III, IV, VI and VII pressure vessels
and by an expert in the case of Group II pressure vessels
and a test certificate has been issued. Where the change
of location is within a works a new acceptance test is only
necessary if there has been a change in the connection
conditions or equipment parts.
(4) In the case of pressurevessels which are used at diffe-
rent places of installation a new acceptance test is not
c necessary after the location has been changed if:
Page 7 Pressure Vessel Order, Edition 01.97 ‘\
.-
,:;
1 ?;I
there is a certificate about an acceptance test carried .?’
out at another location
the mode of operation has not changed with the location
and the connection conditions and equipment parts
remain unchanged and
there are no special requirements as far as installation
is concerned.
Where there are special requirements as far as installation
is concerned it is sufficient for proper installation at the
place of operation to be tested by an expert and a certifi-
cate issued.
(5) In individual cases the supervisory authority may order
an extraordinary test by an authorized inspector or expert
if there is a special reason for this and particularly when
damage or injury has occurred. The operator shall arrange
for this test to be carried out.
Section 12
Testing of specific pressure vessels
In the case of the pressure vessels covered in Appendix II
the tests provided for under Sections 9 to 11 shall be
carried out subject to the provisions deriving from the regu-
lations in Appendix II. Insofar as other or supplementary
tests are provided for in respect of such vessels they may
be put-or returned-into service only after the authorized
inspector or expert has certified that the pressure vessel
is in serviceable condition.
Section 13
Operation of pressure vessels
(1) Anyone operating a pressure vessel shall keep it in a
serviceable condition, operate and supervise it in the pro-
and implement the safety measures that are required
according to the circumstances.
(2) In individual cases the supervisory authority may
arrange for the necessary supervisory work to be carried
i
(3) A pressure vessel may not be operated if it has defects :$
which may endanger employees or third parties.
(4) If pressure vessels of Groups Ill, IV, VI and VII show
damage to walls which have to withstand pressure and
which result in the vessel being taken out of service in
accordance with para. 3 the operator shall notify the autho-
rized inspector and agree the action that is required with
him.
Section 14
Test certificates and inventory of pressure vessels
(1) Pressure vessels shall be furnished with a test mark
as evidence that the initial test has been carried out.
(2) Anyone operating a pressure vessel of Groups IV or
VII shall provide a test book or test document which shall
contain the findings of the recurrent tests and any extraor-
dinary tests by the authorized inspector. The authorized
inspector’s certificates in respect of the initial test and the
acceptance test, together with the relevant documents
(drawing, materials and heat treatment certificate) shall be
attached to the test book or test document.
(3) Anyone operating more than ten pressure vessels that
are subject to recurrent testing by authorized inspectors in
one works shall keep a record of them. The record shall
 . <.,k_. .._-1.... .‘-. _“__-.~-I_--.-.--.
Page 8 Pressure Vessel Order, Edition 01.97
include details of the designation, purpose and place of use
of the pressure vessels, information on makers namepla-
tes and particulars as to the nature of past tests and when
they were carried out. A card index or other documentation
shall be the equivalent of the record according to senten-
ce 1.
(4) The following shall be kept in the works in such a way
that they can be immediately produced to the supervisory
authority on demand :
1. The original or a duplicate of the certificates according
to Section 9 para. 1, para. 4, para. 5 No. 2 or para. 8
and Section 11 paras. 2 and 3
2. original or duplicate of test book or test document
according to para. 2 and
3. the record referred to in para. 2*).
(5) Notwithstanding para. 4 the documents mentioned
therein for pressure vessels of Groups IV and VII which are
portable or set up for use at different locations may be kept
at the registered office of the owner provided the date of
the next test due is legibly applied to such pressure ves-
sels. The test book or test document shall however be pre-
sent at the location of the pressure vessel at the time the
tests are carried out.
Part III
Gas pressure vessels
Section 15
Filling
(1) A gas pressure vessel may only be filled with pressure
gases :
1. if it is furnished with the authorized inspector’s test mark
and test date as well as an indication of the interval
between tests,
2. if the period between tests indicated on the vessel has
not already expired and
3. if the vessel shows no defect which might endanger
employees or third parties.
If items of equipment of the gas pressure vessel are not
furnished with the inspector’s test mark and test date the
vessel may only be filled if such items of equipment are
type-approved.
(2) A gas pressure vessel may only be filled with the pres-
sure gases indicated on it and only in the quantity indicated
by the information on the vessel as regards pressure,
volume and weight. A vessel may only be filled with acety-
lene if the quantity of solvent filled is that indicated by the
information on the vessel.
1 (6) Section 4, para.
Section 16
Tests
(1) The authorized inspector may furnish a gas pressure
vessel with the test mark and test date only if, according
to the results of the test:
1. there is a type approval for the vessel according to Sec-
tion 22 in respect of the design and type of material and
the vessel complies with the approved type,
2. the porous filler and solvent for an acetylene vessel are
approved by the licensing authority and comply with the
approval and
‘) Publisher’s note: this should read para. 3.
3. the vessel is suitable for being filled with the proposed -1
pressure gases and the quantity of these pressure -
gases that is limited by pressure, weight or volume.
If the design and type of material used for the gas pressure
vessel have undergone an EEC test on the basis of Council
Directives 84/525/EEC, 84/526/EEC and 841527lEEC of
17 September 1984 (EC Official Journal No. L 300 p. 1) and
been given an EEC test mark, then the test according to
sentence 1 No. 1 shall not apply. The test according to sen-
tence 1 No. 1 shall also not apply to a gas pressure vessel
that has been exempted from the EEC test on the basis of
the directives quoted above and is marked accordingly. If
the type of the items of equipment in a gas pressure vessel
has been approved separately, they shall bear the symbols
and information determined by the licensing authority.
Type approvals granted on the basis of traffic regulations
are equivalent to the approvals according to sentences 1
and 4.
(2) If the provisions of para. 1 have been met the autho-
rized inspector shall furnish the gas pressure vessel with
the following in addition to the test date and test mark:
1. details of the pressure gases and the quantity of these
pressure gases that may be put into it and which is
limited by pressure, weight or volume,
2. any other symbols and information that are required,
3. the test interval according to Section 23.
(3) If the type approval of the gas pressure vessel has
been withdrawn or revoked the authorized inspector may
furnish a vessel manufactured before the withdrawal or
revocation with the test mark and test date if the vessel
conforms to the withdrawn or revoked approval unless the
authority responsible for the withdrawal or revocation
determines that there is a risk of danger to employees or
third parties. Sentence 1 shall apply as appropriate if the
approval of an item of equipment, a porous filler or a sol-
vent is withdrawn or revoked.
(4) The authorized inspector shall issue a certificate about
the result of the test according to para. 1 on request if he
considers that one of the provisions of para. 1 has not been
met. The competent authority shall decide whether the
requirements of para. 1 have been met on application from
the person who had arranged the test by the authorized
inspector. If the competent authority decides that the requi-
rements of para. 1 have been met the authorized inspector
shall furnish the gas pressure vessel with the test mark and
test date.
(5) Paras. 1 to 4 shall not apply if the competent authority
decides, at the suggestion of the authorized inspector of
the vessel’s type, that a test by authorized inspectors is
not necessary in order to protect employees or third par-
ties.
2 remains unaffected.
Section 17
Modification and repair
(1) If a modification or repair is to be carried out on a gas
pressure vessel whereby safety may be impaired or if the
symbols or particulars applied to the vessel by the autho-
rized inspector are to be altered the opinion of the autho-
rized inspector shall first be obtained.
(2) If a modification or repair within the meaning of para. 1
has been carried out on a gas pressure vessel or if the sym- .L
bols or particulars applied to the vessel by the authorized
inspector have been altered it may only be filled with pres- !’
sure gases if the authorized inspector has tested the vessel

and furnished it with a test mark. Section 16 para. 4 shall
apply as appropriate.
:, Section 18
Special construction
(1) Sections 15 to 17 do not apply to gas pressure vessels
other than vessels for acetylene which are manufactured
to a special design for a given operation. Such a vessel
may only be filled with pressure gases if
1. the authorized inspector has tested it and furnished it
with the test mark, test date and interval between tests,
2. not more than two years have passed since the last test
and
3. it shows no defects whereby employees or third parties
may be endangered.
The authorized inspector may furnish the gas pressure
vessel with the test mark and test date only if the test shows
that the vessel meets the requirements of this Order. Sec-
tion 16 para. 4 shall apply as appropriate.
(2) A gas pressure vessel according to para. 1 may only
be filled with the pressure gases indicated on it and only
in the quantity indicated by the particulars on the vessel as
regards pressure, volume and weight.
(3) If a modification or repair is to be carried out on a gas
pressure vessel according to para. 1 whereby safety may
be impaired or if the symbols or particulars applied to the
vessel are to be altered the opinion of the authorized
inspector shall first be obtained.
(4) If a modification or repair within the meaning of para. 3
has been carried out on a gas pressure vessel according
to para. 1 or if the symbols or particulars applied to the ves-
sel have been altered the vessel may only be filled after
the authorized inspector has tested and furnished it with
a test mark. Section 16 para. 4 shall apply as appropriate.
(5) The competent authority may extend the period menti-
oned in para. 1 No. 2 if the safety of employees or third par-
ties permits this.
Section 19
Gas pressure vessels not subject to testing
by authorized inspectors
(1) Sections 15 to 17 do not apply to gas pressure vessels,
other than vessels for acetylene
1. with a cubic capacity not exceeding 220 cm3
2. with a cubic capacity not exceeding 1000 cm3 and a
required test pressure not exceeding 18 bars which are
intended to be filled only once, or
3. in respect of which the licensing authority has specified
according to Section 16 para. 5 that they are not subject
to testing by authorized inspectors.
(2) Gas pressure vessels according to para. 1 may be
filled with pressure gases or brought within the scope of
this Order when filled with pressure gases only if they have
no defects whereby employees or third parties may be
endangered. In addition gas pressure cartridges with a
cubic capacity exceeding 220 cm3 which are subject to
para. 1 No. 2 may be filled with pressure gases or brought
within the scope of this Order when filled with pressure
gases only if they are approved by the licensing authority
as regards their type, together with their mountings and
discharge equipment, and furnished with the symbols and
particulars as specified by the authority.
P a g e 9 Pressure Vessel Order, Edition 01.97
I
Section 20
Non-application of Sections 15 to 19
(1) Sections 15 to 19 do not apply to gas pressure vessels
j.
1. which are not intended to come within the scope of this
Order,
2. which are taken on board a watercraft or aircraft and are
intended to be used on board these craft,
3. which are temporarily brought within the scope of this
Order or
4. which are operated by the Armed Forces or their civilian
personnel when these are subject to NATOforces regu-
lations.
(2) Gas pressure vessels according to para. 1 may be fif-
led with pressure gases within the scope of this Order only
if they may be conveyed in accordance with the statutory
transport regulations on the transport of dangerous goods.
Section 21
immediate emptying
(1) A gas pressure vessel which has defects which will
endanger employees or third parties shall be emptied
immediately.
(2) If a vessel filled with pressure gases which should not
have been filled according to Sections 15, 18 or 19 para. 2,
has been brought within the scope of this Order it shall be
emptied immediately when taken over by the consignee.
The competent authority may allow an exception to sen-
tence 1 if the vessel complies with the statutory transport
regulations on the transport of dangerous goods and has
no defects which may endanger employees or third parties.
Section 22
Type approval
(1) The competent authority shall decide on type approval
according to the provisions of paras. 2 to 8.
An EEC type approval issued by a Member State of the
European Communities or other Contracting State of the
Agreement on the European Economic Area on the basis
of directives 84/525/EEC, 84/526lEEC or 841527lEEC is
equivalent to the approval according to sentence 1 in
respect of the gas bottle with no items of equipment, for the
following:
1. seamless steel gas bottles
2. seamless gas bottles made of unalloyed aluminium or
aluminium alloys and
3. welded gas bottles made of unalloyed steel.
(2) On application from the manufacturer, or his autho-
rized agent resident in a Member State of the European
Communities or other Contracting State of the Agreement
on the European Economic Area, type approval shall be
issued for the scope of this Order; in respect of the gas bott-
les mentioned in para. 1 sentence 2, it shall also apply to
the area of the Member States of the European Communi-
ties or other Contracting State of the Agreement on the
European Economic Area (EEC type approval). The appli-
cation shall indicate whether approval for the scope of this
Order or an EEC type approval is being applied for.
(3) The licensing authority shall make its decision on the
basis of the opinion of the competent authorized inspector.
Page 10 Pressure Vessel Order, Edition 01.97
On application from the manufacturer or his authorized
agent resident in a Member State of the European Commu-
nities or other Contracting State of the Agreement on the
European Economic Area the authorized inspector shall
verify whether the design and type of material used for the
type in question complies with the requirements of this
Order. Three copies of the drawings necessary to the
inspection and a description of the vessel’s type shall be
enclosed with the application. The authorized inspector
shall send the licensing authority the reports and certifica-
tes on the tests carried out and the results of them.
(4) Approval shall be granted when the vessel complies
with the requirements of this Order; otherwise approval
shall be refused. If there is a test certificate which incorpo-
rates a test report that has been issued by a test centre
nominated according to Article 13 of Directive 761767IEEC
by the Member State or other Contracting State of the
Agreement on the European Economic Area in which the
manufacturer has his head office and according to which
the vessel complies with the requirements of this Order,
then the licensing authority shall base its decision on this
test certificate. The approval can be limited, restricted in
time, issued subject to conditions or linked to certain requi-
rements. The subsequent inclusion, modification or supp-
lementing of requirements is permissible.
(5) The licensing authority shall issue the applicant with a
certificate in respect of the approval. The certificate shall
indicate the most important features of the gas pressure
vessel as well as limitations, time limits, conditions and
requirements. The licensing authority shall send the Deut-
scher DruckbehtilterausschuO (German Pressure Vessel
Committee) a copy of the certificate.
(6) The manufacturer or his representative in a Member
State of the European Communities or other Contracting
State of the Agreement on the European Economic Area
can apply for individual approval of items of equipment;
paras. 2 to 5 shall apply with the proviso that the test
according to para. 3 may also be carried out by the Bundes-
anstalt fur Materialforschung und -prtifung (Federal Materi-
als Research and Testing Institute).
(7) If the type approval has been withdrawn or revoked,
gas pressure vessels or items of equipment manufactured
before the withdrawal or revocation may be operated if they
conform to the withdrawn or revoked approval unless the
authority responsible for the withdrawal or revocation finds
that there is a risk of danger to employees or third parties.
(8) A type approval shall lapse if
1. a period specified in it or not extended has expired with-
out the holder of the approval having started to manu-
facture the approved gas pressure vessels or items of
equipment,
2. the holder of the approval makes no use of it for three
years or has not made gas pressure vessels or items
of equipment for more than three years and the period
has not been extended.
Para. 7 shall apply as appropriate if the type approval
expires.
(9) Paras. 2 to 5, 7 and 8 shall apply as appropriate in
respect of the approval of porous fillers and solvents with
the proviso that the test is carried out by the Bundesanstak
fijr Materialforschung und -prDfung (Federal Materials
Research and Test Institute).
Section 23
Intervals between tests
(1) The intervals betwee,n tests shall be
1. two years for non-portable vessels for pressure gases
which can strongly corrode the material from which the
vessel is made,
2. three years
a) for portable vessels for pressure gases which can :
strongly corrode the material from which the vessel
is made,
b) for acetylene vessels in respect of the first test after
the vessel has been filled with porous filler and six
years in respect of subsequent tests,
3. six years for vessels which do not come under I,2 or 4,
4. ten years for vessels for pressure gases which do not
strongly corrode the material from which the vessel
is made, when the cubic capacity does not exceed
150 litres.
(2) The competent authority may
1. extend the periods according to para. 1 if safety is
ensured by some other means or
2. shorten the periods according to para. 1 if this is
required for the safety of employees or third parties.
(3) Where intervals between tests are specified for gas
pressure vessels in the statutory transport regulations in
respect of traffic which does not cross frontiers these peri-
ods shall apply instead of the intervals between tests
according to paras. 1 and 2.
Section 24
Notification of distribution depots
(1) Anyone who stores filled gas pressure vessels in order
to dispose of them to others shall notify the competent
authority of this without delay. The pressure gases
intended for storage shall be indicated in the notification
according to their nature and maximum quantity as well as
the location and type of storage. _I
(2) Para. 1 shall not apply
,
1. to gas pressure vessels containing non-combustible
non-toxic pressure gases and having a cubic capacity
not exceeding 150 litres if the number of vessels stored
does not exceed 50,
2. to gas pressure vessels with a cubic capacity not
exceeding 1 litre which are intended to be filled only
once, if the number of vessels stored does not exceed
500.
Section 25
Orders by supervisory authorities
(1) In individual cases the supervisory authority may order
an extraordinary test to be carried out by an authorized
inspector if there are special reasons for this and particu-
larly when damage or injury has occurred. The operator
shall arrange for this test to be carried out.
(2) The supervisory authority may order that a gas pres-
sure vessel may no longer be filled or porous fillers or
solvents may no longer be used if defects have occurred
whereby employees or third parties are endangered.
 . . . . . ^
‘. . : . _ .~_ .
__ ‘....
Part IV
Filling plants
Section 26
Licence
(1) The erection and operation of a filling plant in which
gas pressure vessels are filled with pressure gases for
disposal to others shall require a licence from the compe-
tent authority (licensing authority).
(2) The licence shall be applied for in writing. The docu-
ments necessary for the tests, particularly drawings and
type specifications and a description of the mode of oper-
ation of the filling plant shall be attached to the application
in triplicate.
(3) The application and documents shall be submitted to
the authorized inspector. On the basis of the documents
he shall verify whether the type and mode of operation of
the filling plant meets the requirements of the Order. He
shall furnish the document with a test mark and send the
application and documents to the licensing authority with
his comments.
(4) The licence shall be issued if the type and mode of
operation of the filling plant as indicated in the application
meet the requirements of this Order; otherwise the licence
shall be refused. The licence may be restricted, limited in
time, issued subject to conditions or combined with requi-
rements The subsequent inclusion, modification or supp-
lementing of requirements is permissible.
(5) The licensing document and the application docu-
ments shall be kept at the place of operation of the filling
plant.
(6) A licence is not needed for the construction and oper-
ation of filling plants belonging to:
1. A company deriving from the special fund of the Deut-
sche Bundespost (Federal Post Office), where the Fed-
eral Ministry for Posts and Telecommunication exerci-
I the vessels being emptied and if a higher pressure can-
ses his right in accordance with Section 14 para. 2 sen-
tence 1 of the Equipment Safety Law.
2. The Federal Government’s Waterways and Shipping
Directorate,
3. The Bundeswehr (Federal Armed Forces).
Section 27
Major modification
Section 26 shall apply as appropriate to the major modifica-
tion of a filling plant within the meaning of Section 26
para. 1 and the operation of a filling plant after a major
modification. A modification shall be regarded as a major
one if it can impair the safety of the plant.
Section 28
Tests
(1) A filling plant in which gas pressure vessels are filled
with pressure gases may not be put into service after con-
struction or major modification until the authorized inspec-
tor has examined it to confirm that it has been constructed
or modified in accordance with the licence, or, if a licence
is not required, in accordance with the requirements of this
Order, and he has issued a certificate in respect of the
results of his inspection.
: . “_ ” T . _ ,-.-
_.: . . .
.-
-.-:
Page 11 Pressure Vessel Order, Edition 01.97
(2) The competent authority may specify that a filling plant
is to be examined by an authorized inspector within given
periods if this is necessary for the protection of the life and
health of employees and third parties.
(3) The competent authority may specify that filling plants
used by a company which do not require a licence need
not be tested in accordance with para. 1 if such testing is
not necessary for the protection of employees or third par-
ties.
(4) In individual cases the supervisory authority may order
an extraordinary test by an authorized inspector if there are
specific grounds for this, particularly if damage or injury has
occurred. The operator shall arrange for this test to be
carried out.
j (5) Section 4 para. 2 remains unaffected.
Section 29
Non-application of Sections 26 to 28
(1) Sections 26 and 27 are not applicable to filling plants
for filling vessels
1. which are volumetrically filled with pressure gases, the
critical temperature of which is 70 ‘C or more, from
other gas pressure vessels with a cubic capacity not
exceeding 1.50 ktres if the vessels being filled have a
cubic capacity not exceeding 1000 cm3, are equrpped
with the necessary equipment for limiting the maximum
permrsslble filling quantity and if it is ensured that a dan-
gerous overpressure does not arise in the vessels,
2. with a cubic capacity not exceeding 50 cm3 for pressure
gases with a critical temperature of 70 “C or more from
other gas pressure vessels, if not more than 10 kg of
pressure gases are transferred in an hour and if it is
ensured that a dangerous overpressure does not arise
in the vessels being filled,
3. for non-toxic pressure gases with a critical temperature
of less than -10 “C from other gas pressure vessels, if,
in the vessels being filled, the permissible working pres-
sure of the filled gases at 15 “C is not less than that of
not arise in the vessels being filled than in the vessels
being emptied,
4. for non-combustible, non-toxic pressure gases with a
critical temperature of less than -10 “C, if not more than
10 kg of pressure gas can be transferred in an hour and
if it is ensured that a dangerous overpressure cannot
arise in the vessels being filled.
(2) Section 28 paras. 1 to 3 is not applicable to filling plants
in laboratories and institutes or to the filling plants referred
to in para. 1.
Section 30
Operation of filling plants
(1) Anyone operating a filling plant shall maintain it in pro-
per condition, operate it properly, carry out necessary
repair work without delay and implement such safety mea-
sures as are necessary under the circumstances.
(2) Anyone operating a filling plant may allow it to be con-
trolled only by persons who have reached their 18th birth-
day. Such persons shall have the expert knowledge neces-
sary for the control of the plant and be conversant with the
operating instructions and regulations.
(3) The supervisory authority may prohibit the operation
of the filling plant by a person who does not have the neces-
sary expert knowledge or is not sufficiently conversant with

Page 12 Pressure Vessel Order, Edition 01.97
the operating instructions and regulations or has
himself to be unreliable.
(4) A filling plant may not be operated if it has defects whe-
reby employees or third parties are endangered.
Part V
Pipelines
Section 30a
Pre-commissioning tests
(1) Pipelines
1. with a nominal diameter D greater than 25 mm in which
the product of the permissible working pressure p in
bars and the nominal diameter D in mm does not
exceed 2000, apart from pipelines for the conveyance
of liquid gas and very toxic gases, vapours or liquids,
2. of liquid gas plants with a pressure vessel whose capa-
city does not exceed 3 t and in which the gas is con-
veyed in gaseous form
may only be commissioned when
a ) the manufacturer or constructor has subjected the pipe-
lines to a pressure test and certified that the pipelines
are properly constructed and
b ) an expert has subjected them to an acceptance test and
certified that they comply with the requirements to be
met as part of that test.
(2) Pipelines
with a nominal diameter D in excess of 25 mm in which
the product of the permissible working pressure p in
bars and the nominal diameter D in mm is greater than
2000, apart from pipelines for the conveyance of liquid
gas and very toxic gases, vapours or liquids,
with a nominal diameter D in excess of 25 mm for the
conveyance of very toxic gases, vapours or liquids,
of liquid gas plants
a ) with a pressure vessel whose capacity exceeds 3 t,
or
b) with a pressure vessel when the gas is conveyed in
liquid form, or
c) with several pressure vessels
may only be commissioned when an authorized inspector
has subjected them to an initial test and an acceptance test
and certified that they are in proper condition.
(3) If the operator has specified written specifications for
the manufacture and construction of pipelines, particularly
as regards the choice of material, the dimensions and the
design, and for the nature and scope of pipeline tests (test
schedule) and the authorized inspector has examined
these and certified that they will meet the requirements of
this Order, then notwithstanding para. 2, pipelines
1. in which the product of the permissible working pres-
sure p in bars and the nominal diameter D in mm
exceeds 2000, apart from pipelines for the conveyance
of liquid gas and highly toxic gases, vapours or liquids,
2. for the conveyance of highly toxic gases, vapours or
liquids in which the product of the permissible working
pressure p in bars and the nominal diameter D in mm
does not exceed 500
may be commissioned when:
a) the manufacturer or constructor has subjected the pipe-
lines to a pressure test and certified that the pipelines
have been properly constructed according to the written
specifications,
‘_. - . . , ^
shown b ) an expert has subjected them to an acceptance test and
certified that they are in serviceable condition and
c) the authorized inspector has satisfied himself that the
written specifications have been met by way of random
testing.
(4) If the authorized inspector or expert find that the pipeli-
nes are not in serviceable condition, on application the
competent authority shall decide whether the pipelines
may be commissioned.
I (5) Section 4, para. 2 remains unaffected.
Section 30b
Recurrent tests
(1) Pipelines according to Section 30a para. 1 shall
undergo recurrent testing by the expert at intervals to be
determined by the operator on the basis of experience of
the mode of operation and charge material.
(2) Pipelines according to Section 30a para. 2 shall
undergo recurrent testing by the authorized inspector
every five years. In individual cases the supervisory
authority may
1. extend these periods provided that safety is ensured by
other means, or
2. shorten these periods if the protection of employees or
third parties requires this.
(3) If the operator has specified written specifications for
the schedule of recurrent tests for pipelines and the autho-
rized inspector has examined them and certified that they
will meet the requirements of this Order, then notwithstand-
ing para. 2 sentence 1, the recurrent tests by experts may I
be carried out according to these specifications when the
authorized inspector has satisfied himself that the written
specifications have been met by means of random testing.
1,
(4) Notwithstanding paras. 1 and 2 pipelines that are con-
i
nected to pressure vessels and are subject to recurrent
testing by the authorized inspector shall be tested at the
same time as the pressure vessels. I
(5) Recurrent tests of pipelines shall comprise external
tests and pressure tests or other suitable methods.
(6) After the period for the recurrent tests has expired,
pipelines according to para. 2 shall only be operated if the
tests are carried out punctually and the authorized inspec-
tor has certified on the results of the testing that the pipeline
meets specified requirements.
(7) If the authorized inspector has found that the pipeline
is not in serviceable condition, on application the compe-
tent authority shall decide whether the pipeline may conti-
nue to be operated.
(8) Section 13 para. 1 to 3 shall apply as appropriate.
Section 3Oc
Testing in specific cases
(1) If the nature, layout or mode of operation of a pipeline
has been substantially altered, Section 30a shall apply
as appropriate. Any alteration that may adversely affect
the safety of the pipeline shall be regarded as a major
alteration.

(2) If a pipeline has undergone major repairs or if major
components of a pipeline have been replaced the pipeline
may only be commissioned again after the authorized
inspector or expert has tested it for serviceable condition
to the extent determined by the scope of the repair or repla-
cement and on the basis of Section 30a and a test certifi-
cate has been issued. Para. 1 sentence 2 shall apply as
appropriate.
(3) In individual cases the supervisory authority may order
an extraordinary test by an authorized inspector or expert
if there is a special reason for this and particularly if
damage has occurred. The operator shall arrange for this
test to be carried out.
Part VI
Further general regulations, transitional
and definitive regulations
Section 31
Authorized inspectors
(1) Authorized inspectors in respect of the tests specified
or ordered according to Parts II and V of this Order are
1. authorized inspectors according to Section 14 para. 1
and 2 of the Equipment Safety Law,
2. the Technischer ijberwachungsverein Hessen e. V.
(Hesse Association of Technical Supervision) additio-
nally in Hessen, following approval by the competent
authority, with those of its engineers trained in the test-
ing of pressure vessels,
3. the authorized inspectors of a company in which testing
by works employees is indicated according to the
nature of the pressure vessels and the integration of
pressure vessels in process plants, provided the com-
petent authority has accepted the employees for testing
the pressure vessels operated in this company, other
than in the case of pressure vessels which are subject
.
to the statutory nuclear regulations,
4. the authorized inspectors accepted by the Saarland’s
competent mining authorities according to regional pro-
visions for the testing of pressure vessels operated by
mining companies in open-cast mines, except pressure
vessels subject to the statutory nuclear regulations,
(2) In cases described in Section 1 I para. 5 and Section
3Oc the supervisory authority may specify the authorized
inspector.
(3) Authorized inspectors for the tests specified or ordered
according to Sections 3 or 4 of this Order are the authorized
inspectors in accordance with Section 14 para. 1 and 2 of
the Equipment Safety Law.
(4) Authorized inspectors for the tests specified or ordered
according to Parts II and Ill of this Order for vessels which
are subject to the statutory transport regulations on the
transport of dangerous goods are the authorized inspec-
tors specified in those regulations.
(5) Authorized inspectors for the tests specified or ordered
according to Parts II to V of this Order for pressure vessels,
gas pressure vessels, filling plants or pipelines
1. belonging to the Federal Government’s Waterways and
Shipping Directorate are the authorized inspectors
it I appointed by the Federal Ministry of Transport,
3
2. belonging to the Federal Armed Forces are the autho-
I rized inspectors appointed by the Federal Ministry of
Defence,
Page 13 Pressure Vessel Order, E d i t i o n 0 1 . 9 7
3. belonging to the Federal Border Police are the autho-
I rized inspectors appointed by the Federal Ministry of
the Interior.
(6) Authorized inspectors for the pre-commissioning tests
specified or ordered according to Parts II and III of this
Order and for pressure vessels and gas pressure vessels
imported from a Member State of the European Communi-
ties or other Contracting State of the Agreement on the
European Economic Area and tested at the place of manu-
facture according to the method specified in Article 22 of
Directive 761767lEEC are also the test centres notified
according to Article 13 of that Directive by the Member
State or other Contracting State of the Agreement on the
European Economic Area in which the manufacturer has
his head office. In the case of pressure vessels and gas
pressure vessels manufactured in very small numbers as
a result of a contract or in the case of special constructions
as in Sections 9 and 18 for a complicated plant, the tests
referred to in sentence 1 may also be carried out by a test
centre in respect of which the purchaser has reached
agreement with the competent authority according to No. 1
of Appendix IV of the Directive mentioned in sentence 1.
(7) Authorized inspectors for the tests specified or ordered
according to Parts II and Ill of this Order are alsoauthorized
inspectors who are employed at a technical supervision
organisation outside the scope of this Order provided that
this organisation has been recognised by the competent
authority according to regional law.
Section 32
Experts
An expert to whom a test may be entrusted according to
Parts II or V of this Order shall only be someone who
1. by reason of his training, knowledge and experience
gained from practical work can provide an assurance
that he will carry out the test properly,
2. possesses the necessary personal reliability,
3. does not need instruction in respect of his testing activi-
ties,
4. has appropriate test equipment if necessary and
5. can demonstrate via a certificate of successful attend-
ance of a Government or Government approved train-
ing course that he meets the requirements listed in
No. 1. The certificate shall be submitted to the compe-
tent authority on request.
Expert knowledge shall be demonstrated to the competent
authority on request.
Section 33
Notification of defects, test certificates
(1) If on carrying out a test the authorized inspector or
expert finds defects whereby employees or third parties
are endangered he shall notify the supervisory authority
thereof without delay.
(2) In the cases described in Section 11 para. 5, Sec-
tions 25,28 para. 4 or Section 3Oc the authorized inspector
or expert shall issue a certificate on the results of the test
and send a copy to the supervisory authority without delay.
The operator shall keep the certificate within easy reach
of the vessel or filling plant.
 Page 14 Pressure Vessel Order, Edition 01.97
Section 34
Notification of accidents and injury
(1) Anyone operating pressure vessels, gas pressureves-
sels, filling plants or pipelines shall notify the supervisory
authority at once of
1. every accident as a result of the failure of pressurised
parts in which any person is killed or the health of any
person is impaired,
2. an explosion or fire in connection with the operation of
a vessel or pipeline,
3. the rupture of a vessel with a cubic capacity in excess
of 1000 cm3.
The supervisory authority may require the person obliged
to make this notification to arrange for the notifiable occur-
rence to be assessed from the technical safety point of
view at his expense and by an authorized inspector who
is appointed by mutual agreement if possible and shall sub-
mit the assessment to the authority in writing. In particular
this assessment shall cover the determination of:
a) the factors to which the occurrence is attributable,
b) whether the pressure vessel, gas pressure vessel, fill-
ing plant or pipeline was in serviceable condition or not
and whether there was no further risk after the defect
had been rectified and
c) whether fresh knowledge which called for other or
supplementary safety precautions had been obtained.
(2) Para. 1 does not apply to Federal Armed Forces pres-
sure vessels, gas pressure vessels, filling plants and pipeli-
nes.
Section 35
Supervisory authorities for Federal Government
installations and for power plants
(1) The supervisory authority for pressure vessels, gas
pressure vessels, filling plants or pipelines belonging to the
German Federal Post Office, the Federal Government’s
Waterways and Shipping Department, the Federal Armed
forces and the Federal Border Police is the relevant Fed-
/ era1 Ministry or the authority appointed by him. Section 14
para. 2 of the Equipment Safety Law applies accordingly
to plants in accordance with sentence 1 of companies
deriving from the special fund of the Deutsche Bundespost
(Federal Post Office). The first and second sentences of
Section 15 of the Equipment Safety Law shall apply in
respect of other pressure vessels, gas pressure vessels,
filling plants and pipelines that are subject to supervision
by the Federal Government.
(2) The supervisory authorities for pressure vessels, gas
pressure vessels, filling plants or pipelines which are
power plants in the meaning of Section 2 para. 1 of the
Power Production Act (Energiewirtschaftsgesetz) shall be
the authorities that are competent according to regional
law.
Section 36
Deutscher DruckbehtilterausschuB
(German Pressure Vessels Committee)
(1) The German Pressure Vessels Committee is formed
1by the Federal Ministry of Labour and Social Order. The
committee comprises the following expert members:
3 representatives of the relevant specialist departments of
the regional Governments,
.
4 representatives of the technical supervisory organisa-
tions, including 1 representative of the Government’s
technical supervisory service,
1 representative of the statutory accident insurance insti-
tutions,
7 representatives of the manufacturers of installations
according to this Order,
5 representatives of the operators of installations accord-
ing to this Order, including 1 from the operators of the
public supply sector,
1 representative of the ,,Pressure vessels” technical com-
mittee,
1 representative of the Physikalisch-Technische Bundes-
anstalt (Federal Physico-technical Institute),
1 representative of the Bundesanstalt fiir Materialfor-
schung und -prDfung (Federal Materials Research and
Testing Institute),
1 representative of the DIN (German Standards Institu-
tion),
1 representative of the DVGW - Deutscher Verein des
Gas- und Wasserfaches (German Gas and Water Asso-
ciation),
2 representatives of the trade unions.
(2) The task of the German Pressure Vessels Committee
as regards pressure vessels, gas pressure vessels, filling
plants and pipelines is to:
I 1. advise the Federal Ministry of Labour and Social Order
and the Federal Minister of Economic Affairs, particu-
larly in technical matters, and to make proposals for
regulations which reflect the state of the art in science
and technology and
2. determine the rules (technical rules) corresponding to
the state of the art designated in Section 4 para. 1 in
conformity with the regulations for the conduct of busi-
ness.
(3) Membership of the German Pressure Vessels Com-
mittee is honorary.
I (4) The Federal Ministry of Labour and Social Order shall
appoint the members of the committee and a deputy for
each member. The committee shall draw up its standing
orders for the conduct of business and elect the chairman
from among its number. The standing orders and the cho-
I ice of chairman require the approval of the Federal Ministry
of Labour and Social Order.
1(5) The Federal Ministries and the supreme regional
authorities responsible for industrial safety shall be entitled
to send representatives to the committee’s meetings.
These representatives shall be allowed to speak at the
meetings on request.
(6) The Bundesanstalt fijr Arbeitsschutz und Arbeitsmedi-
I zin (Federal Industrial Safety and Medicine Institute) shall
provide the committee’s secretarial services.
Section 37
Transitional regulations for pressure vessels
(1) If a pressure vessel did not undergo any tests that
reflect the tests specified in Sections 9 and 10 before 1 July
1980 the operator shall arrange for the, vessel to undergo
a test that reflects the test specified in Section 9 within 24
months starting from 1 July 1980.
,

(2) The authorized inspectors of operators’ works autho-
rized by the statutory accident insurance institutions before
1 July 1980 shall qualify as authorized inspectors within the
meaning of Section 31 para. 1 No. 3. The competent
authority may withdraw or revoke the authority if the autho-
rized inspector does not have or no longer has the techni-
cal knowledge or reliability necessary to the fulfilment of his
tasks.
(3) The engineers employed on 1 July 1980 in the Land
of Hamburg by the Technischer Uberwachungs-Verein
Norddeutschland e. V. (North German Technical Super-
vision Association) for the testing of pressure vessels shall
qualify as authorized inspectors within the meaning of Sec-
tion 31 para. 1 No. 1 in this area for the period of their occu-
pational relationship with the North German Technical
Supervision Association.
(4) Experts to whom tests according to Part II are
entrusted before 1 May 1989 shall be experts within the
meaning of Section 32.
(5) Those authorized inspectors approved before 1 May
1989 by the competent mining authorities according to
regional regulations for the testing of pressure vessels, gas
pressure vessels, filling plants and pipelines in open-cast
mines shall be regarded as authorized inspectors in this
field within the meaning of Section 31 para. 1. Para. 2 sen-
tence 2 shall apply as appropriate.
Section 38
Transitional regulations for gas pressure vessels
(1) Gas pressure vessels manufactured up to 1 June 1969
and with a cubic capacity in excess of 220 cm3 may
1. be furnished by the authorized inspector with the test
mark and test date if the vessel complies with the regu-
lations in force up to 1 June 1969 and, in the case of
vessels for acetylene, the porous filler and the solvent
comply with the regulations in force up to 1 June 1969
and
2. be filled with pressure gas if the period specified in the
Technical Principles in force up to 1 June 1969 has not
yet expired since the last test; Section 23 para. 3 shall
apply as appropriate.
(2) The containers of constant-pressure fire extinguishers
(Section 3 para. 5 No. 2) manufactured on or within a year
of 1 July 1980 may continue to be used if they comply with
the generally applicable technical regulations or, should
they deviate from these, equivalent safety is ensured by
other means. After 1 July 1980 the containers may only be
filled after they have been tested by an authorized inspec-
tor, furnished with the test mark and test date and an indi-
cation of the interval between tests and the period between
tests which is indicated on the container has not yet
expired. The interval between tests for these containers is
ten years.
(3) Gas pressure vessels with a capacity exceeding
220 cm3, the operation of which in accordance with Appen-
dix I Chapter VIII, Technical Field 6 Clause III No. 6 in con-
junction with number 2 of the Unification Agreement is per-
mitted in the area named in Article 3 of the Unification
Agreement, may
1. be furnished by the authorfsed inspector with the test
mark and test date if the vessel complies with the regu-
lations applicable in the area named in Article 3 of the
Unification Agreement before it came into force and, in
the case of vessels for acetylene, the porous filler and
“_.c_ _.. .‘_.. -_ . . ._...___.~ _
Page 15 Pressure Vessel Order, Edition 01.97 .. <
the solvent correspond to the field specified in Article
3 of the Unification Agreement before it came into force,
and
2. are filled with pressure gas if the period specified in Sec-
tion 23 has not expired since the last inspection.
The provisions in Section 25 remain unaffected.
Section 39
Transitional regulations for filling plants
(1) Filling plants within the meaning of Section 3 para. 6
No. 2 which were constructed before 1 June 1969 may be
operated without a licence in accordance with this Order.
(2) Filling plants within the meaning of Section 3 para. 6
No. 1 which were constructed before 1 July 1980 may con-
tinue to be operated if they are of a nature which complies
with the generally applicable technical regulations or, if
they deviate from these, equivalent safety is ensured by
other means.
Section 39a
Transitional regulations for pipelines
(1) Pipelines within the meaning of Section 3 para. 9 which
were constructed before 1 May 1989 may continue to be
operated if they are of a nature which complies with the
generally applicable technical regulations or, if they devi- ! ...
ate from these, equivalent safety is ensured by other I&
means. The operator shall have an external test and a
pressure test carried out in accordance with Section 30b
within two years of 1 May 1989. Notwithstanding this, pipe-
lines that are connected with pressure vessels shall
undergo these tests at the same time as the pressure ves-
sels. Sections 30b and 30~ shall apply to other tests.
(2) For pipelines which are permitted to be operated in
accordance with Annex 1 chapter VIII Technical Field B
Clause III Number 6 in conjunction with Number 2 of the
Unification Agreement in the area named in Article 3 of the
Unification Agreement, the operator shall have an external
inspection and pressure test performed by 31 December
1996 with Section 30b applied as appropriate. Para. 1 sen-
tences 3 and 4 apply as appropriate.
Section 39b
(deleted)
Section 40
Contravention of regulations
(1) A contravention of regulations within the meaning of
Section 15 para. 2 No. 4 of the Power Production Act is per-
petrated by anyone who, in respect of pressure vessels,
gas pressure vessels, filling plants or pipelines which are
power plants within the meaning of Section 2 para. 1 of the
Power Production Act deliberately or negligently:
1. fails to appoint an experienced and competent person
to carry out the tests in contravention of Section 4
para. 1 in conjunction with No. 5.3 of Appendix I to this
Order,
2. operates a pressure vessel
a) in contravention of Section 9 para. 1 or 2, Section 1 0
para. 10, Section 11 para. 1, 2 or 3, or Section 1 2
sentence 2 before the authorized inspector or expert
has issued a certificate,
b) in contravention of Section 13 para. 3,
Page 16 Pressure Vessel Order, Edition 01.97
3. does not provide or does not properly provide a test
book or test document in contravention of Section 14
para. 2 or does not keep or does not keep a proper list
of pressure vessels in contravention of Section 14
para. 3,
4. 4 fills a gas pressure vessel with pressure gas in con-
travention of Section 15, Section 17 para. 2 sen-
tence 1, Section 18 para. 1 sentence 2, para. 2 or
para. 4 sentence 1, Section 19 para. 2 or Section 20
para. 2,
W brings a gas pressure vessel filled with pressure gas
within the scope of this Order in contravention of
Section 19 para. 2 or
cl does not immediately empty such a pressure vessel
in contravention of Section 21 para. 1,
5. a) constructs or operates a filling plant without a
licence in contravention of Section 26 para. 1 or car-
ries out a major modification to a filling plant or ope-
rates it after a major modification in contravention of
Section 27,
W starts to operate a filling plant before a certificate has
been issued in contravention of Section 28 para. 1,
c) allows a filling plant to be operated by a person who
has not yet reached his 18th birthday in contraven-
tion of Section 30 para. 2 sentence 1,
4 operates a filling plant in contravention of Section 30
para. 4,
6. 4 operates a pipeline before the authorized inspector
or expert has issued a certificate in contravention of
Section 30a para. 1 or 2, Section 30b para. 6 or Sec-
tion 3Oc para. 1 sentence 1 or para. 2 sentence 1,
b) operates a pipeline in contravention of Section 30b
para. 8 in conjunction with Section 13 para. 3 or
Articles 13 and 15
of the Second Law amending the Equipment Safety Law
of 26th August 1992
l
Article 13
Cross References
Where Federal laws and statutory regulations cross-refer
to Sections 24 and 25 of the Trading and Industrial Code
(Gewerbeordnung) in other than the instances cited in
Articles 2 to 9, such references are to the corresponding
provisions of the Equipment Safety Law as amended by
this law. Statutory regulations issued on the basis of Sec-
tion 24 of the Trading and Industrial Code are also consi-
dered to be statutory regulations in accordance with Sec-
tion 3 para. 1 and Section 11 of the Equipment Safety Law
as amended by this law. Authorized inspectors in accord-
7. fails to issue a proper, complete or immediate notifica-
tion in accordance with Section 24 para. 1 or Section 34
para. 1 sentence 1.
(2) In the case of pressure vessels, gas pressure vessels,
filling plants or pipelines which are installations requiring
supervision within the meaning of Section 2 para. 2a of the
Equipment Safety Law, the perpetrator acts
1. in contravention of regulations within the meaning of
Section 16 para. 2 no. 1 (b) of the Equipment Safety .,’
Law in the instances cited in para. 1 nos. 1 to 6,
2. in contravention of regulations within the meaning of
Section 16 para. 2 no. 1 (a) of the Equipment Safety
Law in the instances cited in para. 1 no. 7.
Section 41
(deleted)
Section 42
(deleted)
-1
Section 43
(deleted)
Article 4’)
(Entry into force)
I
This Order shall come into force on 1 May 1989. Notwith-
standing sentence 1 Section 22 shall come into force on
the day following publication.
‘) Editorial note:
On the basis of the second amendment to the GSG SectIon 15 of the GSG
amendment applies until January 1993. j.
ante with Section 24c para. 1 and 2 of the Trading and
Industrial Code are also considered to be such under Sec-
tion 14 para. 1 and 2 of the Equipment Safety Law as
amended by this law.
Article 15
Effective date
This law becomes effective on 1 January 1993. By way of
derogation from sentence 1, Article 1 no. 2, 3(c), no. 6, 11
/.,. ,.
and 13 becomes effective the day following its promulga-
tion.

Appendix I
(to Section 4 para. 1)
1. Pressure vessels
1.1 Construction and equipment
Pressure vessels shall be of such a nature that they
safely withstand the mechanical, chemical and
thermal stresses that can be anticipated on the
basis of the intended mode of operation and remain
tight. In particular they shall
be of such a nature that they can safely withstand
the permissible working pressure and the permis-
sible working temperature,
withstand the stresses attributable to dangerous
reactions during charging unless suitable measu-
res are taken to avoid such reactions or adequately
to reduce the dangers arising from them,
1.1.3 be manufactured of materials which
a) give the finished component the required
mechanical properties,
b) will not be dangerously corroded by the charge
and do not form any dangerous compounds with
it when the materials are exposed to the charge,
c) are corrosion-resistant or protected against cor-
rosion if they are subject to corrosive effects,
1.1.4 be suitably manufactured and made ready for use
before commissioning,
1 .1.5 have items of equipment which safelyfulfil their pur-
pose.
1.2 Installation and operation
. Pressure vessels shall be so installed and operated
that there is no danger to employees or third par-
ties. The necessary safety zones shall be adhered
to. The regulations of the law on building supervi-
sion in respect of the installation of pressure ves-
sels shall remain unaffected.
2 Gas pressure vessels
2.1 Construction and equipment
Gas pressure vessels shall be of such a nature that
they withstand the anticipated mechanical, chemi-
cal and thermal stresses and remain tight. In parti-
cular they shall
2.1 .l be of such a nature that they safely withstand the
required test pressure and a possible underpres-
sure,
safely withstand stresses attributable to dangerous
reactions in the filling charge or special measures
which adequately reduce the risks arising there-
from shall be taken,
2.1.3 be manufactured of materials which
a) give the finished component the required
mechanical properties; where the components
are subjected to the pressure of the filling
charge they shall be so ductile and so tough that
brittle fracture need not be anticipated,
W are not dangerously corroded by the filling
charge and do not form dangerous compounds
with it if the materials are exposed to the charge,
c) are corrosion-resistant or protected against cor-
rosion if they are subject to corrosive effects,
- - _. -_ _ -.
Page 17 Pressure Vessel Order. Edition 01.97
I.
1..
/
2.1.4 be suitably manufactured and made serviceable,
2.1.5 have items of equipment which safelyfulfil their pur-
pose; the items of equipment shall be protected
against damage which may allow dangerous quan-
tities of pressurised gas to escape.
2.2 Operation
Gas pressure vessels shall be operated in accord-
ante with the intended method of operation, specifi-
cally including filling, conveying, storage, emptying
and maintenance. They shall be so operated that
there is no danger to employees or third parties.
3 Filling plants
3.1 Filling plants shall be so constructed and operated
that persons controlling, servicing or supervising
them or are in their vicinity are not put at risk. In par-
ticular, hazardous quantities of mixtures of pres-
sure gas and air shall be prevented in premises
where filling takes place and at outdoor operating
points. If it is possible for dangerous concentrations
to arise these risks shall be countered by appro-
priate choice of filling points and protective measu-
res in areas to be specified. Necessary protection
zones shall be adhered to. The regulations of the
law on building supervision in respect of the con-
struction of filling plants shall remain unaffected.
3.2 Items of equipment for filling plants shall safely fulfil
the purpose of the filling plant as regards material,
dimensions, design and performance when sub-
jected to the anticipated mechanical, chemical and
thermal stresses.
4 Pipelines
4.1 Pipelines shall be of such a nature that they safely
withstand the mechanical, chemical and thermal
stresses which can be anticipated on the basis of
the intended mode of operation and remain tight. In
particular they shall:
4.1 .l be so designed that they can safely withstand the
permissible working pressure and the permissible
working temperature,
4 . 1 . 2 be manufactured of materials which
a) give the finished component the required
mechanical properties,
b ) are not dangerously corroded by the charge and
do not form any dangerous compounds with it
if the materials are exposed to the charge and
c) are corrosion-resistant, or protected against
corrosion if they are subject to corrosive effects,
4.1.3 are equipped with the fittings that are necessary to
safe operation and which safely fulfil their purpose.
I
4.2 Pipelines shall be laid and operated so that employ-
ees or third parties are not endangered.

Page 18 Pressure Vessel Order. Edition 01.97
5 Trials of pressure vessels, gas pressure ves-
sels, filling plants and pipelines
5.1 General provisions for carrying out the trials
During the trials the generally applicable safety
I regulations for normal operation shall be adhered
to the extent that the design of the pressure vessel,
gas pressure vessel, filling plant or pipeline permits.
Safety equipment designed for normal operation
shall be kept functional insofar as the necessary tri-
als and the nature of the pressure vessel, gas pres-
sure vessel, filling plant or pipeline make this pos-
sible. Danger areas in which only those required for
carrying out the trials may remain shall be specified
during the trials.
5.2 Programme
A written programme shall be drawn up for the tri-
als. It shall contain the individual stages of the pro-
. . .
.
gramme and the measures to be taken so that the ,I,
risks involved in the trials are kept to a minimum.
5.3 Control of the trials c
The appointee shall be an experienced and expert
person who will conduct and supervise the trials
responsibly and will be capable of taking the action
needed to avert hazards without delay should irre-
gularities or breakdowns occur.
5.4 Personnel
Only those persons may be entrusted with the trials
work who have reached their 18th birthday and are
familiar with the tasks allotted to them and with the
necessary safety measures, particularly where
safety devices have been by-passed or switched
off. If the work Involved in the trials calls for a parti-
cularly high level of vigilance the period of time
worked by the person entrusted with it shall be
limited.
.

Appendix II
(to Section 12)
Tests of specific pressure vessels
Externally situated heating or cooling apparatus
2. Internally situated heating or cooling pipes
3. Hydraulic pressure vessels
4. Pressure vessels with gas pockets in hydraulic pres-
sure plants
5. Pressure vessels in electrical switchgear and switch-
ing stations
6. Pressure-equalizing vessels for oil-pressure cables
and internal and external Gas-pressure cables
7. Compressed air vessels in rail and road vehicles
6. Pressure vessels on assembly and building sites
9. Air heaters and associated pressure vessels supplied
with compressed air from compressors with oil-lubri-
cated pressure chambers
10. Spray pressure vessels
11. Open vessels heated by steam jackets, for canning,
confectionery or meat products
12. Pressure vessels for sterilizing or steaming foodstuffs
or beverages
13. Storage containers for beverages
14. Pressure vessels in refrigeration plants and heat
pump installations
15. Pressure vessels that are exposed to dynamic stres-
ses
16. Sound attenuators
17. Pressure vessels with rapid-action closures
18. Pressure vessels for fire extinguishers and fire-extin-
guishing agent containers
19. Pressure vessels with cladding or masonry lining
20. Pressure vessels with internal fixtures
s
21. Pressure cushions
22. Stationary pressure vessels for granular or dusty
materials
1. Externally situated heating or cooling apparatus
(1) Recurrent tests may be dispensed with in the case
of externally situated heating or cooling pipes which
are used to heat or cool pressure vessels or open
vessels and are permanently connected to the vessel
jacket.
(2) In the case of externally situated heating or cool-
ing ducts which are used to heat or cool pressure ves-
sels or open vessels and are permanently connected
to the vessel jacket recurrent tests are only necessary
if the seams connecting the duct with the wall of the
vessel are not accessible for inspection.
2. Internally situated heating or cooling pipes
(1) Pressure tests shall also be carried out on inter-
nally situated heating or cooling pipes used to heat or
cool Group III and IV pressure vessels as part of the
tests specified for such pressure vessels.
(2) The authorized inspector shall carry out an initial
test, an acceptance test and recurrent tests with inter-
vals according to Section 10 para. 4 on internally situa-
Page 19 Pressure Vessel Order, Edition 01.97
,
1
ff;
23. Vehicle containers for liquid, granular or dusty materi-
als
24. Plate heat exchangers
25. Pressure vessels for non-corrosive gases or gas mix-
tures
26. Pressure vessels for gases or gas mixtures with oper-
ating temperatures below -10 “C :
1,
27. Pressure vessels for gases or gas mixtures in the
/.
liquid state
28. Combustion chambers, gas heaters or heat exchan-
gers for gas turbine plants
29. Rotating steam-heated cylinders
30. Pans for roasting limestone
31. Vulcanizing presses and moulds
32. Glass pressure vessels
33. Glass reinforced plastics pressure vessels
34. Pressure vessels at risk from stress corrosion
35. Dust filters in gas pipelines
36. Pressure vessels in test stands for rocket propulsion
units
37. Pressure vessels in heat exchange installations
38. Experimental autoclaves
39. Pressure vessels in isostatic presses
40. Heat accumulators and steam converters supplied
with water or steam
41. Steam accumulators in fireless locomotives
42. Pressure vessels in nuclear plants
43. Heating plates in corrugated cardboard production
plants .Z)
44. Water heating installations for drinking or industrial ,.
water
45. Housings for items of equipment
46. Pneumatic wine presses (diaphragm presses, hose
presses)
ted heating or cooling pipes without a primary head or
collector which are used to heat or cool pressure ves-
sels or open vessels if the product of the internal dia- .;
..
meter of the pipe in mm and the permissible working
pressure in bars exceeds the number 2000.
(3) Depending on the classification into test groups
according to Section 8 the authorized inspector or
expert shall carry out an initial test, an acceptance test
and recurrent tests on internally situated heating or
cooling pipes with a primary head or collector which
are used to heat or cool pressure vessels or open ves-
sels.
3. Hydraulic pressure vessels :.
(1) Recurrent pressure tests can be dispensed with :
for hydraulic pressure vessels
1. for water supply services (hydrophores) where the
product of the pressure and the cubic capacity is 1
2000 maximum and in which the working pressure
in normal operation is generated by the water
supply and the water content in normal operation 1
is at least 50% of the cubic capacity,
Page 20 Pressure Vessel Order. Edition 01.97
2. for pressure equalization in drinking water mains
systems or in pipe systems which carry water that
is comparable with drinking water from the point of
view of corrosion effects.
The recurrent internal tests shall be carried out when
the vessels are taken out of operation for repair pur-
poses, but every ten years at the most.
(2) With hydraulic pressure vessels in sprinkler
systems the recurrent pressure tests may be omitted
if the internal tests revealed no defects.
(3) Service tests and the installation test may be
omitted with hydraulic pressure vessels according to
para. 1 and those where the product of pressure and
cubic capacity exceeds 2000. The test of equipment
shall, however, be carried out
1. by the manufacturer or erector for type-approved
pressure vessels and pressure vessels where the
6. product of pressure and cubic capacity is 2000
maximum,
2. by the authorized inspector for pressure vessels
where the product of pressure and cubic capacity
exceeds 2000.
Pressure vessels with a gas pocket in hydraulic
pressure plants
(1) With Group IV pressure vessels with gas pockets
in hydraulic pressure plants, apart from pressure ves-
sels according to No. 5 para. 3, recurrent internal tests
need to be carried out only every ten years provided
the liquids or gases used have no corrosive effect on
the vessel walls.
(2) The recurrent tests may be omitted in the case of
oil intermediate containers in hydraulic oil control
systems.
(3) If pressure vessels in hydraulic pressure plants in
which the gas pocket is separated by a diaphragm or
bubble are replaced by equivalent pressure vessels
without modifying the equipment, the acceptance test
may be omitted provided a copy of the certificate on
the acceptance test for the pressure vessel that has
been replaced is attached to the documents for the
new pressure vessel.
Pressure vessels for electrical switchgear and
switching stations
(1) With Group IV compressed air vessels in electrical
switchgear and switching stations, the recurrent inter-
nal tests can be deferred until an overhaul is due; they
shall, however, be carried out at least every ten years
on main containers and at least every 15 years on
intermediate containers or those directly connected
with the switchgear. Notwithstanding sentence 1, Sec-
tion 10 para. 2 shall apply to compressed air contai-
ners directly connected with switchgear if they are
operated with dry air.
(2) The recurrent pressure tests may be omitted for
compressed air vessels according to para. 1. The
internal tests shall, however, be supplemented by
pressure tests if significant repairs have been carried
out or the internal tests are not sufficient to verify that
the vessel is in a safe operating condition.
(3) Recurrent tests may be omitted for storage contai-
ners for insulating and extinguishing substances and
Group IV hydraulic accumulators in electrical switch-
gear and switching stations if the pressure vessels are
charged with gases or liquids which exercise no corro-
sive effect on the container walls. Leak tests shall,
however, be carried out by the expert in accordance
with the safety requirements.
(4) For Group III and IV pressure vessels in highvol-
tage electrical switchgear and switching stations and
gas-insulated tubular busbars for electric power trans-
mission the initial test, acceptance test and, in the
case of Group IV vessels, the recurrent tests may be
carried out by experts when this electrical equipment ;;:.-
requires extinguishing or insulating agents under :i:
pressure in order to function and does not come under
paras. 1 to 3. The recurrent tests may be omitted if the
pressure vessels are charged with gases or gaseous
mixtures that have no corrosive effect on vessel walls;
leak tests shall, however, be carried out by the expert
in accordance with the safety requirements.
Pressure-equalizing vessels for oil-pressure cab-
les and internal and external gas-pressure cables
With pressure-equalizing vessels for oil-pressure cab-
les and internal and external gas-pressure cables the
pressure test, acceptance test and the recurrent tests
may be omitted provided a leak test is carried out by
the expert before these pressure vessels are put into
service.
I
Compressed air vessels in rail and road vehicles I
(1) The acceptance test and the recurrent tests may
be omitted for compressed air vessels in motor vehic-
les, apart from compressed air vessels for starting
internal combustion engines and for driving vehicles.
(2) The acceptance test may be omitted for com-
pressed air vessels in rail vehicles, apart from com-
pressed air vessels for starting combustion engines
and driving rail vehicles. Recurrent internal tests of
Group IV compressed air vessels need only be carried
out every ten years.
Pressure vessels on assembly and building sites
Compressed air vessels, hydraulic pressure vessels
and containers for mortar, gypsum and plaster on
assembly and building sites which change do not
require a new acceptance test after the place of instal-
lation has been changed provided that the pressure
vessels are equipped with an integral safety device to
protect against excess pressure.
Air heaters and associated pressure vessels
supplied with compressed air from compressors
with oil-lubricated pressure chambers
The authorized inspector shall carry out a test of self-
igniting deposits, particularly oil carbon, on air heaters
and associated pressure vessels supplied with com-
pressed air from compressors with oil-lubricated pres-
sure chambers after the first 500 operating hours. The
operator shall send a copy of the test report to the
supervisory authority.

10. Spray pressure vessels
(1) The authorized inspector shall carry out the initial
. test and acceptance test on spray pressure vessels for
cleaning agents, disinfectants, impregnating agents or
pesticides with a permissible working pressure in
excess of 1 bar and a cubic capacity in excess of
15 litres. Section 9 para. 5 shall apply as appropriate.
(2) The authorized inspector shall carry out recurrent
internal tests with intervals according to Section 10
para. 4 on Group III spray pressure vessels for impreg-
nating agents or pesticides.
11. Open vessels heated by a steam jacket for
canning, confectionery or meat products
The authorized inspector shall carry out the initial test,
acceptance test and recurrent pressure tests and
external tests on the steam jackets of open cooking
vessels for cans, confectionery and meat products
where damage to the walls of the vessel can be antici-
pated for operational reasons and which have a per-
missible working pressure in excess of 1 bar, regard-
less of the capacity of the pressure chamber. Sec-
tion 10 para. 4 shall apply as appropriate to the pres-
sure tests and external tests.
12. Pressure vessels for sterilizing or steaming
foodstuffs or beverages
(1) The authorized inspector shall carry out the recur-
rent tests with intervals according to Section 10
para. 4 on Group Ill pressure vessels for sterilizing or
steaming foodstuffs or beverages.
(2) The recurrent tests may be omitted for pressure
vessels according to para. 1 whose pressure cham-
bers are sealed by a column of water. Recurrent inter-
nal tests only need be carried out every ten years.
(3) The recurrent tests may be omitted for pressure
vessels for steaming in continuous operation, the
pressure chambers of which are sealed by special
devices such as cellular wheel sluices.
13. Storage containers for beverages
(1) The recurrent tests may be omitted for pressure
vessels used for the storage of beverages provided
the expert examines them at least once a year for
visible damage. If the expert finds damage to parts
subject to pressure stress or if they are repaired, how-
ever, internal tests and pressure tests shall be carried
out, by the authorized inspector in the case of
Group IV pressure vessels.
(2) Items of equipment in pressure vessels according
to para. 1 which are filled, emptied or sterilized under
pressure shall be tested initially and recurrently every
five years, by the authorized inspector if the permis-
sible working pressure exceeds 1 bar and by the
expert in other cases.
14. Pressure vessels in refrigerating plants and heat
pump installations
(1) Recurrent tests may be omitted for pressure ves-
sels which are operated with the use of refrigerants in
a closed circuit. If such a pressure vessel is taken out
of service for overhaul, internal examinations and
pressure tests shall be carried out.
(2) Notwithstanding para. 1, every two years the
authorized inspector shall carry out an external test
Page 21 Pressure Vessel Order, Edition 01.97
and a corrosion damage test on those wall sections of
fire- and waste gas- heated pressure vessels of
Group IV that are subject to smoke and waste gas.
The test of the wall sections affected by smoke and
waste gas may be omitted if corrosion is unlikely
because of the fuel used and the mode of operation.
15. Pressure vessels subject to dynamic loads
(1) Pressure vessels for which the number of permis-
sible changes of load (stress reversals) is specified
shall undergo an internal test when half the specified
number of stress cycles has been completed at the
latest.
(2) If the internal test shows that there are no cracks,
the next internal test shall be carried out after the
period specified according to Section 10 para. 4 but
after the specified number of stress cycles has been
completed at the latest.
16. Sound attenuators
(1) Recurrent internal examinations may be omitted
in the case of sound attenuators which are fined into
pipelines,
(2) The initial pressure test, acceptance test and
recurrent tests may be omitted in the case of sound
attenuators connected to the atmosphere.
17. Pressure vessels with rapid-action closures
The authorized inspector shall carry out external exa-
minations of rapid-action closures of Group IV pres-
sure vessels every two years.
18. Pressure vessels for fire extinguishers and
vessels for fire extinguishing agents
(1) In the case of pressure vessels for fire extinguis-
hers which are pressurized only at the time of use and
of stationary vessels for carbonic acid or halon for fire-
extinguishing purposes, recurrent tests may be
carried out when the interval between tests has
expired only if the vessels are refilled. In the case of
vessels for powdered extinguishing agents recurrent
pressure tests may be omitted if no defects have been
found during the internal examinations. *
(2) The authorized inspector only needs to carry out
the initial test and acceptance test on extinguishing
agent containers of portable charging extinguishers if
the permissible working pressure is more than 1 bar
and the product of pressure and cubic capacity
exceeds 300.
1 9 . Pressurevessels with cladding or masonry lining
(1) Recurrent pressure tests of pressure vessels with
cladding may be omitted if no damage to the cladding
was found during the internal examinations.
(2) Pressure vessels according to para. 1 shall be
examined by the expert at such intervals of time as are
necessary for operational safety in addition to the spe-
cified tests by the authorized inspector. A book on the
tests shall be kept.
(3) Recurrent tests of pressure vessels with cladding
may be omitted. Internal examinations shall, however,
be carried out if
1. areas of masonry measuring 1 sq. m or more have
been removed,
2. walls are exposed or
Page 22 Pressure Vessel Order, Edition 01.97
3. corrosion or damage to the walls of the vessel has been
found.
Internal examination and a pressure test shall also be
carried out if the lining’has been completely removed.
(4) In the case of pressure vessels with a lining which
is used only to protect the walls against chemical
action, the lining and accessible parts of the walls shall
be regularly examined for damage by the expert. The
intervals between such examinations shall be deter-
mined from operational experience. In the case of cel-
lulose digesters and wood steamers with a lining, the
examination according to sentence 1 shall be carried
out every four weeks. A book shall be kept about the
examinations.
(5) In the case of pressure vessels which have a
cavity between the cladding and the jacket which is
tested at the works in respect of the leak-tightness of
the cladding, the recurrent tests may be omitted pro-
vided that the authorized inspector has examined the
equipment for its suitability and reliability. A book shall
be kept about the cavity tests. If, at the end of the peri-
ods according to Section 10 para. 4 and as part of
overhaul work, a Group IVvessel of this kind is opened
so that it is accessible for internal testing this test shall
be carried out.
20. Pressure vessels with internal fixtures
Internal examinations need only be carried out every
ten years on Group IV pressure vessels with internal
fixtures where there is no expectation of damage such
as is caused by corrosion and where the internal
examination of all parts of the wall is either not possible
or possible only with great difficulty, provided no
defects are found during the first recurrent internal
examination after five years.
21. Pressure cushions
(1) The authorized inspector shall carry out the initial
test, acceptance test and recurrent tests on pressure
cushions used as lifting devices if the permissible
working pressure exceeds 0,5 bars and the product of
pressure and cubic capacity exceeds 200. Section 9
para. 5 shall apply as appropriate.
(2) The recurrent tests on Group IV pressure cushi-
ons used as devices for protection during transporta-
tion may be carried out by the expert.
(3) Pressure cushions may only be filled with the aid
of filling devices which have undergone an accept-
ance test by an authorized inspector and recurrent
external tests every two years by an expert. Section 9
para. 5 sentence 2 shall apply as appropriate.
(4) Pressure cushions need not undergo the installa-
tion test.
22. Stationary pressure vessels for granular or dusty
materials
Recurrent pressure tests may be omitted in the case
of stationary pressure vessels for granular or dusty
materials.
23. Vehicle containers for liquid, granular or dusty
materials
(1) Vehicle containers for liquid, granular or dusty
materials with no integral safety devices may be filled
or emptied under gas pressure only if the necessary
safety devices are fitted to the connection points and I’
have been tested by the authorized inspector initially I
and recurrently every five years.
(2) The acceptance test may be dispensed with in the
case of vehicle containers according to para. 1 with no
integral safety devices. The periods between recur-
rent tests shall then be calculated from the date of the
initial pressure test.
(3) The recurrent pressure tests may be dispensed
with in the case of vehicle containers for granular or
dusty materials.
(4) The authorized inspector shall carry out external
examinations of Group IV road vehicle containers for
liquid, granular or dusty materials every two years.
24. Plate heat exchangers
(1) In the case of plate heat exchangers which consist
of detachable connected plates and have a permis-
sible working pressure in excess of 1 bar, the autho-
.,ii
rized inspector shall carry out a preliminary test of
those parts of the exchanger that are subject to pres-
sure regardless of the value of the product of pressure
and cubic capacity; the structural test, pressure test,
acceptance test and recurrent tests may be omitted.
(2) The pressure test by the manufacturer, the
acceptance test and the recurrent tests by the expert
may be omitted in the case of plate heat exchangers
which consist of detachable connected plates and
I
have a permissible working pressure that does not
exceed 1 bar.
25. Pressure vessels for non-corrosive gases or gas
mixtures
(1) The authorized inspector need onlycarryout inter-
nal tests every ten years on Group IV pressure vessels
which are not covered with soil and are for gases or
gas mixtures which have no corrosive effect on the
wall of the vessel.
(2) In the case of pressure vessels according to
para. 1, the pressure-bearing wails of which neither
wholly nor partly consist of high-strength close-
grained structural steels, the recurrent pressure tests
may be omitted if the acceptance test was no more
than ten years ago or if no defects were found during
the last internal test that was carried out.
(3) The expert shall carry out external examinations
every two years on pressure vessels for combustible
gases or gas mixtures in the liquid state which have
no corrosive effect on the vessel walls. The authorized
inspector shall carry out external examinations every
two years on heated pressure vessels whose purpose
is the storage of combustible gases or gas mixtures
in the liquid state which have no corrosive effect on the
vessel walls.
(4) In the case of pressure vessels according to
para. 1 which are used as high pressure storage con-
tainers for the public gas supply, the periods between
recurrent internal tests and pressure tests may be up
to fifteen years provided non-destructive tests are
carried out externally every two years by the autho-
rized inspector and no defects are found during them.
(5) In the recurrent testing of pressure vessels
according to para. 1, the inspection of the internal
walls may be omitted if the vessels:

1. are solely used to store propane, butane or mixtu-
res of these which have a standard degree of purity
2. have no internal fittings, e.g. heating or reinforce-
ment rings and
3. have a capacity not exceeding 3 t.
(6) In the recurrent testing of pressure vessels
according to para. 4, the inspection of the internal
walls may be omitted on consultation with the autho-
rized inspector if the vessel is not subject to any parti-
cular stress (e.g. through its installation) or other sui-
table test methods are used.
(7) Group IV soil-covered pressure vessels for gases
or gas mixtures which do not have a corrosive effect
on the vessel walls shall be regarded as equivalent to
the pressure vessels according to para. 1 if they have
particularly effective protection against chemical and
mechanical attack, e.g. :
- bitumen cladding and additional cathodic corrosion
protection
- are designed as pressure vessels with an additional
outer container made of steel and have a cavity that
is monitored for leaks or
- are coated with an outer coating of epoxide or unsa-
turated polyester resin materials so that they will
withstand the stresses that can be anticipated in
proper use.
The special protective measures according to sen-
tence 1 shall be incorporated in the acceptance test.
The efficacy of the cathodic corrosion protection shall
be tested by an expert in the first year of operation. The
function of the cathodic corrosion protection and leak-
monitoring equipment shall be tested as part of the
external tests according to para. 3. An authorized
inspector shall test cathodic corrosion protection
equipment with external current every four years.
(8) The external tests of electrically heated Group IV
pressure vessels for carbonic acid may be carried out
by the expert.
26. Pressure vessels for gas or gas mixtures with
operating temperatures below -10 “C
(1) On pressure vessels for gases or gas mixtures,
the operating temperatures of which are continuously
kept below -10 “C, the initial test and acceptance test
shall be carried out by the authorized inspector if the
product of the pressure and cubic capacity exceeds
200 and the permissible working pressure exceeds
0,l bars. Section 9 para. 5 shall apply as appropriate.
(2) On pressure vessels according to para. 1, recur-
rent internal tests and recurrent pressure tests shall be
carried out by the authorized inspector if a pressure
vessel, the product of the pressure and cubic capacity
of which exceeds 1000, is taken out of service for over-
haul, even if the permissible working pressure is less
than 1 bar.
(3) With pressure vessels according to para. 1 which
are vacuum-insulated the acceptance test shall only
cover the internal vessel.
. (4) The expert shall carry out external examinations
on pressure vessels according to para. 1 for combu-
stible gases or gas mixtures in the liquid state every
two years.
Page 23 Pressure Vessel Order. Edition 01.97
/ .I
I<<;:
(5) The expert may carry out the external tests of elec- : -:
j...:
trically heated Group IV pressure vessels for carbonic
acid.
;.
2 7 . Pressure vessels for gases or gas mixtures in the
liquid state
(1) The authorized inspector shall carry out external
examinations on pressure vessels for combustible
gases or gas mixtures in the liquid state which have
a corrosive effect on the vessel walls every two years.
(2) In the case of pressure vessels for gases or gas
mixtures in the liquid state which are removed from
their place of installation for recurrent testing purposes
and are then installed elsewhere when these tests are
completed, the new acceptance test may be omitted
provided the vessel’s connections and equipment
parts have not been changed, an acceptance test of
a similar pressure vessel has already been carried out
at the new place of installation and a photocopy of the
results of the acceptance test of the replaced pressure
vessel is attached to the test book.
(3) The authorized inspector shall carry out the initial
test and acceptance test of pressure vessels for gases
or gas mixtures in the liquid state which are not kept
or stored at ambient temperatures if the product of the
pressure and cubic capacity exceeds 200 and the per-
missible working pressure exceeds 0,l bars.
(4) The authorized inspector shall carry out recurrent
internal tests and recurrent pressure tests on pressure
vessels according to para. 3 if the product of the pres-
sure and cubic capacity exceeds 1000, even if the per-
missible working pressure is less than 1 bar.
28. Combustion chambers, gas heaters and heat
exchangers of gas turbine plants
(1) The expert may carry out the initial test and
acceptance test of Group III and IV combustion cham-
bers of gas turbine plants.
(2) For gas heaters and heat exchangers of gas tur-
bine plants the intervals between recurrent tests may
be extended up to the next shutdown of the gas turbine
plant.
(3) The recurrent tests of gas turbine plant combus-
tion chambers may be omitted provided the efficiency
of the thermal protection for the walls is continuously
monitored by experts by means of temperature mea-
surements at suitable points. If the temperature mea-
surements show that the permissible working tem-
perature has been exceeded the expert shall verify
whether the combustion chamber may continue to be
operated safely.
29. Rotating steam-heated cylinders
Recurrent pressure tests may be carried out on rotat-
ing steam-heated cylinders only if the cylinders are
dismantled from the machine frame.
30. Pans for roasting limestone
(1) The recurrent internal tests of Group IV limestone
roasting pans shall be carried out every two years.
(2) Every year the authorized inspector shall carry out
a surface crack test on the repaired areas of repaired
limestone roasting pans that are patched.
Page 24 Pressure Vessel Order, Edition 01.97
(3) The surface crack test according to para. 2 shall
be carried out for the fist time no more than six months
after the repair was carried out where there are pat-
ches that are more than 400 mm long in the longitudi-
nal direction.
(4) The tests according to para. 2 may be omitted if
no defects are found after the repaired areas have
been tested five time.
3 1 . Vulcanising presses and moulds
(1) Recurrent pressure tests on vulcanising presses
and moulds for the manufacture and remoulding of
vehicle tyres and inner tubes may be omitted provided
that no defects have been found during the internal
tests.
(2) The authorized inspector shall carry out the initial
test, acceptance test and recurrent tests on vulcanis-
ing presses and moulds according to para. 1 but with
their own steam generation equipment, regardless of
their size.
3 2 . Pressure vessels made of glass
(1) The structural test of pressure vessels made of
glass, other than experimental autoclaves according
to No. 38, shall be carried out by the expert. The pres-
sure test may be omitted in the case of pressure ves-
sels according to sentence 1. Instead they shall be
visually inspected by the expert to ensure that the
walls are free from defects and the wall thickness has
been maintained and by photoelastic methods to
ensure that they are adequately free from internal
stresses.
(2) The recurrent tests of pressure vessels according
to para. 1 may be omitted. If the vessels are subject
to the effects of abrasive media the expert shall mea-
sure the wall thickness at intervals to be determined
according to the working stresses.
(3) The expert shall carry out a leak test of pressure
vessels made of glass before their initial entry into ser-
vice.
33. Pressure vessels made of glass-reinforced
plastics
The authorized inspector shall carry out recurrent
tests on Group Ill pressure vessels made of glass rein-
forced plastics; in addition he shall carry out special
tests which include inspection of the pressure-bearing
wall from the outside on Group IV ones every two
years.
3 4 . Pressure vessels at risk from stress corrosion
In the case of Group IV and VII pressure vessels which
are at risk from stress corrosion, reduced intervals
between recurrent internal tests shall be laid down by
agreement with the authorized inspector at the time of
the acceptance test. The recurrent internal tests may
be replaced by nondestructive external tests if non-
destructive tests to the extent necessary to replace the
internal test were carried out at the time of the initial
test or an internal test.
3 5 . Dust filters in gas pipelines
In the case of Group Ill and IV dust filters in gas pipeli-
nes, other than cyclone filters, the acceptance test
and, in the case of Group IV dust filters the recurrent
tests also, by the authorized inspector may be omitted.
3 6 . Pressure vessels in test stands for rocket
propulsion units
(1) The recurrent tests on Group IV transport, mixing L
and storage containers in test stands for rocket propul-
!
sion units may be carried out by the expert.
(2) The acceptance test and recurrent tests on Group
Ill and IV operational and calibration vessels in test
stands for rocket propulsion units may be carried out
by the expert.
3 7 . Pressure vessels in heat exchange installations
(1) The authorized inspector shall carryoutthefollow-
ing tests on pressure vessels in heat exchange instal-
lations in which organic liquids are heated or in which
such liquids or their vapours are used for heat emis-
sion:
1. an initial test and an acceptance test when the pro-
duct of pressure and cubic capacity exceeds 100
2. recurrent tests if the product of pressure and cubic
capacity exceeds 500.
(2) Heat exchange installations according to para. 1
and pans of such installations may only be put into
operation for the first time following a repair or major
modification if the expert has tested them for leaks.
(3) Heat exchange installations according to para. 1
may only be operated if an expert has tested the heat
transfer medium for continued serviceability as
required and in any case at least once a year.
3 8 . Experimental autoclaves
(1) The authorized inspector shall carry out the initial
test and recurrent tests on experimental autoclaves if
the product of pressure and cubic capacity exceeds
100. The acceptance test and recurrent external tests
may be omitted.
(2) The expert shall test experimental autoclaves
every time they are used.
(3) Notwithstanding para. 1 the pre-commissioning
pressure test shall be omitted in the case of glass
autoclaves. Instead they shall be inspected visually to
ensure that the walls are free from defects and the wall
thickness is maintained and by photoelastic methods
to ensure adequate freedom from internal stresses.
3 9 . Pressure vessels of isostatic presses
(1) The authorized inspector shall carry out the initial
test and acceptance test of pressure vessels of isosta-
tic presses regardless of the product of pressure and
cubic capacity.
(2) As part of the initial test the authorized inspector
shall also verify the stress reversals specified by the
manufacturer and shall, in agreement with the manu-
facturer, specify the areas subject to special attention
in the structural test and recurrent tests and the test
methods to be used.
(3) The authorized inspector shall carry out external
tests at the same time as the internal ones and they
shall also include a functional test of the equipment
parts.

40. Heat accumulators and steam converters
supplied with water or steam
In the case of heat accumulators and steam conver-
ters which are supplied with water or steam the inter-
vals between recurrent internal tests shall be two
years if
1. the product of the cubic capacity in litres and the
steam pressure in bars arising at the permissible
working temperature exceeds 100 000 and
2. the heat accumulators or steam converters are
subject to a varying stress in operation or
3. the internal fixtures can be expected to vibrate
when the heat exchangers or steam converters are
in operation.
41. Steam accumulators in fireless locomotives
Steam accumulators in fireless locomotives may only
be operated if an acceptance test and an external test
that recurs every two years has been carried out by
the authorized inspector at the filling stations.
42. Pressure vessels in nuclear plants
(1) The initial test, acceptance test and recurrent tests
shall be carried out by the authorized inspector on
pressure vessels - regardless of their permissible
working pressure and cubic capacity - other than
pressure vessels in which the pressure only arises
from the weight of a column of liquid and other than
pipelines.
(2) The preliminary test, structural test, liquid level
test and acceptance test as well as recurrent internal
tests and liquid level tests shall be carried out by the
. authorized inspector on pressure vessels in which
pressure arises only from the weight of a column of
liquid. In the case of the liquid level test the pressure
. vessel shall be filled with water to the height of the
venting device.
(3) The initial test and acceptance test shall be carried
out by the authorized inspector on items of pressure
vessel equipment with nominal widths z 80 mm if the
product of the permissible working pressure in bars
and nominal width in mm exceeds 5000. The autho-
rized inspector shall also carry out a test for leaks in
the housing every five years.
43. Heating plates in corrugated cardboard
production plants
Recurrent pressure tests on heating plates in corru-
gated cardboard production plants need only be
carried out when the plates are removed from the
machine frame. Internal tests shall be omitted.
.
Page 25 Pressure Vessel Order, Edition 01.97
44. Water heating installations for drinking or
industrial water
The expert may carry out the acceptance test and
recurrent tests on pressure chambers used to heat
enclosed water chambers in water heating installa-
tions with a permissible heating agent operating tem-
perature of 120 “C maximum. Recurrent tests shall be
carried out every year if heat carrier media contain
substances or products which have hazardous pro-
perties within the meaning of Section 3 No. 3 of the
Chemikaliengesetz (Chemicals Act), with the excep-
tion of irritant or low-toxicity properties. Otherwise
Section 10 para. 2 shall apply as appropriate.
45. Housings for items of equipment
(1) The manufacturer shall subject pressure bearing
housings of fittings and similar devices that are used
as equipment parts of pressure vessels or pipelines to
a pressure test and a leak test if required.
(2) The authorized inspector shall carry out initial
tests on housings according to para. 1 with a permis-
sible working pressure in excess of 1 bar if the product
of pressure and cubic capacity of the housing exceeds
200. The tests according to sentence 1 may be omitted
if the pressure vessels or pipelines are not subject to
any pre-commissioning tests by authorized inspectors
or the test by authorized inspectors according to
Appendix Il.
(3) The tests according to para. 2 sentence 1 may
also be omitted if the pressure chamber of the housing
meets the reauirements of Section 2 oara. 1 No. 9 or
Section 8 para 1 Group 1.
(4) Section 9 para. 5 shall apply as appropriate.
(5) Housings according to para. 1 shall be tested by
the authorized inspector or expert to the required
extent as part of the recurrent test of the pressure ves-
sel or pipeline.
46. Pneumatic wine presses (diaphragm presses,
hose presses)
(1) The recurrent tests of pressure vessels for press-
ing grapes may be omitted provided that the expert
tests them for visible damage at least once a year. If
the expert finds damage to parts subject to pressure
or if repair work is undertaken, however, internal tests
and pressure tests shall be carried out - by the autho-
rized inspector in the case of Group Ill and IV pressure
vessels.
(2) Equipment parts of pressure vessels according to
para. 1 shall be tested initially and then every five
years; the authorized inspector shall test Group IV
pressure vessels, the expert other categories.
Page 26 Pressure Vessel Order, Edition 01.97
-

General Administrative Regulation

superseding General Administrative Regulation for Order
: in accordance with Section 24 of the Industrial Code .

dated 27 February 1980 - Federal Gazette No. 43 of 1 March 1980

The following General Administrative Regulation is issued in accordance with Article 84 para. 2 of the Basic Law and
with the approval of the Federal Council.
Article 2
The General Administrative Regulation on Section 14 para. 2, Section 17 para. 4, Sections 18 and 19 of the Order on
Movable Vessels and on Filling Plants for Pressure Gases of 20 June 1968 (Federal Gazette No. 118 of 29 June 1968)
is replaced by the following version.

General Administrative Regulation

to the Pressure Vessel Order

Section 1 Section 3
If the competent authority carries out a test to see whether If the manufacturer of a pressure vessel or gas pressure
a pressure vessel complies with the requirements of Sec- vessel from another Member State wishes to have a test
tion 4 para. 1 of the Pressure Vessel Order it shall generally carried out as provided for in Article 22 of Council Directive
proceed on the basis that such requirements are met if the No. 76/767/EEC of 27 July 1976 on the harmonization of
pressure vessel complies with the Technical Regulations the statutory regulations of Member States on joint regula-
determined by the “Pressure Vessels” Technical Commit- tions for pressure vessels and methods of testing them
tee at the Zentralstelle fur Unfallverhutung und Arbeits- (EEC Labour Gazette No. L 262 p. 153) the competent
medizin (Central Office for Accident Prevention and Indus- authority (administration of destination) shall take as repro-
trial Medicine) of the Hauptverband der gewerblichen duced in the appendix to this general administrative regula-
Berufsgenossenschaften (Federation of Employer’s Liabi- tion.
lity Insurance Associations) and published by the Federal
Minister of Labour and Social Order in the Federal Labour Appendix
Gazette. Definitions
State of origin: the Member State in which a pressure ves- . ’
Section 2 sel is manufactured.
(1) If the competent authority carries out a test to see whe- State of destination: the Member State into which a pres-
ther a gas pressure vessel or filling plant complies with the sure vessel is to be imported, marketed and/or put into ser-
requirements of Section 4 para. 1 of the Pressure Vessel vice.
Order it shall generally proceed on the basis that such Administration of origin: the competent administrative
requirements are met if a gas pressure vessel or filling authorities of the state of origin.
plant complies with the Technical Regulations determined Administration of destination: the competent administra- i
*I
by the German Pressure Vessels Committee and pub- tive authorities of the state of destination.
lished by the Federal Minister of Labour and Social Order
in the Federal Labour Gazette. Procedure i.

(2) If no Technical Regulations according to para. 1 exist 1. A manufacturer or his authorized agent who wishes
the competent authority shall initially take into considera- to export a pressure vessel or a number of pressure
:.
tion the Technical Principles as listed below, published by vessels of the same design shall apply to the admi-
the Federal Minister of Labour and Social Order in the nistration of destination in accordance with Article
supplement to No. 3/l 970 of the Federal Labour Gazette, 22, either directly or through the importer in the ,
Technical Supplement on Industrial Safety: state of destination, for permission for the tests to
be carried out in accordance with the procedure 1
No. 12 para. 3 and 4 No. 39 applicable in the state of destination, by a test cen- :-
No. 14 No. 45 para. 1 and 2 tre that is not a test centre of the state of destination.
No. 19 para. 1 a n d 2 No. 46 para. 2 :
No. 20 para. 1, 2, 3a, b and d No. 56 The manufacturer or his authorized agent shall
No. 21 No. 57 name the test centre they have selected in their
No. 22 No. 58 application. The test centre shall be selected from
No. 23 para. 1, 2 and 3a No. 61 para. 2 and 3 the list provided by the state of origin in accordance
No. 24 No. 62 with Article 13. If the pressure vessels in question
No. 25 para. 1 No. 63 para. 2 t o 5 are ones of which very few have been manufac-
No. 26 para. 1 and 2 No. 64 para. 1 t o 7 tured as a result of one order or if they are for a
No. 31 para. 2 and 3a No. 66 complicated installation and have been manufac-
No. 32 No. 67 tured to a specification provided by the customer or
No. 33 No. 68 a design bureau nominated by him, then notwith-
No. 35 No. 69 standing this procedure the customer in the state
No. 38 para. 3 No. 70 of origin shall select the test centre - according to

the list within the meaning of Article 13 if applicable
- subject to approval from the administration of
destination.
The administration of destination shall inform the
administration of origin of its decisions in this
respect.
The name of the customer or importer shall be indi-
cated in the application when known.
Enclosed with the application shall be documents
which include the detailed drawings and calcula-
tions for the pressure vessel or pressure vessel
type as well as details of the materials used, the
manufacturing methods employed, the test
methods employed during manufacture and all
other details which, in the opinion of the manufactu-
rer or his authorized agent, are of use in enabling
the administration of destination to determine whe-
ther the pressure vessel or the pressure vessels of
one type which are manufactured according to the
design drawing comply with the pressure vessel
regulations that apply in the state of destination.
These documents shall be enclosed in quadrupli-
cate in the language or languages of the state of
destination or in another language approved by that
state.
2 No. 2.2.1 shall continue but with the time period
2.1 The administration of destination shall acknow-
ledge receipt of the documents as soon as it recei-
ves them.
2.2
2.2.1 If the administration of destination is of the opinion
that the documents received include all the informa-
tion necessary for assessment in respect of the
requirements listed under No. 1 it shall be allowed
a period of three months following receipt of the
documents to verify the essential content of the
information contained therein.
2.2.2 If the administration of destination is of the opinion
that the documents received do not include all the
information required for assessment in respect of
the requirements listed in No. 1 it shall be allowed
a period of one month following receipt of the docu-
ments to notify the applicant of the way in which the
documentary information can be improved in this
respect. Following receipt of the documents that
have been supplemented in accordance with these
particulars the procedure shall continue as in
No. 2.2.1.
2.3
2.3.1 If the verification of the essential content of the
documents shows that the pressure vessel or pres-
sure vessels of one type manufactured or to be
manufactured in conformity with the documents
submitted comply with the pressure vessel regula-
tions in force in the state of destination or can be
accepted notwithstanding such regulations then
the administration of destination shall notify the
applicant of this within the period specified in 2.2.1.
. If the pressure vessel or pressure vessels of one
type which are the subject of the application are not
subject to any regulations in the state of destination
. then the administration of destination may require
Page 27 Pressure Vessel Order, Edition 01.97
them to comply with the pressure vessel regula-
tions in force in the state of origin in respect of the
vessels concerned.
2.3.2 If the verification of the essential content of the
documents shows that the pressure vessel or pres-
sure vessels of one type manufactured or to be
manufactured in conformity with the documents
submitted do not comply with the pressure vessel
regulations in force in the state of destination and
that there can be no departure from these regula-
tions in the case of such pressure vessels then the
administration of destination shall notify the appli-
cant of this within the period specified in No. 2.2.1
and advise which regulations have not been comp-
lied with and which should be complied with so that
the pressure vessel or pressure vessel of one type
can be accepted. In this respect it shall indicate
which design rules and tests are necessary under
the regulations applicable to pressure vessels in
the state of destination.
If the applicant is prepared to carry out all the modi-
fications relating to the design, manufacture and/or
procedures for the testing of the pressure vessel or
pressure vessels of one type so that the stated con-
ditions can be complied with he shall amend his
documents accordingly. Following receipt of the
amended documents the procedure according to
reduced to two months.
2 . 3 . 3 The criteria applied by the administration of desti-
nation in respect of the approval or refusal of the
deviations mentioned in No. 2.3.1 and 2.3.2 shall
be the same as those which the manufacturers in
the state of destination take as a basis.
2.4 The fees, expenses or other costs of verifying the
documents shall be calculated in accordance with
the regulations in force in the state of destination.
3 The test centre selected according to No. 1 shall
take the action requested of it by the administration
of destination.
4 After it has carried out the tests required by the
administration of destination and if it has found that
the results are satisfactory the test centre shall
supply the manufacturer or his authorized agent,
and the administration of destination, with the
reports of these tests and issue them with certifica-
tes to the effect that the test procedures and results
obtained comply with the requirements laid down
by the state of destination.
If the results of the tests are not satisfactory the test
centre shall notify the applicant and the administra-
tion of destination accordingly.
These documents shall be in the language of the
state of destination or another language approved
by that state.
5 The fees, expenses or reimbursements forthe tests
shall be calculated in accordance with the regula-
tion in force at the test centre.
6 The administration of destination shall preserve the
confidential nature of every design drawing or
document submitted to it.
Page 29 Pressure Vessel Order, Edition 01.97
Order
on the Equipment Safety Law and on the Amendment and
to the Pressure Vessel Order
Dated 25 June 1992 (Federal Gazette I p. 1171) amended by the second Order for amendment of the Equipment Safety
Law of 26 August 1992 (Federal Gazette I p. 1564) by the Law for the Implementation of Agreement of 2 May 1992
on the European Economic Area (EEA - Implementation Law) of 27 April 1993 (Federal Gazette I p. 512) and by the
Order on the Equipment Safety Law and for amendment of Order on the Equipment Safety Law of 12 May 1993 (Federal
Gazenel p. 704).
Pursuant to Article 24 of the Trade, and Industrial Code
(Gewerbeordnung) as announced on 1 January 1987
(Federal Gazette I p. 425) in the form of this latest amend-
ment by the Law of 9 November 1990 (Federal Gazette I
p. 2442), the Federal Government hereby orders, after
conferring with the interested parties and, pursuant to Sec-
tion 4 Para. 1, Number 1 of the Equipment Safety Law of
24 June 1968 (Federal Gazette I p.717), and the Federal
Minister for Labour and Social Affairs, after conferring with
the Committee for Technical Working Equipment in Agree-
ment with the Federal Minister for Economics, hereby
orders
Article 1
Sixth Order
on the Equipment Safety Law
(Order for the Entry into Service of
Simple Pressure Vessels - 6. GSGV)
of 25 June 1992 (Federal Gazette I p. 1171)
as amended to 28 September 1995
(Federal Gazette I p. 1213)
Section 1
Scope
(1) This Order applies to the entry into service of simple
pressure vessels.
(2) Simple pressure vessels within the meaning of this
Order are series-produced welded vessels
1. which are not subjected to an internal gauge pressure
exceeding OS bar
2. are designed to take air or nitrogen,
3. are not exposed to the effects of flame,
4. whose pressurized components and connections are
either manufactured from unalloyed quality steel or
unalloyed aluminium or non-age hardening aluminium
alloys,
5. which are either formed by means of
a) a cylindrical part of round cross section, sealed
externally by either dished or flat ends, whereby the
axis of rotation of these ends corresponds to that of
the cylindrical part, or
b ) by two dished ends with the same axis of rotation,
6. whose maximum operating pressure does not exceed
30 bar and for which the product of this pressure and
the capacity of the vessel (product of internal pressure
PS x V) does not exceed 10000 bar x I,
7. whose lowest operating temperature is not below
-50 “C and
8. whose maximum operating temperature in the case of
steel vessels does not exceed 300 “C or 100 “C for alu-
minium or aluminium alloy vessels.
I
(3) This Order shall not apply to:
vessels designed exclusively for use in nuclear engi-
neering and where damage could result in the release
of radioactive substances;
vessels intended solely for the equipping or operation
jt
of waterborne craft or aircraft; I-
fire extinguishers.
Section 2
Safety requirements
(1) Simple pressure vessels whose product of pressure
and cubic capacrty PS x V does not exceed 50 bars x I,
may only be brought into service if they comply with the
essential safety requirements in Appendix I of Council
Directive 871404:EEC dated 25 June 1987 on the approxi-
mation of the laws of Member States for simple pressure
vessels (EEC Official Journal No. L 220 p. 48. corrected
by EEC Official Journal No. L 31 p. 46) as amended by
Council Directive 901488iEEC dated 17 September 1990
(EEC Official Journal No. L 270 p. 25) and Council Direc-
tive 93168iEEC dated 22 July 1993 (EEC Official Journal
No. L 220 p. 1) and, when correctly installed and serviced
and operated in accordance with the regulations, do not
endanger the safety of operators or third parties or of L
domestic animals and property.
(2) Simple pressure vessels whose product of pressure
and cubic capacity PS x V does not exceed 50 bar x I may
only be brought into service if they comply with the require-
ments which correspond to the rules of technology gener-
ally recognised by a Member State of the European Com-
munities or other Contracting State of the Agreement on
the European Economic Area.
Section 3
Condition for bringing into service
(1) When a vessel named in Section 2 para. 1 is brought
into service, the simple pressure vessel shall be provided
with the details in accordance with Appendix II No. 1 of
Council Directive 87/404iEEC and the CE mark, by means
of which the manufacturer or agent established in the Com-
F”
munity or in another Contracting State of the Agreement (’
on the European Economic Area confirms that the require-
1
ments of Para. 3 and 4 are complied with and that he has
met his obligations towards the approved body.
(2) If the simple pressure vessel is also subject to other
legal regulations, which the CE mark stipulates, it is also
confirmed by the CE mark that the simple pressure vessel
also meets the requirements of these other valid legal
regulations. If, however, in accordance with one or more
of these legal regulations, the choice of regulation to be
used is left open to the manufacturer during a transitional
period, the CE marking in this case merely confirms that
the simple pressure vessel complies with the legal regula-
tions applied by the manufacturer in accordance with sen-
I-.-..
‘ . _
tence 1. In these cases, the operating instruction in accord-
ance with Section 5 shall contain the Community Guide-
. lines on which the legal regulations applied are based, giv-
ing their publication in the Official Journal of the European
Communities.
(3) The simple pressure vessel shall comply with the type
model for which one of the approved bodies has certified,
after performing an EC-type test in accordance with Artic-
le 10 of the said Directive, that the type of the vessel comp-
lies with the requirements of the Directive. Instead of the
procedure in accordance with sentence 1, for series-pro-
duced simple pressure vessels which completely comply
with the harmonized European Standards, whose source
has been announced by the Federal Minister for Labour
and Social Affairs in the Federal Gazette, one of the
approved bodies can certify the suitability of the technical
construction file in accordance with Annex II No. 3 of the
Directive.
(4) The simple pressure vessel shall be subjected to EC
verification in accordance with Article 11 of Council Direc-
tive 87/404/EEC if the product of pressure and cubic capa-
city PS x V exceeds 3000 bars x I. If the product of pres-
sure and cubic capacity PS x V does not exceed 3000 bars
x I, then the EC declaration of conformity procedure in
accordance with Article 12 of Council Directive 8714041
EEC can be carried out instead of the EC verification in
accordance with sentence 1.
(5) On the entry into service of a vessel named in Article 2,
para. 2, the simple pressure vessel shall be provided with
the details in accordance with Appendix II No. 1 of Council
Directive 87/404/EEC. It shall not carry the CE mark.
Section 4
CE marking
(1) The details in accordance with Appendix II No. 1 of
Council Directive 87/404/EEC, and also, in the case of
Article 3, para. 1, the CE mark, shall be applied to the ves-
sel or to an identification plate which cannot be removed
from the vessel, in a visible, legible and durable manner.
(2) The CE mark consists of the letters “CE” in accord-
ance with Appendix II of Council Directive 87/404/EEC.
The code number of the approved body authorized to per-
form the EC verification or EC monitoring is given after the
CE marking.
(3) No markings shall be applied to the vessel which could
confuse third parties with regard to the meaning of the CE
marking. Any other marking may only be placed on the ves-
sel or on the identification plate provided it does not impair
the visibility and legibility of the CE marking.
(4) Pressure vessel whose product of pressure and cubic
capacity PS x V exceed 200 bars x I shall not be provided
Page 29 Pressure Vessel Order, Edition 01.97
with the mark specified in the Section 3 para. 4 of the
Equipment Safety Law.
Section 5
Operating instructions
On the entry into service of a simple pressure vessel
named in Article 2 para 1, operating instructions from the
manufacturer, in accordance with Appendix II No. 2 of
Council Directive 87/404/EEC shall be supplied, in the Ger-
man language.
Section 6
revoked
Section 7
Contravention of regulations
A contravention of regulations within the meaning of Sec-
tion 16, para. 1 sentence 1 No. 2 of the Equipment Safety
Law is perpetrated by anyone who, deliberately or negli-
gently,
1. brings into service contrary to Section 3 para. 1 or 2
sentence 1 in conjunction with Section 4 para. 1 a ves-
sel on which the details specified therein, or the CE
mark, is not placed or is not present in the prescribed
manner,
2. contrary to Section 3 para. 5 in conjunction with Section
4 para. 1, brings into service a vessel on which the spe-
cified information is not placed or is not present in the
correct manner, or which carries the CE mark,
3. contrary to Section 5, brings into service a vessel which
is not accompanied by the operating instructions speci-
fied therein or
4. brings into service a vessel on which the CE mark is
placed, even though the preconditions of Section 3
para. 1, 3 or 4 are not complied with.
Section 8
Transition regulation
(1) Simple pressure vessels may be brought into service
up to 31 December 1992 provided they comply with the
regulations valid before 1 July 1992. Section 1 para. 8 of
the Pressure Vessel Order is not applicable to these pres-
sure vessels.
(2) This Order does not apply to simple pressure vessels
which were brought into service before 31 December 1992
in accordance with the regulations applicable before 1 July
1992.
Entry into force
This Order comes into force on 1 July 1992.
 . ~-l_~~-..-;.-.~.l-^,-,-..-~.“.
,. i
. ” IC in ,.. ..::.r _,-.

UDC 621.642.02-98(083.7):614.8:006 Edition August 1988

AD-Merkblatt
AD-Regulations
Fundamentals
Structure, Application and Method Guidelines Gl

T h e AD-Merkblatter a r e c o m p i l e d b y t h e s e v e n t r a d e a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “Arbeitsgemeinschat? Druck

,ehditer” ( A D ) . A D - M e r k b l a t t G 1 c o v e r s t h e c o m p o s i t i o n a n d a p p l i c a t i o n o f t h e A D - R e g u l a t i o n s a n d a l s o t h e p r o c e d u r a l r u l e s .
T h e AD-MerkbUtter c o v e r s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l c o n d i t i o n s o f o p e r a t i o n . I n t h e e v e n t o f s t r e s s e s ovei
2nd above the normal level being anticipated during the operation of pressure vessels, allowance must be made for such stresses bj
neeting special requirements.
Should there be any departures from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standard<
tmbodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis
operating experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e. K (FDBR), Dirsseldorf
Hauptverband der gewerblichen Berufsgenossenschafn e. V, Sankt Augustin
Verband der Chemischen lndustrie e. V. (VU), FrankfurtlMaln
Verband D e u t s c h e r M a s c h i n e n - u n d A n l a g e n b a u e . V . (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhijttenleute (VDEh), Diisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkratierksbetre~ber e . V, E s s e n
V e r e i n i g u n g d e r T e c h n i s c h e n iiberwachungs-Vererne e . V. (VdTiiV), Essen.
i%e AD-Merkbltitter a r e a m e n d e d c o n t i n u o u s l y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l progress. R e l e v a n t p r o p o s a l s shoulc
,e a d d r e s s e d t o t h e p u b l i s h e r :
Vereinigung der Technischen berwachungs-Ven?ine 8. V., Postfach 103834, D&300 Essen 1.

Contents

1 AD Regulations 5 Guidelines for the preparation

2 Sponsor Bodies of AD-Regulations of AD-Merkblatter
3 Structure of AD-Regulations 6 Publication of AD-Merkblatter .
4 Application of AD-Regulations 7 Application of drafts, validity
of AD-Merkblatter

.
1 AD-Regulations VGB Technische Vereinigung der GroOkraftwerksbe~
treiber e.V., Essen
4D Merkblatter represents the generally accepted rules of Vereinigung der Technischen Oberwachungs-Vereina
.
:echnology regarding pressure vessels and contain safety re- e.V. (VdTijV), Essen
Juirements for
- Equipment, The organization responsible for the AD is the Vereinigunh
der Technischen uberwachungs-Vereine (Association o
- Design,
Technical Inspectorates) which also takes on the task 0
- Manufacture and testing, headquarters.
- Materials.
The AD associations represent a balanced combination o
material and pressure vessel manufacturers, operators
employers’ liability insurance associations and Technical In,
2 Sponsor Bodies of AD-Regulations spectorates. From their knowledge of the questions which
arise during the construction and operation of pressure ves.
\D-Merkblatter are compiled by the “Arbeitsgemeinschaft sels the AD associations draw up the technical regulation:
3ruckbehllter” (AD). The members representing the AD are for pressure vessels bringing them constantly in line with tht
:he seven associations (AD Associations) listed below: state of the art. In individual cases the AD consults expert:
Fachverband Dampfkessel-, Behllter- und Rohrlei- from other associations or scientific representatives to s&t
tungsbau e.V. (FDBR), Dijsseldorf special problems.
Hauptverband der gewerblichen Berufsgenossen-
schaften e.V. Sankt Augustin
Verband der Chemischen lndustrie e.V. (VCI), Structure of AD-Regulations
Frankfurt/Main
3.1 Table 1 gives an overview of the structure of AD-
Verband Deutscher Maschinen- und Anlagenbau e.V.
Merkblatter.
(VDMA), Fachgemeinschaft Verfahrenstechnische
Maschinen und Apparate, Frankfurt/Main 3.2 To a large extent AD-Merkblatter are based on DIN
Verein Deutscher Eisenhtittenleute (VDEh), DOssel- standards. Those DIN standards quoted in the AD regula-
dot-i tions are listed in AD-Merkblatt G 2.

Supersedes Edition September 1971; Completely revised

Carl Heymanns VerLag KG

Luxembuqer St&e 449,50939 K M
Gutenbergstrase 3. TO587 Berlin
P a g e 2 ADMerkMan G 1, Ediiim 8.00
Table 1. Overview of structure of AD-Merkblatter
AD-Regulations
AD-Merkblatt Series
Equipment A majorii of the associations represented in the working
Design B groups
Fundamentals G 5.3.2 Results emanating from the AD working group discu-
Manufacture H sions are recorded in the form of AD drafts and the AD as-
Manufacture and Testing HP
Non-metallic materials N
Special cases S 5.4 Adoption of AD Drafts
Metallic materials W
4 Application of the AD-Regulations
4.1 Conditions
AD-Merkblltter contain safety requirements which apply to
normal operating conditions. The necessary conditions are
the satisfactory design, manufacture and operation of the
pressure vessel including the required maintenance. If the
pressure vessel is likely to be subject to excessively high
stresses, it shall be necessary to meet special requirements.
The set of AD regulations follows a unified and consistent lay-
out concept and the use of other recognized rules of techno-
logy to solve minor problems is conditional on the preserva-
tion of the overall concept.
4.2 Deviations from APMerkblltter
If deviations are made to individual provisions of the AD regu-
lations, care should be taken to ensure that the standard of
safety provided by the regulations is upheld in other ways,
e.g. by material tests, trials, stress analyses, or experience.
In doubtful cases the professional engineer is deemed to
have properly discharged his duties by applying the AD-
Merkblatter accordingly.
4.3 Additional regulations
Where AD-Merkblatter do not cover individual questions, re-
oourse shall be made to other generally recognized rules of
technology. In such instances care shall be taken to ensure
that the standard of safety provided by the regulations is
maintained.
5 Guidelines for the preparation of
APMerkbWter
5.1 Preparatory work by the AD Associations
The AD associations begin by preparing a series of discus-
sion documents which are then handed over to the Associ-
ation of Technical Inspectorates (VdTiiV).
5.2 AD working groups
5.2.1 AD working groups are formed to process the discus-
sion documents mentioned in Section 5.1 above and the
technical or other miscellaneous questions arising which
should be dealt with in the AD regulations. Technical experts
are delegated by the AD associations into the working
groups.
5.2.2 Technical experts from other associations and scien-
tific representatives may also be sent to the meetings held
by the working groups.
I
- I
5.3 How the working groups operate d
5.3.1 AD working groups can take decisions if at least four :3
associations are represented. Resolutions within the AD
working groups are usually adopted by mutual agreement. /
If unanimity cannot be achieved, however, the view of the
applies.
.\ - ’
sociations informed accordingly.
5.4.1 The texts arising from discussions within an AD work-
ing group (AD drafts ready for adoption) are presented to the
AD associations for acceptance within a period of 6 weeks.
The results of this procedure are then communicated to the
AD associations.
5.4.2 Should an individual AD association be unable to
agree an AD draft it has 4 weeks to apply to the AD office
for its request to be discussed in an AD Directors’ Meeting.
I
5.4.3 An AD draft is deemed to have been finally adopted
provided:
- an application for a request to be discussed at an AD Di-
rectors’ Meeting has not been made within the specified
time and at least 5 AD associations have agreed the AD
draft, or
- at the end of an AD Directors’ Meeting called to consider
a request, the directors have approved the AD draft.
5.5 Dealing with enquiries and suggestions
Enquiries and suggestions relating to the set of AD regula-
tions should generally be routed via the AD associations to
the authority with overall responsibility-the VdTt&. As such,
they may bring about additions and amendments to the Set
of AD regulations.
6 Publication of AD-Merkblstter
6.1 AD-Merkblatter adopted in accordance with Section 5.4
are published by the VdTiiV within the framework of the set
of AD regulations. References to changes in the set of AD
regulations appear in the following periodicals: BWK
(Brennstoff - Warme - Kraft), Chemie-lngenieur-Technik,
Die Berufsgenossenschaft, DIN-Mitteilungen, Stahl und
Eisen, Tii (Technische Oberwachung), VGB-Kraftwerks-
technik.
6 . 2 AD-Merkblltter are published in a white format, whilst
additions and amendments to current Merkblatter have a
pink format.
7 Application’of drafts, validity of
AD-Merkblstter
7.1 Consultation documents submitted to AD working
groups according to Section 5.21 are designated
“AD-Proposal (Month and Year)“.
7 . 2 Memoranda relating to the results of discussions (See
Section 5.3.2) are designated
“AD-Draft (Month and Year)“.
7 . 3 AD-Merkblatter (white format) may be applied as soon
as they are published. The same applies to additons and
amendments (pink format).
 Edition June 1966

Materials AD-Merkblatt
for General principles for materials
Pressure Vessels w o

%e AD-Merkblatter are compiled by the seven trade associations specified below who together form the ‘Arbeitsgemeinschaf Druck-
)eh&Yter” (AD). AD-Merkbbtt G 7 covers the composition and application of the AD-Regulations and a/so the procedural rules.
‘he AD-Merkblatter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
md a b o v e t h e n o r m a l / e v e / b e i n g a n t i c i p a t e d d u r i n g t h e o p e r a t i o n o f p r e s s u r e v e s s e l s , allowance m u s t b e m a d e f o r s u c h s t r e s s e s b y
neeting special requirements.
Should there be any departures from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis,
operating experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e.K (FDBR), Diisseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.K, Sankt Augustin
Verband der Chemischen lndustrie e. V (VC/j, Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, FrankfurtiMain
Verein Deutscher Eisenhijttenleute (VDEh), Diisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r Groljkraftwerksbetreiber e . V . , E s s e n
Vereinigung der Technischen iibenvachungs-Vereine e.K (VdToV), Essen.
rhe AD-Merkblatter a r e a m e n d e d c o n t i n u o u s l y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
)e addressed to the publisher:
Vereinigung der Tecbnkchen fiberwachungs-Vereine e. V., Postfach 103834, D-4300 Essen 1.

Contents

1 Scope 4 Materials for pressure vessels -

2 General Testing Groups I, ii and V
3 Materials for pressure vessels - 5 Filler metals and consumables
Testing Groups III, IV, VI and VII

1 Scope Materials in contact with the vessel content should suffer

neither serious corrosion attack nor form dangerous corn
The AD-Merkblatter in Series W apply to metals for use in pounds with the same.
different product forms for the manufacture of stressed com-
oonents of pressure vessels. 2 . 2 The operator or the manufacture of the pressure vesse
shall select only materials which, when correctly processed
The AD-Merkblatt lays down general principles for the quality will attain the properties fully compatible with the service con
of the products, their manufacture and testing. ditions of the pressure vessels.
The AD-Merkblatter in Series W regulate the application and 2 . 3 The quality characteristics of materials in the deliver)
the requirements of various product forms, e.g. plate, strip, condition, essential for satisfying the conditions of Sections
tubes. 2.1 and 2.2, and the quality-affecting measures to be adoptec
This AD-Merkblatt does not cover materials for during processing shall be stated in a material specification
Preferably this document should refer either wholly or par
- gaskets,
tially to standards or other technical delivery conditions.
- attachment and installation parts,
- valve casings 2 . 4 The products are normally tested in the manufacturer:
works.
- and other accessories.
The relevant DIN-standards and Stahl-Eisen-Priifblattittei
AD-Merkblatt A 4 covers valve casings, provided they (Test Sheets) apply to the testing procedures, unless other
represent accessories of pressure vessels as defined in wise stated in the material specification (see Section 3.4.1).
Paragraph 3, Section 2 Druckbehalterverordnung.
The AD-Merkblatter in the N-Series cover non-metallic
3 Materials for pressure vessels -
naterials.
Testing Groups III, VI and VII
2 General 3.1 Special requirements
I.1 The materials shall attain the required mechanical 3.1.1 The material specification forms the basis for the
xoperties on the finished structural part. assessment of the suitability of the material for pressure

Supersedes Edition May 1974

- . . .*a
mn neymanns v e n a g nu
Luxemburger StraDe 449,500O K6ln 41
GutenbargatraBe 3. 1000 Berlin 10
.
Page 2 AD-Merkblatl W 0, Edition 6.66
vessels. For meeting the general conditions in accordance
with Section 2 the minimum requirements 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 authority
for non-destructive tests provided such have been stipulat-
ed in the materials specification and
guarantee 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.
The works inspector issuing Test Certificate B for the
manufacturer shall fulfil the conditions of DIN 50049. The
name and the test stamp of the works inspector must be
known to the expert’) in accordance with Paragraph 31
Druckbehalterverordnung.
3.2 Establishment of the suitability of the material
3.2.1 The suitability of the materials shall be established by
the expert on the basis of the material specification in accord-
ance with Section 3.1 .I. If the suitability of the material can-
not be established on the basis of the material specification
the expert shall impose additional essential safety conditions
and appropriate tests for the product.
The expert shall express the result of the suitability check in
writing.
In cases where the suitability check is intended for wider ap-
plication, this can be done in the form of a VdTUV-Werk-
stoffblattz) drawn up in accordance with a procedure set out
in Werkstoffblatter 1255-l 2643).
If a suitability check for general usage is not available, the
expert may issue a single certificate valid for a specific, re-
spectively identical case of application.
3.2.2 The materials listed in the W-Series of the AD-
Merkblatter are suitable for use within the limits quoted in the
relevant AD-Merkblatt. Other application limits are permissi-
ble once suitability in conformity with Section 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
expert that the requirements according to Section 3.1.2 have
been satisfied. This is generally done before the first delivery.
1) Consult Paragraph 31 Dtucktmh&ltenerordnung for a definition of tha term
“expert”.
2) Obtainable from: Verlag TijV Rheinland GmbH, Postfach 10 1750.5ooo
(Kaln) 1.
3) See VdTi&-Merkblatt 1153 - Directions for the suitability testing of filler metals.
Unless previously performed during routine material accept-
ance tests by the expert, the expert shall reassure himself
at 1 to 2 year intervals that the conditions are still satisfied.
3 . 3 . 2 The proof according to Section 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 : i.
check, additional sampling to confirm the uniformity of the
state. The necessary supplementary tests shall be imposed .I I
by the expert.
3.4 Testing, marking and quality certificates
3.4.1 (1) The conditions governing the suitability check in
accordance with Section 3.2 are decisive for the testing and
marking 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 corresponding
AD-Merkblatt of the W-Series.
(2) The quality certificate shall quote the quantitiy delivered,
the typical dimensions and the full wording of the marking.
(3) If the manufacturer uses, for a given product-form, mate-
rials not refined by him, he must be in possession of certifi-
cates supplied by the manufacturer of the initial material stat-
ing the chemical composition, the material designation, the
marking, the relevant dimensions and the quantity delivered.
3 . 4 . 2 If a certificate A or C according to DIN 50049 Sec-
tion 3 is required as evidence of the quality characteristics,
the tests shall be carried out by the expert. In cases such as
these the chemical composition of the cast, the steelmaking
method and the method employed for the manufacture of the
product shall be made known, unless otherwise specified in
the material specification on the basis of the suitability check
in accordance with Section 3.2.
The expert has the right to attend the manufacturing process,
but not to interfere with it.
In circumstances according to Section 3.4.1 para (3), the
authorized inspectors shall be in possession of the certifi-
cates from the manufacturer of the initial material.
3 . 4 . 3 In cases where nondestructive tests have been pre-
scribed a test certificate B to DIN 50049 is generally issued.
3.5 Repairs and repair (final) welds
Material defects may be repaired in conformity with the con-
ditions laid down in the material specification. If the question
of repair (final) welds is not covered in the material specifi-
cation, repair (final) welding (with the exception the repair
welding of steel castings) may only be carried out in agree-
ment with the customer and - whenever the expert is re-
quired to test the product - in the presence of the expert.
In cases of repairs by means of welding, the nature and the
extent of the repairs, as well as the type and the results of
the tests performed on the required area shall be described
in a certificate.
The conditions laid down in DIN 16990, Part 1 apply for repair
welds on steel castings, unless otherwise stated in the mate-
rial specification. A process approval test in accordance with
Stahl-Eisen-Werkstoffblatt 110 is required for repair welds
on steel castings.
3.6 Design characteristics
The characteristic values stipulated in the material specifica-
C0iogne
tion are valid for design purposes unless other values are laid
down in the suitability check in accordance with Section 3.2.

4 Materials for pressure vessels -
Testing Groups I, II and V.
. performed on the repaired area shall be described in a cer-
4.1 Special requirements
The material specification according to Section 2.3 forms the
basis for the assessment of the suitability of the material for
the intended pressure vessel. For meeting the general re-
quirements in accordance with Section 2 this document shall
contain the following information unless otherwise stipulated
for a particular application:
- the demands made on the chemical composition and the
mechanical-technological properties,
- the conditions regarding the processing and heat treat-
ment methods and practices,
- the material testing conditions as well as the type and
the content of the test certificate (certificate according to
DIN 50049 or stamp),
- the marking requirements and
- the requirements relative to the design characteristics.
4.2 Establishment of the suitability of the material
The suitability check and the selection of the material are the
responsibility of the manufacturer of the pressure vessel. He
may rely in this case on the suitability check in accordance
with Section 3.2, provided such a check has already been
carried out.
The material with proven performance in service shall be re-
garded as suitable when it is intended for similar applications.
4.3 Testing, marking and certification of quality
characteristics
The testing and marking practice shall comply with the con-
ditions of the material specification. It shall be confirmed that
i
. these conditions have been strictly observed.
4.4 Repairs and repair (final) welds
’ I Material defects may be repaired in conformity with the re-
quirements of the material specifications. If the question of
repair welds is not covered in the material specification,
repair welding (except repair welding of steel castings) may
be carried out in agreement with the customer.
Page 3 AD-Merkblait W 0, E d i t i o n 6 . 8 6
In cases of repairs by means of welding, the nature and the
extent of the repair, as well as the type and the results of tests
tificate.
The conditions laid down in DIN 1690, Part 1 apply for repair
welds on steel castings, unless otherwise stated in the mate-
rial specification. A process approval test in accordance with
Stahl-Eisen-Werkstoffblatt 1 IO is required for repair welds on
steel castings.
4.5 Design characteristics :
The characteristic values stipulated in the material speciffca-
tion are valid for design purposes.
5 Filler metals and other consumables
5.1 The filler metals, if required in combination with con- I. . ,
sumables, shall be suitable for the fabrication of pressure /<
vessels, i.e. the weld metal must be adapted to the base
metals and to the relevant quality characteristics given in a
“filler metal specification”.
5 . 2 The suitability of solder and adhesives can be estab-
lished in a process approval test.
5 . 3 The suitability for pressure vessels of Groups III, IV, VI
and VII shall be established by an expert’s report on the basis
of the filler metal specificationa). In cases where a suitability
check for general usage has not been carried out, a suitability
for a specific, respectively similar application may be estab-
lished during an extended process approval test.
The suitability of the filler metals quoted in VdTijV-Kennblatt
1000 shall be established within the scope laid down in that
standard.
5.4 The suitability for pressure vessels of Testing Groups
I, II and V shall be established by the manufacturer. He may
rely in this case on the suitability check in accordance with
Section 5.3, provided such has been carried out.
Filler metals and other ‘consumables with proven perfor-
mance in service shall be regarded as suitable, when in-
tended for similar applications.
J) See VdTtiV-Merkblatt 1153 - Directions for the suitability testing of filler met&.
 ICS 23.020.30 Edition February 1998

Materials AD-Merkblatt
Flat products
for
Pressure Vessels of unalloyed and alloy steels W I

The AD-Merkbltter are compiled by the seven associations specified below who together form the ‘Arbeitsgemeinschaft Druck-
behalter” (AD). AD-Merkblatt G 7 covers the composition and application of AD-Regulations and also procedural guidelines.
T h e AD-MerkbBttercontain s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . In t h e e v e n t o f l o a d i n g s e x c e e d i n g
lhe normal level expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
Fequirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied i n t h e s e regulations h a v e b e e n o b s e r v e d b y o t h e r m e a n s , e . g . t e s t i n g o f m a t e r i a l s , e x p e r i m e n t s , s t r e s s analysis, o p e r a t i n g
Experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e.V. (FDBR), Diisseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sankt Augustin
Verband der Chemischen lndustrie e. V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Diisseldorf
VGi3 T e c h n i s c h e V e r e i n i g u n g d e r Grookraftwerksbetreiber e . V . , E s s e n
Verband der Technischen iibenvachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkblatter a r e a m e n d e d conlinuously by the a b o v e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be a d d r e s s e d t o t h e p u b l i s h e r :
Verband der Technischen iiberwachongs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents
1 Scope 5 Certification of quality
2 Approved materials 6 Design strength values
3 Testing Appendix 1
4 Marking

1 Scope 2 Approved materials

. 1 . 1 This AD-Merkblatt covers flat products (plate, sheet,
strip and wide flats; see DIN EN 10079) of unalloyed and
alloyed ferritic steels for the fabrication of pressure vessels
which are operated at temperatures, governed by the
weather or the vessel fluid, ranging from -10 “C up to the
maximum temperatures specified in Section 2.
For vessel fluid temperatures less than -10 “C, AD-Merk-
blatt W 10 shall also apply.
1 . 2 Flat products of austenitic steels are covered by AD-
Merkblatt W 2. Clad plate and sheet are covered by AD-
Merkblatt W 8.
1 . 3 The provisions detailed in Sections 2 to 6 below apply
to flat products for the fabrication of pressure vessels subject
to a final inspection by the authorized inspector (pressure
vessels in Inspection Groups III, IV, VI and VII).
1 . 4 No additional provisions other than those in AD-Merk- higher temperatures.
blatt W 0 are required in the case of flat products for the
fabrication of pressure vessels, for which the manufacturer
has to certify production to specification (pressure vessels in
Inspection Group I, where these are to be used for com-
bustible, corrosive or toxic gases, vapours or fluids, and also
those in Inspection Group II).
The following materials may be used:
2.1 Unalloyed structural steels S235JRG1, S235JRG2,
S235J2G3, S275JR, S275J2G3, S355J2G3, S355K2G3 to
DIN EN 10025 subject to the application limits specified in
Table 1.
2.2 Steels for pressure vessels of simple design to
DIN EN 10207 subject to the application limits specified in
Table 1.
2.3 Unalloyed and alloy high-temperature steels to
DIN EN 10028-2 subject to the application limits specified in
Table 2.
2.4 Weldable normalized fine-grained structural steels to
DIN EN 10028-3 in conjunction with VdTl& Werkstoffbltitter
(Material Specification Sheets) 352/l, 354/i and 35711.
2.5 Low-temperature steels 11 MnNi 5-3, 13 MnNi 6-3,
I 12Ni14,12Ni19andX8Ni9toDINEN10028-4upto50”C.
AD-Merkblatt W 10, Table 3a covers short-time operation at
2.6 Other materials upon approval. Such materials shall
exhibit the property values characteristic of the standard
material and shall meet the following minimum requirements
at room temperature using transverse specimens:
I

Supersedes July 1995 edition; 1 = Amendments relating to previous Edition

Carl Heymanns Verlag KG

Luxemburger StraOe 449, 50939 K&In
 Page 2 A D - M e r k b l a t t W 1 . E d i t i o n 0 2 . 9 8
- Elongation at fracture A 2 16%,
- Impact energy for a V-notched specimen to DIN EN 10045-I
2 27 J (average value from three tests).
3 Testing
3.1 DIN EN 10025 is the standard covering the testing of
flat products produced from the steels specified in
Section 2.1. Testing shall be performed per melt (cast). The
impact test shall be an additional requirement in the case of
steels in the Quality Group JR with nominal thicknesses
116mm.
I Where sheets are delivered which have been produced by
3.2 Flat products produced from steels specified in
Section 2.2 shall be tested in accordance with DIN
EN 10207.
3.3 Flat products produced from steels specified in
Section 2.3 shall be tested in accordance with DIN
EN 10028-l. One tensile test shall be carried out at the
design temperature per cast and dimension range. If the
design temperature is not known, the test shall be performed
at 300 “C.
3.4 Flat products produced from the steels specified in
Section 2.4 shall be tested in accordance with DIN
EN 10028-l. The tensile test shall be performed at elevated
temperature for all steel grades in Series H. If the tempera-
ture is not specified in the order, the test shall be performed at
300 “C. One test shall be performed per cast and dimension
range. The impact test shall be conducted on transverse
specimens.
3.5 Flat products produced from the steels specified in
1Section 2.5 shall be tested in accordance with DIN EN
10028-4. An impact test on transverse specimens shall be
conducted on sheets cut from strip and on lengths of strip.
3 . 6 Flat products produced from other steels specified in
Section 2.6 shall be tested to meet the approval testing requi-
rements.
3.7 Each alloy steel lot submitted for testing shall be
subjected to a materials identification check which shall then
be certified.
3 . 8 The surface condition of each plate/sheet/strip [ength
shall be inspected.
3.9 Testing requirements after further processing are
covered by AD-Merkblatter in the HP Series.
4 Marking
4.1 Flat products shall be marked with at least:
- the manufacturer’s symbol,
- the short designation of steel type or material number,
- the cast number,
- the authorized inspector’s mark (in the case of test certifi-
cate 3.1 ./UC) or works inspector’s mark (in the case of test
certificate 3.1 B).
When the delivery is accompanied by a test certificate to
DIN EN 10204, plates, sheets and strip lengths from which
test pieces have been taken for verification of quality shall
also be marked with the sample numberz).
2) The sheet or strip length number may also be used as the sample number.
Plates/sheets shall be marked at one end such that the mar-
king is perpendicular to the main direction of rolling. Marking
shall be applied by stamping. With nominal thicknesses not
exceeding 5 mm, indelible colour-coding is permissible.
If marking is done by stamping it shall be framed with white
colour.
In the case of sheets cut from a length of strip, the use of inde-
lible colour-coding by the manufacturer is permitted irrespec-
tive of the nominal thickness provided no other form of mar-
king has been expressly specified in the order.
Strip shall be marked with the aid of a tie-on tag. In addition,
the external ends of strip shall be marked with an indelible
colour-coding with the same information.
dividing up a larger rolled panel or a length of strip, the mark-
ing shall be transferred to each sheet. If the sheets are
assembled in stacks, the same marking shall also be put on
a tie-on tag attached to the stack.
4 . 2 For flat products made of the steels to Sections 2.1
through 2.5 the additional requirements of the delivery stan-
dards or VdTijV material specification sheets mentioned
therein shall also apply.
4 . 3 Flat products made of other materials to Section 2.6
shall be marked to meet the approval testing requirements.
5 Certification of quality
5.1 Types of Test Certificates to DIN EN 10204
The certification of quality for flat products shall proceed in
accordance with the requirements stated in Table 3.
5.2 Content of Test Certificates to DIN EN 10204
The test certificates shall contain the information required in
DIN EN 10028-l. In addition, each test certificate shall show
the technical delivery condition (e.g. DIN EN 10028-2) and
the technical rules (e.g. AD-Merkblatt W 1) with which the
delivery is required to comply.
6 Design strength values
6.1 For plate, sheet and strip produced from materials spe-
cified in Section 2.1, the room-temperature yield strength
values specified in DIN EN 10025 shall apply up to 50 “C.
The values in Table 4 shall apply for design temperatures
ranging from 100 “C to 300 “C. The wall thickness quoted in
this table is the wall thickness of the pressure vessel. The
characteristic values given in AD-Merkblatt W 9 shall be
applicable for the production of flanges from plate.
For flat ends and tube sheets to AD-Merkblatt B 5 and produ-
ced from plates, the room-temperature yield strength values
quoted in DIN EN 10025 shall apply with temperatures up to
50 “C. The yield strength values in Table 5 shall apply for
design temperatures ranging from 100 “C to 300 “C.
.6.2 The values specified to DIN EN 10207 shall apply to
flat products produced from steels to Section 2.2.
6 . 3 The values specified in DIN EN 10028-2 shall apply to
flat products produced from steels to Section 2.3.
6 . 4 The values specified in DIN EN 10028-3 shall apply to
flat products produced from steels to Section 2.4.
6 . 5 The values specified in DIN EN 10028-4 shall apply to
I flat products produced from steels to Section 2.5.
6 . 6 The values obtained from approval testing shall apply
to flat products produced from steels to Section 2.6.
 Page 3 AD-Merkblatt W 1, Edition 02.98

6 . 7 The characteristic values quoted in the material specifi-
cation or approval testing for 20 “C shall be applicable for
temperatures up to 50 “C and those quoted for 100 “C shall
be applicable at up to 120 “C. In the remaining temperature
ranges, linear interpolation between the quoted values is
necessary (e.g. for 80 “C, between 20 and 100 “C and, for
180 “C, between 100 and 200 “C) but no rounding up is per-
missible. In the case of individually certified steels (special
material appraisals) individually, the interpolation rule shall
i only apply if there is a sufficiently close interval*) between the
points of support.
I
1 2) This is generally understood to mean a temperature interval of 50 K in the
elevated-temperature proof stress range and an interval of 10 K in the creep
rupture strength range.
I

;:
Table 1 Application limits for flat products produced from steels to DIN EN 10025 and DIN EN 10207

Design Normal
temperature’) delivery
condition

“C

N213)

-, N*)
DIN EN 10025 N*P)
5 300

DIN EN 10207

1 3) In the case of product thtcknesses > 4.75 to 5 25 mm, the products may also be supplied in as-rolled condttlon.

.
*
*;i
Table 2 Application limits for flat products produced from steels to DIN EN 10028-2

Steel type Product Normal delivery

Short Former designation thickness’) conditiont)
designation to DIN 17155 m m

P235GH HI

P265GH H II
N*)
P295GH 17 Mn 4

P355GH 19 Mn6 5 150

16Mo3 15Mo3 N

13CrMo4-5 1 3 CrMo 4 4

1 OCrMoS-10 1 0 CrMo 9 10 N+TorQA

11 CrMoS-10 I 60

1) For products of other thicknesses and other normal delivery conditions. Sectlon 2.6 applies
2) Or in an equwalent condition obtained by normalising rolling.
 Technical Section Steel grade Type of Test Certificate
delivery condition Short designation I to EN 10204

3.1 .B’)

S235J2G3 3.1.8

DIN EN 10025 2.1 S275JR 3.1 .B’)

P235S

DIN EN 10207 2.2 P265S I 3.1.8

P275SL

P235GH 3.1.8

P265GH 3.1.8

P295GH

DIN EN 10028-2 2.3 P355GH

16Mo3
3.1 .AJc
13CrMo4-5 \

1 OCrMoS-10

11 CrMoS-10

P275N I 3.1.B

P275NLl

P275NL2

P355N

DIN EN 10028-3 2.4 P355NH

P355NL 1

P355NL 2

P460N
3.1 .Alc

11 MnNi5-3

13MnNi6-3

DIN EN 10028-4 2.5 lONi14

12Ni19

X8Ni9

In accordance with the requirements

2.6 Others when ascertaining their suitability by
approval testing.

) Test Report required for products < 6 mm thickness.

 _-

. Page 5 A D - M e r k b l a t t W 1, Edition 0 2 . 9 8

Table 4 Design strength values at higher temperatures for steels to DIN EN 10025

. Steel grade Nominal Design strength value K

thickness at design temperature
i.
100°C 200 “C 250 “C 300 “C’)
mm N/mm2 N/mm2 N/mm2 N/mm2 ’i
I.
S235JRGl s 16 187 161 143 122
S235JRG2
S235J2G3 >16tos40 180 155 136 117 /
I
S275JR 5 16 220 190 160 150 ‘:

S275J2G3
>16tos40 210 180 170 140 (::
/:!.:
S355J2G3 5 16 254 226 206 186
S355K2G3 >16tos40 249 221 202 181
1) The design temperature shall not exceed 300 “C even for heated parts. AD-Merkblatt B 0. Table 1 shall be taken ink3 constderabon.

Table 5 Design strength values at elevated temperatures for flat ends and tube sheets made of steels
to DIN EN 10025

S235JRGl
S235JRG2
S235J2G3

S355J2G3
S355K2G3

> 100 to I 150 194 166 146 126

L I
 Page 6 AD-Merkblatt W 1, Edition 02.96

Appendix 1 to AD-Merkblatt W 1 I.-..

Agreement of the AD-Associations on the continued use
of formerly valid DIN Material Standards
General-purpose structural steels USt 37-2, RSt 37-2, RSt
37-2 Cu 3, St 37-3, St 44-2 and St 52-3, listed in the with-
drawn January 1980 Edition of DIN 17 100, high-temperature
steels listed in the withdrawn October 1983 Edition of
DIN 17 155 and weldable, normalised, fine-grained structural 2
steels listed in the withdrawn October 1983 Edition of DIN
17 102, may be used prior to adoption of the EC Directive on
Pressurized Equipment as national law and publication of a
European standard for pressure vessels provided the requi-
rements of AD-Merkblatt W 1 (January 1990 Edition) are also !
taken into consideration.

!
I
I
1 .

f .i
i
;
I/
/
I )I I
I
.,

1
 Materials AD-Merkblatt
for Austenitic steels
Pressure Vessels w2

T h e AD-Merkblatter a r e c o m p i l e d b y t h e s e v e n a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “Arbeitsgemeinschaft Druckbehdlter”

(AD). AD-Merkblatt G 1 covers the composition and application of AD-Regulations and also procedural guidelines.
T h e AD-Merkbl&Wer contain safety requirements which must be adopted for normal operating conditions. In the event of loadings exceeding
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e. V. (FDBR), Dijsseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sankt Augustin
Verband der Chemischen lndustrie e. V. (VU), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhijttenleute (VDEh), Diisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkraftwerksbetreiber e.V., E s s e n
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s l y b y t h e a b o v e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e. V., P.O. Box 103834, D-45038 Essen.

Contents
1 Scope 5 Marking
2 Materials 6 Verification of quality characteristics
3 Requirements for the materials 7 Design characteristics
4 Tests

1 Scope
.
1.1 This AD-Merkblatt is applicable to hot- and cold-rolled
plate and strip, seamless and welded tubes, forged, rolled
and drawn bars and forgings and also to nuts and bolts
(mechanical fasteners) made of austenitic and austenitic-
ferritic steels for the construction of pressure vessels
operated at temperatures dictated by atmosphericconditions
and at temperatures determined by the charge down to
-10 “C and up to the upper temperature limits specified in
Clause 2. In principle the steels are also suitable for use at
temperatures lower than -10 “C but for such applications this
AD-Merkblatt is applicable only in conjunction with AD-
Merkblatt W 10.
1.2 The stipulations in Clauses 2 to 7 below are applicable
to products required for the construction of pressure vessels
to be subjected to structural tests by the authorized inspector
(pressure vessel test groups III, IV, VI and VII).
1.3 Apart from the provisions contained in AD-Merkblatt
W 0, no additional requirements are necessary for products
used in the construction of pressure vessels for which the
manufacturer has to certify correct manufacture (pressure
vessels in test group I, where they are used for combustible,
corrosive or toxic gases, vapours or liquids and in test
group II).
2 Materials
The following materials can be used for the construction of
pressure vessels:
2.1 The austenitic steels and ferritic/austenitic steel 1.4462
listed in table 1 up to the limit temperatures and dimensional
limits specified for them in the light of their resistance to inter-
granular corrosion. Insofar as no other limits are given in the
standards and material specifications in 3.1, the dimensional
limits are also applicable to resistance to intergranular corro-
sion.
2 . 2 The austenitic steels of DIN 17 440, DIN 17 441, DIN
17 457, DIN 17 458 and of SEW 400 up to 550 “C listed in
table 1, except steels 1.4439, 1.4539 and 1.4577 only up to
400 “C. However, this only applies in cases where no inter-
granular corrosion is expected.
2 . 3 Austenitic steels to table 1 of DIN 17440, DIN 17441,
DIN 17457, DIN 17458 and of SEW400 above 55O”C, with the
exception of steel grades 1.4439, 1.4462, 1.4539 and 1.4577.
Consideration should where applicable be given to long-term
high-temperature strength values, if intergranular corrosion
cannot occur and the authorized inspector has verified their
suitability for the envisaged service temperature.
2 . 4 Steels with material numbers 1.4439 and 1.4577 over
400 “C and up to 500 “C, provided that intergranular corro-
sion cannot occur and their suitability for the intended appli-
cation temperature has been verified.

Supersedes September 1998 edition; 1 = Amendments to previous edition

^Garl ._- ,--.
neymanns venag KU Translation: Technlcal Help to txporters SerVlce 01 ml
Luxemburger St&e 449. 50939 Kbln
Page 2 AD-Merkblatt W 2, Edition 01.2000

Table 1. Assignment of steel grades to the relevant DIN standards and SEW (Iron and Steel Materials Sheet) 400

Grade of steel
Material DIN DIN DIN DIN DIN DIN SEW
Abbreviation No. 17440 17441 17457 17458 17459 17460 400

X 5 CrNi 1810 1.4301 X X X X

X 5 CrNi 1812 1.4303 X X
X 2 CrNi 1911 1.4306 X X X X
X 2 CrNiN 1810 1.4311 X X X X
X 6 CrNiTi 1810 1.4541 X X X X
X 6 CrNiNb 1810 1.4550 X X X X

X5CrNiMo 17122 1.4401 X X X X

X 2 CrNiMo 1713 2 1.4404 X X X X
X 2 CrNiMoN 1712 2 1.4406 X X
X 6 CrNiMoTi 1712 2 1.4571 X X X X - -
X 6 CrNiMoNb 1712 2 1.4580 X X

X 2 CrNiMoN 1713 3 1.4429 X X X X

X 2 CrNiMo 1814 3 1.4435 X X X X
X5CrNiMo 17133 1.4436 X X X X
X2CrNiMo 18164 1.4438 X X
X 2 CrNiMoN 1713 51) 1.4439 X X X X

X 4 NiCrMoCuNb 20 18 2 1.4505 - X
X 1 NiCrMoCuN 2520 51) 1.4539 -
X 3 CrNiMoTi 2525 1.4577 - X

X 2 CrNiMoN 225 3’) 1.4462 - t, :

X6CrNi 1811 1.4948 - X X
X 3 CrNiN 1811 1.4949 - X X
X 8 CrNiTi 1810 1.4941 - X X
X 6 CrNiMo 1713 1.4919 - - X X
X 3 CrNiMoN 1713 1.4910 - X X
X 8 CrNiNb 16 13 1.4961 - - X X
X 8 CrNiMoNb 1616 1.4981 - X X .
X 8 CrNiMoVNb 1613 1.4988 - X X
X 5 NiCrAlTi 3120 1.4958 - X X f
X 8 NiCrAlTi 3221 1.4959 - X X

1) Applies to pressure vessels requiring structural test by the authorized inspector in conjunction with VdTiiV Material Sheets 405, 418 or 421.

2 . 5 Nuts and bolts from steel groups A 2 and A 4 in strength suitability is verified in the event that they exceed the
class 50 with dimensions M 6 to M 39, in strength class 70 dimensional limits laid down in DIN standards and SEW 400.
and size M 6 to M 30, in accordance with DIN IS0 3506 and 2 . 8 Austenitic steels complying with other material specifi- i
>’

the austenitic grades of steel specified therein up to design cations, provided that their suitability is verified’).
temperatures of 400 “C. If nuts and bolts are required to be
resistant to intergranular corrosion, their application tem-
perature shall not exceed 300 “C. 3 Requirements for the materials
Nuts and bolts made of Group A 2 and A 4 copper alloy steel 3.1 The following standards are applicable to the chemical
may be used if their suitability and quality properties have composition, heat-treatment condition, mechanical and tech-
been first attested by an approval certificate from the autho- nological characteristics as a function of the dimensional
rized inspector. limits, surface quality and dimensional accuracy of the pro-
ducts*) listed in 2.1 to 2.5:
If steel bars for making nuts and bolts are delivered in a heat-
treated state other than that indicated in table 6 of DIN DIN 17440 - Stainless steels - Technical delivery
17 440, eg. warm work hardened, proof of the suitability of conditions for plates, hot-rolled strip and
the materials shall be provided. bars for pressure purposes, drawn wire
and forgings.
2 . 6 Cold re-drawn bars made of steels with material num- DIN 17441 - Stainless steels - Technical delivery
bers 1.4301, 1.4541, 1.4401 and 1.4571 in the size range conditions for cold-rolled strips and slit
2 4 to 5 20 mm. As a deviation from DIN 17440, an upper coils, strip and sheet cut from such strips
tensile strength limit of 850 N/mm*) and an elongation after for pressure purposes.
fracture value A of 2 20% are permissible here.
1) If verification of suitability has led to a VdToV Mat+als Sheet, please refer to the
VdTCJV Materials Sheets index (available from TUV Verfag GmbH,
2 . 7 Austenitic steels listed in table 1 in a delivery condition P.O. Box 903060, D-51123 Cologne).
other than quenched, e.g. warm work hardened, or if their 2) Dimensional standard, tolerance class and finish are selected by the customer.
 . Page 3 AD-Merkblatt W 2, Edition 01.2000

DIN 17457 - Welded circular austenitic stainless The notched bar impact test shall be performed at thicknes-
steel tubes subject to special require- ses 2 10 mm for plate made of 1.4505 and 1.4577 steels 1,/’
:ments; technical delivery conditions. and at thicknesses > 20 mm for the other steels given in
Table 1.
DIN 17458 - Seamless circular austenitic stainless I
steel tubes subject to special require- 4 . 1 . 4 Dimensional testing and visual examination of both
ments; technical delivery conditions. surfaces
DIN 17459 - Seamless circular high-temperature 4 . 1 . 5 Resistance to intergranular corrosion
austenitic steel tubes; technical delivery 4.1.6 Positive material identification
conditions,
4.2 Tubes
DIN 17460 - High-temperature austenitic steel plate
and sheet, cold and hot rolled strip, bars 4.2.1 Welded tubes
and forgings; technical delivery condi- The following tests are carried out in accordance with
tions. DIN 17457, test class 2:
SEW 400 - Stainless rolled and forging steels, - ladle analysis
- tensile test
DIN IS0 3506 - Corrosion-resistant stainless steel
fasteners; specifications. - notched bar impact test
- technological tests
3 . 2 The requirements for steels given in 2.3, 2.4, 2.7 and - dimensional test and visual examination of the surface ,
2.8 used for pressure vessels to be subjected to structural
- positive material identification
tests by the authorized inspector are based on 1
verification of their suitability. - tightness test
- test for resistance against intergranular corrosion
3.3 For welded tubess), a process test matched to the - non-destructive testing of the weld seam and, in tubes with
manufacturing process shall be available which also includes a wall tickness > 40 mm, of the tube ends.
the type and scope of non-destructive testing.
For welded tubes which do not comply with DIN t7457, the 4.2.2 Seamless tubes
scope of testing of the weld seam zone shall be established The following tests are carried out in accordance with
in such a way as to allow 100 % exploitation of the allowable DIN 17458, test class 2:
design stress. Furthermore the need for and type of heat - ladle analysis
treatment shall be specified.
- tensile test
- notched bar impact test
4 Tests - technological tests
Unless otherwise specified below, individual products shall - dimensional test and visual examination of the surface
be tested in accordance with DIN 17440, 17441, 17457, - positive material identification
17458, 17459 or 17460. Steels complying with SEW 400 are - tightness test
tested in accordance with the above DIN standards, depend- - test for resistance against intergranular corrosion
ing on the type of product. Steels complying with other mate- - non-destructive testing of the tube wall and the tube ends
rial specifications are governed by the stipulations of the sui-
in the case of wall thicknesses > 40 mm.
tability verification.
As a deviation from this, a technological test to test class 1
Austenitic steels belonging to the group of stainless steels is carried out on tubes with an outside diameter 5 42,4 mm
are tested per cast and heat treatment batch for resistance and wall thickness 5 3,6 mm or internal tubes?).
to intergranular corrosion in accordance with DIN EN IS0
I 3651-2. This test may be omitted by agreement with the user. Testing is analogous for tubes made of steels complying with
SEW 400, but the notched bar impact test on tubes made of
4.1 Plate and strip 1.4505 and 1.4577 steels shall be carried out at wall thicknes-
sesz10mm.
4.1 .l Ladle analysis
A minimum of 10% of tubes with outside diameters
4.1.2 Tensile test 5 101,6 mm and wall thicknesses 5 5,6 mm are subjected
As a deviation from table 9 of DIN 17440, testing per batch to ultrasonic testing in accordance with SEP (Iron and Steel
as specified is sufficient for plates made of 1.4541 and Test Sheet) 1915. If tubes tested in this manner show defects
1.4571 steels of thickness % 30 mm instead of ZG 20 mm (in that are of the type that shall be assumed to exist in untested
accordance with DIN 17440). Plates made of 1.4505 and tubes, all tubes shall be subjected to non-destructive testing
1.4577 steels shall be tested per rolled plate, regardless of over their entire length.
thickness. If the tubes complying with the technical delivery conditions
Strip is tested at the beginning and end of each roll, provided of this AD-Merkblatt have to be subjected to a non-destruc-
that the consistency of the characteristics over the length of tive test to SEP 1915, they shall be tested over their entire
the strip is certified. lengths).
c
4.1.3 Notched bar impact test The ultrasonic test can be dispensed with for tubes inside a
pressure vessel (internal tubes)“). This also generally applies
The scope of the notched bar impact test shall correspond
if the pressure inside the tubes is greater than that inside the
to that of the tensile test.
pressure vessel.
3) Welded tubes are those manufactured by mechanized welding in continuous pro-
duction from strip or in series prcdwtion (as single lengths) from lengths Of strip. 4) The order shall spacifiy whether internal tubas are intended.
Tubes or nozzles manufactured individually do not satisfy this definition and are 5) This requirement is also deemed to have been mat if the tubas are tasted jOtnt
, covered by the HP serves of AD-MerkbMttar. to joint.
Page 4 AD-Merkblalt W 2, Edition 01.2000

Table 2. Verification of quality characteristics for plate and strip made of steels specified in table 1 ,.
i
Type of test certification
Grade of steel to DIN EN 10204
Thicknesses Thicknesses
Abbreviation Material No. mm mm

X 5 CrNi 1810 1.4301 5 20 > 20

X5 CrNi 1812 1.4303 9 20 > 20
X2 CrNi 1911 1.4308 9 20 > 20
X2 CrNiN 1810 1.4311 5 20 > 20
X8 CrNiTi 1810 1.4541 5 30 > 30
X8 CrNiNb 1810 1.4550 5 20 > 20

X5 CrNiMo 17122 1.4401 5 20 > 20

X 2 CrNiMo 17132 1.4404 5 20 > 20
X2 CrNiMoN 17122 1.4406 I 20 > 20 3.1. A or
X6 CrNiMoTi 17122 1.4571 9 30 3.1. B > 30 3.1. c
X6 CrNiMoNb 17122 1.4580 5 20 > 20

X 2 CrNiMoN 17 133 1.4429 5 20 > 20

X2 CrNiMo 18 143 1.4435 5 20 > 20
X5 CrNiMo 17133 1.4436 5 20 > 20
X2 CrNiMo 18164 1.4438 5 20 > 20
X 2 CrNiMoN 17135’) 1.4439 5 10 > 10

X 4 NiCrMoCuNb 20182 1.4505 5 20 > 20

X 1 NiCrMoCuN 25205’) 1.4539 5 10 > 10
X 3 CrNiMoTi 2525 1.4577 5 10 > 10

X 2 CrNiMoN 22511) 1.4462 not applicable 5 100

X6 CrNi 1811 1.4948

X3 CrNiN 1811 1.4949
X8 CrNiTi 1810 1.4941
X6 CrNiMo 1713 1.4919
X 3 CrNiMoN 1713 1.4910 not applicable not applicable I 50
X8 CrNiNb 1613 1.4961
X8 CrNiMoNb 1616 1.4981
X8 CrNiMoVNb 1613 1.4988
X5 NiCrAlTi 3120 1.4958
X8 NiCrAlTi 3221 1.4959

1) Applies to pressure vessels requiring strudural testing by the authorized inspector in conjunction with VdTljV Material Sheets 405, 418 or 421.

Table4. Scope of non-destructive random testing of If the installation is such that the ends of some tubes remain
mechanical properties when testing to DIN IS0 untested, other methods shall be used to verify freedom from
3269. defects. This may be done by additional non-destructive tests
or by testing ring specimens. It is not permitted to cut off the
Number of specimen sets for
Quantity untested ends of tubes.
mechanical testing

5 200 1 4.3 Bars and forgings

> 200 to 5 400 2 4.3.1 Ladle analysis
> 400 to 5 8 0 0 3 4.3.2 Tensile test
> 800toS1200 4 Testing in accordance with the “Special purpose bars and
forgings” column in table 9 of DIN 17440.
> 1200 to 5 1600 5
> 1 6 0 0 t o TS 3 0 0 0 6 4.3.3 Notched bar impact test
> 3000 to 5 3500 7 The scope of the notched bar impact test shall correspond
> 3500 DIN IS0 3269 to that of the tensile test. Samples are taken and the test
1 implemented in accordance with clause 8 of DIN 17440. The
If the bolts are from a consignment which can be shown to be from notched bar impact test is carried out for diameters 5 15 mm
a cast with the same heat treatment, the testing of 4 sets of speci-
mens will suffice regardless of the number of items. for bars and forgings made of 1.4505 and 1.4577 steels and
at diameters > 60 mm for the other steels given in table 1.

For forgings (disk, perforated disk, ring and bush), the deci-
sive dimension as shown in figure 3 of DIN 17440 is appli-
.
cable instead of the diameter.
4.3.4 Dimensional’ test and visual examination of the sur-
face
4.3.5 Resistance to intergranular corrosion
4.3.6 Positive material identification
4.3.7 Non-destructive testing
Bars and forgings with diameters or thicknesses > 160 mm
shall be subjected to ultrasonic testing6).
4.4 Nuts and bolts
4.4.1 Nuts and bolts as specified in 2.5 shall be tested to
DIN IS0 3506 and DIN IS0 3269 with reference to table 4.
For non-destructive testing for surface flaws and dimension
testing the number of random samples taken shall be 20. All
specimens shall meet the requirements (acceptance number
A, = 0).
4 . 4 . 2 Nuts and bolts made of other steels or with strength
characteristics deviating from those in table 1 shall be tested
in accordance with the suitability verification.
4.4.3 For machined nuts and bolts 4.3 applies.
4.5 Seamless or welded tubes with outside diameters
up to 600 mm used as pressure vessel shells
Testing is carried out in accordance with DIN 17457 or
I
DIN 17458, test class 2 in either case. The tube wall shall
be subjected to non-destructive testing for tubes complying
with DIN 17458 and DIN 17459 at operating gauge pres-
sures > 80 bar. A minimum of 10% of the tubes with oper-
ating gauge pressures 5 80 bar, with outside diameters
I 101,6 mm and with wall thicknesses 5 5,6 mm shall be
.
subjected to ultrasonic testing in accordance with SEP 1915.
If tubes tested in this manner show defects that are of the type
that shall be assumed to exist in untested tubes as well, all
the tubes shall be subjected to non-destructive testing over
.
their entire length.
5 M a r k i n g
5.1 Products shall be marked clearly and permanently. For
plates, bars and forgings in accordance with Clause 8 in each
case of DIN 17440 and DIN 17460 and strip in accordance
with Clause 8 in each case of DIN 17441 and DIN 17460,
for welded tube in accordance with DIN 17457 Clause 7, for
seamless tube in accordance with Clause 7 in each case of
DIN 174587) and DIN 17459. A symbol for the cast can be
used in the marking instead of the cast number.
5 . 2 Nuts and bolts as specified in 2.5 shall be marked in
accordance with 3.2 of DIN IS0 3506. Nuts and bolts not
covered by that standard shall bear the manufacturer’s sym-
bol and steel grade (abbreviation, material number or other
mark to be agreed, which shall then be indicated in the
inspection certificate). Bolts with dimensions from M 52
upwards shall also bear the cast number. Where an inspec-
tion certificate 3.1.A or 3.1.C is intended, bolts equal to or
higher than M 30 shall bear the test stamp of the authorized
inspector.
.
6) Tasting is possible on application of SEP 1921.
‘) For pipes with outside diameter 5 42.4 mm and wallthickness
. is in accordance with test class 1.
Page 5 AD-Merkblatf W 2. Edition 01.2000
6 Verification of quality characteristics
6.1 Plate and strip
6.1.1 The data in table 2 are applicable to verification of
quality characteristics (mechanical properties, visual inspec-
tion and dimensional test) for plate and strip made of steels
as specified in 2.1 and 2.2.
Verification of quality characteristics for plate and strip made
of steels specified in 2.3,2.4,2.7 and 2.8 is based on the sui-
tability verification.
6.1.2 With regard to ladle analysis and positive material
identification, the provisions of DIN 17440 and DIN 17460
apply to plate and those of DIN 17441 apply to strip.
6.1.3 Verification of resistance to intergranular corrosion
takes the form in all cases of inspection certificate 3.1 .B.
6.2 Tubes
6.2.1 Seamless tubes as specified in 2.1 and 2.2 shall be
certified with inspection certificates 3.1 .A or 3.1 .C for wall
thicknesses over 5.6 mm, or with inspection certificate 3.1 .B
for wall thicknesses not exceeding 5.6 mm. Seamless tubes
made of 1.4311, 1.4429 and 1.4462 steels shall be certified
with inspection certificates 3.1 .A or 3.1 .C, regardless of the
wall thickness.
Welded tubes made of steels specified in 2.1 and 2.2 shall
be certified with inspection certificates 3.1 .A or 3.1 .C. If on
conclusion of process testing, the quality and consistency of
manufacture are verified over a sufficiently long period, the
quality characteristics for wall thickness 9 10 mm can be ver-
ified by inspection certificate 3.1 .B. The decisive factor here
is the number of tubes per size or per size group tested by
the authorized inspector.
The change to an inspection certificate 3.1 .B shall be con-
firmed to the manufacturer and, on agreement with the test-
ing authority, can be made for particular size groups. If use
is made of this provision, the TijO (Technical Inspectorate)
letter of confirmation shall be quoted in the inspection
certificate 3.1 .B.
Verification of quality characterics for seamless and welded
tubes made of steels specified in 2.3, 2.4, 2.7 and 2.8 is
based on the provisions of the suitability verification.
6.2.2 The provisions table 7 of DIN 17457 or DIN 17458
in either case, are applicable to the ladle analysis, verification
of resistance to intergranular corrosion, tightness test, posi-
tive material identification and the result of non-destructive
testing.
6.3 Bars and forgings
6.3.1 Verification of the quality characteristics (mechanical
properties, inspection, dimensional testing) for bars and
forgings made from steel specified in 2.1 and 2.2 is covered
by the information given in table 3. For cold re-drawn bars
to 2.6 the quality properties shall be certified by an inspection
certificate 3.1 .B.
6 . 3 . 2 Bars and forgings made of steels specified in 2.1 and
2.2 which are used as the seamless tubular products within
the meaning of the scope of AD-Merkblatt W 12 with an oper-
ating gauge pressure (r 80 bar shall be certified with an
inspection certificate 3.1 .B, unless otherwise stipulated in the
suitability verification for steels complying with SEW 400.
Steels of material numbers 1.4311 and 1.4406 shall be certi-
fied with inspection certificates 3.1 .A or 3.1 .Ce). For oper-
I
i.
I:
S 3.6 mm, marking 8) On confirmation of compliance with the quality characteristics given in DIN 17440 .I
for these steels, they are ranked as equivalent to the other austenitic steels. 1:
/
..-__ ._ .-.
.w . .._” .j
Page 6 AD-Merkblatt W 2, Edition 01.2000
ating gauge pressures > 80 bar, quality characteristics shall
be certified with inspection certificates 3.1 .A or 3.1 .C.
6.3.3 Verification of quafity characteristics for bars and
forgings made of steels specified in 2.3, 2.4, 2.7 and 2.8 is
based on the provisions of the suitability verification.
6.3.4 The provisions of DIN 17440 and DIN 17460 are
applicable to the ladle analysis and positive material identifi-
cation.
6.3.5 Verification of resistance to intergranular corrosion
takes the form in all cases of inspection test certificate 3.1 B.
6 . 3 . 6 Non-destructive testing shall be certified with inspec-
tion certificate 3.1 B.
6.4 Nuts and bolts
6.4.1 An inspection certificate 3.1 .B is required for nuts and
bolts according to 2.5. The type 3.1 .B inspection certificate
can be replaced by marking with a strength class and manu-
facturer’s symbol, provided the manufacturer has continuo-
usly carried out the test used as a basis for issuing an inspec-
tion certificate 3.1 .B and keeps the results available for
inspection by the authorized inspector. Substituting the test
certificate with a stamp and compliance with the conditions
shall be subject to an agreement.
6 . 4 . 2 Bolts made of steel specified in table 1 not covered
by DIN IS0 3506 and bolts made of other austenitic steels
shall be certified with an inspection certificate 3.1 .A or 3.1 .C.
In the case of machined bolts, the regulations forthe bars are
those contained in 6.3.1. and 6.3.3 provided bolts to DIN IS0
3506, strength class 50, are being tested as finished bolts.
6 . 4 . 3 Nuts and bar material used for nuts shall be certified
with an inspection certificate 3.1 .B.
7 Design characteristics
7.1 For steels specified in table 1, the characteristics to be
used for design are the 1 % yield strength within the given
dimensional limits specified for the relevant products in DIN
17440, DIN 174419), DIN 17457, DIN 17458, 17460 or
SEW 400.
For the steels given in table 1, use in individual cases of the
1 % yield strengthlo) as the design characteristic is also allo-
wable beyond the thicknesses and diameters given in the ,-. ’
relevant standards, provided that the elongation after frac-
ture and notch impact strength values are equal to or greater
than the minimum values given in the relevant standards. If
this condition is not satisfied, the 0,2 % proof stress shall be
taken as the design characteristic.
The strength characteristics for design shall be laid down in
the suitability verifications for austenitic steels complying with
other material specifications. ;>
1
t
7 . 2 In the case of bolts according to 2.5 the corresponding
strength characteristic values in DIN IS0 3506 or table 5
apply. For the 0,2 % proof stress at elevated temperatures
the figures in table 6 apply.
7 . 3 The characteristic strength values at 20 “C stated in the
DIN standards, SEW 400 or suitability assessment proce-
dure documents, shall be applicable up to 50 “C and those
stated for 100 “C shall be applicable up to 120 “C. In other
temperature ranges, linear interpolation between the stated
values is necessary (e.g. for 80 “C, between 20 and 100 “C
and, for 180 “C, between 100 and 200 “C) but no rounding
off is permissible. In the case of materials as specified in 2.4,
the interpolation rule shall apply only where the interval
between the values already known is sufficiently small.ll)
7.4 With regard to long-term values, the temperature is
rounded up to 5, 10, 15 “C etc. Interpolated strength charac- I
teristics shall be rounded down to the nearest whole number.
l
I,
i
9) The data for the longitudinal direction are applicable.
10) The minimum value to be adhered to shall be agreed with the material manu-
facturer.
1’) This is generally understood to mean a temperature interval of 50 K in the
elevated-temperature yield strength range and an interval of 10 K in the creep
rupture strength range.
 Page 7 AD-Merkblatt W 2. Edition 01.2000
L

Table 3. Verification of quality characteristics for bars and forgings made of steels specified in table 1

Type of test certification

: Grade of steel to DIN EN 10204
Thicknesses Thicknesses
Abbreviation Material No. mm m m
X 5 CrNi 1810 1.4301 5 250 > 250
X5 CrNi 1812 1.4303 5 160 > 160
X2 CrNi 1911 1.4306 i 250 > 250 EG’)
X2 CrNi 1 8 1 0 1.4311 5 250 > 250
X 6 CrNiTi 1810 1.4541 5 250 > 250 to I 45C 3.1 .A or 3.1 .C
X 6 CrNiNb 1810 1.4550 5 250 > 250 to 5 45c

X 5 CrNiMo 17122 1.4401 5 250 > 250

X 2 CrNiMo 17132 1.4404 5 250 > 250 EG’)
X 2 CrNiMoN 17 122 1.4406 5 160 > 160

X 6 CrNiMoTi 17122 1.4571 5 250 > 250 to s 45C 3.1 .A or 3.1 .C

X 6 CrNiMoNb 17122 1.4580 5 250 > 250 EG’)

X 2 CrNiMoN 17133 1.4429 I 250 3.1. B >250to%400 3.1.AOr3.1.C

X 2 CrNiMo 18143 1.4435 5 250 > 250

X 5 CrNiMo 17133 1.4436 5 160 > 160 EG’)
X 2 CrNiMo 18164 1.4438 5 160 > 160
X 2 CrNiMoN 17 1352) 1.4439 5 160 > 160 3.1 .A or 3.1 .C

X 4 NiCrMoCuNb 20182 1.4505 5 160 > 160 EG’)

X 1 NiCrMoCuN 252052) 1.4539 5 60 > 60 3.1.A or 3.1.C

X 3 CrNiMoTi 2525 1.4577 5 160 > 160 EG’)

X 2 CrNiMoN 225 1 2, 1.4462 not applicable 5 250

X6 CrNi 1811 1.4948

. X3 CrNiN 1811 1.4949 (.
X8 CrNiTi 1810 1.4941
X 6 CrNiMo 1713 1.4919
X 3 CrNiMoN 1713 1.4910 not applicable not applicable i 350 3.1.A or 3.1.C
X 8 CrNiNb 1613 1.4961
X 8 CrNiMoNb 1616 1.4981
X8 CrNiMoVNb 16 13 1.4988
X5 NiCrAlTi 3120 1.4958

c
X 8 NiCrAlTi 3221 1.4959

1) Individual assessment in accordance with AD-Merkblatt W 0.

2) Applies to pressure vessels requiring structural testing by the authorized inspector in conjunction with VdTijV Material Sheets 405. 418 or 42’.

.
Page 6 AD-Merkblatt W 2. Edition 01.2000

Table 5. Mechanical properties of nuts and bolts made of steel according to 2.5, strength class 70 within the diameter range
greater than M 20 but not exceeding M 30
:.
Bolts Nuts

Tensile 0,2% proof Elongation Test

strength stress after stress
fracture
Steel Strength Diameter R,‘) &O,Z!‘) ALL) SP -’

group class ranges) N/mm2 N/mm2 N/mm2

min. min. min.

A 2 and A 4 70 > M 20 to 500 250 0,4 d 500

1) All values are calculated
2) Elongation after fracture is
faced specimens with a
3) For diameters above M
for the tensile strengths
5 M 30
and relate to the stress area of the thread (see DIN IS0 3506 Annex C).
determined in compliance with the test procedure in 6.4 of DIN IS0 3506 on the appropriate length of the bolt and not on machine
gauge length 5 d. For elongation after fracture values see DIN IS0 3506 Annex D.
30 the strength values shall be agreed between the client and the manufacturer, as other 0.2 % proof stress values are possible
specified in table 5.

Table 6. Characteristic values of the 0,2 % proof stress R,,2 at elevated temperatures for bolts in accordance with 2.5

_’ i

N/mm2

r) All values are calculated and related to the stress area of the thread (see DIN IS0 3506 Annex C).
ICS 23.020.30 January 2000 edition

Materials Cast iron with lamellar graphite AD-Merkblatt ;;

for (grey cast iron) /::;
Pressure Vessels non-alloy and low alloy w 3/l

The AD-Merkblatter are compiled by the seven trade associations specified below who together form the ‘Arbeitsgemeinschaft Druck-
behdlter” (AD). AD-Merkblatt G 1 covers the composition and application of the AD-Regulations and also the procedural rules.
The AD-Merkblatter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
and above the normal level being anticipated during the operation of pressure vessels, allowance must be made for such stresses by
meeting special requirements.
Should there be any departures from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis,
operating experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e.V. (FDBR), Dusseldorf
H a u p t v e r b a n d d e r g e w e r b l i c h e n B e r u f s g e n o s s e n s c h a f t e n e . V . , Sankt Augustin
Verband der Chemischen lndustrie e.V. (VU), FrankfurtlMafn
Verband Deutscher Maschinen- und Anlagenbau e. V, (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Dusseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkraftwerksbetreiber e . V., E s s e n
Verband der Technischen iiberwachungs-Vereine e.V. (VdTDV), Essen
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s i n keeping with technical progress. Relevant proposals should
be addressed to the publisher:
Verband der Technischen iibenvachungs-Vereine e. V., Postfach 103834, D-45038 Essen.

Contents
1 Scope and general 5 Marking
2 Suitable materials * 6 Certification of quality
3 Tests 7 Dimensioning charackteristics
4 Quality of castings Appendix 1

1 Scope and general
1 . 1 This AD-Merkblatt’) applies to unalloyed and low-allo-
yed cast iron with lamellar graphite for the construction of
pressure vessels operating at temperatures determined by
atmospheric conditions and at charge temperatures of
-10 “C up to the limits of temperature given in Clause 2.
AD-Merkblatt W IO also applies where charge temperatures
are below - 10 “C.
1 . 2 In the case of cast iron with lamellar graphite for the
construction of pressure vessels where the structural test has
to be carried out by the authorized inspector, the regulations
contained in the following Clauses 2 to 7 shall apply.
1 . 3 In the case of cast-iron with lamellar graphite for the
construction of pressure vessels where the structural test
does not have to be carried out by the authorized inspector,
no further specifications are necessary in addition to those
contained in AD-Merkblatt W 0.
1 . 4 The production of cast iron with lamellar graphite for the
construction of pressure vessels presupposes an adequate
level of experience on the part of the suppliers. The autho-
rized inspector shall first be given proof of this in the case of
those pressure vessels on which he has to carry out a structu-
ral test.
‘) The Publishers wish to thankthe Verein Deutscher Giel3eMachleute.
and the Fachgemeinschaft Verfahrenstechnische Maschinen und Apparate in the
VDMA. Frankfurt, who, in response to their request, kindly assisted m the drafting
of this specification.
1.5 Cast-iron with lamellar graphite shall only be used for
the construction of pressure vessels if the characteristics of
the material offer operational advantages over other types of
material. For pressure vessels constructed of cast iron with
lamellar graphite the following limits to the permissible work-
ing pressure, or nominal pressure to DIN EN 764, generally
afwly:
25 bar gauge for internal pressure
40 bar gauge for external pressure
In the case of an internal pressure of more than 6 bar (gauge)
and an external pressure in excess of 10 bar (gauge), the
following products of vessel capacity I in litres and the per-
missible operating pressure p in bar shall in general not be
exceeded :
Internal pressure 1. p = 65000
External pressure 1. p = 100 000
If the figures produced are higher than these values, the
agreement of the authorized inspector and the purchaser
shall be obtained if the structural test has to be conducted
by the authorized inspector. If a structural test by the autho-
rized inspector is not required, his agreement is not neces-
sary.
1 . 5 1 Additional specifications for drying cylinders
In the case of steam drying cylinders, the internal pressure
I. p value of 65000 can be exceeded with the agreement of
the authorized inspector under the following preconditions:
Dirsseldorl
(1) The maximum permissible working pressure is limited to
15 bar.

Supersedes November 1986 edition; fully revised

cIan neymanns verlag Kci rransratron: I ecnnrcal Help to Exporters Service of BSI
Luxemburger StraRe 449, 50939 Kijln
Page 2 AD-Merkblatt W 3/l, Edition 01.2000 *
(2) The permissible operating temperature is limited to
300 “C.
(3) The design shall be selected so that peak stresses are
avoided as far as possible. In particular, the toe of cylin-
der flanges shall have a radius of at least D/50 (D = out-
side diameter of cylinder).
(4) At least GG-30 shall be used.
(5) Generally, stress relief annealing shall be provided. Slow
cooling at a rate of less than 30 K/h in the temperature
range 600 “C to 150 “C shall be equated with subsequent
beat treatment, In both cases proof shall be supplied to
the authorized inspector through corresponding measu-
rements that the conditions have been met.
(6) The samples shall be taken from the top and the bottom
of the cylinder.
(7) Contrary to what is stated in 4.2 of AD-Merkblatt W 3/l,
welding on cylinders is not permitted.
1 . 6 Due account shall be taken of casting practice when
designing pressure vessels made of cast iron with lamellar
graphite if blowholes, cracks and peak stresses are to be
avoided.
2 Suitable materials
The following grades of material may be used in the construc-
tion of pressure vessels:
2.1 Cast iron with lamellar graphite (grey cast iron) to DIN
EN 1561 up to wall temperatures of 300 “C:
- EN-GJL-150,
- EN-GJLQOO,
- EN-GJL-250,
- EN-GJL300,
- EN-GJL-350.
Where wall temperatures exceed 300 “C, the minimum grade
shall be EN-GJL 300 with the wall temperatures generally
being limited to 350 “C. In this case, the suitability and tensile
strength of the cast iron materials at the operating tempera-
ture shall be proven initially when determining suitability.
Where appropiate, heat treatment shall be provided.
2.2 Other grades of cast-iron with lamellar graphite are
acceptable, if their suitability and quality characteristics have
first been confirmed by the certificate of suitability.
3 Tests
3.1 In the case of those types of materials listed in 2.1, one
of the properties to be tested shall be tensile strength in
accordance with DIN EN 1561. Where wall thicknesses
exceed 20 mm and if the design so permits, cast-on-speci-
mes shall be used. The minimum requirements shall be in
accordance with those values for tensile strength given in
DIN EN 1561, bearing in mind their relation to wall thicknes-
ses. For wall temperatures above 300 “C the tensile strength
at design temperature shall also be tested.
3.2 The number of samples is at least one per 1000 kg of
the same type of castings supplied (test unit AMH as speci-
fied in DIN EN 1559-l) or per item in the case of castings over
500 kg. DIN EN 1559-l applies with regard to repeat testing.
3.3 Testing of material grades according to 2.2 shall be
defined in the suitability certificate according to type and
scope.
3 . 4 Samples of heat-treated castings shall be heat-treated
together with the castings and cast-on samples shall not be
separated until after heat-treatment has taken place.
3 . 5 Before castings subjected to pressure are coated, they
shall undergo a hydraulic pressure test of sufficient duration,
the test gauge pressure as a general rule being twice that
encountered under normal operating conditions.
If operating conditions are special, an agreement may be
reached between the purchaser (or operator) and the manu-
facturer to determine the tightness of the walls and to test for
flaws in the casting in addition to the hydraulic pressure test.
In such cases the tests to be applied, either singly or in combi-
nation, are as follows:
(1) Leak testing with air (test pressure approximately 0,l
times the operating pressure, but a maximum of 2 bar
gauge). A foaming fluid shall be applied before the hyd-
raulic pressure test is carried out. In special cases a sui-
table gas shall also be used in conjunction with an indi-
cating instrument.
(2) Leak testing using petrol or other similar fluid, e.g. water
with low surface tension (test gauge pressure not more
than 1,5 times the operating pressure) before the hydrau-
lic pressure test.
(3) Radiographic test.
(4) Ultrasonic testing. If doubts exist, this should be used in
conjunction with another test, in particular the radiogra-
phic test.
4 Quality of castings
4.1 The external characteristics of the castings shall be
inspected and a check made of those dimensions which are
important from the point of view of safety. In general, the pro-
visions of DIN EN 1559-1 apply in the case of the quality of
castings.
4 . 2 If possible welding on cast-iron parts for pressure ves-
sels shall be avoided.
In individual cases, following agreement between the autho-
rized inspector and the purchaser, production welding can be
carried out on cast iron pressure vessels following a proce-
dure qualification test.
5 Marking
5.1 Castings made from those grades of material given in
2.1 shall be marked with the manufacturer’s mark, batch
numer (sample number) and the material designation in
accordance with DIN EN 1559-l. The tester’s mark shall also
be stamped on the casting.
5.2 Castings made from grades of material given in 2.2
shall be marked in accordance with the provisions laid down
in the certificate of suitability.
6 Certification of quality
In the case of pressure vessels and parts of pressure vessels ’
subjected to pressure, proof of the quality characteristics
shall be provided in the form of an inspection certificate to
DIN EN 10024.
6.1 For pressure vessels parts made of EN-GJL-150, EN-
GJL-200 and EN-GJL-250 and for wall thicknesses
5 50 mm, proof shall be in the form of inspection certificate
3.1 .B as specified in DIN EN 10204.
-

Page 3 A D - M e r k b l a t t W 3/l, Edition 01.2000

6 . 2 For EN-GJL-300 and EN-GJL-350 and wall

ses’) > 50 mm (all cast grades), proof shall be in
thicknes-
the form
7.1.1 Up to a wall temperature of 300 “C the tensile strength
at ambient temperature shall be as shown in table 1 of DIN
(::.
of inspection certificate 3.1&C as specified in DIN EN EN 1561.
10204. 7 . 1 . 2 At wall temperatures over 300 “C (only EN-GJL-300
6 . 3 In the case of grades of material specified in 2.2 proof and EN-GJL-350 are suitable) the tensile strength at design
shall be in accordance with the provisions of the certificate temperature applies, taking into account the critical wall
of suitability. thickness. The values shall be agreed when formulating the
suitability certificate.
7 Dimensioning characteristics 7 . 2 For material grades according to 2.2 the measurement
characteristics shall be specified in the suitability certificate.
7.1 In the case of material grades specified in 2.1, the mea-
surement characteristics which apply are the values antici- 7 . 3 In the case of enamelled cast-iron, a strength characte-
ristic K of 105 N/mm2 can be anticipated. Higher values shall
pated for tensile strength in the casting which are given in DIN
EN 1561. be verified using cast-on and enamelled specimens. With
multiple-enamelled castings lower strength values shall be
9) Critical wall thickness as specified in DIN 1559-l. used according to the number of annealing processes.

,...
Page 4 A D - M e r k b l a t t W 3/l, Edition 01.2000

I
Appendix 1 to AD-Merkblatt W 3/l I
1
..
Agreement of the AD Associations on the continuous use of previously valid DIN material standards

Cast iron materials GG-15, GG-20, GG-25, GG-30 and GG-35 as specified in the withdrawn May 1985 edition of DIN 1691
may be used until the EC Directive on Pressure Equipment has been adopted into national legislation and a European Stan-
dard has been published on pressure vessels taking into account the specifications of the November 1986 edition of _. .‘.
AD-Merkblatt W 3/l.

.
 Materials Cast iron materials AD-Merkblatt
for Spheroidal-graphite cast iron
Pressure Vessels non-alloy and low alloy W 312

T h e AD-Merkbltter a r e c o m p i l e d b y t h e s e v e n a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “ A r b e i t s g e m e i n s c h a f t DruckbehBlter”
‘AD). AD-Merkblatt G 1 covers the composition and application of AD-Regulations and also procedural guidelines.
T h e AD-Merkblatter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . I n t h e e v e n t o f l o a d i n g s e x c e e d i n g
he normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
.equirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it m u s t b e p o s s i b l e to demonstrate t h a t t h e s a f e t y s t a n d a r d s
embodied in these regulations have been observed by other means, e.g. testing o f materials, e x p e r i m e n t s , s t r e s s a n a l y s i s , o p e r a t i n g
experience.
Fachverband Dampfkessef-, Behdlter- und Rohrleitungsbau e.V. (FDBR), Diisseldoti
H a u p t v e r b a n d d e r g e w e r b l i c h e n B e r u f s g e n o s s e n s c h a f t e n e . V . , Sankt Augustin
Verband der Chemischen lndustrie e.V. (VU), FrankfurNMain
Verband D e u t s c h e r M a s c h i n e n - und A n l a g e n b a u e . V . ( V D M A ) , Fachgemeinschaft V e r f a h r e n s t e c h n i s c h e M a s c h i n e n
und Apparate, FrankfurtlMain
Verein Deutscher Eisenhiittenleute (VDEh), Diisseldorl
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkraftwerksbetreiber e . V., E s s e n
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkbl&ter a r e a m e n d e d c o n t i n u o u s l y b y t h e a b o v e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
5e addressed to the publisher:
Verband der Technischen iibetwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents
1 Scope and general 5 Marking
2 Permissible grades of materials 6 Certification of quality
3 Tests 7 Design strength values
4 Quality of castings

1 Scope and general 2 Permissible grades of materials

1.1 This AD-Merkblatt applies to non-alloy and low-alloy The following grades of materials can be used for the con-
spheroidal-graphite cast iron for the construction of pressure struction of pressure vessels:
vessels and parts operating at temperatures determined by
2.1 Spheroidal-graphite cast iron to DIN EN 1563, grades
atmospheric conditions and at charge temperatures within
the limits given in tables 1 and 2. For temperatures below EN-GJS-400-15, EN-GJS-500-7, EN-GJS-600-3, EN-GJS-
- 10 “C, AD-Merkblatt W 10 shall also be taken into conside- 700-2 and EN-GJS-400-15U, EN-GJS-500-7U, EN-GJS-
600-3U and EN-GJS-700-2U. With an internal pressure of
ration.
more than 6 bar gauge or more than 10 bar gauge in the case
1.2 The production of spheroidal-graphite cast iron for the of the ferritic grade EN-GJS-400-15/15U, the maximum pro-
construction of pressure vessels presupposes an adequate ducts of pressure and capacity given in table 1 shall gener-
level of experience on the part of the suppliers. The autho- ally not be exceeded.
rized inspector shall be provided with initial proof of this.
Higher product values are only permissible with the agree-
1.3 Due account shall be taken of casting practice when ment of the autorized inspector.
designing pressure vessels made of spheroidal-graphite cast
iron if blowholes, cracks and peak stresses are to be avoided. Table 1 Range of application of standard grades to
1.4 For valve bodies, TRB 801, No. 45 applies. I DIN EN 1563
1.5 The stipulations in Clauses 2 to 7 below are applicable
Material grade Operating Nominal Product
to parts for the construction of pressure vessels to be sub-
temperature pressure values
jetted to structural tests by the authorized inspector (pres- “C to DIN 2401 PXf
sure vessel test groups III, IV VI and VII). part 2 (bares x litres)
1.6 Apart from the provisions contained in AD-Merkblatt (m& (mad
W 0, no additional requirements are necessary for parts used EN-GJS-700~2/2U 25 65 000
in the construction of pressure vessels for which the manu- EN-GJS-600-3/3U 25 65 000
facturer has to certify correct manufacture (pressure vessels -10 bis 350
EN-GJS-500-7/7U 64 80 000
of test group I, where they are used for combustible, corro- EN-GJS-400-15l15U 100 100 000
sive ortoxic gases, vapours or liquids, or of test group II or V).

Supersedes June 1985 edition; 1 = Amendments to previous edition

Carl Heymanns Verlag KG Translation: Technical Help to Exporters Service of BSI

Luxemburger Strai-% 449, 50939 Kiiln
 Page 2 AD-Merkblati W 3/2. Edition 01.2000

2 . 2 Spheroidal-graphite cast iron, grades with guaranteed
1 notch impact strength to DIN EN 1563 within the range given
in table 2.
2 . 3 Other grades of sph&oidal-graphite cast iron, when the
properties have been demonstrated initially in the expert
opinion of the authorized inspector.
Table 2 Range of application of grades with guaranteed
I notched impact strength according to DIN EN 1563
Material grade Operating
3 . 6 . 2 If in the individual testing the result of a mechanical
or technological test does not meet the requirements, for
each unsatisfactory specimen two replacement specimens
from the same piece shall be tested and both shall pass.
3 . 6 . 3 If the result of retesting also does not satisfy the requi-
rements, the batch represented by the tests shall be rejected.
3 . 6 . 4 If it can be assumed that unsatisfactory test results
can be ascribed to faulty heat treatment, the casting can be
heat treated again, and the entire test shall be repeated.
temperature “C

EN-GJS-400-18/18U-LT -10 bis 350 3 . 6 . 5 If unsatisfactory test results are clearly attributable to
EN-GJS-350-22/22U-LT -10 bis 350 the effects of testing or to a local defect in the specimen, the
I
test shall be repeated on a new specimen.

3 . 7 Tests on other material grades as specified in 2.3 shall

3 Tests
3.1 In the case of the material grades specified in 2.1 and
2.2, for wall thicknesses up to 60 mm the strength properties
shall be tested in accordance with table 1 of DIN EN 1563 and
for wall thicknesses over 60 mm to 200 mm in accordance
with table 3 of DIN EN 1563. The test described in table 3 of
DIN EN 1563 may be agreed upon for wall thicknesses
between 30 mm and 60 mm.
3 . 2 In the case of the material grades specified in 2.2, the
notch impact energy shall be determined on IS0 V-notch
specimens as specified in DIN EN 10045. Compared with
I DIN EN 1563, the more severe requirements given in table 3
shall be met.
3 . 3 The number of specimens is at least one for the tensile
test and three for the notched-bar impact test per 2500 kg
delivered weight of the same type of castings from the simi-
larly treated cast and the same annealing batch or per casting
for single weights exceeding 500 kg.
be carried out in accordance with the expert opinion of the
authorized inspector.
3 . 8 All castings subjected to pressure shall undergo a hyd-
raulic pressure test of sufficient duration at service pressure
which is generally twice the normal.
3 . 9 If operating conditions are special, an agreement may
be reached between the purchaser (operator) and the manu-
facturer to determine the tightness of the walls and to test for
flaws in the casting in addition to the hydraulic pressure test
specified in 3.8. In such cases the tests to be applied, either
singly or in combination, are as follows:
(1) Leak testing wfth air (test pressure approximately O,?
times the operating pressure, but a maximum of 2 bar
gauge). A foaming fluid shall be brushed on before the
hydraulic pressure test is carried out. In special cases,
a suitable gas shall also be used in conjunction with an
indicating instrument.

3 . 4 Microstructural specimens can also be used for assess-
ing graphite and ferrite formation.
3 . 5 In the case of wall thicknesses over 60 mm to 200 mm
for operating temperatures I 200 “C, the high temperature
limit of elasticity shall be determined. For the material grades
specified in 2.1 and 2.2, the values in table 4b apply as the
minimum requirements.
3 . 6 The procedure for repeat tests is as follows:
3.6.1 In the case of testing of casts or batches, if the result
of a mechanical or technological test does not meet the requi-
rements, for each unsatisfactory specimen it is necessary to
test two replacement specimens (in the case of the notched
bar impact test two sets of 3 specimens) from another piece
in the same test unit and both shall be satisfactory. The cast-
ing from which the unsatisfactory specimen was taken shall
be rejected.
(2) Leak testing using petrol or other similar fluid, e.g. water
with low surface tension (test gauge pressure not more
than 1,5 times the operating pressure) before the hydrau-
lic pressure test.
(3) Radiographic test.
(4) Ultrasonic testing. If doubts exist, this should be used in
conjunction with another test, in particular the radiogra-
phic test.
(5) Surface crack test.
Quality of castings
4.1 The external characteristics of castings shall be
inspected and a check made of those dimensions of import-
ance from the point of view of safety. In general, the provisi-
ons of DIN 1690 apply for the quality of castings.

I Table 3 Minimum impact energy values

I Material grade Wall thickness Test temperature Energy absorbed by ISO-V-notched specimen
Mean value from Individual value
3 specimens
m m “C J J

II EN-GJS-400-18/18U-LT -20
14

12
11

5 60 14 11
I EN-GJS-350-22/22U-LT -40
b 60 bis 2 0 0 12 9
 Page 3 AD-Merkblatt W 3/2, Edition 01.2000
.
Table 4a Characteristic strength values for wall thicknesses up to 60 mm

Material grade Charac- Strength characteristics K in N/mm* at operating temperature in “C I

I 2.50 I 300 350

370 350 320 280

320 300 270 220
270 250 230 200
210 200 180 160
200 190 170 150
180 170 150 140

able 4b Characteristic strength values for wall thicknesses > 60 to 200 mm

Material grade Charac- Strength characteristics K in N/mm* at operating temperature in “C

teristic
value
EN-GJS-700-2/2U Rw.2 380 340 330 320 300 280 250
EN-GJS-800-313U bo.2 340 300 290 280 260 240 190
EN-GJS-500-7/7U ba* 290 250 240 220 200 180 160
EN-GJS-400-15/15U $3.2 240 220 210 190 180 170 150
EN-GJS-400-18/18U-LT bl.2 220 210 200 180 170 160 140
L

4.2 Heat treatment may be necessary to achieve the the manufacturer, the customer (oper$tor) and the autho-
required structural condition or the minimum property values. rized inspector.
I Only EN-GJS-350-22/22U-LT castings may be heat treated 7 . 3 The strength values given in tables 4a and 4b for 20 “C
for ferrite formation. apply up to 50 “C, and the values given for 100 “C apply up
4.3 Welding may only be undertaken on spheroidal-gra- to ii0 “C. In other ranges it is necessary to interpolate line-
phite cast iron vessels with the consent of the authorized arly between the values given (e.g. for 80 “C between 20 and
inspector following a procedure qualification test. 100 “C, for 140 “C between 100 and 150 “C). Values shall not
be rounded up. In the case of individually assessed materials
.
the interpolation rule only applies where the interval between
5 Marking figures is sufficiently small’).
5.1 Castings made of the material grades as specified in 7 . 4 In the case of enamelled castings, samples for deter-
l
2.1 shall be marked with the manufacturer’s mark, batch mining strength values shall be taken from test-pieces which
number (specimen number) and the grade, e.g. EN-GJS- have undergone the heat treatment stages of the enhancing
I 400-l 5. The tester’s mark shall also be stamped on the cast- process.
ing.
5 . 2 Castings made of the material grades specified in 2.2 7.5 Safety factors
shall also be marked with the cast number. When designing pressure vessels in spheroidal-graphite
5 . 3 Castings made of the material grades specified in 2.3 cast iron, account shall be taken of the safety factors S given
shall also be marked in accordance with the expert opinion in table 5 for the 0,2 limit at the operating temperature. In the
of the authorized inspector. case of material grades specified in 2.3 the safety factor is
stipulated in the report issued by the authorized inspector.

6 Certification of quality Table 5 Safety factor S

Quality shall be certified by means of an inspection certificate
I 3.1 .A/C in accordance with DIN EN 10204.

7 Design strength values

7.1 The values given in table 4a are the design strength
values for wall thicknesses up to and including 60 mm. Table EN-GJS-400-18/18U-LT 2,4
4b applies to wall thicknesses above 60 mm and up to EN-GJS-350-22/22U-LT 2,4 I
200 mm.
7 . 2 In the case of castings with wall thicknesses greater 3) This is generally understood to mean a temperature difference equal to 50 K in
than 200 mm, the strength values are to be agreed between the elevated temperature yield pomt range.

.
 DK 669.13:621.642-9661-966 Edltion April 1970
.
Materials Cast iron materials AD-Merkblatt
for Austenitic cast iron with
Pressure Vessels lamellar graphite w 3/3

‘he AD-Merkbliitter are being established by the six trade associations named below which form the ..Arbeitsgemeinschaft
Iruckbehllter” (AD). The Unfallverhiitungsvorschriff ..Druckbeh8/1er” (VBG 17) Issued by the Hauptverband der gewerblichen
?erufsgenossenschaft e. V refers to the AD-Merkblltter as ,,Normal Rules practised in Profession”. AD-Merkblatt G 1 states
tructure and application of the AD-Merkblcitter as we// as the directives for the technical work.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e. V. (FDBR). Dtisseldorf
Verband der Chemischen lndustrie e. V. (VCI), FrankfuH/Main
Verein Deutscher Eisenhtittenleute (VDEh). Dirsseldorf
Verein Deufscher Maschinenbau-Anstalten e. V. (VDMA), Fachgemeinschaft Apparatebau, Frankfurt/Main
VGB Technische Vereinigung der Grosskraftwerksbetreiber e. V.. Essen
Vereinigung der Technrschen Libenvachungs-Vereine e. V. (VdTuV), Essen.
-he AD-Merkblltter are currently adapted 10 technical progress by the six associations. Suggestions to amend and improve the
ID-MerkbWer should be adressed to the publisher
Vsralnlgung dsr Tachnlschsn Ubwwachungs-Verelne e. V., Poslfach 1790, D- 4300 Essan 1.

,. i .

Contents

1. Scope and general 5. Marking

2. Permissible types of material 6. Certification of quality
3. Tests 7. Strength values for calculation
4. Quality of castings

1. Scope’) and General
1.1. This AD-Merkblatt applies to austenitic cast iron with
‘amellar graphite for the construction of pressure vessels (see
also AD-Merkblatt A 4) which are operated at ambient tempera-
tures and at temperatures of the contained medium from
-10°C up to the temperature limits specified in Section 2. At
temperatures lower than -lo%, AD-Merkblatt W 10 should
also be complied with. Types must be selected according to the
use envisaged, taking into consideration the mechanical,
thermal and chemical demands and also the physical proper-
ties. (See DIN 1694).
1.2. For the manifacture of austenitic cast iron with lamellar
graphite for pressure vessels, it is apre-requisite that the
suppliers have adequate experience. Initially, proof of this must
be furnished to the Inspecting Authority
1.3. Austenitic cast iron with lamellar graphite should be used
for the manufacture of pressure vessels when the properties of
the material offer technical advantages over other types of
material. As a rule, the following limits for the maximum
permissible working pressures, or respectively rated pressures
[see also DIN 2401) apply to pressure vessels made from
austenitic cast iron with lamellar graphite:
25 bar in the case of internal pressure
40 bar in the case of external pressure.
In the case of internal pressure over 6 bar and external
pressures over 10 bar, the following mathematical products of
the capacity 1 in litres and the maximum permissible working
pressure p in bar should, in general, not be exceeded:
Internal pressure 1. p = 65000
External pressure I . p = 100000.
For higher values of the product, the agreement of the
Inspecting Authority must be obtained.
‘) The following ADMerkbMtter are already available:
W 3/l -Cast iron with tamellar graphite (greycast iron), non-alloy and
low alloy.
W 3/2 -Spheroidal-graphite cast iron, non-alloy and low alloy.
The following ADMerkMiMter are in preparation:
W 3/4 - Austenitic cast iron with spheroidal graphite.
W 3/S - Malleable cast iron.
1.4. Pressure vessels made from austenitic cast iron with
lamellar graphite must be perfectly free from pipes,cracksand
stress.points arising from the casting process. The contractor
should agree the design of the pressure vessel with the
foundry.
2. Permissible types of material
The following types may be used for the walls of pressure
vessels:
2.1. Austenitic types of cast iron with lamellar graphite to DIN
1694 up to wall temperatures of 360°C. In addition, in special
cases a working temperature of up to 450°C maximum can be
allowed. If the wall temperatures are over 350°C the suitability
and the characteristics of the lamellar graphitic austenitic cast
iron at the working temperature must be initially certified by the
expert opinion of the Inspecting Authority.
2.2. Other austenitic cast iron materials with lamellar graphite,
provided that their suitability and characteristics have been
initially certified by the expert opinion of the Inspecting
Authority.
3. Tests
3.1. In the case of types of austenitic cast iron with lamellar
graphite as clause 2.1. the tensile strength and the chemical
composition are to be determined. DIN 1694 covers the
minimum requirements, and Table 2 applies to the tensile
strength in relation to the wall thickness. In addition, the
rupture elongation must be determined; minimum require-
ments are not laid down. Besides this, for wall temperatures
over 350°C to 460°C the tensile strength and the elongation at
the working temperature must be determined. The following
applies to the selection and manufacture of test pieces and
test procedure:
3.1.1. From the test pieces, which should, if possible, be in the
form of flange-like strips with a thickness correspondingto the
critical wall thickness, and cast as an integral part of the
casting, in sufficient number and size, that the specified
specimens and if necessary specimens for repeat teat, can be
taken from them.

Including 2. AD-Amendment.

Carl Heymonns Verlag KG Translation: Technical Help to Exporters Service of BSl

Luxemborgar Str& 449, X939 K&n 1.

- - - ,,... . _..
J
 Page 2 AD-Merkblatt W 3/3

3.1.2. In castings with wall thicknesses up to 50 mm the
specimens for the tensile tests can be taken from separately
cast test pieces, in which case the cooling conditions should
correspond to those of the casting itself. DIN 1694 and Table 1
cover the dimensions. The fact that the test pieces correspond
to the casting must be guaranteed.
Table 1. Relationship between wall thickness and separately
cast test piece
free from high internal stresses. If necessary, the following heat
treatments should be given:
(1) Annealing at 930 to 960°C and quenching, e.g. in air, oil,
w a t e r and/or
(2) Stress relieving at 600 to 700°C.
4.2. As far as possible, welding should be avoided on cast parts
from austenitic cast iron with lamellar graphite for pressure
vessels. In exceptional cases welding’) and repair welding’)
may be carried out on pressure vessels made from austenitic
cast iron with lamellar graphite, with the agreement of the
Inspecting Authority and the purchaser, after a procedure
qualification test has been made.

5. Marking

II 10 to 30

30 to 50
Y 2, ,,U” specimen and simplified
I ,,U” specimen
ly3
I
I
Castings to clause2.1 areto be marked with the manufacturer’s
mark, the batch number or melt number (test piece number),
and the tyoe in accordance with DIN 1694. Castinos as clause
2.2 are to be marked according to the expert opinion of
Inspecting Authority. In addition, the examiner’s mark should
be stamped on. AD-Merkblatt A 4 applies to valve bodies.
3.13. Furthermore, the following are to be complied with,
where they apply:
Table 2. Guaranteed strength characteristics and values for
DIN 1605 Sheet 1 - Mechanical testing of metals; design purposes
general, and acceptance;
DIN 50125 - Testing of metallic materials: tensile Type Strength value
test pieces; directives for manufac- Tensile
ture; Material at wall thickness
Designation strength
No. in mm
DIN 50 146 - Tensile tests without precision measu- N/mm2
rements of elongation; carrying out GGL-NiMn 13 7 0,6652 4to10 160
and evaluating the tests. 10 to 30 140
3.2. The number of test pieces is at least one test piece for the 30 to 50 120
tensile test per 1000 kgs. of castings of the same kind, or one over 50 100
test piece per casting if the casting in the rough weighs more .-- r i
GGL-NiCuCr Oh-5 4to 10 170
than 500 kgs. DIN 1694 applies to repeat tests. 1562 10 to 30 150
3.3. The kinds of test and the extent of the testing for cast iron (Ni-Resist 1)‘) 30 to 50 130
materials as clause 2.2 are to be determined by the Inspecting over 5 0 110

.1
Authority.
$($NiCuCr Ob= 4to10 200
3.4. Test pieces from heat treated castings must be in thesame 10 to 30 180
heat treated condition as the castings, and be heat treated (Ni-Resist 1 b)‘) 30 to 50 160
together with them. Cast-on test pieces should not be cut off over 5 0 140
until after the heat treatment.
GGL-NiCr 20 2 OAWJ 4to10 170
3.5. Before any coating is applied, all castings which have to (Ni-Resist 2)‘) 10 to 30 150
withstand pressure must be subjected to a hydraulic pressure 30 to 50 130
test of adequate duration and, as a rule, at twice the working over 50 110
pressure. For deviations in the case of valve bodies, see
AD-Merkblatt A4. GGL-NiCr 20 3 46661 4to 10 200
(Ni-Resist 2 b)*) 10to30 180
3.6. If special stress conditions are present, the following tests 30 to 50 160
for establishing that the walls are leak-proof and for testing for over 5 0 140
faults in the material can be agreed upon between the
purchaser and the manufacturer, the tests being conducted GGL-NiSiCr Odw7 4to10 200
separately or in combination: 2043 10 to 30 180
(1) Leak testing with air (test pressure about 0.1 times the 30 to 50 160
working pressure, maximum 2 bar gauge) by painting with a over 50 140
foam-producing liquid after conducting the water pressure GGL-NiCr 30 3 0,6676 4to10 190
test; in special cases also by using a suitable gas and
(Ni-Resist 3)‘) 10to30 170
indicating equipment. 30 to 50 150
(2) Leak testing with pretroleum or another liquid which has over 50 130
the same effect, e.g. water containing a wetting agent
(maximum test pressure equal to 1.5 times the working GGL-NiSiCr OW 4to10 170
pressure), before the hydraulic pressure test. 3055 10 to 30 150
(3) Leakage test with satured or superheated steam (maximum (Ni-Resist 4)‘) 30 to 50 130
test pressure equal to the maximum permissible working over 50 110
pressure), after the water pressure test. GGL-Ni 35 Oh= 4to10 160
(4) Radiographic examination. (Ni-Resist 5)‘) 10to30 140
(5) Examination by ultrasonic, if necessary in combination with 30 to 50 120
another test, in particular radiographic examination. over 50 100

2, Welding carried out by the manufacturer of the castings in the course

4. Quality of castings
4.1. The castings should be visually inspected for their surface
quality, and the dimensions which are important from a safety
standpoint should be verified. In general the requirements of
DIN 1694 apply to the quality of castings. The cast iron must
not show any cracks nor fairly large blow holes, and must be
of manufacture, with the object of ensuring the quality necessary for
the guaranteed characteristics and the purpose for which the casting
is to be used.
“) Repair welds are carried out for the repair of castingswhich have been
damaged during use, by which means the castingis restoredasfares
possible to its original characteristics and usefulness by the defects
being removed.
‘) The items in brackets are trade names and are given for information.
 Page 3 AD-Msrkblatt W 313
.

6. Certification of quality
For pressure vessels and parts of pressure vessels under
pressure, the certification of characteristics and of the hydrau-
lic pressure test is to be furnished in the form of Acceptance
Certificate 3.1 C in DIN 50049. In addition, chemical composi-
tion (ladle analysis) and heat treatment are to be certified by the
manufacturers.
7.2. For austenitic cast iron materials with lamellar graphite to
clause 2.2, the strength values are to be laid down according to
the expert opinion of the Inspecting Authority.
7.3. When designing pressure vessels made from austenitic
cast iron with lamellar graphite, the safety factors5) given in
Table 3 are to be taken into consideration for the tensile
strength.

Table 3. Safety factors

I:-
7. Strength values for calculation
Matenal types as DIN 1694 Safety factors S
7.1. As design stress basis the following should be taken:
a t.:;:
t:‘
7.1.1. Up to wall temperature of 350°C. the tensile strength at not annealed
annealed 6 I:.‘;
room temperature, taking into consideration the wall thickness “:
given in Table 2.
7.1.2. At a wall temperature over 350°C up to 450°C max., the
tensile strength at the design temperature, taking into account
the wall thickness, The values are to be agreed upon between “) The safety factors are given here provisionally, until such time as they
the manufacturer and the Inspecting Authority. are included m AD-Merkblatt 60.

I.

j:

.
 . _ L . . .
..~.-i~ _
^ , , . - ^ . _ _ _ ^ . p . . .
. > _ , . _ , .
*

UDC: 621.642.02-98:669.14:620.1:614.8 Edition May 1992

Materials Tubes made from AD-Merkblatt

for
non-alloyed and alloy steels w4
Pressure Vessels

‘he AD-MerkbHter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
behllter” (AD). AD-Merkblatt G 7 covers the composition and application of the AD-Regulations and a/so the procedural rules.
he AD-MerkblNter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
Ind above the normal level being anticipated during the operation of pressure vessels, allowance must be made for such stresses by
meeting special requirements.
;hou/d there be any departures from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis,
operating experience.
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e.V. (FDBR), Diisseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sanki Augustin
Verband der Chemischen lndustrie e. V. (XI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhijttenleute (VDEh), Dtisseldorf
VGB lechnische Vereinigung der GrooBkraftwerksbetreiber e.V, Essen
Verband der Technischen iiberwachungs-Vereine e. V (VdTiiV), Essen.
‘ h e AD-Merkb/&ter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
)e addressed to the publisher:
Verband der Technischen iiberwachongs-Vereine e. V., Posifach 103834, D-4300 Essen 1.

Contents

1 Scope 6 Design factors

2 Suitable tubes 7 Suitable tubes as pressure vessel shells
3 Tests 8 Appendix 1: Agreement reached by AD Associations
4 Marking regarding the continued use of tubes
5 Certification of quality characteristics

I Scope 2 Suitable tubes

I.1 This AD-Merkblatt is applicable to seamless and
welded tubes made from non-alloyed and alloy ferritic steels
Ised for the construction of pressure vessels which are op-
?rated at temperatures governed by the weather and at tem-
,eratures determined by the charge down to - 10 “C and up
o the upper temperature limits specified in Section 2. Section
7 is also applicable for the use of tubes as pressure vessel
shells.
-or charge temperatures below - 10 “C, AD-Merkblatt W 10
s also applicable.
1.2 For tubes made from austenitic
N 2, “Austenitic steels” is applicable.
1.3 The provisions in the following Sections 2 to 7 are
applicable to tubes for the construction of pressure vessels
Nhich are to be subjected to a construction inspection by the
suthorised inspector (pressure vessels in Test Groups III, IV,
VI and VII).
1.4 No supplementary provisions are required in addition
:o the stipulations in AD-Merkblatt W 0 for tubes for the con-
;truction of pressure vessels where the manufacturer has to
:ertify their correct manufacture (pressure vessels in Test
Sroups I, II and V).
The tubes listed in Sections 2.1 and 2.2 may be used under
internal or external pressure within the application limits ac-
cording to Table 1 a or 2a.
2.1 Seamless tubes
2.1.1 As specified in DIN 1629 “Seamless circular tubes
made from non- alloyed steels with special quality require.
merits”.
2.1.2 As specified in DIN 1630 “Seamless circular tubes
made from non-alloyed steels with very high quality require-
ments”.
steels, AD-Merkblatt
2.1.3 As specified in DIN 17175 “Seamless tubes made
from high-temperature steels”.
2.1.4 As specified in DIN 17 173 “Seamless circular tubes
made from steels with high impact strength at low tempera.
ture”.
2.1.5 As specified in DIN 17 179 “Seamless circular tubes
made from fine-grained structural steels” in conjunction witl-
VdTuV-WerkstoffbHter 351 I2 to 35712.
2.1.6 Seamless tubes made from other grades of steel ac.
cording to assessment of suitability by the authorised inspec
tor. In such case, the application limits shall be stated. The
steel grades shall satisfy the following requirements:

Supersedes Edition January 1990; ( = amendments to previous Edition (e.g. Tables 3 to 5 no longer applicable)
^Cart n e y m a n n s ._^ -
verlag KU Translation: Technical Help to Exporters Service of BSI
Luxemburger StraSe 449, 5ooO K M 41
GutenbergstraOe 3 , 1000 Berlin 1 0
Page 2 AD-Merkblatt W 4, Edition 05.92 ’
Elongation at failure A5 in the longitudinal direction shall be
at least 20%. Elongation at failure 2 14% is nevertheless
sufficient if, during working, the cold deformation of the tubes
at the most unfavourable place does not exceed 5% or if,
after cold deformation exceeding 5 %, the tubes are then heat
treated.
2.2 Welded tubes
Welded tubes as specified in Sections 2.2.1 to 2.2.6 if the
manufacturer originally demonstrated to the authorised in-
spector in a procedure qualification test’) that he has reliably
mastered the welding procedure. The stipulations regarding
the type of material test certificates according to DIN 50049
(see Table 2a) are only applicable if the quality and uniformity
of the product are demonstrated to the authorised inspector
on completion of the procedure qualification test’). If this is
not appropriate, test certificate C is required.
For pressure-welded tubes, the tube or the welded joint shall
be normalised over their entire length after welding. It is con-
sidered that the latter requirement has been fulfilled if the last
shaping process during the manufacture of the tubes is a nor-
malising forming operationz).
In the case of fusion-welded tubes, the provisions in AD-
Merkblatt HP 7/2 are applicable for the heat treatment. If cold
forming of the tubes is envisaged, the heat-treated state of
the welded joint shall be taken into account.
2.2.1 As specified in DIN 1626 “Welded circular tubes
made from non-alloyed steels with special quality require-
ments” apart from steel grade USt 37.0.
2.2.2 As specified in DIN 1628 “Welded circular tubes
made from non-alloyed steels with very high quality require-
ments”.
2 . 2 . 3 As specified in DIN 17 177 “Electric pressure-welded
tubes made from high-temperature steels”.
2.2.4 As specified in DIN 17174 “Welded circular tubes
made from steels with high impact strength at low tempera-
ture”.
2.2.5 As specified in DIN 17178 “Welded circular tubes
made from fine-grained structural steels” in conjunction with
VdTUV-Werkstoffblatter 351/l to 35711.
2 . 2 . 6 Welded tubes made from other steel grades accord-
ing to assessment of suitability by the authorised inspector.
In such case, the application limits shall be stated. Utilisation
of the permissible design stress in the weld under internal
pressure shall be defined in the assessment of suitability.
The requirements placed on tubes made from comparable
steel grades as specified in Sections 2.2.1 to 2.2.5 shall apply
as appropriate as minimum requirements during assessment
of suitability.
3 Tests
3.1 Seamless tubes as specified in Sections 2.1 .l to 2.1.5
shall be tested in accordance with the relevant DIN stan-
dards.
3 . 2 For seamless tubes as specified in Section 2.1.6, the
tests shall be performed in accordance with the stipulations
in the assessment of suitability.
1) See VdTiiV-Merkblatt 1151, obtainable from Verfag TOV Rheinland GmbH.
Postfach 10 1750, 5000 K6ln 1.
2) For a definition of this term, see Stahl-Eisen-Werkstoffblatt 082, available
from Verlag Stahleisen mbH, Postfach 8229, 4000 Dijsseldorf 1.
3.3 Welded tubes as specified in Sections 2.2.1 to 2.2.5
shall be tested in accordance with the relevant DIN stan-
dards.
3 . 4 For welded tubes as specified in Sections 2.2.6, the
tests shall be performed in accordance with the stipulations
in the assessment of suitability.
~’ ‘
3 . 5 If a non-destructive test (e.g. an eddy current test ac-
cording to Stahl-Eisen-Priifblatt 1925) is used as a leak test
instead of the hydraulic test, the suitability of this procedure
shall originally be established by the authorised inspector. !
I
3.6 If tubes according to the Technical Specifications
stated in this AD-Merkblatt are to be subjected to non-de-
structive testing according to SEP 1915, the tubes shall be i.__
b-1
tested over their entire length3).
If the installation is such that ends of tubes remain un-
tested, evidence of freedom from defects shall be provided
in another way. This can be achieved by supplementary
non-destructive testing or by the testing of ring specimens.
It is also permissible to cut off the untested tube ends.
4 Marking
4.1 Tubes as specified in Sections 2.1.1 to 2.1.5 and
2.2.1 to 2.2.5 shall be marked in accordance with the stipu-
lations in the relevant DIN standards.
4.2 Tubes as specified in Sections 2.1.6 and 2.2.6 shall
be marked in accordance with the stipulations in the as-
sessment of suitability.
5 Certification of quality characteristics
5.1 Quality characteristics shall be certified according to
Tables 1 a and 2a.
5.2 The tube manufacturer shall additionally certify the
following:
(1) That the material used for the tubes meets the require-
ments in the relevant DIN standards or the assessment
of suitability for the appropriate steel grade and, if appli-
cable, Quality Level or Test Class, that all tubes have
passed the leak test and that, over their entire length,
they are in the proper delivery condition according to the
appropriate material specification or in the delivery con-
dition agreed at the time of ordering.
(2) The non-destructive testing stipulated in the relevant DIN
standards or the assessment.of suitability with test cer-
tificate B according to DIN 50049 has been carried out.
(3) The result of the ladle analysis in the case of alloy steels
insofar as this is required in the material specifications.
(4) The utilisation of the permissible design stress in the
case of tubes as specified in Section 2.2.1 with a test cer-
tificate and in the case of tubes as specified in Section
2.2.6.
(5) That tests have been carried out to make sure that the
correct material has been used in the case of tubes made
from alloy steels according DIN 17 173, 17 174, 17 175
and 17177.
3) It is considered that this requirement has been fulfilled if the tubes tested
are joined.

6 Design factors
6.1 The design factors for tubes as specified in Sections
2.1 .l ,2.1.2,2.2.1 and 2.2.2 are to be taken from the technical
delivery conditions contained therein.
6 . 2 For tubes as specified in Section 2.1.3, the characte-
ristic design values shall be taken from DIN 17175.
6 . 3 For tubes as specified in Section 2.2.3, the characte-
ristic design values shall be taken from DIN 17 177.
6 . 4 For tubes as specified in Sections 2.1.4 and 2.2.4, the
values stipulated in DIN17 173 and DIN 17 174 are applica-
ble. AD-Merkblatt W 10 contains characteristic hot yield
stress values which are valid for short-time operation.
6 . 5 For tubes as specified in Sections 2.1.5 and 2.2.5, the
values stipulated in DIN 17 178 and DIN 17 179 are applica-
ble with the reduced values for the elevated temperature
properties series being divided by 1,2 for the basic series up
to 300 “C. This also applies to the high impact strength at
low temperature series and the special series with high im-
pact strength at low temperature provided that no agree-
ments were made at the time of ordering regarding evidence
of the 0,2 % proof stress at elevated temperature (see Note
in Table 3).
6 . 6 For tubes as specified in Sections 2.1.6 and 2.2.6, the
values stipulated in the assessment of suitability are appli-
cable.
6 . 7 The stress coefficients stated in the material specifica-
tions or assessments of suitability and in Section 6.1 for
20 “C are applicable up to 50 “C and those stated for 100 “C
are valid up to 120 “C. in other temperature ranges, linear
interpolation between the values stated is necessary (e.g. for
80 “C, between 20 “C and 100 “C and for 180 “C, between
100 “C and 200 “C), no rounding-up being permissible. For
materials with individual certificates, the interpolation rule
shall only apply where the interval between the figures is suf-
ficiently smal14).
7 S&t$Ae tubes as pressure vessel
The tubes listed in Sections 7.1 and 7.2 may be used under
internal or external pressure within the application limits in
Table 1 b or 2b.
7.1 Seamless tubes
7.1.1 As specified in DIN 1629 “Seamless circular tubes
made from non-alloyed steels with special quality require-
ments”.
7.1.2 As specified in DIN 1630 “Seamless circular tubes
made from non-alloyed steels with very high quality require-
ments”.
7.1.3 As specified in DIN 17175 “Seamless tubes made
from high-temperature steels”.
‘) In general. this is understood to mean a temperature difference equal to
50 Kin the high-temperature yield pomt range and 10 Kin the creep-strength
range.
Page 3 AD-Merkblatt W 4, Edition 05.92
7 . 1 . 4 As specified in DIN 17 173 “Seamless circular tubes
made from steels with high impact strength at low tempera-
ture”.
7 . 1 . 5 As specified in DIN 17 179 “Seamless circular tubes
made from fine-grained structural steels” in conjunction with
VdTUV-Werkstoffblatter 35112 to 35712.
7 . 1 . 6 Seamless tubes made from other steels according to
assessment of suitability by the authorised inspector. In
doing so, the application limits shall also be stated. The steels
shall satisfy the following requirements:
(1) The elongation at failure A5 as a % in the transverse di-
rection shall be at least 14 %. When testing in a longitu-
dinal direction, this value shall be two units higher.
(2) The notched-bar impact strength shall correspond to the
values which characterise the material. For steels having
a minimum tensile strength not exceeding 740 N/mm2,
the average value obtained from three transverse IS0 V-
notch specimens at room temperature shall be at least
27 J. When testing in a longitudinal direction, this value
shall be at least 43 J.
For steels having a minimum tensile strength exceeding
740 N/mm2, the attention shall be given to non-suscep-
tibility to brittle fracture when stipulating the minimum val-
ues for impact strength.
7.2 Welded tubes
Welded tubes as specified in Sections 2.2.1 to 2.2.6 if the
manufacturer originally demonstrated to the authorised in- .,”. I“::
Spector in a procedure qualification test’) that he has reliably
mastered the welding procedure. The stipulations regarding
the type of material test certificates according to DIN 50049
(see Table 2b) are only applicable if the quality and uniformity
of the product are demonstrated to the authorised inspector
.
on completion of the procedure qualification test’). If this is
not appropriate, test certificate C is required.
For pressure-welded tubes, the tube or the welded joint shall
be normalised over their entire length after welding. It is con-
sidered that the latter requirement has been fulfilled if the last
shaping step during the manufacture of the tubes is a nor-
malising forming operationz).
In the case of fusion-welded tubes, the provisions in AD-
Merkblatt HP 7/2 are applicable for the heat treatment. If cold
forming of the tubes is envisaged, the heat-treated state of
the welded joint shall be taken into account.
7.2.1 As specified in DIN 1626 “Welded circular tubes
made from non-alloyed steels with special quality require-
ments” apart from steel grade USt 37.0.
7.2.2 As specified in DIN 1628 “Welded circular tubes
made from non-alloyed steels with very high quality require-
ments”.
7 . 2 . 3 As specified in DIN 17 177 “Electric pressure-welded
tubes made from high-temperature steels”.
7.2.4 As specified in DIN 17174 “Welded circular tubes
made from steels with high impact strength at low tempera-
ture”.
7.2.5 As specified in DIN 17178 “Welded circular tubes
made from fine-grained structural steels” in conjunction with
VdTUV-Werkstoffblatter 351/l to 35711.
 Page 4 AD-Merkblatl W 4, Edition 05.92
7 . 2 . 6 Welded tubes made from other steel grades accord-
ing to assessment of suitability by the authorised inspector.
In doing so, the application limits shall be stated. Utilisation
of the permissible design stress in the weld under internal
pressure shall be defined in the assessment of suitability.
The requirements placed on tubes made from comparable
steel grades as specified in Sections 7.2.1 to 7.2.4 shall apply
as appropriate as minimum requirements during assessment
of suitability.
7.3 Tests
For the testing of tubes as shells of pressure vessels, the fol-
1 lowing Sections 7.3.1 to 7.3.4 are applicable. Table 3 pro-
vides an overview.
7.3.1 Tubes having an outside diameter c 660 mm as
specified in Sections 7.1 and 7.2 shall be tested according
to the standards mentioned in these paragraphs. Provisions
which deviate are stipulated in Section 7.3.1.1.
7.3.1.1 For tubes having outside diameters 2 325 up to
c 660 mm made from steel grades 14 MoV 6 3, X 20 CrMoV
121,26CrMo4,10Ni14,12Ni19andX8Ni9andfrom
steel grades having a minimum tensile strength > 520 N/mmz,
tensile tests and, where provision is made, impact tests shall
be performed on 10 % of the tubes, but on one tube per cast
and heat-treatment batch at least.
7 . 3 . 2 For tubes having an outside diameter 2 660 mm as
specified in Sections 7.1 and 7.2, tensile tests and, where
provision is made, impact tests shall be performed on 10 %
of the tubes, but on two tubes per cast and heat-treatment
batch at least. Provisions which deviate are stipulated in Sec-
tion 7.3.2.1.
7.3.2.1 For tubes made from steel grades 14 MoV 6 3,
X20CrMoV121,26CrMo4,10Ni14,12Ni19andX8Ni9
and for tubes made from steel grades having a minimum ten-
sile strength > 520 N/mm’, tensile tests and, where provision
is made, impact tests shall be performed on one end of each
tube.
For tubes made from steel grades 14 MoV 6 3, X 20 CrMoV
12 1,26 C r MO 4 and X 8 Ni 9, these tests shall be performed
on both ends of each tube at opposite points 180 ’ apart in
the case of lengths > 4 m.
7 . 3 . 3 The specimens for the mechanical and technical tests
shall be taken at an angle to the tube axis or to the weld in
the case of tubes having an outside diameter 2 660 mm.
7 . 3 . 4 Tubes made from steel grades which are hardened
and tempered in air or liquid and have an outside diameter
> 100 mm shall be subjected to a hardness test to ascertain
uniform hardening and tempering. For tubes having outside
diameters > 100 mm up to < 325 mm, the test is performed
on one end with the complete scope of testing including both :. _\,
ends. For tubes having an outside diameter 2 325 mm, both
ends are hardness tested. The hardness test is omitted for
those tubes on which a tensile test is performed on both ends
in accordance with Section 7.3.2.1.
7.4 Marking
The provisions in Section 4 are applicable regarding marking
and, for tubes having an outslde diameter 2 660 mm, special
marking, e.g. a test number, shall be used to establish that
the consignment is covered by the material test certificate.
7.5 Certification of quality characteristics
Quality characteristics shall be certified according to Tables
1 b and 2b; Section 5.2 shall be taken into account. The mate-
rial test certificate shall additionally state that the tubes
satisfy the requirements in AD-Merkblatt W 4, Section 7.
7.6 Design factors I-,
The provisions in Section 6 are applicable.
i
 Page 5 AD-Merkblatl W 4, Edition 05.92
.
T a b l e la Application limits and certification of quality characteristics for Seamless tubes

Application limits
Certification of
:, quality characteristics
Standard Section Steel grades Outside Working Design by material test
d i a m e t e r d, pressure temperature’) certificate act. to
m m bar “C DIN 50049

5 219,l 5 64

St 3 7 . 0 > 219,l up to 5 25 2.22)

IN 1629 2.1.1 St 4 4 . 0 I 660 5 300
St 52.0 > 660 5 16
all < 160 3.1 63)

St 3 7 . 4
1IN 1 6 3 0 2.1.2 St 4 4 . 4 all no limit 5 300 3.1 B
St 52.4
st 35.0, St 45.8: 3.1 B
Quality Level I
all 5 160 1450
17Mn4, t9Mn5: 3.1 c
Quality Level I

Up to the
St 3 5 . 8 : temperature limits
all no limit 3.1 B
Q u a l i t y L e v e l Ill stated in the
)IN 17175 2.1.3 standard

St 45.8, 17 Mn 4, Up to the
19Mn5:
temperature limits
Q u a l i t y L e v e l Ill no limit 3.1 c
all stated in the
alloy steels
standard
always
Quality Level Ill
-lTSt 35 N 3.1 B

l-rst 35 v
26 CrMo 4 Test Class 1 :
)IN 17173 2.1.4 11 MnNi 53 I160 See AD-Merkblatt
1 3 MnNi 6 3 all Test Class 2 : WlO 3.1 c
10 Ni 14 no limit
12 Ni 19
X8Ni9
StE 255, WStE 255,
StE 2 8 5 a n d
Basic series 5300
WStE 285:
3.1 B

Elevated temperature Other steel grades:

properties series Without NDT: % 400 3.1 c
(W series) 5 160
all
High impact strength at With NDT: % 300
IN 1717g4) 2.1.5 low temperature series no limit
. fT series) 5 400, if certifi-
c a t i o n o f 0,2% p r o o f
stress at elevated
Special series with temperature is 3.1 c
high impact strength agreed at time of
at low temperature ordering
(E series)

2.1.6 other According to stipulations in assessment of suitability

1) See AD-Merkblatl B 0. Section 5.

2) The test certificate can be replaced by stamping in the case of tubes which are subject to external Pressure Only.
3) A test report is sufficient for tubes which are subject to external pressure only.
4) In wnjunction with VdTijV-Werkstoffblatter 351/2 t0 35712.
Page 6 AD-M&blab W 4, Edition 05.92

Table lb Application limits and certification of quality characteristics for seamless tubes as pressure vessel shells
I A p p l i c a t i o n s limits Certificate of
quality characteristics
Steel grades Outside Working Design by material test
standard Section temperature’)
diameter d, pressure certificate act. to
m m bar “C DIN 50049

r11629 7 ‘.l .l
St
st
st
-
“g 2.22)

3.1 B

I 1with NDT act. 1

N1630 7 . ’1.2
st ,37.4
8 : 44.4
St 52.4
I all
to SEP 1915:
no limit
I
5 300

I I

S t 35.6, St 45.8: all 80 ; 450 3.1 B

Q luality L e v e l I

1’ 7Mn4,19Mn5: all : 80 2 450 3.1 c

c quality L e v e l I

Jp to the
emperature limits 3.1 B
S it 35.6: all 0 limit
IN 17175 7..1.3 stated i n t h e
C )uality Level Ill
standard

I it 45.6 17 Mn 4, up to the
1 9 Mn 5: temperature limits
C luality L e v e l I l l stated in the 3.1 c
all IO l i m i t
a 1110~ steels standard
salways
(;luality Level Ill

1rTSt 35 N
rest Class 1:
l-rst 35 v % 80
!6 CrMo 4 all rest Class 2: See AD-Merkblatt
)IN 17173 i‘.1.4 3.1 c
1 1 MnNi53 70 limit w 10
13 MnNi 6 3
10 Ni 14
12 Ni 19
X8Ni9

Basic series.

r( Dt$ steel grades:

E l e v a t e d temperature
properties series
jW series) Without NDT: I

High impact strength at s 80 15 300

DIN 1717g3) 7.1.5 low temperature series all
With NDT: 5 400, if certifi-
FT series) no limit c a t i o n o f 0,2% p r o o f
stress at elevated
3.1 c
Special series with temperature is
high impact strength agreed at time of
at low temperature ordering
(E series)
I II 1
I, I
7.1.6
‘) See APMI srkblatt B 0, Section 5.
II other According to stipulations in assessment of suitability

2) T h e t e s t cf trtiricate can be replaced by stamping the case of tubes which are subject to external pressure only.
3) In conjunctron with VdTBV-Werkstoffblatter 35112 to 35712.
 Page 7 AD-Merkblatl W 4, Edition 05.92

Table 2a Application limits and certification of quality characteristics for welded tubes

Application limits
Certification of
c
quality characteristics
Standard Seition Steel grades Outside Working Design by material test
d i a m e t e r d, pressure temperature’) certificate act. to
m m bar “C DIN 50049

5 219,l I 64 2.23)
for utilisation
> 219,l up to of permissible
5 25
st 37.0 I 660 design stress of
IIN 1626 2.2.1 s1 4 4 . 0 5 300 90%;
St 52.0 > 660 5 16 For 100%: 3.1 B2)

St 3 7 . 4
IIN 1 6 2 8 2.2.2 St 4 4 . 4 all no limit 5 300 3.1 62)
St 52.4
St 37.8:
I160 _c 450
Quality Level I

all Up to the 3.1 eq

St 37.8: no limit temperature limits
Q u a l i t y L e v e l Ill stated in the
standard

St 42.8
5 160 5 450 3.1 82)
)IN 17177 2.2.3 Quality Level I

all no limit Up to the

St 42.8: temperature limits
3.1 c
Quality Level Ill stated in the
standard

Up to the
temperature limits
15Mo3 all no limit 3.1 c
stated in the
standard

lTSt 35 N 3.1 B2)

Test Class 1:
l-i-3 35 v I160
11 MnNi 53 all Test Class 2: See AD-Merkblatt
IIN 17174 2.2.4
13 MnNi 6 3 no limit w 10 3.1 c
10 Ni 14
12 Ni 19
X8Ni9
StE 255, WStE 255,
StE 2 8 5 a n d
Basic series 5 300
WStE 285:
without NDT 3.1 82)
Elevated temperature of the basic Other steel grades:
properties series material: 5 400 3.1 c
(W series) I160
High impact strength at with NDT: 5 300
DIN 171785) 2.2.5 low temperature series all of the basic
il series) 5 400, if certifi-
material: c a t i o n o f 0,2% p r o o f
no limit stress at elevated
temperature is 3.1 c
Special series with
agreed at time of
high impact strength ordering
at low temperature
(E series)

2.2.6 other According to stipulations in assessment of suitability

1) See AD-Merkblatl B 0, Section 5.

2) The stipulations regarding the type of material test certificates according to DIN 50049 are only applicable if the authorisad inspector is provided wi
evidence of the quality and uniformity of the product on completion of the procedure qualification test. If this is not appropriate, test Certificate C
required.
3) The test report can b-s replaced by stamping in the case of tubes which are subject to extemaf Pressure only.
“) A test report is sufficient for tubes which are subject to external pressure Only.
5, In conjunction with VdTiiV-Werkstoffblatter 351/Z to 357/l.
P a g e 10 AD-Merkblatl W 4. Edition 05.92

Appendix 1 to AD-Merkblatt W 4

Agreement reached by AD Associations

regarding the continued use of St 34-2 grade steel tubes

rtz
to DIN 1626 part 3 (01.1964)

DIN 1626 no longer contains steel grade St 34-2 to DIN 1626

part 3 of January 1964. Since there is a continuing need for Characteristic values K for wall thickness
this grade of steel, it may still be used within the limits given 5 16 mm and design temperature in “C
in line 1 of Tables 2a and 2b. The characteristic values are Steel grade
shown in the adjacent table. (i, I (1% I 2oo I 250 I 300
N/mm2

S t 34-2 250 167 147 128 108

ICS: 23.020.30 Edition February 1998

Materials AD-Merkblatt
for Cast steel
Pressure Vessels W5
:.

The AD-Merkblltter are compiled by the seven associations specified below who together form the “Arbeitsgemeinschafl Druck-
behdlter” ( A D ) . AD-Merkblatt G 1 c o v e r s t h e c o m p o s i t i o n a n d a p p l i c a t i o n o f A D - R e g u l a t i o n s a n d a l s o p r o c e d u r a l g u i d e l i n e s .
T h e AD-Merkblalter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . In t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e.V. (FDBR), Diisseldorf
H a u p t v e r b a n d d e r g e w e r b l i c h e n B e r u f s g e n o s s e n s c h a f t e n e . V . , Sanki Augustin
Verband der Chemischen lndustrie e. V. (XX), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschafi Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiiftenleute (VDEh), Diisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkraftwerksbetreiber e. V., Essen
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s l y b y ihe a b o v e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be a d d r e s s e d t o the p u b l i s h e r :
Verband der Technischen oberwachungs-Vereine e.V., P.O. BOX 103834, D-45038 Essen.

Contents
1 Scope 6 Marking
2 Approved cast steel 7 Certification of quality
3 Quality levels 8 Design strength values
4 Heat treatment and production welding Annex 1
5 Testing

1 Scope 2 Approved cast steel

1 .l This AD-Merkblatt covers cast steel used for the fabri- The following cast steel types may be used:
cation of pressure vessels and pressure vessel components
2.1 Ferritic cast steel GS-38 and GS-45 to DIN 1681 up to
which, depending on the temperature of the weather and of
a temperature’) of 300 “C.
the vessel fluid, are operated at temperatures from
- 10 “C to the upper temperature-use limits specified in Sec- 2 . 2 Cast steel for use at room temperature and elevated
tion 2. For vessel fluid temperatures less than -10 “C, temperatures in accordance with DIN EN 10213-2, but only
AD-Merkblatt W 10 shall also apply. grades GP240GH, G20Mo5, G17CrMo55, G17CrMo9-10,
G17CrMoV5-10, GX8CrNil2 and GX23CrMoV12-1 up to the
1 . 2 The provisions detailed in Sections 2 to 8 below apply
wall thicknesses*) specified in this standard. In its normalised
to cast steel for the fabrication of pressure vessels and pres-
state, steel grade GP240GH shall only be used up to a maxi-
sure vessel components subject to a final inspection by the
mum wall thickness of 100 mm.
authorized inspector (pressure vessels in Inspection Groups
III, IV, VI and VII). 2 . 3 Cast steel GS-20 Mn5N and GS-20 MnSV to DIN 17182
up to a wall thickness of 100 mm and up to a wall temperature
1.3 No supplementary requirements other than those in
AD-Merkblatt W 0 are necessary in the case of cast steel for I of 350 “C.
the fabrication of pressure vessels and pressurevessel com- 2.4 Cast steel for use at low temperatures to DIN
ponents for which the manufacturer has to certify production EN 10213-3, but only grades G17Mn5, G20Mn5, G9Nil 0 and
to specification (pressure vessels in Inspection Group I, G9Nil4 up to the wall thicknesses*) specified in the standard,
where these are used for flammable, corrosive or toxic and also GX3CrNil3-4 in conjunction with VdTiiV-Werk-
gases, vapours or liquids, and also those in Inspection stoffblatt 452.
Groups II and V).
1 . 4 For bodies of equipment components in accordance 1) For definition of wall temperature and working temperature, see Section 5 Of
AD-Merkblatt B 0.
with Appendix II of 9 12 of the Pressure Vessel Ordinance, 2) Specifiad wall thiiknesses may be increased upon agreement with the authorized
TRB 801 No. 45 applies. inspector.

Supersedes December 1996 edition; 1 = Amendments relating to preViOUS edition

CarI Heymanns Verlag K G

Luxemburger StraRe 449, 50939 Kbln
 Page 2 AD-Merkblatt W 5, Edition 02.98
2.5 Low-temperature cast steel grades GS26CrMo4,
GS-1 ONi6, GS-1 ONil4 and G-XGCrNil810 in accordance
with Stahl-Eisen-Werkstoffblatt (SEW) 685 up to a tempera-
ture of 50 “Cl).
12.6 Other ferritic or martensitic cast steel upon proof of qua-
lification by the authorized inspector, which shall also include
the application limits, requirements, test and inspection
I instructions, marking and instructions on further processing
(forming, heat treatment, welding). The cast steel shall exhi-
bit the property values characteristic of the standard material
and shall meet the following minimum requirements:
- Elongation at fracture A at room temperature - not less
than 15%,
- Impact energy (notch toughness) at room temperature on
V-notched specimen to DIN EN 10045-l - not less than
27 J (34 J/cm2).
A requirement of the above tests is that the fracture behavi-
our is ductile. The results of additional brittle fracture tests,
obtained in the qualification procedure may justify other mini-
mum values.
2 . 7 Austenitic cast steel types to DIN EN 10213-4, but only
grades 1.4308, 1.4552, 1.4408 (up to 300 “C) and 1.4581 up
to the temperatures stated for the minimum proof stress
values indicated in Table 2 of this standard, note being taken
of the specifications concerning resistance to intercrystalline
j corrosion given in Table A.1 of DIN EN 10213-l.
2 . 8 Other austenitic cast steel upon proof of qualification by
the authorized inspector, which shall also include the applica-
tion limits, requirements, test and inspection instructions,
j 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 - not less
than 20 %,
- Impact energy (notch toughness) at room temperature on
V-notched specimen to DIN EN 10045-l - not less than
35 J (44 J/cm2).
2 . 9 For other cast steel specified in Sections 2.6 and 2.8,
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 Quality levels
3.1 Depending on the differing requirements for the internal
and external surface condition of castings, cast steel shall
be delivered in qualities classified to DIN 1690 Part 2. The
assigment of qualities (see Table 1) depends on the allo-
wable working temperature and the allowable working pres-
sure unless a higher quality is required due to special oper-
ating conditions. In any case, quality 5 of DIN 1690 Part 2 will
not suffice.
3 . 2 Where pressure and temperature do not fall under the
same quality, the quality with the more exacting requirements
shall take precedence.
‘) For defimtlon of wall temperature and working temperature, see Section 5 Of
AD-Merkblati B 0.
Table 1 Assignment of Quality Levels
Quality Level Allowable Allowable
to DIN 1690 working working
Part 2 temperature pressure
“C bar
Welding ends
1’)
2 > 450 > 80
3 > 400 to 5 450 > 32 to 5 8 0
4 5 400 5 32
1) Linear or aligned indications as speclffed in DIN 1690 Part 2 when detected
by surface crack testing, are not permitted.
4 Heat treatment and production welding
4.1 For heat treatment purposes, the specifications given
in DIN EN 10213-l or in the relevant DIN standards / Werk-
stoffblatter (material specifications) apply.
4.2 For production welding, the specifications in DIN
EN 10213-1, Section 6.3, apply. The required welding proce-
dure qualification is covered by Stahl-Eisen-Werkstoffblatt
(SEW) 110.
5 Testing
5.1 Cast steel components specified in Sections 2.1 to 2.5
and 2.7 shall be tested in accordance with the standards and
material specifications contained therein. Testing shall be
I performed on a cast by cast basis so that components having
undergone the same heat treatment are comprised. 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 .O %
proof stress, the 0.2 % proof stress shall also be determined.
The 0.2% proof stress shall be 25 N/mm2 lower than the
1.0% proof stress.
5 . 2 For cast steel components specified in Sections 2.6 and
2.8, the testing requirements shall be laid down in the qualifi-
cation test.
5 . 3 All castings shall be inspected for their external condi-
tion. Safety-relevant dimensions shall be checked. The che-
mical composition shall be determined by ladle analysis.
5 . 4 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 hard-
ness between the hardest and softest component tested in
the test batch shall not exceed 30 HB).
5 . 5 All hollow components shall be subjected to a hydraulic
pressure test of sufficient duration, usually at double the
working gauge pressure which shall not exceed 1.5 times the
safety factor against yield stress at 20 “C. The pressure test
may be performed on machined or mounted cast steel com-
ponents. In special cases, e.g. the in case of very large ope-
nings which can only be closed with the aid of special auxili-
ary equipment, the pressure testing of individual castings
may be waived with the consent of the authorized inspector.
I

.
The pressure test is generally performed on at the purcha-
ser’s premises. If it has to be carried out on the casting manu-
F facturer’s premises, this shall be stated in the order.
5 . 6 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.
5.7 The castings shall be subjected to non-destructive
testing to verify the use of the correct qualities as specified
in Section 3 and shall be assessed according to Tables 1 to
4 in DIN 1690 Part 2.
The extent of testing is defined in Table 2 of this AD-Merk-
blatt. Castings weighing in excess of 1000 kg shall be tested
individually.
For welding ends and construction welds, radiographic
examination shall be carried out in accordance with
DIN 54111 Part 2, Test Category B.
Table 2 Extent of testing to verify the Quality level as speci-
fied in DIN 1690 Part 2
Quality
Level to Extent of testing in relation
DIN 1690 to the number of components
Part 2
1 100%
2 100%
3 1. Prototype: 100 %
2. Pilot lot: 100% on at least 10 compo-
nents
3. Series production: 100 % on areas iden-
tified 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 difficult-to-
. lated in DIN EN 10213-3 apply.
cast locations.
All components shall be subjected to sur-
face crack detection.
4 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 sur-
face crack detection.
5 . 6 For austenitic steel castings to DIN EN 10213-4, testing
for resistance to intercrystalline corrosion in accordance with
DIN 50914 shall be performed for each cast and heat treat-
ment batch. This test may be waived by agreement with the
user.
6 Marking
The minimum requirement shall be indelibly marked with at
least the following:
- Manufacturer’s symbol
- Designation of material
- Cast number
- Autorized inspector’s or works inspector’s test stamp
Page 3 AD-Merkblatl W 5, Edition 02.98
7 Certification of quality
The quality shall be certified as follows:
7.1 For cast steel specified in Section 2.1, by acceptance
test certificate 3.1 .B to DIN EN 10204.
7 . 2 For cast steel specified in Sections 2.2 to 2.5, accept-
ance test certificate 3.1.A or 3.1.C to DIN EN 10204 is
required. For cast steel grade GP240GH, acceptance test
certificate 3.1 .B to DIN EN 10204 will suffice provided the
component weight does not exceed 500 kg.
7 . 3 For cast steel specified in Section 2.7, by acceptance
test certificate 3.1.A or 3.1.C to DIN EN 10204. For unit
weights less than 200 kg, acceptance test certificate 3.1 .B to
DIN EN 10204 will suffice.
7.4 For cast steel specified in Sections 2.6 and 2.8, in
accordance with the approval testing requirements.
7.5 By means of acceptance test certificate 3.1.8 to
DIN EN 10204, the manufacturer shall confirmz) that the
requirements in Tables 1 to 4 in DIN 1690 Part 2 are satisfied
with regard to the qualities concerned. If quality is proved by
acceptance test certificate 3.1 .A or 3.1 .C to DIN EN 10204,
the results of the non-destructive tests on welding ends and
j castings of quality levels Sl , S2, Vl and V2 shall finally be
evaluated by the authorized inspector. For radiographic
examination, the evaluation shall be made on 100% of the
castings for ultrasonic examination and surface crack testing,
a reevaluation shall be carried out on 10 % of the castings.
8 Design strength values
8.1 For cast steel specified in Sections 2.1 and 2.3, the
values in Table 3 apply.
8 . 2 For cast steel specified in Section 2.2, the values stipu-
lated in DIN EN 10213-2 apply.
8 . 3 For cast steel specified in Section 2.4, the values stipu-
8 . 4 For cast steel specified in Section 2.5, the values stipu-
lated in SEW 685 apply.
18.5 For cast steel GX3CrNil3-4, the values stipulated in
VdTiiV-Werkstoffblatt 452 apply.
8 . 6 For cast steel specified in Section 2.7, the values stipu-
lated in DIN EN 10213-4 are applicable, but they should be
reduced by 25 N/mm* for calculation purposes (please refer
to DIN EN 10213-4, Table 2, footnote 5).
8.7 For cast steel specified in Sections 2.6 and 2.8 the
values laid down in the qualification apply.
8 . 8 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 tem-
perature 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 intervalh) between the points of
support.
s) This confirmation may also be included in the cetiflcatfon 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.
Page 4 A D - M e r k b l a t t W 5, Edition 0 2 . 9 8

Table 3 Design strength values for cast steel according to Sections 2.1 and 2.3

>40 to 5 100 300 216 205 197 193 186 178

1) The design temperature shall not exceed 300 “C resp. 350 “C even for heated pans. AD-Merkblatl B 0. Table 1 shall be taken into consideration.

Appendix 1 to AD-Merkblatt W 5

Agreement of the AD-Associations on the further application of formerly valid DIN Material Standards and
Stahl-Eisen Material Specifications (SEW)
Heat-resistant ferritic cast steel complying with the withdrawn DIN standard DIN 17245, December 1987 edition, austenitic
cast steel complying with the withdrawn DIN standard DIN 17445, November 1984 edition and low temperature cast steel
complying with SEW 685 may be applied until the EC Directive on pressure equipment is adopted as German law and a
European standard is published covering pressure vessels based on the provisions of AD-Merkblatt W 5, July 1995 edition.
 ICS 23.020.30 January 2000 edition

Materials Aluminium and aluminium alloys AD-Merkblatt

for
Wrought materials W 6/l
Pressure Vessels
:,

The AD-Merkblatter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
behalter” (ADj. AD-Merkblatt G 7 covers the composition and application of the AD-Regulations and also the procedural rules.
The AD-Merkblhtter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
and above the normal level being anticipated during the operation of pressure vessels, allowance must be made for such stresses by
meeting special requirements.
Should there be any departures from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis,
operating experience.
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e. V. (FDBR), Diisseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sank? Augustin
Verband der Chemischen lndustrie e. V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Diisseldod
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkraftwerksbetreiber e. V., Essen
Verband der Technischen Oberwachungs-Vereine e. V. (VdTiiV), Essen
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e.V., Postfach 103834, D-45038 Essen.

Contents
1 Scope 6 Marking
2 Suitable materials 7 Certification of quality
3 Requirements to be met by the materials 8 Strength values for calculation
4 Processing Appendix 1
5 Test

. 1 Scope 2.1 The materials given in tables 1 and 2 in the defiverycon-

1.1 This AD-Merkblatt applies to sheet, plate and strip
(including circles), extruded rods/bars, tubes’) and profiles’)
and forgings made of aluminium and aluminium alloys for the
construction of pressure vessels operated at charging mate-
rial temperatures within the limits given in clause 2.
ditions and areas of application stated. The delivery condi-
tions stated apply only to specific product forms.
The expert opinion of the authorized inspector is required for
dimensions and product forms not given in tables 1 and 2 or
any extended areas of application.

1 . 2 The materials shall be selected in accordance with the 2 . 2 Those materials given in tables 1 and 2 in other condi-
purpose for which they are intended, the mechanical, thermal tions, e.g. strain hardened, if their suitability and quality are
and chemical stresses being taken into account. verified by the expert opinion of the authorized inspector.

1 . 3 The stipulations in clause 2 to 7 below are applicable
for parts for the construction of pressure vessels to be sub-
jetted to a structural test by the authorized inspector (pres-
sure vessel test groups Ill, IV, VI and VII).
1 . 4 Apart from the provisions in AD-Merkblatt W 0, no addi-
tional requirements are required for parts for the construction
of pressure vessels for which the manufacturer has to certify
correct manufacture (pressurevessel test groups I, II and V).
2 Suitable materials
The following may be used for the construction of pressure
vessels:
1) In the case of tubes and profiles pressed using the bridge or porthole method,
initial approval of the manufacturing method of each supplier’s works is required.
2 . 3 Other materials not specified in table 1, if officially ver-
ified as suitable.
3 Requirements to be met by the materials
3.1 Tables 1 and 2 apply to the chemical composition, deli-
very condition and quality of the materials in accordance with
2.1. The data in these tables may deviate from that in the
standards referred to there.
3 . 2 The requirements for the materials specified in 2.2 and
2.3 and the materials specified in 2.1, tables 1 and 2 in the
dimensions, product forms and areas of application not in-
cluded there are based on the report prepared by the autho-
rized inspector in agreement with the material manufacturer
unless already specified in table 2.

Supersedes January 1990 edition; completely revised

^ . .,^ -Translatron: -1 eCttnlCal Help
- to txponers
^ .~ 01 I tjsl
-es
cian neymanns venag fvi bervlce
Luxemburgar StfaOe 449. 50939 K6ln
Page 2 AD-Merkblatt W 6/l, Edition 01.2000
The elongation after fracture and notched bar impact
strength values shall characterize the materials. The elonga-
tion after fracture value A in the transverse direction shall be
at least 14 %. In the case of strain hardened materials as spe-
cified in 2.2 and 2.3, this elongation after fracture value can
be less if proof is provided of adequate ductility (e.g. in the
burst test).
3 . 3 The following apply with regard to dimensional accu-
racy:
EN 485-3 Aluminium and aluminium alloys - Sheet,
strip and plate - part 3: Tolerances on
dimensions and form for hot-rolled pro-
ducts
EN 485-4 Aluminium and aluminium alloys - Sheet,
strip and plate - Part 3: Tolerances on
dimensions and form for cold-rolled pro-
ducts
Aluminium and aluminium alloys - For-
EN 586-3
gings -Part 3: Tolerances on dimensions
and form
prEN 754-7 Aluminium and aluminium alloys - Cold-
drawn rod/bar and tube - Part 7: Seam-
less tubes, tolerances on dimensions and
form
EN 755-3 Aluminium and aluminium alloys -
Extruded rod/bar, tube and profiles - Part
3: Round bars, tolerances on dimensions
and form
EN 755-5 Aluminium and aluminium alloys -
Extruded rod/bar, tube and profiles -
Part 5: Rectangular bars, tolerances on
dimensions and form
EN 755-6 Aluminium and aluminium alloys -
Extruded rod/bar, tube and profiles -
Part 6: Hexagonal bars, tolerances on
dimensions and form
prEN 755-7 Aluminium and aluminium alloys -
Extruded rod/bar, tube and profiles -
Part 7: Seamless tubes, tolerances on
dimensions and form
prEN 755-8 Aluminium and alluminium alloys -
Extruded rod/bar, tube and profiles -
Part 8: Porthole tubes, tolerances on
dimensions and form
prEN 755-9 Aluminium and aluminium alloys -
Extruded rod/bar, tube and profiles -
Part 9: Profiles, tolerances on dimensions
and form
EN 941 Aluminium and aluminium alloys - Circle
and circle stock for general applications -
Specifications
4 Processing
For processing and heat treatment, the HP series of the AD-
Merkblatter applies.
5 Tests
The following tests shall be carried out on the indivdual pro-
ducts in accordance with the relevant ENS and the require-
ments of this clause:
5.1 Plate and stripz)
5.1 .l Cast analysis
51.2 Tensile test transverse to the direction of rolling
(1) for plate thicknesses 4 10 mm, test 10 %a) of the rolled
plates, but at least one rolled plate per cast4), dimension
and same heat treatment,
(2) for plate thicknesses > 10 mm and for materials as spe-
cified in 2.2 and 2.3, test each rolled plate,
(3) for strip, test each strip.
In the case of unalloyed aluminium materials, proof of the
1 ,O % yield strength shall be provideds). The requirements of
6.1.3.4 of EN 485-l apply for the position of the samples.
5.1.3 Notched bar impact test transverse to the direction of
rolling, 1 set (= 3 individual specimens) per product form,
thickness. cast and heat treatment batch, but only in the case
of materials for which requirements are specified in tables 2A
and 28. In the case of materials EN AW-5754 and EN AW-
5049 for thicknesses > 25 mm, in the case of material EN
AW-5083 for thicknesses > 15 mm. In the case of materials
specified in 2.2 and 2.3, in accordance with theexpertopinion
of the authorized inspector.
5.1.4 Dimensional check and visual examination of both
surfaces of each plate or strip.
5.2 Tubes and profiles as long as they are not pressure
vessel shells
(see 5.4)
5.2.1 Cast analysis
5.2.2 For diameters up to 200 mm, tensile test in the longi-
tudinal diameter. above that if possible, in the transverse
direction for each cast4), cross-section and test unit. For deli-
vered quantities of up to 100 tubes, the whole delivered
amount is regarded as the test unit. For delivered quantities
> 5 t, the initial 5 t is regarded as the test unit. At least two
tensile tests are required per cast. In the case of tubes in
coils, for delivered quantities of up to 300 kg the delivered
amount is regarded as the test unit, for larger quantities, each
initial 300 kg. For unalloyed aluminium materials, proof of the
1 ,O % yield strength shall be provided5). The requirements of
6.1.3.4 of EN 755-l apply for the posiiton of the samples.
5.2.3 Notched bar impact test, if possible transverse to the
direction of rolling, 1 set (= 3 individual specimens) per pro-
duct form, thickness, cast and heat treatment batch, but only
in the case of materials EN AW-5754 H112 and EN AW-5049
H1126) for thicknesses > 25 mm and in the case of material
EN AW-5083 H112 for thicknesses > 15 mm and in the case
of the materials specified in 2.2 and 2.3, in accordance with
the expert opinion of the authorized inspector.
5.2.4 A ring test carried out at one end of each length pro-
duced in the case of seamless tubes and hollow profiles as
long as the working pressure is not less than 25 bar gauge.
If the working pressure is less than 25 bar gauge, the ring test
in the scope of the tensile test at one end of the specimen
tube is adequate.
i
2) Including circles made from it.
3) In the case of unalloyed alumlnium alloys, the scope of testing can be reduced
to 5% if it can be proven with adequate statlstical certainty that the test results
meet the requrements.
4) With continuous casting, the term cast is to be taken to mean a sequence of
castings made directly one after the other.
5) In the case of unalloyed alummum materials, both the 0.2% and 1 .O% yield
strenath values shall be determined until adeouate documentation is avaIlable on
the riio of the two values.
6) Not standardized in EN 755-2

For the ring test, the following applies:
Up to 18 mm outside diameter (nominal size): flattening test
as descibed in EN 10233. Here, the distance between thetwo
platens is determined using the equation given in EN 10233
with the factor c = 0,lO.
Over 18 mm to 146 mm outside diameter (except for star pro-
files made of material EN AW-6060 T4): ring expansion test
as described in EN 10236. The test can be stopped once the
expansion reaches 30 %.
For star profiles made of the material EN AW-6060 T4 in all
sizes, drift expanding test as described in EN 10234. The test
can be stopped once the expansion reaches 30 %.
Over 146 mm outside diameter: ring tensile test as described
in EN 10237.
If the ring tensile test cannot be carried out because of the
cross-sectional form, a different test shall used, e.g. macro-
etching.
5.2.5 Dimensional check and visual examination of the out-
side and, if possible inside surfaces of each tube or hollow
profile.
5.2.6 Internal hydraulic pressure test’) on all seamless
tubes and hollow profiles with a test pressure of 50 bar
(gauge). However, the test pressure selected shall not be so
high that the safety factor does not fall below 1 ,l with regard
to the 0,2 % yield strength for aluminium alloys or 1,4 with
regard to the 1 ,O % yield strength for unalloyed aluminium
materials5).
5.3 Bars, profiles8) and forgings
5.3.1 Cast analysis
5 . 3 . 2 Tensile test, if possible in the transverse (tangential)
direction, for each caste) and size for each 300 kg of gross
weight. For other products of the same cast4) and size, one
specimen is adequate per 500 kg delivered quantity, but a
maximum of one tensile test per piece. The uniformity of the
. pieces shall be proven by a hardness test. For unalloyed alu-
minium materials, proof of the 1,O % yield strength shall be
provideds). The requirements of 6.1.3.4 of EN 755-l apply
for the position of the samples.
5.3.3 Notched bar impact test, if possible in the transverse
(tangential) direction, 1 set (= 3 individual specimens) per
product form, thickness, cast and heat treatment batch, but
only in the case of materials EN AW-5754 0 and H112, EN
AW-5049 0 and H1126) for diameters > 50 mm or equal
cross-sectional areas, and in the case of material EN AW-
5083 H112 for diameters > 30 mm or equal cross-sectional
areas and in the case of the materials specified in 2.2 and
2.3, in accordance with the expert opinion of the authorized
inspector.
5.3.4 Dimensional check and visual examination of each
piece.
5.4 Tubes as pressure vessel shellsg)
Tubes for pressure vessel shells shall be tested up to an out-
side diameter 5 200 mm or a wall thickness 5 10 mm in the
same way as tubes specified in 5.2.
7) me internal pressure test can b-e carried out with other test mediums or. by agree-
ment with the authorized inspector, can be replaced by a procedure recognized
as equivalent, e.g. eddy current test.
In the case of seamless tubes and hollow profiles used as pressure vessel shells
as specified in 5.6 including stubs, the internal hydraulic test can be replaced by
the pressure test described in AD-Mehblatt HP 30 as long as the whole outside
surface can be taken into accuunt in the pressure test.
8) Solid and hollow profiles as specified in EN 755-l.
9) If tubes tested as described in 5.2 are used for this, the tests not specified can
be carried out subsequently.
Page 3 A D - M e r k b l a t t W 6/l, Edition 01.2000
For an outside diameter > 200 mm or a wall thickness
10 mm a tensile test and a notched-bar impact test shall be
carried out on 10% of the tubes.
For hollow bodies for working pressures > 80 bar (gauge),
an ultrasonic test shall be carried out over the whole length
of the components on the basis of the Stahl-Eisen-Priifblatt
1915 and 1918.
For outside diameters > 200 mm, the ring test as described
in 5.2.4 is limited to 10 % of the tubes if a 100 % untrasonic
test is carried out on the basis of Stahl-Eisen-Priifblatt 1915
and 1918.
6 Marking
All products shall be marked with the manufacturer’s mark,
the material grade and condition, the cast number, the stamp
of the authorized inspector and, if appropriate, the specimen
number. The cast number mark is omitted for tubes with an
outside diameter < 100 mm. Tubes shall be marked with the
ring test number. The requirements of EN 10028-l or DIN
17175 apply with regard to the arrangement.
If tubes, rods or sections are delivered in bundles, for tubes
with an outside diameter 5 18 mm and for rods with a thick-
ness (diameter, edge length, width across flats and width)
5 25 mm a collective mark is permitted on the bundle in the
form of a tag.
Unless otherwise agreed, marking is by means of a punch.
For sheet 55 mm thick and thin-walled tubes, only paint
marking or some other permanent marking is permitted. If
paint marking is used, the paint shall be water-insoluble. Roll
stamping over the whole length is permitted.
7 Certification of quality
Certification of the quality characteristics of parts subject to
pressure shall be provided by means of a certification of
compliance with the order, test report and/or inspection certi-
ficate as specified in EN 10204. The inspection certificates
3.1 Al3.1 .C shall be issued by the authorized inspector. The
following applies specifically:
7.1 The cast analysis is verified by a test repot-V’).
7 . 2 The tightness test on the tubes is verified by acertificate
of compliance with the orderlo).
7 . 3 The following proof shall be provided for the mechanical
properties, visual examination and dimensional check:
7.3.1 For unalloyed aluminium materials as specified in 2.1,
inspection certificate 3.1 .B.
7.3.2 For wrought aluminium alloys 3003, 3103, 6060,
5754, 5049 and 5083 as specified in 2.1, inspection certifi-
cate 3.1 A/3.1 .C. An inspection certificate 3.1 .B is adequate
if the manufacturer has provided the authorized inspector
with proof of adequate statistical reliability and has kept the
results available for inspection at any time.
Confirmation of a change to an inspection certificate 3.1 .B
shall be indicated to the manufacturer and can also be initi-
ated for each size group. If use is made of this procedure,
The TUO confirmation letter shall be included in the inspec-
tion certificate 3.1 .B.
At specific intervals, (approximately 1 or 2 years) the autho-
rized inspector shall satisfy himself that the preconditions
continue to be met assuming this does not happen within the
framework of continuous inspection tests.
10) This confirmation may also appear in the next highest certificate.
.
Page 4 AD-Merkblatl W 6/l, Edition 01.2000

Linear interpolation shall be effected between the values 4

7 . 3 . 3 For materials specified in 2.2 and 2.3, inspection cer-
given for operating temperatures > 20 “C, the strength ) !-
tificate 3.1 A/3.1 .C as long as nothing else is specified in the
report of the authorized inspector. values being rounded down to the nearest full unit.
The temoerature is rounded to the next full 5 “C in the range t
of longterm values. The interpolated strength values shall be
8 Strength values for calculation rounded down to the nearest full unit.
8.1 Table 3 applies to calculation values. The calculation
8 . 2 As safety factor S = 1,5 shall be included for the calcu-
values given in table 3 for the temperature range from -196
lation (internal pressure stress).
or -270 to +20 “C also apply to pressure vessels operated
under ambient conditions.
:
Table 1. Suitable materials; composition, delivery condition and field of application

EN symbol Composition Delivery condition Working temperature

according to according to product form range
(see table 2)

I A.
EN
Materials for general application
AW-1098 EN 573-3 0, H112 -270 “C t o 100 “C
EN AW-1 080A EN 573-3 0, H112 -270 “C t o 100 “C
EN AW-1070A E N 573-3 0, H112 -270°C to 100 “C
EN AW-1050A EN 573-3 0, H112 - 2 7 0 “C t o 300 “C
EN AW-5754 EN 573-3 0, H112 -270°C to 150°C
EN AW-5049 EN 573-3 0, H112 - 2 7 0 “C t o 250 “C
EN AW-5083 EN 573-3 0, H112 - 2 7 0 " C to 8 0 “C’)

B. Materials for certain low-temperature applications (see table C.2)

EN AW-3003 EN 573-3 F, 0 -270 “C to 50 “Cl)
EN AW-3103 EN 573-3 0, H112 -270 “‘2 to 50 “Cl)
EN AW-6060 EN 573-3 T4 - 196 “C to 50 “Cl)

‘) For short periods, higher temperatures are permItted (e.g. when detrostrng retngeratmg plant) up to 150 “C are permissible prowded that the pressure
is reduced to half the workino pressure for a pertod up to 8 hours and to atmospheric pressure for a period up to 24 hours.
 . ,

Table 2. Mechanical properties at room temperature (minimum values)l)

A. Semi-finished products in the soft statez)

Material Product forms and dimensional limits Mechanical properties

Plate@) Tubes Bars E l o n g a t i o n a f t e r f r a c t u r e A6) Notched

Thickness Wall bar impac
Round Square Hexagonal Rectangular 0,2-%- 1 ,o-%- Tensile Plates Tubes Bars
Thickness Diameter Edge-length Width- Thickness limit limit strength (round, flat. strength
DVM
across-flats etc.)
m m m m m m m m m m m m N/mm* N/mm* N/mm* % % % J/cm2
E N AW-1098 0 s5 1 to 30 2 to 30 3 to 30 2 to 6 17 40 -
33 29
E N AW-1098 0 > 5 to 20 - - 17 40 30
EN AW-1080A 0 56 0,3 to 16 2 to 30 2 to 30 3 to 30 2 to 6 -9 22 60 40 27 27
EN AW-1080A H112 5 25 - 18 22 60 -
21
EN AW-1070A 0 cc6 -9 25 60 40
EN AW-1070A H112 5 25 - 18 25 60 21
EN AW-1050A 0 5 25 0,3 to 16 2 to 30 2 to 30 3 to 30 2 to 6 204) 30 65 35 25 25
E N AW-1050A H112 5 50 20 30 75 20 -

E N AW-5754 0 0,3 to 10 2 to 100 2 to 60 3 to 60 2 to 20 80 - 180 - 17 16 30

EN AW-5754 0 I 25 - 80 190 18 - 30
E N AW-5754 H112 25 to 50 - 80 190 30
14
EN A W - 5 0 4 9 0 - 0,3 t o 1 0 80 - -
180 17 30
EN AW-5049 0 5 25 - 80 190 18 30
EN AW-5049 H112 25 to 50 80 190 -
14 30
EN AW-50835) 5 50 125 275 25
17
EN AW-5083 0 to 10 to 100 to 100 to 100 2 to 50 110 270 - 14 14 25
EN AW-5083 H112 530 - - - 125 275 14 25

1) Values applicable for longitudinal and transverse directions.
2) The term “sott” is used to designate a material state which is achieved by Soft
annealing following cold- and hot-working, or which is achreved dwctlywithout
any soft annealing by hot-working with such high degrees of deformation and
at such high temperatures that the guaranteed procperties specified I” table 2A
are maintained.
3) Also applicable for strip up to 10 mm.
4) The following maximum values shall be noted: EN AW-1060 0 max. 50 MPa,
EN AW-1050 A, plates max. 55 MPa, tubes, bars max. 60 MPa.
5) For a plate thickness 5 30 mm, a reduction of area 2 30% shall be ensured
and for a plate thickness > 30 5 50 mm. a reduction of area Z 20%.
6) As a deviation from the provisions of the relevant ENS. specifying a gauge length
of 50 mm (A50) for wall thicknesses 5 12,5 mm 2 3 mm, testing with a propor-
tional test piece (A) is generally specified in this AD-Merkblatt.
Table 2.

B. Semi-finished products in the pressed state with no subsequent heat treatment, or forged’)

Material Product forms and dimensional limits Mechanical properties

Bars Extruded Forgings 0,2-%- 1 ,O-%- E l o n g a t i o n a f t e r f r a c t u r e A4) Notched

profiles (drop ant limit limit bar
Tubes Round Square Hexagonal Rectangular Tensile Tubes Profiles, Bars Forg
Wall hammer impact
Wall Diameter Edge-length Width- strength hollow (round, ings2)
Thickness Cross- thickness forgings) strength
Thickness across-flats profiles flat
section Wall DVM
etc.)
thickness
m m m m m m m m m m mm2 mm2 m m MPa MPa MPa % % % % J/cm2
EN AW-1098 H112 2,5to35 - - 17 40 27 - - - -

EN AW-1080A HI12 2,5 to 35 10 to 250 10 to 250 10 to 250 2 to 4 0 2 0 to8000 2 1 - 22 60 25 25 25 - -

EN AW-1050A H112 2,5 to 35 10to250 10 to 250 10 to 250 2 to 4 0 2 0 to 8000 21 I 100 20 30 70 25 25 25 23 -

EN
EN
EN
AW-5754
AW-5049
AW-5083
HI
HI
HI
12
12
12
3 to 35
3 to 35
3,5 to 35
10 to 250
lOto
10 to 250
10to250
lOto
10 to 250
10 to 250
lOto
10 to 250
2 to 40
2 to 40
2 to 40
2 0 to 8000
2 0 to 8000
2 0 to 8000
5 1.5
2 1,5
5 I,7
5 100 80
100
130
J
EN AW-5083 HI 12 - - 5 100 110

1) Values applicable for longitudinal and transverse directions.

I
2) Drop forgings, intended only as guide values for hammer forgings.
3) For the size ranges specified in this AD-Merkblatt. the values deviating from the standards are well substantiated statistically. Therelore, they can be ordered in accordance with the relevant ENS.
4) As a deviation from tha provisions of the relevant ENS, specifying a gauge length of 50 mm (ASO) for wall thicknesses d 12.5 mm, testing with a proportional test piaCa (A) is generally specified in this AD-Merkbran.

. 1
-.)---- - -u -.
3
.‘
L.

Table 2.

C. Semi-finished products for specific applications at low temperatures

Material Product forms and dimensional limits Mechanical properties

State Application Plates’) Tubes Rectangular Extruded 0,2-%- 1 ,O-%- Tensile E l o n g a t i o n a f t e r f r a c t u r e A7) Notched bal
Thickness Wall Diameter bars profiles limit limit strength Tubes Profiles, Bars impact
thickness Thickness Wall hollow (round, strength
thickness profiles flat etc.) DVM
m m m m m m m m m m MPa MPa MPa % % % J/cm2

EN AW-3003 F*) drawn frames for - 5 to 40 40 (15O)Z) - (160)‘) - UW) uw -

-
E N A W - 3 0 0 3 03) annealed Plate-type 5 to 40 40 35 95 21 21
evaporators

EN AW-3103 H112 pressed heat exchangers 1 t o 2,5 to 20 - 35 95 17

EN AW-3103 0 son heat exchangers 1 to 2,5 to 20 - 35 - 95 22

EN AW-3103 0’) son plate-type 0,35 to 6,0 - 35 - 90 - 189 -

evaporators 235)
35 106 - 189 - -
EN AW-3003 0’) son plate-type 0,35 to 6,O -
evaporators 235)

EN AW-6060 T4 cold age- star-sections for 1 to 10 656) - 130 - 15

hardened cold vaporisers

1) Plate and strip, also colder-clad, If brazing is used. the requirements in VdTOV-Werkstoffblatt 397 shall be noted.
2) As-delivered condition and assembly condition prior to brazing not an acceptance condition.
3) Acceptance condition: heat effect from brazing simulated by annealing at 600 “C/l h.
4) For thicknesses _’ 0,s mm and gauge length 50 mm.
5) For thicknesses > 0.6 mm and gauge length 50 mm.
a) Also applies to not tully stressed welded joints.
7) As a deviation from the provisions ot the relevant ENS, specifying a gauge length of 50 mm (A50) for wall thicknesses 5 125mm to z 3 mm, testing with a proportional test piece (A) Is generally specKed In this AD-Merkblatt for this thickness range.
Page 8 AD-Merkblatt W 6/l, Edition 01.2000

Table 3. Design characteristic values in N/mm2

Material and state Characteristic D e s i g n t e m p e r a t u r i n “C

-2706) to 20 50 100 150 200 250

EN AW-1098 0 and H112 R pt.0 17 15 13

E N A W - 1 0 8 0 A 0 a n d H112 R P l .o 22 20 18
EN AW-1070A 0 and H112 RPl ,o 25 23 20
EN AW-105OA 0 and H112 R PI,0 30 29 27
- 27 18 11 8
EN AW-1050A 0 and Hl12 &eo5

EN AW-3003 02)5) Rpo.2 35 35

E N A W - 3 1 0 3 0 a n d H112 ‘%x2
35 35
EN AW-6060 T4 %1.2
65 65
EN AW-5754 0 and H112 ho.2 80 80 70
EN AW-5754 0 and H112 R mi105 (80) 45
E N A W - 5 0 4 9 0 and H112 80 80 70
5x12

EN AW-5049 0 and Hl12 R (100) 48 22 16

MO5

E N A W - 5 0 4 9 a n d H112’) fb.2 100 100 90

EN AW-5049 and H112’) (120) 60 25 20
&ylo5
-
E N AW-5083 0 and Hl 122) %.2 125 125 (120)
E N A W - 5 0 8 3 Hl 1 23) 40.2 130 130 (120)
E N A W - 5 0 8 3 0 a n d Hl 1 24)5) ho.2
110 110 (120)
Modulus of elasticity E 70 000 69 000 68000 66000 63 000

1) The design characteristic values also apply to welded components as the material is not in the work-hardened State.
2) Plates sofl and hot-rolled as specified in EN 465-2
3) Tubes, bars and profiles, pressed as specified in EN 765-2
4) Forgings as specified !n EN 566-2
5) Tubes. bars and profiles, soft as specified in EN 755-2
6) For material EN AW-6060, - 196 “C to 20 “C applies
 i.
Page 9 A D - M e r k b l a t t W 6/l, Ediion 01.2000

Appendix 1 to AD-Merkblatt W 611

Agreement of the AD Associations on the continuous use of previously valid DIN material standards

Aluminium as specified in the withdrawn DIN 1712 Part 3 and aluminium alloys as specified in the withdrwan DIN 1725 Part
1 may be used until the EC Directive on Pressure Equipment has been adopted into national legislation and a European
Standard has been published on pressure vessels taking into account the specifications of the January 1990 edition of
AD-Merkblatt W 6/l.
UDC 621.642.02-96.03:669.35.016.26:620.1:614.1 Edition May 1968

Materials AD-Merkblatt
for Copper and copper alloys
Pressure Vessels W 612

‘he AD-Merkblatter are compiled by the seven trade associations specified below who together form the ‘Arbeitsgemeinschaft Druck-
)ehalter” (AD). AD-Merkblatt G 1 covers the composition and application of the AD-Regulations and a/so the procedural rules.
‘he AD-Merkblatter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
tnd above the normal level being anticipated during the operation of pressure vessels, allowance must be made for such stresses by
neeting special requirements.
Should there be any departures from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
tmbodied i n t h e s e r e g u l a t i o n s h a v e b e e n obsemed b y m e a n s o f a l t e r n a t i v e a p p r o a c h e s , e . g . t e s t i n g o f m a t e r i a l s , t e s t s , s t r e s s a n a l y s i s ,
operating experience.
Fachverband Dampfkessel-, Behalter- und Rohrfeitungsbau e.V (FDBR), Dusseldorf
Hauptverband der gewerblichen Berufsgenossenschafien e. V, Sankt Augustin
Verband der Chemischen lndustrie e.V. (VU), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaff Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Diisseldod
V G B T e c h n i s c h e V e r e i n i g u n g d e r Groakraftwerksbetreiber e. V. E s s e n
Vereinigung der Technischen iiberwachungs-Vereine e.V (VdTBV), Essen.
he AD-Merkblatter a r e a m e n d e d c o n t i n u o u s / y b y the t r a d e a s s o c i a t i o n s i n k e e p i n g with technical progress. Relevant proposals should
)e addressed to the publisher:
Vereinigung der Technischen lberwachungs-Vereine 8. K, Postfach 103834, D-4300 Essen 1.

Contents

1 Scope 5 Marking
2 Suitable materials 5 Certification of quality
3 Requirements 7 Values for calculation
4 Testing Appendix: Tables 1 to 16

i.,

1 Scope erature limits given. For product shapes and limit values for
dimensions, Tables 2 to 4 apply.
1.1 This AD-Merkblatt applies to sheets, strips, plates,
seamless tubes and rods made of copper and copper alloy 2 . 2 Products made from other copper alloys and wroughl
n the construction of pressure vessels operated at weather- copper alloys may be used when declared suitable by the au
dependent temperatures and at the temperatures of the thorized inspector. Information regarding application limits.
:harging equipment within the temperature limits’) in requirements, test conditions, marking and further proces
Table 1. sing instructions (shaping, heat treatment, welding) shall be
given for this purpose.
1.2 In the case of products used to construct pressure ves- The materials shall meet the following requirements:
sels subject to structural testing by the authorized inspector
[vessels in Test Groups III, IV, VI and VII), the provisions con- Elongation at failure A, shall display the values characterip
!ained in Sections 2 to 7 apply. ing the materials. However, for sheets, strips, plates and rods
the minimum value shall be 14 % regardless of the directior
1.3 In the case of products used to construct pressure ves- of the test specimen. If it is only possible to test with the speci.
sels for which the manufacturer is required to supply certifi- men in an axial direction, elongation at failure A, shall be a
cation of correct manufacture (vessels inTest Groups I, II and least 16%. Values may fall below those indicated above i
V), no regulations apart from the provisions contained in AD- adequate malleability properties are demonstrated (e.g. ir
Merkblatt W 0 are necessary. the bursting test).
2.3 The use of these materials is not permitted when
acetylene is present if they contain in excess of 65 % by mas:
Suitable materials of copper (see accident prevention regulations contained ir
VBG 61 “Gase”).
2.1 In the case of sheets, strfps, plates, seamless tubes and
rods, the materials in Table 1 can be used within the temp- If copper and zinc alloys are being used, for example, cart
should be taken to ensure that they are sufficiently resistan
to the media in question and that no dangerous chemica
s~ADb4arkbhlt
reactions take place (see, for example, the chart of gases ir
1) For a definition of wall terrpsrahlra and ssrM3 kMWtWW%
8 0, Section 5. Appendix 2 of VBG 61).

srl H e y m a n n s V e r l a g K G
lxemburger StraBe 449, 5000 Kbln 41
utenbergstraBa 3, 1000 Beriin 10
Page 2 AD-Merkblatl W 6/2, Edition 5.66

3 Requirements
3.1 For details regarding composition, material conditions,
mechanical-technological properties and the long-time heat-
resistant properties, Tables 5 to 14 apply.
3 . 2 The associated standards covering composition, deliv-
ery condition and quality characteristics are listed below.
Copper and wrought copper alloy tubes for
DIN 1785
condensers and heat exchangers,
D I N 1788 Seamless drawn copper tubes for piping
systems,
DIN 1787 Copper; Semi-finished products,
DIN 17660 Wrought copper alloys; copper-zinc atlo@
(brass), (special brass); composition,
D I N 17664 Wrought copper alloys; copper-nickel alloys;
composition,
DIN 17665 Wrought copper alloys; copper-aluminium al-
loys (aluminium bronze); composition,
DIN 17670 Wrought copper and copper alloy plate, sheet
and strip
Part 1: Properties,
Part 2: Technical specifications,
DIN 17671 Wrought copper and copper alloy tubes
Part 1: Properties in conjunction with the
technical specifications according to
DIN 1785,
DIN 17672 Wrought copper and copper alloy rods and
bars
Part 1: Properties,
Part 2: Technical specifications,
DIN 17675 Plates of copper and wrought copper alloys for
condensers and heat exchangers
Part 1: Strength properties,
Part 2: Technical specifications.
Where the provisions of this Merkblatt differ from those set
out in the DIN standards, this AD-Merkblatt applies.
3 . 3 In their delivery condition, copper and zinc alloy pro-
ducts shall be free of internal stresses likely to lead to stress
corrosion cracking.
DIN 1785 Copper and wrought copper alloy tubes for :
condensers and heat exchangers, -.
DIN 1786 Seamless drawn copper tubes for piping
systems, i
DIN 1767513 Plates of copper and wrought copper alloys for
condensers and heat exchangers; dimen-
sions,
DIN 59753 Seamless drawn tubes of wrought copper and
copper alloys for capillary soldering; dimen-
sions.
4 Testing
The tests conducted on the individual product shapes shall
be as follows:
4.1 Composition
Determination shall be made of the alloying elements of the
melts or casting operations used for the production batch2)
and cited in the corresponding material standards. The
manufacturer shall analyse each melt or casting operation
and keep an ongoing record of the analyses made.
With modern continuous casting processes it is not always
possible to assign the semi-finished products directly to the
melt. In this case the term “melt” should be interpreted to
mean a succession of casting operations effected one im-
mediately after the other.
When making the semi-finished product, if no separation
takes place after melting or casting, analyses shall be made
of the completed semi-finished product within the scope of
the tensile test.
4.2 Dimenisions and surface quality
Each piece shall be checked to ensure that surface quality . 1
meets the requirements and limiting dimensions are main-
tained.
1
4.3 Miscellaneous tests
4.3.1 Sheets, strips and plates j
- Tensile test

3 . 4 For CuZn38Snl the 1 % time creep values are estima- Unit for tensile
test
tions made on the basis of orientation values.

3 . 5 Where products made of SF-Cu are annealed in an at- Strip all Strip beginning
mosphere containing hydrogen (for example, when welding and end
or brazing using a naked flame), they shall not show any
signs of hydrogen embrittlement. Sheet 120 10 % of rolled at one
plate panels/plates, but at end Across
least on one piece the
3 . 6 With respect to the determination of dimensions and to-
of each production product
lerance limits, the following standards apply:
batch
DIN 1 7 5 1 Sheets and sheet strips of copper and wrought
copper alloys, cold-rolled, > 20 Roiled panel/plate
DIN 1754 Seamless draw copper tubes,
/
DIN 1755 Seamless drawn wrought copper alloy tubes, For each unit and sample location a tensile test shall be car-
DIN 1756 Copper and wrought copper alloy rods with tied out at room temperature. Values f?,,2 or R,,,o, R, and
sharp edges, A5 shall be determined. Where the condition of the material
is soft, Rpl,O shall be determined, with the exception of
D I N 1759 Copper and wrought copper alloy rectangular CuAllONi5Fe4. In the case of work-hardened materials and
bars with sharp edges, CuAIlONi5Fe4, R,,2 shall be determined.
DIN 1 7 6 1 Copper and wrought copper alloy square bars
with sharp edges, 2) A production batch is defined as the volume of the semi-finished product of an
order made from a material of identical dellvery condition. identical dimensions
DIN 1763 Hexagonal drawn copper and wrought copper and, where appliible, of the same melt, which has been made continuously in
alloy bars with sharp edges, the same production sequence and with the same production equipment.
 s’.
I

Page 3 AD-MerkMait W 6/2, Edition 5.88 1:

I(),.,
4.3.2 Seamless tubes CuAIlONi5Fe4, f?p,,D shall be determined. In the case of a
workhardened materials and CuAIIONiSFe4, Rp0,2 shall be !
- Tensile test
determined.
Diameter 0. Unit for tensile Location Direction
(mm) test of sample
5 Marking
1500mofa
S 76 production batch
at one 5.1 All products shall be marked with:
axial
500 kg of a end - the manufacturer’s symbol,
> 76 production batch - the material code or material number,
- the number of the production batch*)
- the symbol of the external authorized inspector or in-
For each unit and sample location a tensile test shall be ca- house authorized inspector.
rried out at room temperature. At least two tensile tests, how-
ever, shall be carried out per production batch*). The values 5 . 2 Paint that is insoluble in water or some other kind of suit-
to be determined shall be R,,Z or Rpl,O, R, and As. Where able permanent marking shall be used.
the condition of the material is soft, I?,,,~ shall be determined.
5 . 3 Sheets, strips and plates shall in addition be marked
In the case of work-hardened materials, R,,Z shall be deter-
with the sample number.
mined.
In the case of sheets and strips not exceeding 5 mm made
- Drift expanding test from copper and zinc alloys, marking by means of punches
According to the number of tensile tests, drift expanding tests is not permitted.
shall be conducted at both ends of the specimen tubes in ac-
cordance with DIN 50 135. A 30 % expansion of the external 5 . 4 In the case of seamless tubes with wall thicknesses not
diameter shall not cause cracks to appear. exceeding 5 mm made from copper and zinc alloys, marking
by means of punches is not permitted. Roll-stamping over the
- Leak test entire length is acceptable in the case of tubes and bars. If
All tubes shall be leak tested in either the hard or soft state the tubes or bars are supplied in boxes or bundles, it is per-
using the eddy current method in accordance with DKI-Mate- missible for the boxes to be marked as batches through the
rial-Test-Specification 781, Test Class A3). Should the pur- attachment of an adhesive label or for the bundles to be
chaser so require, the internal pressure test specified in marked as batches through the attachment of a tag, in the
DIN 50 104 may be adopted instead of the eddy current test. case of tubes with an external diameter not exceeding 20 mm
The test pressure shall be 50 bar maximum. and in the case of bars with a thickness (diameter, edge
- Examination of structure length, across-flats- width or breadth) not exceeding 25 mm.
An examination shall be made of the structure every 1000
tubes, which is, however, only a maximum within the scope
of the tensile tests, during which the mean grain diameter 6 Certification of quality
(see DIN 1785) shall be determined.
6.1 The quality and the leak testing of the tubes shall be
- Stress crack testing certified by an acceptance Test Certificate B in accordance
Within the scope of the tensile test, stress crack tests shall with DIN 50049.
be carried out in mercurous nitrate (DIN 50911) for copper/
zinc alloy tubes or in ammonia or copper tetraamine 6.2 Sheets, strips and plates
(DIN 50916). The following certificates in accordance with DIN 50049 are
required for the mechanical properties, the surface quality
4.3.3 Rods and bars and for the dimensional tests:
- Tensile test - Products made of Acceptance Test Certificate 84)
SF-Cu
‘11 - Products made of
CuAll ONi5Fe4
Acceptance Test
or C
Certificate A

Production batch, dimensions The following applies for all other materials:
- strip Acceptance Test Certificate 84)
- Sheet and plate not
intended for tube
Rods and bars with approximately the same dimensions can plates
be obtained in one test unit, unless there are varying prop- IZ 20 mm thickness Acceptance Test Certificate B4)
erties of the individual parts caused by different deformation. > 20 mm thickness Acceptance Test Certificate A
The uniformity of the parts shall be established by hardness or C
testing.
- Sheet and plate for
For each unit and sample location a tensile test shall be car- tube plates
ried out at room temperature. At the most four tensile tests, 5 60 mm thickness Acceptance Test Certificate B4)
however, shall be carried out per production batch’). The val- > 60 mm thickness Acceptance Test Certificate A
ues to be determined shall be R,,Z or I?~,,~, R, and As. Where or C.
the condition of the material is soft, with the exception of
;‘,
4) The manufacturer shall provide the authorized inspector with evidence, sub-
divided into sze ranges. of adequate statistical certamty This proCess shall be 1i:i”
r”
J) Another test class may be agreed in the case of tubes subject to more stringent repeated at certain intervals (1 to 2 years) unless this occurs as part of other On- ,?
requirements. going acceptance procedures. I:
II
Page 4 AD-Merkblatt W 6/2, Edition 5.88
- i:.:
p:-:...
6.3 Seamless tubes (short-term values). For the calculation of pressure vessels
made of ductile copper materials, the 1 ,O % proof stress can (:“-:
The following certificates in accordance with DIN 50049 are
required for the mechanical-technological properties, stress be used instead of the 0,2% proof stress in the short-time
range, if the ratio of the 0,2% proof stress to the tensile
crack testing, the structure, the surface quality and for the
strength at room temperature does not exceed 0,5 and the ?I
dimensional tests:
elongation at failure in a transverse direction is at least 25 % I
- Products made of Acceptance Test Certificate 64) or in an axial direction at least 27%.
SF-Cu
The following applies for all other materials: 7.2 Time creep values as a function of temperature and
time envisaged are given in Tables 14.1 to 14.3. Here it is
5 2,0 mm thickness/ Acceptance Test Certificate B4)
a case of the lower scatter limits for the time creep limits, and
diameter
in addition for SF-Cu F25 it is a case of the mean value of
> 2,0 mm thickness/ Acceptance Test Certificate A
the creep rupture strength. The mean value of the creep rup-
diameter or C.
ture strength generally used for steels cannot be used for
6.4 Bars and rods copper and copper alloys, because this results in excessive
plastic deformation.
The following certificates in accordance with DIN 50049 are
required for the mechanical properties, the surface quality 7 . 3 Tables 15.1 to 15.4 contain the stress KIS permitted in
and for the dimensional tests: all cases. It results from the lowest value of the 0,2 % proof
- Products made of Acceptance Test Certificate 84) stress/l ,5 in all cases or the 1 ,O% proof stress/l ,5 and the
SF-Cu 1 % time yield limit/l ,O. For SF-Cu F20 and F22 the permitted
- Products made of Acceptance Test Certificate A stress K/S results from tensile strength/3,5 for welded and
CuAll ONi5Fe4 or c untreated parts or tensile strength/4 for soldered parts, al-
though the possibility cannot be excluded that the component
The following applies for all other materials: experiences plastic deformation of more than 1 % in the
5 60 mm thickness/ Acceptance Test Certificate 84) course of the operation time.
diameter
The permitted stresses at room temperature are valid up to
> 60 mm thickness/ Acceptance Test Certificate A
50 “C. For other temperatures linear interpolation shall be ef-
diameter or C.
fected between the given values.

7.4 For welded, brazed or heat-treated components the

7 Values for the calculation
7.1 The minimum values for 0,2% or 1 ,O% proof stress,
for SF-Cu F20 and F22 also the minimum tensile strength,
are given in Tables 7 to 10 as a function of the temperature
values for the soft material conditions shall be a basis for the
calculation.
7 . 5 Table 16 contains data on the modulus of elasticity. The
scatter is f 5 %.

‘/ s1
i,
 Page 5 AD-Merkblatt W 6I2. Edition 5.88
.
Table 1. Suitable materials

Material Material conditions

Material code Limit temperature’)
number soft work-hardened

SF-Cu 2.0090 F20, F22 F24, F25 - 269 to 250 “C

CuZn40 2.0360 F34 F40, F41 - 196 to 250 “C

2.0372 F34 F40, F41 - 196 to 250 “C

CuZn39Pb05

CuZn20Al2 F30. F34, - 10)) to 250’) ’ C

2.0460 F39
(CuZn20AV) F33, F39

CuZn28Snl 2.0470 F32, F36 - - 269 to 250’) “C

CuZn38Snl F40 - 103) to 250 “C

2.0530 F34
(CuZn39Sn) *)

CuZn38SnAt 2.0525 F39 F43 - 196 to 250 “C

CuNilOFelMn F28, F29,

2.0872 F32. F35 - 269 to 300 “C
(CuNilOFe) *) F30

CuNbOMnlFe F34, F35, - 269 to 350 “C

2.0882 F41
(CuNi30Fe) *) F37

CuAIlONi5Fe4 - - 103) to 250 “C

2.0966 F63, F64
(CuAIlONi) 2,

CuNi30Fe2Mn2 2.0883 F42 - - 269 to 250 “C

1) The lowest gwen limit temperatures apply to unwelded parts: The authorwed inspector specifies the lowest temperatures for Use for welded Parts.
2) Material codas that are still valid for plate materials. They can still be used until revision of DIN 17675.
J) These materials are also suitable for lower temperatures for use. Test results are not available at present.
4) CuZn20A12 F30, F33 and CuZnPBSnl F32 only up to 150 “C.
Page 6 AD-Merkblatl W 6/2, Edition 5.66

Table 2. Suitable materials, material conditions and dimensions for sheets, strips and plates

Thickness in mm
Material code Material condition Material number
Sheet, strip Plate

F20 2.0090.10’) > 5to515 > 15 to I120

F22 2.0090.10 2 0.2 to 5 5 -
SF-Cu F24 2.0090.26 10,2 t o 515 -
F25 2.0090.26 - b-15 t o I 4 0

F34 2.036610’) LO,3 t o 515 > 15 to I120

CuZn40 F40 2.0360.26 - >15 t o I 80
F41 2.0360.26 2 0,3 to 5 5 -

F34 2.0372.10’) IO,3 to 5 15 > 15 t o I120

CuZn39Pb0,5 F40 2.0372.26 - >I5 t o I 80
F41 2.0372.26 LO,3 t o I15 -

F30 2.0460.07 - > 15 to I 80

CuZn20Al2
(CuZn2OAf) 2, 2.0460.10 1 3to115 -
F33
F39 2.0460.26 1 3tos15 > 15 t o I 40
CuZn28Snl F32 2.0470.10 1 3 to<15 -

CuZn38Sn 1 F34 2.0530.10’) 1 3to115 > 15 to I120

(CuZn39Sn) 2, F40 2.0530.26 - >15 t o 5 80

CuZn38SnAl F39 2.0525.10’) 1 3 to I15 > 15 t o I160

F43 2.0525.26 - > 15 t o 5 120

CuNilOFelMn F30 2.0872.10’) 10.3 to 515 > 15 t o I120

F32 2.0872.26 - > 15 t o 5 60
(CuNilOFe) 2, F35 2.0872.30 - > 15 to I 6 0

CuNi30Mnl Fe F35 2.0882.10’) 2 0,3 to I 15 > 15 to I120

(CuNi30Fe) 2, F41 2.0882.26 - > 15 t o I 60 1
_ !,
CuAIlONiSFe4
(CuAIlONi) 2, F63 2.0966.10’) 1 3 to I15 > 15 t o I 80 i
‘) The figure .07 added to the and applies to the plate products. .
2) Material codes that are still valid for plate materials. They can still be used until reviston of DIN 17675.
 Page 7 ADMerkblan W S/2, Edition 5.88
.
Table 3. Suitable materials, material conditions and dimensions for Saamk?SS tubes

Material Material Wall thickness maxmium diameter

Material code: mm mm
condition number
F20 2.0090.10 >3 200
SF-Cu F22 2.0090.10 13 76
F25 2.0090.26 15 76

2.0460.19 15 76
CuZn20Al2 F34
F39 2.0460.29 55 76

F32 2.0470.19 15 76
CuZn28Snl F36 2.0470.29 15 76

CuNilOFelMn F29 2.0872.19 55 76

CuNbOMnlFe F37 2.0882.19 55 76

CuNi30Fe2Mn2 F42 2.0883.19 13 42

Table 4. Suitable materials, material conditions and dimensions for rods and bars

Material Material Diameter (round) Thickness (flat)

Material code m m
condition number mm

F20 2.0090 10 > 6 to 5 100 > 5 to I60

SF-Cu F22 2.0090.10 5 6 _(5
F24 2.0090.26 i 40 55

F34 2.0360.10 2 10 to I100 > 6 to I60

CuZn40 F41 2.0360.26 I 40 56
CuNilOFel Mn F28 2.0872.10 1 1 0 to 5 100 -
.
CuNi30Mnl Fe F34 2.0882.10 1 1 0 to 5 100 -

CuAIlONi5Fe4 F64 2.0966.97 1 1 2 to I 80 -

.

1” the -se of rods and bars in square-section, hexagonal section and polygon-section. the width-across-flats romssponds to tha diameter.

Table 5. Composition of the materials

Composition in Composition in
Material code Material code
accordance with accordance with

CuZn38Snl
SF-Cu DIN 1787 (CuZn39Sn) 7)
DIN 17 660
CuZn40 CuZn38SnAl

CuNilOFel Mn
CuZn39Pb0,5 (CuNilOFe 1)2)
DIN 17 660 CuNi30Mnl Fe DIN 17 664
CuZn20Al2 (CuNi30Fe) ‘)2)
(CuZn20Al) ‘)
CuNi30Fe2Mn2

CuAIlONiSFe4
CuZn28Snl DIN 17 665
(CuAIlONi ‘)

1) Matanal &esthat are stall valid for plate materials. They can Ml be uSed Wtlt re~sl~n Of DIN 17675.
2) Special reqwements for purity shall ba met (see DIN 17664. table 1. footnote 1).
P a g e 6 AD-Merkblatt W 612, Edition 5.66
.

Table 6. Mechanical properties at room temperature for sheets and strips

S F - C u

CuZn40

CuZn39Pb0,5

CuZn20Al2

;.
c
Page 9 AD-Metkblatl W 6/2. Edition 5.99

Table 7. Mechanical properties at room temperature for plates

.
Material ” Material Thickness 40.2 Rp1 ,o hll 4
Direction N/mm2 N/mm2 N/mm2 %
code condition mm
at least at least at least at least

F20 > 15 t o 5 120 40 60 200 40

SF-Cu
F25 > 15 to 5 40 180 - 240 15

>15 t o I 40 120 140 340 35

F34 > 40 t o I 8 0 100 120 310 35

CuZn40

F40

F34

CuZn39Pb0,5

F40

F30
CuZn20Al2
(CuZnPOAl)
F39
across the
product

F34
CuZn38Snl
(CuZn39Sn)

F40

F39

CuZn38SnAl
F43

F30
CuNilOFelMn
(CuNilOFe) F32

F35

> 15 t o I 6 0
F35
CuNi3OMnl Fe
(CuNi30Fe)
F41 > 15 t o I 6 0 300 - 410 14

CuAIlONi5Fe4 > 15 to I 8 0 270 - 630

(CuAIlONi) F63 14
Page 10 A D - M e r k b l a t l W 6’2, E d i t i o n 5 . 8 8

Table 8. Mechanical properties at room temperature for seamless tubes

I I I

F20 40 60 200 40

SF-Cu F22 45 65 220 40

F25 150 250 30

F34 120 130 340 55

CuZn20Al2
F39 150 160 390 45

F32 100 105 320 55

CuZn28Snl
F36 140 150 360 45

CuNilOFelMn

CuNi30Mnl Fe

CuNi30Fe2Mn2

i
Table 9. Mechanical properties at room temperature for rods and bars

4YJ.2 R pt.0 Rn 4 !
Material
Material code Direction N/mm2 N/mm2 N/mm2 %
condition
at least at least at least at least

F20 40 60 200 36
/
SF-Cu F22 45 65 220 36

F24 160 - 240 14 l

120 140 340 35 !~,$

CuZn40 along the
product 250 - 410 20 -\
,
CuNilOFelMn 100 125 280 30 I
i.‘;/
CuNDOMnl Fe ‘1’;
120 140 340 35 I
CuAll ONi5Fe4 270 - 640 15

i.
 Page 11 AD-Merkbtatl W 612, Edition 5.88

table 10. Mechanical properties at increased temperature for sheets and strips

:, Minimum value at temperature “C

Material code Material condition Typ of test value 50 ( 100 I150 I200 I250 I 300 I 350 ;I
N/mm2 /

; . :.
;:

:f.;::
>‘if.? : :
i : ‘(
Cufn40 and 1::
I/ .

/
I...
!- . .
1,.
! ;’

I
:::

I:
I;
CuAIlONi5Fe4 F63 40.2 270 265 260 260 250
I--

! -1.-
Page 1 2 AD-Merkblatt W 6/2, Edition 5.88

Table 11. Mechanical properties at increased temperature for plates

Minimum value at temperature “C

Material Thickness Typevalue
of
Material code condition m m test 5 0 ) 100 ) 1 5 0 ( 200 1 250 1 300 ) 350
N/mm2

F20 >15 to (120 R PI.0 60 55 55

SF-Cu Rrn 200 200 175 150 125

F25 >15 to 5 40 RPQ.2 180 170 160 150

>15 to 5 40 R Pl .o 140 137 137 132

F34 > 40 to I 80 R Pl.0 120 115 115 110
CuZn40 >80 to 5120 R p1.0 110 104 104 100
and
CuZn39Pb0,5 >15 to I 40 &,2 200 190 180
F40 > 40 to I 80 R pa.2 180 170 160

CuZrQOAl2 F30 > 15 to I 80 R PI 0 100 86 86

(CuZn20Al)
F39 >15 to I 40 RPOZ 240 230 225

> 15 to I 40 R PI.0 175 172 168

F34 > 40 to I 80 R P1.0 170 153 148
CuZn38Snl >80 to 5120 R Pl 0 160 153 148
(CuZn39Sn)
F40 > 15 to _c 40 R PO2 200 190 180
> 40 to c 80 R PO.2 180 170 160

F39 ~15 to 1160 R Pf 0 180 175 172 170

CuZn38SnAl > 15 to s 40 R PO2 200 185 185 175

F43 > 40 to 5 80 RN2 190 175 175 165
>80 to 5120 R,, 180 165 165 155

F30 >15 to 5 60 R PI .o 145 138 133 128 123 118

>60 to 5120 R PI 0 125 118 114 109 104 99
CuNilOFelMn
(CuNilOFe) F32 > 15 to i 60 ‘7,,2 200 190 185 175 170 165

F35 > 15 to -( 60 R PO.2 250 235 225 220 210 205

F35 > 15 to I 60 R Pl .o 175 163 158 153 148 143 138

CuNi30MnlFe >60 to 5120 R Pl.0 140 130 126 123 120 117 112
(CuNi3OFe) F41 > 15 to 5 60 R pa.2 300 275 265 260 255 245 24C

CuAllONi5Fe4
(CuAIlONi) F63 > 15 to s 80 R PO.2 270 265 260 260 250
 Page 13 AD-Mefkblan W 6!2. E d i t i o n 5 . 8 8
.

Table 12. Mechanical properties at increased temperature for seamless tubes

Material code Material condition

SF-Cu

CuZn2OAl2

CuZn28Snl

t:
i-
1.
,:
-’
Table 13. Mechanical properties at increased temperature for bars and rods _, )

Material code Material condition Type of test value

N/mm2
1

CuNilOFelMn
P a g e 14 AD-Merkblan W 6l2, Edition 5.88

rable 14.1. Long-time heat resistant properties

for SF-Cu F20 and F22

2 % time creep value for

Temperature
10OOOh I30OOOh( 5 0 0 0 0 h 1lOOOOOh
“C
N/mm2

100 58 57 57 56
110 57 56 56 55 ;.
120 56 54 54 53
130 55 54 53 52
140 54 53 52 51
150 53 51 50 49
160 52 50 49 47
170 51 49 48 46
180 49 47 46 44
190 47 45 44 42
200 46 43 42 40
210 44 41 40 38
220 42 39 38 36
230 40 37 36 34
240 39 36 34 32
250 37 34 32 30

Table 14.2. Long-time heat resistant properties for SF-Cu F24 and F25

1 % time creep value for Long-time strength (mean value) for

Temperature
10OOOh 13 0 0 0 0 h 1 5 0 0 0 0 h ~1OOOOOh 10OOOh ( 3 0 0 0 0 h 150OOOh ( IOOOOOh
“C
N/mm2 N/mm*

150 160 153 146 145 212 204 200 195

160 154 145 141 136 207 196 192 187
170 147 138 133 126 202 188 184 177
180 139 128 123 117 196 180 175 166
190 130 118 113 106 188 171 164 155
200 122 108 103 94 180 161 153 143
210 112 98 91 82 170 148 139 129
220 102 86 79 69 159 134 124 114
230 90 73 65 55 145 120 111 99
240 78 61 52 42 128 103 94 82
250 66 49 39 28 109 84 76 64
.
Table14.3. Long-time heat resistant properties for materials in accordance with Table 1, with the exception of SF-Cu

1 % time creep value for

Material code Temperature 10000h 1 30000h 1 50000h ) 100000h
and
"C
Material conditions N/mm2

100 145 135 130 125

110 139 126 120 114
120 130 117 111 104
130 120 106 100 93
140 108 95 89 82
150 96 84 78 72
CuZnrlOF34,F4O,F41; 160 84 72 67 61
CuZn39Pb0,5F34,F40,F41; 170 72 61 56 50
CuZn38Snl(CuZn39Sn)') 180 60 51 46 40
W&F40 190 48 39 35 31
200 37 30 27 24
210 29 23 21 18
220 23 18 16 13
230 18 14 12 9
240 14 11 9 7
250 12 9 7 5
100 175 167 164 160
110 165 156 152 148
120 155 146 142 137
130 145 136 131 126
140 135 125 120 115
150 125 114 109 104
160 116 104 98 92
CuZn2OAl2(CuZn2OAll)') 170 106 93 87 81
F34,F39 180 96 83 76 70
190 86 72 65 59
200 77 62 55 48
210 67 52 46 38
220 57 43 36 29
230 46 33 27 21
240 34 24 20 15
250 24 16 13 10
150 112 104 100 96
160 107 97 92 87
170 100 87 81 74
180 92 75 67 58
190 81 63 55 46
CuZn28SnlF36 200 68 52 44 36
210 54 40 34 27
220 43 31 26 20
230 33 24 20 15
240 25 17 14 10
250 19 13 11 8
 Material code 1 % time creep value for
Temperature 10OOOh 1 30OOOh 1 50000h 1 1OOOOOh
and
"C
Material conditions N/mm2

100 144 138 137 132

110 137 131 128 125
123 130 124 121 118
130 123 116 113 110
140 116 108 105 101
150 108 100 96 92
160 100 91 87 82
170 91 81 77 72
CuZn38SnAIF39,F43 180 82 72 67 62
190 73 63 58 53
200 64 54 49 44
210 55 45 41 36
220 46 37 33 29
230 38 30 26 22
240 31 23 20 16
250 24 17 14 11
200 98 96 95 94
210 96 94 93 92
220 94 92 91 90
230 92 90 89 88
240 90 88 87 86
CuNilOFelMn (CuNilOFe)') 84 83
250 88 85
F28,F29,F3O,F32,F35
260 86 83 82 80
270 83 80 79 77
280 80 76 75 73
290 77 72 70 68
300 74 68 65 62
200 107 104 103 102
210 105 102 101 100
220 104 101 100 99
230 102 99 98 97
240 101 98 97 96
250 99 96 95 94
260 98 95 94 92
CuNi30MnlFe(CuNi30Fe)') 270 96 93 92 91
F34,F35,F37,F41 280 95 92 91 89
290 93 90 89 88
300 92 89 88 86
310 90 87 86 84
320 89 86 85 83
330 87 84 83 82
340 86 83 82 80
350 84 81 80 78
150 252 242 237 232
160 243 233 228 224
170 236 226 221 216
180 229 219 214 209
190 223 213 208 203
CuAIlONi5Fe4 (CuAIlONi)') _ 198
200 218 207 202
F63,F64 197 193
210 213 202
220 210 199 193 188
230 207 196 190 185
240 205 194 188 182

250 204 192 186 180

7) Material codes that are S~III valid for plate materials. They can still be used until revision of DIN 17676.
 Page 17 AD-Metlcblatf W 6/2, Edition 5.88

Table 15.1. P e r m i t t e d s t r e s s K/Sf o r s h e e t o r s t r i p

I Permitted stress K/Si n N / m m * f o r e n v i s a g e d t i m e hi n

CuZn40 andCuZn39Pb0,5

F34 I F41

10000 100000 10000

20150 57 50 63 55 120 120 93 93 160 160

100 57 50 63 55 113 113 91 91 145 125

110 56 49 62 54 112 112 91 91 139 114
120 54 48 60 53 111 111 91 91 130 104
130 53 46 59 51 109 109 91 91 120 93
140 51 45 57 50 108 108 91 82 108 82

150 50 44 56 49 107 107 91 72 96 72

160 49 43 54 48 106 106 84 61 84 61
170 47 41 53 46 104 104 72 50 72 50
180 46 40 51 45 103 103 60 40 60 40
190 44 39 50 44 101 101 48 31 48 31

200 43 38 49 43 100 94 37 24 37 24
210 41 36 47 41 99 82 29 18 29 18
220 40 35 46 40 97 69 23 13 23 13
230 39 34 44 39 90 55 18 9 18 9
240 37 33 43 38 78 43 14 7 14 7

250 36 31 41 36 66 41 12 5 12 5

P e r m i t t e d s t r e s sK/Si nN / m m * f o r e n v i s a g e d t i m ehi n

CuZn20Al2 CuZn28Snl CuZn38Snl

Temperature
"C
F33 F39 F32 F34

to 100000 10000 100000 to 100000 10000 100000

20/25 67 160 160 70 117 117

100 57 153 153 69 115 115

110 57 153 148 68 114 114
120 57 152 137 68 114 104
130 57 145 126 67 113 93
140 57 135 115 67 108 82

150 57 125 104 67 96 72

160 116 92 84 61
170 106 81 72 50
iao 96 70 60 40
190 no 86 59 no 48 31
application application
200 above 77 48 above 37 24
210 150°C 67 38 150°C 29 18
220 57 29 23 13
230 46 21 18 9
240 34 15 14 7

24 10 12 5

‘) soldered
r I Permitted stress K/Sin N/mm2forenvisaged

CuNilOFelMn
time in h

CuNiSOMnlFe CuAIlONi5Fe4
1
Temperature
"C F30 F35 F63

10000 100000 10000 looooo to 100000 to 100000

2’.

20150 120 120 83 83 93 180

100 117 117 79 79 87 177

110 116 116 78 78 86 176
120 116 116 78 78 86 175
130 115 110 77 77 85 175
140 115 101 77 77 85 174

150 108 92 76 76 84 173

160 100 82 75 75 a4 173
170 91 72 75 75 83 173
180 82 62 74 74 83 173
190 73 53 74 74 82 173

200 64 44 73 73 82 173
210 55 36 72 72 82 172
220 46 29 71 71 81 171
230 38 22 71 71 81 169
240 31 16 70 70 80 168

250 24 11 69 69 80 167
260 69 69 80
270 8 68 68 79
280 67 67 79
290 67 67 78

300 66 62 78
310 77
320 77
330 76
340 75

350 75
 Page 19 AD-Merkblatt W 6/2, Edition 5.88

Table15.2.Permitted stress K/Sfor plates

. Permitted stressin NImmzforenvisaged

time in h
:. K/S

SF-Cu Cui!n20Al2(CuZn2OAl)
Temperature
"C F20 F20') F25 F30 F39

to 100000 10000 100000 to 100000 10000 100000

20150 57 50 120 120 67 160 160

100 57 50 113 113 57 153 153

110 56 49 112 112 57 153 148
120 54 48 111 111 57 152 137
130 53 46 109 109 57 145 126
140 51 45 108 108 57 135 115

150 50 44 107 107 57 125 104

160 49 43 106 106 116 92
170 47 41 104 104 106 al
180 46 40 103 103 96 70
190 44 39 101 101 no 86 59
application
200 43 38 100 94 above 77 48
210 41 36 99 a2 150°C 67 38
220 40 35 97 69 57 29
230 39 34 90 55 46 21
240 37 33 78 43 34 15

250 36 31 66 41 24 10

Temperature
"C
Tt F34z) T
Permitted stress K/Sin N/mmzforenvisaged time in h

CuZn40undCuZn39Pb0,5

F403)

10000 100 000 10000 1ooooc

20150 93 93 120 120

100 91 91 113 113

110 91 91 112 112
120 91 91 111 104
130 91 91 109 93
140 91 a2 108 a2

150 91 72 96 72
160 a4 61 a4 61
170 72 50 72 50
la0 60 40 60 40
190 48 31 48 31

200 37 24 37 24
210 29 la 29 la
220 23 13 23 13
230 ia 9 la 9
240 14 7 14 7

250 12 5 12 5

‘) soldered 3) 24.0tos .30mm

2) 215too 4Omm 4) z80to-ClzOmm
Page 20 A D - M e r k b l a t t W 6/Z. E d i t i o n 5 . 6 6

Table 15.2. (continuation)

PermittedstressK/S
inN/mm*forenvisagedtimein
h

CuZn38Snl(CuZn39Sn)
remperature
"C
F342) F343) F34') F402) F403)

10000 100000 10000 100000 10000 100 000 10 000 100000 10000 100000

2Ol50 117 117 113 113 107 107 133 133 120 120

100 115 115 102 102 102 102 127 125 113 113
110 114 114 101 101 101 101 125 114 112 112
120 114 104 101 101 101 101 124 104 111 104
130 113 93 100 93 100 93 120 93 109 93
140 108 82 99 82 99 82 108 82 108 82

150 96 72 96 72 96 72 96 72 96 72
160 84 61 84 61 84 61 84 61 84 61
170 72 50 72 50 72 50 72 50 72 50
180 60 40 60 40 60 40 60 40 60 40
190 48 31 48 31 48 31 48 31 48 31

200 37 24 37 24 37 24 37 24 37 24
210 29 18 29 18 29 18 29 18 29 18
220 23 13 23 13 23 13 23 13 23 13
230 18 9 18 9 18 9 18 9 18 9
240 14 7 14 7 14 7 14 7 14 7

250 12 5 12 5 12 5 12 5 12 5

Permitted stress KISin N/mm2forenvisaged

time in h

CuZn38SnAl
Temperature
"C F433) F43')
F39 F432)

10000 100000 10000 100000 10000 100000 10000 100000

20150 120 120 130 130 123 123 117 117

100 117 117 123 123 117 117 110 110

110 116 116 123 123 117 117 110 110
120 116 116 123 118 117 117 110 110
130 115 110 123 110 117 110 110 110
140 115 101 116 101 116 101 110 101

150 108 92 108 92 108 92 108 92

160 100 82 100 82 100 82 100 82
170 91 72 91 72 91 72 91 72
180 82 62 82 62 82 62 82 62
190 73 53 73 53 73 53 73 53

200 64 44 64 44 64 44 64 44
210 55 36 55 36 55 36 55 36
220 46 29 46 29 46 29 46 29
230 38 22 38 22 38 22 38 22
240 31 16 31 16 31 16 31 16

250 24 11 24 11 24 11 24 11

J
2) 215toc- 4Jmm ') >‘lotos 60 ‘) >6otoc12a

,
 Page 21 AD-MerkMatt W 6/2, Edition 5.66

Table 15.2. (continuation)

290 77 68 67 67 77 68 77 68

300 74 62 66 62 74 62 74 62

Permitted stress K/S in N/mm2 for envisaged time in h

CuNi30Mnl Fe (CuNi30Fe) CuAIlONiSFe4 (CuAIlONi)

Temperature
“C
F35 5, F35 ‘) F41 F63
.
loo 000 to 100000

20150 200 180

100 183 177

150 177 173

200 173 173

210 157 172
220 141 1 7 1
230 125 169
240 109 168

250 94 167
260 92
270 91
280 89
290 88

300 86
310 84
320 83
330 82
340 80

350 78

5) 215105 6Omm
6) >60to~lMmm

c
Page 22 AD-Merkblatl W 6/2. E d i t i o n 5 . 8 8

Table 15.3. Permitted stress K/S for seamless tubes

c
Permitted stress K/S in N/mm2 for envisaged time in h
Temperature SF-Cu CuZn20Al2
“C F20 F20’) F22 F22’) F25 F34 F39
t o 100000 10 000 100 000 10 000 100000 10000 100 000
20/50 57 50 63 55 100 100 87 87 107 107
100 57 50 63 55 90 90 83 83 99 99
110 56 49 62 54 89 89 83 83 98 98
120 54 48 60 53 89 89 83 83 97 97
130 53 46 59 51 88 88 83 83 97 97
140 51 45 57 50 88 88 83 83 96 96
150 50 44 56 49 87 87 83 83 95 95
160 49 43 54 48 86 86 83 83 95 92
170 47 41 53 46 85 85 82 81 94 81
180 46 40 51 45 85 85 81 70 93 70
190 44 39 50 44 84 84 81 59 86 59
200 43 38 49 43 83 83 77 48 77 48
210 41 36 47 41 83 82 67 38 67 38
220 40 35 46 40 82 69 57 29 57 29
230 39 34 44 39 81 55 46 21 46 21
240 37 33 43 38 78 43 34 15 34 15
250 36 31 41 36 66 41 24 10 24 10

CuZn28Snl CuNilOFelMn CuNi30Mnl Fe CuNi30Fe2Mn2

Temperature F32 F36 F29 F37 F42
“C
to 100000 10000 100000 t o 100 000 to 100000 to 100 000
20150 70 100 100 77 93 97
100 69 96 96 72 87 93
110 68 I
95 95 72 86 92
120 68 95 95 71 86 92 .’ I
130 67 94 94 71 85 91
140 67 94 94 70 85 91
150 67 93 93 70 84 90
160 93 87 70 84 88
170 92 74 69 83 87
180 91 58 69 83 86
190 81 46 68 82 84
200 68 36 68 82 83
210 54 27 67 82 83
220 43 20 67 81 82
230 no 33 15 66 81 82
240 application 25 10 66 80 81
250 above 19 8 65 80 80
260 150°C 65 80
270 64 79
280 63 79
290 63 78
300 62 78
310 77
320 77
330 76
340 75
350 75
 Page 23 AD-Merkblatl W 6/2, Edition 5.66
.
Table 15.4. Permitted stress K/S for rods and bars

‘) soldered
 Material code

CuAIlONiSFe4 (CuAIlONi) ‘) 128 123 122 120 120 116 115 115 110 - -

- 156 - - - _ - - - /
CuNi30Fe2Mn2 i

‘) Material codes that are still valid for plate materials. They can still ba used until revtsion of DIN 17675.

I
ICS 23.020.30 January 2000 edition

Materials AD-Merkblatt
Bolts and nuts made
for
Pressure Vessels from ferritic steels w7

The AD-Merkbl&ter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
behalter” (AD). AD-Merkblatt G 7 covers the composition and application of the AD-Regulations and also the procedural rules.
The AD-Merkblatter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
and above the normal /eve/ being anticipated during the operation of pressure vessels, allowance must be made for such stresses by
meeting special requirements.
Should there be any departures from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis,
operating experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e. V. (FDBR), Dtisseldorf
Hauptverband d e r g e w e r b l i c h e n B e r u f s g e n o s s e n s c h a f t e n e . V . , Sankt Augustin
Verband der Chemischen lndustrie e. V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Diisseldorf
VGB Technische Vereinigung der Gronkraftwerksbetreiber e. V., Essen
Verband der Technischen iiberwachungs-Vereine e. V. (VdTiiV), Essen
T h e AD-MerkbHter a r e a m e n d e d c o n t i n u o u s l y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e. V., Postfach 103834, D-45038 Essen.

Contents
1 Scope 5 Marking
2 Suitable materials 6 Certification of quality
3 Requirements 7 Dimensioning characteristics
4 Testing Appendix 1

1 Scope
1.1 This AD-Merkblatt applies to bolts and nuts and to bars
used to make them of unalloyed and alloy ferritic steels for
the construction of pressure vessels operating at temperatu-
res determined by atmospheric conditions and at charge
temperatures up to - 10 “C up to the limits of temperature
given in Clause 2.
2.1 Steels for strength classes 5.6 and 8.8’) for bolts and
steels for strength classes 5-2 and 8 for nuts to DIN 267
Part 13 and DIN EN 20898 Part 1 and Part 2 up to a thread
diameter of 39 mm, a permissible service pressure of 40 bars
and a temperature’) of 300 “C.
The use of free-cutting steels and basic Bessemer (Thomas)
steels is not permitted.

AD-Merkblatt W 10 will also apply where charge temperatu-
res are below - 10 “C.
AD-Merkblatt W 2 applies for bolts and nuts made from aus-
tenitic steels.
1 . 2 The stipulations in Clauses 2 to 7 below are applicable
to bolts and nuts for the construction of pressure vessels to
be subjected to structural tests by the authorized inspector
(pressure vessel test groups Ill, IV, VI and VII).
1.3 Apart from the provisions contained in AD-Merkblatt
W 0, no additional requirements are necessary for bolts and
nuts used in the construction of pressure vessels for which
the manufacturer has to certify correct manufacture (pres-
sure vessels of test group I, where they are used for combu-
stible, corrosive or toxic gases, vapours or liquids, or of test
group II).
2 . 2 High-temperature steels C 35 (for nuts only), Ck 35,
35 B 23) 24 CrMo 5, 21 CrMoV 5 7 and X 22 CrMoV 12 1
(tensile strength range 800-950 N/mm*) to DIN 267 Part 13
and DIN 17 240.
2 . 3 Low temperature tough steels 26 CrMo 4 and 12 Ni 19
to DIN 267 Part 13 and DIN 17280. AD-Merkblatt W 10,
table 3a, is applicable in the case of short-term service at ele-
vated temperatures.
2 . 4 Other steels on the basis of suitability assessment by
the authorized inspector. The steels shall meet the require-
ments of 3.2.
3 Requirements
3.1 Bolts and nuts and bar steel for bolts and nuts as speci-
fied in 2.1 to 2.3 shall meet the requirements of DIN 267

1) Wlthout verification of hot yield strength. bolts made from steels for strength
2 Suitable materials class 8.8 shall only ba used at up to 50 “C.
2) For dehnition of wall temperature and service temperature, see Clause 5 of
The following materials may be used for production of bolts AD-Merkblatl B 0.
and nuts by both machining and chipless forming processes: 3) In conjunction with VdTljV-Merkblatt 490.

Supersedes April 1996 edition; 1 = Amendments to previous Edition

Carl Iieymanns Verlag KG Translation: Technical Help to Exporters Service of BSI

Luxemburger StraOe 449. 50939 Kbln
Page 2 AD-Merkblatt W 7. Edition 01.2000
Part 13, DIN EN 20898 Parts 1 and 2, DIN 17240 and
DIN 17280. For steel X 22 CrMoV 12 1 in diameters
5 60 mm, a value of 52 J shall be maintained in the notch
impact test. This value shall be the average from three
V-notched specimens and only one individual value shall fall
below the required minimum value but not by more than
30%.
The permissible maximum and minimum hardness values
shall be obtained from the standard tensile strengths stated
in DIN 17240 and DIN 17280 after conversion in accordance
with DIN 50 150. In the case of nuts, the requirements stated
in DIN EN 493 are applicable for the expansion test.
3 . 2 The steels for bolts and nuts specified in 2.4 shall have
the properties characteristic of the particular material and
shall meet the following requirements at room temperature
on longitudinal specimens:
- elongation after fracture A 2 14%;
- IS0 V-notch impact energy of 2 52 J in the case of
hardened and tempered alloy steels and of Z 40 J in the
case of unalloyed steels.
The impact energy values shall be average values from three
specimens; only one individual value may be below the
required minimum but not by more than 30 %.
3 . 3 The bolts and nuts shall be in the heat-treated condition
specified for each material to obtain the minimum properties.
The material shall not exhibit any unacceptable embrittle-
ment up to the maximum temperature prevailing in service.
In the case of hardened and tempered steels, the tempering
temperature shall always exceed the maximum service tem-
perature by an appropriate amount.
3 . 4 The bolts and nuts may be produced by hot- or cold
forming or by machining. Bolts produced by cold forming
require subsequent heat treatment. This is also the case with
cold-formed nuts as specified in 2.2 to 2.4. Surface smooth-
ing and thread rolling do not count as cold forming operations
in the above context. Subsequent heat treatment shall be
given in the case of bolts and nuts produced by hot forming
from the steels specified in DIN 17240 and other hardened
and tempered steels (except in the case of nuts of C 35
steel).
3 . 5 The design and dimensional accuracy of bolts and nuts
shall comply with the requirements of DIN IS0 4759 Part 1,
Product Class B.
4 Testing
4.1 Bolts and nuts specified in 2.1 to 2.4 produced by
chipless forming
4.1 .l The bolts shall be mechanically tested in accordance
with DIN EN 20898 Part 1 (test programme A) in conjunction
with DIN EN 26157 Part 3. If test programme A cannot be
carried out, the bolts shall be tested using test programme B
in which the impact test is performed on threeV-notched spe-
cimens in each case. In the case X 22 CrMoV 12 1 steel in
diameters of up 60 mm, a notch impact energy value of 52 J
shall be maintained in the notch impact test. This value shall
be the average from three V-notched specimens; only one
of the three values may be lower than the required minimum
but not more than 30% lower.
For mechanical testing, bolts made from steels specified in
2.2 and 2.3 (except X 22 CrMoV 12 1) shall be assigned to
strength class 5.6. Bolts made from X 22 CrMoV 12 1 steel
shall be assigned to strength class 8.8.
Bolts and nuts made from other steels specified in 2.4 shall
be tested in compliance with suitability assessment procedu-
res.
4.1.2 Hardness tests and expansion tests shall be per-
formed on nuts. The scope of hardness testing shall be as
specified in 4.1.4 and the scope of expansion testing shall be
as specified in table 1.
4.1.3 The acceptance test for bolts and nuts shall be as
specified in DIN IS0 3269. The number of sets of specimens
.
required for mechanical testing is specified in table 1. If 1
notched impact specimens are required, three individual
specimens shall constitute a set. Surface inspection and
dimensional verification of bolts and nuts shall be carried out
in accordance with 4.1.4. The surface of each individual bolt
and nut shall be visually inspected in the case of bolts and
nuts made from X 22 CrMoV 12 1 steel and other steels to
2.4 which are comparable with X 22 CrMoV 12 1.
4.1.4 In the case of tests to DIN IS0 3269, the scope of
destructive mechanical testing shall be, as a deviation from
DIN IS0 3269, be as specified in table 1. The number of ran-
dom samples shall be 20 in the case of hardness testing, non-
destructive testing for surface defects and dimension checks.
All specimens shall satisfy the requirements (acceptance
number Ac = 0).
Table 1 Scope of random samples for destructive mecha-
nical testing
Number of products Number of sets of specimens
for mechanrcal testina
5 200 1
> 2 0 0 to 5 4 0 0 2
> 400 to 5 8 0 0 3 0
> 800to5 1200 4 I
> 1 2 0 0 to I 1 6 0 0 5
*.
> 1600 t o I 3 0 0 0 6
> 3000 to 5 3500 7
5’
> 3500 DIN IS0 3269
If evidence is produced to show that the bolts and nuts in a speci-
1.”
fic delivery originate from a single cast subjected to identical heat
treatment, it shall be considered sufficient to test four sets of
specimens regardless of the number of products. This reduction
in the number of specimen sets does not apply to bolts and nuts
referred to in 2.4.
4.2 Bolts and nuts specified in 2.1 to 2.4 produced by
machining
4.2.1 Where production by machining is followed by heat
treatment, testing shall be performed in accordance with in
4.1 the same way as for hot- and cold-formed bolts and nuts.
4.2.2 If no heat treatment is given after machining, testing
of the steel grade used in accordance with DIN 17240 or
DIN 17280 shall be sufficient for verification of mechanical
properties. Inspection of the condition and dimensional
accuracy shall be carried out in accordance with 4.1.3. In the
case of steels referred to in 2.4, the tests specified in the sui-
tability assessment procedure shall be performed.
4 . 3 Steel bar for the manufacture of nuts and bolts shall be
tested in accordance with the standards applicable to steel

.
bar. Steel bar of grade X 22 CrMoVl21 shall also be sub-
jected to ultrasonic testing and surface crack testing. If in the
course of manufacture of nuts and bolts of steel bar of the
X 22 CrMoV 12 1 grade re-heat treatment is carried out, a fur-
ther surface crack detection test shall be performed on all
nuts and bolts. For steel bar of steels in accordance with 2.4
the specifications of the suitability assessment procedure
apply.
4.4 If one of the specimens prescribed for destructive
mechanical tests fails to meet specified requirements, two
more specimens shall be taken which shall meet the speci-
fied requirements. If this is not the case, the entire test batch
shall be rejected. This test batch can, however, be submitted
for inspection a second time by the producer after re-heat
treatment. If the specimens still fail to meet the requirements
on this occasion, the test batch shall be finally rejected.
4 . 5 If one of the specimens prescribed for the hardness
test, non-destructive inspection for surface defects or dimen-
sional verification fails to meet the requirements, a further
random sample of 20 specimens shall be taken, all of which
shall meet the stipulated requirements. If this is not the case,
the entire batch shall be rejected. In the case of the hardness
test, however, the producer can submit this batch for inspec-
tion again after re-heat treatment. If the specimens still fail
to meet the requirements, the batch shall be finally rejected.
4.6 If the authorized inspector has reasonable doubts
regarding the consistency of the quality of a delivery, he can
call for any tests he deems suitable (e.g. hardness test, spec-
troscope tests).
4 . 7 If the cast analysis shows marked deviations from the
element composition limits specified for high-temperature
steels, the authorized inspector shall have the right to call for
verification of the elevated-temperature strength properties.
. fied in 2.1 to 2.3 produced by machining without subsequent
4 . 8 In the case of bolts and nuts made of alloy steels, the
producer shall ensure, by an appropriate test, that no grade
mixing has occurred.
. inspection certificate 3.1 .A or 3.1 .C to EN 10024
5 Marking
5.1 Bolts and nuts as specified in 2.1 to 2.3 shall be marked
with the manufacturer’s mark and the strength class or sym-
bol for the steel grade quoted in DIN 267 Part 13.
Bolts with thread diameters of 52 mm or more shall
additionally be marked with the cast number and authorized
inspector’s mark.
5 . 2 Bar steel with a diameter 2 25 mm for bolt and nut pro-
duction by machining shall be marked at one end with the
manufacturer’s mark and symbol for steel grade and also
with the authorized inspector’s mark. With bar steel of
< 25 mm diameter, the bar bundle only shall carry a tie-on
tag showing the manufacturer’s mark, the symbol for steel
grade, the authorized inspector’s mark and, in the case of
alloy steels, also with the cast number.
5 . 3 Bolts and nuts made from steels quoted in 2.4 shall be
marked in accordance with suitability assessment proce-
dure. Bolts from M 30 upwards shall be marked with the
authorized inspector’s stamp and bolts from M 52 upwards
shall additionally be marked with the cast number.
. proceed in accordance with 6.2.1 and 6.2.2.
6 Certification of quality
6.1 Bolts
6.1 .l Bolts of strength class 5.6 as specified in 2.1, pro-
duced by machining, shall be certified with an inspection cer-
.
Page 3 AD-Merkblatt W 7, Edition 01.2000
tificate 3.1.8 to EN 10204 (DIN 50049). If the conditions sti-
pulated in 6.6 are met, the inspection certificate 3.1.8 to
EN 10204 (DIN 50049) may be replaced by marking with the
strength class and manufacturer’s mark4).
For bolts in strength class 8.8, an inspection certificate 3.1 .A
or 3.1.C to EN 10204 (DIN 50049) shall be provided. An
inspection certificate 3.1 .B to EN 10204 (DIN 50049) shall
be adequate for bolts in strength class 8.8 in the case of pres-
sure vessels where the product of the capacity I in litres and
the pressure p in bars (I x p) < 5000.
6.1.2 Hot- and cold-formed bolts as specified in 2.2 (except
for Ck 35 and 35 B 2) and 2.3 shall be certified with an inspec-
tion certificate 3.1 .A or 3.1 .C to EN 10204 (DIN 50049). An
inspection certificate 3.1.8 to EN 10204 (DIN 50049) shall
be adequate in the case of bolts made of Ck 35 and 35 B 2
steels.
If bolts with a thread diameter I 39 mm of Ck 35 and 35 B 2
steels are used at allowed service pressures I 40 bars and
service temperatures 5 300 “C, marking in accordance with
5.1 may be substituted for inspection certificate 3.1.8 to
EN 10204 (DIN 50049) provided the conditions in 6.6 are
complied with4).
6.1.3 For bolts produced by machining with subsequent
heat treatment as specified in 2.1 to 2.3, certification shall be
.‘
in accordance with 6.1 .l and 6.1.2. ‘:“I
6.1.4 In the case of bolts as specified in 2.1 to 2.3 produced
by machining without subsequent heat treatment, the bar
steel shall be certified in accordance with table 2. Testing of
the condition and dimensional accuracy of bolts as specified
in 2.1 to 2.3 produced by machining without subsequent heat
treatment shall be certified in the same way as bolts as speci-
fied in 2.1 to 2.3 produced by hot- and cold forming. Testing
of the condition and dimensional accuracy of bolts as speci-
heat treatment, the feedstock for which has to be certified by
the authorized inspector, can be certified by the bolt manu-
facturer using an inspection certificate 3.1.8 provided an
(DIN 50049) for the feedstock has been supplied to him. A
precondition of this procedure is that the bolt manufacturer
has been audited to AD-Merkblatt W 0.
6 . 1 . 5 The specifications of the suitability assessment pro-
cedure apply to bolts made of steels in accordance with 2.4. I-:,I
6.2 Nuts
6.2.1 Nuts as specified in 2.1 shall be certified with an
inspection certificate 3.1.8 to EN 10204 (DIN 50049). This
inspection certificate 3.1 .B to EN 10204 (DIN 50049) can be
replaced by marking with the strength class provided the con-
ditions in 6.6 are met4).
6 . 2 . 2 Nuts as specified in 2.2 and 2.3 shall be certified with
an inspectjon certificate 3.1.9. to EN 10204 (DIN 50049).
This inspection certificate 3.1.8 to EN 10204 (DIN 50049)
can, in the case of nuts made from C 35, Ck 35 and 35 B 2
steels, be replaced by marking with the steel grade symbol
provided the conditions in 6.6 are met4).
6.2.3 In the case of nuts specified in 2.1, produced by
machining with subsequent heat treatment, certification shall
4) Replacement of the test cartificate by marking and compliance with the conditions
shall be the subject of an agreement.
Page 4 AD-Merkblatt W 7, Edition 01.2000

6 . 2 . 4 In the case of nuts specified in 2.1 to 2.3, produced
by machining without subsequent heat treatment, the bar
steel shall be certified as indicated in table 2. Testing of the
condition and dimensionat accuracy shall be certified in the
same way as with the corresponding hot- and cold formed
nuts as specified in 2.1 and 2.3.
6 . 2 . 5 In the c&se of nuts as specified in 2.4, the require-
ments of the suitability assessment procedure shall be appli-
cable.
6 . 3 If an inspection certificate 3.1 .A or 3.1 .C to EN
(DIN 50049) is to be provided, the manufacturer shall
the cast analysis, the result of the hardness test and the
of the inspection for surface cracks using an inspection
ficate 3.1.8 to EN 10204 (DIN 50049).
6 . 4 The heat treatment condition shall be certified by the
manufacturer. In the case of hardened and tempered steels,
the tempering temperature shall also be stated.
6.5 The inspection certificate 3.1 .B. to EN 10204
(DIN 50049) available for the bar steel can, in the case of
bolts and nuts to be produced by machining without subse-
quent heat treatment, be replaced by a written confirmation
from the manufacturer. This confirmation shall state that the
requirements of the appropriate material standards or of
AD-Merkblatt W 7 have been met and shall also report the
results of the visual inspection and dimensional accuracy
check. Copies of the test certificates shall be provided if
required.
In the case of bolts and nuts as specified in 2.1, made from
C 35, Ck 35 and 35 I3 2, the written confirmation from the
manufacturer can be replaced by marking with the strength
class or steel grade symbol and manufacturer’s mark pro-
vided the conditions in 6.6 are complied with (see footnote 4
on the previous page).
6.6 Where the inspection certificate 3.1.8 to EN 10204
(DIN 50049) is to be replaced by marking, the manufacturer
shall have continuously performed all the tests’required for
an inspection certificate 3.1 .B and shall keep the results in
readiness for examination by the authorized inspector at all
times (see footnote 4 on the previous page).
10204
certify
result 7 Dimensioning characteristics
certi- 7.1 For bolts as specified in 2.1, the dimensioning characte- k”
,: .
ristics shall be taken from DIN 267 Part 13.
7 . 2 For bolts as specified in 2.2 and 2.3, the relevant values
in DIN 17240 or DIN 17280 shall be applicable.
i
7 . 3 The characteristic strength values at 20 “C stated in the
DIN standards or suitability assessment procedure docu-
ments shall be applicable up to 50 “C and those stated for
100 “C shall be applicable up to 120 “C. In the other tempera-
ture ranges, linear interpolation between the stated values is
necessary (e.g. for 80 “C, between 20 and 100 “C and, for
180 “C, between 100 and 200 “C) but no rounding up is per-
missible. In the case of steels as specified in 2.4, the interpo-
lation rule shall apply only where the interval between the
already known values is sufficiently smalls).
5) This is generally understood to mean a temperature interval of 50 K 1” the
elevated-temperature yield strength range and an mterwl of 10 K in the creep
rupture strength range.

I
Table 2 Survey of suitable materials for bolts and nuts and materials test certificates to EN 10204 (DIN 50049)
.
.
Standard Product Steel grade or Type of test certificate
strength class to EN 10204 (DIN 50049)
Bar steel Bolts Bar steel Nuts
for bolts for nuts ‘7

5.6 3.1.8 3.1.8’) - -

Bolts
DIN 267 Part 13 a.0 3.1 ./I/c?) 3.1 A/c*) - t
DIN EN 20898
Parts 1 and 2 5-2 3.1.8 3.1 .B’)
Nuts
8 3.1.8 3.1 .B’)
DIN 17240 Ck 35 3.1 .B 3.1 .B’)4)
Bolts and nuts
VdTijV-WBI. 490 35 B 23) 3.1.B 3.1 .B’)4) 3.1.8 3.1 .B’)

Nuts c 35

DIN 17240 Bolts and nuts 24 CrMo 5

21 CrMoV 5 7 3.1 .AIc 3.1 .A/C5) 3.1.B 3.1.8
X 22 CrMoV 12 1
DIN 17280 Bolts and nuts 26 CrMo 4 3.1.Alc 3.1.NC5) 3.1.8 3.1.B
12 Ni 19

1) For conditions in which the Inspection certificate 3.1 .B to EN 10204 (DIN 50049) can be replaced by marking see 6.6.
2) In the case of pressure vessels where the product of the capacity I in litres and the pressure p in bars (I x p) 5 5000. an inspection certificate 3.1 .B to EN 10204
(DIN 50049) shall be adequate.
3) In conjunction with VdTuV Material Sheet (Werkstoffblatt) 490.
6) Up to a thread diameter of 39 mm. a service temperature of 300 “C and an allowable service pressure of 40 bars. the inspection certficate X1.8to EN 10204
(DIN 50049) can be replaced by marklng.
5) In the case of bolts produced by machming without subsequent heat treatment, an inspection certificate 3.1 .B to EN 10204 (DIN 50049) shall be adequate for testing
the condition and dlmenslonal accuracy (see 6.1.4).
y- ” -c.T-~1-:-7?T.=eTr n-i c,-.YcA :_ ---:.xp . I-_--. . __.~.. x:i-ir--.--.7.*-
~~~~-.~^ii,.^“_;_^*I^_^_ ,--. --‘^-.r”‘ ^. _ ^ ““.=-yyy-,u.Z Yl 6.. ,. .- ‘“pi:.“,‘i.-‘~‘ii-ir.~~~~-
,..
*

j::.;

Page 5 AD-Merkblatl W 7. Edition 01.2000

.
: i
.!

Appendix to AD-Merkblatt W 7
a
I
Agreement of the AD Associations on the continuous use of nuts as specified in the August 1663 edition
of DIN 267 Part 4
I
Nuts as specified in the withdrawn DIN 267 Part 4 and bolts and nuts of Steel grade cq 35 (replaced by 35 B 2) as specified
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UDC 669.146.699.2/.6:621.642.02-9861-988 Edition July 1987

Materials AD-Merkblatt
for Clad steels
Pressure Vessels W8

‘he AD-Merkbl3tter a r e c o m p i l e d b y t h e s e v e n t r a d e associations s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e ‘Arbeitsgemeinschaft Oruck-

)ehd/ter” (AD). AD-Merkblatt G 1 covers the composition and application of the AD-Regulations and a/so the procedural rules.
rhe AD-MerkblBtter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
2nd above the normal /eve/ being anticipated during the operation of pressure vessels, allowance must be made for such stresses by
neeting special requirements.
should there be any departures from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis,
operating experience.
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e.V. (FDBR), Diisseldotf
Hauptverband der gewerblichen Berufsgenossenschaften e. V., Sankt Augustin
Verband der Chemischen lndustrie e.V. (VU), FrankfurtlMam
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaff Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher fisenhiittenleute (VDEh), Dtisseldorf
VGB Technische Vereinigung der Groflkraftwerksbetreeiber e.V. Essen ,_
Vereinigung der Jechnischen iiberwachungs-Vereme e.V (VdTilV), Essen.
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s shoulc
5e addressed to the publisher:
Vereinigung der Technischen iiberwachungs-Vereine e. K, Postfach 103834, D-4300 Essen 1.

Contents

1 General and scope 6 Heat treatment

12 Suitability of cladding process 7 Testing
3 Suitable materials 8 Marking
4 Requirements 9 Certification of quality
5 Repairing defects 10 Design principles

1 General and scope
1 .l Clad steels are inseparable bonds formed between the
base metal and the cladding metals and are made by means
of an explosive or a rolling’) process. The materials used for
cladding may be steels or non-ferrous metals.
1.2 This AD-Merkblatt applies to steels clad on one side,
both or all sides, with or without intermediate layers which
may, for example, be applied by a galvanizing process. It
deals with this type of product used in the construction of
pressure vessels intended for operation at climatic temper-
atures and carrying substances down to -10 “C and up to
the upper temperature limits given in the relevant AD-
Merkblatter.
Where the temperature of the contents is below - 10 “C, AD-
Merkblatt W 10 also applies.
1.3 This AD-Merkblatt does not apply to the following:
(1) metallic or non-metallic layers applied by dipping, gal-
vanizing, diffusion or spraying or using organic or inor-
ganic binders;
1) An AD-Merkblatt covering welded claddings is in course of preparation.
(2) coatings, even when they are welded to the base mate
rial;
(3) layers which are soldered together.
1 . 4 In the case of clad steels used in the construction o
pressure vessels obliged to undergo structural tests carriec
out by an authorized inspector (i.e. pressure vessels in tes
groups III, IV, VI and VII), the provisions set out in Sections :
to 10 below apply.
1 . 5 In the case of clad steels used in the manufacture o
pressure vessels for which the makers are obliged to provide
certification proving correct manufacture (i.e. pressure ves
sels of test groups I, II and V), no other specifications art
necessary other than those set out in AD-Merkblatt W 0.
2 Suitability of cladding process
The authorized inspector shall determine whether the clad
ding process is suitable, whether the requirements of Set
tion 4 have been met and whether the mechanical ant
technological properties given for the base materials in tht
AD-Merkblatter of Series W or the VdTUV specificatior
sheets have remained unchanged. If the cladding process al
ters these properties, new limits of application shall be set.

Supersedes Edition February 1980; ( = Amendments relating to previous edition

-
Gat’I H e y m a n n s V e r l a g K G
Luxemburger StraOe 449, 5 0 0 0 K&n 41
GuienbergstraOe 3, 1000 Berlin 10
Page 2 AD-Merkblatt W 8, Edition 7.87

If the requirements of Section 4 are not met, special instruc-
tions shall also be given for processing when suitability is
being determined.
3 Suitable materials
The following materials may be used:
3.1 As base materials, grades of steel complying with the
AD-Merkblatter of Series W, within the limits of application
set out therein.
3.2 As cladding, all metallic materials.
Determination of suitability in accordance with AD-Merkblatt
W 0 shall only become necessary if the provision under Sec-
tion 10.2 becomes applicable.
4 Requirements
Clad steels shall comply with the following general regula-
tions:
4.1 In the case of clad steels where the cladding has a lower
degree of elasticity than that of the base metal, a tensile test
on the cladding after the base has been removed should
show an elongation at break A, of at least 12%.
4 . 2 The bond between the base and the cladding materials
shall be of such a nature that there is no delamination either
in the course of manufacture or in service. Unless otherwise
stipulated in the order, the shear strength of cladding with a
tensile strength of less than 280 N/mm2 shall be more than
half the minimum tensile strength of the cladding material
and, for all other cladding materials, shall not be less than
140 N/mm*, regardless of the direction of testing.
4 . 3 The bonded area shall cover at least 95%*) of the entire
surface and no single unbonded area shall cover more than
50 cm*. In the case of clad steels which are highly stressed
during manufacture (e.g. dished ends) or when in service
(e.g. tube plates), additional requirements imposed by the
purchaser (operator) may be necessary.
4.4 The cladding material shall have a surface texture
which corresponds to the cladding process and be of uni-
form thickness with tolerances not exceeding those given in
Table 1.
ment of the purchaser and the authorized inspector. The AD- * i
Merkbltitter of Series HP should be consulted in this respect.
5 . 3 Repair welds on the cladding at the manufacturer’s may
be carried out without reference to the purchaser (operator)
only to the extent laid down in and in respect of defects of
a size spezified in the order.
The following points apply if there are no restricting provi-
sions in the order and the determination of suitability in ac-
cordance with Section 2 permits:
(1) Bonding defects up to 50 cm* in area are not repaired.
(2) Defects in the cladding which cannot be removed by
grinding according to Section 5.1. will be repaired by
welding.
(3) Individual defects 3) i.e. deep-running defects and bond-
ing defects, covering an area up to 5% of the clad surface
but not exceeding 1200 cm* in extent, shall be repaired
by welding.
5 . 4 Explosion cladding, even when carried out in conjunc-
tion with welding, is permissible for the repair of defects only
within the scope of the suitability determination according to
Section 2.
5 . 5 A report on the repairs carried out in accordance with
Sections 5.2, 5.3 and 5.4 shall be prepared and include the
following details:
(1) description of the repaired material (e.g. material
number, number of the melt and sample number),
(2) position, size and depth of the repaired areas in the plate,
(3) information on the repair - e.g. how the defective or de-
tached cladding was removed (by grinding, chipping,
etc.), on preheating (giving the temperature and the
means of heating used), on the filler metal (type and
diameter), on the number of passes, surface treatment
following repair (grinding, polishing, pickling) and on the
type of heat treatment following the repair,
(4) information on non-destructive testing.
Table 1. Permissible thickness tolerances for cladding
materials on clad steels
Nominal thickness Permissible tolerance on thickness l) *) 3
_.

4.5 The permissible tolerances for the base material are in mm mm

given in the relevant dimensional standards for the various
170 -0,lO .’ - .
products. ;,I.

135 -0,15
4 . 6 With the exception of surface defects according to Sec- 270 -0,20
tion 5.1, the total area of defects on the cladding material 23 -0,25
shall not exceed 20% of the clad surface. 3,O -0,35
3,5 -0,45
4,O -0,50
5 Repairing defects 495 -0,50
Defects may be repaired as follows: 25,O -0,50
5.1 Surface defects in the base and cladding materials 7) Deviations from the values in this table are subject to special agree-
may be removed by grinding as long as thicknesses do not ment.
fall below the minimum thicknesses given in Sections 4.4 2) For intermediate thicknesses the permissible tolerance indicated for the
next smallest thickness in the table applies.
and 4.5.
5 . 2 Defects running deep into the surface of the base metal,
i.e. those the removal of which would reduce the wall thick-
5 . 6 In individual cases it may be agreed to carry out the re-
ness below the permitted minimum thickness according to
pair welds and the necessary non-destructive tests on the
Section 4.5, may be repaired by welding only with the agree-
finished component if such treatment seems reasonable.
2) The rulings here laid down only hold insofar as nothing to the contrary is
agreed between the manufacturer, purchaser (operator) and inspecting Au- 3) A defect is defined as local if ft is 100 mm or more from the next closed
thority. defect.
 Page 3 AD-Merkblatl W 8. Edition 2.87

7.2.1 Tensile test ii:::

6 Heat treatment
.
Any heat treatment which might be necessary shall be reg- 7.2.1.1 Tensile tests on flat products (cladded specimens)
ulated when determination of suitability is carried out in ac- The marks for measuring elongation shall be made on the
cordance with Section 2. base material

7 Testing
7.1 The extent and nature of the tests, the number and
positions of the specimens depend on the provisions laid
down in the W-Series of the AD-Merkblatter4) for the respec-
tive types of products and fields of application of the base
materials and in Section 7.2, provided nothing to the contrary
has been specified in the determination of suitability carried
out in accordance with Section 2.
7 . 2 The tests shall be caried out with the following speci-
mens (see Fig. 1):
4) Bend test to Section 7.3.1 is waived.
c7 = guarantee value (yield point, 0,2% proof stress, 1 ,O%
elastic limit, tensile strength)
s = nominal wall thickness
Indices: G = base material
A = cladding material
pl = clad steel
In cases where up, gives a lower value than that calculated
from the formula or where no significant value is to be ex-
pected (e.g. relative to the base material when the cladding
material is very hard or very soft), the tensile test shall be
carried out on a specimen with the cladding removed. This
does not apply in cases according to Section 10.2.
a

------s-m-
,/f-y---
-

------------

/ I 1

/ -Ii-,------------
/

----- NJ
I I” 1 \ I /
f cladding material

\
f
Fig. 1: Specimen positions

Dimensions of specimens Test Layout

Thickness: a = 10 mm
Width: b = thickness of finished product not greater
than 80 mm (base and cladding material).
If finished product is over 80 mm thick the
base material may be removed.
Length: I = not less than 130 mm
a = 180”

Test procedure
According to DIN 1605 Part 4, February 1936 edition

Fig. 2: Side bend test

Page 4 AD-Merkblatt W 8, Edition 7.07
7.2.1.2 Tensile testing pressed parts
The tensile test shall be carried out on circular specimens
in accordance with DIN 50 125. the largest possible speci-
men
diameter shall be chosen. In instances according to Section
10.2 the tensile test shall be carried out in accordance with
Section 7.2.1.1.
7 . 2 . 2 Notched bar impact bend test with notch at right ang-
les to the surface.
7.2.3 Technological tests in the case of tubes on speci-
mens with the cladding.
7 . 3 The following tests shall be carried out in addition to
Section 7.1 (position of the specimen as shown in Fig. 1):
7.3.1 Side Bend Test
The scope of the test shall be in accordance with the provi-
sions specified by the determination of suitability.
Test procedure is in accordance with Fig. 2.
7 . 3 . 2 Shear test according to DIN 50 162
The scope of the test shall be in accordance with the deter-
mination of suitability, but shall be carried out on at least 10%
of the production batch. Where batches contain less than 10
items, at least one shear test shall be carried out.
7.3.3 Further examinations such as macro-examinations,
microscopic examinations of the grain structure and hard-
ness tests in accordance with provisions of the determination
of suitability in Section 2.
7 . 4 Surface quality and conformity to dimensions shall be
tested.
7 . 5 The bond between the base material and the cladding
shall be tested ultrasonically according to SEL 072 with a
2 0 0 mm screen.
7.6 Areas which have been repaired by welding or by
explosion shall be put through a nondestructive test.
7 . 7 At all points where repairs have been made conformity
with the minimum thickness shall be tested.
7 . 8 If the result of a test does not comply with the require-
ments, the following procedure shall be carried out:
7.8.1 If it can be assumed that unsatisfactory test results
can be attributed to faulty heat treatment, the products may
be heattreated again and the entire test repeated. The heat
treatment process may only be repeated more than once if
sanctioned by the authorized inspector.
7 . 8 . 2 If unsatisfactory test results are due to elements per-
taining to the test procedures or to a narrowly restricted de-
fective area, the specimen may be discounted when deciding
whether the requirements have been met and the test in
question may then be repeated.
7 . 8 . 3 For every failed tensile test specimen, side bend test
specimen and shear test specimen, two further specimens
shall be tested and both shall meet the requirements.
7 . 8 . 4 A new set of specimens shall be tested for every un-
satisfactory mean value obtained from the notched bar im-
pact bending test. The mean value of the six individual tests
on both sets of specimens shall conform with the guaranteed
mean value.
8 Marking
Clad steels shall be permanently marked on the base mate-
rial side. Besides the marks specified in the AD-Merkblatter,
the following information shall also appear:
- grade of cladding material
(material number or designation),
- melt number of the cladding material,
- thickness of the cladding material,
- thickness of the base material.
9 Certification of quality
9.1 Unless other provisron were made when the determina-
tion of suitability was carried out, the quality certification is
based on the base material. The minimum requirement, how-
ever, is a B-class acceptance certificate to DIN 50 049.
9 . 2 Non-destructive tests shall be certified by acceptance
certificates, class B, in accordance with DIN 50 049.
9 . 3 The chemical composition of the base material and the
cladding and, if appropriate, the resistance to intercrystalline
corrosion shall be certified by works certificates according to
DIN 50 049.
10 Design principles
10.1 With the exception of those cases cited in Section 10.2,
the thickness of the loadbearing wall is the wall thickness of
the base material, based on its strength characteristics.
1 0 . 2 The inclusion of the cladding in the loadbearing wall
thickness may in special cases be agreed between the ma-
nufacturer of the pressure vessel, the purchaser (operator)
and the authorized inspector.
 Materials AD-Merkblatt
for Steel flanges
Pressure Vessels w9

The ADMerkbl2tter are compaed by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
bekilter” (AD). AD-Merkblatf G 7 covers the composition and application of AD-Regulations and a/so procedural guidelines.
T h e AD-Merkblatter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . I n t h e e v e n t o f l o a d i n g s e x c e e d i n g
!he normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-MerkblaiT, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, BehBlter- und Rohrleitungsbau e.V. (FLIER), Dijsseldorf
H a u p t v e r b a n d d e r g e w e r b l i c h e n B e r u f s g e n o s s e n s c h a f t e n e . V . , S a n k t Augustin
Verband der Chemischen lndustrie e. V. (VCI), FrankfufiiMain
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Diisseldorf
VGB Technische Vereinigung der GroBkraftwerksbetreiber e.V., Essen
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s l y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e.V., P.O. Box 103834, O-45038 Essen.

Contents
1 Scope 5 Marking
2 Suitable materials 6 Certification of property compliance
3 Requirements for the materials 7 Design parameters
and for manufacture Appendix 1: Specimen
4 Testing
.

1 Scope 1.4 No additional provisions other than those in AD-Merk-

. blatt W 0 are required for flanges for the fabrication of pres-
1 .l This AD-Merkblatt covers:
- forged and seamless roiled flanges,
- flanges formed by bending from sections, bar steel or strip
stock and flash-butt welded flanges,
- flanges cut from plates/sheets,
- flanges manufactured by machining from rolled or forged
sectional steel and bar steel,
- cast flanges made of cast steel.
The above are made of ferritic and austenitic steels for the
fabrication of pressure vessels which are operated at tem-
peratures, governed by the weather or by the vessel charge,
ranging from - 10 “C up to the maximum temperatures limits
specified for the starting material in Section 2 and in the rele-
vant AD-Merkbltitter. For vessel charge temperatures less
than -10 “C, AD-Merkblatt W 10 shall also be consulted.
1.2 This AD-Merkblatt does not cover integrally cast flan-
ges or flanges produced by the pressure vessel manu-
facturer.
1.3 The provisions detailed in Sections 2 to 7 below apply
to flanges for the fabrication of pressure vessels which are
subject to a construction inspection by the authorised inspec-
tor (pressure vessels in Inspection Groups III, IV, VI and VII).
sure vessels for which the producer has to certify production
to specification (pressure vessels in Inspection Groups I, II
and V).
2 Suitable materials
The following materials may be used:
2.1 For forged or seamless rolled flanges
2.1.1 General-purpose structural steels USt 37-2, RSt
37-2, St 37-3 and St 52-3 to DIN 17 100 up to a design tem-
perature’) 5 300 “C where the product of the maximum
1 inside diameter d, of the pressure vessel or the built-on part
in mm and the permissible service pressure p in bars di . p
I 20000. These application limits are only applicable to steel
grade USt 37-2 provided that the thickness’) according to the
stipulations in DIN 17 100 does not exceed 16 mm. The flan-
ges shall be delivered in the normalized condition. Flanges
with flange-plate thickness < 30 mm are excluded.
1) See AD-Merkblatt B 0, Section 5
2) For the application limit c 16 mm, the determinative factor in the case of neck
weld flanges IS the flange thickness at the transltlon point sF and, in the case of
other flanges, ‘12 the flange plate height hF according to AD-Merkblatt B 8.

Supersedes Edition May 1992; ( = Amendments to previous Edition

L2arl Heymanns Verlag Kti - - .--.

Translation: Technical Help to Exporters SetvIce ot BSI
Luxemburger StraBe 449. 50939 Kbln
Gutenbergstrafle 3, 10587 Berlin
Page 2 AD-Merkblatl W 9, EditIon 07.95
2 . 1 . 2 Weldable fine-grained structural steels to DIN 17 102
and DIN 17 103 in conjunction with the appropriate VdTuV-
Werkstoffblatter (Material Specification Sheets).
2.1.3 Weldable high-temperature steels to DIN 17243.
VdTiSV-Werkstoffblatter 184, 110 and 350/3 shall also be
consulted for steel grades 14 MoV 6 3, X 20 CrMoV 12 1 and
C 22.8.
2.1.4 Steel with high impact strength at low temperature,
grade 10 Ni 14 to DIN 17280 up to 50 “C. AD-Merkblatt W 10,
Table 3a covers short-time service at higher temperatures.
2.1.5 Steel grades specified in AD-Merkblatt W 2.
2.2 For flanges formed by bending from sections,
bar steel or strip stock and flash-butt welded
Steel grades specified in AD-Merkblatter W 1, W 2, W 10 and
w 13.
2.3 For flanges cut from plates and manufactured by
machining
Steel grades specified in AD-Merkblatter W 1, W 2 and W 10
in conjunction with Section 6.9.
2.4 For flanges manufactured by machining from rolled
and forged sectional steel and bar steel
Steel grades specified in AD-Merkblatter W 2, W 10 and
W 13 in conjunction with Section 6.9.
2.5 For cast flanges
Cast steel specified in AD-Merkblatt W 5.
2.6 For flanges regardless of the method
of manufacture
Other materials assessed as suitable by the authorised
inspector. The minimum requirements for other materials in
Series W AD-Merkblatter shall be taken into account for
these materials.
3 Requirements for the materials and for
manufacture
3.1 For the chemical composition, delivery condition,
mechanical and technical characteristics as a function of
dimensional limits, surface finish and dimensional accuracy
of the product forms specified in Sections 2.1 to 2.6, the
stipulations in the relevant AD-Merkblatter, standards or
VdTijV-Werkstoffblatter are applicable.
3 . 2 Flanges made of steel grades specified in Section 2.1 .l
with flange-plate thicknesses < 30 mm may be supplied in
the hot-forged state.
3 . 3 Neck weld flanges and weld collars shall not be cut in
the form of circles from plate. If they are manufactured from
plate, strips shall be cut in the rolling direction and bent in
such a manner that one surface of the plate faces inwards
towards the axis of the flange (see also AD-Merkblatt B 8).
4 Testing
4.1 Inspection and dimensional checks
The flanges shall be inspected in the as-supplied state and
their dimensions checked.
4.2 Destructive material tests
4.2.1 Forged or seamless rolled flanges made of steels
specified in Section 2.1.1 (see also Table 4)
The flanges are tested in batches. A test batch includes flan-
ges produced from one cast with the same kind of hot working
and heat treatment. A test batch may also include flanges
produced from one cast which have differing dimensions and
have been heat treated separately but in the same way,
provided that the uniform quality of the heat treatment is
demonstrated by means of hardness tests on 10 % of the
flanges, but on three flanges at least. The hardness test
measures are also applicable to flanges that have not been
treated.
For each test batch, with unit weights 5 300 kg, one tensile
test specimen and three notched-bar impact test specimens
shall be tested at test temperatures in accordance with DIN
17 100. In the case of unit weights > 300 kg, the flanges are
tested in accordance with Section 4.2.2. Hammer-forged
flanges with unit weights > 300 kg are tested individually.
Specimens are cut transversely or tangentially to the material
fibre. With flange-plate thicknesses > 30 mm, the speci-
mens shall be cut at a distance of at least 25 % beneath the
front and side face.
To obtain the specimens, either the flanges themselves shall
be utilized in the appropriate numbers or all the flanges that
are intended for testing shall have the necessary additional
margin of material for the test piece. When flanges are pro-
duced by drop-forging, the waste core of material which
results from the piercing can be used to obtain the specimens
provided that the thickness of the core is not less than 75 %
of the flange-plate thickness.
If flanges originating from one cast are rolled or forged at dif-
ferent times, for each cast atest piece-or where appropriate
several test pieces - of a size comparable with that of the
flanges can be produced and subjected, stage-by-stage, to
the individual heat treatments for the flanges. This presuppo-
ses that the forming for the flanges and the test pieces is com-
parable.
The mean value obtained from three specimens shall be
regarded as the result of the impact test and no single value
shall be less than 70% of the required value. The impact
energy for the transverse/tangential direction using V-
notched specimens shall be 2 27 J.
4.2.2 Forged or seamless rolled flanges made of steels
specified in Sections 2.1.2 to 2.1.4 in the norma-
lized state (see also Table 4)
The flanges are tested in batches as shown in Table 1. A test
batch includes flanges produced from one cast with the same
kind of hot working and heat treatment. A test batch may also
include flanges produced from one cast which have differing
dimensions and have been heat treated separately but in the
same way, provided that the uniform quality of the heat treat-
ment is demonstrated by means of hardness tests on 10 %
of the flanges, but on three flanges at least. The hardness
test measures are also applicable to normalized flanges.
In each test batch, for two flanges a tensile test specimen and
three notched-bar impact test specimens shall be tested.
However, for each cast, hot-working process and heat-treat-
ment process, a maximum of four sets of specimens are
tested.

.
Table 1 Test batches
Unit weight in kg Number of flanges
per test batch’)
5 15 5 150
> 15tocc150 % 100
> 150to cc 300 % 50
> 300 5 25
1) The test specimens do not count as part of the test batch
In the case of unit weights up to 1000 kg and quantities up
to 10 flanges inclusive and in the case of unit weights up to
15 kg and quantities up to 30 flanges inclusive, it is sufficient
for one flange to be tested using one tensile test specimen
and three notched-bar impact test specimens.
Hammer-forged flanges with unit weights > 300 kg are
tested individually.
Specimens are cut transversely or tangentially to the material
fibre. With flange-plate thicknesses > 30 mm, the speci-
mens shall be cut at a distance of at least 25 % beneath the
front and side face. The stipulations in Section 4.2.1 regard-
ing the removal of specimens and the inclusion of test pieces
in the individual heat-treatment processes are also appli-
cable.
The mean value obtained from three specimens shall be
regarded as the result of the impact test and no single value
shall be less than 70% of the required values.
4.2.3 Forged or seamless rolled flanges made of steels
specified in Sections 2.1.2 to 2.1.4 in the har-
dened-and-tempered state (see also Table 4)
The flanges are tested in batches. A test batch includes flan-
ges produced from one cast with the same kind of hot forming
. and heat treatment. A test batch may also include flanges
produced from one cast which have differing dimensions and
have been heat treated separately but in the same way, pro-
vided that the uniform quality of the heat treatment is con-
.
firmed by the hardness tests.
All flanges shall be subjected to hardness tests. Where flan-
ges are produced on a quantity basis (at least 50 flanges of
the same size from one cast), the hardness tests are per-
formed on only 10% of the test batch, but on 20 flanges at
least. In each test batch, for the flange with the lowest hard-
ness and for the flange with the highest hardness, a tensile
test specimen and three notched-bar impact test specimens
shall be tested.
In the case of unit weights up to 1000 kg and quantities up
to 10 flanges inclusive and in the case of unit weights up to
15 kg and quantities up to 30 flanges inclusive, it is sufficient
for one tensile test specimen to be tested for the flange with
the lowest hardness and for three notched-bar impact test
specimens to be tested for the flange with the highest hard-
ness.
Hammer-forged flanges with unit weights > 300 kg are
tested individually.
Specimens are cut transversely or tangentially to the direc-
tion of the material fibre. With flange-plate thicknesses
> 30 mm, the specimens shall be cut at a distance of least
25 % beneath the front and side face. Specimens are taken
and test pieces allocated to the individual heat-treatment
process in accordance with Section 4.2.1.
The mean value obtained from three specimens shall be
regarded as the result of the impact test and no single value
shall be less than 70% of the required values.
Page 3 AD-Merkblatt W 9, Edition 07.95
4.2.4 Forged or seamless rolled flanges made of steels
specified in Section 2.15 shall be tested in the same way as
forgings according to AD-Merkblatt W 2.
4 . 2 . 5 Flanges specified in Section 2.2 shall be tested as
indicated in Table 2. The testing of specimens welded sepa-
rately is permissible if this is stipulated during process control
(same geometrical dimensions).
4.2.6 In the case of flanges specified in Section 2.3, the
plates shall be tested in accordance with AD-Merkblatt W 1,
W2orWlO.
4 . 2 . 7 In the case of flanges specified in Section 2.4, the
starting material shall have been tested in keeping with the
intended application in accordance with AD-Merkblatt W 2,
W100rW13.
4.2.8 Flanges specified in Section 2.5 shall be tested in
accordance with AD-Merkblatt W 5.
4 . 2 . 9 Flanges made of other steels specified in Section 2.6
shall be tested accordance with the suitability assessment
procedures.
4.3 Non-destructive tests
4.3.1 Forged or seamless rolled flanges made of steels
specified in Section 2.1.1
Flanges with unit weights > 300 kg shall be inspected ultra-
sonically by the manufacturer according to Stahl-Eisen-
Prufblatt (SEP) 1921, requirements for Test Group 3, Size
Class E and Frequency Class e.
4.3.2 Forged or seamless rolled flanges made of steels
specified in Sections 2.1.2 to 2.1.4 in the norma-
lized state
Flanges with unit weights > 300 kg shall be inspected ultra-
sonically by the manufacturer.
4.3.3 Forged or seamless rolled flanges made of steels
specified in Sections 2.1.2 to 2.1.4 in the har-
dened-and-tempered state
Flanges with unit weights > 300 kg shall be inspected ultra-
sonically and surface-crack-tested by the manufacturer with
reference to AD-Merkblatt HP 513.
4.3.4 Forged or seamless rolled flanges made of steels
specified in Section 2.1.5
Flanges with unit weights > 300 kg shall be inspected ultra-
sonically or radiographically by the manufacturer.
4.3.5 Flanges made of steels specified in Section 2.2
4.3.5.1 The plates or strip stock shall be subjected to non-
destructive testing by the manufacturer in accordance with
SEL 072, Table 1, Class 2. Special flanges such as bayonet
catches, quick-closing mechanisms and the like shall
additionally be subjected to non-destructive testing in
accordance with SEL 072, Table 2, Class 1.
4.3.5.2 Flanges made of steels in Material Groups 1 (1) and
6 in Table 2 are subjected by the manufacturer to ultra-
sonic inspection with reference to AD-Merkblatt HP 5/3
Appendix 1, Test Class A in the weld zone or to radiographic
inspection to the extent defined in Table 3. As a rule, flanges
that are produced by continuous welding with the same
machine setting are grouped together to form a test batch.
 Page 4 AD-Merkblatt W 9, Edition 07.95
. r
1Table 2 Scope of testing and test certificates according to EN 10204 (DIN 50049) for flanges specified in Section 2.2 1.~
-1
Material Scope of testing *)3) Test certificate according to
groups’) EN 10204 (DIN 50049)
Tensile test”) impact tests) Starting Heat Finished product
(&HI &v A) material treatments) NDT Mechanical/
technological
tests

1 (1)‘) - 2.213.1 I3 2.2 2.2

1 w9 1 1
per heat treatment per heat treatment 2.2 2.2 3.1 .B 3.1 .wc
batch batch

2 1 1
per 25 flanges per 25 flanges
/ 2.2 2.2 3.1 .B 3.1 .wc
3 1 1
for every 10 flanges for every 10 flanges
4 from a cast from a cast

5a 1 1
for every 25 flanges for every 10 flanges 2.2 2.2 3.1.B 3.l.WC
from a cast from a cast

5b to 5d 1 1
for every 10 flanges for every 10 flanges 2.2 2.2 3.1.8 3.1 .wc
from a cast from a cast

6 3.1 .B/3.1 .WC 2.2 2.2

7 1 1
for every 10 flanges for every 10 flanges 2.2 2.2 3.1 .B 3.1 .wc
from a cast from a cast

1) Classification in accordance with Table 1 of AD- Merkblatt HP 0

2) The specimens shall be cut from the weld zone.
3) For hardened-and-tempered flanges, a hardness test shall be performed as directed in Section 4.2.3. Annually, for two finished flanges, the basic material and the
weld zone are tested with reference to AD-Merkblatl HP 512 to determine of the cross-sectional area, geometry and scope of testing.
4) If stipulated for the starting material, a further tensile test shall be performed for each test batch at the workmg temperature.
5) For each impact test, three specimens are tested with the notch root sited in the middle of the weld seam.
6) Certification in accordance with Appendix 1 of this AD-Metkblan.
7) With the exception of steel grades 15 MO 3, 17 Mn 4, 19 Mn 5. 16 MO 5.19 Mn 6 and StE 355.
8) Only steel grades 15 MO 3. 17 Mn 4. 19 Mn 5, 16 MO 5, 19 Mn 6 and StE 355.

4.3.5.3 In the case of flanges made of steels in Material
Groups 1 (2), 2 to 5 and 7 in Table 2, each flange is subjected
by the manufacturer to ultrasonic inspection or radiographic
inspection in the weld zone with reference to AD-Merkblatt
HP 513 Appendix 1, Test Class A.
4.3.5.5 Employing suitable methods in accordance with
AD-Merkblatt HP 513, Appendix 1, all welds shall be tested
by the manufacturer for the presence of surface cracks.
The following materials constitute exceptions: RSt 37-2,
USt 37-2, H I, H II, C 21, C 22.3 and C 22.8.

4.3.5.4 Flanges with unit weights > 300 kg shall be 4.3.6 Flanges specified in Section 2.3
inspected ultrasonically or radiographically by the manufac-
turer. The plates shall be subjected to non-destructive testing by
the manufacturer in accordance with SEL 072, requirements
for Class 2 in Table 1.
Table 3 Scope of non-destructive testing for flash-butt
welded flanges
4.3.7 Flanges specified in Sectlon 2.4
Number of Scope of Minimum of: In the case of flanges with unit weights > 300 kg, the starting
flanges per test non-destructive material shall have been subjected to non-destructive testing
batch testing in keeping with the intended application. The ultrasonic
_
inspection shall be performed in accordance with Stahl-
2 1 to5 20 100% Eisen-Prufblatt 1921, requirements for Test Group 3, Size
> 20 to 5 50 50 % 20 flanges Class E and Frequency Class e. In the case of flanges with
> 50 to 5 200 25% 25 flanges unit weights > 300 kg made from hardened-and-tempered
> 200tos 1000 15% 50 flanges steels, testing for the presence of surface cracks shall be per-
> 1000 10% 150 flanges formed with reference to AD-Merkblatt HP 513 Appendix 1.
 Page 5 AD-Merkblatt W 9. Edition 07.95
r
i: .’
4.3.8 Flanges specified in Section 2.5 Table 4 Scope of testing on flanges specified in
Flanges with unit weights > 300 kg shall be tested by the Sections 2.1 .l and 2.1.2
manufacturer using the radiographic technique, if necessary -t
langes as Unit Test Scope of testing for each test batch;
in conjunction with the ultrasonic technique, in accordance specified weight’) batches Hardness Tensile Impact
with the details in StahCEisen-Prufblatt 1922. Additionally, in in kg as defined test test test3)
testing for surface cracks is required (using the magnetic- Section in Section
particle method wherever possible).
9 300 4.2.1 1 1
2.1.1
4.3.9 Flanges specified in Section 2.8 > 300 4.2.2
none4)
The flanges shall be subjected to the tests in accordance with
2.1.2
the suitability assessment procedures. (norma- 4.2.2 2 2
lized)
4 . 4 Flanges made of alloy steels shall be subjected to a
suitable test by the manufacturer to ascertain that no grade 2.1.2 -
mixing has occurred. hardened
4.2.3 100%5) 26) w
a n d tem-
4.5 Repetition of tests pered)

If the results obtained from a test do not meet the require-
ments, the procedure to be adopted is as follows:
4.5.1 If it can be assumed that test results which are un-
satisfactory are attributable to improper heat treatment, the
heat treatment of the flanges may be repeated, whereupon
the entire test shall be repeated. More than one repetition of
the heat treatment process is only permissible following con-
sultation with the authorised inspector.
1) Hammer-forged flanges wth unit weights I” excess of 300 kg are tested mdwldually.
2) For reduction of scope of testmg, see Secttons 4.2.2 and 4.2.3.
3) For each Impact test. 3 spec~mans are tested.
4) In the case of flanges that have been sublected to heat treatments separately but w
t h e s a m e w a y , m o r d e r t o m a k e u p a t e s t b a t c h t h e uniform quality o f t h e h e a t treatmenl
can be demonstrated by means of hardness tests on 10 % of the flanges, but on 3 flan-
ges at least.
5) For flanges manufactured on a quanbty basis (at least 50 flanges 01 the same SCE
made from the same cast). hardness tests on 10%. but on 20 flanges at least
6) These speclments shall be removed from those flanges for which, in the hardness
tests, the lowest and the highest hardness values were found

4 . 5 . 2 If unsatisfactory test results can be attributed to fac-
tors associated with the testing technique or to a defect of
very limited size in a specimen, the specimen in question
may be left aut of consideration when deciding whether the
requirements have been met and the test in question may be
repeated.
4 . 5 . 3 For every specimen that fails to meet the minimum
requirements, two further specimens shall be tested and both
.
of these shall satisfy the requirements.
. 5 Marking
The flanges shall be punch-marked as follows:
- Code number or material number for the grade of steel,
- Manufacturer’s symbol,
- Nominal bore/pipe outside diameter,
- Nominal pressure.
j When delivered with a test certificate according to EN 10204
(DIN 50049) the flanges shall additionally be marked with:
- Cast number or symbol,
- Test batch number with the product which provided the
specimen being specially identified,
- Test stamp of the authorised inspector orworks inspector,
- Stamp for non-destructive testing if required.
6 Certification of property compliance
Property compliance is certified by means of certificates
I according to EN 10204 (DIN 50049).
6.1 For flanges made of steels specified in Section 2.1.1 -
with the exception of St 52-3 - by means of a test report
according to EN 10204 (DIN 50049).
In the case of flanges with DN 5 1000, the test report may
be dispensed with if the requirements in Section 6.8 are met.
For flanges made of material St 52-3, a test certificate 3.1 .B
according to EN 10204 (DIN 50049) is required.
6.2 For flanges made of steels specified in Sections
j 2.1.2 to 2.1.4, test certificate 3.1 .B for the following steel
grades:
- StE 255, WStE 255, StE 285 and WStE 285 to DIN 1 7 102
or DIN 17103,
- C 22.8 to DIN 17243.
j Test certificate 3.1 A/3.1 .C for all other steel grades.
6 . 3 For flanges made of steels specified in Section 2.1.5,
in accordance with AD-Merkblatt W 2.
6 . 4 For flanges specified in Section 2.2, Table 2 is appli-
j::’
cable. Evidence shall be furnished in respect of the starting
material in accordance with AD-Merkblatter W 1, W 2, W 10 /
or W 13. The testing of the starting materials by the autho-
rised inspector may be dispensed with if the flange is to be
tested by the authorised inspector.
.‘: :
6.4.1 For flanges made of steels in Material Groups 1 (1)
j and 6 in Table 2, a test report according to EN 10204
(DIN 50049) (see specimen in Appendix 1) shall be prepared
by the manufacturer covering the results of the tests and
also the nature of the heat treatment and the heat-treated
state.
In the case of flanges made of steels USt 37-2, RSt 37-2 and
St 37-3 where the product d, . p 5 20000 and DN 5 1000,
the test report and the certificates for the starting material
may be dispensed with if the requirements in Section 6.8 are
met.
6 . 4 . 2 For flanges made of steels in Material Groups 1 (2), t
1 2 to 5 and 7 in Table 2, a certificate according to EN 10204
(DIN 50049) covering the results of the tests shall be
prepared; the type of the certificate is determined by
applying the stipulations in AD-Merkblatter W 1, W 2 or
j W 13 as appropriate. A test report according to EN 10204
(DIN 50049) (see specimen in Appendix 1) shall be prepared
by the manufacturer covering the nature of the heat treatment
and the correctness of the heat-treated state.
Page 6 AD-Merkblatl W 9. Edition 07.95

6.5 For flanges specified in Sections 2.3 and 2.4, the T a b l e 5 Characteristic design parameters at higher
necessary certificates for the starting material shall be fur- temperatures for steels specified in DIN 17100
nished in accordance with AD-Merkblatter W 1, W 2, W 10
and W 13. During the course of production, it shall be Steel Nominal Characteristic parameter K
ensured by means of restamping that a clear correlation is grade thickness at design temperature
established between starting material and finished product. 00°C (200°C (250°C 1300°C
m m N/mm*
6 . 6 For flanges specified in Section 2.5, in accordance with
AD-Merkblatt W 5. USt37-2 5 16 187 161 143 122

6.7 For flanges specified in Section 2.6, in accordance with 5 16 187 161 143 122
the suitability assessment procedures. RSt37-2 > 1 6 t o s 40 180 155 136 117
st37-3 > 40t0~100 173 149 129 112
6 . 8 If a test repotvcertificate is compliance with the order >100t0~150 159 137 115 102
is dispensed with, the assumption is that the manufacturer
5 16 254 226 206 186
has performed the necessary tests, which constitute the
> 16tos 40 249 221 202 181
basis for the issuing of a test report/certificate of compliance
with the order, continuously and that he keeps the results I St 52-3 I
> 4 O t o s 63
> 6 3 t o I 80
234
224
206
196
186
176
186
156
available for scrutiny by the authorised inspector at any time.
This arrangement requires an agreement between the’flange
manufacturer and the authorised inspector.
I I > 80to%100
4100toI150
214
194
186
166
166
146
146
126

7 . 2 For flanges made of steels specified in Sections 2.2

8.9 If flanges are produced from forged or cast flange
blanks by mechanical processing or from plates or sectional
steel and bar steel by mechanical of thermal cutting with no
changes in the material characteristics, the question of
ensuring correct processing, testing and restamping of the
flanges shall be the subject of an agreement between
manufacturer and authorised inspector.
6.10 Performance of the hardness tests and the test to
ascertain that no grade mixing has occurred shall be certified.
7 Design parameters
7.1 For flanges made of steels specified in Section 2.1.1,
the room-temperature yield strength values specified in
DIN 17 100 shall apply up to 50 “C; the values in Table 5 shall
apply for design temperatures from 100 “C to 300 “C.
For flanges made of steels specified in Section 2.1.2, the
values set out in DIN 17 102 or DIN 17 103 apply. For flanges
made of steels specified in Section 2.1.3, the values set out
in DIN 17243 and VdTijV Werkstoffblatt 35013 (C 22.8)
apply.
to 2.5, the values stated in the relevant AD-Merkblatter are
applicable.
7 . 3 For flanges made of steels specified in Section 2.6, the
values stipulated in suitability assessment procedures are
applicable.
7 . 4 The characteristic values quoted in the material specifi-
cation or suitability assessment procedures for 20 “C shall be
applicable for temperatures up to 50 “C and those quoted for
100 “C shall be applicable at up to 120 “C. In the remaining
temperature ranges, linear interpolation between the quoted
values is necessary (e.g. for 80°C between 20 “C and
100 “C and for 180 “C, between 100 “C and 200 “C) but no
rounding up is permissible. In the case of materials subject
to individual audits, the interpolation rule shall only apply
where the interval between the already known values is
sufficiently small3).
3) This is generally understood to mean a temperature interval to 50 K in the
elevated-temperature y!eld strength range and an interval of 10 K in the creep
rupture strength range.
 Page 7 A D - M e r k b l a t t W 9 , Edition 07.95

Appendix 1 to AD-Merkblatt W 9

-$.,P$
Specimen
I
I Test report according to EN 10204 (DIN 50049) . I/

Hot-formed, flash-butt welded steel flanges and rings made from forged bars, strip stock or rolled bar steel observing the
requirements in AD-Merkblatt W 9.

Approval by (TOO) (Technical Inspectorate)

of

Item Number Designation and dimensions I Material Cast Specimen

Heat treatment of the flanges following bending and welding not required in accordance with the expert opinion of the

0 (TOO) (Technical Inspectorate)

0 Normalizing at - “C, quenching in still air

0 Hardening and tempering: hardening at - “C, quenching in , tempering at - “C

0 Solution treatment at __ “C, quenching in water at 20 “C

0 We confirm that ultrasonic inspection of the plates used as starting material has been carried out in accordance with
AD-Merkblatt B 8.

Testing of the flanges: inspection and measurements: no deficiencies

0 Testing for the presence of surface cracks

Cl Ultrasonic inspection
. 0 Radiographic inspection

The components, as far as necessary, have been restamped and marked with the manufacturer’s symbol.

i
 Page 2 AD-Merkblatt W IO, Edition 05.2000
3 Stress categories
The classification as specified in 3.1 to 3.3 applies taking into
consideration the stipulations for heat treatment to AD-
Merkblatt HP7/2 or HP7/3 and the stipulations for stress
relieving as indicated in table 2 for static or quasi-static load-
ing without exceptional stress, e.g. corrosion.
3.1 Stress category I
Pressure vessels and components of pressure vessels are
deemed to belong to stress category I if their design has
been based on the stress coefficients given in series WAD-
Merkbltitter and the factors of safety given in AD-Merk-
blatt B 0.
Pressure vessels manufactured on site are deemed to
belong to stress category I as long as no other stress cate-
gory has been verified. Bolts belong to stress category I.
When determining the lowest permissible operating tem-
perature of the bolt, any temperature difference between the
charge of the pressure vessel and the bolt may be taken into
account.
3.2 Stress category II
Pressure vessels and components of pressure vessels are
deemed to belong to stress category II if their design stress
does not exceed 75% of stress category I, peak stresses
have been avoided as far as possible by suitable design and
manufacture and cracks are not expected to arise during ser-
vice.
For dimensioning the pressure vessel components, either
the factor of safety is increased by a factor of 413 or, if the
steam pressure of the charge is critical for the dimensioning,
the temperature-dependence of the steam pressure is taken
into account. For this purpose, the steam pressure shall not
exceed 75% of the design pressure p.
Notwithstanding the stipulations in AD-Merkblatt HP 7/2,
stress relief heat treatment is required to reduce internal
stresses. For materials belonging to material groups 1 and
I 5.1 in table 2 of AD-Merkblatt HP 7/2, stress relief heat treat-
ment can be omitted for wall thicknesses not exceeding
10 mm; for materials belonging to the other material groups,
stress relief heat treatment may be omitted provided that tab-
le2 in AD-Merkblatt HP712 does not specify postweld heat
treatment and that adequate toughness of welded joint has
been verified on a separately welded specimen.
In addition, for pressure vessels with wall thicknesses greater
than 10 mm but not exceeding 20 mm made from grades of
1 steel in material groups 1 and 5.1 in table 2 of AD-Merkblatt
HP 7/2, stress relief heat treatment may be omitted provided
that the factor of safety has been increased by a factor of 2
or the steam pressure does not exceed 50% of the design
pressure p.
3.3 Stress category 111
Pressure vessels and components of pressure vessels are
deemed to belong to stress category III if their design stress
does not exceed 25% of stress category I, peak stresses
have been avoided as far as possible by suitable design and
manufacture and cracks are not expected to arise during ser-
vice.
. . .?” .
For dimensioning the pressure vessel components, either
the factor of safety is increased by a factor of 4 or, if the
steam pressure of the charge is critical for the dimensioning,
the temperature-dependence of the steam pressure is taken
into account. For this purpose, the steam pressure shall not
exceed 25% of the design pressure p.
In the case of the grades of steel in line 1 in table 1 which are
not normally intended for use at temperatures below
-10 “C, with wall thicknesses exceeding 20 mm stress relief
heat treatment can only be omitted if adequate toughness
has been verified at room temperature on a separately
welded specimen.
3.4 Other stress categories
For pressure vessels which cannot be assigned to the stress
categories as specified in 3.1 to 3.3, the material, lowest per-
missible operating temperature, manufacturing and test con-
ditions shall be specified with reference to the provisions in
this AD-Merkblatt by agreement between the manufacturer,
user and authorised inspector.
4 Lowest permissible operating temperature
The lowest permissible operating temperatures for the vari-
ous stress categories are given in table 1. The lowest permis-
sible operating temperature for stress category I was speci-
fied in such a way that the material still shows adequate
toughness at this temperature. The reduced toughness of the
materials at the lower permissible operating temperatures for
stress categories II and III is taken into account by the special
conditions stipulated in 3.2 and 3.3 regarding an equal resi-
stance to brittle fracture.
5 Testing of materials and certification
of quality
5.1 The materials as specified in 2.1 .l, 2.2.1 and 2.2.2 are
tested in accordance with the stipulations in the relevant
standards, Stahl-Eisen-Werkstoffbltitter, VdTiiV-Werk-
stoffblatter and AD-Merkblatter. Table 1, columns 8 to 10
applies to certification of toughness.
The quality characteristics shall be certified according to
table 1, column 11.
5 . 2 The stipulations in the verification of suitability apply to
the testing and certification of the quality of materials accord-
ing to other material specifications.
6 Dimensioning characteristics
The values stipulated in series W AD-Merkblatter or in the
verification of suitability for room temperature are appli-
cable. For the grades of steel specified in DIN 17173, DIN
17 174, DIN 17280, DIN EN 10028-4 and for grades of cast
steel as specified in DIN EN 10213-3 or SEW 685, if calcula-
tion values are required for the 0,2 % proof stress at elevated
temperatures, the values given in tables 3a, 3 b or3c are app-
licable.
In the case of welded joints, for dimensioning, the lower cha-
racteristic value specified in the verification of quality shall be
taken into account for the filler metal as appropriate.
Table 1 of AD-Merkblatt W 10, Edition 05.2000

Table 1. Grades of steel and grades of cast steel for pressure vessels for low temperatures

b Type of steel Grade of steel, Lowest possible Maximum Maximum Verification of toughness Proof of quality
grade of cast steel operating rermissible permissible characteristics
temperature “C for thickness, diameter (certification in accordance
S 5s car wall with DIN EN 10204)
I II Ill thickness Shape, position and direction Test Require-
for tubes of test piece and scope of test tem- ments
perature
m m “C

1 2 3 4 5 6 7 8 9 10 11
-
Grades of steel and grades Suitable grades of steel
of cast steel as specified in or grades of cast steel as
AD-Merkblatter W 1, W 4, specified in column 2
1 W5, W8, W 12 and W 13 in accordance with the requirements of
Unkilled and semi-killed gra- -10 -60 -85 the AD-Merkblatter given in column 2
des of steel are excluded in
the case of operating tempe-
ratures below - 10 “C.
-
Fine-grained structural steels Basic series and elevated V-notch test pieces, test (W) StE 255 to (W) StE 285
temperature properties series
t piece position in accordance and P275N (NH); inspection
suitable for welding, norma- -20 -70 -100 70’) 70’) -20
lized according to DIN 17 102 (W) StE 255 to (W) StE 500, with DIN 17102, DIN 17103 c e r t i f i c a t e 3 . 1 .B
(only for rolled long products), P275N (NH) to P460N (NH) or EN 10028-l; (T; E) StE 255
DIN 17103 and DIN EN test piece direction and to (T; E) StE 285 and
High impact strength at low scope of test in accordance P275NLl (NL2).
10028-3 in conjunction with
temperature series T
VdTUV Werkstoffblatter 351 with the W series AD-Merk- to (W; T; E) StE 3i5 to
TStE 255 to TStE 420 and blatt applicable to the speci- DIN 17102, (W; T: E) StE 500.
to 358
P275NL1, P355NL1, -60 -110 -140 60’) 60’) fic product shape P355N (NH; NLl ; .NL2) and
DIN 17103
TStE 460, P460NLl -50 -100 -130 20’) 20’) -40 P460N (NH; NLl ; NL2):
or
TStE 500 -40 -90 -120 20’) 20’) i n s p e c t i o n c e r t i f i c a t e 3 . 1 .C
DIN EN
Special series with high 10028-3
impact strength at low tem- &t report 3.2
perature
EStE 255 to EStE 315 and
P275NL2 -70 -120 -150 60’) 60’)
EStE 355 to EStE 420 and
P355NL2 -60 -110 -140 60’) 60’) -50
2
EStE 460, EStE 500 and
P460NL2 -60 -110 -140 20’) 20’)

Welded tubes made from Basic series and elevated 40’)9) V-notch test pieces; (W) StE 255
fine-grained structural steels temperature properties series for test piece position and to (W) StE 285;
as specified in DIN 17178 in (W) StE 255 to (W) StE 460 -20 -70 -100 welded - direction in accordance with -20 i n s p e c t i o n c e r t i f i c a t e 3 . 1 .B
conjunction with VdTUV tubes DIN 17178 or DIN 17179
High impact strength at low to
Werkstoffblatter 351 to 357. and AD-Merkblatt W 4 (T; E) StE 255
temperature series DIN 17178
Seamless tubes made from to (T; E) StE 285;
TStE 255 to TStE 420 -60 -110 -140 or
fine-grained structural steels -40 (W; T; E) StE 355
TStE 460 -50 -100 -130 DIN 17179
as specified in DIN 17179 in to (W; T; E) StE 460:
conjunction with VdTUV Special series with high inspection certificate 3.1 .C
Werkstoffblatter 351 to 357. impact strength at low 65’)2)g) or
for est report 3.2
temperature
EStE 255 and EStE 285 -70 -120 -150 seamless -60
EStE 355 and EStE 460 -60 -110 -140 tubes
 Stainless austenitic steels as Symbol Material No. V-notch test pieces; Inspection certificate 3.1 .B
specified in DIN 17440 test piece position and or 3.1 .C as specified in AD-
XSCrNil8-10 .4301 250 direction in accordance with Merkblatt W 2, the lowest
X4CrNi18-12 .4303 160 DIN 17440 and AD-Merkblatt temperature limit for inspec-
XGCrNiNbl B-10 .4550 450 w2 tion certificate 3.1 .B being
X5CrNiMo17-12-2 .4401 250 the minimum operating
X2CrNiMo17-12-2 .4404 -200 -255 -270 250 in temperatures in column 4
XGCrNiMoNbl7-12-2 .4580 250 accordance
X2CrNiMo18-14-3 .4435 75 250 +20 with AD-
X3CrNiMol7-13-3 .4436 160 Merkblatt
X2CrNiMoN17-13-5 1.4439$ 160 w2
X2CrNil9-11 1.4306 250
XGCrNiTil B-10 1.4541 450
-2703) -270 -270
XGCrNiMoTil7-12-2 1 . 4 5 7 1 450
X2CrNiN18-10 1.4311 250

X2CrNiMoNl7-11-2 1.4406 160

-270 -270 -270
X2CrNiMoN17-13-3 1.4429 400

Stainless austenitic steels as X5CrNilB-10 1.4301 I n s p e c t i o n c e r t i f i c a t e 3 . 1 .B

specified in DIN 17441 XGCrNiNbl8-10 1.4550 or 3.1 .C as specified in AD-
XSCrNiMol7-12-2 1.4401 Merkblatt W 2, the lowest
-200 -255 -270
X2CrNiMol7-12-2 1.4404 temperature limit for inspec-
X2CrNiMol8-14-3 1.4435 tion certificate 3.1 .B being
X2CrNiMoN17-13-5 1.4439’ the minimum operating
6 temperatures in column 4
X2CrNil9-11 1.4306
XGCrNiTil8-10 1.4541 - 2703) -270 -270
XGCrNiMoTil7-12-2 1 . 4 5 7 1
X2CrNiN18-10 1.4311
X2CrNiMoN17-1 l-2 1.4406 -270 -270 -270
3 X2CrNiMoN17-13-3 1 . 4 4 2 9

Welded tubes made from X5CrNi1810 1.4301 V-notch test pieces: I n s p e c t i o n c e r t i f i c a t e 3 . 1 .B

stainless austenitic steels as X 6 CrNiNb 18 10 1.4550 test piece position and or 3.1 .C as specified in AD-
specified in DIN 17457 X 5 CrNiMo 17 12 2 1.4401 direction in accordance with Merkblatt W 2, the lowest
X 2 CrNiMo 17 13 2 1.4404 DIN 17457 or DIN 17458 ant in temperature limit for inspec-
-200 -255 -270 accordance
Seamles tubes made from X 2 CrNiMo 18 14 3 1.4435 AD-Merkblatt W 2 t i o n c e r t i f i c a t e 3 . 1 .B b e i n g
stainless austenitic steels as X 2 CrNiMoN 17 13 5 1.4439’ with the minimum operating
specified in DIN 17458 X 6 CrNiMoNb 17 12 25) 1.4580 50 +20 DIN 17457 temperatures in column 4
or
X2CrNi1911 1.4306 DIN 17458
X 6 CrNiTi 18 10 1.4541
- 2703) -270 -270
X 6 CrNiMoTi 17 12 2 1.4571
X 2 CrNiN 18 10 1.4311
X 2 CrNiMoN 17 13 3 1.4429 -270 -270 -270

Stainless austenitic grades of GX5CrNil9-10 1.4308 -200 -255 -270 306) V-notch test pieces; +20 in Inspection certificate 3.1 .C
cast steel as specified in GXSCrNiNbl S-11 1.4552 -105 -165 -200 1506) test piece position, direction +20 accordance
DIN EN 10213-4 GX5CrNiMol9-1 l-2 1.4408 -200 -255 -270 1506) and test scope in accordance -196 with DIN
with DIN EN 10213-l EN 10213-4

Cold formed stainless auste- as specified in in accordance with

A 2 in strength -200
nitic headless bolts as speci- n/a n/a not required 1
A 4 1 classes 50 and 70 -200 AD-Merkblatt W 2 AD-Merkblatt W 2
fied in DIN IS0 3506
Cold formed stainless auste- A 2 in strength -200 as specified in in accordance with
nitic bolts with head as speci- n/a n/a not required
I:^-1 :^ n,r, IPA QC:nC A 4 ) classes 50 and 70 -60 AD-Merkblatt W 2 AD-Merkblatt W2
- _- _-----~~~
Steels with high impact % 50 5 75 V-notch test pieces; I n s p e c t i o n c e r t i f i c a t e 3 . 1 .ClO)
26 CrMo 4 -65 -115 -145
strength at low temperature >50%70 >75510t test piece position in accord-
as specified in DIN 17280 ante with DIN 17280 or DIN
11 MnNi 53
13MnNi63 EN 10028-l ; test piece direc- in
-60 -110 -140 5 70 5 105
tion and scope of test in accordance
accordance with the W series with
AD-Merkblatt applicable to DIN 17280
10 Ni 14 I - 1 0 5 I-155 l-185 p~~x/;~~;~
the specific product shape

I
d 30 5 45 -120
1 2 Ni 1 9 -120 -170 -200 > 30 5 50 > 4 5 5 75 -110

x a Ni 9 -200 -255 -270 5 70 5 105 -196

Steels with high impact 11 MnNi5-3 -60 -110 -140 I 50

strength a t l o w t e m p e r a t u r e 13MnNi6-3 in
as specified in DIN EN accordance
10028-4 12Ni14 -105 -155 -185 5 50
with DIN
5 25 EN 10028-4
12Ni19 -120 -170 -200 > 25 5 30
4 > 30 5 50
XaNi9 -200 -255 -270 9 50
Seamless tubes made f r o m lTSt 35 N -50 -100 -130 5 10 V-notch test pieces; I n s p e c t i o n c e r t i f i c a t e 3 . 1 .B
steels with high impact test piece position and
direction in accordance with Inspection certificate 3.1 .C
strength at low temperature TTst 35 v -50 -100 -130 >2;$40
as specified in DIN 17 1 7 3 DIN 17173 or DIN 17174 and
26 CrMo 4 AD-Merkblatt W 4
Welded tubes rrl a d e f r o m -65 -115 -145 I 40
(seamless
\-~ onlvl,,
steels with hinh imoact
-.. ...J’ ‘...r---~
strenath at low temperature 11 MnNi53
-60 -110 -140 5 40
as s p e c i f i e d i n D I N 1 7 1 7 4 13MnNi63

10 Ni 14 -105 -155 -185 ,2:$40 -

-1
12 Ni 19 -120 -170 -200 >;5T40 -

X 8 Ni 9 -200 -255 -270 5 40 -

-
Cast steel with high impact Gl7Mn5 -40 -90 -120 5 506) V-notch test pieces: -40 in I n s p e c t i o n c e r t i f i c a t e 3 . 1 .C
strength at low temperature G20Mn5 -40 -90 -120 I 100”) test piece position, direction -40 accordance
as specified in G9NilO -70 -120 -150 5 35”) - and scope of test in accord- -70 with DIN
DIN EN 10213-3 G9Nil4 -90 -140 -170 5 356) ance with DIN EN 10213-l OI -90 EN 10213-3
5 GX3CrNil3-4’) -120 -170 -200 5 3006) SEW 685 and AD-Merkblatt -120
w5
Cast steel with high impact GS-26 CrMo 4 -50 -100 -130 5 756) -50 27 J
strength at low temperature GS-10 Ni 6 -50 -100 -130 5 356) _ -50 27 J
as specified in Stahl-Eisen- GS-10 Ni 14 -90 -140 -190 5 356) -90 27 J
Werkstoffblatt 685 G-x 6 CrNi 18 10 -255 -270 -270 5 2506) -196 50 J
-
1) If the operating temperalure is higher than the lowest permtsslble operating temperature, the maximum permtsslble 5) Only lor seamless lubes.
thrckness or maximum permtsslble drameter mueases by 2 mm/K. 6) MaxImum rulmg wail thickness.
2) For seamless tubes 40 mm for the specral serbes wth hrgh Impact strength at low temperature. ‘) In con]unctlon with VdTUV-Werksloffblatt 452.
3) If the lowest operating temperatures are below - 200 “C lo - 270 “C. testing of notched bar Impact strength al - 196 “C 8) In con~unctton wtth VdTuV-Werkslolfblatf 405.
on V-notch test preces, rrxnrrrwm requwement 40 J for thrcknesses or wall thicknesses E 10. or for dtameters 2 15 mm 9) For welded and seamless tubes made of TStE 460 and EStE 460 5 20 mm.
for bars and brgings. ‘0) For nuts and bars lor nuls, the provwons of AD-Markhk~tt W 7 are applrcable.
4) Only in the case of welded tubes if no filler melal IS used.
 Page 3 AD-Merkblatl W IO. Edition 05.2000

Table 2. Classification of stress categories and stress relief heat treatment for ferritic grades of steel after welding

Stress category I II III

Factor of safety S, s, = s s, = v3 s s,=2s s,=4s

or
Steam pressure of the
charge 100% 75 % 50 % 25 %

Stress relief heat According to Deviating from AD-Merkblatt HP 7/2 According to

treatment required AD-Merkblatt for wall thicknesses’) in mm AD-Merkblatt
HP 7/2 HP 7/24)
5 102) > 10 > 10 5 203) > 20

In the case of steels in material group 5.4 welded with austhenitic or Ni filler material, post-
weld heat treatment does not always improve the properties of the welded joint; postweld
heat treatment is therefore to be agreed upon in each individual case.
‘) The reference thickness means the thickness of the pressure part in question or the thickness of the weld; in the case of flat ends, weld-on flanges and similar parts,
reference thickness means the thickness of the welded joint.
2) Only for steel grades in material groups 4.1, 4.2, 5.2, 5.3 as indicated in table 1 of AD-Merkblatt HP 0. Stress relief heat treatment can be omltted for these grades
if adequate toughness has been verified on a separately welded specimen.
3) Only for steel grades in material groups 4.1, 4.2, 5.2, 5.3 as indicated in table 1 of AD-Merkblatt HP 0.
4) For the steels in line 1 of table 1 which are normally not intended for use at temperatures below - 10 “C. stress relief heat treatment may be omitted for wall thicknesses
exceeding 20 mm only if adequate toughness has been verified on a separately welded specimen at mom temperature.

Table 3a. Design strength values Kat design temperatures, valid only for short-term operationl) for the steelgrades specified I:
I in DIN 17 173, DIN 17 174, DIN 17 280 and DIN EN 10028-4 in the possible product forms and dimensions

Steel grade Design strength values K

at design temperature
Symbol Material DIN 17173 DIN 17174 DIN EN 10028-4,
. No. DIN 17280
Wall t h i c k n e s s Thickness s*) or 100 “C 200 “C 250 “C 300 “C
diameter d
mm m m N/mm* N / m m 2 N / m m * N/mm2
-ITSt 35 N 1.0356 S” 1 0 S% 10 Not included in 175 145 130 115
this standard
l-rst 35 v 1.0356 s 5 40 s 5 40 Not included in 185 155 140 125
this standard
26 CrMo 4 1.7219 s I 40 Not included in ss70;d%105 320 300 290 280
this standard
11 MnNi53 1.6212 s 5 40 s 5 40 s<70;d%105 210 170 155 140
13 MnNi 6 3 1.6217 s 5 40 s s 40 si70;d~105 260 220 205 190
10 Ni 141 1.5637 s % 40 s 5 40 s~70;d1105 245 205 190 170
12Ni14
12 Ni 19 1.5680 s II 4 0 s 5 40 s<70;d< 7 5 260 220 200 180
X8Ni9 1.5662 s 5 40 s 5 40 ss70;d<105 370 335 315 300
1) Toughness at low temperatures may deteriorate in the event of long-term use at elevated temperatures (see Clause 6).
2) For products specified in DIN EN 10028-4, thickness f YG 50 mm applies.
 Page 4 AD-Merkblatt W 10, Edition 05.2000

Table 3b. Design strength values K at design temperatures, valid only for short-term operationl) for the grades of cast steel

I i
specified in SEW 685 .I

Grade of cast steel ’ Material No. Reference wall Design strength values K at the design
thickness temperature
mm 100 “C 150°C 200 “C 250 “C 300 “C
maximum N/mm* N/mm2 N/mm2 N/mm2 N/mm”

GS-26 CrMo 4 1.7219 75 220 200 195 190 180

GS-10 Ni 6 1.5621 35 185 170 155 140 125
GS-10 Ni 14 1.5638 35 255 235 215 190 175
G-X 6 CrNi 18 10 1.6902 250 130 115 105 95 90
1) Toughness at low temperatures may deteriorate in the event of long-term use at elevated temperatures (see clause 6).

.”
Table 3c. Design strength values K at design temperatures, valid only for short-term operation’) for the grades of cast steeP)
specified in DIN EN 10213-3

Grade of cast steel Material No. Reference wall Design strength values K at the design
thickness temperature
m m 100 “C 150°C 200 “C 250 “C 300 “C
maximum N/mm’ N/mm2 N/mm2 N/mm2 N/mm2

100 220 190 180 175 170

35 255 235 215 190 175
300 515 500 485 470 455

1) Toughness at low temperatures may deteriorate in the event of long-term use at elevated temperatures (see clause 6).
2) No values for elevated temperatures are available for the grades of cast steel G 17 Mn 5 or G 9 Ni 10 as specified in DIN EN 10213-3.
UDC 669.14-465:621.642-96 Edition August 1988

Materials Seamless hollow components made AD-Merkblatt

for from non-alloyed and alloy
Pressure Vessels steels for pressure vessel shells WI2

The AD-Merkblatter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
5ehalter” (AD). AD-Merkblatt G 1 covers the composition and application of the AD-Regulations and also the procedural rules.
The AD-Merkbldtter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses ovet
snd above the normal /eve/ being anticipated during the operation of pressure vessels, allowance must be made for such stresses by
meeting special requirements.
Should there be any departures from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis,
operating experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e.V (FDER), Diisseldotf
H a u p t v e r b a n d d e r gewerblichen B e r u f s g e n o s s e n s c h a f t e n e . V . , S a n k t Augustin
Verband der Chemischen lndustrie e. V (VCI), Frankfurt/Ma/n
Verband Deutscher Maschinen- und Anlagenbau e.V (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhuttenleute (VDEh), Dusseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroRkraftwerksbetreiber e.V, E s s e n
Vereinigung der Technischen iiberwachungs-Vereine e.V (VdTiiV), Essen.
T h e AD-Merkbldtter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s shoula
be addressed to the publisher:
Vereinigung der Technischen iiberwachungs-Vefeine e. V., Posifach 103834, D-4300 Essen 1.

Contents

1 Scope 5 Marking
2 Suitable steel grades 6 Certification of quality characteristics
3 Manufacture and heat treatment 7 Design factors
4 Testing

1 Scope 1 . 3 No supplementary provisions are required in additior

to the stipulations in AD-Merkblatt W 0 for hollow compo
1.1 This AD-Merkblatt is applicable to seamless hollow nents as shells of pressure vessels where the manufacture1
components, hollow parts and part-shells - hereafter refer- has to certify their correct manufacture (pressure vessels ir
red to simply as hollow components-made from non-alloyed Test Groups I, Ill, and V).
and alloy steels for pressure vessel shells which are operated
at temperatures governed by the weather and at tempera-
tures determined by the charge down to - 10 “C. 2 Suitable steel grades
Hollow components can be manufactured by forging, press-
ing, rolling and drawing or by machining’). Depending on the In the case of internal or external pressure, the steel grade5
manufacturing processes, they are produced with open as specified in Sections 2.1 to 2.3 may be used within the
ends, with ends closed on one or both sides by flanging or application limits according to Tables 1 and 2 or accordin{
drawing in and with pressed or forged-on ends. to the stipulation in the ascertainment of suitability.
AD-Merkblatt W 4, Section 7 is applicable to shells of press- 2.1 Hollow components made from seamless tubes manu
ure vessels made from tubes having ends which are not factured by drawing in or flanging may be manufactured frorr
formed. steel grades as specified in Sections 2.1 .l to 2.1.5. Use i:
For charge temperatures below - 10 “C, AD-Merkblatt W 10 governed by the application limits in Table 1.
is also applicable. 2.1 .l Steel grades as specified in DIN 1629 entitled “Seam
1.2 The provisions in the following Sections 2 to 6 are less circular tubes made from non-alloyed steels with specia
applicable to hollow components as shells of pressure ves- quality requirements” but only for wall thicknesses up tc
sels which are to be subjected to a construction inspection 30 mm.
by the authorized inspector (pressure vessels in Test Groups 2.1.2 Steel grades as specified in DIN 1630 entitled “Seam
III, IV, VI and VII). less circular tubes made from non-alloyed steels with ver!
high quality requirements”.
1) In the case of hollow components manufactured by machining, it may be necess- 2.1.3 Steel grades as specified in DIN 17175 entitlec
ary, depending on the material and dimensions. to carty out heat treatment after
boring. “Seamless tubes made from high-temperatures steels”.

Supersedes Edition June 1977; completely revised

Luxemburger StraBe 449, 50939 Kdln

Page 2 AD-Merkblatt W 12, Edition 8.88
2.1.4 Steel grades as specified in DIN 17173 entitled
“Seamless circular tubes made from steels with high impact
strength at low temperature”.
2.1.5 Steel grades as specified in DIN 17179 entitled
“Seamless circular tubes made from fine-grained structural
steels” in conjunction with VdTUV-Werkstoffblatter 351/2 to
35712 2).
2.2 Hollow forgings may be manufactured from steel
grades as specified in Sections 2.2.1 to 2.2.3. Use is gov-
erned by the application limits in Table 2.
2.2.1 Steel grades as specified in DIN 17243 entitled
“Forgings and rolled or forged bar steel made from high-
temperature steels suitable for welding”; steels grades
14 MoV 6 3 and X 20 CrMoV 12 1 in conjunction with VdTUV-
Werkstoffblatter 184 or 110.
2.2.2 Steel grades as specified in DIN 17280 entitled
‘Steels with high impact strength at low temperature -Tech-
nical specifications for plate, strip, wide flat steel, profile steel
bars, bar steel and forgings”; steel grades 14 MnNi 6
and X 7 NiMo 6 only according to ascertainment of suitability
by the authorised inspector.
2.2.3 Steel grades as specified in DIN 17 1033) entitled
“Forgings made from fine-grained structural steels suitable
for welding” in conjunction with VdTUV-Werkstoffblatter
351t3 to 357132).
2 . 3 Hollow components made from other steel grades ac-
cording to ascertainment of suitability by the authorized in-
spector; in so doing, the application limits shall be stated.
The steels shall satisfy the following requirements:
(1) Elongation at failure A5 in the transverse direction shall
be at least 14%. When testing in a longitudinal direction,
this value shall be two units higher.
(2) The notched-bar impact strength shall correspond to the
values which characterize the material. For steels having
a minimum tensile strength not exceeding 740 N/mm”,
the average value obtained from three transverse ISO-V-
notch specimens at room temperature shall be at least
27 J. When testing in a longitudinal direction, this value
shall be at least 43 J.
For steels having a minimum tensile strength exceeding
740 N/mm2, the susceptibility to brittle fracture should be
observed when stipulating the minimum values for im-
pact strength.
3 Manufacture and heat treatment
The hollow compenents are manufactured by hot or cold
forming, possibly in conjunction with machining. After form-
ing or, in the case of parts cut from a solid blank, the entire
component shall be subjected to heat treatment appropriate
for the material, noting footnote 1.
4 Testing
Sections 4.1 to 4.10 are applicable to the testing of the hollow
components. Tables 3 and 4 provide an overview. Testing
of the impact strength is performed with wall thicknesses not
less than 5 mm for steel grades as specified in Sections 2.1.4,
2.1.5 and 2.2.2 and with wall thicknesses not less than 10 mm
*) VdTUV-WerkstoffIMteer 35112 lo 356/Z 351i3 to 353l3 and 355i3 to 357l3 am
cunently I” draft form.
J) Currently I” draft form.
for steel grades as specified in Sections 2.1 .l, 2.1.2, 2.1.3,
2.2.1 and 2.2.3. For other steel grades as specified in Section
2.3, the impact strength is tested in accordance with the as-
certainment of suitability. The hollow components shall be
tested after the final heat treatment.
If no provision is made for individual testing, testing is per-
formed in batches. A batch includes hollow components pro-
duced from one cast having the same diameter and wall
thickness and originating from one heat-treatment batch.
4.1 Mechanical testing of hollow components made
from seamless tubes
4.1’.1 For hollow components having an outside diameter
less than 660 mm as specified in Section 2.1, tensile tests
and, if necessary, impact tests shall be performed on speci-
mens from 2 % of the hollow components in a batch or from
at least two hollow components. For batch sizes less than
10, testing on one hollow component is sufficient.
Provisions to the contrary are stipulated in Section 4.1 .l .l.
4.1.1 .l For hollow components having an outside diameter
not less than 325 mm and less than 660 mm made from
steel grades 14 MoV 6 3, X 20 CrMoV 12 1, 26 CrMo 4,
10 Ni 14, 12 Ni 19 and X 8 Ni 9, including steel grades having
a minimum tensile strength exceeding 520 N/mm’, tensile
tests and, if necessary, impact tests shall be performed on
specimens from 10 % of the hollow components in a batch
or from at least two hollow components.
E
4 . 1 . 2 For hollow components having an outside diameter
exceeding 660 mm as specified in Section 2.1, tensile tests
and impact tests shall be performed on specimens from 10 %
of the hollow components in a batch or from at least two hol-
low components.
Provisions to the contrary are stipulated in Section 4.1.2.1.
I
4.1.2.1 For hollow components made from steel grades .
14MoV63,X20CrMoV12 1,26CrMo4,10Ni14,12Ni19 i
and X 8 Ni 9, including steel grades having a minimum tensile
strength exceeding 520 N/mm2, tensile tests and impact tests .
shall be performed on specimens from one end of each hol-
low component.
For hollow components, made from steel grades 14 MoV 6 3,
X 20 CrMo 12 1,26 CrMo 4 and X 8 Ni 9, in the case of lengths
exceeding 4 m, testing shall be performed at both ends at
points offset by 180”.
_’
4.2 Mechanical testing of hollow forgings 1
4.2.1 For hollow components as specified in Section 2.2
having an inside diameter less than 600 mm, tensile tests
and, if necessary, impact tests shall be performed on speci-
mens from 2% of the hollow components in a batch or from
at least two hollow components. For batch sizes less than
10, testing on one hollow component is sufficient.
Provisions to the contrary are stipulated in Section 4.2.1 .l .
4.2.1.1 For hollow components having an inside diameter
not less than 300 mm and less than 600 mm made from steel
grades 14 MoV 6 3, X 20 CrMoV 12 1,26 CrMo 4,iO Ni 14,
12 Ni 19 and X 8 Ni 9, including steel grades having a
minimum tensile strength exceeding 520 N/mm2, tensile tests
and, if necessary, impact tests shall be performed on test
specimens from 10% of the hollow components in a batch
or from at least two hollow components.
4 . 2 . 2 For hollow components having an inside diameter not
less than 600 mm as specified in Section 2.2, tensile tests
and impact tests shall be performed on specimens from 10 %

.
of the components in a batchor from at least two hollow com-
ponents.
. tected.
Provisions to the contrary are stipulated in Section 4.2.2.1.
4.2.2.1 For hollow components made from steel grades
14MoV63,X20CrMo121,26CrMo4,10Ni14,12Ni19
and X 6 Ni 9, including steel grades having a minimum tensile
strength exceeding 520 N/mmz, tensile tests and impact tests
shall be performed on specimens from one end of each hol-
low component.
For hollow components made from steel grades 14 MoV 6 3,
X 20 CrMoV 12 1, 26 CrMo 4 and X 6 Ni 9, in the case of
lengths exceeding 4 m, testing shall be performed at both
ends at points offset by 180”.
4 . 3 Hollow components made from other steel grades as
specified in Section 2.3 shall be tested by the authorised in-
spector in accordance with the ascertainment of suitability.
The scope of testing shall correspond to that for comparable
steel grades.
4.4 Removal of specimens
4.4.1 The specimens shall generally be taken in a trans-
verse or tangential direction provided that specimens which
conform to standards can be produced without dressing. In
the case of inside diameters less than approximately 200 mm
or in the case of low wall thicknesses, longitudinal specimens
may be taken.
4.4.2 The testing of hollow components is performed on
ring sections which should be removed from the cylindrical
part after the final heat treatment. For this purpose, excess
lengths should be left on all hollow components or further test
pieces should be made available for testing depending on the
required number of specimens.
l
4 . 4 . 3 If the ends of the hollow components are reduced or
closed by hot forming, sufficiently wide ring sections4) shall
be cut off after having been marked appropriately before
. further processing and then subjected to the same heat treat-
ment as the hollow components. In the case of hardened and
tempered steels, account should be taken of special heat
treatment conditions. The specimens shall be assembled in
a suitable ways) to produce a test block which undergoes the
same heat treatment as the hollow component.
4.4.4 If testing on ring sections cannot be carried out on ring
sections or is not practicable, particularly in the case of large
hollow components (inside diameter exceeding approxi-
mately 800 mm), special agreements shall be made.
4.5 Dimensional inspection
The dimensions of the hollow components which are impor-
tant in terms of safety shall be inspected. Where the specifi-
cations contain no tolerances, the following permissible de-
viation from the nominal dimensions apply:
Inside or outside diameter: +I- 1%
Wall thickness: -O/+25%
Different tolerances can be agreed.
. 4.6 Visual examination
Hollow components which are descaled on the inside and
outside shall be visually examined. They shall have a smooth
4) Width 2 x wall thickness. minimum 150 mm
5) In the case of liquid quenching and tempering, by a circumferential weld (Seal
welding).
c
P a g e 3 AD-Merkblan W 1 2 . Edition 0 . 0 3
external and internal surface equivalent to the as-manufac-
tured condition so that significant surface defects can be de-
4.7 Hardness test
A hardness test shall be performed for hollow components
made from steels which are hardened and tempered in air
or in liquids; the following stipulations apply:
- Hollow components having an outside diameter less than
325 mm shall be tested at one end.
- Hollow components having an outside diameter not less
than 325 mm and not more than 2 m long shall be tested
at both ends around their circumference at points offset
by 180”.
- Hollow components having an outside diameter not less
than 325 mm and longer than 2 m shall be tested to a suit-
able extent over their entire length.
- The ring sections cut off according to Section 4.4.3 shall
also be subjected to a hardness test.
/‘-:
4.8 Non-destructive testing
All seamless hollow components for working pressures ex-
i’
ceeding 80 bar shall be subjected to ultrasonic examination
over therr entire length.
Before forming of the ends, hollow components shall be sub-
jected to ultrasonic examination for longitudinal flaws and, in
the case of outside diameters exceeding 200 mm, to addi-
tional ultrasonic examination for transverse flaws.
For wall thicknesses not exceeding 30 mm, testing and as-
sessment is In accordance with the requirements in SEP 1915
or SEP 1918.
For hollow forgings having wall thicknesses exceeding
30 mm, testing is in accordance with SEP 1921, Test Class 4.
For hollow components made from seamless tubes having
wall thicknesses exceeding 30 mm, testing is also according
to SEP 1921, Test Class 4, pending stipulation of special pro-
visions.
The shaped areas of hollow components for working pres-
sures exceeding 80 bar shall be subjected to a surface crack
test. Testing is performed by the manufacturer using suitable
methods in agreement with the authorized inspector.
4.9 Testing to ascertain that correct materials have
been used
Hollow components made from alloy steels shall be sub-
jetted to testing to ensure that the correct materials have
been used.
5 Marking
The finished hollow components shall be marked as follows:
steel grade,
i
cast number or abbreviation for the cast,
manufacturer’s brand mark,
designation number of the hollow component (factory N O.,
serial No., etc.)
mark for the ultrasonic examination performed,
authorized inspector’s stamp.
Page 4 AD-Merkblalt W 12, Edition 8.88
6 Certification of quality characteristics
6.1 Certification of quality characteristics shall be provided
in accordance with Tables :l and 2.
6 . 2 In addition, the manufacturer shall certify that:
- the material corresponds to the steel grade and, if applic-
able, the Quality Level or Test Class in the relevant DIN
standard or ascertainment of suitability taking into account
the special stipulations in this AD-Merkblatt,
- the hollow components are in a proper heat-treated con-
dition appropriate to the steel grade (e.g. normalized or
hardened and tempered),
- 1
- the non-destructive testing with test certificate B according
to DIN 50049,
- the result of the ladle analysis,
- the results of further tests to be performed by the manufac-
turer,
- the result of the test to ensure that the correct materials
have been used in the case of alloy steels.
7 Design factors
The stipulations in AD-Merkblatter W 4 and W 13 are applic-
able for the design factors.

. . .

I
 Page 5 AD-Merkblatt W 12. E d i t i o n 8.88

Table 1. Application limits and certification of quality characteristics for hollow components made from seamless tubes , :5

Application limits Certification of

7, quality characteristics
Standard Section Steel grade Working Design by Material Test
pressure temperature Certificate according
bar “C to DIN 50049

St 37.0
IIN 16292) 2 . 1 . l St 44.0 5 80 5 300 3.1 B
St 52.0

5 80
st 37.4 With non-destruc-
IIN 1630 2.1.2 St 44.4 tive testing accord- I 300 3.1 B
St 52.4 ing to SEP 1915:
without limit

St 35.8, St 45.8,
Quality Level I 5 80 I 450 3.1 B

17Mn4,19Mn5,
Quality Level I 5 80 5 450 3.1 c

Up to the tempera-
St 35.8
DIN 17175 2.1.3 Without limit ture limits given 3.1 B
Quality Level Ill in the standard

St 45.8, 17 Mn 4, Up to the tempera-

19Mn5,
ture limits given
Quality Level Ill, Without limit 3.1 c
in the standard
alloy steels always
Quality Level Ill
l-TSt 35 N Test Class 1: See AD-Merkblatt 3.1 B
% 80 WlO
l-rst 35 v
26 CrMo 4
Test Class 2:
DIN 17173 2.1.4 13MnNi63
11 MnNi53 without limit 3.1 c
10Ni 14
12 Ni 19
X8Ni9
Basic series Without non- cc 300 StE 255, WStE 255,
destructive testing: StE 285 and WStE 285
s 80 3.1 B

High-temperature With non-destruc- 5 400 Other steel grades:

series (W series) tive testing: 3.1 c
without limit
DIN 171793) 2.1.5 High impact strength s 300
at low temperature
series (T series) 5 400, if certifica-
tion of 0,2 %
Special high impact proof stress at high 3.1 c
strength at low temperature is
temperature series agreed when
(E series) ordering

2.3 Other According to stipulations in ascertainment of suitability

1) See AD-Merkblatt S 0. Section 5
2) W&t thickness up to 30 mm. Wall thickness above 10 mm: impact test. Values and testing according t0 DIN 1630
J) In conjunction wth VdTljV-WerkstoffblBer 35112 to 35712

.
Page 6 AD-Merkblatl W 12. Edition 6.66

Table 2. Application limits and certification of quality characteristics for hOllOW forgings

Application limits Certification of

quality characteristics
Standard Section ’ Steel grade Working Design by Material Test
pressure temperature l) Certificate according
bar “C to DIN 50049

C 22.8 % 80 3.1 B

17Mn4 With non-destruc- Up to the tempera-

20Mn5N tive testing: ture limits given
IIN 17243 2.2.1 20Mn5V without limit in the standard 3.1 c
15Mo3
13CrMo44
lOCrMo9 10
14MoV63
X20CrMoV121

26 CrMo 4 % 80
11 MnNi53 With non-destruc-
13MnNi63 see AD-Merkblatt
IN 17280 2.2.2 tive testing: 3.1 c
10 Ni 14 WlO
without limit
12 Ni 19
X8Ni9

Without non- 5 300 StE 255, WStE 255,

Basic series destructive testing: StE 285 and WStE 285
s 80 3.1 B

High-temperature With non-destruc- 4 400 Other steel grades:

series (W series) tive testing: 3.1 c
without limit
DIN 17103 2.2.3 High impact strength d 300
2) 3, at low temperature
series (T series) 5 400, if certifica-
tion of 0,2 %
Special high impact proof stress at high 3.1 c
strength at low temperature is
temperature series agreed when
(E series) ordering

2.3 Other According to stipulations in ascertainment of suitability

1) See AD-Merkblatt B 0. Section 5
2) Currently in draft form
3) In conpnction with WIT@/-WerkstolfblMer 35112 to 35712
 Pagt, 7 AD-Merkblati W 12, Edition 8.68 1:.

Table 3. Overview of scope of testing for hollow components made from seamless tubes

Scope of testing l)
.
Outside diameter
Standard Section Steel grade 2%, at least 2; up lo%, at 100%
mm to 10 components, least 2 one end
1 i s sufficient
I
4.1.1 St 3 7 . 0 < 660 x3
DIN 1629 ’ st 4 4 . 0
4.1.2 St 5 2 . 0 1660 x 2)

4.1.1 St 3 7 . 4 < 660 X

DIN 1630 St 4 4 . 4
4.1.2 St 52.4 L 660 X
I
I
All except c 660 X
4.1.1
14MoV63
DIN 17175 and
4.1.2 X 20 CrMoV 12 1 z 660 X

4.1 .l < 325 X

I I
2 325
14MoV63
DIN 17175 1.1.1.1 to X
X20CrMoV121
< 660

4.1.2.1 2 660 x 3)
I I
4.1.1 lTSt 35 N < 660 X
l-rst 35 v
11 MnNi53
4.1.2 13MnNi63 2 660 X

4.1.1 I < 325 I

.
DIN 17173
4.1.1.1
10 Ni 14
12 Ni 19
I ::I I 1660 X
4.1.2.1

4.1.1 < 325 X

I
z 325
26 CrMo 4
4.1 .l .l to X
X8Ni9
< 660

4.1.2.1 2 660 x 3)
I I
All series < 660 X
4.1 .I
StE 225
StE 285
4.1.2 StE 355 2 660 X

4.1.1 < 325 X

I
DIN 17179 I I
All series 1325
4.1.1.1 StE 420 I to X
StE 460 < 660

4.1.2.1 2 660 X
I
4.3 Other According to stipulations in ascertainent of suitability
1) Note Section 4.; I as far as hardness test is cmcmed
2) For tubas auwrr ding IO DIN 1629. wall thickness up to 30 mm
3) For lengths exceeding 4 m, test at both ends at points offsat by 180”
P a g e 8 A D - M e r k b l a t t W 1 2 , E d i t i o n 8.88
n

Table 4. Overview of scope of testing for hollow forgings .:

Scope of testing I)
Inside diameter
Standard Section Steel grade 2%, at least 2; up lo%, at 100%
mm to 10 components, least 2 one end
1 i s sufficient i,., :
4.2.1 All except < 600 X
DIN 17243 14MoV63
and
4.2.2 X20CrMoVl21 2 600 X

4.2.1 < 300 X

_.,.:
2 300
DIN 17243 4.2.1 .l 14MoV63 to X
X20CrMoVl21
< 600
i::
4.2.2.1 2 600 x *I
4.2.1 11 MnNi53 < 600 X
1:

4.2.2 13MnNi63 5 600 X

4.2.1 < 300 X

i..
10 Ni 14 L 300
4.2.1 .l to X
12 Ni 19
DIN 17280 < 600

4.2.2.1 L 600 X

4.2.1 -=I 300 X

26 CrMo 4 2 300
4.2.1 .l to X
X8Ni9
< 600

4.2.2.1 2 600 x *I

4.2.1 All series -c 600 X

StE 225 . j
StE 285
4.2.2 I 600 X
StE 355
4.2.1 < 300 X
DIN 17103
All series 2 300
4.2.1 .l StE 420 to X
StE 460 < 600
4.2.2.1 L 600 X

4.3 Other According to stipulations in ascertainment of suitability

I) Note Section 4.7 as far as hardness test IS concerned
2) For lengths exceeding 4 tn. test at both ends at points offset by 18Q
 ICS 23.020.30 Edition February 1998

Materials Forgings and rolled components AD-Merkblatt

for
Pressure Vessels made of non-alloyed and alloy steels w13

The AD-Merkblatter are compiled by the seven associations specified below who together form the ‘Arbeitsgemeinschaft Druckbehalter”
‘AD). AD-Merkblatt G 7 covers the composition and application of AD-Regulations and a/so procedural guidelines.
T h e AD-Merkbletter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . In t h e e v e n t o f l o a d i n g s exceeding
he normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
.equirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
sxpefience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e. V. (FDBR), Dusseldorf
Hauptverband der gewerblichen Berufsgenossenschaf e. V., Sankt Augustin
Verband der Chemischen lndustrie e. V. (VCI), FrankfurtlMain
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, FrankfurtlMain
Verein Deutscher Eisenhtittenleute (VDEh), Dusseldorf
VGB T e c h n i s c h e V e r e i n i g u n g d e r GroBkraftwerksbetreiber e. V., Essen
Verband der Technischen Dberwachungs-Vereine e. V. (VdTiiV), Essen.
The AD-Merkblatter are amended continuously by the above associations in keeping with technical progress. Relevant proposals should
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents
1 Scope 4 Marking
2 Approved materials 5 Certification of quality
3 Testing 6 Design strength values

. 1 Scope 1 . 6 The provisions detailed in Sections 2 to 6 below apply

to components for the fabrication of pressure vessels which
1.1 This AD-Merkblatt covers forgings (hammer forgings or are subject to a final inspection by the authorized inspector
drop forgings) including bar-shaped forgings and compo- (pressure vessels in Inspection Groups III, IV, VI and VII).
. nents produced on ring rollers (e.g. seamless rolled rings),
hot-pressed hollow components with end plates and hot-
1.7 No additional provisions other than those in AD-Merk-
rolled and extruded longitudinal products (e.g. bar steel) -
blatt W 0 are required for components for the fabrication of
hereafter referred to as components - made of non-alloyed
pressure vessels for which the manufacturer has to certify
and alloy ferritic steels for the fabrication of pressure vessels
production to specification (pressure vessels in Inspection
which are operated at temperatures, governed by the wea-
Group I, where these are to be used for combustible, corro-
ther or by the vessel fluid, ranging from -10 “C up to the
sive or toxic gases, vapours or fluids, and also those in
maximum temperature-use limits specified in Section 2 (see
Inspection Groups II and V).
DIN EN 10079) for definitions of the various forms of products.
For vessel fluid temperatures less than -10 “C, AD-Merkblatt
W 10 applies additionally.
2 Approved materials
1.2 For components made of austenitic steels, AD-Merk-
blatt W 2 applies. The following materials may be used
1 . 3 For hollow components specified in Section 1.1 used
2.1 General-purpose structural steels USt 37-2, RSt 37-2,
as pressure vessel shells, AD-Merkblatt W 12 applies. Nozz-
St 37-3, St 44-2, St 44-3, and St 52-3 to DIN 17 100 used for
les and similar components having an outside diameter
forgings within the application limits of Table 1.
5 220 mm without any limit on length and an outside diame-
ter > 220 mm up to a length of 400 mm, that are connected
to a pressure vessel are not considered to be pressure vessel 2.2 Unalloyed structural steels S235JRG1, S235JRG2,
S235J2G3, S275JR, S275J2G3, S355J2G3, S355K2G3 to
shells.
DIN EN 10025 used for longitudinal products within the appli-
1.4 For flanges, AD-Merkblatt W 9 applies. cation limits of Table 1.
1 . 5 If the components are to be further processed, e.g. by
forming or welding, AD-Merkblatter in the HP series covering 2 . 3 Steels for simple pressure vessels to DIN EN 10207
such further processing and testing after further processing used for longitudinal products within the application limits 01
shall be taken into consideration. Table 1.

Supersedes July 1995 edition; completely revised edition

^
Larl Heymanns ‘.&lag KG
Luxemburger Sw3.z 449, 50939 Kdn
Page 2 AD-Merkblati W 13. Edition 02.98

Table 1 Application limits for steels to DIN 17100, DIN EN 10025 and DIN EN 10207

Technical Steel grade Design Normal 4 . P2)

delivery condition ’ tempera- delivery
Short designation Designation to turel) condition
to EN 10027-l DIN 17100 “C

S235JRG13) USt 37-23)

S 235JRG2 RSt 37-2

S235J2G3 St 37-3 N
DIN EN 10025/
S275JR St 44-2 5 300 N4) 5 20000
DIN 171005)
S275J2G3 St 44-3 N

S355J2G3 St 52-3 N

S355K2G3

P235S

DIN EN 10207 P265S

P275SL -

1) See AD-Merkblatl B 0, Section 5

2) Product of the greatest internal diameter d,, in mm, of the pressure vessel and the allowable working pressure, p, in bar
3) Allowable up to a thickness of 16 mm
4) For forgings it is not permitted to substitute normalizing by normalizing forming
5) For thicknesses > 100 mm in conjunction with SEW 011.

2 . 4 Weldable fine-grained structural steels to DIN 17 102 3 Testing

(used for longitudinal products only) and to DIN 17 103 in
conjunction with the pertinent VdTijV material specification
sheets.
2.5 Weldable high-temperature steels to DIN 17243. For
the steel types 14MoV 6 3 and X 20 CrMoV 12 1 VdTijV
material specification sheets 184 and 110 apply additionally.
2 . 6 Low-temperature steels 26 CrMo 4, 11MnNi 5 3 ,
13MnNi63,10Ni14,12Ni19,andX8Ni9toDIN17280
up to 50 “C. AD-Merkblatt W 10, Table 3a (new version in
course of preparation) covers the short-time service of these
steels at higher temperatures.
2 . 7 Other materials upon approval testing. Such materials
shall exhibit the property values characteristic of the standard
material and shell meet the following requirements:
2.7.1 The elongation at fracture A shall be at least 14 % and
at least 16 % with the specimen taken in transversejtangen-
tialz) direction and longitudinal direction’) respectively.
2 . 7 . 2 The impact energy KV on a V-notched specimen in
the case of grades of steel having a minimum tensile strength
of up to and including 590 N/mm2 shall be at least 27 J and
at least 39 J with specimens taken in transverse/tangential’)
direction and longitudinal direction’) respectively.
2.7.3 In the case of grades of steel having a minimum ten-
sile strength in excess of 590 N/mm*, the minimum values
for the impact energy are to be stipulated taking the service
loadings into account.
3.1 DIN 17 100 is the standard governing the testing of
components made of materials to Section 2.1. Testing shall
be performed per melt (cast). Impact testing shall be perfor-
med on materials with thicknesses 2 6 mm where standard
specimens can be taken.
For components from which no longitudinal specimens can
be taken, the fulfilment of the impact energy requirements to
clause 2.7.2 shall be verified accordingly. For components
made of RSt 37-2 and St 44-2 (DIN 17 100) an impact energy
z- 23 J at room temperature shall be verified for thicknesses
> 63 mm.
3.2 DIN EN 10025 covers the testing of longitudinal pro-
ducts made of steels to Section 2.2. Testing shall be perfor-
med per melt (cast). Impact testing shall be performed additi-
onally for the steel type of grade JR with a thickness 2 6 mm.
3 . 3 DIN EN 10025 covers the testing of longitudinal pro-
ducts made of steels to Section 2.3.
3 . 4 The testing of components made of steels to Section
2.4 is governed by DIN 17 102 or DIN 17 103 in due conside-
ration of the pertinent VdTuV material specification sheets.
3 . 5 The testing of components made of materials to Sec-
tion 2.5 shall be performed to DIN 17243 and of the steel
types 14MoV 6 3 and X 20 CrMoV 12 1 in due consideration
of VdT& material specification sheets 184 and 110. For
series production components made of quenched and tem-
pered steels with unit weights I 15 kg, notwithstanding
DIN 17243, one set of specimen shall be taken, if practicable,
from the two components having the lowest and highest
hardness value per melt and heat treatment batch.

f) The reqwements of DIN 17243 apply.

3 . 6 Components made of materials to Section 2.6 shall be
2) Non-machmed condition. tested to DIN 17280.
 Page 3 AD-Merkblatt W 13. Ediiion 02.98
.
3.7 Components made of other materials as specified in DIN EN 10025, DIN EN 10207 and DIN 17102). In the case
Section 2.7 shall be tested to comply with the approval testing of diameters < 160 mm the specimens may also be taken in
requirements. longitudinal direction.

3.8 Hollow components and rings with unit weights 3.10 For unit weights > 1000 kg each component shall be
Z 300 kg*) fabricated by forging, hollow forging or rolling tested individually.
shall be subjected to ultrasonic testing for detecting internal
3.11 The test pieces used for tensile and notched-bar
defects.
impact specimens shall generally be taken from a finished
Hollow components with an internal diameter > 80 mm fabri- heat-treated component. In the case of forgings the dimensi-
cated by extrusion or drawing to finished size shall be subjec- ons of which do not permit the taking of the required speci-
ted to ultrasonic testing for detecting defects in the main for- mens, one test piece having reference dimensions shall be
ming direction. produced from the same melt (cast) using identical proces-
ses and shall be subjected to the required heat treatment
Other components with unit weights > 300 kg*) shall be sub-
together with the components of the consignment to be
jected to ultrasonic testing for internal defects.
tested.
During ultrasonic testing for internal defects (except for die
forgings) each volume element shall be tested, if practicable, 3.12 Repeat tests are covered by DIN EN 10021. If a test
with 2 sound beam entry directions offset by 90”. The follow- unit consists of several components, the component for
ing individual defects may be accepted: which unsatisfactory test results were obtained shall be dis-
carded and two further specimens shall be taken from addi-
s 5 50mm 5 individual defect size 3 tional components, and these specimens shall both satisfy
s > 50 mm 5 100 mm 5 individual defect size 4 the requirements. In the case of large components, agree-
s > 100 mm 5 150 mm I individual defect size 5 ment shall be reached with regard to taking retest specimens.
s > 150mm 5 individual defect size 6
If the cause of failure in the test can be removed by appro-
3.9 The tensile and notched-bar impact test specimens priate heat treatment of the components, the rejected compo-
shall be taken in transverse/tangential direction (except for nents may be submitted for retesting after such heat treat-
materials to DIN 17100 and longitudinal products to ment.

Table2 Design strength values at elevated temperatures for steels to DIN 17100SEW 011 as well as for longitudinal
products to DIN EN 10025

r Steel type
to
DIN 17100/
SEW 011

USt 37-2’) > 16 to 4 40

RSt 37-2
St 37-3

St 44-2
St 44-3

>16tos40

St 52-3
S355K2G3

>80to<lOO 214 186 166 146

> 100 to 5 150 194 166 146 126

I) Permitted up to a thickness of 16 mm
 .__.
Page 4 AD-Merkblatt W 13, Edition 02.98
4 Marking
4.1 Components shall be marked with:
- Manufacturer’s symbol
- Short designation or material number for type of steel
- Cast (melt) number.
When delivered with a test certificate according to DIN EN
10204 the components shall additionally be marked with:
- Specimen number or test batch number
- Authorised inspector’s stamp
- Stamp to indicate performance of ultrasonic testing, if any.
4 . 2 In the case of bar steel having a thickness (diameter,
edge length, width across flats or width) < 25 mm, marking
of the bundle by means of a tie-on tag is permitted.
5 Certification of quality
5.1 Type of test certificate to DIN EN 10204
When ordering components made of materials specified in
Sections 2.1 to 2.6, the type of test certificate to DIN EN
10204 shall be agreed as follows:
5.1.1 Test report for steel types with thicknesses < 6 mm
- of quality level 2 to DIN 17100 and
- of quality level JR to DIN EN 10025.
5 . 1 . 2 Acceptance test certificate 3.1 .B for the steel types
- specified in Section 2.1 to DIN 17 100, except for quality
level 2 with thicknesses < 6 mm
- specified in Section 2.2 to DIN EN 10025, except for qua-
lity level JR with thicknesses < 6 mm
- St E 255, WStE 255, StE 285, and WStE 285 to DIN 17 102
or DIN 17103
- C 22.8 to DIN 17243.
51.3 Acceptance test certificate 3.1 .AIC for all steel types
not mentioned in clauses 5.1 .l and 5.1.2.
5 . 1 . 4 For components made of other materials specified in
Section 2.7, the approval testing requirements apply.
5.2 Details in the test certificate to DIN EN 10204
5.2.1 For components made of materials specified in Sec-
tion 2.1, the certificate shall contain the following details:
the type of steel
the prevailing technical conditions of delivery (DIN 17 100,
SEW 011, if applicable) and technical rules (AD-Merkblatt
w 13)
the supply schedule and dimensions of the components
the delivery condition
the marking
the chemical composition obtained from ladle analysis
with numerical values for the relevant elements in the cor-
responding table in DIN 17 100
-.
- the steel-making process
- the results of the tests performed.
5.2.2 For components made of materials specified in Secti-
ons 2.2 to 2.6 the requirements in the standards mentioned
in those sections apply.
5.2.3 For components made of other materials specified in
Section 2.7, the approval testing requirements apply.
1
6 Design strength values
6.1 For components made of materials specified in Section
2.1, the room-temperature yield strength values specified in
DIN 17 100 and SEW 011 apply up to 50 “C. The values in
Table 2 apply to design temperatures ranging from 100 “C
to 300 “C.
6 . 2 For longitudinal components made of materials speci-
fied in Section 2.2, the room-temperature yield strength
values specified in DIN EN 10205 apply up to 50 “C. The
values in Table 2 apply to design temperatures ranging from
100 to 300 “C. The wall thickness indicated in this table refers
to the pressure vessel wall thickness.
6 . 3 For longitudinal products made of steels specified in :i
Section 2.3, the values stipulated in DIN EN 10207 apply.
j;
6 . 4 For components made of materials specified in Section i
2.4 the values stipulated in DIN 17 102 or DIN 17 103 apply
taking the relevant VdTijV material specification sheets into
consideration.
6 . 5 For components made of materials specified in Section
2.5 the values stipulated in DIN 17243 apply taking VdTiiV
material specification sheets 184 and 110 for the materials
I
14MoV 6 3 and X 20 CrMoV 12 1 into consideration.
6 . 6 For components made of materials specified in Section
2.6 the values stipulated in DIN 17 280 apply. .
6 . 7 For components made of other materials specified in
Section 2.7 the values of the approval testing procedure
.
apply.
6 . 8 The design strength values given in the material specifi-
cations or approval testing methods for 20 “C apply up to
50 “C, and those given for 100 “C apply up to 120 “C. In the
remaining temperature ranges, there shall be linear interpo-
lation between the given values (e.g. for 80 “C between 20 “C
and 100 “C and for 180 “C between 100 “C and 200 “C), in
which case no rounding up is permitted. For individually certi-
fied materials (special material appraisal) the interpolation
rule shall only apply if there is a sufficiently close intervala)
between the points of support.
3) As a rule. this means a temperature interval of 50 K within the range of elevated-
temperarum proof stress and of 10 K withln the creep rupture strength range.
- P
ICS: 23.020.30 Edition December 1996

Manufacture and General principles AD-Merkblatt

Testing of of design, manufacture and
Pressure Vessels associated tests HP 0

The AD-MerkblZitter are compiled by fhe seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
behdlter” (AD). AD-Merkblatt G 7 covers the composition and application of AD-Regulations and a/so procedural guidelines.
T h e AD-Merkb@ttercontain s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . In t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblait, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e. V. (FDBR), Diisseldotf
H a u p t v e r b a n d d e r g e w e r b l i c h e n B e r u f s g e n o s s e n s c h a f t e n e . V . , San& Augustin
Verband der Chemischen lndusrrie e. V. (VCl), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), fachgemeinschafi Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEhj, Dijsseldod
VGB Technische Vereinigung der GroBkraftwerksbetreiber e.V., Essen
Verband der Technischen iiberwachungs-Vereine e. V. (VdTUV). Essen.
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s l y b y t h e t r a d e assooations in keeping w/th technical p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e. V., P.O. Box 103834, D-45038 Essen.

Contents
1 scope 5 Testing
2 Principles 6 Modification and repair work
3 Prerequisites 7 Supplement
4 Marking

1 Scope 1.2 If AD-MerkblBtter in the HP Series contain no provisions

for the fabrication and testing of individual materials, the pro-
1 .l AD-Merkblstter in the HP Series deal with the rules con- cedure is as follows:
cerning the design and manufacture of pressure vessels and
pressure vessel components which are wholly or predomi- (1) In the case of pressure vessels which are to be subjected
nantly under static load’) and their joining with non-pressure to a construction inspection by the authorised inspectors),
parts, e.g. by welding. These Merkblatter follow up AD- agreements shall be reached between the manufacturer,
Merkbltitter in the W Series and specify the tests to be per- user and authorised inspector on the basis of Series HP AD-
formed before, during and after manufacture either by the Merkblatter,
authorised inspectorz) or by the manufacturer unless other- (2) In the case of pressure vessels which are not to be sub-
wise stipulated in Series 500 Technical Regulations for jetted to a construction inspection by the authorised inspec-
Pressure Vessels (TRB), in particular the following: tars), stipulations shall be made by the manufacturer - in
- TRB 511 Testing by authorised inspectors, initial test- agreement with the purchaser if applicable.
ing - Design approval, For non-metallic materials, AD-Merkblgtter in the N Series
- TRB 512 Testing by authorised inspectors, initial test- shall also be observed.
ing - Construction inspection and pressure
1.3 The provisions in TRB 500 Section 8.1 are applicable
test, in the case of multi-compartment pressure vessels.
- TRB 521 Certificate of correct manufacture,
- TRB 522 Testing by the manufacturer, pressure test. 1 . 4 AD-MerkblBtter in the HP Series include the following:
HP 0 - General principles of design, manufacture and
AD-Merkbltitter in the HP Series do not deal with acceptance associated tests
tests, inservice tests and testing for special cases. Supplement: Synoptic Tables: Conditions under
which no postweld heat treatment is
required, type and scope of produc-
tion tests and non-destructive testing
1) AD-Merkblatt S 1 delineates various types of loading from each other depending
on design and manufaCture.
2) Where the term “authorised Inspector” is mentioned in the text, it refers to the 3) In this connection, see also the test group classification according to 58
authorised inspector as defined in 5 31 DruckbehV [Pressure Vessel Act]. DruckbehV or the provisions rn Appendix II of the DruckbehV.

Supersedes Edition July 1989; ) = Amendments to previous edition

CarI Heymanns Verlag KG

-Translation:- I ecnntcal
,... Help to wponers
- ^service ,^A.
01 Ubl
Luxemburger StraEe 449. 50939 K6ln
 II .-t..-.*~ll.^ ; ,.*.
Page 2 A D - M e r k b l a t t H P 0 , E d i t i o n 1 2 . 9 6

- !
H P 1 - Design and construction ments for welding supervisors and welders are laid down in I

H P 2 - Procedure qualification testing for joining process
11: Procedure qualification testing for welded
joints : I 3.4 Manufacturers of pressure vessels which are to be sub-
/2: Procedure qualification testing for weld clad-
dinga)
/3: Procedure qualification testing for brazed
joints4)
14: Procedure qualification testing for bonded
joints and other joining processes4)
H P 3 - Welding supervisors, welders
H P 4 - Test supervisor and testers in non-destructive
testing
H P 5 - Manufacture and testing of joints
/I : Principles of welding practice
/2: Production testing of welds, Testing of base
metal after postweld heat treatment
13: Non-destructive testing of welded joints
Appendix 1: Minimum requirements for non-
destructive testing methods
H P 7 - Heat treatment
/l : General principles
12: Ferritic steels
13: Austenitic steels
/4: Aluminium and aluminium
H P 8 - Testing
I1 : Testing of pressings made from steel, alumi-
nium and aluminium alloys
/2: Testing of steel part-shells
HP 30 - Performance of pressure
2 Principles
2.1 Manufacture of the pressure vessels shall be based on
the pertinent drawings and relevant documents.
2 . 2 The manufacturer of pressure vessels or pressure ves-
sel components shall arrange for all the necessary jobs to be
carried out properly, making sure that this is done in accord-
ance with good engineering practice, particularly in accord-
ance with AD-Merkbltitter.
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-Merkb&tter, e.g. dynamic load, corro-
sion allowance, additional tests and their scope, reduced
tolerances, use of certain materials, joining processes and
filler metals, additional heat treatment, these shall be made
known to the manufacturer by the user (purchaser) in good
time so as to allow the manufacturer to take these points into
account in the design and manufacture of the pressure ves-
sels.
3 Prerequisites
AD-Merkblatt HP 3 and those for test supervisors and testers !
are laid down in AD-Merkblatt HP 4.
jetted to a construction inspection by the authorised inspec-
tor and which are welded or joined by means of other
methods (e.g. brazed or bonded) shall provide the authorised
inspector with evidence, in the form of a procedure qualifica-
tion test adapted to the manufacturing process, that they are
fully conversant with the welding procedures or other joining
processes used. Supplementary tests are necessary if the
materials, dimensions or joining processes, for example, are
changed beyond the scope and validity of the procedure qua-
lification test.
For pressure vessels which are not to be subjected to a con-
struction inspection by the authorised inspector, the manu-
facturer shall ensure that he is fully conversant with the
joining processes used.
13.5 If manufacturing jobs such as forming or heat treatment
are contracted out to other manufacturers, the latter shall
also be qualified to do these jobs according to the conditions
1 specified in Sections 3.1 to 3.4.
I 3.6 In the case of pressure vessels which are to be sub-
jected to a constructlon inspection by the authonsed inspec-
alloys tor, the latter shall satisfy himself, wlthin the framework of his
inspection duties, that the prerequisites specified in Sections
I 3.1 to 3.5 are being met. The production sequence shall not
be adversely affected in so doing.
tests
4 Marking
4.1 The marking of materials shall be maintained through-
out the process of manufacture. If original 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
so as to allow the material specifications to be 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 to
ensure that there is no possibility of confusion in the 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 list.
4 . 2 In the case of pressure vessels which are to be sub- . ,.
jected to a construction inspection by the authorised inspec-
tor, markings shall be transferred observing Section 4.1 in
accordance with Sections 4.2.1 to 4.2.3.
4.2.1. In the case of materials for which a certificate 3.1 A
I or 3.1 C to DIN EN 10204 is required, the markings shall be
transferred by the authorised inspector. This does not apply
to small part+) made from tested products such as stay bars,

I 3.1 Manufacturers shall meet the welding requirements of

DIN EN 729-3.
stay tubes, stay bolts, nipples, nozzles, flanges, compensat-
ing rings and covers. The transfer of markings can be done
by the works employee in charge.
I 3.2 Manufacturers shall have available the necessaryfacili-
tiess) to ensure that the materials are properly processed and The provisions in AD-Merkblatt W 7 apply to marking for
the necessary tests can be performed. screws and nuts made from tested products.
13.3 Manufacturers shall have their own supervisory staff
and trained workers for production purposes. The require-

‘) Ill preparation. 6) Depending on the importance of the component concerned. the traknfer of mark-
5) Places elsewhere which have the required facilities may be used. ing may be restricted or dispensed with.
 Page 3 AD-Merkblatt HP 0, Edition 12.96
.

4 . 2 . 2 In the case of materials which may be delivered with

Material Groups Authorised inspector’s
1 certificates 2.2 or 3.1 B to DIN EN 10204, markings may be act. to Table 1 consent required:
transferred by the manufacturer or supplier after having
reached written agreement with the authorised inspector. In 2 Regardless of the Welding in particularly difficult
this agreement, the name of the works employee in charge material fixed position, e.g. where
and the works mark used by him shall be stated in writing. space is restricted or where
Section 4.2.1, second sentence, applies to small parts. high degrees of distortion are
to be expected, e.g. rein-
4 . 2 . 3 In the case of parts which are to undergo further pro- forced structures, large-area
cessing at the construction site, where markings are trans- welding, patch welding and
with short repair cavities with
ferred by the employee in charge at the manufacturer’s a ratio of repair length to
works, the said pans shall be accompanied, on request, by repair depth of 2 or less
papers certifying the transfer. These papers shall state
that the markings have been transferred in agreement with 3 If subsequent heat treatment
is dispensed with for technical
the authorised inspector. Alternatively, a note to this effect reasons even though heat
may be included in the material test certificate according to treatment would be required
1 DIN EN 10204. according to stipulations in
AD-Merkbltitter

5 Testing 6.1.3 In the case of repeated modifications and repairs,

As a rule, testing of pressure vessels and pressure vessel
components, which must be in a condition suitable for testing,
is performed at the place of manufacture.
including those during manufacture, the consent of the
authorised inspector shall be obtained in advance.
6.1.4 The authorised inspector’s permission can also be
obtained in the form of a general approval of repair instruc-
tions.

6 Modification and repair work
6.1 Pressure vessels to be subjected to a construction
inspection by the authorised inspector
6.1.1 The authorised inspector shall be informed of modifi-
cations and repairs during manufacture.
6 . 1 . 2 The authorised inspector’s consent shall be obtained
in the following cases for modifications and repair work on
a finished component after non-destructive testing:
6.1.5 The authorised inspector’s permission shall be
obtained before the start of modification and repair work after
the construction inspection or partial construction inspection.
6 . 2 In the case of pressure vessels which are to be sub-
jected to a construction inspection by the expert (see TRB
502 Supplement 1) according to Appendix II DruckbehV, the
provisions in Sections 6.1 .l to 6.15 are applicable to the
expert’).

Material Groups Authorised inspector’s 7 Supplement

act. to Table 1
1 1, 2, 5.1, 5.2, 6, 7
4.1, 5.4, Al 1
3, 4.2, 5.3, 8, Al 2, Al 3,
Ni 1, Ni 2, Ti 1
consent required:
for depth of repair > 20 mm
and, at the same time, length
of repair > 300 mm
for wall thicknesses
>20mm
always required
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 of
production tests and non-destructive testing of welded pres-
sure vessels or pressure vessel components. For details, see
AD-Merkblatter HP 7 and HP 5.
7) Where the term “expert” is mentioned in the text, it refers to the expert as defined
in 5 32 OruckbehV.
Page 4 AD-Merkblatt HP 0, Edition 12.98
; ” 1..
Footnotes for Synoptic Table 1

1) Other materials to be assigned to comparable Material Groups according to material specifications as stated in the assessment of
suitability. Where components made from different Material Groups are welded together, the Group having the greater scope of testing
is applicable.
Q) U = unannealed, W = heat treated.
3) Applies irrespective of stress categories according to AD- Merkblatt W 10.
‘) Notch position at right angles to surface.
Q) Notch position, as far as possible, parallel to the surface; for specimens I 10 mm thick, at right angles to the surface.
Q) H o t t e n s i l e t e s t a c c o r d i n g t o D I N 5 0 1 4 5 o n l o n g i t u d i n a l s p e c i m e n s t a k e n f r o m t h e w e l d m e t a l i f t h e w o r k i n g t e m p e r a t u r e > 3 5 0 “C; f o r
fine-grained structural steels, hot tensile test as stated above if the working temperature 2 200 “C.
7) LN = Longitudinal welds and butt welds under full stress
RN = Circumferential welds (butt welds and flap-welded fillet welds as specified in AD-Merkblatt HP 1, S e c t i o n 2 . 4 : f o r w e l d e d e n d s ,
see AD-Merkblatt HP 92, Section 5
S t = Joints between LN (longitudinal welds) and RN (circumferential welds) or between LN and LN ;‘:.;:
5:::::
Q) KN = The fillet welds to be tested are welds connecting weld-on parts, including assembly aids, to the pressure-heating wall :..:
_..-:
StN = Nozzle welds. .:
Q) Scope of testing to be extended accordingly if caustic crack resistance is required. i ;:,
10) If conditions under which no postweld heat treatment is required are met. , .-
11) G = as for base metal.
IQ) If experience has been proved as stated in AD-Merkblatt HP 5/3, Section 2.2.1, the scope of testing is reduced to 10%.
13) If experience has been proved as stated in AD-Merkblatt HP 513, Section 2.2.1, the scope of testing is reduced to 2%. Generally it is
sufficient to include the circumferential welds by testing the joints when making random tests on the longitudinal welds.
14) T o b e t e s t e d o n w e l d l e n g t h , n o t n e c e s s a r i l y o n c e r t a i n o b j e c t s . I n t h e c a s e o f p r e s s u r e v e s s e l s w h i c h a r e t o b e s u b j e c t e d t o a c o n s t r u c t i o n
inspection by the authorised inspector, the places to be tested shall be agreed with the authorised inspector.
IQ) G e n e r a l l y i t i s s u f f i c i e n t t o i n c l u d e t h e j o i n t s a n d c i r c u m f e r e n t i a l w e l d s b y t e s t i n g t h e j o i n t s w h e n m a k i n g r a n d o m t e s t s o n t h e l o n g i t u d i n a l
welds.
IQ) If experience has been proved as stated in AD-Merkblatt HP 513, Section 2.2.1, for Material Groups 1, 5.1 and 6 the scope of testing
is reduced to the same extent as for wall thicknesses I 15 mm.
17) S h o u l d v i s u a l e x a m i n a t i o n a s s t a t e d i n A D - M e r k b l a t t H P 5 1 3 , S e c t i o n 2 . 1 g i v e r i s e t o d o u b t s , a n o n - d e s t r u c t i v e t e s t s h a l l b e p e r f o r m e d .
I*) I f m o r e t h a n 1 0 n o z z l e s a r e w e l d e d t o a p r e s s u r e v e s s e l w h i c h a r e s i m i l a r i n t e r m s o f d i m e n s t o n a n d w e l d i n g p r o c e d u r e , t h e s c o p e o f
testing can be reduced to 5% of the nozzle welds but at least 2 nozzle welds shall be tested.
IQ) I f e x p e r i e n c e h a s b e e n p r o v e d a s s t a t e d i n A D - M e r k b l a t t H P 5/3, S e c t i o n 2 . 2 . 1 , a n o n - d e s t r u c t i v e t e s t s h a l l o n l y h a v e t o b e p e r f o r m e d
i f v i s u a l e x a m i n a t i o n a s s t a t e d i n A D - M e r k b l a t t H P 513 S e c t i o n 2 . 1 h a s g i v e n r i s e t o d o u b t s .
QQ) fn the case of steel X 20 CrMoV 12 1, testing of impact strength shall be carried out regardless of the wall thickness, i.e. including
5 15 mm to 2 5 mm. In addition, the hardness of each weld shall be test.
21) T e s t i n g o f i m p a c t s t r e n g t h s h a l l b e c a r r i e d o u t r e g a r d l e s s o f t h e w a l l t h i c k n e s s , e . g . i n c l u d i n g 5 1 5 m m t o 2 5-m. T h e t e c h n o l o g i c a l
bend test shall be performed for wall thicknesses c 5 mm.
QQ) H e a t t r e a t m e n t d o e s n o t a l w a y s s i g n i f y a n i m p r o v e m e n t i n p r o p e r t i e s . T h e p o s s i b l e b e n e f i t s o f d i s p e n s i n g w i t h h e a t t r e a t m e n t s h o u l d
also be considered in the case of wall thicknesses > 50 mm. Special agreements shall be made.
a) If used in the temperature range below -10 “C according to AD-Merkblatt W 10.
24) As far as this is required by the purchaser.
QQ) If steels in Material Groups 5a to 5.4 are used at lowest operating temperatures 2 -10 “C and the requirements in AD-Merkblatt
W 10 are met, the same provisions apply as for Material Groups 1 to 3.
AD-Merkblatt HP 0, Table 1, Edition 12.96
Synoptic Table 1 l Conditions under which no postweld heat treatment is required, type and scope of production tests and non-destructive testing (steels)
Mate Steel grades Conditions to be met when omitting postweld heat treat- Type and scope of production test and non-destructive testing
rfal ment. Postweld heat treatment can be omitted provided
Grouf
‘1
the additional requirements in Column 5 depending or
wall thickness and steel grade are met.
Production test
- T
c
Surface crack test

s>15mm Scope of testing Test method and test Nozzle and fillet welds*) Scope of testing
Wall Steel grades Other additional Notch impact specimens LN7 St 7) RN7 category in relation to in relation to
thickness within relevant requirements Test I Number wall thickness for wall thickness
iimiis iviaieriai ! E
0 ’ temperature : Columns 17. i a, 19 for LN, St and RN
Group n
$4 , ii 5 C Wall thickness
.- scope Test method
2 $’ 2 E C’
u ‘5 of and test
E g
VI 5 test- category
d:: 3 c
ing
mm “C ’ % % mm % mm %

1 2 3 4 5 9 10
i1 114) 125) ia 19 20 21 22 23
-
Steels in the following analysis 4 30 all none
groups (ladle analysis) with
17
minimum yield point z. 30 I 3E Basic and I 30 25’3 D(A) or US(A) 1

- z 370 N/mm29) except steels with high-tempera. none > 30 I 38’0) 2 G”) /: 3 1 1 1 macro 25 10’6)
high impact strength at low ture Series of > 38 5 50 ‘0) G”) 3 3 1 1 25 > 30 d 60 D(B) or US(B) 10’6)
temperature if used act. to fine-grained ,
structural > 60 5 90 US(B)
AD-Merkblatt W 16 in stress 3.1 or 4
category I below - 10 “C steels act. to
DIN 17102, > 90 US(C)
I 30 2 G”) 100 25 ‘2 17
C 5 0,22 s 0,20 DIN EN 10028.3, 1
>3os50 ii I 25’2 ()18)19
Si 5.G 0,50 5 0,50 17178and 100 G”) 1 macro 100
> 50 3 - 1 1 100 25
Mn 5 1.6 I 0.8 17179and G”) 10’6)
MO - ’ 5 0,65 steel grades
P, S each I 0,05 each I 0,05 which, act. to
other material
total 5 0,a 5 0,5 specification,
2 _ I,- - ‘7
Nozzle and fillet
> 50 10 MP
other meet same I 15 ‘9 2’3) welds are to be
single 5 0,3 I 0.3 minimum im- >15r30 G”) 3 -
1 macro
100 ‘6) 2’3) ‘7
; subjected to a sur-
pact strength face crack test.
requirements Additional ultra-
sonic or radio-
> 38 5 50 All steel Simple geometrical shape graphic examina-
grades with a (sphere, cylinder); 100 % tion to be per-
specified im- nondestructive testing; formed for nozzles
pact strength load stress during pres- having an inside
131JatO’C sure test I o,a5 R&, at diameter
/
in transverse room temperature; special L 120 mm where
dlrection
(ISO-V-notch
briiile fracture investiga-
tion. Components with i I thickness of con-
necting cross-
specimen) nozzles and weld-on parts sectional area
to be heat treated be- exceeds 15 mm.
forehand Test method
--_- (Column 20) to be
selected on basis
2 ?ne-grained structural steels with s 30 Basic and
of dimension t
ninimum yield point r 370 to high-tempera- ione
c’50 D(B) or US(B) (see AD-Merkblatt
c 430 N/mm2 except steels with ture Series of
HP 5/3, Fig. 1
ligh impact strength at low fine-grained
25 ‘2) 10’6) to 3). Fillet welds
emperature if used act. to structural U 1 macro >50 5 70 US(B)
25 10 with throat thick-
4D-Merkblatt W 10 in stress steels act. !o
ness (a) exceed-
:ategdry I below -10 “C DIN 17102, >7ir WC)
ing 15 mm also to
DIN EN 10028-3.
be subjected to
17176and. > 30 5 70 10
ultrasonic exami- MP
17179 and > 70 25
nation where the
steel grades
throat thickness
which, act. to
rather than wall
material
thickness deter-
specification, 5 30 100 25’2) IO’@)
1 macro mines the test
meet same > 30 100 25 10
category.
minimum im-
pact strength
requirements

3 Yne-grained structural steels with ‘one

ninimum yield point L 430 N/mm2
U 100 I 30 1 macro 100 100
rxcept steels with high impact s 20 D(B) or US(B)
#trength at low temperature if
sed act. to AD-Merkblatt W 10 > 20 5 40 US(B) and D(B)
1 stress category I below - 10 “C 0hJs~c)
5 20 10
tigh-temperature structural Iee assessment of suitability z 40 US(C) > 20 25
teels 5 50 100 100
W 100 1 macro
1 NiMoV 5 3, 13 MnNiMo 5 4, > 50 100 100
7 MnMoV 6 4, 20 MnMoNi 5 5,
5 NiCuMoNb 5, 22 NiMoCr 3 7,
2 MnNiMo 5 5, 20MnMoNi45
‘.
AD-Merkblatt HP 0, Table 1 (Continued), Edition 12.96
Synoptic Table 1. Conditions under which no postweld heat treatment is required, type and scope of production tests and non-destructive testing (steels)

Mate- 1 Steel grades Conditions to be met when omitting postweld heat treat- -I- Type and scope of production tests and non-destructive testing
nal i ment. Postweld heat treatment can be omitted provided --____________--_
Group
.I
/
I
the additional requirements in Column 5 depending OI
wall thickness and steel grade are met. -- Production test
.-------_-U!trasonic
1---.-
or radiographic examination T -
Surface crack test

s>15mm Scope of testing Test method and test Nozzle and fillet weldsa) Scope of testing Test meihod
Wall Steel grades Other additional Notch impact specimens LN 7) St 7) RN’ ) category in relation to in relation to for Column 23
thickness within relevant 1 requirements Test wall thickness for wall thickness
iimits i Material temperature Columns 17, ta, 19 for LN, St and RN
1 Group
Wall thickness
Scope Test method
of and test
test- category
ing

I% %
mm * “C % mm % mm %
2 3 4 5 10 17 ia 19 20 21 22 23 24

4.1 High-temperature steels: Postweld heat treatment necessary

t -

5 50 D(B) or US(B)
13CrMo44, lOCrMo910,
, 12 CrMo 19 5, X 10 CrMo 9 1 I 30
> 30
G”)
G”)
3
3
1 macro 3.1 or 4 Ii1 100’2
100
100
100
25’2
25
> 50 5 70 US(B)

> 70
25’2) > 30 I 70
> 70
10
25
MP

US(C)

4.2 High-temperature steels: postweld heat treatment necessary

I 20 D(B) or US(B)

t100
114MoV63
i X20CrMoV121 > 20 I 40 US(B) and D(B) I 20 10
2 G") 3 20) 1 macro 100 100 MP
I I or US(C) > 20 25

> 40 Ufw)

!
5.1 Finegrained structural steels I 30 all none

t
- -
act. DIN 17102, DIN EN 10028-3,

Ial 00 12:
’ 30 I 3f Basic and none
17 178 and 17 179 in Series with 1 Nozzle and fillet
high-tempera- I I: 30 22') 32’) 32') 100 25'3) I 30 D(A) or US(A) 17
high impact strength at low tem-
perature and special Series with
ture Series of > 30 5 38'0) 32’) 32') - 1 macro 100 100 25 10’8)
1 welds are to be
subjected to a sur-

I
fine-grained > 38 I 50'0)
high impact strength at low tem- 32’) 32') 1 100 100 25 > 30 5 60 D(B) or US(B) 10 ‘8) face crack test.
structural
perature having a minimum yield
steels act. to
point c 370 N/mm2. Fine-grained > 60 5 90 US(B) 1 ultrasonic or
i
DIN 17102,
structural steels act. to
DIN 17102, DIN EN 10028-3,
DIN EN 10028-3, 5 90 US(C)
I radiographic
examination io be
17178and
1717aand!7179inbasicand 1 performed for
17179 and
high-temperature Series with 1 nozzles having an
steel grades If the lowest
minimum yield point 1 inside diameter

i1;;;)‘5
which, act. to operating
< 570 N/mm2 if used with 5 30 22’) 32’) 321) ’ - ! go
3.1 or 4 i 100 25 ‘2) I 1 12@ mm where
material temperatures
AD-Merkblatt W 10 in stress > 30 d 50 32’) 32’) - 1 macro , : 8 7 ; 1 4 )thickness
( of con- > 50 I 90 10
100 25 ‘2)
specification, ice. to MP
category I below -10 “C. Steel > 50 32’) 32’) 1 100 25 10 ;a) . netting cross- > 90 25
meet same AD-Merkblatt
grades lTSt 35 N and 7TSt 35 V I sectional area
minimum im- W 10 are
act. to DIN 17173and 17174 1exceeds 15 inm.
and steel grades 11 MnNi 5 3
pact strength
requirements
used, test at
gen. tempera-
I Test method
and ! 3 MnNi 6 3 act. to
DIN 17280.17173 and 17174at
lowest operating temperatures
-
38 I 50
- -~-
All steel
‘?--

Simple geometrical shape

grades with a (sphere, cylinder); 100 %
tures in
Table 1,
Column 9. If
j --I (Column 20) to be
selected on basis
of dimension t
down to -60 “C25) inclusive. specified im- non-destructive testing; (see AD-Merkblatt
working I;
pact strength load stress during pres- 5 15 22’) 32’) 32’) - 1 5 215 HP 5/3, Fig. 1
temperature 1 )
1 macro 3.2 or 4 2’4) to 3). Fillet welds
2 31 J at 0 “C 1sure test 2 0.85 R,,,, at > 15 5 30 32’) 32’) - 10’6) I 00 ‘6) 2’5)
s higher than I
in transverse ; room temperature; special with throat thick-
lowest ,
direction ! brittle fracture investiga- 1 ness (a) exceed-
operating
(ISO-V-notch 1 tion. Components with 1 ing 15 mm also to
temperature
specimen) nozzles anal weld-on parts I be subjected to
for stress
to be heat treated be- I ultrasonic exami-
category I,
j forehand I nation where the
testing need I
1 throat thickness
only be per-
1
i rather than wall
formed at the
5.2 Fine-grained structural steels I 30 all none thickness deter-
lowest
act. to DIN 17102,17178 and I mines the test
intended
5 15 22’) 32’) 32’) ( 1 100 ‘2) 100 25 ‘2) category.
17 179 in Series with high impact working 1 macro 550 D(B) or US(B)
>15%30 32’) 32’) ! 1 100 100 25
strength at low temperature and temperature
special Series with high impact 1 950 I70 US(B)
strength at low temperature -- 3.1 or 4 , > 30 5 70 10
M P
having a minimum yield point >70 US(C) > 70 25
1370N/mm2 to < 430 N/mm2 if - I - - -
used with AD-Merkblatt W 10 in 5 30 22’) a20 321) 1 1
1 macro
100’2) 100 25 ‘2)
> 30 32’) 100 100 25
stress category I below - 10 “C. 32’) 1
Steel grade lTSt 35 V act. to
DIN 17 173 and 17 174 at lowest
operating temperatures down to
-60 “C25) inclusive.
I

I
t\
1 i
AD-Merkblatt HP 0, Table 1 (Continued), Edition 12.96
Synoptic Table 1 l Conditions under which no postweld heat treatment is required, type and scope of production tests and non-destructive Jesting (steels)
date- Steel grades Conditions to be met when omitting postweld heat treat- Type and scope of production tests and non-destructive testing
rial ment. Postweld heat treatment can be omitted provided
jroup the additional requirements in Column 5 depending on Ultrasonic or radiographic examination
wall thickness and steel grade are met. --
‘1 z
D
c gz 2 6
c cu 7
Wall Steel grades Other additional
thickness within relevant requirements
limits Material I!ii ~~ ;;;;) fv&
Group

mm

1 2 3 4 5 .a:’
1 7 8 ~~~~~t~~~ 9 10
15 114) ~~L~::~~
125)
16 13 14
17 18 19 20 21 22 23 24

5.3 Fine-grained structural steels act. 5 30 all none If the lowest I

to DIN 17102, DIN EN 100283, operating
17 178 and 17 179 with minimum temperatures
yield point 2 430 N/mm* in Series act. to
with high impact strength at low AD-Merkblatt i
I 20 D(B) or US(B)
temperature and special Series W 10 are
with high impact strength at low used, test at
U 100 I 30 1 - 100 100 1004 > 20 Ior 40 US(B)US(C)
and D(B) 100
temperature. Fine-grained struc- 22’) 32’)
gen. tempera- 32’) 1 macro 3.1 or > 20 25 MP
W 100 all 22’) 32’) 32’) 1 - 100 100 100 100
tural steels act. to DIN 17 102, tures in
DIN EN 10028-3,17178 and Table 1, > 40 WC, I
17 179 with minimum yield point Column 9. If
L 430 N/mm2 in basic and high- c. working .
temperature Series if used accord- temperature
ing to AD-Merkblatt W 10 in stress is higher than
category I below - 10 “CY). lowest
: operating Nozzle and fillet
5.4 Steels with high impact strength I 5022) X8Ni9 Welding using austenitic welds are to be . .
Welding using austenitic or
at low temperature act. to 10 Ni 14 or nickel-based alloy filler nickel-based alloy filler metals subjected to a sur-
DIN 17280.17173and 1717425) . 12 Ni 19 metals face crack test.
I 50’ D(B) or US(B)
Additional
> 50 5 70 US(B)
L ‘,.,~~e~321)~321)~ l _ > 70

5 30’ 10 Ni 14 Base metal and weld

12 Ni 19 metal are of the same type ii ::: #ii: 22’) a*‘) a*‘) ’

! thickness of con-
, 1
* netting cross- v
6 Austenitic steels act. to none all The additional require- ! 1 macro sectional area
DIN 17440, 17441, 17457 and I ments as specified in U 100 5 50 2 .I 3
G “)*3) - 1 1 (IK resis- 100’2) 100 ‘25’2)5 30 D(A) or US(A) 171 exceeds 15 mm.
17458 as well as SEW 400 Section 4 of AD-Merkblatt tance 24)) . Test method
HP 713 are to be observed ,3.1or4
1 macro > 30 5 60 D(B) 01’ US(B) (Column 20) to be
1 100’2) 17 selected on basis >30590 1 0
W 100 5 50 I 2 G “)*3) y-1; ; (IK resis- 100 25 ‘2) 1 FE
> 50 ! - G1’)23) ’ 100 106 25 > 60 I 90 US(B) 17 of dimension t > 90 25
, tance 24))
(see AD-Merkblatt
1 macro I > 90 US(C) HP 5/3, Fig. 1
’
U, W 85 5 15 I 2 I - II _ ’ _ I _ _ (IK resis- 3.2 or 4 2’4) ‘5) 2’5) 17
to 3). Fillet welds
>15~31, - , G”) -;-
3 - 1 7
10’6) 100’6) 2 ’ 5 ) i with throat thick-
tance24))
I I . ness (a) exceed-
7 t Ferriteifree austenitic steels but none all The addi!ional require- ing 15 mm also to
possibly with ferrite in the weld ments as specified in be subjected to
metal and austenitic steels in Section 4 of AD-Merkblatt * ultrasonic exami-

i 1 !
Material Group 6 provided they HP 7/3 are to be observed 1 I 550 D(B) or US(B)
I nation where the
are welded using filler materials
U 100 all 2, G”) i3 - 1 micro 3.1 or 4 100 100 25 350 I 70 10 throat thickness < 70 10
with I 3% delta ferrite in weld FE
W 100 all 2 G”) ’ (IK resis- US(B) rather than wall > 70 25
metal, e.g. 3 -i: : 1 100 100 25 10
tancez4)) thickness deter-
>70 US(C) mines the test
X 8 CrNiNb 16 16,
X 8 CrNiMoVNb 16 13 category.
I
8 X 8 CrNiNb
Ferritic austenitic
16 13,steels, I1 1
I
e.g. none all none

1
, ,

U 100 all 2 : G”) 3 3 1 - 1 micro 3.1 or 4 100 100 25 10

X 2 CrNiMoN 22 5 3 I I MP
2230 D(l)or US(A)
I 60 25 and
9 30 I 60 D(B) or US(B) FE

85 all 2 i G”) 3 3 1 - 1 micro 3.2or4 25 100 10 ‘7 1

i
. .
AD-Merkblatt HP 0, Table 2, Edition 12.96
Synoptic Table 2. Conditions under which no postweld heat treatment is required, type and scope of production tests and non-destructive testing (aluminium and aluminium alloys)

Mate-
rial
Types of material
l- Conditions to be met when omitting postweld heat treat-
ment. Postweld heat treatment can be omitted provided
Group l) the additional requirements in Column 5 depending on Production test Non-destructive testing
wall thickness and types of material are met. I

s> 15mm Test method and test Nozzle Test method

Wall Types of material 1 Notch impact specimens%) category in relation to and and test
thickness within relevant Test wall thickness for fillet category
ilmits Materiai temperaiure Columns 17, 18, 19 weldsa) for column 21
Group
Wall thickness

mm “C Section %

2 3 10 16 21 22

Al 1 Al 99,98 R W4, F4 Nozzle and fillet

Al 99,8 W6, F6 5 5027) 1 welds are to be
Al 99,7 W6, F6 subjected to a sur-
D(B) or US 10’8)
Al 99,5 W7, F7, F8 face crack test.
Additional
> 5027) According to assessment of suitability ultrasonic or
radiographic
examination to be
performed for
i 5027) 228) i - - 1 - 1 macro 3.2 or 4 2’4) '5) 2’5) - D(B) or US 17
1
nozzles having an
I inside diameter
Al 2 AfMn W9, FlO, WlO none 2 120 mm where
AlMnCu WlO 5 5027) 2 2fJ) G”) 3 -‘l - 1 macro 3.1 dr 4 100’2) 100 25 ‘2) thickness of con-
AlMg3 W18, W19, F18 necting cross-
AfMg2Mn0,8 W18, W19, F18, F19, F20 sectional area
18)31)
AlMg4,5Mn W27, W28, F27 exceeds 15 mm.
% 5027)
228) I G”) 3 - 1 - 1 macro 3.2 dr 4 2’4) '5) 2’5) - D(B) or US 10 Test method
[Column 20) to be
selected on basis
> 5027) According to assessment of suitability 1 100 1 100 1 25 1 >f dimension t
[see AD-Merkblatt
I HP 513, Fig. 1
Al 3 AIMgSi0.5 F13 none all lo 3). Fillet welds
According to assessment of suitability 100 100 loo=) - D(B) or US 100 Nith throat thick-
less (a) exceed-
ng 15 mm also to
I ! )e subjected to
Jltrasonic exami-
’ I iation where the
hroat thickness
‘ather than wall
hickness deter-
nines the test
:ategory.

Footnotes 1) to 25). see Synoptic Table 1.

26) Testing of impact strength is only performed in case of pressure vessels where possibility of
shock loading must be anticipated.
*‘) Relatively littla welding and testing technical experience is currently available for wall
thicknesses exceeding 30 mm.
2e) For thicknesses > 15 mm, side bend test specimen according to DIN 50121.
23) Valid for AIMg4,5Mn only if experience has been proved as stated in AD-Merkblatt HP 5/2 Section 3.1.3.
30) A scope of testing equivalent to 10% is sufficient for circumferential welds up to an outside
diameter of 50 mm.
31) For fillet welds between joints in non-load bearing elements, e.g. inner retaining rings, and the pressure vessel wall.
a surface crack test may be omitted provided that visual examination according to AD-Merkblatt HP 513
gives no rise to doubts and the results of surface crack tests performed at least 300 m from such welds gave
satisfactory results.
 AD-Merkblatt HP 0, Table 3, Edition 12.96
Synoptic Table 3. Conditions under which no postweld heat treatment is required, type and scope of production tests and non-destructive testing (nickel and nickel-based alloys as well as titanium, zirconium, tantalum, hafnium and other metallic materials)
Types of material Conditions to be met when omitting postweld heat treat-
Mate- Type and scope of production tests and non-destructive testing
rial ment. Postweld heat treatment can be omitted provided
Group’) the additional requirements in Column 5 depending on G7 Production test Non-destructive testing
wall thickness and types of material are met. ii
,o s> 15mm Scope of testing Test method and test Nozzle Test method
Y!?
: ;ii r” Notch impact specimens=) category in relation to and and test
Wall Types of material Other additional E s s LN’) St’) RN’)
s =,ge; *g n,
thickness within relevant requirements \q .E’ Test 1 Number 2 --E a wall thickness for fillet category
I 1 Qc;‘otps rnQ I z I .c R g L
limits Materiai .- c uih3 temperature E
.- 2, ColiimnS 17, 18, 19 welds*) for column 21
zzi .1; +j P, g- 7 B 0 @In 5; 8!2=lu
Group “E 3s S>OS 7
$5E &’ 2 GS co@ Wall thickness
t- a .- 5 5 ! L
08 -.g .o $f i7l.e .- 2 2% L &‘J’
E b d=‘Qal E C rn$ alQ.Ei 2 ii
m=fAI/j $32 zla n car”
u)c 3.E = v)x 2 ZE ZgE %E
sg m cu.0 0 V I Eki $j fj
E d I
3 @Jo
or ia 3 Bs ti d:: $2 I”tis 22 z zia

mm '0
/o mm “C Section % % % mm %
1 2 3 4 5 6 7 8 9 10 11’) 125) 13 14 15 16 17 18 19 20 21 22

Ni 1 LC-Ni 99 none all none u,w l o o all 2 G”) 3 - 1 19 1 macro 3.1 or 4 100 106 25 5 30 D(A) or US(A) 10 Nozzle and fillet
> 30 I 60 D(B) welds are to be
. 85 all 2 G”) 3 - - - 1 macro 3.2or 4 25 100 10 or US(B) 17
1 subjected to a sur-
face crack test.
Additional
ultrasonic or
radiographic
examination to be
performed for
nozzles having an
inside diameter
1 120 mm where
thickness of con-
Ni 2 Nickel alloys netting cross-sec-
none all none u, w 100 all 2 G”) 3 332) 1 19 1 micro 3.1 or4 100 100 25 I 50 D(B) 10
tional area
e.g. (IK resis- or US(B) and
exceeds 15 mm.
NiCu 30 Fe tance) 32) Surface crack test
Test method
NiCr 15 Fe
(Column 20) to be
NiMo 16 Cr 15
selected on basis
NiMo 16 Cr Ti
of dimension t
NiCr 21 MO
(see AD-Merkblatt
NiMo 28
HP 5/3, Fig. 1
Xl0 NiCr AlTi 32 20
to 3). Fillet welds
with throat thick-
ness (a) exceed-
ing 15 mm also to
Ti 1 Titanium 1 - 1 micro 3.1 or 4 100 1 100 25 ’ I l5D(6)a n d 16 be subjected to
See assessment of suitability U,W’ l o o all 2 G”j 8 -
Zirconium ultrasonic exami-
Surface crack test
Tantalum nation where the
Hafnium throat thickness
and other metallic materials rather than wall
thickness deter-
mines the test
category.

Footnotesl) to 25) see Synoptic Table 1, Footnotes”) to 31). see Synoptic Table 2
32) Only in case of NiMo 16 Cr 15, NiMo 16 Cr Tf, NiMo 28

c
Table 1. Type and scope of non-destructive testing;
Table 1. Type and scope of non-destructive testing;
extract from synoptic table 1 in AD-Merkblatt HP 0 (Continued)
-
U&Z
rid
Steel grades
T
-
Type and s!mpe 0‘ "o"-destr"tii"e testing

l”x
1) T scupe 0‘ tesnng
LN’ RN’ m relation to
wall thickness
for LN. St ““d RN

Test method
Of and test
test category
i”Q
% % % nnl %

1 6 17 18 19 20 21 22 23

4.1
5 50 D(B) or US(S)
13CrMO44.10CrMOQ10. 25’2 > 30 c 70 10
w
c 30 00’: 100 25’2 MP
100 > 5 0 5 7 0 US(B) 25
I.? CrMo 19 5. X 10 CrMo 9 1 > 30 too 100 25 > 70 25

> 70 WC)
- - - - - -
4.2 High-temperature seek
5 20 D(B) or US(B)
14 MO” 6 3 and
> 2 0 5 4 0 US(B) and D(B)
XPOCrMo”121 100 ai1 100 100 100 IOC 5 20 10
MP
or US(C) >20 25

> 40 US(C)
- - - - -
5.1

5 30
5 30 10-2: 100 25’3) D(A) or US(A)
100 > 30 5 3Lv) 100 100 25 > 3 0 5 6 0 D(B) or US(S)
> 38 5 50’0) 100 100 25
> 60 5 90 US(B)

> 90 WC)
- - -

pm”, < 370 NimmP ,f used acd. to

AD-Merkblan W 10 in stress cate-
gory I below -10 “C 5 30 ,O’> 100 25’2)
Steel grades TTSt 35 N and 7-M w 100 > 30 5 50 10’2 100 25’9 > 50 5 90 IO
MP
35”,oDIN,7173and17,74and > 50 100 100 25 > 90 25
steel grades 1, MnNi 5 3 and
13 M,nN, 6 3 to DIN 17280. 17173
and 17 174 a, lowest operabng
temperatures down to -50 “C25) - - -
I”CI”SI”B

5 15 2’“) ‘5) 2’5) 1’)

1. W 85
>,5530 0’“) 00’6) 2-y ‘9

- - - - -
52
5 50 D(S) or US(B)

” 100
30’2 100 25’2)
> 50 s 70 US(B)
100 100 25
> 70 US(C)
- - -
> 30 5 70 10
MP
> 70 25

W
30’2 100 25’2)
00 IO0 25

- - - - -
Table 1. Type and scope of non-destructive testing;
autrnrt frnm cvnnntirtableI i n AlXMerkhlntt
H P ll (Cnntinuedl
 P a g e 5 AD-Merkblati HP 0. Edition 12.96

AD-Merkblatt HP 0, Edition 12.96, Supplement to Synoptic Table 1

Examples of correlation between steel grades and Material Groups in Synoptic Table 1

Material specification within application limits

Steel grade
Material act. to
Steel grade Material DIN VdTuV-
Group AD-Merkblatt W
code number number Werkstoffblatt

S235JRGi 1.0036 EN 10025 1

S235JRG2 1.0038 EN 10025 1
S235J2G3 1.0116 EN 10025 1
S275JR 1.0044 EN 10025 1
S275J2G3 1.0144 EN 10025 1
S355J2G3 1.0570 EN 10025 1
S355K2G3 1.0595 EN 10025 1
USt 37-2 1.0036 17 100 9 13
RSt 37-2 1.0038 17 100 9 13
St 37-3 1.0116 17 100 9 10 13
St 44-2 1.0044 17 100 13
St 44-3 1.0144 17 100 10 13
St 52-3 1.0570 17 100 9 10 13

SPH235 EN 10027 1
SPH265 EN 10027 1
SPH275 EN 10027 1
St 37.0 1.0254 1 626 4
St 37.0 1.0254 1 629 4 12
St 44.0 1.0256 1 626 4
St 44.0 1.0256 1 629 4 12
St 52.0 1.0421 1 626 4 10
St 52.0 1.0421 1 629 4 10 12

St 37.4 1.0255 1 628 4 10

St 37.4 1.0255 1 630 4 10 12
St 44.4 1.0257 1 628 4 10
St 44.4 1.0257 1 630 4 10 12
St 52.4 1.0581 1 628 4 10
St 52.4 1.0581 1 630 4 10 12

St 35.8 1.0305 17 175 4 12

St 37.8 1.0315 17 177 4
St 42.8 1.0498 17 177 4
St 45.8 1.0405 17 175 4 12
17Mn4 1.0481 17 175 4 12
P295GH (17 Mn 4) 1.0481 EN 10028-2 1
17Mn4 1.0481 17 243 9 12 13
19Mn5 1.0482 17 175 4 12
15Mo3 1.5415 17 175 4 12
15Mo3 1.5415 17 177 4
16 M o 3 (15 MO 3) 1.5415 EN 10028-2 1
15Mo3 1.5415 17 243 9 13
P355GH (19 Mn 6) 1.0473 EN 10028-2 1 9
20Mn5 1.1133 17243 9 12 13

C21’) 1.0432 39913 9 13

C21”) 1.0432 39911 1
C 22.32) 1.0427 364 9 12 13
C 22.a2) 1.0460 17 243 12 13
C 22.82) 1.0460 17 243 350/l 1
c 22.82) 1.0460 17 243 35013 9

P235GH (H I) 1.0345 EN 10028-2 1 9

P265GH (H It) 1.0425 EN 10028-2 1 9

StE 255 1.0345 17 102 351/l 1 9

StE 255 1.0461 17 178 4
StE 255 1.0461 17 179 35112 4 12
WStE 255 1.0462 17 102 351/l 1 9
WStE 255 1.0462 17 178 4
WStE 255 1.0462 17 179 35112 4 12
P 2 7 5 N (StE 285) 1.0486 EN 10028-3 352/l 1 9
StE 285 1.0486 17 178 4
StE 285 1.0486 17 179 352l2 4 12
StE 285 1.0486 17 103 352l3 9 12 13
Page 6 AD-Merkblatt HP 0, Edition 12.96

Steel grade Material specification within application limits

Material act. to
Steel grade Material DIN VdTiiV-
Group AD-Merkblatt W
code number number Werkstoffblatt

P275NH (WStE 285) 1.0487 EN 10028-3 352/l 1 9

WStE 285 1.0487 17 178 4
WStE 285 1.0487 17 179 352f2 4 12
WStE 285 1.0487 17 103 352/3 9 12 13
StE 315 1.0505 17 102 35311 1 9
WStE 315 1.0508 17 102 35311 1 9
P355N (StE 355) 1.0562 EN 10028-3 35411 1 9
StE 355 1.0562 17 178 4
StE 355 1.0562 17 179 35412 4 12
StE 355 1.0562 17 103 35413 9 12 13
P355NH (WStE 355) 1.0565 EN 10028-3 35411 1 9
WStE 355 1.0565 17 178 4
WStE 355 1.0565 17 179 35412 4 12
WStE 355 1.0565 17 103 35413 9 12 13

2 St E 380 1.8900 17 102 355/l 1 9

WStE 380 1.8930 17 102 355/l 1 9
StE 420 1.8902 17 102 35611 I 9
StE 420 1.8902 17 178 4
StE 420 1.8902 17 179 35612 4 12
StE 420 1.8902 17 103 35613 9 12 13
WStE 420 1.8932 17 102 35611 1 9
WStE 420 1.8932 17 178 4
WStE 420 1.8932 17 179 35612 4 12
WStE 420 1.8932 17 103 35613 9 12 13

3 P460N (StE 460) 1.8905 EN 10028-3 35711 1 9

StE 460 1.8905 17 178 4
StE 460 1.8905 17 179 35712 4 12
StE 460 1.8905 17 103 35713 9 12 13
P460NH (WStE 460) 1.8935 EN 10028-3 357/l 1 9
WStE 460 1.8935 17 178 4
WStE 460 1.8935 17 179 35712 4 12
WStE 460 1.8935 17 103 35713 9 12 13
StE 500 1.8907 17 102 35811 1 9
StE 500 1.8907 17 103 35813 9 12 13
WStE 500 1.8937 17 102 35811 1 9
WStE 500 1.8937 17 103 35813 9 12 13
11 NiMo V 5 3 1.6341 278 1
17MnMoV64 1.8817 376 1
15 NiCuMo Nb 5 1.6368 37711 1
15 NiCuMo Nb 5 1.6368 37712 4 12
15 NiCuMo Nb 5 1.6368 37713 12 13
12 MnNiMo 5 5 1a8809 378 1
13 MnNiMo 5 4 1.8807 384 1
20 MnMoNi 4 5 1.6311 440 1 4 10 12 13

4.1 13CrMo4-5 (13 CrMo 4 4) 1.7335 EN 10028-2 1

13 CrMo 4 4 1.7335 17 175 4 12
13 CrMo 4 4 1.7335 17243 9 12 13
lOCrMoS-10 (10 CrMo 9 10) 1.7380 EN 10028-2 1
lOCrMo910 1.7380 17 17.5 4 12
lOCrMo910 1.7380 17 243 9 12 13
11CrMoS-10 1.7383 EN 10028-2 1
12CrMo 195 1.7362 007/l 1
12 CrMo 195 1.7362 00712 4 12
12CrMo195 1.7362 00713 9 12 13

4.2 14MoV63 1.7715 17 175 4 12

14MoV63 1.7715 17 243 9 12 13
X 20 CrMoV 12 1 I .4922 17 175 4 12
X20CrMoV 12 1 1.4922 17 243 9 12 13

5.1 StE 255 1.0461 17 102 351/l 1 9 10

StE 255 1.0461 17 178 4 10
StE 255 1.0461 17 179 35112 4 IO 12
WStE 255 1.0462 17 102 351/l 1 9 10
WStE 255 1.0462 17 178 4 10
WStE 255 1.0462 17 179 35112 ‘4 10 12
 Page 7 AD-Merkblatt HP 0, Edition 12.96

T-
1
Material specification within application limits
Steel ,ade
Material act. to
Steel grade Material DIN VdTijV-
Group AD-Merkblatt W
code number number Werkstoffblatt
- - - - -
TStE255 1.0463 17102 351/l 1 9 10
TStE255 1.0463 17178 4 10
TStE255 1.0463 17179 35112 4 10 12
EStE255 1.1103 17102 351/l 1 9 10
EStE255 1.1103 17178 4 10
EStE255 1.1103 17179 351/2 4 10 12
P275N(StE285) 1.0486 EN10028-3 352/l 1 9 10
StE285 1.0486 17178 4 10
StE285 1.0486 17179 352l2 4 10 12
StE285 1.0486 17103 352l3 9 10 12 13
P275NH(WStE285) 1.0487 EN10028-3 352/l 1 9 10
WStE285 1.0487 17178 4 10
WStE285 1.0487 17179 352/2 4 10 12
WStE285 1.0487 17103 352l3 9 10 12 13
P275NLl(TStE285) 1.0488 EN10028-3 352/l 1 9 10
TStE285 1.0488 17178 4 10
TStE285 1.0488 17179 352l2 4 10 12
TStE285 1.0488 17103 352l3 9 10 12 13
P275NL2(EStE285) 1.1104 EN10028-3 352/l 1 9 10
EStE285 1.1104 17178 4 10
EStE285 1.1104 17179 352/2 4 10 12
StE 315 1.0505 17102 353/l 1 9 10
WStE315 1.0506 17102 35311 1 9 10
TStE315 1.0508 17102 353/l 1 9 10
EStE315 1.1105 17102 353/l 1 9 10
P355N(StE355) 1.0562 EN10028-3 35411 1 9 10
StE 355 1.0562 17178 4 10
StE 355 1.0562 17179 35412 4 10 12
StE355 1.0562 17103 35413 9 10 12 13
P355NH(WStE355) 1.0565 EN10028-3 354/l 1 9 10
WStE355 1.0565 17178 4 10
WStE355 1.0565 17179 35412 4 10 12
WStE355 1.0565 17103 35413 9 10 12 13
P355NLl(TStE355) 1.0566 EN10028-3 354/l 1 9 10
TStE355 1.0566 17178 4 10
TStE355 1.0566 17179 35412 4 10 12
TStE355 1.0566 17103 35413 9 10 12 13
P355NL2(EStE355) 1.1106 EN10028-3 35411 1 9 10
EStE355 1.1106 17178 4 10
EStE355 1.1106 17179 352l2 4 10 12
lXt35N 1.0356 17173 17174 4 10 12
11 MnNi5 3 1.6212 17173 1717r 4 10 12
11 MnNi53 1.6212 17280 388 1 10 13
12MnNi63 1.6213 388 1 10 13
13MnNi63 1.6217 17173 17174 4 10 12
13MnNi63 1.6217 17280 388 1 10 13
- - - - -
5.2 StE380 1.8900 17102 35511 1 10
WStE380 1.8930 17102 355/l 1 E! 10
TStE380 1.8910 17102 35511 1 9 10
EStE380 1.8911 17102 355/l 1 9 10
StE420 1.8902 17102 35611 1 9 10
StE420 1.8902 17178 4 10
StE420 1.8902 17179 35612 4 10 12
StE420 1.8902 17103 35613 9 10 12 13
WStE420 1.8932 17102 356/l 1 9 10
WStE420 1.8932 17178 4 10
WStE420 1.8932 17179 35612 4 10 12
WStE420 1.8932 17103 35613 9 10 12 13
TStE420 1.8912 17102 356/l 1 9 10
TStE420 1.8912 17178 4 10
TStE420 1.8912 17179 35612 4 10 12
TStE420 1.8912 17103 35613 9 10 12 13
EStE420 1.8913 17102 356/l 1 9 10
EStE420 1.8913 17178 4 10
EStE420 1.8913 17179 35612 4 10 12
l-rst35v 1.0356 17173 1717, 4 10 12
- - - - -
Page 8 AD-Merkblatt HP 0. Edition 12.96

Material specification within application limits

Steel grade
Material act. to
Steel grade Material DIN VdTi&-
Group AD-Merkblatt W
code number number Werkstoffblatt

5.3 P460N (StE 460) 1.8905 EN 10028-3 35711 1 9 IO

StE 460 1.8905 17 178 4 10
StE 460 1.8905 17 179 35712 4 10 12
StE 460 1.8905 17 103 35713 9 10 12 13
P460NH (WStE 460) 1.8935 EN 10028-3 357/l 1 9 IO
WStE 460 1.8935 17 178 4 10
WStE 460 1.8935 17 179 35712 4 10 12
WStE 460 1.8935 17 103 357r3 9 10 12 13
P460NLl (TStE 460) 1.8915 EN 10028-3 35711 1 9 10
TStE 460 1.8915 17 178 4 10
TStE 460 1.8915 17 179 35712 4 10 12
TStE 460 1.8915 17 103 35713 9 10 12 13
P460NL2 (EStE 460) 1.8918 EN 10028-3 35711 1 9 10
EStE 460 1.8918 17 178 4 IO
EStE 460 1.8918 17 179 35712 4 10 12
StE 500 1.8907 17 102 35811 1 9 10
StE 500 1.8907 17 103 35813 9 10 12 13

WStE 500 1.8937 17 103

102 35813
35811 A 1: ;: 13
TStE 500 1.8917 17 102 35811 1 9 10
TStE 500 1.8917 17 103 35813 9 10 12 13
EStE 500 1.8919 17 102 358/l 1 9 10
5.4 10 Ni 14 1.5637 17 280 1 9 10 12 13
10Ni 14 1.5637 17 173 17 174 4 10 12
12 Ni 19 1.5680 17 280 1 10 12 13
12Ni19 1.5680 17 173 17 174 4 10 12
X8Ni9 1.5662 17 280 1 10 12 13
X8Ni9 1.5662 17 173 17 174 4 10 12

3 X5CrNi 18 10 1.4301 17 440 17 441 2 10

X5CrNi 18 10 1.4301 17457 17458 2 10
X5CrNi1812 1.4303 17 440 17 441 2 10
X2CrNi 19 11 1.4306 17 440 17 441 2 10
X2 CrNi 19 11 1.4306 17 457 17 458 2 10
X2CrNiN 1810 1.4311 17 440 17 441 2 10
X2CrNiN1810 1.4311 17 457 17 458 2 10
X6CrNili 1810 1.4541 17 440 17 441 2 10
X6CrNiTi1810 1.4541 17 457 17 458 2 IO
X 6 CrNiNb 18 10 1.4550 17440 17441 2 10
X 6 CrNiNb 18 10 1.4550 17 457 17 458 2 10
X 5 CrNiMo 17 12 2 1.4401 17 440 17 441 2 10
X 5 CrNiMo 17 12 2 1.4401 17 457 17 458 2 10
X 2 CrNiMo 17 13 2 1.4404 17 440 17 441 2 10
X 2 CrNiMo 17 13 2 1.4404 17457 17458 2 10
X 2 CrNiMoN 17 12 2 1.4406 17 440 17 441 2 10
X 6 CrNiMon 17 12 2 1.4571 17440 17441 2 10
X 6 CrNiMolI 12 12 2 1.4571 17 457 17 458 2 10
X 6 CrNiMoNb 17 12 2 1.4580 17 440 17 458 2 10
X 2 CrNiMoN 17 13 3 1.4429 17440 17441 2 10
X 2 CrNiMoN 17 13 3 1.4429 17 457 17 458 2 10
X2CrNiMo18143 1.4435 17440 17441 2 10
X 2 CrNiMo 18 14 3 1.4435 17 457 17 458 2 10
X5CrNiMo17133 1.4436 17440 17441 2 10
X5CrNiMo17133 1.4436 17 457 17 458 2 10
X 2 CrNiMo 18 16 4 1.4438 17440 17441 2 10
X 4 NiCrMoCuNb 20 18 2 1.4505 SEW 400 2 10
X 3 CrNiMoIi 25 25 1.4577 SEW 400 2 10

7 X 2 CrNiMoN 17 13 5 1.4439 17440 17441 405 2 10

X2CrNiMoN17135 1.4439 17 457 17 458 2 10
X 1 NiCrMoCuN 25 20 5 1.4539 SEW 400 421 2
X 8 CrNiNb 16 13 1.4961 104 2
X 8 CrNiMoNb 16 16 1.4981 104 2
X 8 CrNiMoVNb 16 13 1.4988 104 2

6 X 2 CiNiMoSi 19 5 1.4417 385 2

X 2 CrNiMoN 22 5 3 1.4462 SEW 400 418 2
UDC 621.642-98:620.1:614.8 Edition January 1995

Manufacture and AD-Merkblatt

Testing of Design and construction
Pressure Vessels HP 1

The AD-Merkbldtter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
behtilter” (AD). AD-Merkblatt G 1 covers the composition and application of AD-Regulations and a/so procedural guidelines.
The AD-Merkblatter contain safety requirements which must be adopted for normal operating conditions. In the event of loadings exceeding
the normal level expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience. ‘
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e. V. (FDBR), Diisseldorf
Hauptverband d e r gewerblichen B e r u f s g e n o s s e n s c h a f t e n e . V . , S a n k t Augustin
Verband der Chemischen lndustrie e.V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiiftenleute (VDEh), Diisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GrooRkrafiwerksbetreiber e. V., Essen
Verband der Technischen iibetwachungs-Vereine e. V. (VdTiiV), Essen.
T h e AD-Merkbldtter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s t o k e e p w i t h t h e s t a t e - o f - t h e - a r t . R e l e v a n t p r o p o s a l s s h o u l d b e
addressed to fhe publisher
Verband der Technischen iiberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents
1 Scope
2 Design and construction
3 Peaks and valleys
4 Local deviations below the minimum wall thickness
( Appendix 1: Explanatory notes re clause 3

1 Scope the form of circumferential welds in individual cases up to wall

thicknesses of 8 mm if both sides of the lap joint are welded.
This AD-Merkblatt contains provisions for the design and
construction of welded pressure vessels, or parts thereof and 2 . 5 Projection welds are acceptable up to a wall thickness
the associated tests. of 8 mm.
2 . 6 In the case of torispherical ends made of cold-formed
ferritic steel which are not heat-treated as specified by sub-
2 Design and construction clause 2.5 of AD-Merkblatt HP 712, it is not permitted to heat
The welds in a pressure vessel are covered by DIN 8562 - the metal to temperatures between 550 and 750 “C or to
“Welding in the construction of vessels and containers; metal carry out welding in the region of the knuckle.
containers; welding principles”. 2 . 7 In cases where pressure vessels are subjected to vibra-
2.1 Pressure vessel operators or production engineers tions caused, for example, by compressors mounted on
commissioned by them shall ensure that the construction of them, avoid making a direct connection between the source
a pressure vessel also makes it possible for periodic tests to of the vibrations and the wall of the pressure vessel using
be carried out where these are required by the Pressure Ves- feet, pedestals or other rigid connecting parts. If the point
sel Order. of connection has been so designed that stress peaks are
avoided or if suitable measures have been adopted to
2 . 2 At the design and build stages, operators or production dampen the vibration, the use of support plates may be
engineers commissioned by them shall take into considera- dispensed with.
tion attack by corrosion, especially in crevices.
2 . 8 Allowance shall be made for increases in stress due to
2 . 3 If butt welds have to be made on parts of different wall additional forces as specified in subclause 4.5 of AD-Merk-
thickness, the provisions set out in subclauses 2.7 and 2.8 blatt B 0.
of AD-Merkblatt HP 5/l shall be complied with.
2 . 9 Pressure-bearing welds shall be able to be tested at
2 . 4 Lapped joints with fillet welds’) connecting shell ele- least once during fabrication using the appropriate non-
ments, ends and tubes to each other, shall only be made in destructive test. It should be borne in mind at the design
stage that joints made by welding from one side can be diffi-
1) See DIN 1912 part 1, table 1, line 2.3 cult to evaluate.

Supersedes Edition April 1991; 1 = amendments to the previous Edition

Ca rl Heymanns Verlag KG Translation: Technical Help to Exporters Service of BSI

LU.xemburger StraBe 449, 50939 K6ln
GutenbergstraBe 3, 10587 ’ Berlrn
Page 2 AD-Merkblatl HP 1, Edition 1.95
2.10 Where stresses occur due to vibration, refer to the pro-
duction requirements specified in AD-Merkblatter S 1 and
s 2.
2.11 The mean external diameter of cylindrical pressure
vessels, calculated from the circumference dimension, shall
not deviate from the dimensions specified by more than
k1,5%.
2 . tDmax - Dmin)
2.12 Out-of-roundness . 100 expressed
&,a, + Qmn
in % shall not exceed the values shown below:
Table 1 Permitted out-of-roundness
Wall-thickness-to- Maximum permitted
diameter ratio out-of-roundness when exposed to
internal pressure external pressure
s/D 5 0,Ol 2.0 % 1,5 %
0,Ol <s/D 5 0,l 1,5 % 1,5 %
s/D > 0,l I,0 % l,o %
When determining out-of-roundness, deduct the elastic
deformation due to deadweight. Even individual bulges and
dents shall lie within the permitted tolerance levels. It is also
required that such bulges and dents follow a flat course and
that their depth, measured as a deviation from the normal
curvature or from the line of the shell, does not exceed 1 %
of their length or breadth.
2.13 Departure from a straight line shall not exceed 0,5 %
of the cylindrical length.
2.14 The manufacturer shall test compliance with the requi-
rements set out in subclauses 2.11 to 2.13.
2.15 In the case of pressure vessels with an outside dia-
meter > 1200 mm and where s/D wall-thickness-to-diameter
ratios > 0,Ol , in the case of exposure to external pressure
starting with external diameters > 200 mm and regardless
of the wall-thickness-to-diameter ratio, the measured values
shall be entered in a dimension record sheet.
3 Peaks and valleys
3.1 Peaks and valleys h are determined by measuring the
cross-sectional profile in the area of longitudinal welds, by
using suitable test aids at the point of maximum shape devia-
tion or alternatively in the middle of each shell element and
additionally approximately 100 mm from the ends as long as
no points having a marked shape deviation are visible.
The measuring length shall be l/3 D,, however, it need not
generally be longer than 500 mm.
3 . 2 In the case of exposure to internal pressure, for peaks
and valleys h = 10 mm is permitted where D&s,-cc2) < 40
and h = 5 mm is permitted where D&s,-c2) 140 provided
the following conditions do not give any lower values:
- The values according to table 2 apply without detailed
proof; in the case of greater peaks and valleys up to
h = z&--c2 acceptability may be determined by special
verification according to subclause 3.4.
- In the event of exposure to steady internal pressure,
h c: s,-cq is permissible.
Table 2 Permitted peaks and valleys h in the case of expo-
sure to internal pressure
Se-G Permitted h
mm I mm I
s, - c2 < 4 1,5
4ss,-cp<6 2,5
6%s,-cp<9 390
9 c: s, - c2 ‘I3 (s, - c,)
Instead of (sp - c,), (s - c, - cp) can also be inserted in the
above expressions.
3.3 In the case of exposure to external pressure, the follow-
ing shall apply, without detailed proof
h % $. (s, - cz),
in the case of steady exposure to external pressure,
h 2 $. (s, - c,)
3.4 Detailed proof
Departure may be made from the values of subclauses 3.2
and 3.3 if in individual cases detailed knowledge is available
regarding the nature of deviations in shape e.g. by trials with
components, stress analyses, operating experience etc.
3.5 Stress-cycle assessment
Where a stress-cycle assessment subject to the criteria of
AD-Merkblatt S 1 has to be carried out according to AD-
Merkblatt S 2, a theoretical or experimental stress serves as
the basis of assessment. Here the respective size of any
peaks and valleys shall be taken into account, or alternatively
the sizes specified in table 2.
3.6 Avoidance of cracking due to corrosion
Where cracking in the presence of the corrosion types named
in DIN 50 922 (table in explanatory notes) or cracking in
compressed hydrogen at ambient temperature are to be
expected due to reaction with the contents, special measures
shall be taken. To avoid cracking in compressed hydrogen
at ambient temperature, the stress-reducing measures to be
taken during production according to clauses 10 and 11 of
AD-Merkblatt S 2 shall be taken into account. Peaks and val-
leys shall be restricted as far as possible and the permissible
values shall be specified in the drawing. Regardless of the
limits specified in subclauses 3.2 and 3.3, these values shall
be tested in the context of the preliminary testing according
to AD-Merkblatt S 2 clause 13. By derogation from AD-
Merkblatt HP 5/l subclause 2.2, welding measures as in CS
assessment groups do not apply here.
Compliance with these values shall be confirmed by the
construction inspection.
4 Local deviations below the minimum wall
thickness
Subject to the conditions set out below, local deviations
below the minimum wall thickness s are permitted without
the necessity of providing theoretical proof of strength.
(1) The deviation below minimum wall thickness s shall not
exceed 0,05 . s or 5 mm, whichever is the smaller.

(2) It shall be possible to enclose the area affected by the
thickness deviation below the minimum wall thickness in
a circle the maximum diameter of which is equal to s or
to 60 mm, whichever of the two values is the smaller.
(3) The distance between two areas where the wall thick-
ness falls below the minimum wall thickness and the
distance between such an area and potential weak
points e.g. nozzles shall be at least cs. 2)
(4) The sum of all such areas shall not be more than 2 % of
the total surface area.
In addition to the above, local deviations below the minimum
wall thickness s are acceptable if
Page 3 AD-Merkblatt HP 1, Edition 1.95
(1) the diameter of the deviation is not greater than that of
an unreinforced section permitted by AD-Merkblatt B 9.
It shall not, however, exceed 200 mm;
(2) the remaining wall thickness is greater than the plate
thickness C = 0,35 specified by AD-Merkblatt B 5 for the
diameter of the area covered by the deviation below the
minimum wall thickness. Where it extends beyond 3 . s
it shall, however, be greater than 60% of the wall thick-
ness which has been reduced by the amount of the
design allowances.
Deviations below the minimum wall thickness shall be
checked by the manufacturer and entered into the dimension
record sheet.
2) D = outside diameter of pressure vessel
Page 4 AD-Merkblatt HP 1, Edition 1.95
Appendix 1 to AD-Merkblatt HP 1
Explanatory notes re clause 3
Clause 3 covers peak-shaped, longitudinal form deviations
(“peaks”) and flat longitudinal valleys in cylindrical compo-
nents which are subjected to pressure. Circumferential
peaks are rare and therefore do not require general regula-
tion.
1 Determination of peaks and valleys
Peaks and valleys are generally determined by means of
templates. Apart from templates, devices with comb-like fee-
lers for detecting the peaks have proved succesful. First of
all the roundness of the component in the unaffected area
shall be measured.
2 Assessment by internal pressure
Peaks under internal pressure create deformation-depen-
dent bending stresses which increase with the height of the
peak and which are of a secondary nature as they cannot
increase indefinitely in ductile materials and when over-
stressed.
The normal stress and elongation limits contained in the AD-
Merkblaitter shall be taken as the criteria for the acceptability
of such deviations in shape, in particular in this instance for
balancing-out and restriction of plastic elongation. This
means that for elastically-calculated bending stresses for
ductile materials, double the yield point is permissible. Corro-
sion is not directly taken into account initially in such conside-
rations. See clause 4 of these explanatory notes for this.
The calculation of the bending stresses shall be linear and
elastic in accordance with [l] for the specifications of this
AD-Merkblatt. In this way safe assessments may be specified
without detailed calculations being necessary. Where in indi-
vidual cases more precise evaluations should be carried out,
calculations using the 2nd order theory can be made [3-6],
i.e. taking into account the deformation occurring on expo-
sure to pressure and reduction of the bending stresses.
In general peaks are permissible below a third of the wall
thickness as the secondary bending stresses associated with
them meet the 3 S, criterium and therefore remain limited,
see figure 1. The verification according to AD-Merkblatt S 2
of the overall stress calculated elastically as the double yield
point can be carried out using equation (31) and results for
example in 500 permissible stress cycles for StE 500, 2300
permissible stress cycles for 13 CrMO 4 4 and 3350 permis-
sible stress cycles for H II if no other special features are
present and corrosion can be excluded.
In the case of statically-operated pressure vessels, from the
point of view of calculation, a peak height up to three times
the size is regarded as permissible without special measu-
res. See figure 2.
Exceeding the limit of l/3. (s, - c,) is not possible without
detailed proof in line with AD-Merkblatt G 1 subclause 4.2.
Only in the case of thin-walled vessels may use be made
of any rounding-off effect occurring in practice without
calculated proof. Such a rounding-off effect has been in-
corporated into table 2 for wall thickness up to 9 mm. In the
case of wall thicknesses exceeding 9 mm, the limit of
l/3 (s, - c,) shall apply.
In the case of large vessels, the absolute limits of 5 or 10 mm
also apply as normal engineering practice in the production
of these vessels. The limits are in line with TRD 201.
3 External pressure
The bending stresses occurring under external pressure are
not of a secondary nature, by contrast to bending stresses
occurnng as a result of internal pressure. They are therefore
evaluated as primary bending stresses at 1,5 K/S. This
results in numerical values which are half as great as for
exposure to internal pressure.
4 Corrosion
It should be expressly stated that cracking due to the reaction
of steels with the contents as described in DIN 50 922 signifi-
cantly reduces the load-bearing capacity. As well as stress
corrosion cracking, dangerous cracking can occur due to cor-
rosion fatigue, elongation-induced corrosion cracking and
cracking In compressed hydrogen at ambient temperature,
e.g. in the presence of peaks under repeated stress. More-
over it shall be taken Into account that in addition to the mate-
rials which promote cracking and which are present during
normal use, the process-related formation of such materials
has the same effect. In particular in the case of periodic expo-
sure to pressure, as the reaction of ferritic vessels with the
contents combined with increases in stresses as a result of
peaks greatly shortens the serviceable life by accelerating
the growth of cracks, careful load-cycle assessment is
required in such cases.
The shortening of the serviceable life can be effectively com-
batted by grinding the welds of ferriticvessels on the contents
side.
5 Serviceable life
Subclause 3.5 refers in its entirety to AD-Merkblatt S 2 and
also serves as clarification.
6 Creep
In the creep range the reaction of “useable” stress to the
primary stress is greater than below the creep range if the
secondary stresses relax, i.e. become ineffective to some
extent. This applies to peaks as the bending stresses on
exposure to internal pressure are classified as secondary.
In the determination of the permissible limits in accordance
with subclause 3.2, relaxation is not taken into account. In the
creep range the limits according to subclause 3.2 therefore
result in safe assessments. Where special proof is provided,
derogation may be made from this rule.

7 Literature
[l] Schmidt, K.: Zur Spannungsberechnung unrunder
Rohre unter Innendruck. (On the stress calculation of
non-circular pipes subject to internal pressure).
Z VDI 98 (1956) pp 121-125.
[2] S c h m i d t , K . : Beanspruchung unrunder Druckbehalter
(Stresses on non-circular pressure vessels).
Z VDI 102 (1960) pp 11-15.
[3] Pith, R.: Der Zusammenhang zwischen Unrundheit van
Kesseltrommeln und den zugehorigen Biegezusatz-
spannungen (The connection between the out-of-
roundness of boiler drums and the associated additional
bending stresses).
Mitt. VGB (1966), Vol. 103, pp 270-279.
Page 5 AD-Merkblatt HP 1, Edition 1.95
[4] Pith, R.: Betrachtungen iiber die durch den inneren
Uberdruck in dijnnwandigen Hohlzylindern mit un-
rundem Querschnitt hervorgerufenen Biegespannun-
gen. (Considerations regarding the bending stresses
occurring due to internal pressure in thin-walled hollow
cylinders with out-of-round section).
Mitt. VGB (1964), pp 406-415.
[5] Kunz, A.: Formelsammlung, Teil II, Unterlagen fur die
Festigkeitsberechnung von Konstruktionselementen
des Behalter-, Apparate- und Rohrleitungsbaues (For-
mulary, Part II, Data for the strength calculation of
design elements in the construction of vessels, appara-
tus and piping).
VGB, Essen, 2nd edition 1976.
[6] Zeman, Josef L.: Aufdachungen an Langsnahten zylin-
drischer Schusse. (Peaks in longitudinal joints of cylind-
rical part-shells).
Techn. Uberwachung 34 (1993), pp 292-295.
 his, = 1
Not permissible

Permissible with special prOOf - Limit HP 1

- - TRD 201 ior &Is, E 40

e e - - TRD 201 for Dal.% -C 40

h/s, = 5
No
- A D Bl, s u b c l a u s e 6.1
action
required
here. See
1ND-Mbl. B
subclause
6.1
Note:
I -I Stress-cycle considerations
D --
I shall be carried out separately
15
10
5
0
(se - s) W-4

Figure 1. Permissible peaks in the case of exposure to internal pressure

 Not permissible

Permissible without proof Limit HP 1

- - TRD 201 for O,fs, 140

. m - - TRD 201 for Oalse -C 40

AD Bl, subclause 6.1

subclause
6.1

0
(se - 9) [mm1

Figure 2. Permissible peaks in the case of exposure to steady internal pressure

KS: 23.020.30 January 2000 edition

Procedure qualification testing

Manufacture and for joining processes AD-Merkblatt
Testing of
Procedure qualification testing HP 2/l
Pressure Vessels
for welded joints

T h e AD-MerkblBtter a r e c o m p i l e d b y t h e s e v e n a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “ A r b e i t s g e m e i n s c h a f t Druckbehdlter”
(AD). AD-Merkblatt G 1 covers the composition and application of AD-Regulations and also procedural guidelines.
T h e AD-Merkbl3tter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . In t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materiaials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behdlfer- und Rohrleitungsbau e. V. (FDBR), Diisseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e. V., Sankt Augustin
Verband der Chemischen lndustrie e. V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhtittenleute (VDfh), Diisseldorf
VGB Technische Vereinigung der GroBkrafiwerksbetreiber e.V., Essen
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkblstter a r e a m e n d e d c o n t i n u o u s l y b y t h e a b o v e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e. V., P. 0. Box 103834, D-45038 Essen.

Contents

1 Scope
2 Procedure qualification
3 Principles of testing

1 Scope 3.2 Supplementary testing for procedure qualification

tests on steel
This AD-Merkblatt regulates the procedure qualification test
for welded joints as a condition for the manufacturer of 3.2.1 Material groups
welded pressure vessels or welded pressure vessel compo-
In addition to the group classification given in table 3 in
nents.
8.3.1.1 of DIN EN 288 Part 3, the following shall also be
observed:
2 Procedure qualification
(1) Procedure qualification tests shall be adapted to suit
2.1 Manufacturers of welded pressure vessels or compo- materials which have to meet special requirements
nents of pressure vessels shall prove to the authorized regarding corrosion (e.g. caustic crack resistance).
inspector using a procedure qualification test suited to the (2) A procedure qualification test on killed steels in Group 1
manufacturing process that they have mastered the welding is not valid for unkilled steels unless welding was per-
procedure in use. Supplementary testing is necessary if formed using basic-covered electrodes or filler wire/flux
materials, dimensions or welding procedures have changed combinations with basic flux.
beyond the scope of the procedure qualification test.
In addition to table 4 of DIN EN 288 Part 3 the following fur-
2 . 2 The testing shall be performed under the supervision ther material combinations are allowed under the following
of the authorized inspector. The authorized inspector shall conditions.
satisfy himself that the procedure qualification test has been
properly performed and shall state his expert opinion on the (For table, see page 2).
results of the tests. The results of the procedure qualification By way of deviation from table 4 of DIN EN 288 Part 3 an
test shall be available prior the commencement of produc- existing procedure qualification test for mixed joint 9 welded
tion. to 2 does not include mixed joint weld 9 welded to 3.

3 Principles of testing 3.2.2 Welding conditions

3.1 The suitability of the welding procedure shall be deter- Procedure qualification tests for multipass welds are not valid
mined in accordance with 5.1.1 of DIN EN 288 Part1 by for single pass welds.
means of procedure qualification testing, for steel to DIN EN
288 Part 3 and for aluminium and aluminium alloys to DIN EN 3.2.3 Weld positions
288 Part 4. The relevant DIN EN standards apply for other The weld positions which occur during production shall be
materials. verified in the procedure qualification tests.

Supersedes September 1998 edition; j = Amendments to previous edition

Carl Heymanns Verlag KG Translation: Technical Help to Exporters Service of BSI

Luxemburger StraOe 449. 50939 K6ln
Page 2 AD-Merkblatt HP 211 Edition 01.2000
Existing procedure
qualification test for
a steel group or
mixed joint
5 (10 CrMo 910) 4 welded to 5
welded to 4 (13 CrMo 4 4)
4 welded to 1
4 welded t o 2
(R, < 430 N/mm2)
5 5 welded t o 1
5 welded to 2
6 welded to 4 6 welded to 5
6 welded t o 2
6 welded to 1
3.2.4 Welding filler metals
The regulations given in 8.4.5 of DIN EN 288 Part 3 are
waived if the scope of the procedure qualification test is
covered by an assessment of suitability for the type of filler
metal used.
3.2.5 Gas welding
A test undertaken on wall thickness s for wall thickness range
0,75 to 1,25 s applies when gas welding.
3.2.6 Tests
3.2.6.1 Scope of test
By way deviation from 7.1 and table 1 of DIN EN 288 Part 3,
the following specimens shall also be taken from the samp-
les.
(1) Weld metal tensile test specimen of IO mm diameter
where Lo = 5d for samples with a thickness exceeding
20 mm in the case of materials where the welding condi-
tions may have a significant influence on the quality of
the weld. This applies to steels of material groups 2 (high
temperature resistant steels only), 4 and 6. This test shall
also be performed on material group 7 if post-weld heat
treatment is intended.
(2) Where wall thicknesses exceed 5 mm, notch impact test
specimens shall always be taken from the centre of the
weld metal for each weld position.
(3) For material groups 2, 4, 5, 6, 7 and 9 (delta ferrite con-
tent in the weld metal not exceeding 3%) notch impact
test specimens shall also be taken from the weld inter-
face zone for each weld position. For wall thicknesses of
10 mm and above they are taken with the notch position
parallel to the surface, the base of the notch touching the
fusion line (see figure 1).
(4) Microsection for alloy steels (DIN EN 10020). The struc-
tural constitution shall be described and illustrated.
(5) Analysis of weld metal for alloy steels (DIN EN 10020).
i \ / I
Figure 1 Notch position for notch impact test specimens
from the HA2
3.2.6.2 Taking specimens
Specimens are taken in accordance with 3.2.3. The speci-
men position as shown in figures 6, 7, 8 and 9 of 7.2 of DIN
EN 288 Part 3 take precedence over the third sentence of 7.2
of DIN EN 288 Part 3.
3.2.6.3 Test requirements
Table 1 is applicable for destructive tests and AD-Merkblatt
HP 5/3 applies to non-destructive tests.
3.3 Supplements to procedure qualification tests for
aluminium and aluminium alloys
3.3.1 Material groups
(1) By way of deviation from tables 4 and 5 in 8.3.1 .l of DIN
I EN 288-4 a procedure qualification test on AIMg4,5Mn
covers all the materials of groups 22.1 and 22.2. If proce-
dure qualification tests are performed on other materials
in this group, these tests are only valid for the material
in question.
(2) Procedure qualification tests performed on materials of
group 23 are only valid for the welded material.
(3) A procedure qualification test on a different material in
group 22.1 or 22.2 with a material in group 21 covers all
welded joints of this material of group 22.1 with any mate-
rial of group 21.
(4) Procedure qualification tests for welded joints between
materials of groups 23 and 21 are valid for material com-
binations of both groups.
3.3.2 Weld conditions
Procedure qualification tests for multipass welds are not valid
for single-pass welds.
3.3.3 Weld position
The weld positions occurring in production shall be verified
in the procedure qualification test.
3.3.4 Tests
3.3.4.1 Scope of test
By way of deviation from 7.1 and table 1 and 7.2 and figures
5 and 6 of DIN EN 288-4 the following specimens shall also
be taken from the samples:
(1) Notch impact test specimens for wall thickness exceed-
ing 5 mm for material groups 22.1 and 22.2 from the cen-
tre of the weld metal. If a procedure qualification test is
performed on specific objects for pressure vessels not
subject to shock stresses, the notch impact bending test
can be dispensed with for groups 22.1 and 22.2.
(2) Microsection for all groups of materials. The structural
constitution shall be described and illustrated.
(3) The weld metal analysis may be omitted if particulars of
the filler wire analysis are available.
3.3.4.2 Taking specimens
The specimens shall be taken in accordance with 3.3.3. The
position of the specimens in accordance with figures 56, 7
and 8 in 7.2 of DIN EN 288 Part 4 takes precedence over the
third sentence of 7.2 of DIN EN 288 Part 4.
3.3.4.3 Test requirements
Table 2 applies for the destructive tests. If for aluminium
alloys of Groups 22a and 22b with thicknesses exceeding

20 mm the minimum value of the tensile strength for the
parent metal is not achieved in the tensile test transverse to
the direction of the weld, an additional tensile test shall be
performed on a weld-metal specimen 10 mm in diameter
where Lo = 5d during which the 0,2% proof stress, tensile
stress and elongation at failure shall be determined.
AD-Merkblatt HP .5/3 applies for non-destructive testing.
3.4 Storage of specimens
The specimens subjected to testing and the remaining sec-
tions of the samples shall be stored until the report on the pro-
cedure qualification test has been completed.
3.5 Working temperatures
3.5.1 Procedure qualification tests are valid from -10 “C
up to the applicable upper operating temperature for the base
metal or the filler metal.
3.5.2 Where the temperature of the charge is less than
- 10 “C, procedure qualification testing in stress category I
is valid down to the lowest test temperature at which the
requirements regarding impact strength were met, but not
lower than the lowest permissible operating temperature for
the base metal or filler metal. If procedure qualification testing
was performed at the lowest operating temperature as speci-
fied in column 4 of table 1 in AD-Merkblatt W 10, it is also valid
for the lowest temperatures in stress categories II and Ill.
3.5.3 If testing is performed at a temperature higher than
that specified in column 4 of table 1 in AD-Merkblatt W 10,
the same temperature differences as for the base metals
apply if the procedure qualification test is utilised for stress
categories II and Ill.
3.6 Heat treatment condition
The procedure qualification test is valid for the heat treatment
condition prevailing at the time when testing is performed.
Heat treatment of the test piece shall be performed in such
a manner that the heat treatment condition achieved is com-
parable to that achieved for the component itself.
j made of materials of material groups 1 and 6 as specified in
3.7 Aggravating conditions
Aggravating conditions shall be taken into account. They are
present if space is limited and welding is carried out in a
difficult situation and, in some cases, on construction sites.
Procedure qualification tests shall be formulated to make
allowances for these conditions.
P a g e 3 AD-Merkblatt HP 211, Edition 01.2000
3.8 Special cases
Should there be a need for procedure qualification tests
which are designed to cater for special cases, e.g. projection
welds, welding of clad steels, studding and difficult weld
repairs during production involving steels sensitive to weld-
ing, then in the case of pressure vessels which are to be sub-
jected to a structural test by the authorized inspector, the lat-
ter shall be consulted to determine its scope. In the case of
other pressure vessels, the manufacturer shall make the
appropriate stipulations.
3.9 Welding pipes/tubes into plates
A procedure qualification test shall be performed based on
VdTijV-Merkblatt 1158 for mechanically stressed welded
joints used to join pipes in plates.
3.10 Supplementary testing and repetition of proce-
dure qualification testing
3.10.1 Should the specified conditions be altered to any
appreciable extent, a supplementary test is required. The
supplementary test can be performed as a production test.
3 . 1 0 . 2 In the event of the production of pressure vessels or
pressure vessel components being discontinued for a period
in excess of one year, procedure qualification testing shall be
repeated.
3.11 Qualification testing of welders
Satisfactory completed procedure qualification tests are
recognised as repeat tests taken by the welders concerned
only within the scope of the welding workcarried out by them.
3.12 Welding-in of nozzles
Procedure qualification tests for butt welds on sheet or pipe
table 1 of AD-Merkblatt HP 0 are also valid for the welding
of set-in or set-on nozzles with fillet weld connection if the
other conditions are satisfied.
If a minimum penetration results from the calculation, this
shall be verified in a procedure qualification test. This test
covers all welds with less penetration.
Page 4 AD-Merkblatl HP 2/l, Edition 01.2000

Table 1. Test requirements for welded joints in steel

Type of test Requirements

Tensile test at right angles to the weld Tensile strength as stipulated for the base metal or in the assessment of suitability for the filler
metal

Tensile test on a weld-metal Y i e l d p o i n t o r 0,2 % p r o o f s t r e s s , t e n s i l e s t r e n g t h a n d e l o n g a t i o n a t f a i l u r e a s s t i p u l a t e d f o r t h e

specimen base metal or in the assessment of suitability for the filler metal

I m p a c t test’)z) o n m a t e r i a l f r o m Where charge As stipulated for the base metal for transverse direction.
middle of weld metal on V-notch temperatures are Test temperature same as for testing the base metal but not
specimen to DIN EN 10045 - 1 0 “C o r h i g h e r : lower than -10 “C. Where ferritic-austenitic, austenitic and
Part 1 nickel basic-alloy filler metals are used 2 4 0 J

Where charge At lowest working temperature

temperatures are Where ferritic filler metals are used 2 27 J3)
below -10 “C: where ferritic-austenitic, austenitic and nickel basic-alloy filler
metals are used 2 32 J3)

I m p a c t test’)z) o n m a t e r i a l c u t f r o m Where charge 2 2 7 J3) +‘). T e s t t e m p e r a t u r e s a m e a s f o r t e s t i n g t h e b a s e m e t a l ,

the vicinity of the weld interface zone temperatures are but not lower than -10 “C.
on V-notch specimen - 1 0 “C a n d a b o v e :

Where charge ~16 J3) at lowest working temperature.

temperatures are
below - 10 “C:

Technological bend test Bending S t r e n g t h categorys) Bending

angle mandrel
diameter

1806) Ferritic steels with

minimum tensile strength < 4 3 0 N/mm2 2.a
minimum tensile strength 2 430 to < 460 N/mm* 2,5 a

1806) Stainless and austenitic steels with high impact strength

at low temperature 2.a
High-temperature austenitic steels 3.a
F e r r i t i c s t e e l s w i t h m i n i m u m t e n s i l e s t r e n g t h 2 4 6 0 N/mm2 3.a

If a bending angle of 180” is not attained, the following applies:

2 90 E l o n g a t i o n (L, = w i d t h o f w e l d + w a l l t h i c k n e s s , s y m m e t r i c a l r e l a t i v e t o w e l d )
z minimum elongation at failure A of base metal
or
< 90 E l o n g a t i o n o v e r w i d t h o f w e l d > 3 0 % ‘) a n d f r a c t u r e f r e e f r o m a n y e v i d e n c e
of defects

Assessment of The macrosection of the welded joint shall provide evidence of satisfactory weld buildup and full
macro/microsection penetration welding.
Microsections shall be examined for presence of microcracks. Only hot cracking is permissible
to the extent that they ate rated as isolated hot cracks in terms of numbers and location and the
authorized inspector agrees that they are permissible given the material and application area.

Hardness test In the heat-affected zones, the hardness shall not exceed 350 HV IO.
Higher peak hardness values in narrow transition zones are acceptable if the results of the
technological tests meet the requirements.

‘) For spec~rnens which do not correspond to the standardised 10 mm width, the requirements regarding impact strength reduce in proportion to the Cross-SeCtiona
area of the specimen.
2) If no requirements are stipulated regarding V-notch specimens for the base material the test shall be performed on DVM test specimens.
‘) Only one individual value shall fall below the minimum mean value, but by no more than 30%.
‘) In the case of welding joints on X 20 CrMoV 12 1, a value of up to 10 % less is permitted.
‘) The relevant thickness where the tensile strength is concerned is the smallest thickness range.
‘) A bending angle of 180” shall be deemed to have been attained if the bending test met the requirements in DIN 50121 and the specimen was forced through tha
supports without the appearance of any surface cracks.
‘) In the case of welded steels of different properties (e.g. X 8 Ni 9). other values may be agreed in consultation with the authorized inspector.
 Page 5 A D - M e r k b l a t t H P 2/i, Edition 01.2000

Table 2. Test requirements for welded joints in aluminium and aluminium alloys

Type of test Requirements

Tensile test at right angles to the weld Tensile strength as stipulated for base metal or in the assessment of suitability for the fi
metal

Tensile test on a weld-metal 0,2% p r o o f s t r e s s , t e n s i l e s t r e n g t h a n d e l o n g a t i o n a t f a i l u r e s a m e a s s t i p u l a t e d f o r b a s e mt

specimen or in assessment of suitability for the filler metal

Impact test’) on material cut from At room temperature: 2 16 J, no single value below 12 J
middle of weld metal (mean value
from three V-notch specimens) Where charge 2 14 J, no single value below 12 J
temperatures are
below -50 “C:

Technological bend test Bending Material and material condition Bending

angle mandrel
forsS15mm diameter
to 5.2.1 of DIN 50121 Part 1;
180 A199.98 R W4 and F4 2-a
fors>15mm
to 5.2.3 of DIN 50121 Part 1 A199.8 W6 and F6
Al99,7 W6 and F6
Al99.5 W7, F7, F8
AlMn W9. WIO, FIO

180 AlMnCu WlO 4.a

AIMg3 Wl8. W19. F18
AIMg2Mn0.8 W18. Wl9. F18. F19, F20
AIMg4.5Mn W27. W28. F27
I
I f a b e n d i n g a n g l e o f 180” i s n o t attamed. t h e f o l l o w i n g a p p l i e s :
2 90 Elongation (L, = width of weld + wall thickness symmetrical relative to WI
2 minimum elongatron at failure A of base metal
or
< 90 E l o n g a t i o n a c r o s s w i d t h o f w e l d 3> 2 0 % a n d f r a c t u r e f r e e f r o m a n y e v i d e
of defects.

Assessment of T h e m a c r o s e c t i o n o f t h e w e l d i n g joint s h a l l provide e v i d e n c e o f s a t i s f a c t o r y b u i l d u p a n d f u l l pe

macroimicrosection tration welding. Microsections shall be examined for presence of microcracks. Cracks are not
permissible.

1) Only for alumimum alloys I” material group Al 2 as specified in AD-Merkblatt HP 0. Table 2. If a procedure quallficatlon IS performed on specific objects for pressure
vessels not subjected to shock stresses, the notch impact test may be omitted.
L
ICS: 23.020.30 Edition April 1996

Manufacturing and AD-Merkblatt

Testing of Welding supervisors, welders
Pressure Vessels HP 3

The AD-Merkblstter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
beh2lter” (AD). AD-Merkblatt G 7 covers fhe composition and application of the AD-Regulations and also the procedural rules.
The AD-Merkb/&‘ter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
and above the normal /eve/ being anticipated during the operahon of pressure vessels, allowance must be made for such stresses by
meeting special requirements.
Should there be any departures from the provisions of this AD-Merkblat?, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis,
operating experience.
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e.V. (FDBR), Dijsseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e. V., Sankt Augustin
Verband der Chemischen lndustrie e. V. (VU), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), D&se/doff
VGB Technische Vereinigung der GroBkraftwerksbetreiber e.V., fssen
Verband der Technischen iiberwachungs-Verelne e.V. (VdTiiV), Essen.
T h e AD-Merkbltitter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e associat!ons in keeping with technical progress. Relevant proposals should
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e.V., Postfach 103834, D-45038 Essen.

Contents

1 Scope 3 Welders
2 Welding supervisors 1

1 Scope 2.2 Grades of welding supervisors

This AD-Merkblatt deals with the requirements for super-
vision in welding and the qualification test to be passed by
welders as conditions which have to be met in the manufac-
ture of welded pressure vessels or pressure vessels com-
ponents.
2 Welding supervisors
2.1 General requirements
2.1 .l Manufacturers shall employ their own welding super-
visors. In the case of pressure vessels which are to be sub-
jetted to a construction inspection by the authorized inspec-
tor, the manufacturer shall make the name of the supervisor
known to the authorized inspector.
2.1.2 The welding supervisor shall have all the necessary
,qualifications in both technical and personal terms to deal
with the matters within his range of responsibility. Above ail,
he shall have practical experience in the field of welding engi-
neering which applies to the manufacture of vessels at the
works concerned.
2.1.3 The welding supervisor’s tasks and responsibilities
are given in DIN EN 719. The welding supervisor shall ensure
that the relevant provisions in the HP series of AD-Merkblat-
ter are adhered to.
2.1.4 If a manufacturer designates several welding super-
visors, their individual spheres of responsibility shall be
clearly defined.
Welding supervisors shall be persons who, by virtue of their
training, experience and ability, are considered suitable for
( the job after an adequate training period. As regards qualifi-
cation, the following distinctions are made:
2.2.1 Welding engineers with comprehensive technical
knowledge in accordance with DIN EN 719 Clause 5.22 can
be employed without any limitation on their range of duties.
2.2.2 Welding technicians with special technical know-
ledge in accordance with DIN EN 719 Clause 5.2.3 can be
employed with limitations as supervisors of the welding of
certain materials.
2 . 2 . 3 Welding specialists with basic technical knowledge in
accordance with DIN EN 719 Clause 5.2.4 can be employed
ad supervisors in the welding of components which are easy
to fabricate and do not require heat treatment.
2 . 2 . 4 Other personnel suitable for welding supervisors, but
not possessing proof of suitable qualification may, for those
particular areas of work in which they have achieved expe-
rience, be employed as appropriate in the same way as the
persons named in Clauses 2.2.1 to 2.2.3.
3 Welders
3.1 Qualification test principles
3.1.1 Qualification tests for welders are based on DIN EN
287 Part 1 in the case of steel and DIN EN 287 Part 2 in the
case of aluminium and aluminium alloys. For copper and
nickel including their alloys, qualification tests are based on

Supersedes Edition November 1992; 1= Amendments to previous Edition

Carl Heymanns veriag KG I ranslatron: I ecnnrcal Help I0 kxponers Servrce 01 031

Luxemburger StraDe 449.50939 K&
 Page 2 AD-Merkblatt HP 3 Edition 04. 96
DIN 8561. Other materials shall be similarly classified under
these standards in a manner appropriate to their properties.
A test of welders’ job knowledge in accordance with DIN EN
287 Part 1 Annex D, and/or DIN EN 287 Part 2 Annex C is
necessary.
3.1.2 Other test conditions
3.1.2.1 In addition to DIN EN 287 Part 1 Clause 7.5 the fol-
lowing separate tests are necessary for the various groups
of materials:
(1) Group W 02 - high-temperature steel X 20 CrMoV 12 1
The notch impact strength of the tube with a minimum
wall thickness of 7 mm, welded at weld position PF (pre-
I ferably from weld positions (PF) and (PE), on three speci-
mens from the centre of the weld, notch vertical to the
surface, DVM type specimen). This test is waived in the
case of repeat tests.
(2) Group W 03 - nickel steels with high impact strength at
low temperature where the base metal and weld metal
are of the same type, e.g. 10 Ni 14, 14 Ni 6, 12 Ni 19 or
nickel steels with high impact strength at low temperature
containing 4% Ni e.g. X 8 Ni 9 welded with high-alloy filler
metals
For test specimens where the base metal and weld metal
are the same, the notch impact test (three specimens
from the centre of the weld for each weld position, with
the notch position vertical to the surface, V-notch speci-
men) at the lowest application temperature of the steel
used in the test. If the base metal and weld metal are not
the same for the test specimen, the tensile strength shall
be determined.
(3) Group W 03 - fine-grained structural steels hardened
and tempered with a minimum yield point exceeding
520 N/mm2
The tensile strength shall be determined on test speci-
mens transverse to the weld and the hardness pattern
shall be determined (HV 10 on the transverse section).
The tensile test and impact test shall be performed in
accordance with the requirements as stated in AD-Merkblatt
HP 2/l Table 1.
3 . 1 . 2 . 2 The base metal can be used within the scope speci-
fied in DIN EN 287 Part 1 Table 4, with the following excepti-
ons:
(1) A test of materials of Group W 03 does not include Group
w 02.
(2) A test of materials of Group W 02 includes Group W 03,
provided special tests in accordance with Clause 3.1.2.1
are not required.
(3) A test of materials of Group W 04 does not include
Groups W 01 and W 02.
(4) A test of materials of Group W 11 includes none of the
other groups.
3.1.2.3 The scope specified in DIN EN 287 Part 1 Table 6
for the type of stick electrode sheath can be used, with the
following exceptions:
A qualification test of welders where a root was welded at one
side with a Type B stick electrode, does not include root
welds having the same parent and weld metal and made
using Types A, AR, 0, R, RR or RR (B) stick electrodes.
For welding procedures 135 (MAGM welding) and 136 (MAG
welding with cored wire electrode) where the test specimens
were welded using Group C protective gas, no new test is
necessary when changing over to gas mixtures. The same
applies when changing from one gas mixture to the other. For
cored wires the specifications for stick electrodes apply as
I
appropriate depending on the filling. For Group W 11, wel-
ding procedures 131 (MIG welding) and 135 cover one an-
other in each case provided the wire-gas combination has
been checked for suitability.
3.1.2.4 By way of deviation from DIN EN 287 Part 1
Clause 7.4 Table 8:
- X-ray tests and ultimate breaking point tests are necessary
for qualification testing of welders using procedures 131,
135 and 311 (gas welding);
- microsections (one section for each weld position) shall be
prepared and tested when using filler metals with less than
3 % delta ferrite constituents.
3.2 Training
The training of welders shall take place at centres where wel-
ders are trained systematically and where all the necessary
conditions are met to ensure that the welders are trained
according to the requirements for qualification tests.
3.3 Initial qualification testing of welders
3.3.1 These tests can be performed by:
3.3.1 .l the authorized inspector;
3.3.1.2 after agreement with the authorized inspector by
(1) the welding supervisor trained as stated in Clause 2.2.1
at the manufacturer’s works;
(2) Welding training and research establishments (SLV) and
welding training establishments (SL) of the German
Association of Welding Technology (DVS);
(3) Welding training establishments of the Deutsche Bahn
AG.
All tests shall be carried out subject to the welders having
undergone training as stated in Clause 3.2 and to the avai-
lability of suitable equipment and of personnel qualified to
train welders and conduct tests.
The test results shall be recorded in writing and kept available
for inspection. The test certificate shall contain the words
“The qualification test was conducted in agreement with the
authorized inspector of . (name of the Technical Super-
visory Body concerned)“. The authorized inspector shall
make periodic checks to ensure that the qualification tests
are carried out in the correct manner.
3.3.2 Operators of mechanized welding stations are
required to do test welds at the manufacturer’s works in
accordance with the procedure qualification or in agreement
with the authorized inspector.
3.4 Repeat tests
3.4.1 Repeat tests are conducted by the persons men-
tioned in Clause 3.3.
3.4.2 Training as stated in Clause 3.2 is not required in the
case of repeat tests.
3.4.3 A repeat test shall be taken at intervals of two years
or if a welder has had a break in his work of more than 6
months.
3.4.4 Satisfactorily completed procedure qualification and
production tests are recognised as repeat tests taken by the
welders concerned only within the scope of the welding work
carried out by them.
3.4.5 During continuous production, the results obtained
for non-destructive tests on specific test objects as part of the
construction inspection shall be regarded as repeat tests.
This does not include tests in accordance with procedures
131, 135 and 311.
3.5 Test certificates
Test certificates shall be kept at the welder’s place of work.
I rnc en1 7%o5:621.791.053:621.642-98 Edition July 1989

Manufacture and AD-Merkblatt

Test supervisors and testers
Testing of
in non-destructive testing HP4
Pressure Vessels

Be ADMerkbl2tter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
teh#ter” (AD). AD-Merkblatt G 1 covers the composition and application of the AD-Regulations and also the procedural rules.
-he AD-Merkbl%er cover safety requirements which must be adopted for normal conditions of operation. In the ever2 stresses over
Ind above the normal /eve/ being anticipated during the operation of pressure vessels, allowance must be made for such stresses by
neeting special requirements.
;hou/d there be any departures from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by means of alternatlve approaches, e . g . t e s t i n g o f m a t e r i a l s , t e s t s , s t r e s s a n a l y s i s ,
jperatrng experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e.V. (FDBR), Dijsseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.K, Sankt Augustin
Verband der Chemischen lndustrie e.V. (VU), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemernschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Vereln Deutscher Eisenhtittenleute (VDfh), Dtisseldorf
VGE Jechnische Vereinigung der Grookraftwerksbetreiber e.V., Lessen
Vereimgung der Jechnischen iiberwachungs-Vereine e.V (VdJiiV), Essen.
he AD-Merkblatter are amended conbnuously by the trade assoc/atlons in keeping with technical progress. Relevant propOSals should
re a d d r e s s e d t o t h e p u b l i s h e r :
Vereinigong der Technischen iiberwachungs-Vereine e. V., Postfach 703834, D-4300 Essen 1.

Contents

1 Scope
2 General principles
3 Test supervisors
4 Testers

I Scope
This AD-Merkblatt deals with the requirements for test super-
Jisors and testers in non-destructive testing of welds on pres-
sure vessels or pressure vessel components.
2 General principles
2.1 As a rule, the non-destructive tests stipulated in AD-
Merkblatt HP 513 shall be performed by the manufacturer.
The test supervisors and testers will normally be employees
it the manufacturer’s works. The manufacturer may use out-
;ide testers who satisfy the requirements in Section 4 in order
o perform non-destructive tests.
!.2 In some cases, the authorised inspector may be in
:harge of test supervision and testing or, in the case of pres-
sure vessels where the authorised inspector is to perform the
:onstruction inspection, he may consent to having another
)erson or persons entrusted with the task of test supervision.
3 Test supervisors
3.1 Test supervisors shall have the necessary knowledge
3nd basic experience in welding techniques. They shall be
‘ully conversant with the testing procedure according to the
*equirements laid down in AD-Merkblatt HP 513. They shall
also make sure that the testers have the necessary training
and that the test equipment is in good condition.
3 . 2 The test supervisor shall be independent from produc,
tion departments and the manufacturer shall make the name
of the test supervisor known to the authorised inspector ir
the case of pressure vessels which are to be subjected tc
a construction inspection by the authorised inspector.
3 . 3 The test supervisor shall give instructions on the testing
procedure to be adopted and how the tests are to be con
ducted in detail, as laid down in AD-Merkblatt HP 513. He ma!
do this after consulting the purchaser and he shall also allo-
cate work to the testers.
3 . 4 The test supervisor shall sign the test report to be pre-
pared as stated in AD-Merkblatt HP 513.
4 Testers
Testers shall have adequate basic knowledge and arc
expected to be fully conversant with the testing procedures
according to the requirements laid down in AD-Merkblat
HP 513. The welding supervisor shall be supplied with evi,
dence of these facts. Adequate basic knowledge can be as,
sumed if a welder has been trained in accordance witt
DGZfP training guidelines for example.

Supersedes Edition April 1975; completely revised

-Translation:
Carl Heymanns Verlag KG I echnlcal Help to txponers 3erwce UT c W
Luxemburger StraBe 449,50939 K6ln
GutenbergstraBe 3, 10587 Berlin
ICS 23.n20.30
.-- --_---.-- Januarv !NlfMl
. , -“-”
wiitinn
--...-..

Manufacture and Manufacture and testing of joints AD-Merkblatt

Testing of
Pressure Vessels Principles of welding practice HP 5/l

The AD-Merkblatter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
behalter” (AD). AD-Merkblatt G 1 covers the composition and application of AD-Regulations and a/so procedural guidelines.
T h e AD-MerkbWer c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . I n t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal level expected during the operation of pressure vessels, allowance shalt be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e,g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e. V. (FDBR), Dusseldorf
Hauptverband der gewerblichen Berufsgenossenschahen e. V., Sank7 Augustin
Verband der Chemischen lndustrie e. V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Vetfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhijttenleute (VDEh), Dusseldorf
VGB Technische Vereinigung der GroBkraftwerksbetreiber e. K, Essen
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkbldtter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iibetwachongs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents

1 Scope 3 Principles of technique for brazed,

2 Principles of technique for bonded and other joints
welded joints

1 Scope No. 16 Excessive root reinforcement,

This AD-Merkblatt deals with the principles of technique for No. 18 Misalignment h in double-sided circumferential
joining pressure vessels or pressure vessel components welds, Figure B,
made of steel as well as aluminium and aluminium alloys by j No. 19 Incompletely filled groove2),
brazing, soldering, bonding and other methods of joining. No. 20 Excessively unequal leg length in case of fillet
It applies as appropriate to pressure vessels and pressure welds,
vessel components made of other non-ferrous metals. No. 21 Root concavity (local),
and as specified in DIN EN 30042 for the following dis-
continuities:
2 Principles of technique for welded joints No. 7 Surface voids,
2.1 For pressure vessels that are subject to a structural test No. 15 Excessive reinforcement of weld,
by the authorized inspector, welds shall be executed in No. 19 Excessive root reinforcement.
compliance with the previously examined drawings and the
relevant documents as well as with the stipulations for the The provisions in AD-Merkblati HP 5/3 apply to the internal
procedure qualification test. For other pressure vessels, appraisal.
welds shall be executed according to the manufacturer’s
relevant documents. 2.3 The following applies to arc strikes and spatter (in
accordance with DIN EN 25817):
2 . 2 Butt welds and fillet welds as joint welds in pressurised No. 24 Arc strikes are not permissible away from the weld-
components shall be executed so that from their external ing groove.
assessment they correspond to quality level B as specified
in DIN EN 25817 (steel) and DIN EN 30042 (aluminium). As
a deviation from this, quality level C as specified in DIN EN 2) In TIG orbital welding with no filler metal, the following dimensions of incompletely
25817 is adequate for the following discontinuities: filled groove/excess penetration in the 12 o’clock position and root concaVitY/tOp
reinforcement I” the 6 o’clock position are permitted in the PF, PG welding posi-
No. 11 Undercut’), tions:
No. 13 Excessive reinforcement of weld (fillet welds), h s 0 . 2 t + 0,12b , m a x 0 , 6 m m
where
t = is the wall thickness
b = IS the width of the weld
‘) Not permissible if uninterrupted. This also applies to fillet welds. h = is the incompletely filled groove/top remforcement

Supersedes July 1995 edition; 1 = Amendments to previous edition

CArI Heymanns Verlag KG Translation: Technical Help to Exporters Service of BSI

Luxemburger StraBe 449, 50939 K6ln
P a g e 2 AD-Merkblatt HP 5/l, Edition 01.2000

No.25 Adhering spatter that has solidified and the areas
heat affected by this are to be removed both on the
weld and on the base metal if adverse effects on the
material or malfunctions can be expected.
No.26 Multiple discontinuities in the cross section are not
used in this Merkblatt (equivalent to No. 24 as spe-
cified in DIN EN 30042).
2.4 The welding points shall be protected against the in-
fluence of weather such as rain and wind. The necessary
measures shall be taken if welding or cutting jobs are carried
out at ambient temperatures below +5 “C.
2 . 5 If undercuts can only be removed by hard surfacing, the
appropriate rules of welding practice shall be observed. The
same applies to other repair welds.
2 . 6 Each weld shall be marked so that its position and the
welder concerned can be identified at any time. To comply
with this condition, both can be entered on the drawings or
on the welding plans. Special arrangements can be made in
case of pressure vessels manufactured in series.
2 . 7 Weld-on parts, including those that are removed later,
shall be welded on according to the rules of welding practice
which apply to the pressure vessel material, i.e. in two passes
if necessary, without significant intermediate cooling. As a
rule, welding-on shall be performed prior to heat treatment.
Welding work after the final heat treatment is only permissible
if the purchaser has given his consent; for pressure vessels
that are subject to a structural test inspection by the autho-
rized inspector, the consent of the authorized inspector is
also required.
Longitudinal welds
hi 5 0,15. t,; 3 mm max.
hz 5 0,3 . t,; 6 mm max.
t,-t, 5 0,3 . t,; 6 mm max.
2 . 8 The requirements in figure 1 apply to misalignment with
unequal wall thicknesses in the case of double-sided welds.
The requirements in figure 2 apply to unequal wall thicknes-
ses in the case of single-sided welds. If the requirements in
figure 1 or 2 are exceeded, the thicker wall shall be tapered
at not more than 30 degrees towards the thinner wall.
Longitudinal and circumferential welds
h, 5 0,l . t,; 2 mm max.
Figure 2. Permissible misalignment on the root side for
single-sided welds
2 . 9 For clad plate, depending on the type and thickness of
the cladding, smaller variations may be necessary.
2.10 The instructions given in the regulations, e.g. stan-
dards, material specification sheets (Werkstoffblatter) and
specifications, shall be observed when processing materials.
“Stahl-Eisen-Werkstoffblatt 088” (Steel/Iron Material Speci-
fication Sheet) applies to fine-grained structural steels.
3 Principles of technique for brazed, bonded
and other joints
3.1 Until this AD-Merkblatt is expanded to include the
above methods, the principles of technique for brazed,
bonded and other joints in pressure vessels which are sub-
ject to a structural test by the authorized inspector shall be
agreed between the manufacturer, user and authorized
inspector.
3 . 2 For pressure vessels which are not to be subjected to
a structural test by the authorized inspector, stipulations may
be made by the manufacturer - in agreement with the pur-
chaser, if necessary.

Circumferential welds
h 5 0,2 .t,; 5mmmax.
hz 5 0,4 . t,; 10 mm max.
t2-t, 5 0,4 . t,; 10 mm max.

Figure 1. Permissible misalignment with unequal wall

thicknesses for double-sided welds
UDC 621.791.053:621.642-98:620.1 Edition Julv 1989

Manufacture and Manufacture and testing of joints AD-Merkblatt

Testing of Production testing of welds, Testing of
Pressure Vessels base metal after postweid heat treatment HP 5/2

%e AD-MerkblBtter are compiled b y t h e s e v e n t r a d e a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e

“Arbeitsgemeinschaft Druck-
jehdlter” (AD). AD-Merkblatt G 7 covers the composition and application of the AD-Regulations and also the procedural rules.
he AD-Merkblatter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
Ind a b o v e t h e n o r m a l l e v e l b e i n g a n t i c i p a t e d d u r i n g t h e o p e r a t i o n o f p r e s s u r e vessels, allowance m u s t b e m a d e f o r s u c h s t r e s s e s b y
neeting special requirements.
;hould there be any departures from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis,
operating experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e. V (FDBR), Diisseldorf
H a u p t v e r b a n d d e r g e w e r b l i c h e n Berufsgenossenschafien e . V . , S a n k t Augustin
Verband der Chemischen lndustrie e. V. (VCI), Frankfurt/Main
Verband D e u t s c h e r M a s c h i n e n - und Anlagenbau e . V. ( V D M A ) , F a c h g e m e i n s c h a f t V e r f a h r e n s t e c h n i s c h e Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhijttenleute (VDEh), Diisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkraftwerksbetreiber e.V., E s s e n
V e r e i n i g u n g d e r T e c h n i s c h e n iiberwachungs-Vereine e . V . (VdTiiV), Essen.
h e AD-Merkbldtter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
te addressed to the publisher:
Vereinigung der Technischen iibenvachongs-Vereine e. V., Postfach 103834, D-45038 Essen.

Contents

1 scope 5 Number of test pieces with welded ends

2 Type of test pieces 6 Selecting and dimensioning the test
pieces
3 Number of test pieces with
longitudinal seams 7 Testing the welded joints
4 Number of test pieces with 8 Welded joint requirements
circumferential seams (test pieces 9 Testing of the base material following
welded separately) post-weld heat treatment

I Scope plates and rings required according to Section 4 shall be

welded separately.
rhis AD-Merkblatt covers the testing of the quality charac-
eristics of welded seams. This AD-Merkblatt covers the test-
ng of the quality characteristics of welded joints and the test- 3 Number of test pieces with longitudinal
ng of the base materials following post-weld treatment in the seams
:ase of pressure vessels and pressure vessel components
,productions tests) made of steel or aluminium alloys. In the The number of test pieces depends on the materials used,
:ase of other non-ferrous metals, the following regulations the number of cylindrical parts and the design stress Ieve,
should be applied as appropriate. of the welded joint which may be 85% or 100% of the design
stress (K/S) in accordance with Tables I,2 or 3. The followin
test pieces are required:

2 Type of test pieces 3.1 Design stress levels equal to 100% of the permis-
sible design stress
In the case of pressure vessels or parts thereof with longitud-
inal seams’) or of longitudinal and circumferential seamsfab- 3.1 .l Materials of Groups 1, 4.1, 5.1, 6, 7 and Al 1
ricated by the same welding method, the test pieces required One test piece per vessel, irrespective of the number of casts
under Section 3 shall be welded in elongation of the longitud- and two test pieces if there are more than five cylindrical part:
‘nal seam. If only circumferential welds are made, or if cir- per vessel.
:umferential seams are welded by other methods, the test In the case of heat-treated pressure vessels there shall be
one test piece per heat treatment batch. In the case of X 10
CrMo 9 1 steel from Material Group 4.1, Section 3.1.2
1) Longitudinally welded nozzles are treated as cylindrical parts. applies. In the case of shells (cylindrical parts, heads, sec-

Supersedes Edition May 1982; completely revised

-I rawlawn:
,.. IY--L-:__,
ecnnrcar nelp I,^, -
to txponers - * or U31
servrce --a
Carl Heymanns Verlag KG
Luxemburger StraRe 449, 50939 Kdln
GutenbergstraOe 3, 10587 Berlin
P a g e 2 AD-Merkblatl HP 5/2, EditIon 07.89
tions) made of different materials, all the materials used shall
be included. Two grades of material may be included in one
test piece.
3.1.2 Materials of Groups2,3,4.2,5.2,5.3,5.4,8 and Al 2
One test piece per cast and vessel and two test pieces in the
case of pressure vessels with more than five cylindrical parts
of the same cast. Two casts may be included on one test
piece.
Section 3.1 .l applies in the case of Group 2 and 5.2 materials
requiring no heat treatment, Groups 3 and 5.3 where wall
thicknesses are under 20 mm or according to the wall thick-
ness limit and for which the assessment of suitability permits
the waiving of heat-treatment, and Group 5.4 if no heat-treat-
ment has been carried out.
3.1.3 Relaxation of the regulations
The number of test pieces may be reduced to 10% subject
to the following conditions:
(1) From the 50th vessel in series manufacture or within the
scope of one procedure qualification in the case of ma-
terials in Groups 1,2,6, Al 1 and Al 2 after 25 production
tests and after 50 production tests in the case of mate-
rials from Groups 3, 4, 5 and 7.
(2) The results of the previous production tests shall have
met the requirements in Table 4 or Table 5.
Where changes have occurred in the authorities supervising
the welding, or in the case of lengthy breaks in production,
a relaxation of the regulations may only be contemplated if
knowledge and experience gained has been retained.
The rules cannot be relaxed for steel where special condi-
tions have to be observed, e.g. X 20 CrMoV 12 1, 14 MoV
6 3, fluid-tempered fine-grain structural steels.
3.2 Design stress level equal to 85% of the permissible
design stress
In as far as design stress level of 85% of the permissible de-
sign stress is applied as stated in Tables 1, 2 or 3, one test
piece shall be required on 2% of the cylindrical parts. The
minimum number of test pieces, however, is one per year for
each material group and each welding method.
4 Number of test pieces with circumferential
seams (test pieces welded separately)
Where pressure vessel shells are joined with circumferential
seams or where the welding procedures for the circumferen-
tial and longitudinal joints are different, one test piece per
year for each material group and welding procedure are
required.
5 Number of test pieces with welded ends
5.1 Ends manufactured from welded blank discs
In the case of welds on ends fabricated from welded blank
discs (not including hemispherical ends), proceed according
to section 4 if the weld or its extension intersects the crown
area of 0,6 . D, (see also AD-Merkblatt B 3, Figs. 8 and 9
[left-hand side of drawing]).
5.2 Ends welded from pressings
In the case of welds on ends welded from pressings (not in-
cluding hemispherical ends), proceed according to Section
4 if the weld or its extension intersects the crown area of
0,6 . D, (see also AD-Merkblatt B 3, Figs. 8 and 9 [left-hand
side of the drawing]).
6 Selecting and dimensioning the test
pieces
6.1 In the case of tests which do not depend on the cast,
the test pieces may be taken from parts of similar thickness
(deviations of t 20% are permissible). In tests which are de-
pendent on cast, the test pieces shall correspond to the
manufactured pressure vessel in thickness and cast. Where
relaxed rules apply as set out in Section 3.1.3, test pieces
from casts of comparable composition may be used.
With thicknesses less than 10 mm the total tolerance may
be shifted to one side.
6 . 2 Selection of the test pieces shall be such that the speci-
mens required in accordance with Tables 1,2 or 3 and those
which may be needed in accordance with Section 9 can be
cut from them; selection shall also allow for the possibility of
spare specimens being obtained. The length of the weld shall
not exceed 300 mm.
Where test pieces are welded separately, the dimensions
and the welding conditions shall conform to the component
itself.
7 Testing the welded joints
Test pieces shall be in the heat-treated state corresponding
exactly with that of the last heat-treatment of the vessel. In
the case of ends fabricated from welded blank discs or
welded from pressings, the testpieces shall be in the identical
heat-treatment state as that of the last heat treament of the
ends. Where, in the case of torispherical ends, the require-
ment to heat-treat after cold-forming may be waived, the test-
pieces shall be in the same heat-treated state as the original
plates. The samples shall then be removed and tested.
In the case of pressure vessels requiring to be tested by the
authorized inspector, the test shall be carried out in his pre-
sence. The scope of the test depends on the material, the
wall thickness and the heat treatment, and can be found in
Tables 1, 2 or 3.
In special cases agreement may be reached to use supple-
mentary or non-standard specimens.
Specimens are sectioned and tested as appropriate in accor-
dance with AD-Merkblatt HP 2/i.
Where the lowest operating temperature is below -200 “C,
the notched bar impact test at - 196 “C is carried out subject
to the following conditions:
(1) that in the procedure qualification and the final production
test the notch impact strength is tested at - 196 O C and
at the lowest operating temperature and that the results
of the tests carried out at the lowest operating tempera-
ture are not substantially lower than those obtained at
-196 “C:
(2) that in the further production tests the results obtained
from the notched bar tests do not differ significantly from
those determined in the procedure qualification or in the
first production test.
 P a g e 3 AD-Merkblatl HP 512. Editron 07.89

8 Welded joint requirements fall short of the minimum values by 5-10% if it can be de-
monstrated that:
See Table 4 or 5.
(1) heat treatment was carried out correctly;
(2) the requirements jr-r respect of the notch impact strength
9 Testing of the base material following post- of the base material are satisfied;
weld heat treatment (3) the dimensioning of the pressure vessel is still adequate.

9.1 Testing of the base materials following post-weld heat- 9 . 3 In the case of Material Groups 2, 3, 4.2, 5.2 and 5.3,
treatment is carried out using the test pieces stipulated in the tensile strength, yield point and elongation at break are
Sections 3.1.1 and 3.1.2. determined using tensile specimens, and the notch impact
strength using notch impact specimens, which are cut from
9 . 2 In the case of Material Groups 4.1 and 5.1, the tensile the base material of the test-pieces for each melt unaffected
strength and yield point of the base material are tested only by the welding process, Elongation at break and notch impact
during the performance of the tensile test in accordance with strength shall satisfy the requirement for the base material
Table 1, column 13 (specimen configuration to DIN 50 120, (testing shall as far as possible be in the transverse direc-
Fig. 1, but with the test length equalling the weld width + at tion). In individual cases it is permissible for the yield-point
least 80 mm). If the results of the tests do not allow an as- and tensile-strength values to fall slightly short of the
sessment to be made of the base material, it is necessary minrmum values by up to 5%. Yield-point and tensile-
for a tensile specimen to be cut from the base material of the strength values may fall short of the minimum values by
test pieces which is unaffected by the welding process. In in- 5-10% if it can be demonstrated that:
dividual cases it is permissible for the yield point and tensrle
(1) heat treatment was carried out correctly;
strength values to fall slightly short of the minimum values
by up to 5%. The yield-point and tensile-strength values may (2) the dimensioning of the pressure vessel is still adequate.

Footnotes to Table 1

‘) Depending o n t h e m a t e r i a l s p e c i f i c a t i o n , o t h e r m a t e r i a l s s h a l l b e a s s i g n e d t o c o m p a r a b l e m a t e r i a l g r o u p s i n a c c o r d a n c e w i t h t h e
assessment of suitability. Where parts from different material groups are welded together, the group with the greater scope of testing
applies.
2) U = Unannealed, W = heat-treated
3) Applies irrespective of stress categories according to AD-Merkblatt W 10.
4, Notch position perpendicular to surface.
5) N o t c h p o s i t i o n p a r a l l e l t o s u r f a c e w h e r e p o s s i b l e ; f o r s p e c i m e n s n o t e x c e e d i n g 1 0 m m t h i c k , n o t c h p o s i t i o n i s p e r p e n d i c u l a r t o s u r f a c e .
6) H o t t e n s i l e t e s t t o D I N 5 0 1 4 5 o n l o n g i t u d i n a l s p e c i m e n s f r o m t h e w e l d m e t a l o r a n a n a l y s i s o f t h e w e l d m e t a l i f o p e r a t i n g t e m p e r a t u r e
e x c e e d s 3 5 0 “C; i n t h e c a s e o f f i n e - g r a i n e d s t r u c t u r a l s t e e l s , t h e h o t t e n s i l e t e s t s h a l l b e a s s p e c i f i e d i f t h e o p e r a t i n g t e m p e r a t u r e e x c e e d s
200 “C.
9) If resistance to caustic cracking is required, the scope of the tests shall be extended accordingly.
10) I f c o n d i t i o n s a r e m e t u n d e r w h i c h n o p o s t - w e l d h e a t t r e a t m e n t i s r e q u i r e d .
ji) G = as for base material
20) With X 20 CrMo(W)V 12 1 steel, a notched bar impact test shall be carried out irrespective of the wall thickness, e.g. including
I 15 mm to 2 5 mm. Also, test the hardness of each weld.
2’) The notched bar impact strength test is carried out regardless of wall thickness, e.g. including s 15 to 2 5 mm. For walls < 5 mm
thick carry out a technological bending test.
23) If applied in temperature range below -10 “C, see AD-Merkblatt W 10.
p4) If required by the manufacturer.
25) I f s t e e l s i n t h e M a t e r i a l G r o u p s 5 . 1 t o 5 . 4 a r e u s e d a t o p e r a t i n g t e m p e r a t u r e s n o t l e s s t h a n - 1 0 “C a n d t h e r e q u i r e m e n t s o f A D - M e r k b l a t t
W 10 are met, the rules covering Material Groups 1 to 3 apply.
Page 4 AD-Merkblatl HP 5/2, Edition 07.89

Table 1. Type and scope of production tests;

extract from Synoptic Table 1 in AD-Merkblatt HP 0

Aate- Steel grades’ Type and scope of production tests

rial
Production test

:
[

i
Section

9 10 i 114) 125) I 13 /I 14 / 15 16

I I
2

: - 1- (
1

I
steels in the following analysis
groups (ladle analysis) with
5 30 G!‘) 3 -
ninimum yield point
U 100 > 30 5 38’0) -2 :
G”) ’ 3 3 1 1 I 1 ) 1 macro
: 370 N/mm2 9) except steels with
- /

II
ligh Impact strength at low temp- > 38 5 50’0) G ” ) ‘313 1 ) ’ 1
xature if used act. to AD-
tierkblatt W 10 in stress Category - -I T .-__-__-_
LJ 3.1 or 4
below - 10 “C

c 0,22 c 0.20 5 30 2 G”) 3 - - -

2 G“) 3 -
w 100 > 3 0 5 50 1 - - 1 macro
3 c 0.50 5 0,50
G”) 3 - 1 1
Wn c 1,6 5 0.8 > 50 1 -
bno - 5 0,65
‘, S each 5 0,05 each 5 0.05 -
Ither
Jtal 5 0.8 5 0,5
5 15 2
Bther ‘1 w 85 3 -- - 1macro 3.2 or 4
.Ingle 5 0,3 5 0,3 > 15 c 30 G“)

2 t =ine-grained structural steels witt

nmimum yield point 2 370 to
- -
-I- 7
< 430 N/mm* except steels with
1: ‘ligh impact strength at low temp- 5 15 2
i , erature if used act. to AD- U 100 1 macro
> 15 zz 30 G”)
Merkblatt W 10 in stress Category
/I I below -10 “C

- - L 3.1 or 4

i
5 30 2 G”) 1 macro
W 100
> 30 G”)

3
i
Fine-grained structural steels wit1
- - t :

r
minimum yield pomt 2 430 N/mm U 100 5 30 G”) 1 macro
I 6except steels with high Impact
strength at low temperature If
j jJsed act. to AD-Merkblati W 10
- i
n stress category I below - 10 “C 3.2 or 4
t tiigh-temperature structural
!j steels 5 50 2 G”) 1 1
1 macro
11 NiMoV 5 3, 13 MnNiMo 5 4
W 100
> 50 G”) 1 1
17MnMoV64 20 MnMoNi 5 5
15NiCuMoNb5, 22NiMoCr37
I 12 MnNiMo 5 5, 20 MnMoNi 4 5
-!- - I
 Page 5 AD-Merkblatl HP 512. Edition 07.89

Table 1. Type and scope of production tests:

extract from Synoptic Table 1 in AD-Merkblatt HP 0 (Continued)
-
MZ Ge- Steel grades Type and scope of ProductIon tests
ri ial I
Gr O”P Production test
‘) I s>15mm I i I
Notch impact specimens

mm Section

8
I 141 15 16
1 2
I L
I !
1.1 ligh-temperature steels:
I I
3CrMo44,lOCrMoQlO. 530 ‘2) G’l) 13 - 1 ; 11 m a c r o 3.1 or 4
2 CrMo 19 5. X 10 CrMo 9 1 100 G”) 13 3 , 1
> 30 I - I
I /
I I I
I t
I
4.2 iigh-temperature steels:
4 MoV 6 3
100 all 2 G”) 320) 3 1 : 1 ;’ 1 m a c r o 3.1 or 4
: 20 CrMoV 12 1

-
5.1 ‘ine-grained structural steels act.
)IN17102,17178and17179in
series with high impact strength 32’) 32’)
5 30 22’) -
it low temperature and special 32’) 1 1 i 1 macro
U 100 ~>3OC38’0) - 32’)
series with high Impact strength 32’) 1
) >30(38’“)’ - 32’) ’ (
it low temperature having
ninimum yield pomt
< 370 N/mm>. Fine-gramed struc-
,ural steels act. to DIN 17102,
17178 and 17179 In basic and - c - 3.1 or 4
ligh-temperature Series with
I
ninimum yield point < 370 N/mm f the lowest ’
‘used act. to AD-Merkblatt W 10 lperatmg
5 30 22’) 32’) 32’)
lstresscategorylbelow-10%. emperatures -
32’) 32’) 1 macro
steel grades lTSt 35 N and lTSt w - xc. to AD-
32’) 32’) 1
15 V act. to DIN 17 173 and Werkblatt
7 174 and steel grades vV 10 are
liMnNi53andl3MnN163acc. Jsed, test at
ofJIN17260,17173and17174 gen. tempera -I

r
0 lowest operating temperatures - tures in c -
I-
jown to -80 ‘C25) inclusive. Table 1,
Column 9. If
workmg
22’) 39 39
L I, w 85 temperature
is higher that1’ 3”) 32’)
1 macro 3.2 or4

lowest
operating
temperature
for stress

-
5.2 Fine-grained structural steels act
toDIN17102,17178and17179
- -
c a t e g o r y I,
testing need
only be per-
formed at thl
lowest m-
tended work
32’) 32’)
T 1
T
---r

in Series with high impact strengtl 7 u 100

22’) ing tempera-
3”) 32’) 1
1 macro
at low temperature and special ture
Serres with high Impact strength, i I J 3.2 or 4

1
at low temperature having
minimum yield point 2 370 N/mm 2
to < 430 N/mm?. Fine-grained 22’) 32’) 32’) 1
w 100 1 macro
structural steels act. to DIN - 32’) 39 1
17102,17178and17179~nbasi~
and high-temperature Series witt 1
minimum yield point 2 370 N/mrr 12
to > 430 N/mm? if used act. to
AD-Merkblatt W 10 III stress
category I below -10 “C. Steel

-
grade TrSt 35 V act. to DIN
17173 and 17174 at lowest
operating temperatures below
-80 “C=).
- - J - - ---
j
Page 6 AD-Merkblatf HP 5/Z, Edition 07.89

Table 1. Type and scope of production tests;

extract from Synoptic Table 1 in AD-Merkblatt HP 0 (Continued)
-
Mi ate- -r Steel grades’ Type and scope of production tests 1
ial
G: oup Production test
!
‘) s>15mm
Notch impact specimens
Test NW
FI temperature
2
3
5 E! 5
gg E
EZ P
2% 3

2 g ; : / 114) 125) 13 I 14 15
1
I L
5.3 :ine-grained structural steels act. ( If the lowest
operating
j :
sDIN17102,17178and17179
vith minimum yield point , temperatures ,
: 430 N/mm2 in Series wrth high j act. to 1 ~
AD-Merkblatt ;
npact strength at low tempera- / ’ ~
ure and special Series with high ) WlOare i
~used. test at ! 3~1)
I
mpact strength at low tempera- 5 30 22’) 32’) ’ - 1 macro 3.1 or 4
ure. Fine-grained structural gen. tempera- 32’) 32’) ’ 1 : -
all 22’)
iteels act. to DIN 17102.17 178 tures r
ind 17 179 wth minimum yreld Table 1
Joint t 430 N/mm2 In basic and Column 9 If
ligh-temperature Series If used w o r k i n g
a ccording to AD-Merkblatt W 10 temperature
ir1 stress category I below IS hrgher than’
-10 “C25). lowest
-
5.4 E jteels with high Impact strength
I-
operatrng
temperature
, for stress
I- It low temperature act. to DIN
1 7280, 17173 and 17174z5) category I.
testrng need
only be per-
all formed at the i I : 32’) / 1 ~
1 macro
all l o w e s t I”- I ’ 32’)
i *
1 1 3.1 or 4

tended work-
I ing tempera-
ture
! ! ;

- I L 1 macro
6 Austenrtic steels act. to DIN j- t
T 17440,17441,17457and17458
as well as SEW 400 t 5 50 G")*3) IK resis-
ante z4))

1 macro
1 3.1 or 4
G”)=) :IK resis I
100 G”)=) :ance24)) I

1 macro
,
-
J, ‘/
-
a5

-
G”)
(IK resis
tancez4): II 3.2 or 4

7 -t Ferrite-free austenitic steels but

possibly with ferrite in the weld
metal and autstenitic steels in
Material Group 6 provided they
are welded using filler materials 1 micro
U 100 all G”) 3.1 or 4
with s 3% delta ferrite in weld
metal, e.g.
W 100 all G”I
(IK rests
tancea4) )
X 8 CrNiNb 16 13,
X 6 CrNiNb 16 16.
X 8 CrNiMoVNb 16 13

c 1
8 Ferntx austenrtic steels, e.g.
X 2 CrNiMoN 22 5 3

G”) 1 micro 3.1 or 4

U 100 all

G”) 1 micro 3.2 or 4

65 all

- -
 P a g e 7 AD-Merkblatt HP 512, Edition 07.89

Table 2. Type and scope of production tests:

extract from Synoptic Table 2 in AD-Merkblatt HP 0

Wate- Types of material Type and scope of production tests

rial
;roup Production test
7
‘1
I s>15mm
% gg
3 v) Notch impact specimen+) E 2
I 2
5, -be2 Test Number 2 .Ss E
8, g.9 co-CL m g8 ‘“I
bE cg $182 temperature E z
=a .zm i ‘ij d&T 25 PO=
mBz:! T5
;E 22 5> g-,z FL J .P mm zg;
a, ‘B .gE::+j 5 0’
.- UIL s $L
04
:z- r0.g E !$a2 ;E $m$
s;Ez ‘D g .E .%i 2: nmr
==
SC-3 $EL =cnYu, @E ;sE ZE ES I
gggg VI E 8
-2:: P
us Ra 3 ! $2 182 F1 z’z:9
% mm “C Section

1 2 6 7 8 9 10 114) 125) 13 14 15 16
- -
Al 1 Al 99,98 R W4, F4
Al 99,8 W6, F6 w w 100 5 5027) 2 28) - - 1 - 1 macro 3.1 or 4
Al 99,7 W6, F6
Al 99.5 W7, F7, F8

u, w 100 > 502’) According to assessment of suitability

Al 2 AlMn W9. FlO. W10

AlMnCu WlO
AIMg3 W18, W19, F18
AIMg2Mn0.8 W18, W19.
F18, F19, F20
AIMg4,5Mn W 2 7 , W 2 8 . lf. W 185=) 5 502’) 228) G”) 3 - 1 - 1 macro I 3.2 or 4
F27

u, w 100 > 5027) According to assessment of suitability

Al 3 AIMgSiO,S F 1 3
u. w 100 5 10 According to assessment of suitabrlity

Footnotes’) to 25) see Synoptic Table 1.

!6) Testing of impact strength is only performed in case of pressure vessels where possibility of shock loading must be anticipated.
!r) Relatively little welding and testing technical experience is currently available for wall thicknesses exceeding 30 mm.
la) For thicknesses z 15 mm, side bend test specimen according to DIN 50121.
m) Valid for AIMg4,5Mn only if experience has been proved as stated in AD-Merkblatt HP 512 Section 3.1.3.
Page 8 AD-Merkblatt HP 5/2, Edition 07.89

Table 3. Type and scope of production tests;

extract from Synoptic Table 3 in AD-Merkblatt HP 0

Mate- Types of material

l- Type and scope of production tests
rial
Sroup Production test
‘)
s>15mm
Notch impact specimen+)
Test NUI n b t
temperature
P
6
E
9
s
“C

1 2 10 11”)
L
Ni 1 LC-Ni 99 all G”) 3 1 1 macro 3.1 or 4

85 all G”) 3 1 macro 3.2 or 4

T
1
T
Ni 2 Nickel alloys u, w all G”) 3 3 32) 1 macro 3.1 or 4
e.g. (IK resis-
NiCu 30 Fe tance)32)
NiCr 15 Fe
NiMo 16 Cr 15
NiMo 16 Cr Ti

-
NiCr 21 MO
NiMo 28
X10 NiCr AlTi 32 20

Ti 1 Titanium
Zirconium
-
u. w
-
100 all G”)
-L
3 T 1 micro 3.1 or 4

Tantalum
Hafnium

I
and other metallic
materials

-
Footnotes’) to 25) see Table 1. Footnotes26) to 29) see Table 2
- -
32) Only in case of NiMo 16 Cr 15, NiMo 16 Cr Ti, NiMo 28
 P a g e 9 AD-Merkblatt HP 5/2, Edition 07.89

Table 4. Requirements for testing welded steel joints (for testing the parent metal following post-weld heat treatment, see
Section 9).

Type of test Requirements

Tensile test at right angles to Tensile strength as required for the parent metal or as specified for the weld filler metal by the
the weld assessment of suitability

Tensile test on a specimen of weld Elastic limit or 0,2% proof stress, tensile strength and elongation at break as required for the
metal parent metal or as specified for the weld filler metal by the assessment of suitability

Notched bar impact bending test from At charging temperatures As specified for parent metal in the transverse direction.
the centre of the weld on the of -10 “C and above: Test temperature as when testing the parent metal, but not lower
ISO-V-notch specimen than - 10 “C. When using ferritic-austenitic, austenitic and nickel-
b a s e d a l l o y w e l d f i l l e r s 2 40 J.

At charging temperatures At lowest operating temperature

below -10 “C: 2 2 7 J*) w h e n u s i n g f e r r i t i c w e l d f i l l e r m e t a l s ;
2 3 2 Jz)6) w h e n u s i n g f e r r i t i c - a u s t e n i t i c , a u s t e n i t i c a n d n i c k e l -
based alloy weld fillers

Notched bar impact bending test in the At charging temperatures 2 27 J*) 7) on the ISO-V-notch specimen. Test temperature as
region of the weld transition on the of -10 “C and above: w h e n t e s t i n g t h e p a r e n t m e t a l b u t n o t l o w e r t h a n - 1 0 “C
ISO-V-notch specimen

At charging temperatures 2 16 Jz) at lowest operating temperature

below - 10 “C:
I
Technological bending test Bending angle Strength groups) Diameter of
Degrees mandrel

1809 Ferritic steels with a

minimum tensile strength < 430 n/mm2 12.a
: minimum tensile strength 2 430 to < 460 N/mm2 1 2,5 a
1 804) Stainless and low-temperature austentitic steels, 2.a
High-temperature austenitic steels, 3.a
Ferritic steels with a mlnimumtensile strength
) 2 460 Nlmm2 3.a

If a bending angle of 180” is not achieved, the following applies:

2 90 1Elongation (L,, = width of weld + wall thickness, symmetrical to weld)

2 Minimum elongation at break A, of the parent metal
or
< 90 Elongation over the width of the weld > 30 %5) and defect-free fracture
appearance

Metallographic section assessment I n t h e m a c r o - s e c t i o n t h e w e l d e d j o i n t m u s t m a n i f e s t p e r f e c t l a y e r structure a n d w e l d p e n e t r a t i o n .

In the case of micro-sections an examination must be carried out for cracks. Only clinks are
acceptable and then only if they are shown to occur occasionally.
Agreement must also have been obtained from the authorized inspector thatthey are acceptable
in the light of the material and the field of application.

Hardness testing In the heat-affected areas the hardness rating must not exceed 350 HV 10. Peak hardness
v a l u e s a b o v e t h i s l i m i t i n n a r r o w t r a n s i t i o n z o n e s m a y b e d i s r e g a r d e d i f t h e result o f t h e
technological tests meets the requirements.

1) in the case of specimens not of standard 10 mm width, the requirements regarding impact strength diminish in proportion to the cross-section of the
specmen.
2) Only one single value may fall below the minimum mean value, though by not more than 30%.
3) Tensile strength relates to the smallest area of thickness.
4) The 180” requirements are deemed fulfilled if the bending test has been carried out to DIN 50 121 and the specimen has been pressed through the
supports without cracking.
5) In the case of steels which have been welded differently, e.g. X 8 Ni 9, different values may be agreed with the authorized inspector for pressure vessels
on which he IS required to carry out a structural test.
6) Where the lowest operating temperature is under -200 “C the notched bar impact test is carried out at - 196 “C provided that
- in the procedure test and the first production test the impact strength is tested at - 196 “C and at the lowest operating temperature. The results of
the tests shall show no appreciable drop for the lowest operating temperature as compared with the test at - 196 “C;
- In the further production tests the results for the notched bar impact strength shall not vary significantly from those obtained in the procedure test or
In the first production test.
7) For welded joints on X 20 CrMoV values may fall below this value by 10%.
P a g e 10 AD-Merkblati H P 5/Z, E d i t i o n 0 7 . 8 9

Table 5. Requirements for testing welded joints (aluminium and aluminium alloys)

Type of test Requirements

Tensile test at right angles to the weld Tensile strength as for the base material or as specified for the weld filler in the assessment of
suitability

Tensile test on a specimen of the 0,2% proof stress, tensile strength and elongation at break as for the base metal
weld metal or as specified for the weld filler in the assessment of suitability

Notched bar impact bending test’) from At room temperature: 2 16 J, but no value under 12 J
the centre of the weld metal
( m e a n v a l u e f r o m 3 ISO-V-notch At charging temperatures s 14 J, but no value under 12 J
specimens) less than -50 “C:
I
Technological bending test Bending angle Material and material condition ( Diameter of
Degrees

WhensI15mmtoDIN50 121,partl, 1 8 0 Al99,98 R W4 and F4

Section 5.2.1, Al99,8 W6 and F6
Whens>15mmtoDIN50 12l,partl, Al99,7 W6 and F6
Section 5.2.3 Al99,5 W7, F7, F8
AlMn W9, W10. FIO -1’
180 AlMnCu W 0 4.a
A I M g 3 W 1 8 , W19, F 1 8
AIMg2Mn0,8 W18, W19, F18, F19, F20
AIMg4.5Mn W27, W28, F27

1I f a b e n d i n g a n g l e o f 1 8 0 ” i s n o t a c h i e v e d , t h e f o l l o w i n g a p p l i e s :
~ <18Os90 Elongation (L, = width of weld + wall thickness symmetrical to the weld)
2 Minimum elongation at break A, of the parent metal

‘or i 90 Elongation over the width of the weld > 20 % and defect-free fracture
appearance

Metallographical assessment In the micro-section the welded joint must manifest perfect layer structure and weld penetration
(macro-section)

1) Only for aluminium alloys in Material Group Al 2 to AD-Merkblati HP 0, Table 2 for pressure vessels likely to be subjected to Impact stresses.
 Januarv 2000 edition

Manufacture Manufacture and testing of joints AD-Merkblatt

and Testing of Non-destructive testing of
Pressure Vessels welded joints HP 93

T h e AD-Merkbltitter a r e c o m p i l e d b y t h e s e v e n a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “ A r b e i t s g e m e i n s c h a f t Druckbehdlter”
( A D ) , AD-Merkblai? G 7 c o v e r s t h e c o m p o s i t i o n a n d a p p l i c a t i o n o f AD-Regulations a n d a l s o p r o c e d u r a l g u i d e l i n e s .
T h e AD-Merkbltitter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . I n t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behdlter- und Rohr/eitungsbau e. V. (FDBR), Diisseldorf
H a u p t v e r b a n d d e r g e w e r b l i c h e n B e r u f s g e n o s s e n s c h a f t e n e . V., S a n k t Augustin
Verband der Chemischen lndustrie e.V. (VC/), FrankfurtlMain
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhtittenleute (VDEh), Diisseldorf
VGB Technische Vereinigung der GrooRkraftwerksbetreiber e.V., Essen
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkb/&ter a r e a m e n d e d c o n t i n u o u s / y b y t h e a b o v e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p f o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iibeiwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents
1 Scope 5 Supervision of testing by the authorised inspector
2 Type and scope of non-destructive tests 6 Deviations
3 Scheduling of non-destructive tests 7 Test report
4 Assessment of test findings

1 Scope For fusion welds in steel grades in material groups 1 to 8 as

specified in table 1 and for all materials in material groups as
This AD-Merkblatt deals with the type and scope of non- specified in tables 2 and 3, the relevant higher requirements
destructive tests and the assessment of test findings on are to be adopted.
welded joints in pressure vessels and pressure-bearing pres-
sure vessel components made from materials as specified For mixed joints between ferritic and other materials (e.g.
in tables 1 to 3 as well as the supervision of testing. austenitic, nickel-based alloys), the test methods and scope
of testing are to be agreed between the parties concerned?.
The requirements for non-destructive test methods are
stated in Appendix 1 to this AD-Merkblatt. The surface crack test stipulated in columns 23 and 24 of
table 1 is to be performed on both sides of the welded joint
within the scope of testing stated therein. If only one side is
accessible, testing within the stated scope takes place on
2 Type and scope of non-destructive tests one side only.
2.1 General stipulations Where other welding procedures are used, the test method
shall be agreed between the parties concerned?
Welded joints shall be visually examined before non-destruc-
tive tests are performed. 2.2 Stipulations which vary the scope of testing
Fusion welds shall be tested as a function of the material 2.2.1 Reduction in scope of testing
group, wall thickness s’) and use of the permissible design
The experience required as a prerequisite for reducing the
stress in accordance with the test methods, test categories scope of testing as stated in tables 1 and 2 is deemed to be
and scope of testing specified in tables 1 to 3. The dimen- adequate if the following conditions are met:
sions t or a to be used as a basis for the welded wall thick-
nessl) are shown in figures 1 to 3. (1) From the 50th pressure vessel during batch production
or within the scope and validity of a procedure qualifica-

1) s, t or a are to be based on the drawing dimensions. 2) See 1.2 of AD-Merkblatt HP 0.

Supersedes September 1998 edition; ( = Amendments to previous edition

Carl Heymanns Verlag KG Translation: Technical Help to Exporters Service of 56.1

Luxemburger StraOe 449, 50939 Kdln
Page 2 AD-Merkblatt HP 5/3, Edition 01.2000
Figure 1.
Figure 3.
tion test with any of the materials in groups 1, 2,6,7, A l 1
and Al 2, after 25 production tests and, with materials in
groups 4.1, 5.1 and 5.2, after 50 production tests.
(2) If there has been a change in welding supervision or
where manufacture has been discontinued over a pro-
longed period, experience shall have been maintained.
(3) The test method is the same.
(4) The results of previous non-destructive tests have reve-
aled no serious deficiencies or systematic defects.
These rules may be relaxed in the case of circumferential
welds welded using fully mechanised procedures if, in the
case of material groups 1, 2, 6, Al 1 and Al 2, a weld length
of 150 m and, in the case of material groups 4.1, 5.1 and 5.2,
a weld length of 300 m has been welded within the scope and
validity of a procedure qualification test. Conditions (2), (3)
and (4) shall be adhered to.
2.2.2 Increase in scope of testing
The following items are to be tested in addition to the scope
of testing mentioned in 2.1:
(1) Points where butt welds intersect;
(2) Butt welds near bores and cut-outs if the distance be-
tween the butt weld and the edge or the bore or cut-off
leaves a butt-weld wall thickness . < 3;
(3) Single-sided longitudinal welds and other single-sided
fully stressed welds (e.g. corner welds as specified in 2.3
of AD-Merkblatt B 2) are to be treated the same as for
a permissible design stress of 100 % in terms of the
scope of non-destructive testing. Where advantage is
taken of the reduced scope of testing, the non-destruc-
tive test shall not be performed on specific objects;
(4) Connecting welds of dished ends without a cylindrical
edge on sections;
(5) Welded joints near the knuckle and cylindrical flange in
the case of ends welded together from single compo-
nents with subsequent forming; the surface crack test is
performed:
- on the outside for hot-formed ends
- on the inside and outside for cold-formed ends;
(6) Welded joints in areas which are highly stressed during
operation (7.2.2 of AD-Merkblatl S 1).
Figure 2.
2.2.3 Arc strike and contact points
Arc strike and contact points with fused material are to be
ground off. They shall be subjected to a surface crack test
where this is required because of the material used and the
expected stress.
2.2.4 Procedure in the case of repairs
If, during testing, defects are detected which need repairing,
the scope of testing percentage in the affected weld areas
or welds shall be doubled, taking into account the reason for
the defect (e.g. lack of dexterity on the part of the welder)
unless such welds have already undergone 100 % testing.
In the event of systematic weld defects, characterised by the
frequent occurrence of the same type of defect over long
weld sections, the scope of testing shall be increased to
100%.
If, during testing not performed on specific objects, defects
are detected which need repairing, the increased scopsof
testing shall apply until the cause of the defect has been
found and eliminated.
3 Scheduling of non-destructive tests
Where a welded joint is subjected to heat treatment or form-
ing after welding, the non-destructive tests shall be carried
out in principle after the last heat treatment or forming pro-
cess.
If welded joints are no longer accessible after the last heat.
treatment, other agreements may be made between the par-
ties concernedz).
In the case of welded joints which are subjected to both ultra-
sonic and radiographic examination, they may undergo
radiographic examination prior to the last heat treatment.
4 Assessment of test findings
4.1 General notes
The criteria in the following subclauses for assessing the test
findings from the ultrasonic and radiographic examination
2) See 1.2 of AD-Merkblatt HP 0.

and the surface crack test are used as reference values.
Deviations may be agreed between the parties concerned,
making allowance for the design and stressing of the pres-
sure vessel, the type of welding procedure, the external
appearance of the welded joint, the mechanical and techno-
logical properties of materials used and the measuring tole-
rances of the testing systems.
If assessment of the test findings, taking into account the
following criteria gives rise to doubt, a repair or check test
using other suitable test techniques or methods or by open-
ing the weld on a spot-check sample basis is necessary.
4.2 Test areas
The test area includes the weld metal and heat-affected
zones.
4.3 Assessment of radiographic images
4.3.1 Cracks, incomplete fusion, root defects
Cracks and lack of side wall fusion are not permissible.
Incomplete root fusion is not permissible in the case of single-
sided welds.
Flat root concavity and flat root shrinkage is permissible in
the case of non-machined roots of single-sided welds.
lnterrun fusion defects in three-pass or multipass welded
joints and root defects in double-sided welds shall be treated
as inclusions as specified in 4.3.2.
4.3.2 Solid and gaseous inclusions
4.3.2.1 Multipass welded joints
Solid inclusions (including oxides in aluminium welded
joints), linear porosity, wormholes parallel to the surface and
strings of tungsten inclusions with the reference values indi-
cated in table 4 can be left as they are, taking into account
the overall impression (from the depth, shape and direction
that can be assessed from the density).
Where several inclusions appear in succession, they may be
left as they are if the conditions in table 4 are met, provided
their total length is less than t or a over a weld length of
6 . t or 6 . a and provided the faultfree weld metal between
two neighbouring defects extends over at least twice the
length of the larger of the two inclusions. This condition app-
lies proportionally to weld lengths of less than 6 . t or 6 . a.
The area of pores which can be detected on the radiographic
image shall not exceed 1,5 . t or 1,5 . a (in mm2) referred to
a weld length of 150 mm. The maximum pore diameter shall
not exceed 0,25 . f or 0,25 a (4 mm max.).
Pores which occur locally in concentration as pore clusters
shall only be present in isolated cases.
Wormholes at right angles to the surface are only permissible
if they occur as isolated defects in the case of connecting
cross-sectional areas exceeding 10 mm and taking into
account their depth (which can be assessed from the den-
sity).
Tungsten inclusions shall not be longer than 3 mm in the case
of wall thicknesses up to 12 mm and, in the case of larger
wall thicknesses, shall not exceed the value t/4 or a/4 (5 mm
max.). Local concentrations of pores shall only occur in iso-
lated cases (no more than three per metre).
4.3.2.2 Single-pass welded joints
In the case of single-pass welded joints, isolated pores may
be left as they are if their diameter does not exceed
0,25 . t or 0,25 a.
P a g e 3 AD-Merkblatt HP W3, Edition 01.2000
4.4 Assessment of findings of ultrasonic examination
4.4.1 General
Where test findings cannot be unambiguously assessed with
regard to nonpermissible defects by means of ultrasonic
examination, check tests, e.g. radiographic examinations,
shall be performed. If this confirms the defect, it shall be
repaired. If unambiguous proof of a permissible defect is pro-
vided, it may be left as it is.
Repair shall be performed if the check test does not unambi-
guously establish that the cause of the ultrasonic indication
w a s insignlficant.
Table 4. Reference values for permissible lengths of inclu-
sions in multipass welded joints in the assessment
of radiographic images
t or al) Length
mm mm
5 10 7
>10to< 7 5 25 t or 2/3 a
>75tocr150 5 0
213 t or 2,~ a with defects at a distance of more
than 10 mm from the finished surface2)
> 150 50
100 with defects at a distance of more than
10 mm from the flnrshed surface”)
2) The depth of Indxatlon can be ascertained by ultrasomc Or radlographlc
exarmnat~o” wlfh a stereo phofograph
4.4.2 Testing for longitudinal flaws
Assessment is according to the reference values stated in
table 5.
Where several indications having the same depth appear in
succession, the distance between them shall be at least twice
the length of the longer indication. If this condition is not satis-
fied, the indications in question shall be regarded as conti-
nuous and assessed according to table 5.
Where several superimposed indications appear, the
distance between them in the direction of the thickness shall
exceed the length of the longer indication.
Defect lengths which will pass the 50 mm check tests as per-
missible shall be more than 10 mm below the finished sur-
face.
If the criteria for permissible defects are exceeded, adjacent
reflection points up to 6 dB below the registration limit shall
be included in the assessment in order to determine the
repair area.
4.4.3 Testing for transverse flaws
All defects which are indicated during testing for transverse
flaws, where no definite proof can be furnished that they
originate from a longitudinal flaw which has already been
detected, shall be regarded as transverse flaws. Only 3
defects at the most are permissible per metre of weld as
transverse flaws extending over a recording length of up to
10 mm and with echo amplitudes up to 6 dB above the regi-
stration limit. Where echo indications which cannot be sepa-
rated from each other (groups of indications) occur during
testing for transverse flaws, the defects shall be repaired
even if the indications are below the registration limit. For this
purpose, the test sensitivity shall be set so that it is possible
to record indications which, when the DGS method is used,
P a g e 4 AD-Merkblatt HP 5/3, Edition 01.2000

exceed the echo amplitude of a circular reflector having a dia- 4.5 Assessment of findings of surface crack test
meter of 1 mm or, when the reference block or reference line Linear indications which can be attributed to the separation
method is used, are up to 12 dB below the specified registra- of materials are not permissible.
tion limit. No deviation from this method of assessment is
Isolated surface pores are permissible.
permitted unless definite proof has been furnished that the
indications do not originate from cracks by opening the weld
on a spotcheck basis. 5 Supervision of testing by the authorised
inspector
Table 5. Reference values for permissible ultrasonic In the case of pressure vessels which are to be subjected to
examination findings during testing for longitudi- a structural test by the authorised inspector, the latter shall
nal flaws satisfy himself that the tests were performed correctly, parti-
cularly with regard to the type, extent and selection of the
recording lengths tested locations and the proper drawing up and assessment
of the findings. If he comes across serious deficiencies, he
shall demand that tests or repairs be repeated.
Where radiographic examination is used, films and test
reports, including the photographs made before repairs, shall
be submitted to the authorised inspector. The authorised
inspector decides whether he agrees with the assessment of
the films, as a rule by carrying out spot-checks. If he encoun-
ters any discrepancy in assessment, he shall assess all the
films which come within the scope of testing.
Where ultrasonic examination is used, the authorised inspec-
tor appraises the test reports. The results of the ultrasonic
examination performed at the works are monitored by the
authorised inspector on a spot-check basis extending up to
10% of the scope of testing not necessarily on specific
objects.
assumed for determining the total of all Where the surface crack test is used, the test reports shall
recording lengths wth 10 mm.
be submitted to the authorised inspector.
MaxImum permissible amount by which echo amplitude may exceed registration
limit: up to 6 df3.
For wall thicknesses z 10 mm. y be one indication hawng an echo ampli-
tude excess up to 12 dS with a I 10 mm per metre of weld. Nevertheless, 6 Deviations
s necessary for such indications. Radio-
t-check basis, for instance, may
Any deviation from the stipulations in this AD-Merkblatt or
from Appendix 1 to this AD-Merkblatt shall be agreed be-
tween the parties concerned2).

7 Test report
Test reports relating to the non-destructive tests shall be
4.4.4 Additional assessment criteria drawn up. The minimum details which they shall contain are
Indications which suggest a zonal character and recordable stated in table 6.
indications during testing using a tandem scan constitute
grounds for doubt (see 4.1). 2) See 1.2 of AD-Merkblatt HP 0.
 Page 5 AD-Merkblatt HP 5/3, Edition 01.2000

Footnotes for table 1.

1) O t h e r m a t e r i a l s s h a l l b e a s s i g n e d t o c o m p a r a b l e m a t e r i a l g r o u p s a c c o r d i n g t o m a t e r i a l s p e c i f i c a t i o n s a s s t a t e d i n t h e a s s e s s m e n t o f
suitability. Where components made from different material groups are welded together, the group having the greater scope of testing
is applicable.
2) U - unannealed, W - heat treated.
3) Applies irrespective of stress categories according to AD- Merkblatt W 10.
7) LN = Longitudinal welds and butt welds under full stress
R N = Circumferential welds (butt welds and lap-welded fillet welds as specified in 2.4 of AD-Merkblatt HP 1; for welded ends, see clause
5 of AD-Merkblatt HP 5/2)
S t = Joints between LN (longitudinal welds) and RN (circumferential welds) or between LN and LN.
8) KN = The fillet welds to be tested are welds connecting weld-on parts, including assembly aids, to the pressure-bearing wall
StN = Nozzle welds.
9) Scope of testing to be extended accordingly if caustic crack resistance is required.
10) If conditions under wihich no postweld heat treatment is required are met.
I*) If experience has been proved as stated in 2.2.1 of AD-Merkblatt HP 5/3, the scope of testing is reduced to 10 %.
13) I f e x p e r i e n c e h a s b e e n p r o v e d a s s t a t e d i n 2.2.1 o f A D - M e r k b l a t t H P 5/3, t h e s c o p e o f t e s t i n g i s r e d u c e d t o 2 % . G e n e r a l l y i t i s s u f f i c i e n t
to include the circumferential welds by testing the joints when making random tests on the longitudinal welds.
14) T o b e t e s t e d o n w e l d l e n g t h , n o t n e c e s s a r i l y o n c e r t a i n o b j e c t s . I n t h e c a s e o f p r e s s u r e v e s s e l s w h i c h a r e t o b e s u b j e c t e d t o a s t r u c t u r a l
test by the authorised inspector, the places to be tested shall be agreed with the authorised inspector.
1s) G e n e r a l l y i t i s s u f f i c i e n t t o i n c l u d e t h e j o i n t s a n d c i r c u m f e r e n t i a l w e l d s b y t e s t i n g t h e j o i n t s w h e n m a k i n g r a n d o m t e s t s o n t h e l o n g i t u d i n a l
welds.
16) I f e x p e r i e n c e h a s b e e n p r o v e d a s s t a t e d i n 2 . 2 . 1 o f A D - M e r k b l a t t H P 5/3, f o r m a t e r i a l g r o u p s 1, 5 . 1 a n d 6 t h e s c o p e o f t e s t i n g i s r e d u c e d
to the same extent as for wall thicknesses 5 15 mm.
17) Should visual examination as stated in 2.1 of AD-Merkblatt HP 513 give rise to doubts, a non-destructive test shall be performed.
18) I f m o r e t h a n IO n o z z l e s a r e w e l d e d t o a p r e s s u r e v e s s e l w h i c h a r e s i m i l a r i n t e r m s o f d i m e n s i o n a n d w e l d i n g p r o c e d u r e , t h e s c o p e o f
testing can be reduced to 5 % of the nozzle welds but at least 2 nozzle welds shall be tested.
‘9) I f e x p e r i e n c e h a s b e e n p r o v e d a s s t a t e d i n 2 . 2 . 1 o f A D - M e r k b l a t t H P 5 1 3 , a n o n - d e s t r u c t i v e t e s t s h a l l o n l y h a v e t o b e p e r f o r m e d i f v i s u a l
e x a m i n a t i o n a s s t a t e d i n 2 . 1 o f A D - M e r k b l a t t H P 5/3 h a s g i v e n r i s e t o d o u b t s .
25) If steels in material groups 5.1 to 5.4 are used at lowest operating temperatures 2 -10 “C and the requirements in AD-Merkblatt
W 10 are met, the same provisions apply as for Material Groups 1 to 3.
33) T h e M P m e t h o d s h a l l b e u s e d p r e f e r a b l y i f t h e r e i s a d e q u a t e p e r m e a b i l i t y p,
Page 6 AD-Merkblatt HP 5/3, Edition 01.2000

Table 2. Type and scope of non-destructive testing;

extract from synoptic table 2 in AD-Merkblatt HP 0
Mate- Types of material : Type and scope of non-destructive testing
rial
grow’) Scope of testing Test method and test Nozzle Test method
and test
.N’) 3’) IN’) category in relation to and
wall thickness for fillet category for ..
columns 17,18,19 weld@) column 21

w all thickness

% % mm %

18 19 20 21 22
1 2

Nozzle and fillet

\I 1 \I 99,98 R W4. F4
J. W 100 00’2) 100 !5’3) welds are to be
\I 99.8 W6, F6
subjected to as su1. _
\I 99,7 W6. F6 -
- - D (6) or US 10’8) face crack test.
\I 99.5 W7, F7. F6
Additional ultrasoni c
J. W 100 > 5027) 100 100 25
or radiographic
- examination to be
-
performed for nou: -
85 5 5027) 2’4) 2’5) 0 (6) o r u s 1’) les having an inside
J. W ‘7
diameter 2 120 ml1 1
- - where thickness of
connecting cross-
41 2 IIMn W9, FlO, W10
J, W 100 5 502’) 100’2) 100 25’5) sectional area
‘SMnCu Wl 0
exceeds 15 mm.
,IMg3 W18, W19. F18 - - -
- Test method
,IMg2Mn0,8, W18. la)rl)

- (column 20) to be
V19, F18. F19. F20 10
J. W 8529) 5 502’) 2’4) ‘5) 2’5) D (B) or US
selected on basis cIf
,IMg4,5Mn W27.
dimension t (see
V26, F27 - -
figures 1 to 3 in AC )-
100 > 5027) 100 100 25 Merkblatt HP 513).
J, W
Fillet welds with
- - throat thickness (a:I
exceeding 15 mm
\I 3 rlMgSiO.5 F13
100 5 10 100 100 003: I - D(B) or US 100 also to be subjecte ,d
J, W
to ultrasonic exam,
nation where the
throat thickness
rather than wall
thickness determi-
nes the test cate-
WY.

- - -
For footnotes 1) to 25), see table 1
27) Relatively little welding and testing technical experience IS currently available for wall thickness exceeding 30 mm.
29) Valid for AIMg4.5Mn only if experience has been proved as stated in 3.1.3 of AD-Merkblatt HP 512.
m) A scope of testing equivalent to 10% is sufficient for circumferential welds up to an outside diameter of 50 mm.
d
3?) For fillet welds between joints in non-load bearing elements, e.g. inner retaining rings, and the pressure vessel wall, a surface crack test may be omitted provide 5
that visual examination according to AD-Merkblatl HP 513 gives no rise to doubts and the results of surface crack tests performed at least 300 m from such weld
gave satisfactory results.
 Page 7 AD-Merkblatt HP 513, Edition 01.2000

Table 3. Type and scope of non-destructive testing;

extract from synoptic table 3 in AD-Merkblatt HP 0
Mate-
rial
group’)
Types of .material Type and scope of non-destructive testing

Scope of testing Test method and test Test method

1
-N’) St’) F 3N’) category in relation to and and test
wall thickness for fillet category for
columns 17, 18. 19 wekw) column 21

Vail thickness

% % % nnm %

1 2 17 18 19 20 21 22

li 1 .C-Ni 99 100 100 25 5 30 O(A) or US(A) 10

> 30 5 60 D(B) doule and fillet
25 100 10 or US(B) ‘7) velds are to be sub
ected to as surface
:rack test.
Mditional ultrasonic
x radiographic
zxaminatlon to be
lerformed for nou-
es having an inside
jiameter 2 120 mm
Nhere thickness of
- -
zonnecting cross-
Ni 2 Nickel alloys u. w 100 100 100 25 c 50 D(B) 10 ;ectional area
or US(B) and exceeds 15 mm.
,.g. Surface crack test rest method
NiCu 30 Fe :column 20) to be
NCr 15 Fe selected on basis o
NiMo 16 Cr 15 jimension t (see
NiMo 16 Cr Ti figures 1 to 3 in AD
NiCr 21 MO Merkblatl HP 513).
NIMO 28 Fillet welds with
X10 NiCr AlTi 32 20 throat thickness (a)
exceeding 15 mm
IISO to be subjected
- - -
o ultrasonic exami-
ri 1 u. w 100 all 100 100 25 5 15 D(B) 10 labon where the
!irconium and hroat thickness
rantalum Surface crack test ather than wall
iafnium hickness determl-
md other metallic les the test cate-
naterials WY.

- - - -
For footnotes I) to 25), see table 1
Table 6. Details required in the test repot?

Details regarding Details concerning test technique Further details

test object Magnetic particle Penetrant flaw Ultrasonic Radiographic
flaw detection detection examination examination

Unambiguous Surface condition, Surface condition, Test category, Test category, Test findings
correlation with Test equipment, Test facility system according Surface condition, Radiation source/type (findings of ultrasonic and
test object by Type of magnetisation to DIN 54152 Part 1, Test equipment, of tube, radiographic examination
means of: according to DIN 54130, Penetrant, Probes, Film manufacturer and type, are to be documented so
- Maker’s number Tangential field strength, Penetrant cleaner, Couplant, Screens, that indication points can
- Drawing No., Test apparatus Developer, Scan positions, Tube voltage, be retrieved in reproducible
- Material, Type of precleaning and Adjusting reflectors Tube current, form)
- Dimensions, intermediate cleaning, (type, sonic path lengths), Activity, For radiographic
- Welding procedure, Temperature of test piece, Registration limit, Source-to-film distance, examination:
- Tested area, Penetration time, Echo amplitude of adjusting Camera arrangement IQI s e n s i t i v i t y a c c o r d i n g
- Specification Assessment time reflector, according to DIN EN 1435 to DIN EN 1435
Gain allowance, Exposure time, achieved
Transfer correction, Tube focus/source size,
Assessment,
Attenuation if applicable Correlation of film with
Remarks concerning
Correction values for test section,
repairs,
adjustment on
Deviations,
calibration block,
Time of testing
according to clause 3,
Name of tester,
Test supervisor’s signature
ICS 23.020.30 Januarv 2000 edition

Non-destructive testing of welded joints Appendix 1 to

Manufacture
AD-Merkblatt
and Testing of Minimum requirements for
Pressure Vessels non-destructive testing methods HP 5/3

T h e AD-MerkbBtter a r e c o m p i l e d b y t h e s e v e n a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “Arbeitsgemeinschaft Druckbehdlter”

( A D ) . AD-Merkblatt G 7 c o v e r s t h e c o m p o s i t i o n a n d a p p l i c a t i o n o f A D - R e g u l a t i o n s a n d a l s o p r o c e d u r a l g u i d e l i n e s .
T h e AD-Merkbkitter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . In t h e e v e n t ofloadings exceeding
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband DampfkesseL, Behtilter- und Rohrleitungsbau e. V. (FDBR), D&se/doff
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sanki Augustin
Verband der Chemischen lndustrie e. V. c/Cl), FrankfurtlMain
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, FrankfurtlMain
Verein Deutscher Eisenhiittenleute (VDfh), Diisseldorf
VGt3 Technische Vereinigung der GroBkraftwerksbetreiber e.V., Essen
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-MerkblBtter a r e a m e n d e d c o n t i n u o u s / y b y t h e a b o v e a s s o c i a t i o n s i n k e e p i n g w i t h technical progress. Relevant proposals should
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents
1 Preliminary remarks 3 Ultrasonic examination
2 Radiographic examination 5 Surface crack test

1 Preliminary remarks
This AD-Merkblatt describes the minimum requirements for
non-destructive testing and gives several examples of the
assessment of test findings. The stipulations in this AD-
Merkblatt are largely in line with the latest standards and
guidelines available in draft form’).
2 Radiographic examination
The requirements of DIN EN 1435 apply for carrying out the
radiographic examination.
3 Ultrasonic examination
3.1 Butt welds
3.1.1 Test categories
In the test for longitudinal flaws according to test category A,
it is usually sufficient to test the weld from one surface and
one side of the weld only (positions 1, 2, 3 or 4 in figure 1)
at one testing angle.
‘) For example “Richtlinie ijber Priifung van StumpfschweiOnahten mit Ultraschall
der Deutschen Gesellschaff fijr Zerstdrungsfreie Prijfung e.V. [Guidelines on
ultrasonic examination of butt welds published by the German Association for
Non-destructwe Testing.]
When testing for transverse flaws, scan from the surface of
the weld (positions 1 and 2 in figure 2). If this is not possible
because the final run is too rough, scan from the surface of
the base metal (positions 3 and 4 or 5 and 6 in figure 2).
In test category 8, the weld shall be tested from both sides
(in positions 1 and 2 or positions 3 and 4 as shown in figure
1 when testing for longitudinal flaws and in positions 1 and
2 as shown in figure 2 when testing for transverse flaws). If
this is not possible because the final run is too rough, it is per-
missible to scan from the surface of the base metal (positions
3 to 6 in figure 2).
In test category C, testing for longitudinal flaws shall be per-
formed as in test category B and testing for transverse flaws
shall be performed from the weld surface, i.e. from positions
1 and 2 in figure 2. In some cases this may entail obtaining
probe-to-specimen contact by machining the top bead run.
This operation shall take place prior to testing for longitudinal
flaws. With wall thicknesses > 100 mm, an additional test
shall be performed using a tandem scan for longitudinal or
transverse flaws.
3.1.2 Beam angle
In the case of surfaces which are not curved in the direction
of testing, the beam angle shall not be less than 45 degrees.
For test categories A and B and in test category C in the wall
thickness range < 40 mm, the beam angle shall be chosen
so that the angles of incidence do not exceed 70 degrees on
the surfaces to be tested.

Supersedes July 1989 edition; ( = Amendments to previous edition

ban neymanns verlag w2 Translation: Technical Help to Exporters Service of BSI

Luxemburger StraOe 449, 50939 KBln
P a g e 2 AD-Merkblatt HP 513 Appendix 1, Edition 01.2000
Angles of incidence are the angles between the main sound
beam and the normal of the surface at the point of incidence
(example: angle p, and h in figure 4). If necessary, in order
to meet this condition for the angle of incidence, appropriate
beam angles shall be used or the specimen shall be scanned
from other test surfaces.
For wall thicknesses > 40 mm, an angle probe shall be used
- if the geometry of the weld so permits - in order to test for
longitudinal, oblique and transverse flaws with the angle
probe making it possible to include zones near the surface
at an angle of incidence < 60 degrees. Furthermore, in test
category C with the said wall thicknesses, an angle probe
shall be used having a main beam which impinges at right
angles, if possible, upon zonal defects occurring at a right
angle to the surface. If it is found that these conditions are
best met with normal incidence, a normal probe shall be used
for this purpose.
When testing for defects which are at a right angle or approxi-
mately at a right angle to the surface using a tandem scan,
this testing replaces the additional beam angle required
above.
3.1.3 Width of test surface
The width of the surface strip to be prepared as a test surface
is determined by the requirement that, for each element of
volume of the zone adjacent to the weld, testing for longitudi-
nal flaws shall be performed in the range of at least two half
skip distances unless the test is performed by scanning from
another surface at a second appropriate beam angle.
For wall thicknesses > 40 mm and test category C, the width
of the test surface is determined by the requirement that the
evaluation range includes the entire skip distance in the case
of the smaller beam angle and includes the half skip distance
in the case of the large beam angle.
The zone adjacent to the weld includes the weld metal and
the adjoining base metal on both sides to a width of:
- 10 mm each side for wall thicknesses 5 30 mm,
- l/3of the wall thickness each side for wall thicknesses
> 30 to cr 60 mm,
- 20 mm each side for wall thicknesses > 60 mm.
3.2 Nozzle welds and connecting welds
3.2.1 The weld metal and the adjoining base metal shall be
included during testing as far as possible.
3.2.2 When testing for longitudinal flaws, it is sufficient in
test category A to test from one side of the weld with one
beam angle (e.g. positions 1 or 2 in figure 5).
In test categories B and C, testing is performed from both
sides of the weld with one beam angle (e.g. positions 1 and
2 in figure 5).
In addition, for wall thicknesses s > 40 mm in test category
C, a further scan position is to be used (e.g. position 3 in
figure 5).
When testing for longitudinal flaws, the weld metal and the
adjoining base metal shall be included in the complete skip
distance as far as possible.
3.2.3 When testing for transverse flaws, it is sufficient in test
categories A and B and in test category C for wall thicknesses
s 5: 40 mm to test at an acute angle at the half skip distance
using one beam angle and from one surface (e.g. positions
4 and 5 in figure 5).
In test category C for wall thicknesses s > 40 mm, an addi-
tional test from a further surface is required (e.g. positions 6
and 7 in figure 5).
3.2.4 If, because of the geometrical configuration of the
component, a scan position other than that shown in figure
5 is more favourable in terms of the test evidence it provides,
this scan position shall be adopted.
3.3 Direction of testing
Apart from the directions of testing for longitudinal and trans-
verse flaws which need to be applied carefully, all deflections
in between these directions shall be taken into consideration
with regard to the possible location of flaws and all directions
of testing shall be applied to suit this purpose. In addition to
moving the probe to and fro when testing for longitudinal and
transverse flaws, it is sufficient to repeat this operation by
turning the probe in a fanning movement.
In the case of curved surfaces, adequate probe-to-specimen
contact shall be ensured because of the continually changing
contact conditions. In the case of large-scale pool welding
(e.g. electroslag welds), an additional direction of testing for
oblique flaws shall be applied at a side angle of 45 degrees
(figure 3).
In the case of circumferential welds with a diameter
5 101,6 mm, no testing for transverse flaws is necessary.
3.4 Surface condition
Probe-to-specimen contact areas shall be free from bumps
or depressions to allow the probe to make full contact every-
where and to prevent it from tIppIng as well as to make sure
that the beam angle is clearly defined. The probe-to-speci-
men contact area shall be free from rust. scale, spatter and
other contamination which might interfere with probe-to-spe-
cimen contact. Grooves which are at a right angle to the main
sound beam which might have a significant effect on the tests
shall be removed.
3.5 Test frequencies
Generally speaking, a frequency of 4 MHz and a frequency
of 2 MHz shall be used respectively for wall thicknesses
5 40 mm and wall thicknesses > 40 mm.
3.6 Sensitivity adjustments
3.6.1 Recording limits
3.6.1.1 DGS method
The relevant echo heights for the disc-shaped reflectors
given in table 1 are applicable to echoes not due to external
contours.
The echo height of a disc-shaped reflector of 6 mm diameter
is applicable for a tandem scan.
3.6.1.2 Reference block or reference line technique
An indication height of 50% (gain allowance: 6 dB) of the
echo height for the adjusting reflectors stated in figure 6 is
applicable.
3.6.2 Lowering of recording limit when testing for
transverse flaws
If echo indications which cannot be separated (groups of indi-
cations) occur when testing for transverse flaws, the test sen-
sitivity shall be set so that indications are recorded which,
when using the DGS method, exceed the echo height of a
disc-shape reflector having a diameter of 1 mm or, when
using the reference block or line technique, are up to 12 dB
below the soecified recordina limit.
 Page 3 AD-Merkblatt HP 513 Appendix 1, Edition 01.2000

3.6.3 Transfer correction Where recording lengths are more than 10 mm, the lengths
The limit values for recordings given in 3.6.1 only apply after shall be stated. Point-like recordable indications are logged
transfer correction in order to take into account changing pro- as 5 10 mm.
be-to-specimen contact and attenuation conditions in the test If a plateau is clearly recognisable in the echo envelope curve
piece or the differences as compared with the adjusting when the probe is moved or if other signs give an indication
block. This correction shall be checked at various points, pay- of a zonal characteristic, this shall be stated in the test report.
ing special attention to the sonic path lengths in the weld
metal and the uniformity of the surface conditions. Table 2. Echo height undershoot for determining the
recording length’)
Transfer corrections determined at comparable points on the
component shall be used for the testing of nozzle welds and t or a’) Echo height undershoot
connecting welds. mm below registration limit
dB
3.7 Reflection points due to external contour
For shape echoes which may occur at the flanks of beads 5 IO 0
(figure 7, position l), proof of this shall be considered as valid >lOto%40 6
provided that no echo is indicated from the probable location
of the reflection point when scanning from the other side of 5 40 12
the welded joint (figure 7, position 2). ‘) The accuracy of measurement of the recording length may be increased by
means of addltlonal probes taking Into account the sound beam opening. e.g.
A test block with the same thickness, sound velocity and, if probes wth higher test llmlts or focusing probes.
applicable, curvature as the test object having a 1 x 1 mm 2) See figures 1 to 3 of AD-Merkblatt HP 93.
rectangular notch shall be used to furnish proof of shape
echoes in welds having a narrow root. Mark the location of
the maximum echo height of the notch on the screen. Mea-
sure the reduced projection on the test block (figures 8a and 4 Surface crack test
b). Scan the reflection points to be investigated in accord-
ance with figures 8c and d so as to superimpose the base 4.1 Magnetic particle flaw detection (MP)
of the echo indications thus obtained- ignoring the maximum 4.1 .l Preparation of surface
echo height - on the previously determined mark on the The weld bead and the transition zones shall be clean and
screen (figure 8e). Mark the dimension for the reduced pro- free from scale. If there is any suspicion of cracks or if cracks
jection a’ determined according to figure 8a on the surface have already appeared, the test shall be performed on surfa-
(figure 8~). Unless otherwise agreed, proof shall be consi- ces which have been ground.
dered as valid if both marks are at least 3 mm apart. Other-
wise the echo indications shall not be classified as shape 4.1.2 Direction of magnetisation
echoes (figure 8d).
Each part of the surface shall be tested with two different
Table 1. Recording limit as a function of welded wall thick- directions of magnetisation which, if possible, should differ
ness for longitudinal and transverse flaws from each other by 90 degrees. The angles between the two
field directions shall be within the 50 degrees to 130 degrees
tl)*) or a*) Diameter of disc-shaped reflector range.
mm mm
Ferrous materials Aluminium materials 4.1.3 Field strength and test fluid
The intensity of the tangential field on the surface shall not
Angular Normal Angular be less than approximately 2 kAim and shall not exceed
incidence incidence incidence 6,5 kA/m. These values shall be checked either by measur-
515 1k-J zo 13 ing or the test conditions under which the said values can be
>15tos20 1,5 zo 1,5 maintained shall be found. The test medium (test fluid) shall
> 2 0 to 5 4 0 2,0 2s 24 be spot-checked by the Berthold test on the magnetised test
>40 38 3,o w piece.
‘) See figures 1 to 3 of AD-Merkblatt HP 513.
2) In case of ditferent wall thicknesses, the lesser thickness applies without tak- 4.1.4 Points of contact with self-circulation
ing the height of the bead Into account.
4.1.4.1 If testing is performed using self-circulation, consu-
mable electrodes (e.g. lead-tin alloys) shall be used if pos-
sible. Ensure that overheating of the material to be tested is
The procedure is similar in the case of fillet welds with indica- avoided in areas of contact.
tions from the root opening unless the root opening has to 4.1.4.2 If overheated areas nevertheless occur, they shall
be considered as an integration defect. be marked, ground after completion of testing and subjected
In nozzle welds with deliberately designed unwelded gaps, to a surface crack test, preferably using magnetic particle
it is considered a defect if, on account of the half-value tole- flaw detection with yoke magnetisation.
rance, the test shows that the gap extends in depth more than
4.2 Penetrant method
3 mm in excess of the intended as-designed dimension. It is
advisable to use a suitable test piece. The test is performed and the test medium is tested accord-
ing to DIN 54152
3.8 Extension of reflection points
When the recording limit is exceeded, the length of reflection 4.3 Other methods
points is indicated by the distance of the probe when the echo If any methods other than those described in 4.1 and 4.2 are
heights dropped below the recording limit as specified in employed, the necessary requirements shall be agreed with
3.6.1 by the df3 values stated in table 2. the parties concerned.
Page 4 AD-Merkblat! HP 5/3 Appendix 1, Edition 01.2000

Pos.1 Pos.2

Pos:O Pos.4

Figure 1. Probe positions when testing for longitudinal

flaws
Test category A: pos. 1, 2, 3 or 4
Test category B
and C: pos. 1 and 2 or pos. 3 and 4

Figure 4. Angle of incidence where geometry of material is

curved in direction of testing

Pos.1
Pos.3

0 1
R

1
6/
Pos.5

f t
t

Pos.4
c20
h!
I
Pos.2
0 Pos.6

Weld

Figure 2. Probe positions when testing for transverse flaws

T e s t category A: pos. 3 and 4 or pos. 5 and 6 if pos. 1 and
2 not possible
T e s t category 9: pos. 3 to 6 if pos. 1 and 2 not possible
T e s t category C: pos. 1 and 2

@ 0 Testing for transverse flaws in two opposite

450< Pos.4 @ 0 directions of testing with angle of impingement relative
to the weld
Pos.3

R
Pos.2
63 1

II
d Test Wall thickness
catgofy s
mm
Pos.1 0 or 0 0 and 0
A all
m- B all
0 and 0 0 and 0
5 40
-
C
> 40 0 and 0 a n d 0 @ and 0 and
@ and 0
Figure 3. Probe positions when testing for longitudinal,
oblique and transverse flaws
Pos. 1: Longitudinal flaws Figure 5. Test catgories for ultrasonic examination of
Pos. 2: Oblique flaws nozzle welds and connecting welds
Pos. 3 or 4: Transverse flaws
 P a g e 5 AD-Merkblatt HP 50 Appendix 1, Edition 01.2000

s 5 10

Hole d i a m e t e r = 3 m m

15<.sS20

Hole diameter = 3 mm b= s,- 10

20 < s I 4 0

Sj-10
Hole diameter = 3 mm b=2

40 < s 5 8 0

sj- 10
Hole diameter = 3 mm b=?

80 < s

sj-10
Hole diameter = 3 mm b=-
4

Figure 6. Adjusting or comparison block for sensitivity adjustment in case of oblique incidence
P a g e 6 AD-Merkblatt HP 513 Appendix 1, Edition 01.2000

Pos. 1: Pos. 2:
E c h o mdlcation N o e c h o mdlcation

Figure 7. Example of proof of shape echo

a’ a’

a) d) Defect

Pos. 1 Pos. 2 and 3

b) a’ e) a’

Figure 8. Proof of shape echoes by comparison with the echo indication

for a groove
 n

UDC 621.785:621.642-98 Edition July 1989

Manufacture and AD-Merkblatt

Heat treatment
Testing of
Pressure Vessels General principles HP 7/l

T h e AD-Merkbl&ter a r e c o m p i l e d b y t h e s e v e n t r a d e a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “ A r b e i t s g e m e i n s c h a f t Druck-
,eh#ter” (AD). AD-Merkblatt G 7 covers the composition and application of the AD-Regulations and also the procedural rules.
T h e AD-Merkbltitter cover s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l c o n d i t i o n s o f o p e r a t i o n . I n t h e e v e n t o f s t r e s s e s o v e r
snd above the normal level being anticipated during the operation of pressure vessels, allowance must be made for such stresses by
neeting special requirements.
Should there be any departures from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis,
Jperating experience.
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e. % (FDBR), Diisseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V.. Sankt Augustin
Verband der Chemischen lndustrie e. K (VCI), Frankfurt/Main
Verband D e u t s c h e r M a s c h i n e n - u n d A n l a g e n b a u e . V. ( V D M A ) , F a c h g e m e i n s c h a f t Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Diisseldoti
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkraftwerksbetreiber e.V., E s s e n
V e r e i n i g u n g d e r T e c h n i s c h e n iiberwachungs-Vereine e . V. (VdTiiV), Essen.
T h e AD-Merkbl@ter a r e a m e n d e d c o n t i n u o u s l y b y t h e t r a d e a s s o c i a t i o n s In k e e p r n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
,e addressed to the publisher:
Vereinigung der Technischen iiberwachungs-Vereine e. V., Postfach 103834, D-4300 Essen 1.

Contents

1 Scope
2 Principles of heat treatment
3 Certificates

I Scope points to suit the size of the equipment or the workpiece.

rhis AD-Merkblatt specifies the prerequisites and types of
lest treatment for pressure vessels or pressure vessel com-
Ionents after cold forming, hot forming and types of postweld
ieat treatment. Tests after forming are dealt with in AD-
vlerblatter HP 811 and HP 8/2.
2 Principles of heat treatment
!.1 Manufacturers shall have the
?nable the heat treatment processes
jut properly. Equipment not owned
)e used provided it meets these
!.2 The equipment used in heat treatment shall make it
)ossible to maintain sufficient accuracy and uniformity of
emperature in the workpiece when applying the chosen type
If heat treatment. This applies, in particular, to materials
vhere the range of temperature allowed in heat treatment is
;mall.
skilled personnel shall be employed in the operations of heat
reatment and temperature measurement.
n the case of stationary equipment used in heat treatment,
he temperature curve shall be recorded throughout by re-
:ording instruments with an adequate number of measuring
Where, in the case of movable equipment for heat treatment,
no recording instruments are used, the measured results
shall be noted down.
2.3 The temperature measuring equipment shall be
checked at reasonable intervals with data on check-ups
being recorded. In the case of pressure vessels which are
to subjected to a construction inspection by the authorised
inspector, the latter is entitled to inspect the records.
2 . 4 As a rule, pressure vessel components shall be sub-
necessary equipment to jetted to heat treatment as a whole. Variations are allowed
in the case of stress relief and tempering heat treatment of
in question to be carried
by the manufacturer may welds and in locally formed regions if the heat treatment fully
covers the welded joint or the deformation zone, e.g. a cylin-
prerequisites.
drical section of adequate width in the case of cylindrical
components or a sufficient width of the weld zone over the
length of the weld in the case of longitudinal welds in open
part-shells. Abrupt changes of temperature are to be
avoided.
2.5 The temperature and duration of heat treatment de-
pend on the material and the component. Details on this are
generally stated in the material specifications. The heating
and cooling rates shall also be determined depending on the
material, wall thickness and component dimensions.
Where different types of materials are joined, it may be
necessary to use temperatures other than those stated. In

Supersedes Edition April 1975; completely revised

Page 2 A D - M e r k b l a t l H P 7/l, E d i t i o n 0 7 . 8 9
such cases the appropriate conditions for
shall be decided, if necessary, as part of the
fication test. Where stipulations exist for
materials which are frequently used, such
be applied.
2 . 6 Where individual test pieces are to be heat treated for
material tests, measures shall be taken to ensure that the
control of temperature is the same as for the corresponding
pressure vessels or pressure vessel components. This usu-
ally requires special measures where small test pieces are
put in for heat treatment together with large components.
3 Certificates
3.1 A certificate relating to heat treatment for all pressure
vessels and pressure vessel components which have under-
heat treatment gone heat treatment shall be issued by the works where the
procedure quali- heat treatment was carried out, stating the temperature,
combinations of method of cooling and, if applicable, the holding time. It shall
stipulations shall also certify that evidence of the suitability of the equipment
used for heat treatment has been furnished. This certificate
is not necessary in the case of pressure vessels which are
not to be subjected to a construction inspection by the
authorised inspector provided an attestation of correct manu-
facture is made.
3.2 For hot-formed pressure vessel components which
were not subjected to heat treatment after hot-forming, an at-
testation stating that the forming was started and completed
within the range of temperatures stated in the material
specification for the material shall be issued by the manufac-
turer of the said components. The cooling conditions shall
also be stated.
IIDC621.785:621.642-98-034.15-l 94.57
--- -- -_.____ -..- .- -- ~~ Edition Julv 1989 I

Manufacture Heat treatment AD-Merkblatt

and Testing of
Pressure Vessels Ferritic steels HP 712

The AD-MerkblStter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck
5ehSlter” (AD). AD-Merkblatt G 1 covers the composition and application of the AD-Regulations and a/so the procedural rules.
The AD-Merkblatter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses eve,
snd above the normal /eve/ being anticipated during the operation of pressure vessels, allowance must be made for such stresses b]
neeting special requirements.
Should there be any depan’ures from the provisions of this AD-Merkblatf, it must be possible to demonstrate that the safety standard:
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis
operating experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e. l ! (FDBR), Diisseldorf
Hauptverband der gewerblichen Berufsgenossenschafien e.V., Sankt Augustin
Verband der Chemischen lndustrie e. V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Diisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r Grob’kraftwerksbetreiber e . K, E s s e n
V e r e i n i g u n g d e r T e c h n i s c h e n iibenvachungs-Vereine e . K (VdTiiV), Essen.
T h e AD-Merkbl&ter a r e a m e n d e d c o n t i n u o u s l y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s shoull
be addressed to the publisher;
Vereinigung der Technischen iiberwachungs-Vereine e. K, Postfach 103834, D-4300 Essen 7.

Contents

1 Scope 4 Heat treatment after welding

2 Heat-treatment after cold-forming 5 Heat treatment of pressure vessels,
3 Heat-treatment after hot-forming or parts thereof, with special requirements

1 Scope 2.2 In the case of pressure vessels operating at charge

medium temperatures below -10 “C, the heat-treatmen
This AD-Merkblatt specifies the methods of heat-treatments (normalizing or tempering) of parts shall comply with the
for pressure vessels and pressure vessel parts of ferritic material specifications in the case of the following stee
steels after cold-forming, hot forming and welding. It does not grades:
include stainless and heat-resistant ferritic chrome steels’). (1) Steel grades to DIN 17102, 17173, 17174, 17178
17179 and 17280 with the exception of 10 Ni 14,12 h
19 and X 8 Ni 9 where deformation exceeds 2%.
2 Heat-treatment after cold-forming
(2) SteelgradeslONi14,12Ni19andX8Ni9toDIN1728~
Before cold-forming takes place, the condition in which the where deformation exceeds 5 %.
materials are supplied shall comply with the provisions con-
tained in the W-series of the AD-Merkblatter. With regard to 2.3 Cold-formed ends and those fabricated from weldel
the possible changes in the properties of materials due to blank discs shall be heat-treated (normalizing and temper
cold-forming or ageing, the following principles shall be ing) in accordance with the material specifications.
adhered to: 2 . 4 The provisions contained in Sections 2.1 to 2.3 may bc
2.1 Parts for pressure vessels which operate at tempera- waived if evidence is supplied that the material properties arc
tures subject to weather conditions or at charge medium such that they withstand the stresses to which the pressure
temperatures down to -10 “C shall be heat-treated (nor- vessel is subjected during operation.
malizing or tempering) in accordance with requirements of 2 . 5 Cold-formed torispherical ends in RSt 37-2 or St 37-Z
the material specification where deformation exceeds 5% to DIN 17100, H I or H II to DIN 17155 or StE 255 to DIF
(for cylindrical parts and spherical segments s > 0,05 . D,). 17 102 and also in other grades of steel of comparabk
strength do not require heat treating provided the charge
1) Until these steels are made the subject of an AD-Merkblatt. the VdTijV-
Werkstoffbl&ler apply. medium temperature does not fall below - 10 “C and the cal

Supersedes Edition September 1981; completely revised

Carl Heymanns Verlag KG Translation: Techntcal Help to txponers betvlce 01 ubl

Luxemburger StraBe 449, 5000 Kijln 41
GutenbergstraBe 3, 1000 Berlin 10
P a g e 2 AD-Merkblatt HP 7/2, Edition 07.89
culated temperature as stated in AD-Merkblatt B 0, Section 4,
does not exceed 120 “C and the nominal wall thickness does
not exceed 8 mm.
2 . 6 In the case of cold-bent tubes with a radius r, -s 1,3 ’ da
of steel grades conforming to the DIN standards cited in AD-
Merkblatt W 4, heat-treatment is not necessary for external
diameters not exceeding 133 mm. Heat-treatment is not
usually necessary for the pipes which comply with the DIN
standards cited in AD-Merkblati W 4 and which have been
cold-bent with a radius r,,, 2 2,5 . da. The exceptions are low-
temperature steel tubes with wall thicknesses over 2,5 mm
and cold-bent tubes which have to be heat-treated due to
their exposure to corrosive conditions or because parts ex-
posed to loading need to be welded outside the neutral zone.
2 . 7 Where the permissible degrees of deformation are ex-
teed in cold-forming, heat-treatment shall normally be
applied prior to welding.
2 . 6 In the case of pressure vessels (or parts thereof) of clad
elate. heat-treatment shall be applied to correspond with the
base.material, unless special a;r&gement have been made
on account of the plating.
3 Heat-treatment after hot-forming
3.1 Following hot-forming, heat-treat the pressure vessel
parts in accordance with the instructions in the material
specification.
3 . 2 If forming has been started and completed within the
temperature range cited in the material specification, post-
forming normalizing may be dispensed with in the case of
normalized steels. Air-hardening steels require a final tem-
pering process.
3 . 3 The provisions in Table 1 apply where pressure vessel
parts are formed locally, provided that prior to forming the
pressure vessel parts correspond with the condition of the
material as supplied (heat-treatment condition) as stated in
the W-series of the AD-Merkblatter.
4 Heat-treatment after welding
4.1 The need for post weld heat-treatment and the method
used depend on the chemical composition of the materials
and the fillers, the shape of the components, the wall thick-
ness, welding conditions, strength properties, the extent of
non-destructive testing and any additional rules which may
have to be followed.
4.2 No heat-treatment is required after welding if all the
conditions in Table 2 are met and if all the parts are in the
same heat-treatment condition before welding as specified
in Section 2 and 3 or in the W-series AD-Merkbltitter.
4.3 As a rule, if heat-treatment is required after welding,
stress relief heat-treatment or tempering are sufficient.
4 . 4 Taking into account the mechanical properties of the
weld material, workpieces shall be normalized or quenched
and tempered if
(1) the properties required of the welded joint can only be
attained by normalizing or quenching and tempering;
(2) the workpiece has been col-formed prior to welding with-
out subsequent heat-treatment and 2 % or 5 % levels of
deformation are exceeded (see Section 2).
4.5 With clad pressure vessel parts, heat-treatment shall
be carried out according to the base material, provided no
special arrangements have to be made regarding the clad-
ding.
4 . 6 Parts shall be welded into or onto pressure vessels prior
to heat-treatment. This rule may be waived for small parts
if the welded joints and the properties of the materials under
service conditions so permit. In the case of pressure vessels
which have to be structurally tested by the authorized inspec-
tor, his permission shall be obtained.
5 Heat-treatment of pressure vessels, or
parts thereof, with special requirements
Where special requirements apply with regard to the heat-
treatment condition (e.g. if there is a corrosion risk), these
shall be agreed before the order is placed. The authorized
inspector shall give his consent in cases where the heat-
treatment agreed would substantially impair the properties of
the material. If a different heat-treatment is applied, this shall
be mentioned in the certificate described in Section 3 of
AD-Merkblatt HP 7/l.
 Page 3 AD-Merkblatt HP 712, Edition 07.89

Table 1: Examples of local forming and heat-treatment required for cylindrical components and vessel ends

Steel components in the delivery condition as listed

Forms of construction
Normalized Air-hardened Others

d No heat-treatment With shapes B and Renewed heat-

for steels with
minimum tensile
strength
R, < 470 N/mm2 1).
With steels having a
minimum tensile
strength
R, 2 470 N/mm’
the entire compo-
nent shall be nor-
malized
C the cylinder set- t r e a t m e n t o f t h e e n
tion in question is tire component in
tempered’). accordance with the
With shapes A (A’), i n s t r u c t i o n s i n t h e
the entire compo- m a t e r i a l specifica-
nent is air- tion for each of the
hardened. steel grades in
question.

Necking: d / D C 0 . 8

Temper the whole

component

Heat-treatment zones are represented by the hatched areas.

1) Except for special steels such as fine-grain structural steels to DIN 17102, 17178 and 17179 and low-temperature steels to DIN 17280, 17173 and 17174.
2) Annealing of cylinder sections, provided there is no interactIon in the annealing process.
P a g e 4 AD-Merkblatl HP 7/2, Edition 07.89

Table 2: Conditions under which no postweld heat treatment is required

Extract from Synoptic Table 1 in AD-Merkblatt HP 0

laterial Steel grades Conditions to be met when om#ting postweld heat treat-
3roup merit. Postweld heat treatment can be omrtted provided
‘) the additional requrrements rn Column 5 depending on
wall thickness and steel grade are met.

Wall Steel grades Other additional

thickness within requirements
limits relevant
Material
Group

mm

1 2 3 / 4 5

1 Steels in the following analysis 5 30 / all none

groups (ladle analysis) with
minimum yield point > 30 5 38 / Basic and , none
<: 370 Nlmm29) except steels with ; high-temper- i
high impact strength at low temper- ( ature Serves
I of fine-grarned I
ature if used act. to AD-Merkblatt
W 10 in stress category I below structural (
-10°C steels act. to
DIN 17102, /
C 5 0.22 5 0.20 17176 and
Si 5 0,50 17179 and
c; 0.50
Mll 5 1.6 25 08 (steel grades
MO - 5 0.65 i which. act. lo
P, S each 5 0,05 each 5 0,05 material
other 1 speciflcatron.
total 5 0,8 5 0,5 I meet same
other ’ mrmmcm Im-
single 5 0,3 5 0,3 Ipact strength
requirements :

> 36 zz 50 All steel Simple geometrlcal

i grades wrth a shape (sphere, cylrnder);
1specified rm- 100 % non-destructrve
1 pact strength I testmg. load stress dur-
2 31 J at 0 “Cl mg pressure test
m transverse / 2 0.85 R,,,,at room tem-
dIrectron (ISO-, perature; special brrnle
V-notch specs- fracture Investigation.
men) Components with nozzles
and weld-on parts to be
heat treated beforehand

2 Fine-grained structural steels with s 30 Basic and none

minimum yield point high-tempera-
? 370 to < 430 N/mm2 except ture Series of
steels with high impact strength at fine-grained
low temperature if used act. to AD- structural
Merkblatt W 10 in stress category f steels act. to
below - 10 “C DIN 17102,
17178 and
17179 and
steel grades
which, act. to
material
specification,
meet same
minimum im-
pact strength
requirements

3 Fine-grained structural steels with 5 30 all none

minimum yield point 2 430 N/mm2
except steels with high impact
strength at low temperature if
used act. to AD-Merkblatt W 10
in stresscategory I below -10°C

High-temperature structural See assessment of suitability

l%Mo”53 , 13MnNiMo54,
17 MnMoV 6 4, ZOMnMoNi55,
15 NiCuMoNb 5, 22NiMoCr37,
12 MnNiMo 5 5, 20MnMoNi45
 P a g e 5 AD-Merkbiatl HP 7/2, Edition 07.69

Table 2: Conditions under which no postweld heat treatment is required

Extract from Synoptic Table 1 in AD-Merkblatt HP 0
(Continued)

ateriai Steel grades Conditions to be met when omitting postweld heat treat-
lroup ment. Postweld heat treatment can be omitted provided
‘) the additional requirements in Column 5 depending on
wall thickness and steel grade are met.

Wall Steel grades Other additional

thickness wfthin requirements
limits relevant
Material
Group

m m

1 2 3 ! 4 5

4.1 High-temperature steels: Postweld heat treatment necessary

13CrMo44,10CrMo910,
12 CrMo 19 5, X 10 CrMo 9 1

4.2 High-temperature steels: Postweld heat treatment necessary

14MoV63
X 20 CrMoV 12 1

5.1 Fine-grained structural steels act. 5 30 all none

DIN17102.17178and17179in
Series with high impact strength > 30 C 38 Bas’c a”d “One
at low temperature and specfal hfgh-temper-
Series with hfgh impact strength ature Serves of
at low temperature having fine-gralned
minimum yield point structural
< 370 N/mm*. Fine-gramed struc- ’ steels act to
tural steels act. to DIN 17 102, DIN 17102.
17178 and 17179 in basic and 1 17178and
high-temperature Series with 17179 and
minimum yield point < 370 N/mm* i steel grades
if used act. to AD-Merkblatt W 10 which, act. lo
in stress category I below - 10 “C. material
Steel grades TTSt 35 N and specfficatfo”. 1
lTSt 35 V act. to DIN 17 173 and meet same
17 174 and steel grades 11 MnNi mrnimum im-
5 3 and 13 MnNi 6 3 act. to pact strength ;
D I N 17280,17173and17174at requirements
lowest operating temperatures
down to -60 “C25) inclusive. z 38 _( 50 All steel Simple geometrical
grades with a shape (sphere, cylinder);
specified im- 100 % non-destructive
pact strength testmg; load stress dur-
2 31 J at 0 “C ing pressure test
in transverse 2 0365 R,,,, at room tern
direction (ISO- perature; special brittle
V-notch speci- fracture investigation.
men) Components with nozzle S
and weld-on parts to be
heat treated beforehandI

5.2 Fine-grained structural steels act. 5 30 all none

toDIN17102,17178and17179
in Series with high impact strength
at low temperature and special
Series with high impact strength
at low temperature having
minimum yield point 2 370 N/mm2
to < 430 Nlmmn. Fine-grained
structural steels act. to DIN
17102,17178and17179inbasic
and high-temperature Series with
minimum yield point 2 370 N/mm2
to > 430 N/mm2 if used act. to
AD-Merkblatt W 10 in stress
category I below -10 “C. Steel
grade lTSt 35 V act. to DIN
17173 and 17174 at lowest
operating temperatures below
-60 “W).
Page 6 AD-Merkblatt HP 7/Z, Edition 07.89

Table 2: Conditions under which no postweld heat treatment is required

Extract from Synoptic Table 1 in AD-Merkblatt HP 0
(Continued)
r
MZ aterial Steel grades Conditions to be met when omitting postweld heat treat-
E iroup merit. Postweld heat treatment can be omitted provided
‘) the additional requirements in Column 5 depending on
wall thickness and steel grade are met.

Wall Steel grades Other additional

thickness within requirements
limits relevant
Material
Group

mm

1 2 3 4 5
5.3 Fine-grained structural steels act. 5 30 all none
toDIN17102.17176and17179
with minimum yield point
B 430 N/mm2 in Series with high
impact strength at low tempera-
ture and special Series with high
impact strength at low tempera-
ture. Fine-grained structural
steelsacc. to DIN 17102,17 178
and 17179 with minimum yield
point P 430 N/mm* in basic and
high-temperature Series if used
according to AD-Merkblatf W 10
in stress category I below
-10 “C25).
I
5.4 Steels with high impact strength I 5022)
at low temperature act. to YE’:% i ~$$.::::d;$$
DIN17280,17173and1717425) metals

530 ~ mw; Base metal and weld

metal are of the same
type

6 Austenitic steels act. to none all The addltional require-

DIN 17440, 17441, 17457 and merits as specified in Set
17458 as well as SEW 400 tion 4 of AD-Merkblatt
HP 7/3 are to be observec

7 Ferrite-free austenitic steels but none all The additional require-

possibly with ferrite in the weld merits as specified in
metal and austenitic steels in Section 4 of
Material Group 6 provided they AD-Merkblatt HP 7/3 are
are welded using filler materials to be observed
with 5 3% delta ferrite in weld
metal, e.g.
X 8 CrNiNb 16 13,
X 8 CrNiNb 16 16,
X 8 CrNiMoVNb 16 13

8 Ferritic austenitic steels, e.g. none all none

X 2 CrNiMoN 22 5 3

Footnotes for Table 2

I) Other materialsto be assigned to comparable Material Groups according to material specifications as stated in the assessment of suitability. Where com-
ponents made from different Material Groups are welded together, the Group having the greater scope of testing is applicable.
9, Scope of testing to be extended accordingly if caustic crack resistance is required.
**) Heat treatment does not always signify an improvement in properties. The possible benefits of dispensing with heat treatment should also be considered
in the case of wall thicknesses > 50 mm. Special agreements shall be made.
25) If steels in Material Groups 5.1 to 5.4 are used at lowest operating temperatures 2 - 10 “C and the requirements in AD-Merkblatt W 10 are met, the same
provisions apply as for Material Groups 1 to 3.
UDC
--- 621.785:621.642-98-034.15-l
--~-~--~~ ~~ ~~ 94.56 Edition Julv 1989

Manufacture and AD-Merkblatt

Heat treatment
Testing of
Pressure Vessels Austenitic steels HP 7/3

T h e AD-Merkblstterare c o m p i l e d b y t h e s e v e n t r a d e a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “ A r b e i t s g e m e i n s c h a f t Druckbehdl-
ter” (AD). AD-Merkblatt G 1 covers the composition and application of the AD-Regulations and a/so the procedural rules.
The AD-Merkbl&ter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
and above the normal /eve/ being anticipated during the operation of pressure vessels, allowance must be made for such stresses by
meeting special requirements.
S h o u l d t h e r e b e a n y d e p a r t u r e s f r o m t h e p r o v i s i o n s o f t h i s A D - M e r k b l a t t , i t mu.9 b e p o s s i b l e t o d e m o n s t r a t e t h a t t h e s a f e t y s t a n d a r d s e m b o -
died in these regulations have been observed by means of alternative approaches, e. g. testing of materials, tests, stress analysis, operating
experience.
Fachverband Dampfkessel-, BehBlter- und Rohrleitungsbau e. V. (FDBR), Dtisseldorf
Hauptverband der gewerb/jchen Berufsgenossenschaften e.V., Sankt Augustin
Verband der Chemischen lndustrie e. V. (VU), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschafi Verfahrenstechnische Maschinen und
Apparate, Frankfurt/Main
Verein Deutscher Eisenhiji?enleute (VDEh), Dijsseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkraftwerksbetreiber e. V., Essen
Vereinigung der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
The AD-Merkbldtter are amended continuously by the trade associations in keeping with technical progress. Relevant proposals should
be addressed to the publisher:
Vereinigung der Technischen iiberwachungs-Vereine e. V., Postfach 103834, D-4300 Essen 7.

Contents

1 Scope 4 Heat treatment after welding

2 Heat treatment after cold-forming 5 Heat treatment of pressure vessel parts
3 Heat treatment after hot-forming with special requirements

1 Scope the required minimum values for elongation at break AS are

less than 30 %, if the acceptance certificate shows that elon-
This AD-Merkblatt specifies the methods of heat treatment gation at break A, is not less than 30 %;
for pressure vessels or parts thereof made of austenitic steel 2.2.2 with levels of cold-forming above 15 %, proof can be
and listed in Table 1, following cold-forming, hot-forming or
furnished in individual cases that residual elongation at break
welding. The heat treatment of other austenitic steels will
A, after cold-forming remains at least 15 %;
depend on the provisions of the assessment of suitability.
2.2.3 with semi-ellipsoidal, torispherical and hemispherical
ends, the acceptance certificate for the base materials show
the following values for elongation at break A,:
2 Heat treatment after cold-forming (1) 2 40 % in the case of wall thicknesses 5 15 mm at
charge medium temperatures down to - 196 “C,
2.1 Accepted types of heat treatment are solution anneal-
(2) 2 45% in the case of wall thicknesses > 15 mm at
ing and quenching or stabilizing in accordance with columns
charge medium temperatures down to -196 “C,
5 to 7 in Table 1.
(3) 2 50 % at charge medium temperatures below - 196 “C;

2.2 Solution-annealed and quenched or stabilized mate-

rials do not require heat treatment after cold-forming if 2.2.4 deformation does not exceed 10% in the case of
pressure vessel parts (excluding) ends operating at charge
medium temperatures below - 196 “C.
2.2.1 in the case of austenitic steels with required minimum
values for elongation at break A5 2 30 %, a 15 % level of cold
deformation is not exceeded on the base material or if evi- 2 . 3 As a rule, cold-bent tubes at rm 2 1,3 . d, bending radii
dence is supplied that there is a minimum post cold-forming do not require heat treatment.
residual elongation A5 of 15%. Such evidence shall be Section 2.2.4 applies in the case of cold-bent tubes operated
deemed supplied in the case of dimensional ranges where at charge medium temperatures below - 196 “C.

Supersedes Edition April 1975; completely revised

l;an Heymaws Verlag Kti

- - .--.
T r a n s l a t i o n : T e c h n i c a l H e l p t o E x p o r t e r s Serwce ot BSI
Luxemburger StraBe 449, 5000 K6ln 41
GutenbergstraBe 3, 1000 Berlin 10
Page 2 A D - M e r k b l a t t H P 713, Edition 07. 8 9
3 Heat treatment after hot-forming-
For heat treatment or the waiving of heat treatment after hot-
forming, see Table 1. : It may be that, where special demands are made on hot or
4 Heat treatment after welding
Post welding heat treatment is not usually necessary.
5 Heat treatment of pressure vessel parts
with special requirements
cold-formed pressure vessel parts or welded joints -e.g. with
regard to machining, dimensional accuracy, risk of stress
corrosion, resistance to intercrystalline corrosion or applica-
tion at high-temperatures in the creep range, the provisions
in Sections 2, 3‘and 4 may not always be sufficient. In such
cases a suitable condition of heat treatment shall be agreed
when the order is placed.
 P a g e 3 AD-Merkblatt HP 7/3. Edition 07. 89

Table 1: Synopsis of heat treatment of formed austenitic steels

Steel Grade Conditions under which Data Solution

postforming heat treatment on heat treatment Annealing -
may be waived: w h e n s t a b i l i z i n g l) Type of Cooling
Abbreviation Material Non-welded Welded Non-welded Welded s 2 6 mm (W, SL)
Number parts parts parts parts s -c 6 mm (L)
1 2 3 4 5 6 7

Stabilized steels Forming started Forming started

K 6 CrNiTi 18 10 1.4541 at 1000 to at 1000 to 900 + 20 “C 920 k 20 “C 2 1 0 2 0 “C
X 6 CrNiNb 1 8 1 0 1.4550 1150°C and 1150°C and 0-J
finished at finished at
K 6 CrNiMoTi 17 12 2 1.4571 > 750 “C > 750 “C
X 6 CrNiMoNb 17 12 2 1.4580 (fastest
c o o l i n g ) . possible c[fastest
o o l i n g ) possible not permitted not permitted
X4 NiCrMoCuNb 20 18 2 1.4505 2 1 0 5 0 “C
Starting temp. of
Steels with 5 0,03 % C 1 0 0 0“C m a y be
lowered if part
X2CrNi1911 1.4306 900 + 20 “C 920 + 20 “C
X 2 CrNiN 1 8 1 0 1.4311 qwas
u e n cin
h ethe
d state u-1 W3) j z looo”c
X 2 CrNiMo 17 13 2 1.4404 prior to and stabilized
X 2 CrNiMo 18 14 3 1.4435 hot-forming. fillers 2 1 0 2 0 “C
X 2 CrNiMoN 17 12 2 1.4406 960 + 20 “C 980 k 20 “C
v-)4) W3)“)
X 2 CrNiMoN 17 13 3 I,4429 2 1040°C
X 2 CrNiMo 18 16 4 1.4438
X2CrNiMoN17155 1.4439 or non-stabilized

I ~~~~~ C in
weld metal

Steels with 5 0,07 % C Forming started Forming started

X 5 CrNi 18 10 I .4301 at 1000 to at 1000 to not permitted not permitted i 2 1 0 0 0 “C
X5CrNi1812 1.4303 1 1 5 0 C2), a n d 1 1 5 0 OCZ), a n d I
finished at finished at
X 5 CrNiMo 17 12 2 1.4401 L=- 875 “C > 875 “C not permitted not permitted 1 2 1 0 5 0 “C
X 5 CrNiMo 17 13 3 1.4436 ( q u e n c h i n g in/ (quenching in/
with water for with water for
wall thicknesses wail thicknesses
2 6 mm). ?6mm)
Starting temp. of
1 0 0 0 “C m a y b e and stabilized
lowered if part fillers
was in the
quenched state or non-stabilized
prior to fillers with
hot-forming. 5 0,06%C.

1) Stabilizing or corresponding annealing in the case of non-stabilized steels with approx. 30 min critical Interval.
?) Minimum critical interval 5 mm.
3) Stabilizmg not permissible if stabilized fillers are used.
:) Steels 1 A.406 and 1.442g may be stabilized at lower temperatures if the authorized inspector IS supplied with proof Of their equivalence.
:L) Cooling in/with air;
(W, SL) Quenching m/with water or cooling in air flow
IJDC 621.786:621.642.02-98.002.2:621.642.02-034.71 Edition July 1989

Manufacture and AD-Merkblatt

Testing of Heat treatment
Pressure Vessels Aluminium and aluminium alloys HP 714

h e AD-Merkbldtter a r e c o m p i l e d b y t h e s e v e n t r a d e a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “ A r b e i t s g e m e i n s c h a f t Druckbehdl-
?r” ( A D ) . AD-Merkblatt G 1 c o v e r s t h e c o m p o s i t i o n a n d a p p l i c a t i o n o f t h e A D - R e g u l a t i o n s a n d a l s o t h e p r o c e d u r a l r u l e s .
he AD-Merkblatter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
nd above the normal /eve/ being antfcipated during the operation of pressure vessels, allowance must be made for such stresses by
leeting speoal requirements.
;hou/d t h e r e b e a n y d e p a r t u r e s f r o m t h e p r o v i s r o n s o f t h i s A D - M e r k b l a t t , i t m u s t b e p o s s i b l e t o d e m o n s t r a t e t h a t t h e s a f e t y s t a n d a r d s embo-
lied i n t h e s e r e g u l a t i o n s h a v e b e e n o b s e r v e d b y m e a n s o f alternafive a p p r o a c h e s , e . g . t e s t i n g ofmaterrals, tests, stress analysis, operating
xperience.
Fachverband Dampfkessel-, Behdlter- und Rohrleltungsbau e.V. (FDBR), Dijsseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e. V., Sank? Augustin
Verband der Chemischen lndustrje e. V. (VCI), FrankfuriJMain
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen und
Apparate, Frankfurt/Main
Vereln Deutscher fisenhiittenleute (VDEh). Dtisseldorf
V G B Technrsche Veremigung d e r GroBkraftwerksbetreiber e . V . , Lessen
Vere,nfgung d e r T e c h n i s c h e n iiberwachungs-Vereine e . V . (VdTijV), Essen.
-he A D - M e r k b l a t t e r a r e a m e n d e d cont!nuous/y by the trade associabons in keeping with technical progress. Relevant proposals should
)e addressed to ihe publrsher.
Vereinigung der Technischen iiberwachungs-Vereine e.K, Postfach 103834, D-4300 Essen 1.

Contents

1 Scope 4 Postweld heat treatment

2 Heat treatment after cold forming 5 Heat treatment of pressure vessel components where
3 Heat treatment after hot forming special requirements exist

Scope 2 Heat treatment after cold forming

‘his AD-Merkblatt deals with the heat treatment (soft anneal- 2.1 Heat treatment may be omitted if the conditions speci-
lg) of pressure vessels or pressure vessel components fied in Table 1 are satisfied.
lade from aluminium and aiuminium alloys after cold form-
lg, hot forming or welding.

'able 1. Conditions governing the omission of heat treatment after cold forming

Material group Cylindrical part-shells, spherical D o m e d e n d s Cold-bent pipes/tubes

or material segments, conlcal part-shells I
with or without flange Residual elongation ~
Permissible degree of cold forming ; a t faliure B e n d i n g r a d i u s rm
% %

A199.98 R I
A199.8
I I
Al99,5 5 15’) 2 15 2 1.3 d,
AlMn
AlMnCu
_~.--.-_ T-
AIMg3
5 52) 2 12 2 4 d,
AIMg2Mn0.8 I I
--~
Heat treatment (
AIMg4.5Mn 5 52) , 2 4 d,
always necessary (

AIMgSiO,S According to stipulations in assessment of suitability

1) This is ach!eved I” the case of cylbdrlcal part-Sheik lf s 5 0.15 f &

2) Ths s achieved in the case of cyllndrlcal part-shells if S 5 0.05 D,

Supersedes Edition July 1984; completely revised

- ^ , ^^.
Carl Heymanns Verlag KG Translation: TechnIcal Help to txporters SetvIce or t(>l
Luxemburger StraBe 449,50939 K6ln
Gutenbergstrak 3 . 1 0 5 8 7 Berlin
P a g e 2 AD-Merkblatf HP 714, Edition 07. 89

2 . 2 In addition to the permissible degrees of cold forming
specified in Table 1 for cylindrical part-shells, spherical seg-
ments and conical part-shells with no flange, the following
conditions are applicable for the residual elongation at fai-
lure:
(1) For materials in Group Al 1 1 15%;
(2) For materials in Group Al 2 2 12%;
(3) In special cases, e.g. in the case of corrugation-stiffened
part-shells, the minimum elongation at failure shall be
established in a suitable manner.
3 Heat treatment after hot forming
In the case of pressure vessels which are to be subjected to
a construction inspection by the authorised inspector, heat
treatment after hot forming may be omitted if the authorised
inspector is first provided with evidence, in the form of a pro-
cedure qualification test, showing that the values stated in
AD-Merkblatt W 6/l, Table 2A are being maintained. In the
case of other pressure vessels, the manufacturer shall make
the decision regarding such heat treatment.

Table 2. Temperatures for the soft annealing of aluminium

and aluminium alloys

Material Soft annealing ‘) 4 Postweld heat treatment

Material
group “C
There is no need as a rule for any postweld heat treatment.
A199,98 R W4, F4 In the event of postweld heat treatment being performed, the
Al99,8 W6, F6 300 to 400
temperatures to be observed for such treatment are those sti-
Al 1 A199,7 W6, F6 pulated in the assessment of suitability.
A199,5 W7, F7, F8
AlMn W9, WlO, FlO
AlMnCu WlO
/ AIMg3 W18. W19, F18, F19
Al 2 AIMg2Mn 0.8 WI& W19, 300 to 450
F18, F19, F20 5 Heat treatment of pressure vessel compo-
AIMg4,5Mn W27, W28, nents where special requirements exist
F27
If there are special requirements (e.g. having regard to the
’ According to risk of corrosion) for the heat-treated state, such require-
stipulations in ments shall be determined at the time when the order is
Al 3 AIMgSi0,5 F13 j assessment of
suitability
placed. Should the agreed heat treatment signify any appre-
ciable impairment of the properties of the material, the con-
1) The holding tme shall be selected so that the values for the particular materlal sent of the authorised inspector is required in the case of
are obtamed as speclfled m AD-Merkblatf W 611, Table 2 A
pressure vessels which are to be subjected to a construction
inspection by the authorised inspector. The differing heat
2 . 3 For soft annealing, the limit temperatures specified in treatment adopted shall be stated in the certificate according
Table 2 are applicable. to AD-Merkblatt HP 7/l, Section 3.
KS: 23.020.30 Edition September 1998

Manufacture and AD-Merkblatt

Testing of
Testing of pressings made from
Pressure Vessels
steel, aluminium and aluminium alloys HP 8/l

T h e AD-MerkblBtter a r e c o m p i l e d b y t h e s e v e n a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e ‘Arbeitsgemeinschai? Druckbehdlter”

(AD). AD-Merkblatt G 7 covers the composition and application of AD-Regulations and also procedural guidelines.
T h e AD-Merkblstter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . I n t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e. V. (FDBR), Diisseldorf
Hauptverband der gewerblichen Berufsgenossenschaffen e.V., Sank7 Augustin
Verband der Chemischen lndustrie e. V. (VU), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Ven‘ahrenstechnische Maschinen
und Apparate, FrankfurtlMain
Verein Deutscher Eisenhijttenleute (VDEh), Diisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroRkraftwerksbetreiber e.V., E s s e n
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s l y b y t h e a b o v e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be a d d r e s s e d t o t h e p u b l i s h e r :
Verband der Technischen iiberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents

1 Scope 5 Repeat tests

2 Material tests 6 Visual examination and dimensional check
3 Scope of material test and removal 7 Marking
of specimens 8 Test certificates
4 Requirements Appendices 1 to 3: Examples of certificates

1 Scope to AD-Merkblgtter HP 712, HP 7/3 or HP 7/4; testing is then

performed after forming. Notwithstanding this, testing of the
1 .l This AD-Merkblatt deals with the testing of the strength starting products is sufficient in the case of torispherical ends
and toughness properties of pressings made from flat pro- for which, according to AD-Merkblatt HP 712, Section 2.5,
ducts, regardless of the manufacturing process, as well as heat treatment is not required and is not carried out. If the
visual examination and dimensional checks. Pressings heat treatment of the pressing consists of stress relieving, the
include ends, segments and other preformed components. specimen sections may be removed beforehand and may be
heat treated in the same manner (see AD-Merkblatt HP 711,
1.2 This AD-Merkblatt is also applicable to pressings Section 2.6).
manufactured from individual components by welding and
subsequent forming. AD-Merkbl&er HP 2/l, HP 5/2 and
2 . 2 The scope of the material testing of pressings is defined
HP 5/3 deal with the testing of such welded joints before and in Section 3. This is on condition that the starting flat products
after forming. meet the requirements in Series W AD-MerkbUter. When
pressings are tested individually by the authorised inspector,
notwithstanding Series W AD-Merkblatter, the starting flat
2 Material tests products may be tested by the works authorised inspector of
This AD-Merkblatt is applicable on condition that the forming the material manufacturer.
process and the equipment have been verified according to
AD-Merkblatt HP 0 or W 0. A procedure qualification test For pressings which are manufactured by cold forming with-
according to AD-Merkblatt HP 2/l which also covers the for- out subsequent heat treatment, flat products tested accord-
med welded joint is required in the case of pressings as spe- ing to Series W AD-Merkbltitter shall be used.
cified in Section 1.2.
2 . 3 In the case of pressings made from clad flat products,
2.1 Material tests on pressings as defined in Table 1 take Section 3 applies analogously as far as the scope of material
place after the heat treatment which follows forming. Testing testing is concerned. The basic material is decisive when
is required even if heat treatment may be omitted according assigning materials to the Material Groups in Table 1. Special

Supersedes July 1989 edition; ) = Amendments to previous edition

Carl Heymanns Verlag KG Translation: Technical Help to Exporters Service of BSI

Luxemburger Strak 449. 50939 Ktiln
Page 2 AD-Merkblatt HP 8/l Edition 09.98
agreements may be necessary if a different heat treatment
has to be used for the basic material because of the cladding
material.
2 . 4 For hardened-and-tempered steels where batch testing
is carried out, a hardness test performed by the manufacturer
on 10% of the pressings, but on at least three pressings, is
required in order to demonstrate the uniformity of hardening
and tempering.
2 . 5 The testing of pressings made from materials according
to other material specifications takes places according to the
assignment to a Material Group as defined in AD-Merkblatt
HP 0, Synoptic Tables 1 and 2 as stated in the assessment
of suitability, unless the assessment of suitability stipulates
individual testing.
3 Scope of material test and removal of
specimens
3.1 For pressings having a length or diameter 4 4 m, the
scope of the material test is defined in Table 1. A production
batch shall only comprise pressings made from flat products
from the same cast and, in the case of steels in Material
Groups 2 to 4.1, 5.1 to 5.4 (excluding X 8 Ni 9) and 7, from
the same cast and with the same subsequent heat treatment.
The wall thickness of pressings in a production batch shall
not differ from the average wall thickness by more than 20%.
One specimen section shall be removed in each case.
3 . 2 For pressings having a length or diameter > 4 m, the
material test shall be performed on each pressing (individual
testing). This applies to pressings which are heated and for-
med as a whole or heat treated as a whole as well as to pres-
sings which are manufactured from individual components
by welding and subsequent forming. These specifications do
not apply to pressings made of materials of Material Group 1
(1) regardless of thickness and Material Group 6 forthicknes-
ses 5 30 mm for material 1.4541 and 1.4571 and Z? 20 mm
for other materials.
3.2.1 A specimen section shall be removed from each pres-
sing having a length or diameter > 4 m and % 6 m. If a pres-
sing contains single components from more than one cast,
a specimen section shall be removed for each cast.
3.2.2 A specimen section shall be removed from two oppo-
site sides in the case of pressings having a length or diameter
> 6 m. If the pressing consists of two or more single compo-
nents from the same cast, the two specimen sections shall
be removed from two single components. If a pressing con-
tains single components from more than one cast, a speci-
men section shall be removed for each cast.
3 . 3 Excess lengths shall be provided for the removal of spe-
cimen sections. If this is not possible, the removal of speci-
men sections shall be agreed, with the authorised inspector
if applicable. For materials in Material Groups 1 and 5.1, spe-
cimen sections which were subjected to a heat-treatment
process identical that for the pressings themselves may be
tested.
3.3.1 If it is possible to remove pieces from pressings
having a length or diameter > 6 m, such pieces may replace
the specimen sections taken from excess lengths.
3 . 3 . 2 Where batch testing is carried out, it is not necessary
to provide excess length for the removal of specimen secti-
ons on all the pressings in a batch.
3 . 4 One set of specimens consisting of a tensile test speci-
men and three notch impact specimens shall be cut in each
case from the test sections. If starting flat products are used
which were not tested according to Series W AD-Merkblstter,
the tests to be performed are governed by the requirements
in Series W AD-MerkbBtter. The specimens shall be remo-
ved at right angles’) to the rolling-direction. In the case of
1 pressings made from steels as specified in DIN EN 10 025,
the notch impact specimens shall be cut parallel to the rolling-
direction.
4 Requirements
The requirements stipulated for the starting products in
Series W AD-MerkblBtter are applicable, depending on the
nominal wall thickness of the pressings, unless AD-MerkbBt-
ter HP 712, HP 713 or HP 714 stipulate other provisions. The
provisions in AD-Merkblatt HP 512, Section 8 shall be obser-
ved.
For pressings which were hot-formed or heat treated, the
upper limit of the tensile strength range may be exceeded by
approximately 5% provided that the other properties of the
finished component meet the requirements.
5 Repeat tests
5.1 If the results do not meet the requirements, the proce-
dure to be adopted is as follows:
5.1 .l If the unsatisfactory results of a test are self-evidently
attributable to deficiencies In the testing techniques emplo-
yed or to a defect of very limlted size in a specimen, the nega-
tive results shall be disregarded in deciding whether the
requirements have been met and the relevant test shall be
repeated.
51.2 If the unsatisfactory results of a test are attributable
to improper heat treatment, the pressings in the relevant test
lot can be subjected again to the heat treatment process,
whereupon the entire test shall be repeated.
5.1.3 In the event of specimens removed in the correct
manner failing to meet the requirements, the following proce-
dure shall be adopted:
5.1.3.1 Where testing is carried out on an individual product
basis, if the results of the tensile test fail to meet the require-
ments, the test shall be repeated using two additional tensile
test specimens cut from the specimen section; the results for
both specimens shall satisfy the requirements. If the results
for the three notch impact specimens tested do not meet the
requirements, three further specimens shall be removed
from the specimen section and tested. The mean value from
the six individual tests shall then meet the requirements. Of
the six individual values only two may be below the minimum
value, but no more than one individual value shall be more
than 30% below the minimum value.
5.1.3.2 Where batch testing is carried out, the pressing that
has failed to meet the requirements shall be segregated from
the batch. For every unsatisfactory tensile test specimen and
if the results for the three notch impact specimens tested
should fail to meet the requirements, tests shall be performed
on two other pressings in the same batch and the results from
these tests shall satisfy the requirements.
5.1.3.3 Where batch testing is carried out according to
Table 1, Column 5 for Material Group 1 (2) and for Material
Group 6 in the case of steels X 6 CrNiTi 18 10 and X 6 CrNi-
MoTi 17 12 2 with a wall thickness >30 mm or in the case
of other grades in Material Group 6 with a wall thickness
> 20 mm, if the results of the tensile test or the impact test
do not meet the requirements, the method stated in Section
1) A dewation of up to 20 degrees from this direction is permissible.
 Page 3 AD-Merkblan HP 8/i, Edition 09.98

5.1.3.2 shall initially be applied to the tested production 8 Test certificates

batch. If the test result for one of the replacement specimens
j 8.1 A certificate according to DIN EN 10 204 shall be issued
fails to meet the requirements, the test shall be extended to
for the results of tests in the case of pressure vessels which
include two further production batches. If the test results for
are to be subjected to a structural test by the authorised
a further production batch does not meet these requirements,
inspector.
the relaxation of the scope of testing in Columns 4 and 5 in
Table 1 are not applicable until further notice. The type of the certificate depends on the stipulations in
Series W AD-Merkblatter according to the material grade and
6 Visual examination and dimensional check nominal wall thickness of the pressing.

Pressings which are delivered with a inspection certificate For pressings made from aluminium alloys as specified in
1 according to DIN EN 10 204 shall be visually examined in the AD-Merkblatt W 6/l, Section 2.1, after individual testing of 30
as-delivered state by the works authorised inspector or the pressings with inspection certificates 3.1 .A or 3.1 .C (issued
authorised inspector and shall be subjected to a dimensional by the authorised inspector), transition to inspection certifi-
check. The result of any visual examination and dimensional cate 3.1 .I3 is possible in accordance with the provisions in
check performed shall be stated in the inspection certificate. AD-Merkblatt W 6/l. Section 7.3.2.
In the case of pressings which are delivered with a certificate
of compliance with the order or test report, visual examination See the examples in the Appendices of this AD-Merkblatt for
and dimensional checking are performed by the manufactu- details of the content of certificates relating to hot or cold-for-
rer of the pressings. med pressings.

8 . 2 In addition, the nature of the heat treatment and the fact

7 Marking that the material is in the correct heat-treated state according
to AD-Merkblatt HP 7/l and correct restamping shall be certi-
In the case of pressure vessels which are to be subjected to
fied.
a structural test by the authorised inspector, the pressings
shall be marked according to the provisions in Series W AD-
8 . 3 For hot-formed or heat treated pressings made from
Merkblatter but the brandmark of the manufacturer of the
starting material may be omitted. In addition, the brandmark stainless austenitic steels as specified in DIN 17 440, resi-
of the manufacturer of the pressings shall be included in the stance to Intercrystalline corrosion shall be certified unless
marking. Where batch testing is carried out, the batch to the user dispenses with this.
which the pressings belong shall be apparent. Pressings
from which specimens were removed shall be marked accor-
Appendices
dingly.
- .
Appendix 1 Example of a certificate for hot-formed pres-
For pressings manufactured from single components by wel-
sings made from ferritic steels
ding and subsequent forming, these stipulations apply to
each single component. Appendix 2 Example of a certificate for hot-formed pres-
sings made from austenitic steels
The provisions in Table 2 are applicable for the marking of
small pressings with an outside diameter or nominal width up Appendix 3 Example of a certificate for cold-formed pres-
to 220 mm. sings

Footnotes for Table 1 in AD-Merkblatt HP 8/l

1) G r o u p c l a s s i f i c a t i o n f o r t h e m a t e r i a l g r a d e s a c c o r d i n g t o A D - M e r k b l a t t H P 0 , S y n o p t i c T a b l e 1 o r 2 . T h e c o r r e l a t i o n o f t h e y i e l d - p o i n t
groups refers to the lowest thickness range in the relevant standard or material specification sheet. Pressings made from other steel grades
should be assigned to the comparable Material Groups according to the stipulations in the assessment of suitability. In the case of clad
steels, the scope of testing generally depends on the basic material (see Section 2.3.).
2) I n t h e c a s e o f t o r i s p h e r i c a l e n d s f o r w h i c h , a c c o r d i n g t o A D - M e r k b l a t t H P 7/2 S e c t i o n 5 . 2 , h e a t t r e a t m e n t i s n o t r e q u i r e d a n d n o t p e r f o r m e d ,
testing of the starting flat products is sufficient.
3) For sheet in the “normalising rolled” condition, testing is performed on separately normalised specimens until further notice.
‘) Austenitic steels X 4 NiCrMoCuNb 20 18 2, X 5 CrNiMoTi 25 25 and X 5 CrNiMo 17 13 3 are to be treated as for Material Group 7.
5) In the case of pressings made from austenitic steels for which, according to AD-Merkblatt HP 7/3, heat treatment is not required and
not performed, testing of the starting flat products is sufficient.
6, Thickness data are relative to nominal wall thicknesses of the pressing.
Page 4 AD-Merkblatt HP a/l, Edition 09.98

Table 1. Scope of material testing on pressings having a length or diameter d 4 m

Material M a t e r i a l grade+) Scope of testing Scope of testing with relaxation
Group’) without relaxation
Prerequisites Scope of testing

1 2 3 4 5

1 (1) Plain steels with a lower ten-
sile strength limit
s 4 4 0 N / m m * e x c l u d i n g fine-
grained structural steels.
Testing of initial plate with - -
specimens from specimen
sections which were separa-
tely heat treated or removed
from the finished heat-treated
platea)

1 (2) Alloy steels and fine-grained
s t r u c t u r a l s t e e l s w i t h mini-
mum yield point
< 3 5 5 N/mm2 a s w e l l a s
P295GH and P355GH to DIN
E N 1 0 0 2 8 - 2 a n d S355J2G3
to DIN EN 10025 excluding
steels with high impact
strength at low temperature.
See Footnote’) for
torispherical ends
1. Testing of initial plate with
specimens from specimen
sections which were separa-
tely heat treated or removed
from the finished heat-treated
plate3)
2. Testing of pressings per
production batch: production
batches
up to 10 units 1 pressing
up to 25 units 2 pressings
u p t o 1 0 0 u n i t s 3 pressmgs
1 pressing for each additional
100 units
30 production batches must 1. Testing of initial plate with
initially be tested without specimens from specimen
rejection (proof of correct pro- sections which were separa- ,
duction) e x c l u d i n g “ o t h e r tely heat treated or removed
materials” for which individual from the finished heat-treated
testing is stipulated in the plate3) a n d
a u t h o r i s e d i n s p e c t o r ’ s cettifi- 2 . T e s t o n e p r e s s i n g f o r each
cate o f c o n f o r m i t y 100 pressings made from the
same material with the same
subsequent heat treatment

1 (3) Fine-grained structural steels

with minimum yield point
2 355 N/mm2 to
< 370 N/mm* excluding
steels with high impact
strength at low temperature

2 Fine-grained structural steels

with minimum yield point
2 370 to c 430 N/mm’
excluding steels with high
impact strength at low
temperature

3 Fine-grained structural steels Testing of each pressing 30 pressings must initially be 1. Testing of initial plate with
with a minimum yield point (individual testing) tested without rejection (proof specimens from specimen
2 4 3 0 N/mm2 e x c l u d i n g o f c o r r e c t p r o d u c t i o n ) exclu- sections which were separa-
steels with a high impact ding “other materials” for tely h e a t t r e a t e d o r r e m o v e d
strength at low temperature. w h i c h i n d i v i d u a l t e s t i n g i s sti- from the finished heat-treated
Hardened-and-tempered pulated in the authorised plates)
high-temperature structural i n s p e c t o r ’ s c e r t i f i c a t e o f con- 2. Testing of pressings per
steels formity production batch; production
11 NiMoV53 batches
17MnMoV64 up to 10 units 1 pressing
15 NiCuMoNb 5 up to 25 units 2 pressings
12 MnNiMo 5 5 up to 100 units 3 pressings
13 MnNiMo 5 4 1 pressing for each additiona
20 MnMoNi 5 5 100 units
2 2 NiMoCr 3 7
20 MnMoNi 4 5

4.1 High-temperature steels:

13CrMo44
1 0 CrMo 9 1 0
1 2 CrMo 1 9 5
XlOCrMo91

4.2 High-temperature steels: Testing of each pressing -

1 4 MoV 6 3 a n d (individual testing)
X20CrMoV121
 Page 5 AD-Merkblatt HP 8/l, Edition 09.98

Table 1. ScoDe of material testing on pressings having a length or diameter 5 4 m (continued)

7
Scope of testing Scope of testing with relaxation
Material M a t e r i a l grades6)
Group’) without relaxation
Prerequisites Scope of testing
I
n
4 4 5
1 2

5.1 Fi n e - g r a i n e d s t r u c t u r a l s t e e l s Testing of each pressing 30 pressings must initially be t 1. Testing of initial plate with
tested without rejection (proof specimens from specimen
tC ) D I N E N 1 0 0 2 8 - 3 o f t h e (individual t e s t i n g )
of correct production) exclu- sections which were separa-
I C)w-temperature series and of
ding “other materials” for tely heat treated or removed
tt te l o w - t e m p e r a t u r e s p e c i a l
which individual testing is Sti- from the finished heat-treated
Series with a minimum yield
pulated in the authorised plate3)
P oint < 370 Nlmmz. Fine- 2. Testing of pressings per
inspector’s certificate of con-
9 ,rained structural steels t0 production batch; production
C UN E N 1 0 0 2 8 - 3 o f t h e b a s i c formity
batches
a Ind h i g h - t e m p e r a t u r e Series
u p to IO units 1 pressing
V vith a m i n i m u m y i e l d p o i n t
up to 25 units 2 pressings
< : 370 N/mm’ if they are usec
up to 100 units 3 pressings
il n a c c o r d a n c e w i t h AD-
I pressing for each additiona I
h Jerkblatt W 10 in stress
100 units
C:ategory 1 below -10 “C.
: steel grades 11 MnNi 5 3
i ind 13 MnNi 6 3 in accord-
3nce w i t h D I N 1 7 2 8 0 a t m i n i
num a p p l i c a t i o n temperatu-
‘es d o w n t o a n d i n c l u d i n g
- 6 0 “C.

5.2 F i n e - g r a i n e d s t r u c t u r a l steels
3 DIN EN 10028-3 of the
ow-temperature series and o’
h e l o w - t e m p e r a t u r e special
;eries w i t h a m i n i m u m y i e l d
)oint 2 370 N/mm2 to
< 4 3 0 N/mm’. F i n e - g r a i n e d
;tructural s t e e l s t o D I N E N
10028-3 o f t h e b a s i c a n d
iigh-temperature series with
a minimum yield point
2 370 N/mm’ to 430 N/mm2
If t h e y a r e u s e d i n a c c o r d -
ance with AD-Merkblatt W 1 r
in stress category 1 below
- 1 0 “C.

5.3 Fine-grained structural steels

to D I N E N 1 0 0 2 8 - 3 o f t h e
tow-temperature series and (
the low-temperature special
series with a minimum yield
p o i n t 2 4 3 0 Nlmmz. Fine-
grained structural steels to
DIN EN 10028-3 of the basic
a n d h i g h - t e m p e r a t u r e SerieS
with a minimum yield point
2 430 N/mm 2 if they are
used in accordance with
A D - M e r k b l a t t W 1 0 i n stress
catego 1 below - 10 “C.

2 6 CrMo 4
5m m
11 MnNi 53
g?Liz
1 3 MnNi 6 3
-,5”
rig 1 4 NiMn 6
.r - 10 Ni 14
s--,9 12 Ni 19
++;
y m m X7NiMo6
vl%cu -Jr
zz-2 X8Ni9 No relaxation No relaxation
rl
P a g e 6 AD-Merkblatt HP 8/l, Edition 09.98

Table 1. Scope of material testing on pressings having a length or diameter i 4 m (continued)

Material Material grade+) Scope of testing Scope of testing with relaxation
Group’) without relaxation
Prerequisites Scope of testing

1 2 3 4 5

6 X 6 CrNiTi 18 10 Testing of initial plate with - -

5 30 mm, specimens from specimen
X 6 CrNiMoTi sections which were separa-
17 12 2 2 30 mm, tely heat treated or removed
‘; Other grades from the finished heat-treated
3 520mm plate
z
g X 6 CrNiTi 18 10 1. Testing of initial plate with 30 production batches must 1. Testing of initial plate with
s > 30 mm, specimens from specimen initially be tested without specimens from specimen
9 X 6 CrNiMoTi sections which were separa- rejection (proof of correct pro- sections which were separa-
3 tely h e a t t r e a t e d o r r e m o v e d duction) e x c l u d i n g “ o t h e r tely h e a t t r e a t e d o r r e m o v e d
17 12 2 > 30 mm,
Li Other grades from the finished heat-treated materials” for which individual from the finished heat-treated
“m plates) testing is stipulated in the plates)
s >20mm
E 2. Testing of pressings per authorised inspector’s certifi- 2 . T e s t o n e p r e s s i n g f o r eact
zi production batch; production cate o f c o n f o r m i t y 100 pressings made from the
0
:5 batches same material and with the
s
z up to IO units 1 pressing same subsequent heat treat-
4’ up to 25 units 2 pressings ment
up to 100 units 3 pressings
1 pressing for each additional
100 units

7 Ferrite-free austenitic steels,
but if appropriate, with ferrite
components in the weld metal
a n d a u s t e n i t i c s t e e l s o f Mate-
rial Group 6 as long as they
are welded with filler metal
with s 3% delta ferrite in the
weld metal, e.g. X 8 CrNiNb
16 13, X 8 CrNiNb 16 16,
X 8 CrNiMoVNb 16 13.
Testing of each pressing 30 pressings must initially be 1. Testing of initial plate with
(individual testing) tested without rejection (proof specimens from specimen
of correct production) exclu- sections which were separa-
ding “other materials” for tely heat treated or removed
w h i c h i n d i v i d u a l t e s t i n g i s sti- from the finished heat-treatea
pulated in the authorised plate
i n s p e c t o r ’ s c e r t i f i c a t e o f con- 2. Testing of pressings per
formity production batch; production
batches
up to 10 units 1 pressing
up to 25 units 2 pressings
up to 100 units 3 pressings
1 pressing for each additiona
100 units

Al 1 Al 99, 98 R Testing of initial plate with - -

Al99,8 specimens from specimen
A199,7; Al99,5 sections which were separa-
tely heat treated or removed
Al 2 (1) AiMnl ; AlMnCu from the finished heat-treated
plate

Al 2 (2) AIMg3 530mm 1. Testing of initial plate with 30 production batches must 1. Testing of initial plate with
AIMg2Mn0,8 z30mm specimens from specimen initially be tested without specimens from specimen
AIMg4,5Mn 515mm sections which were separa- rejection (proof of correct pro- sections which were separa-
tely heat treated or removed duction) e x c l u d i n g “ o t h e r tely heat treated or removed
from the finished heat-treated materials” for which individual from the finished heat-treatec
plate testing is stipulated in the plate
2. Testing of pressings per authorised inspector’s certifi- 2 . T e s t o n e p r e s s i n g f o r eacl
production batch; production cate o f c o n f o r m i t y 1 0 0 p r e s s i n g s m a d e f r o m the
batches same material and with the
up to 10 units 1 pressing same subsequent heat treat-
up to 25 units 2 pressings ment
up to 100 units 3 pressings
1 pressing for each additional
100 units

Al 2 (3) AIMg3 >30mm Testing of each pressing 30 pressings must initially be 1. Testing of initial plate with
AIMg2Mn0,8 > 30 mm (individual testing) tested without rejection (proof specimens from specimen
AIMg4,5Mn >15mm of correct production) exclu- sections which were separa-
ding “other materials” for tely heat treated or removed
w h i c h i n d i v i d u a l t e s t i n g i s sti- from the finished heat-treater
pulated i n t h e a u t h o r i s e d plate
i n s p e c t o r ’ s c e r t i f i c a t e o f con- 2. Testing of pressing per
formity production batch; production
batches
up to 10 units 1 pressing
up to 25 units 2 pressings
up to 100 units 3 pressings
1 pressing for each addition?
100 units
 Page 7 AD-Merkblatl HP 8/i, Edition 09.98

Table 2. - of small pressings with an outside diameter or nominal width up to 220 mm

Marking’)

Outside Material Group Marking Test certificate Test certificate

d i a m e t e r o r act. to for the starting material
nominal Appendix
width2)

5 50 1 (1) steel grades act. to None 1,2or3 Kept by manufacturer of

DIN EN 10025 pressings
A i l
> 50 Material symbol and 1,2or3 Kept by manufacturer of
to 5 220 manufacturer’s pressings
brandmark

5220 1 (1) except steel grades act. to Material symbol and 1, 2 or 3 Kept by manufacturer of
DIN EN 10025 manufacturer’s brand- pressings
1 G-3 mark
6
7
Al 2 (1)
Al 2 (2)

5 aa, Other Material Groups Material symbol and 1, 2 or 3 Test certificate is enclosed
manufacturer’s brand-
mark as well as autho-
rised inspector’s test
mark

> 88,9 act. to Section 7 1,2or3

1) With thickness greater than 3 mm for steel and 5 mm for aluminium, marking is obtained by stamping or impression. Ink marking or engraving is used for smal-
ler thicknesses
2) Small axns of nominal width in the case of oval components
 P a g e 8 AD-Merkblatt HP 8/i, Edition 09.98

Appendix 1 to AD-Merkblati HP 8/l

I Inspection certificate 3.1 .B

Test report
Certificate of compliance with the order
for hot-formed pressings made from ferritic steels

Purchaser: Order No.:

Manufacturer: Job No.:

Basis of testing: AD-Merkblatt HP 8/i

Delivery date:

Item No. Quantity Object/dimensions Material Melt Specimen No.

Plate Pressing

We hereby confirm that the forming process was performed act. to AD-Merkbiatt HP 712, Section 3.2.
Heat treatment after forming: (state holding temperature, holding time and cooling conditions)
The hot-pressing process was monitored by (Technical Supervisory Body). Evidence was provided of suitability of the equip-
ment used for heat treatment in accordance with AD-Merkblatt HP 7/l Section 3.1.
1 Plate/supplied by yourselves*)/according to enclosed*)/ in our possession*)/test certificate(s) to DIN EN 10 204 were used:
(state type, test No., date, issuer)
The plate used was restamped where necessary. The pressings are also marked with the following details:
- Pressing manufacturer’s brandmark
- Specimen number
- Batch number and identification of product which provided the specimen if applicable
- Mark of tester

Testing of the pressings

1. Visual examination and dimensional check
2. Material test
3. For welded ends:
3.1 The requirements in AD-Merkblatt HP 5/2 were met
3.2 Non-destructive testing according to AD-Merkblatt HP 513
Surface crack test
Radiographic examination
Ultrasonic examination
satisfied in accordance with Enclosure

Date Signed

Enclosures

‘) Delete inapproprtate items

 Page 9 AD-Merkblatt HP 8/l, Edition 09.98

Appendix 2 to AD-Merkblatt HP 8/l

I

I Inspection certificate 3.1.6

Test report
Certificate of compliance with the order
for hot-formed pressings made from austenitic steels

Purchaser: Order No.:

Manufacturer: Job No.:

Basis of testing: AD-Merkblatt HP 8/l

Delivery date:

Item No. Quantity Object/dimensions Material Melt Specimen No.

Plate Pressing

We hereby confirm that the conditions in AD-Merkblatt HP 7/3, Table 1, column 3’)/4*) were adhered to for the forming process.
Heat treatment after forming: (state solution annealing and quenching or stabilising)
The hot-pressing process was monitored by (Technical Supervisory Body). Evidence was provided of suitability of the equip-
ment used for heat treatment in accordance with AD-Merkblatt HP 7/l Section 3.1.
1 Plate/supplied by yourselves*)/according to enclosed*)/ in our possession*)/test certificate(s) to DIN EN 10 204 were used:
(state type, test No., date, issuer)
The plate used was restamped where necessary. The pressings are also marked with the following details:
- Pressing manufacturer’s brandmark
- Specimen number
- Batch number and identification of product which provided the specimen if applicable
- Mark of tester

Testing of the pressings

1. Visual examination and dimensional check
2. Material test
3. For welded ends:
3.1 The requirements in AD-Merkblatt HP 5/2 were met
3.2 Non-destructive testing according to AD-Merkblatt HP 513
Surface crack test
Radiographic examination
Ultrasonic examination
satisfied in accordance with Enclosure

Date Signed

Enclosures

‘) Delete inappropriate items

 Page 10 AD-Merkblatt HP 8/l, Edition 09.98

Appendix 3 to AD-Merkblatt HP 8/l

I Inspection certificate 3.1 .B

Test report
Certificate of compliance with the order
relating to cold-formed pressings

Purchaser: Order No.:

Manufacturer: Job No.:

Basis of testing: AD-Merkblatt HP 8/l

Delivery date:

Item No. Quantity Object/dimensions Material Melt Specimen No.

Plate Pressing

We hereby confirm that normalising*)/solution annealing*) at . . . “C with a holding time of . . . min with subsequent cooling in
/with . . /no heat treatment*) was performed. The heat treatment meets the stipulations in AD-Merkblatter HP 712 or HP 713.
Further heat treatment . . .
The forming process was monitored by (Technical Supervisory Body). Evidence was provided of suitability of the equipment
used for heat treatment in accordance with AD-Merkblatt HP 7/l Section 3.1.
1 Plate/supplied by yourselves’)/according to enclosed*)/ in our possession*)/test certificate(s) to DIN EN 10 204 were used:
(state type, test No., date, issuer)
The plate used was restamped where necessary. The pressings are also marked with the following details:
- Pressing manufacturer’s brandmark
- Specimen number
- Batch number and identification of product which provided the specimen if applicable
- Mark of tester

Testing of the pressings

1. Visual examination and dimensional check
2. Material test
3. For welded ends:
3.1 The requirements in AD-Merkblatt HP 5/2 were met
3.2 Non-destructive testing according to AD-Merkblatt HP 5f3
Surface crack test
Radiographic examination
Ultrasonic examination
satisfied in accordance with Enclosure

Date Signed

Enclosures

‘) Delete lnapproprlate items

UDC 621.642.02.002.2-98:669.14-41:621.785:620.172:620.178.74:614.8 Edition July 1989

Manufacture and AD-Merkblatt

Testing of Testing of steel part-shells
Pressure Vessels HP 812

T h e AD-Merkbl&terarecompiled by theseven t r a d e associationsspecifiedbelow w h o t o g e t h e r f o r m t h e “ A r b e i t s g e m e i n s c h a f t Druckbehdl-

ter” (AD). AD-Merkblatt G 7 c o v e r s t h e c o m p o s i t i o n a n d a p p l i c a t i o n o f t h e AD-Regulations a n d also t h e p r o c e d u r a l r u l e s .
The AD-Merkblatter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
and above the normal /eve/ being anticipated during the operation of pressure vessels, allowance must be made for such stresses by
meeting special requirements.
Should there be any departures from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards embo-
died in these regulations have been observed by means of alternative a p p r o a c h e s , e . g. t e s t i n g o f m a t e r i a l s , t e s t s , s t r e s s a n a l y s i s , o p e r a t i n g
experience.
Fachverband Dampfkessel-, Behllter- und Rohrleitungsbau e. V. (FDBR), Diisseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sank? Augustin
Verband der Chemischen lndustrie e. V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen und
Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Dtisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r Groakraftwerksbetreiber e. V., Essen
V e r e i n i g u n g d e r T e c h n i s c h e n iiberwachungs-Vereine e . V . (VdTiiV), Essen.
T h e AD-MerkblZtter a r e a m e n d e d c o n t i n u o u s l y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g with technical progress. Relevant proposals should
be addressed to the publisher:
Vereinigung der Technischen iiberwachungs-Vereine e.V., Posifach 103834, O-4300 Essen 1.

Contents

1 Scope 5 Repeat tests

2 Material tests 6 Visual examination and dimensional check
3 Scope of material test and removal 7 Marking
of specimens 8 Test certificates
4 Requirements

1 Scope resistance to intercrystalline corrosion is required if the user

1.1 This AD-Merkblatt deals with the testing of the strength
and toughness properties of the basic material used for part-
shells where, after the forming of the plates, heat treatment,
excluding stress relieving, is carried out. Testing is also
required if the heat treatment is performed as part of a hot-
forming process (see AD-Merkblatt HP 7/2 Section 3.2). It
also deals with the visual examination and dimensional
checking of part-shells.
1.2 The testing of welded joints is dealt with in the AD-
Merkblatter HP 2/l, HP 512 and HP 513.
2 Material tests
2.1 In the case of part shells which are heat treated accord-
ing to the provisions in AD-Merkblatt HP 712, Sections 2 and
3, testing of the basic material is carried out after the final nor-
malising or hardening-and-tempering treatment. In the case
of part-shells made from austenitic steels which are heat
treated according to the provisions in AD-Merkblatt HP 713,
Sections 2 and 3, testing of the basic material is carried out
after the final quenching or stabilising process.
For hot-formed or heat treated part-shells made from stain-
less austenitic steels as specified k-r DIN 17440, testing for
does not dispense with such testing.
3 Scope of material test and removal of
specimens
3.1 The scope of the material tests for part-shells is defined
in Table 1. Where plates are used that have not been tested
according to the provisions in AD-Merkblatter in Series W,
the scope of the tests on the part-shells is governed by the
requirements in Series W AD-Merkblatter.
3.2 The test pieces shall be cut from bending-ends, test
rings, waste sections or plates from the same melt and with
the same thickness. In the event of test pieces being cut prior
to the final heat treatment, it shall be ensured that the test
pieces are subjected to the same heat treatment process or
undergo heat treatment of the same kind as that for the com-
ponent (see AD-Merkblatt HP 7/l, Section 2.6). It is not
necessary to use test pieces that have been formed.
3 . 3 One set of specimens consisting of a tensile test speci-
men and three notch impact specimens, shall be cut in each
case from the test pieces. Where plates are used that have
not been tested according to the provisions in AD-Merkblatter
in Series W, the scope of the tests on the part-shells is

Supersedes Edition January 1982; completely revised

Carl Heymanns Verlag KG Translation: Technical Help to Exporters Service of BSI

Luremburger StraOe 449, 5000 K61n 41
GutenbergstraBe 3, 1000 Berlin 10
Page 2 AD-Merkblatt HP 812, Edition 07. 89
governed by the requirements in Series W AD-Merkblstter.
The specimens shall be removed at right angles to the rolling-
direction of the plate. In the case of part-shells made from
steels as specified in DIN 17 100, the notch impact speci-
mens shall be cut parallel to the rolling-direction of the plate.
3 . 4 Testing of the basic material as specified in Table 1 can
also be carried out as part of the production tests in accord-
ance with AD-Merkblatt HP 5/2. In this case, the test pieces
defined in Section 3.2 shall be used as specimen plates for
the test object.
4 Requirements
The requirements are dealt with in AD-Merkblatter in
Series W.
5 Repeat tests
5.1 If the results do not meet the requirements, the proce-
dure to ,be adopted is as follows:
5.1.1 If the unsatisfactory results of a test are self-evidently
attributable to deficiencies in the testing techniques used or
to a defect of very limited size in a specimen, the negative
results shall be disregarded when deciding whether the
requirements have been met and the relevant test shall be
repeated.
5.1.2 If the unsatisfactory results of a test are attributable
to improper heat treatment, the part-shell or, where batch
testing is carried out, the entire test batch can be subjected
again to the heat treatment process, whereupon the entire
test shall be repeated.
5.1.3 In the event of specimens removed in the correct
manner failing to meet the requirements, the following proce-
dure shall be adopted:
5.1.3.1 Where testing is carried out on an individual product
basis, if the tensile test specimen fails to meet the require-
ments, the tests shall be repeated using two additional tensile
test specimens cut from the test piece; the results for both
specimens shall satisfy the requirements. If the results for the
three notch impact specimenstested do not meet the require-
ments, three further specimens shall be removed from the
test piece and tested. The mean value obtained from the six
individual tests shall then meet the requirements. Of the six
individual values, only two shall be below the stipulated mini-
mum value, but no more than one individual value shall be
more than 30% below the minimum value.
5.1.3.2 Where batch testing is carried out, the part-shell
that has failed to meet the requirements shall be segregated
from the batch. For every unsatisfactory tensile test speci-
men and if the results for the three notch impact specimens
tested should fail to meet the requirements, tests shall be per-
formed on two other part-shells in the same batch and the
results from these tests shall satisfy the requirements.
6 Visual examination and dimensional check
Part-shells which are delivered with a test certificate accord-
ing to DIN 50049 shall be visually examined in the as-deliver-
ed state by the works authorised inspector or the authorised
inspector and shall be subjected to a dimensional check. The
results of any visual examination and dimensional check per-
formed shall be stated in the test certificate. In the case of
part-shells which are delivered with a certificate of com-
pliance with the order or test report, visual examination and
dimenslonal checking are performed by the manufacturer of
the part-shells.
7 Marking
In the case of pressure vessels which are to be subjected to
a construction inspectlon by the authorised inspector, the
part-shells shall be marked according to the provisions in
Series W AD-Merkblatter. In the case of individual-product
testing, the part-shell shall be marked additionally with the
specimen number and, where batch testing is carried out,
with the batch number, the part-shells that are tested in the
batch being marked additionally with the specimen numbers.
8 Test certificates
In the case of pressure vessels which are to be subjected to
a construction inspection by the authorised inspector, the
results of the mechanical tests shall be presented in material
test certificates according to DIN 50049, the type of the certi-
ficates being determined through reference to the relevant
stipulations in Series W AD-Merkblatter. The type of the heat
treatment and the fact that the material is in the correct heat-
treated state according AD-Merkblatt HP 7/l shall be certi-
fied. With regard to dimensional checks and visual examina-
tion (see also TRB 512 if applicable) based on stipulations
made at the time the order was placed, acertificate according
to DIN 50049 shall be prepared, its type also being deter-
mined as indicated in the first sentence in this paragraph.
 P a g e 3 AD-Merkblatt HP 812, Edition 07. 89

Table 1. Scope of material test for normalised and hardened-and-tempered (Material Groups 1 to 5.4)
or quenched or stabilised (Material Groups 6 and 7) part-shells

Material Group’) Material grades Scope of testing

I 1 I 2
+
1.1 A l l s t e e l g r a d e s i n M a t e r i a l G r o u p 1,
Table 1 in AD-Merkblatt HP 0 except those specified No testing required
under 1.2
+
1.2 Steel grades with a minimum yield point For each melt, but at least one set of specimens per
2 3 5 5 N/mm2 u p t o < 3 7 0 N/mm2 5 part-shells
c
2 One set of specimensz) per part-shell
L

3 One set of specimens’) per part-shell

t
4.1 One set of specimens per part-shell.
For 13 CrMo 4 4 per melt, but at least one set of
specrmens per 5 part-shells.

I 4.2 I One set of specimens*) per part-shell

I 5.1 I As m Table 2 of AD-Merkblatt HP 0

One set of specimensz) per part-shell.
; Notch-impact testing is performed at test temperature
for the verrfication of toughness according to
AD-Merkblatt W 10.

For wall thicknesses < 20 mm, no testing requrred.

For wall thicknesses 2 20 mm, one set of specrmens
per 5 part-shells.

For each melt, but at least one set of specimens per

5 part-shells

‘) Group classification for material grades according to AD-Merkblan HP 0. Synopttc Table I.

For the correlation of the yield-point groups. the data gwen for the smallest wall-thickness area 10 the relevant standard or Material Sheet (Werkstoffblan) are
applicable.
2) When a number of part-shells are subjected to heat treatment together, one set of spec!mens per melt wll suffice.
ICS 23.020.30 Edition Februarv 1998

Manufacture and AD-Merkblatt

Testing of Performance of pressure tests
Pressure Vessels HP 30

The AD-Merkbl2tter are compiled by the seven associations specified below who together form the “Arbeitsgemeinschaft Druck-
behdlter” ( A D ) . AD-Merkblatt G 1 c o v e r s t h e c o m p o s i t i o n a n d a p p l i c a t i o n o f A D - R e g u l a t i o n s a n d a / s o p r o c e d u r a l g u i d e l i n e s .
T h e AD-Merkb&tter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . I n t h e e v e n t o f l o a d i n g s e x c e e d i n g
!he normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e.V. (FDBR), Dijsseldorf
H a u p t v e r b a n d d e r g e w e r b l i c h e n B e r u f s g e n o s s e n s c h a f t e n e . V . , Sankt Augustin
Verband der Chemischen lndustrie e. V. (VU), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhtittenleute (VDEh), Dfisseldotf
V G B T e c h n i s c h e V e r e i n i g u n g d e r Groflkraftwerksbetreiber e. V., Essen
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
The AD-MerkbLWter are amended continuous/y by the above associations to keep with the state-of-the-art. Relevant proposals should be
addressed to the publisher
Verband der Technischen iiberwachungs-Vereine e. V., P.O. Box 103834, D-45038 Essen.

Contents
1 Scope 3 Scheduling of the test
2 General 4 Performance of the test

1 Scope (4) as a rule, prior to the application of linings and galva-

nized coatings,
Except where other provisions are made in AD-Merkbltitter
Series N for pressure vessels made from non-metallic mate- (5) where appropriate provision is made in the test docu-
rials, the performance of pressure tests on pressure vessels mentation: after non-destructive tests or special leak
and pressure-vessel components in the case of initial and tests.
periodic testing is covered by the provisions in this AD-
Merkblatt. TRB 801 No. 45 applies to the pressure-testing of
valve bodies. The appropriate AD-MerkbKitter in Series W 4 Performance of the test
apply to the pressure testing of castings.
4.1 As a rule, a pressure test shall be a hydraulic test using
water as test fluid insofar as this is permitted by the type or
2 General mode of operation of the pressure vessel or its fluid contai-
ned. Other suitable liquids may be used if this is expedient.
3y means of pressure testing it shall be determined whether
:he pressure-retaining walls are leak-tight under the test 4.2 If a hydraulic test is not possible or is inadvisable,
Xessure and whether any critical deformation with respect the pressure test may be a pneumatic test provided special
:o safety occurs. safety precautions, especially those of clause 4.16 are taken
if provision has been made for pneumatic testing in the test
documentation (e.g. design-approved drawings).
3 Scheduling of the test
4 . 3 In the case of vessels having a number of compart-
3.1 Pressure tests shall be scheduled so that the person ments, each pressurized compartment shall be subjected
ssponsible for the test is able to make adequate inspections individually to a pressure test. It is permissible to deviate from
>f all pressurised components. If this is not possible at the this rule if a wall between a pair of pressurized compartments
‘inal stage, the initial pressure test takes the form of a partial is designed only for the pressure differential and if it is
:est with the apparatus in a state which allows performance ensured, by means of practical measures, that one com-
Df the test. partment is not subjected to pressure independently of the
other. In such cases, the adjacent compartments shall first
3.2 The initial pressure test is performed: be pressurized individually in keeping with this pressure
(1) after the final heat-treatment process before enamelling differential and then the relevant compartments shall be
of enamelled pressure vessels, subjected simultaneously to the test pressure p’.
(2) as a rule, after cladding and machining operations, 4 . 4 It shall be possible to check the pressure indicated by
(3) prior to the application of coats of paint, insulation, rubber the pressure gauge during the test by means of suitable
coatings, brickwork etc., measures (e.g. master pressure gauge).

Supersedes January 1995 edition; 1 = Amendments relating to previous edition

Cal 1 Heymanns Verlag

KG
LU> emburger SE& 449. 50939 Kbln
P a g e 2 AD-Merkblatt HP 30, Edition 02.98

4 . 5 Where hydraulic tests are performed, the pressureves- In the case of double-shell vessels, other considerations may
sel shall be evacuated such that it is completely filled with the also be necessary
test fluid. The pressure vessel shall be supported such that Point at which
there is no possibility of individuals being put at risk or of the the test pressure
is measured
pressure vessel being damaged.

4 . 6 During the hydraulic test, the external walls of the pres-

sure vessels shall be dry. At ambient temperatures 5 0 “C,
a hydraulic test shall only be performed if it is ensured that
no freezing of the vessel contents or of the pressure gauge
T
and inlet lines can occur.

4 . 7 Where the deformability (ductility of the material or the

component) imposes a limit on the test temperature or the
rate at which the pressure is increased, this shall be taken
into account and be noted in the test documentation.

4 . 6 Until the arrival of the person responsible for the test,

the pressure vessel shall be pre-pressurized only up to the -
allowable working pressure. Only after consultation with the A
person responsible for the test shall the pressure be
increased slowly up to the test pressure.

4 . 9 If strain measurements are to be made during the pres-

sure test, the procedure including filling, pre-pressurizing etc.
.shall be agreed with the person responsible for the test.

4.10 Unless otherwise stipulated in the test documentation, Y

in the case of pressure vessels in which the static pressure
of the liquid column has to be taken into account (during ser-
vice or during a hydraulic test), the pressure test shall be per-
formed with the vessel in a vertical position or it shall be
repeated if the vessel was tested in a horizontal position and
if, when determining the test pressure, it was not possible to
make allowance for the static pressure of the liquid column
in the vessel when vertical. Y
The maximum test pressure to be reached on the pressure
gauge during the pressure test is indicated in subclauses
4.10.1 to 4.10.3 (for notations and units used, see fig. 1).

4.10.1 In the case of a pressure test carried out with the

vessel vertical, the pressure measured at the highest point 7% 577
of the vessel shall be:
P P = FP. p; Fig. 1.
where the working fluid has a greater relative density than
the test fluid, the test pressure to be measured shall be
increased to: P = Pressure at the highest point in the vertical vessel
(= allowable working pressure according to TRB
PP = FP. p + a1 (YF . HF - yp . HI,
002 subclause 1.4.1 or 1.4.2) in bar
in which the following shall always apply
PP = Pressure applied during the pressure test, mea-
PP 2 FP . P. sured at point “A” (= test pressure according to
pressure vessel dossier), in bar
4.10.2 If a pressure test is carried out beforehand on a
horizontal vessel (column), the measured pressure shall be: H = Maximum filling level (= filling level during the
hydraulic test) in m
pp=fp.p+O,l yp.$
HF = Maximum filling level during operation (safeguarded
by filling-level limiter or comparable safeguard) of
Here, the second term of the sum takes into account the the (liquid) working fluid in m
hydrostatic portion of pressure between the highest shell line
YP = Relative density of the test fluid in dN/dm3 (= 1 in
of the horizontal vessel and the measuring point “A” at the
top of the vessel vertical centreline (see fig. 1). the case of water)
YF = Relative density of the working fluid in dN/dm3
4 . 1 0 . 3 If only one pressure test is carried out in the horizon-
Di = Inside diameter of the vessel in m
tal position, the pressure measured shall be
FP = Test pressure factor according to subclauses 4.17
to 4.19.
[ +0,1 Yp. (u+g) 1
pp = Fp . p + max 4.11 At the latest when the pressure test is performed, and

I + 031 Y P -++ o,l YF ’ HF

I
/
where there is a number of pressurized compartments, at the
latest when the final pressure test is performed, the pressure

vessel shall be provided with the stipulated marking (e.g.
name plate). Any deviation from this requirement, e.g. in the
case of enamel coatings, shall be stated in the test documen-
tation.
4.12 In order to seal pressure vessels for the performance
of pressure tests, use may be made of aids such as flanges,
covers, bolts, gaskets, additional welded joints etc. only if the
closures that are provided to put the pressure vessel in its
operational state do not form part of the items supplied with
the pressure vessel. The material and dimensions of the aids
employed shall be appropriate for the loadings occurring
during the pressure test.
4.13 After performance of the pressure test, all aids which
can be detached shall either be removed at once in their
entirety or they shall be marked such as to exclude the possi-
bility of their being used in error for operation of the pressure
vessel.
4.14 When closures are being closed up, all bolts provided
shall always be used. The latter shall be tightened uniformly
to a degree no greater than is necessary for effecting a seal.
For tightening, only tools intended for this purpose shall be
used.
4.15 Tell-tale holes for checking the leak-tightness of inac-
cessible welds shall be open during the pressure tests.
4.16 In the case of hydraulic pressure tests with test pres-
sures exceeding 100 bar’), in the case of hydraulic tests
where the test fluid is at temperatures exceeding 50 “C, and
in the case of pneumatic pressure tests, the following require-
ments shall also be observed:
4.16.1 Pressure tests shall be performed in a room or in a
section of a shop to which only personnel involved in the
testing shall have access during the course of the test.
4 . 1 6 . 2 If a special room is not available, suitable precau-
tions shall be taken, e.g. the setting up of protective walls.
The area in direct vicinity of the pressure vessel to
be tested shall be sealed off and warning signs shall
be used to designate this area as a danger zone and
prohibited area.
4 . 1 6 . 3 It shall be possible to ascertain the pressure that is
indicated from a safe distance or from a protected location.
4 . 1 6 . 4 As a rule, direct visual examination shall be carried
out only when the pressure vessel has been subjected to the
test pressure for a sufficiently long period of time and when,
subsequently, in the case of hydraulic tests, the pressure has
1) Where other test fluids are used, this limit shall be changed in keeping with
the relevant compressibility factors.
P a g e 3 AD-Merkblatt HP 30, Edition 02.98
been reduced to approximately the allowable working pres-
sure and when, in the case of pneumatic test, the pressure,
where necessary has been reduced still further to a pressure
in keeping with the leak testing procedure.
4.17 Except where another value is specified in the test
documentation, the magnitude of the test pressurep’ relative
to the highest point in the pressurized compartment is 1,3 . p
for a hydraulic test. This stipulation applies to:
- Steel and malleable non-ferrous wrought materials,
- Cast steel,
- Cast iron with lamellar graphite or nodular cast iron and
malleable cast iron.
The reader should refer to AD-Merkblatt B 0, clause 4 for the
determination of the pressure p.
4.18 Where hydraulic tests are performed on pressure ves-
sels with linings which will not withstand the test pressure as
specified in subclause 4.17, e.g. enamel, porcelain, the test
pressure may be reduced to 1 .l times the allowable working
pressure.
4 . 1 9 For a pneumatic pressure test as initial pressure test,
in establishing the test pressure distinction shall be made
between the following:
4.19.1 A test during which the pressure vessel is located
in a place where nobody is present in the immediate danger
area while the pressure vessel is subjected to the test pres-
sure. For tests of this kind, the test pressure shall be selected
according to subclause 4.17. As a rule, the place referred to
above is a special chamber capable of withstanding catastro-
phic failure (bursting) of the pressure vessel or it can be a
water basin in which the pressure vessel, where required, is
adequately secured and precautions have been taken to pre-
vent parts from being ejected.
4 . 1 9 . 2 A test which is not performed as described in sub-
clause 4.19.1 and for which measures have been taken in
order to protect the personnel involved in the testing (see also
subclauses 4.16.1 to 4.16.4). In tests of this kind, the test
pressure is p’ = 1 .l . p.
4 . 1 9 . 3 If provision is made for a pneumatic pressure test as
the initial pressure test, at least 10% of the longitudinal welds
in the case of subclause 4.19.1 and 100% of the longitudinal
welds in the case of subclause 4.19.2, including all joints and
10% of the circumferential welds, shall undergo test-object
specific non-destructive testing.
4 . 1 9 . 4 The measures required in orderto protect personnel
shall be agreed between the manufacturer and the com-
petent Federal Accident Insurance Corporations and the
Factory Inspectorate.

All rights reserved. No part of this publication may be reproduced,
stored in a retrieval system, or transmitted in any form or by any
m e a n s , e l e c t r o n i c , m e c h a n i c a l , p h o t o c o p y i n g , r e c o r d i n g o r other-
wise withouth the written consent of the publisher.
The Carl Heymanns Verlag has taken all reasonable measures
to ensure the accuracy of this translation but regrets that no
responsibility can be accepted for any errors, omissions or inac-
curacies.
In cases of doubt or dispute, the latest edition of the German text
only, is valid.
I
Page 2 AD-Merkblatt N 1, Edition 7.87
3.2.2 Additives
Additives may be used for pressure vessels of glass-fibre
reinforced thermosetting plastics to achieve specific proper-
ties (e.g. regarding thixotropy, fire resistance) when their
suitability and compatibility has been verified in tests accord-
ing to Section 5. Dyes and colour pigments shall only be in-
troduced into the outer protective layers. For the application
of protective thermosetting layers consult Section 3.6.
3.2.3 Glass fibre reinforcement
The reinforcement shall consist of glass fibres which form a
satisfactory bond with the plastic or are provided with suitable
adhesion promoters. The glass fibre reinforcement shall be
introduced in accordance with the selected laminate struc-
ture into the resin and distributed as evenly as possible over
the separate supporting layers.
3.2.4 Properties
The characteristic properties of the raw materials shall be
guaranteed by the supplier and certified by a test report to
DIN 50049 - 2.2.
3.3 Materials - Requirements
3.3.1 Manufacture of materials
The manufacturer guarantees by means of quality control
plus corresponding records the proper manufacture and pro-
cessing of the materials as well as the fulfilment of the prop-
erty requirements stipulated in quality specifications or in
material data sheets.
3.3.2 Materials - Applications
The raw materials of the composite material (e.g. resin sys-
tem, glass fibre reinforcement) and the protective layers (see
Section 3.6) shall be chosen to suit the intended application,
appropriate allowance being made forthe expected mechan-
ical, chemical and thermal demands made on the pressure
vessel. The chosen criterion of suitability at environmental
temperatures postulates that the elastic modulus in bending
(3 point-bend test) or the shear modulus of the material at
50 “C and 23 “C shall not drop by more than 30 %. This shall
be verified in tests according to Section 5.
3.4 Adhesives
The adhesives shall be suitable for the indended application.
The suitability shall be confirmed in tests according to Sec-
tion 5.
3.5 Processing conditions
3.5.1 Styrene content
For the use of textile glass fibre reinforced unsaturated plas-
tics a concentration of 2 %-wt, relative to the proportion of
resin, shall not be exceeded. This shall be confirmed in tests
according to Section 5.
3.5.2 Acetone-soluble constituents
If textile glass fibre reinforced unsaturated polyesters are
used, the difference in the acetone-soluble constituents be-
fore and after additional heat treatment carried out in accor-
dance with the resin manufacturer’s instructions regarding
processing conditions (e.g. temperature, time), shall not
exceed 2 %-wt relative to the proportion of resin. Verification
shall be furnished in the form of tests described in Section 5.
3.5.3 Susceptibility to creep
The susceptibility of the material to creep established in long-
time bend tests as the difference in the deflections after 24
hours and after 1 hour, related to the 1 -hour-value, shall not
be greater than the maximum value specified in the material
certificate. This shal! be confirmed in tests according to Sec-
tion 5.
3.6 Protective layers
The supporting layers of the material shall be provided on
both sides with protective layers affording protection against
damage caused e.g. by the action of the vessel contents and
environmental factors.
The protective layers shall consist of the same or similar re-
sins forming an intimate bond with the supporting layers and
shall completely cover the textile glass fibre reinforcement.
A transitional layer (e.g. chopped strand mats) shall be intro-
duced between the protective layer and the supporting
layers. Dyed protective layers on the outside may only be
applied after tests on the supporting layers and then only
when the quality of supporting layers can be assessed in the
internal test.
The protective layers may also consist of other materials
(e.g. lining, coating, internal hose) provided their suitability
has been demonstrated.
In the case of laminate structures special attention shall be
paid to the bond strength and the compatibility of the elastic
properties. For laminate structures with non-bonding linings
this holds exclusively for the compatibility of the elastic prop-
erties.
3.7 Characteristic values for calculations
The mechanical properties of the material (strength, elastic
moduli) depend on the proportion of glass fibre and on the
orientation of the glass fibre reinforcement. Certain charac-
teristic values applicable for specific directions shall be used
for the respective strength and stability analysis. The require-
ments of the quality specification or material data sheets
apply for these characteristic values.
3.8 Tests and confirmation of material quality
The quality characteristics of the materials shall be de-
monstrated in accordance with the requirements of the mate-
rial data sheets, the quality specification and tests in accor-
dance with Section 5 with certification to DIN 50049.
4 Calculations
4.1 General
4.1.1 This AD-Merkblatt contains calculating methods for
the design of pressurized components of textile glass fibre
reinforced thermosetting plastic pressure vessels. In indi-
vidual cases employing other, generally recognized technical
regulations (e.g. multi-axial stress allowances) the design of
the vessel shall be based on the elastic-plastic behaviour of
the material.
4.1.2 Glass fibre reinforced thermosetting plastic pressure
vessels shall be so designed that any developing distortions
and changes in material properties do not impair the ser-
viceability of the component part, not even during long-term
stressing. This shall be demonstrated in tests according to
Section 5.1.
4 . 1 . 3 Protective layers shall not be included in the determi-
nation of required wall thickness.
4.1.4 As far as multi-layer laminates provided with protec-
tive layers or linings are concerned, care shall be exercised
that the elongation of the stressed wall does not exceed the
permissible elongation of the inner layer.
4.1.5 Pressure vessels in glass fibre reinforced plastics
with supporting layers e.g. glass fibre reinforced plastic
(GFWAI) require separate calculations.
 Page 3 AD-Merkblatt N 1, Edition 7.87

4.2 Symbols and units 4.3 Mechanical properties

b width mm The following mechanical properties are introduced: - tensile
d diameter of branch and opening, mm strength K,, the bending strength KS and, in the presence of
flange, bolt etc. external pressure, the compressive strength KD or the rele-
vant elastic modulus E in the relevant direction. The charac-
dL diameter of bolt hole m m
teristic values determined in the tests in Section 5.1 .I at room
h height m m temperature are valid for temperatures from -30°C to
I length of shell mm t50 “C. The characteristic values applicable to pressure
P design pressure/permissible operating bar vessels operated outside this temperature range shall be de-
pressure termined at the permissible operating temperature.
Pkrit critical external pressure bar
4.4 Safety factor and material weakening factor
r radius of a knuckle m m
4.4.1 The permissible stresses of the material are derived
S required wall thickness m m from the characteristic values K for the mechanical properties
SA required wall thickness at edge of m m and E for the elastic moduli, the material-independent safety
opening factor S and the material-weakening factor A (the product of
SK wall thickness fo knuckle m m partial factors A, to A4) for the material-related influences.
sv thickness of ‘connecting laminate’ m m 4.4.2 Compared with the critical characteristic values for a
ss wall thickness of connecting piece, mm specific shear application the factor of safety S amounts to
socket 2,0 (security against fracture, security against buckling), al-
V strength reduction factor - lowing for Section 4.4.3.
X damping length mm 4.4.3 The partial factors A, to A, in Table 1 apply only if it
A material weakening factor can be demonstrated that the material requirements accord-
- ing to Section 3.3 and the conditions to Sections 4.4.4 to 4.4.9
A, . ..A4 partial factors
are strictly observed.
compressed/load-supporting cross -
AdA,
section (see AD-Merkblatt B 9) The partial factors A, to A, may be reduced if justified by long-
shape factors term tests on representative material samples in the case
Cl, c2
of mechanical, chemical and thermal stresses or by strain
B coefficient -
measurements or long-term compression tests on repre-
4 outside diameter m m sentative vessel samples and if such a reduction is con-
ER elastic modulus in bending of stiffening N/mm2 firmed by material quality specifications.
ring in circumferential direction The product from A. S shall not however fall below the value
Es elastic reference modulus of wall N/mm’ 4,0 and the permissible stress shall remain below the crack
ELI,, ELB elastic bending modulus of wall mate- N/mm* initiation limit (see Section 4.4.8) for the relevant method of
rial in circumferential and longitudinal load application.
direction
Euz9 62 elastic modulus in tension of wall mate- N/mm2 Table 1: Material-related partial factors
rial in circumferential and longitudinal r I 1
direction Influence of long-term behaviour up
A, = 2,0
to 2 x lo5 hours
J planar moment of inertia mm4 i
KZ tensile strength of laminate in relevant N/mm2 Influence of vessel contents and A2 = 1,2
direction of stress environment
KS bending strength of laminate in rele- N/mm2 Influence of operating temperatures
vant direction of stress A3 = 1,4
from -30 “C to +50 “C
&I compressive strength of laminate in N/mm2
relevant direction of stress Influence of inhomogeneities and
A4 = 1,2
disoersion
K zv tensile strength of ‘top laminate’ and N/mm’ 1 I I

‘jointing laminate’
4 . 4 . 4 The partial factor A, = 2,0 for the long-term behaviour
KI peeling (stripping) resistance normal to N/mm2
face applies in the absence of any further proof for materials con-
taining a minimum of 40 %-wt textile glass fibre and a
M bending moment for flange calculation Nmm
maximum of 10 %-wt. additives. For materials of other com-
R radius of a dished end m m position or for a reduction the partial factor A, shall be con-
S safety factor firmed in long-term rupture tests or creep tests according
0 to Section 5.2.2 (7). The minimum value introduced is
P angle
0 A, = 1,25.
w angle
cs stress N/mm2 4 . 4 . 5 In the presence of suitable protective layers the par-
t shear strength of laminate N/mm* tial factor A2 = 1,2 for the influence exerted by the vessel con-
shear strength of bonded connection N/mm2 tents and the atmospheric conditions applies in the absence
TKI
of any further proof, when, judging from previous experience
& strain and proof, the influence of the vessel content is no more se-
G strain normal to reinforcing fibres for vere than that of water. Otherwise A2 shall be confirmed in
unidirectionally reinforced laminates creep tests according to Section 52.2 (7) after saturation in
V Poisson’s ratio contact with the vessel contents.
Page 4 AD-Merkblatt N 1, Edition 7.87

4 . 4 . 6 The partial factor A, = 1,4 applies for the influence different in the two directions, the greater of the wall thick-
of atmospheric conditions and operating temperatures bet- nesses determined according to Sections 4.5.2.2 and
ween -30 “C and +50 “C, when the shear modulus curve 4.5.2.3 shall be used for the design.
or the bending modulus falls by no more than 30 % at 50 “C
and 23 “C. For other operating temperatures the partial factor 4.5.2.2 The required wall thickness s for stresses in cir-
A3 will have to be experimentally confirmed in tests according cumferential direction ist given by
to Section 5.2.2 (5), (6), (7).
A, . A,. A3 can be confirmed by creep tests according to Sec-
tion 5.2.2 (7) after saturation in contact with the vessel con-
tents and at an elevated temperature. 4.5.2.3 The required wall thickness s for stresses in lon-
4.4.7 The partial factor A4 = 1 ,O may be adopted provided gitudinal direction is given by
that statistically characteristic values are employed in the de- Da P
s =
sign calculations. Taking a normal logarithmic distribution the KZ G-9
5 % fractile values (see DIN 53598 Part 1) shall be regarded 40’ A.S
as statistically significant for a probability of P = 75 % in an
evaluation of at least 10 single values. 4.5.3 Conical shells
4 . 4 . 8 No experimental proof of crack formation (e.g. con- The following design regulations are valid for conical shells,
firmed by loading tests using dye penetrants or sound emis- when the ratio s/D, is 2 0,005 at the wide end.
sion) is needed when the supporting laminate begins and
ends with a layer of randomly orientated fibres of approxi- 4.5.3.1 The stresses acting the knuckle at the wide end in
mately 450 g/m2 and when the elongation at the edge attains both directions and the stress acting at the wide end in the
a maximum of 0,5 %/A, and does not exceed 0,35 %, even direction of the shell line (bending stress) and in the circum-
at the test pressure. ferential dIrectron (tenslle stress) are the cntical factors de-
termining the dimensions of the wall thickness. The design
At the test pressure the strain Ed transverse to the orientation calculations for the conlcal shell are given in Sections 4.5.3.2
of the fibres in the spun (wound-on) laminates shall not ex- and 4.5.3.3 and for the knuckle in Sections 4.5.3.4 and
ceed 0,2 % in any one layer. 453.5 where, in each, the greater of the calculated wail
The permissible strains at the edge of lined vessels (protec- thicknesses shall be taken.
tive layer, liner) shall be specified in accordance with the The required bending strength shall be taken in circumferen-
strain behaviour of the linings. Micro-cracks in the supporting tial and meridional directron.
laminate are acceptable provided suitable protective layers
are used. 4.5.3.2 The permissible wall thickness s of the shell for the
stress acting in the circumferential direction of the cone is
4 . 4 . 9 The long-term performance shall also be taken into given by:
consideration when the material is subjected to external
pressure. In keeping with the expected service conditions 4 P .___ 1
s =
the product of the safety factor and the material reduction fac- KZ cos 5% (3)
20’ A.S
tor shall be so stipulated that is never falls below the value
A . S = 2.7 against instability during service life forming the
basis of the vessel design. The value tlq can be introduced 4.5.3.3 The required wall thickness s of the shell for the
into the calculations instead of A,. stress acting in the longitudinal direction of the cone is given
by
4.5 Calculation against internal pressure
The undermentioned design calculations apply for cylindrical (4)
and spherical shells under internal pressure where L&ID,
does not exceed 1,2.
4.5.3.4 The required wall thickness s of the shell at the wide
4.5.1 Connecting joints end of the conical shell for stresses in circumferential direc-
tion is given by
The mathematical proof for the loadability of the joints (lami-
nate points, adhesive joints) shall be furnished with the val-
ues
permissible rK, = 1 N/mm2 and
permissible uK = 0,5 N/mm2 as well as with 4.5.3.5 The required wall thickness s of the knuckle at the
the tensile strength of the connecting laminate KN. wide end of the conical shell for the stress acting in longitu-
The thickness of the connecting laminate shall be determined dinal direction is given by
on the basis of the strength of the tested and the to-be- Da. KJ . C,
evaluated wall material. The connecting laminate shall ex-
(6)
tend over a width of at least x = d-on both sides of the
two components about to be joined and then gradually taper
out. The width of adhesive joints shall be at least ten times 4.5.3.6 The shape factor C, based on the angle I/J formed
the smaller wall tickness of the parts to be joined. by the shells joined by a knuckle depends on the ratio r/D,
between the knuckle radius and the design diameterr/D, and
4.5.2 Cylindrical shells the angle q or v of Table 2.
4.5.2.1 The required wall thickness s shall be obtained from
the stress in longitudinal or circumferential direction. Since 4.5.3.7 Conical shells shall have a knuckle with the ratio
the strengths of textile glass fibre reinforced plastics may be rJD, 2 0,l.
 P a g e 5 AD-Merkblatt N 1, Edition 7.87

1 4.5.5 Dished ends

Table 2: Shape factor C, and numerical value -
COSrFl

for the knuckle and shell design of cones

I

4.5.3.8 Where the knuckles of conical shells are reinforced,

the reinforcing laminate shall be continued in the same thick-
ness on both sides of the knuckle over a width x 2 v 0, sK
and gradually taper off.

4.5.4 Spheres
Fig. 3 Reinforcement of knuckles and joints
The required wall thickness s is given by:
Da P 4.5.5.1 Where dished ends are used the Korbbogen- or the
S=
KZ hemlspherical type shall be preferred to the Klopper type.
4 0 - Shallow dished ends or flat flanged ends shall not be used.
A.S
4.5.5.2 The required wall thickness skr for the knuckle is
given by

(8)

where the shape factors C2 shall be taken from Table 3.

The required bending strength KB shall be taken in both cir-
cumferential and longitudinal direction.
4.5.5.3 The required wall thickness s for the crown and
with hemispherical ends is given by

where the shape factors C, shall be obtained from Table 3

and where 0, represents the outside diameter of the shell.
Table 3: Shaoe factor C, for the calculation of dished ends

Type of end Shape

factor
C2
Hemispherical 12
ends
Korbbogen
typ ends
R = 0,8. 0, crown area 13
h, 2 3,0 ‘SK
r = 0,154.D, knuckle area 3,5

Kloppertype ends
R = 0, crown area 2,4
r = 0,l . 0,
h, 2 3,5 ‘SK knuckle area
with sKIDa = 0,005 53
= 0,Ol 534
= 0,02 571
= 0,03 4,75
= 0,04 4,45
= 0,05 42
L 0,06 470
Figs. 1 and 2: Types of conical shell design I-
Page 6 AD-Merkblatt N 1, Edition 7.87

4.5.5.4 For Kltipper- and Korbbijgen-type ends the wall 4.5.6.3 The required wall thickness sA at the edge of open-
thickness of the knuckle shall not fall below 0,005 . D,. ings in spherical shells and crown sections of dished ends
is given by
4.5.5.5 When the knuckles of dished ends are reinforced Da.P
(see Fig. 3), the reinforced laminate shall extend over the 6A =
Kz (11)
crown-shaped part of the end and the shell to a thickness 20 “A A . s

of x r q’ and then gradually taper off.

where D, = the outside diameter of the sphere.
4.5.6 Openings The tensile strength Kz of this connecting joint shall be main-
tained in the cut-out and reinforced wall, in both directions
4.5.6.1 Since far too few results are currently available on
of the opening.
the performance of openings in pressure vessels made from
textile glass fibre reinforced thermosetting plastics, the de- 4.5.6.4 The weakening factor v,of non-reinforced pad-rein-
sign shall be based on the elastic strength of disc-shaped or forced or tube-reinforced openings may be taken from Table 4.
similarly shaped openings. Only tip-stretched or laminated- Added-on and flush-fined branches shall not be considered
on branches are acceptable. as reinforcement and require a separate evaluation.
The lamination for the disc-shaped pad reinforcement at the Table 4: Weakening factor vA for the calculation of open-
edges of openings shall gradually taper off at the outer edge inns
down to the wall thickness of the pressure vessel.
1 2 3 4 5
4.5.6.2 The required wall thickness sA at the edge of the
opening in cylindrical and conical shells is given by
43 P unreinforced or pad-
SA =
KZ (10) reinforced according 0,44 0,33 0,27 0,22 0,lS
20. “ A ,J, s
to Figs. 4a and 4b
In the circumferential direction the reinforced wall shall attain pad- and tube-
the tensile strength K Z of this joint. Longitudinally the re- reinforced according
inforced wall shall attain at least half the quoted tensile t0 Fig. 5 (s&A = 1) 0,60 0,47 0,38 0,32 0,28
strength. This applies for the diameter ratios d , / D , 4 0 , 4 . and according to
For concial shells D, represents the outer diameter at the Fig. 6 (s,/sA P 0,8)
centre of the opening.

‘-G---r-

Fig. 4a. Pad-reinforcement Fig. 4b. Pad-reinforcement

(thermosetting protective layer) (thermoplastic protective layer)

I I
i

Fig. 5. Pad- and tube-reinforcement for openings Fig. 6. Pad- and tube-reinforcement for openings
(shaped branch) (continuous, through-passing branch)
 Page 7 AD-Merkblatt N 1, Edition 7.87

4.5.6.5 The width of the pad-reinforcement shall be x, 2 4.7 Stability check

vm [though with a minimum of 10 times the wall thick-
4.7.1 Calculation of the permissible compressive
ness of the shell] and the height of the tube-reinforcement
stress
shall be xa 2 qmA with some attention being paid to the
designs in Figs 5 and 6. 4.7.1.1 The permissible operating pressure (external pres-
sure) for the stress acting in a circumferential direction upon
4.5.6.6 The interaction between adjacent openings shall be cylindrical shells is given by
checked in compliance with AD-Merkbiatt B 9. The following
formula shall be used for the ‘planar comparison method’:
P
-. 4 . -.-.---
’ K
‘0 A, vc A.S 4.7.1.2 The permissible operating pressure (external pres-
sure) for the stress acting in a longitudinal direction is given
where vc = 0,65 for pad- and tube-reinforcements
vG = 0,8 for shaped branches
by
The proof may also be furnished in the form of strain mea- 40 . s . KI,
in undisturbed zone
surements. ’ = D,.A.S
in zone covering ‘influenced
4.5.6.7 The knuckles of ends shall be free from openings. 20 s K,
width’ b for rigid rings and (18)
Where branches are required, their internal diameter shall ’ = D;A.S
endsb=0,3.-
not exceed dz. The wall thickness of the branch shall
be equal to the wall thickness of the knuckle. In addition the
4.7.2 Calculation against instability
qualification test shall establish that the permissible stresses
and strains are not exceeded. The critical buckling pressure depends on the elastic prop-
erties and the geometry of the cylinder.
4.5.7 Flanges The permissible pressure is given by
Flanges with conical or cylindrical attachment in the form of Pkr,t
continuous laminate, joining the branch tube at a distance P Z”I = -
A.S
of at least x = m from the rim of the flange or with the
upper laminate of the branch reinforcement, can be calcu- 4.7.2.1 Non-stiffened cylinders
lated according to the preliminary standard DIN 2505 (Oc-
tober 1964). The number fo bolts shall be as large as possible The critical buckling pressure for non-stiffened cylinders
and the bolt spacing (pitch) not greater than 5 dL. The having a length 5 6 . D, can be calculated, without any spe-
minimum number of bolts is four. cial proof, according to formula (20)
The lamination shall be continued from the branch to the rim pkr,, = 23,5 Es . -+ 5’2
of the flange and rounded off.
Formula 13 serves as reference value for the calculation
according to the preliminary standard DIN 2505 (October l-O,1 LQL
1964): 61,
The critical buckling stress of non-stiffened cylinders having
a length I greater than 6 . D, shall be calculated with formula
The bending strength in the relevant direction shall be taken (21)
3
as the bending strength Kg. 20 . EUB
f&it= (l-vL.vu) . (21)
Blank flanges and flat plates shall be dimensioned in accor-
The formula vL. vu = O,l.can’be employed for ordinary lami-
dance with AD-Merkblatt B 5 where, instead of --&, the term nates.
KB 3
has to be introduced.
1,5.S.A This gives&, = 22 . f”a ’

4.6 Deformation check

4.7.2.2 Ring-stiffened cylinders
The prevailing average stresses in the operating and testing
conditions for the individual groups of prefabricated parts can The cylindrical shell between stiffeners shall be evaluated in
be determined for the envisaged wall thicknesses using the accordance with Section 4.7.2.1, where I = la denotes the
expressions given in Section 4.5.1. spacing between two adjoining stiffening rings. Wherever
there are variations in the ring spacings, instead of Ia, the
In particular the following applies: average value from the two maximum adjoining ring spacings
VL
--. shall be introduced into the calculation of ok&
EL=; E
2 ” a”

Eu=*-*. (J,
%I LL
Total instability
where EL, Eu represent the elastic moduli laid down in the
material quality certificate. It is permitted to rely on the con- For the calculation of the permissible pressure in terms of
tinuum theory (layer-by-layer fracture analysis) [1] or the total instability the formula for stiffened cylindrical shells read
lattice theory [3] with an allowance being made for Sec- 20 . Es . s
tion 4.4.8. Pknt =
Da . -*
The derived strains .c~ and E”
shall be smaller than the values permitted for the correspond- (rP-l)80~ER.J;
+ (22)
ing load case (see Section 4.4.8). Da3 . lR
Page 8 AD-Merkblatl N 1, Edition 7.87

where n 2 2 represents the integral number of the possible 4.7.3.1 Strength calculations
indenting undulations in circumferential directions; n shall be The permissible external pressure of ends is obtained for
so chosen that p is reduced to the smallest value. knuckles using the following formula:
E, is the reference modulus according to formula (20a) of the KB
wall for the determination of the rigidity regarding the co-sup- 4o’s A.S (25)
porting width 1, (formula 24). p= .-
Da . G
B shall be determined as follows: and for the crown using the following formula:

4o+$g
(26)
where 1 represents the spacing between two end plates or P=
Da. G
p 03 I
two effective stiffeners for which J 2 applies.
8. E The form factor C2 shall be taken from Table 3 in Section
R 4.5.5.3.
Stiffenings with a lower J-value do not lead to a shortening
of shell length 1. 4.7.3.2 Stability calculations
ER represents the bending modulus of the stiffening ring in- The permissible buckling pressure of the spherical shell of
cluding the supporting width of the shell for which an allow- radius R is given by
ance has been made. This parameter shall be determined
on large-scale specimens (e.g. quarter segments). p = 366 AL.
A. s
The planar moment of inertia J, of the elastic reinforcement
(Fig. 8) is made up of the moment of inertia of the ring with The smallest of the direction-dependent values in the mate-
height he and the moment of inertia of the supporting width rial quality certificate shall serve as bending modulus.
1,. When a satisfactory shear-resistant connection exists be-
tween the stiffening ring and the shell, the total moment of
interia refers to the common centre of gravity. When a perfect Tests
ring/shell connection cannot be guaranteed, the total mo-
ment of inertia J, represents only the sum of the individual 5.1 Process approval test
moments of inertia. In this case an allowance will have to be
The process approval test shall be carried out in the works
made for any differences in the elastic modulus.
of the manufacturer on the basis of the information supplied
1, indicates the spacing between the rings (Fig. 7). by him on his production equipment, skilled personnel,
methods of quality control and materials used. The fabrica-
tion and extraction of specimens representative of the con-
struction for material testing purposes shall be carried out
during the process approval test.
A report describing the design of the pressure vessel, the
models, materials and fabrication processes shall be issued
on the adopted procedure and the results of the process
I--. ____.-_-. - .-.__-. - _- approval test.
Fig. 7. Spacing between stiffening rings A supplementary test is needed whenever there are changes
e.g. deviations in the diameter in excess of 50 %, changes
The supporting shell length 1, is given by in the supports or joints as well as in the dimensions of the
branches or openings.
1, = b , + bR (24)
b , 5 1,l G 5 20. s Wa) 5.2 Material tests
5.2.1 General
5.2.1.1 The material characteristics and partial factors
significant for the design and fabrication of the structural
part shall be determined before or at the start of production
and recorded in a material quality certificate. Any changes
in material or manufacturing process and any additions to the
conditions of operation (e.g. operating temperature, feed
I material) require a supplementary material quality certificate.
!
5.2.1.2 The purpose of material testing is to determine the
j
I characteristic values which underlie the calculation de-
i--- _ _ _ _ - - - -.---.- / J scribed in Section 4. Materials are verified on the basis of an
initial material quality specification using an identity test of
Fig. 8. Dimensions of stiffening rings
the material or, in individual instances, a material quality
2h,sb,s20h, specification,
.sshR% 4 s
5.2.1.3 The type-related properties of the raw materials
according to Section 3.2 shall be confirmed by certificates
4.7.3 Curved ends under external pressure according to DIN 50049 - 2.2 (test reports). The material
When curved ends are used the Korbbogen- or hemispher- of semi-finished products shall be confirmed by certificates
ical-type shall be preferred to the Klopper-types. Shallow according to DIN 50049 - 2.3 (Manufacturer’s test certifi-
CurX?d and flat flanged ends shall not be employed. cate).

5.2.1.4 The specimens required for material testing shall be
taken from the structural component or the material speci-
mens which correspond to the material of the structural com-
ponent as regards raw materials, structure and fabrication.
The specimens shall be taken in the direction of the principal
stresses acting in the textile glass fibre reinforcement.
5.2.1.5 Whenever pressure vessels are fabricated for type
testing, the product shall be routine tested in accordance with
TRB 505. The scope of these routine tests shall be set out
in the material quality certificate.
5.2.2 Determination of the characteristic values
The following values shall be determined in the material
tests:
(1) Percentage by weight of glass fibre in accordance with
DIN EN 60, if required separately for the laminate of the
supporting layers and the protective layers as well as for
the layer structure giving the respective percentage
weight.
(2) Bulk density according to DIN 53479, if required for the
laminate of the supporting layers and the protective layer.
(3) Proportion of styrene according to DIN 53394 for glass
fibre-reinforced unsaturated polyester (UP) and acetone-
soluble proportions according to DIN 53700 on textile
glass fibre-reinforced moulding materials (EP), each re-
lated to the proportion of resin, or the suseptibility to
creep in 24 h bending test in accordance with DIN 53444/
DIN EN 63.
(4) Tensile strength, elongation at fracture and modulus of
elasticity according to DIN EN 61 (preferably using test
specimen II of 50 mm width).
(5) Bending strength, deflection on fracture and modulus of
elasticity according to DIN EN 63 (preferably using test
specimens having a width of 50 mm and a length corres-
ponding to twenty-four times the thickness at a distance
between the supports corresponding to twenty times the
thickness) at 23 “C and at 50 “C.
(6) Failure load of laminated joints and adhesive joints in ten-
sile test in accordance with DIN EN 61 or in bending test
in accordance with DIN EN 63 using specimens corres-
ponding to the geometry of the structural component at
23 “C and at 50 “C.
(7) Creep strain in long-term or in long-term bending test in
accordance with DIN 53444/DIN EN 61 and DIN EN 63
at the principal working stress, at 23 “C and at 50 “C over
a minimum of 1000 hours.
At operating temperatures below -30 “C and above +50 “C
the tests according to (5) (6) and (7) shall be supplemented
by additional tests at the corresponding test temperatures.
The test conditions shall be quoted in the results report.
5.2.3 Material quality certificate
5.2.3.1 The material quality certificate confirms that the
requirements according to Section 3.3 and the conditions
according to Sections 4.4.4 to 4.4.9 have been satisfied. The
findings of material quality certificates can be collated in
Material Data Sheets (Werkstoffblatter).
5.2.3.2 The quality certificate is first issued before the start
of fabrication or in special cases at the start of fabrication on
the basis of the test results obtained on the material accord-
ing to Section 5.2. The average values of the results accord-
ing to (l), (2) and (3) of Section 5.2.2 taken from at least five
specimens each, the average values and standard devia-
tions of the results according to (4), (5) and (6) taken from
Page 9 AD-Merkblatt N 1, Edition 7.87
at least ten specimens each as well as the average values
of the results according to (7) taken from at least 20 speci-
mens each shall form the basis of the material quality cet-tifi-
cate.
5.2.3.3 On submission of a material quality certificate, the
performance of an identity test as material conformity test is
a necessary and sufficient requirement. In the identity test,
tests (1) (2) and (3) of Section 52.2 shall be carried out on
a minimum of two specimens each and the test according
to (5) of Section 5.2.2 on a minimum of 4 specimens each
at 23 “C.
If there are any variations from the submitted material quality
certificate all the tests according to Section 5.2.2 and in spe-
cial cases a material quality certificate will be required.
5.3 Vessel tests
5.3.1 Initial tests for granting material quality certifi-
cate
5.3.1.1 TRB 511 applies for the preliminary test. In addition
the following particulars are required:
- a buildup of the laminate employed for the components
and joints of component parts,
- resin systems and reinforcing materials used including
possible thermal after-treatments,
- composition and buildup of protective layers,
- shear modulus curve of resins,
- nature of vessel content, its chemical composition,
physical state and weight when in the vessel,
- design basis quoting sources whenever design differs
from Section 4,
- the intended service life of the pressure vessel,
- cyclical and other dynamic stresses which have to be
taken into account in pressure vessel design,
- transport and assembly instructions.
5.3.1.2 Structural tests shall comply with TRB 512
5.3.1.3 Pressure testing shall comply with TRB 512. During
testing, strain and/or deformation measurements shall be
used to determine whether changes in shape likely to occur
during operation are insignificant from the safety viewpoint.
At no point shall the strain values measured during the tests
conducted in accordance with (2) to (5) below exceed the
maximum permitted values specified in the material quality
specification:
(1) On the vessel prior to filling (zero measurement);
(2) during filling (various pressure levels);
(3) at a minimum of 3 pressure levels-e. g. at half maximum
permitted operating pressure, at maximum permitted
operating pressure and at 1,3 times maximum permitted
operating pressure;
(4) at maximum permitted operating pressure over 1000
hours, creep behaviour being determined at the most
highly stressed points;
(5) during increasing or alternating loads expected in normal
conditions of operation;
(6) when internal pressure increases until failure occurs due
to a burst or a leak.
The strain measurements according to (4) and (5) may be
restricted taking into consideration the results of the mea-
surements made in accordance with (l), (2) and (3).
Page 10 A D - M e r k b l a t l N 1, E d i t i o n 7 . 8 7
In the case of a single pressure vessel the determination of
the pressure at which failure occurs shall be replaced by
strain measurements taken at additional pressure levels
according to (3) and/or by special test procedures (e.g.
sound emission measurements).
5.3.2 Certification of correct manufactureand pressure
testing
Certification confirming that the manufacturer has made and
pressure tested a vessel correctly shall be carried out in
accordance with TRB 521 or TRB 522.
5.3.3 Acceptance testing
In the case of groups Ill, IV, VI and VII, acceptance tests
shall be carried out by the authorized inspector to TRB 513
and, in the case of group I, II and V vessels, by an expert to
TRB 531.
5.3.4 Type testing
Type testing shall be to TRB 505. When testing for the first
time, consideration shall be given to the conditions set out
in Section 5.3.1.
53.5 Follow-on inspections
Subsequent inspections after specified intervals on group III,
IV and VII pressure vessels shall be carried out by an
authorized inspector according to TRB 514 and on group I,
II, V and VI pressure vessels by an expert according to
TRB 532.
6 Literature
t11 Puck, A.: ,Konstruieren und Berechnen von GfK-Teilen”,
Beiheft zur Fachschrift )bKunststoffberater<t, Umschau-
Verlag, FrankfuNMain 1969.
PI Zoit, A., und G. Nonhoff: ,,AuOendruckbehalter aus glas-
faservertarktem Kunststoff“ (Vortrag auf der 10. of-
fentlichen Jahrestagung der Arbeitsgemeinschaft Ver-
starkte Kunststoffe, 3. bis 6. Oktober 1972 in
Freudenstadt).
131 Outwater, J. 0.: ,,Filament wound internal pressure ves-
sels” Zeitschrift ,,Modern Plastics” Bd. 40 (Marz 1963)
s. 135139.
UDC 661.66:621.642.02-986 Edition June 1971

Pressure Vessels Pressure vessels made AD-Merkblatt

made of non- of electro-graphite
metallic materials N2
and hard burned carbon

The AD-Merkblltfer are being established by the six trade associat;ons named below which form the ,,Arbeitsgemeinschaft
DruckbehBlter” (AD). The Unfallverhtitungsvorschnft ,,Druckbehl/ter” (VBG 17) issued by the Hauptverband der gewerblichen
Berufsgenossenschaft e. V. refers to the AD-Merkblltter as ,,Norma/ Rules practised in Profession” AD-Merkblatt G 1 states
structure and app/;cation of the AD-Merkblltter as we// as the directives for the technical work.
Fachverband Dampfkessel-. Behalter- und Rohrleitungsbau e. V. (FDBR), Dtisseldorf
Verband der Chemischen lndustrie e. V. (VCl), Frankfurt/Mam
Verein Deutscher Eisenhijttenleute (VDEh). Dijsseldorf
Verein Deutscher Maschinenbau-Anstalten e. V. (VDMA). Fachgemeinschaft Apparatebau, Frankfurt/Marn
VGB Technische Vereinigung der GrosskraftwerksbetreIber e. V, Essen
Vereinigung der Techmschen Liberwachungs-Vereine e V. (VdTlJV). Essen.
The AD-MerkbWter are currently adapted to technical progress by the six assooations Suggestions to amendand improve the
AD-Merkbltitter should be adressed to the publisher
Verelnlgungder Technischen i)berwachungs- Vereelne e. V., Postfach 1790, D- 4300 Essen 1.

Contents

1. S c o p e 7. Strength value
2. G e n e r a l 6. Basis for calculations
3 . Materials 9. Tolerances and surface finish
4. Tests 10. Pressure testing
5 . identification marking 11. Literature
6. Certification of quality

Annex 1: Specimen of an acceptance certificate

Annex 2: Explanatory comments for AD-Merkblatt N 2

1. Scope
1.1. This AD-Merkblatt applies to electro-graphite and hard
Durned carbon, impervious to gases and/or liquids, as mate-
rials for the manufacture of pressure vessels, parts of pressure
vessels and fittings subjected to pressure, which are operated
at wall temperatures ranging from -60°C to +4OO”C, the limits
for the maximum wall temperatures of the materials being fixed
according to the expert opinion of the Inspecting Authority.
1.2. The materials must be selected to correspond to the
purpose, taking into account the mechanical, thermal and
chemical demands made on them.
1.3. In the case of pressure vessels made from electro-graphite
or hard burned carbon, as a rule the following limits apply to
the maximum permissible working pressure:
25 bar for exchangers of block construction
16 bar for tubular exchangers
10 bar for hollow cylinders up to NW 200, with internal
pressure
6 bar for hollow cylinders over NW 200, with internal
pressure
16 bar for hollow cylinders up to NW 200, with external
pressure
10 bar for hollow cylinders over NW 200, with external
pressure.
In the case of internal pressures greater than 0,5 bar and
external pressures greater than 1 bar, in general the following
mathematical products of thevessel capacity I in litres and the
maximum permissible working pressure p in atmospheres
should not be exceeded:
in the case of internal pressure: I x p = 6 5 0 0 0
in the case of external pressure: I X p = 100000
For deviations from these stipulations, the agreement of the
Inspecting Authority is to be obtained.
1.4. If the materials are used for cladding or with armouring
which substantially bears the stresses, the above limits do not
apply.
2. General
2.1. If electro-graphite or hard burned carbon are used as
materials for pressure vessels, parts of pressure vessels or
fittings, their special properties must be taken into account.
2.2. A pre-requisite for the manufacture of electro-graphite and
hard burned carbon is that the producing factory is adequately
experienced. Aonce-and-for-all certificateto thiseffect is to be
produced to the Inspecting Authority.
2.3. Vessels under pressure, parts of vessels and fittings made
from electro-graphite or hard burned carbon are used by
preference because of the high resistance tp corrosion of these
materials. They are resistant to almost all organic and inorga-
n i t media, provided that these media do not have a strong
oxidising action.
2.4. The materials are of a brittle nature; they are insensitive to
temperature changes. Peak stresses should be kept as low as
possible by a suitable design.
2.5. The manufacture of semi-finished articles’) is carried out
with the procedures usual in the ceramic industry, such as
extrusion presses or block presses. Parts with complicated
shapes can be made from semi-finished articles by machining.
2.6. Non-detachable joints in parts are made be cementing,
and the strength characteristics of the joints must be guaran-
teed to be adequate. Aonce-and-for-all certificateto thiseffect
is to be produced to the Inspecting Authority.
2.7. Detachable joints can be made by means of, among other
things, anchor bolts, or bolts and flanges, e.g. made fro& steel,
with, as a rule, soft gaskets2) being used.
‘) e.g. hollow cylinders. tubes, solid rods, plates and blocks.
*) See AD-Merkblatt B 7. table 1, line 1.

Carl Heymanns Verlag KG

Luxemburger StraOe 449, 50939 K6ln
GutenbercstraSe 3. 10587 Berlh
Page 2 AD-Merkblatt N 2
3. Materials
3.1. Definitions and characteristics
3.1.1. In the case of hard burned carbon and electro-graphite
materials, a distinction is drawn between the two kinds of
material - Jmpregnated” and ,,non-impregnated”:
(1) Impregnated electro-graphite and impregnated hard bur-
ned carbon exhibit a certain drop in their strength as the
temperature increases, The amount of this drop in strength
and the limit of the maximum permissible wall temperature
depend on the impregnating medium.
(2) Non-impregnated electro-graphite and non-impregnated
hard burned carbon exhibit no drop in strength as the
temperature increases.
3.1.2. Electra-graphite and hard burned carbon are divided
into the following strength classes, depending on the average
value of the tensile strength at 20°C:
(1) In steps of 2 N/mm2 in the range of tensile strength between
4N/mm2 to 20 N/mm’. and
(2) In steps of 4N/mm2 from a tensile strength of 2 0 N / m m *
upwards.
The grading into the strength classes is carried out by means of
the average value obtained in accordance with clause 4.3.
Deviations of individual values from the average value by
220 %3) are permissible.
3.2. Once-for-all certificate of quality characteristics
For each kind of material and each impregnating medium, the
changes in strength wrth the temperature, the relahonship of
the bending strength to the tensile strength, and the maximum
permissible wall temperature are to be proved once-for-all by
the manufacturer to the Inspecting Authority. For this, work
reports can be recognlsed.
3.3. Abbreviated designation of materials and qualities
Abbreviated designations are used for materials. In these the
letter K means hard burned carbon and the letter G electro-
graphite. The first number following the letter indicates the
lower limit of the range of the strength class at 20°C in N/mm’;
the second number the drop in this value in per mil per 10°C
rise in temperature, and the third number the maximum
permrssible wall temperature. Thus, if for instance a non-im-
pregnated hard burned carbon with a tensile strength of
6 N/mm2, having no drop in strength as the temperature riSeS.
and with a maximum permissible wall temperature of 400°C is
designated as:
K 6 - 0 - 400
and an impregnated electro-graphite with a tensile strength of
12 N/mm , a drop in strength of 8”/, and a maximum wall
temperature of 165°C is designated as:
G 12 - 8 - 165
4. Tests
4.1.The test pieces for ascertaining the properties of the
material should be taken from semi-finished articles. If this is
Impossible, the test informationshould beobtained on compa-
rable parts of the charge”).
4.2. For each charge the tensile strength, bending strength and
if necessary the resistance to pressure (for the shape and
dimensions of the test specimens see Annex) are to be
determined at room temperature.
In the case of parts of small dimensions or with thin wall
thicknesses, e.g. tubes, the bending strength (bending tensile
strength) is ascertained instead of the tensile strength. Grading
into the strength classes, as clause 3.1.2. is carried out on the
basis of the bending strength, due account being taken of the
relationship between the bending strength and the tensile
strength
4.3. Obtaining the average value and repeat tests
4.3.1. From each charge 5 test pieces are taken. Decisive for
determining the tensile strength is the average value of the
individual results of the tensile test, or respectivelythe bending
‘) For special cases, see clause 4.3.2.
‘1 Semi-finished articles which are made from the same miXture.
undergo the same manufacturing process and are of comparable
dimensions. are valid as a charge.
tests carried out in its place. Deviations of individual values
from the average value by f20 % are permissible.
4.3.2. If an individual value fails below the average value by
more than 20 % a replacement test piece must be tested. If two
individual values or the result of the replacement test on the
individual test piece do not meet the requirements, 5 further
test pieces are to be tested. If then the requirements are not
reached, the products made from this charge may be classified
in a lower strength class, or rejected. The decisivevalueforthe
lower classification is the new average value, or, if an individual
v a l u e d i f f e r s f r o m t h e n e w a v e r a g e v a l u e b y m o r e t h a n 2 0 %, t h e
lowest individual value.
4.3.3. For obtaining the new average value, when testing an
individual replacement test piece or a complete set of test
pieces, the test pieces which have been replaced are ignored.
4.3.4. If one or two individual values come above the average
value by more than 20 %. these are ignored, and the average
value is obtained only from the remaining individual values.
4.4. Testing the variations in size and the surface finish takes
place as a rule during the constructional tests on the pressure
vessel.
5. identification marking
5.1. In the case of semi-finished articles, a co-ordination with
the acceptance certificate must be ensured until such time as
they are incorporated in the pressure vessel. This is done as a
rule by an identification mark.
5.2. Parts of the finished pressure vessel which have to
withstand pressure must be provided with the abbreviated
designation of the quality of material and with the manufactu-
rer’s mark. In the case of a test by the Inspecting Authority, its
testing stamp must also be applied.
5.2.1. In the case of small parts it must be confirmed by the
manufacturer in a Works Certificate that the required quality of
material has been used. As a rule, no identification marking is
carried out on the parts.
6. Certification of quality
6.1. The tests stipulated in section 4 are carried out and
recorded by the manufacturer as production proceeds. The
Inspecting Authority checks that the tests are properly carried
out, including the factory records. For that purpose it can be
present during manufacture and testing, and satisfy itself as
to the correctness of the works testing by making random tests.
6.2.The kind of quality certificate is determinded to the
satisfaction of the Inspecting Authority by the once-for-all test
of the material and the impregnating medium in accordance
with clause 3.2. In the case ofsufficientlywell-known materials
an Acceptance Certificate 3.1 B as DIN 50 04g5) is sufficient. In
the Acceptance Certificate arestated onlythe test results of the
type of test (tensile or bending) which are decisive for the
grading of the material into the strength class.
6.3. The manufacturing works have to state in the Attestation of
Conformity by means of an abbreviated designation the
impregnating medium and the quality of cement. In addition, in
the case of non-detachable joints, adequate strength and
temperature resistance for the operating conditions corre-
sponding to the once-for-all certificate have to be confirmed by
the manufacturing works.
7. Strength value
7.1. The strength value K at room temperature is the bottom
limit of the tensile strength scatter of each strength class. In the
case of materials as clause 3.1.1 (1) the strength value K at
temperatures over 20°C is taken as the strength value K at room
temperature diminished by the drop in the tensile strength, and
the strength values are rounded off downwards to tenths. At
temperatures below +2O”C, the strength value K is taken as at
+20°c.
7.2.The influence of time of a mechanical stress on the
strength values may be ignored.
5, For a specimen, see Annex 1
 Page 3 AD-Merkblatt N 2

8. Basis for calculations Annex 1 to AD-Merkblatt N 2

8.1. For design calculations of pressure vessels or parts of

pressure vessels, the AD-Merkblltter of Series Bare to be used,
with the following alterations or additions. Acceptance Certificate
8.2. In the case of electro-graphite and hard burned carbon the
corrosion allowance stipulated in the AD-Merkblatter is dis-
pensed with.
with reference to DIN 50049/3.1 B
8.3. The safety coefficient S as concerns the strength value K,
in the case of the maximum permissible working pressure and
the maximum permissible temperature is S = 9; in the case of
the test pressure the safety coefficient S’ = 6,6.
Order placed by:
8.4. In design calculations for cylindrical shells under external
pressure, the calculation to cover elastic buckling as AD-Merk-
Manufacturer:
blatt B6 is dispensed with. In calculation to cover plastic
deformation the usual strength value K, but increased by a
factor of 2.5, is used in formula (3) of AD-Merkblatt B6. The Test subject:
foregoing also applies throughout the scope of AD-Merkblatt
86 for diametrical ratios 1,2 $ D,/D, 9 1,3.
Test conditions: AD-Merkblatt N 2
8.5. In design calculations for tubes under external pressure in
accordance with AD-Merkblatt B 11, the strength value K can
be increased by a factor of 2. Quality of material: corresponding to:

identification mark
quality of material: Manufacturer’s mark:
9. Tolerances and surface finish
9.1. Tolerances should be agreed upon between the manufac-
turer and the customer; otherwise the Works Standards of the
manufacturer apply.
Item
No.
I Number of
1 oieces 1
I I
I Subject Test results
N/mm*
9.2. Permissible deviations where no tolerances are stated in
accordance with DIN 7168, ,.coarse” degree of accuracy, need
not be taken into consideration in the calculations. Any falling
below the wall thicknesses in excess of this must be taken into
consideration.
9.3. Agreement has to be reached between the manufacturer
and the customer on the surface finish and the admissibility of
a layer of impregnating medium on the surface; otherwise this
is left to the manufacturer.

1. By our current tests during manufacture and by the factory

10. Pressure testing
10.1. The test pressure is 1.3 times the maximum permissible
working pressure. In the case of working pressures up to 1 bar
the test pressure must exceed the maximum permissible
working pressure by not less than 0,3 bar.
10.2. If it is not possible at the manufacturer’s works to
assemble a pressure vessel for the purpose of carrying out the
pressure test, the test can be done on the individual parts.
Clause 10.1 applies for the values of the test pressure.
10.3. Before putting the pressure vessel into service it must be
subjected to a pressure test in the assembled condition on the
erection site in the presence of the Inspecting Authority.
s u p e r v i s i o n o f t h e I n s p e c t i n g A u t h o r i t y _. _. i t i s
ensured that the characteristics determined by the specifi-
cation of the material quality are adhered to.
2. The parts are impregnated with synthetic resin Type
3. For the cementing of parts to item Nos cement type
.,.... has been used. Adequate strength and temperature
resistance for the working conditions and the pressure test
guaranteed.
4. The small parts have been manufactured from tested
semifinished material of material quality..

Dated _. _. at..
Il. Literature
Linder, H.: Graphit im Druckbehllterbau.
Techn. Llber-wach. 9 (1968) No. 1, pages 12114. Works inspector
Page 4 AD-Merkblatt N 2
Annex 2 to AD-Merkblatt N 2
Explanatory comments for AD-Merkblatt N 2.
Pressure vessels made from electro-graphite and hard
burned carbon
Re 2: General
Hard burned carbon and electro-graphite are produced as
follows:
Coke and pitch can be used as the raw materials. They are first
mixed and then brought to the shape required for the semi-
finished parts by pressing. These semi-finished parts, known
as “green shapings”, are then burnt at about 1000°C for
example in a ring furnace. The resulting product after this
burning is called “hard burned carbon”.
Electra-graphite is made from hard burned carbon in a further
burning process in a graphitising furnace at about 3000°C.
As a rule, the hard burned carbon and electro-graphite thus
obtained are not tight against gases and/or liquids. The neces-
sary gas-tightness and liquid tightness for pressure vessels is
achieved by impregnation with a synthetic resin.
Re 3.3 and 4: Abbreviated designation of materials and tests
In the example K 6 -0 - 400, the figure 6 indicates the strength
class, in which the average tensile strength covers the range
between 6.0 N / m m * and 7.9 N/mm*. For the next higher
strength class the average tensile strength range lies between
8.0 N/mm’ and 9.9 N/mm*. Exceedina the too limit of the
tensile strength of a relevant strength class is permissible
provided that there are no adverse effects as regards the drop
in tensile strength with temperature and the top limit of the
thermal stresses.
Re 8: Basis fiir calculations
The relationship of the bending strength tothetensilestrength
(bending factor) in the materials dealt with here is > v, so that
in itself a higher strength value K could be taken in the case of
bending strains. As, however, the calculations for components
of electro-graphite or hard burned carbon subjected to
bending stress are made, for example, in accordance with
AD-Merkblatt B 5, the above-mentioned bending factor is
ignored, because the corresponding formulae contain a
support factor of the same amount for ductile materials.
In the case of electro-graphite and hard burned carbon the
relationship of the compression strength to the tensile strength
is at least +.
However, for design calculation for external pressure in accor-
dance with AD-Merkblatt B 6, the factor 2.5 has been selected,
so as to cover any additional stress effects.
Re 9: Tolerances and surface finish :
As a rule, in the manufacture of components of electro-
graphite and hard burned carbon the work will be carried out in
accordance with the permissible variations on measurements
where no tolerance are stated, DIN 7168, ,,coarse” degree of
accuracy. In the design calculations any diminution of the wall
thickness resulting from this can be ignored, because in .
comparison with the wall thickness it is very small.
The machinina of workpieces is done as a rule before the
impregnating. If the surfaces of workpieces must not have any -
coating of an impregnating medium, this has to be agreed upon
between the manufacturer and the customer.
UDC 661.663621.642.02-966 Edition November 1971

Pressure vessels AD-Merkblatt

Appendix 1 to AD-Merkblatt N 2,
made of N2
non metal materials
June 1971 edition
Appendix 1

The AD-Merkb/&ter are compiled by the seven trade associations specified below who together form the “Arbeltsgemeinschaf DruckbehBI-
ter” (AD). AD-Merkblatt G 7 covers the composition and application of the AD-Regulabons and also the procedural rules.

The AD-Merkbl&!tter cover safety requirements whrch must be adopted for normal conditions of operation. In the event of stresses over
and above the normal level bemg anticipated during the operabon of pressure vessels. allowance must be made for such stresses by
meeting special requirements.

Should there be any departures from the provfsions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards embo-
died in these regulations have been observed by means of alternative approaches, e. g. testing of materials, tests, Stress analysfs, Operating
experience.

Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e.V. (FDBR), Diisseldorf

Hauptverband der gewerblichen Berufsgenossenschaften e. V.. Sankt Augustin
Verband der Chemischen Industne e. V. (VCI), FrankfurtlMafn
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemefnschaft Verfahrenstechnische Maschinen und
Apparate, FrankfuNMain
Verem Deutscher fisenhdttenleute (VDfh), D&se/doff
VGB Techmsche Vereinfgung der GroBkraftwerksbetre!ber e.V., fssen
Vereimgung der Technischen iiberwachungs-Vereme e V. (VdTijV), Essen.

The AD-MerkblBtter are amended cont/nuous/y by the trade assooat/ons KJ keepmg with techmcal progress. Relevant pfOpOSa/S should
be addressed to the pubifsher:

Vereinigong der Technischen iibetwachungs-Vereine e. V., Postfach 103834, O-4300 Essen 1.

This appendix, as annex 3 to AD-Merkblatt N2 Pressure vessels made of electro-graphite and hard burned carbon, gives
the test specificatrons.
Annex 3 to AD.Merkblatt N 2

Test specifications

(Shape of Test specimensof electro-graphite and hard burned

carbon, and test procedure).

1. The tensile strength is to be obtained on test specrmens rn

conformity with Figure 1.

2. The bending strength is to be obtained on test bodies of

dimensions 20 x 20 x 120 mm; distance between supports
shall be 100 mm, and the samples are to be loaded centrally.
In the case of components of small dimensions or low wail
thickness specimens of lower, square cross-section (sg.
10 X 10 or 5 X 5 mm) may be used; however, a ratio of 1 : 5 is
to be observed between the cross-sectional edge length and
the length of surface support when testing. In the case of
tubes the tube-sections may be used to obtain the bending
strength (support interval = 5 x external diameter),

3. The compression resistance is to be determined on test

SpeCimenS of 20 X 20 X 20 mm. In the case of components
with lower dimensions or lower wall thickness samples of
small, square cross-section (e.g. 10 x 10 x 10 mm or
5 X 5 X 5 mm) may be used and in the case of tubes
tube-sections (length = diameter) may be used for determi-
ning compression resistance.

4 . AS electro-graphite and hard burned carbon are brittle

materials suitable measures shall be taken when testing to
avoid stress peaks at the points where force is applied. Figure 1. Test specimen.

Carl Heymanns Verlag KG Translation: Technical Help to Exporters Service of BSl

luxemburger Strof3e 449,50939 K61n
UDC 621.642.02-033.5-98:620.22:658.562:539.4.001.24:614.8 Edition September 1983

Pressure Vessels AD-Merkblatt

made of non-
Pressure vessels made of
metallic materials glass N4

‘he AD-Merkbldtter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
,eh#ter” (AD). AD-Merkblatt G 1 covers the composition and application of the AD-Regulations and also the procedural rules.
‘he AD-Merkblatter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
tnd a b o v e t h e n o r m a l / e v e / b e i n g a n t i c i p a t e d d u r i n g t h e o p e r a t i o n o f p r e s s u r e vessels, allowance must be made for such stresses by
neeting special requirements.
;hou/d there be any depaltures from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis,
operating experience.
Fachverband Dampfkessel-, Behdfter- und Rohrleitungsbau e. VI (FDBR), Diisseldorf
Hauptverband der gewerblichen Berufsgenossenschafien e. V., Bonn
Verband der Chemischen lndustrie e. V. (VCIJ, FrankfurflMa~n
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Apparatebau, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Dtisseldorf
VGB lechnische Vereinigung der GroBkraflwerksbetreiber e.V., Essen
Vereinigung der Technischen iibenvachungs-Vereine e. V (VdTiiV), Essen.
T h e AD-MerkbMtter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s should
)e addressed to the publisher:
Vereinigung der Technischen ijbetwachungs-Vereine e.V., Postfach 103834, D-4300 Essen 1.

Contents

1. Scope 8. Construction of installations consisting

2. General observation of glass pressure vessels
3. Material 9. Modifications and repairs
4. Certification of quality characteristics 10. Dlrections for operational safety
5. Strength characteristics for design Il. Bibliography
6. Design calculations Appendix 1, AD-Merkblatt N 4:
7. Marking Explanatory notes

1 Scope 3 Material
This A D - M e r k b l a t t i s a p p l i c a b l e f o r p r e s s u r e v e s s e l s ’ ) , p r e s s u r e ves- 3.1 Application limits
jel components and fittings2) made from borosilicate glass 3.3 to For the construction of pressure vessels, pressure vessel compo
XN/ISO 3 5 8 5 w i t h a c o e f f i c i e n t o f l i n e a r e x p a n s i o n o f (3,30 i 0,05)
nents, and fittings for pressure vessels, only glass as specified ir
lo-6 K-1. Table 1 may be employed.
rypes o f g l a s s w h o s e s t r e n g t h i s c o n s i d e r a b l y i n c r e a s e d t h r o u g h t h e
Jse o f s p e c i a l m e t h o d s o f m a n u f a c t u r e ( t o u g h e n e d glasss)) d o n o t 3.2 Quality
‘all within the scope of this AD-Merkblatt. Also excluded is laboratory The glass must be free from residual stresses and from those defects
~pparatustoDIN12476,DIN12491,DIN12347andDIN12348. which have an appreciable adverse influence on strength.
As regards the assessment of defects, Supplement 1 4, i s a p p l i c a b l e .

2 General observation
4 Certification of quality characteristics
The manufacture of pressure vessels, pressure vessel components,
and fittings made from glass as defined in Section 1 presupposes By marking as defined in Section 7, the manufacturer guarantees
adequate experience. the following:
( 1 ) t h a t t h e t y p e o f g l a s s d e s i g n a t e d t h r o u g h t h e a p p l i c a t i o n o f his
b r a n d n a m e h a s t h e s p e c i f i e d p h y s i c a l a n d c h e m i c a l propertie:
1) For definition of pressure vessel, see 5 3 Abs. 1 DruckbehV (1980). of borosilicate glass 3.3;
2) Fittings, inasmuch as they are items of equipment for pressure vessels in
the sense of 5 3 Abs. 2 DruckbehV (1980).
3) For example, glass for inspection ports is covered by DIN 7080, DIN 7081,
DIN 8902 and DIN 8903. 4) Currently being compiled.

Supersedes June 1974 Edition

Carl Heymanns Verlag KG,

Luxemburger StraDe 449. 5000 K6ln 41
GutenbergstraBe 3, 1000 Beriin 10
P a g e 2 AD-Merkblatt N 4. Edition 9.03

(2) t h a t t h e s h a p e , d i m e n s i o n s a n d w a l l t h i c k n e s s h a v e b e e n o b s e r - 5.1.4 The characteristics given in Sections 5.1 .l to 5.1.3 already

ved; embrace a safety factor S for which no figure has been specified
which makes allowance for practical experience and for the theore-
(3) a n d t h a t t h e m a n u f a c t u r i n g p r o c e d u r e s e m p l o y e d w e r e c o r r e c t .
tical findings [3) relating to the strength behaviour of borosilicate
glass 3.3 determined in experiments. Even with the application of
a continuous maximum permissible load under unfavourable
Table 1. Characteristic values, application limits and chemical
ambient conditions, a sufficiently low failure probability is ensured.
resistance of borosilicate glass 3.3

Coefficient of linear expansion %a300 = 6 Design calculations

to DIN 52328 (3,30 2 0,05) lo-6 K-1
6.1 Symbols and units
Mean thermal conductivity h = 1,3W/mK
b e t w e e n 2 0 a n d 2 0 0 “C specific thermal capacity in J/kg K
Mean specific thermal capacity C = 910J/kgK external diameter in mm
b e t w e e n 2 0 a n d 2 0 0 “C Internal diameter in mm
modulus of elasticity in N/mm’,
D e n s i t y a t 2 0 “C Q = 2,23 g/cm3
kN/mm2
Modulus of elasticity E = 6 4 kN/mmz factor for the tensile strength -
Poisson’s ratio (transverse v = 0,2 strength characteristic in N/mm2
contraction ratio) resrstance value for stress corrosion
Transformation temperature’) 6, = 530°C cracking -
to DIN 52324 safety factor -
Service temperature & = 300°C required wall thickness in mm
Section 10.3 should permissible stress to be employed for
be noted. calculations in N/mm2
A p p l i c a t i o n r a n g e in t h e e v e n t o f a d d i t i o n a l t h e r m a l s t r e s s e s temperature difference between inner and in K
i n k e e p i n g w i t h t h e design pnnclples given in Section 6.3. outer surface of the wall
Chemical resistance (the resistance declines as the number 01 temperature of the medium around the in “C
the class increases: Class 1 is the best class): pressure vessel
service temperatur in “C
Hydrolytic Class to DIN 12 111: 1
Acid Class to DIN 12116: 1 transformation temperature i n “C
Alkali Class to DIN 52322: 2 temperature of the medium in the i n “C
pressure vessel
‘) The transformation temperature IS determined for estimating the tem- load-application time in s, h , a
perature during stress-rellewng, and for calculation the highest ser- coeffiiient of linear expansion i n K-l
vice temperature for glass.
coefficient of linear expansion over i n K-l
t h e r a n g e b e t w e e n 2 0 a n d 3 0 0 “C
heat transfer coefficient at the inner in II.
surface of the wall K m2
5 Strength characteristics for design heat transfer coefficient at the outer i n -fL
surface of the wall K m2
5.1 Design characteristics5)
thermal conductivity in W/m K
5 . 1 . 1 T h e p e r m i s s i b l e stress f o r b o r o s i l i c a t e g l a s s 3 . 3 , o c c a s i o n e d Poisson’s ratio (transverse contraction -
by tensile and bending stresses, is ratio)
K density in g/cm3
- = 6 N/mm2
S thermal wail stress, stress as a in N/mm2
consequence of non-uniform temperature
if the surface is ground and polished or simply ground, or if an initially
flame-polished undamaged surface is altered as a result of mecha- rise
nical effects (e.g. scratches) when being utilised in the manner inten- tensile strength with load-application in N/mm2
ded, or if it is possible for it to be altered under service conditions. t i m e t,
tensile strength with load-application i n N/mm2
5.1.2 The permissible stress for borosiiicate glass 3.3, occasioned t i m e t2
by tensile and bending stresses, is
K
-= lON/mm2 6.2 General preliminary comments and assumptions
S
if the flame-polished surface produced during the hot-forming pro- 6.2.1 Thermal wail stresses with internal heating
cess has neither been subjected to further mechanical processing, (thermal gradient with temperature falling from the inside
nor has been altered as a consequence of mechanical effects (e.g. to the outside)
scratches), and if this flame-polished state can be prevented from
undergoing any alterations during the planned service period When the charge material is heated in vessels whose outer surface
through the application of a protective surface finish firmly bonded is in contact with the ambient air, stresses are established in the ves-
to the glass, and through the adoption of other safety measures. sel wall. The magnitude of the stresses can be calculated from the
temperature difference in the vessel wall, which is a function of the
5.1.3 The permissible compressive stress5) for borosilicate glass thermal gradient between the charge material and the ambient air
3.3 that is applicable here is: (see Section 6.3.2.1).
K
- = 100 N/mmz. 6.2.2 Thermal wail stresses with external heating
S
(thermal gradient with temperature decreasing from the
outside to the inside)
Pressurised g l a s s c o m p o n e n t s m a y b e h e a t e d b y m e a n s o f a n e x t e r -
“) For further particulars, see explanations given in the Notes in Appendix 1. nal supply of heat if the manufacturer states that this is permissible.

6.3 Design principles
6.3.1 AD-Merkblltter covering design calculations
The required wall thickness s is calculated in accordance with the
AD-Merkblatter Series 8, using the design characteristics given in
Section 5.1.
Notes:
1. There is no need for margins to be added to the calculated wall
thickness s. If forms are adopted for which calculations in accor-
dance with AD-Merkblatter Series B are not possible, it is neces-
sary to demonstrate that the dimensions are adequate for the ser-
vice conditions envisaged.
2. Thick-walled cylindrical shells and spheres also, made of glass
and subjected to an internal overpressure, are calculated using
A D - M e r k b l a t t B 1. T h e c u t - o f f p o i n t f o r c a l c u l a t i o n s s p e c i f i e d i n
the latter for diameter ratios DJD, 5 1,2 has no relevance here.
6.3.2 Calculation of thermal wall stresses
Stresses as a consequence of a non-uniform temperature rise in the
wall vary in proportion with the temperature difference, the coefficient
of expansion, and the modulus of elasticity. Account must be taken
of thermal stresses perpendicular to the wall, observing Sectrons
6.3.2.1 to 6.3.3. Thermal stresses parallel to the wall do not need
t o b e t a k e n i n t o consderation i f , t h r o u g h t h e a d o p t i o n o f a s u i t a b l e
configuration or mode of operation, it is ensured that they cause the
stresses in the wall to increase only slightly. Deformations of thermal
origin must not be inhibited by the manner in which the vessel is
installed and the means employed for its restraint.
6.3.2.1 In the case of a linear temperature gradient perpendicular
t o t h e w a l l o f t h e v e s s e l , t h e s t r e s s e s c a n b e c a l c u l a t e d f o r t h e fle-
xurally-stiff case (wall of axisymmetrical hollow bodies) as follows:
a.E.AJ
Stress at the wall surfaces of = ___ (1)
2 (1 -v)
(see Ill).
d, ( F i g . 1) g i v e s t h e t e n s i l e s t r e s s a t t h e c o l d e r s u r f a c e a n d a l s o t h e
compressive stress in the hotter surface.
6.3.2.2 With a non-linear temperature gradient, e.g. during the hea-
ting and cooling of glass components, a, can assume larger values
depending on the rate of temperature variation, and may increase
t o a m a x i m u m o f t w i c e t h e v a l u e ( s e e [2]).
6.3.3 Superimposition of stresses of thermal and mechanical
origin
If the stresses attributable to the service overpressure are increased
simultaneously by thermal wall stresses a, in accordance with
e q u a t i o n (l), t h e n t h e v a l u e
5-0~ i n s t e a d o f $ m u s t b e s u b s t i t u t e d i n t h e c a l c u l a t i o n s a s d e f i n e d
in Section 6.3.1
7 Marking
7.1 The glass component must be marked permanently with the
name of the manufacturer or processor, the type of glass or brand
name, the permissible service overpressure, and the permissible
t e m p e r a t u r e d i f f e r e n c e A J.
7.2 For glass components included in catalogues or fists and those
which, in respect of their principal dimensions (including nominal dia-
meter) and their external shape, correspond to dimensions specified
i n c a t a l o g u e s , t h e r e i s n o n e e d f o r t h e p e r m i s s i b l e s e r v i c e overpres-
sure and the permissible temperature difference to be indicated on
the glass component if, in his catalogue or in his list, the manufac-
turer specifies this pressure as a function of the temperature diffe-
r e n c e A Jfor t h e n o m i n a l s i z e . T h r o u g h a p p r o p r i a t e m a r k i n g , i t m u s t
be ensured that it is possible to establish a clear correlation between
the component and the relevant edition of the catalogue or list.
P a g e 3 AD-Merkblatt N 4, Edition 9.83
7 . 3 F o r h e a t e x c h a n g e r s m a d e o f g l a s s w h i c h a r e i n c l u d e d i n cata-
logues o r l i s t s , i t i s s u f f i c i e n t t o s p e c i f y AJ for the exchange surface
in the catalogue or list.
7.4 Pressure vessels which are made up from glass components,
o r i n s t a l l a t i o n s w h i c h c o n s i s t o f a n u m b e r o f g l a s s p r e s s u r e vessels6)
must be provided with a permanent and prominently sited maker’s
nameplate which gives the following particulars:
Manufacturer
Serial number or drawing number’)
Year of manufacture of the installation
Permissible service overpressure in bar
Capacity of the pressurised compartments in litres
P e r m i s s i b l e s e r v i c e t e m p e r a t u r e i n “C
Permissible temperature differences perpendicular to the walls
of the individual pressurised compartments or glass components
In K.
8 Construction of installations consisting of
glass pressure vessels
8.1 During assembly, the vessels must be secured in such a manner
that at the points where they are restrained they are subjected in the
main to compressive stresses, and in such a manner that thermal
deformations - inasmuch as no provision has been made for the lat-
t e r In a c c o r d a n c e w i t h S e c t i o n 6 . 3 . 2 . - a r e a b l e t o t a k e p l a c e u n i m -
peded.
8.2 Clamping bolts must be tightened uniformly, using a repeated
c y c l e o f t i g h t e n i n g o p e r a t i o n s . T h e m a n n e r i n whrch p i p e c o n n e c -
tions are attached must afford a degree of flexibility which is such
that, under service conditions and when operation is discontinued,
no appreciable additional stresses occur.
8.3 The leak-tightness test must be performed at ambient tempera-
ture using a test pressure which must be no higher than the permis-
sible service overpressure.
9 Modifications and repairs
Modifications and repairs must be executed in an expert manner,
and records must be kept. The modified or repaired component
should be marked with the symbol of the organisation responsible
for the work. Where necessary, the component must be re-marked
in accordance with Section 7.
10 Directions for operational safety
10.1 External heating
The contents of the vessel should be heated where possible by
means of a liquid bath.
An electric heating system is permissible if the heating is effected
uniformly and does not give rise to any local temperature peaks.
External heating systems of other kinds for pressurised glass com-
ponents are permissible only if local temperature peaks are avoided.
If this condition cannot be observed, or if the above-mentioned types
of heating cannot be utilised, the charge material must be directly
heated or heated by means of immersion heaters.
10.2 Temperature changes
Rapid changes of temperature produce high stresses for short inter-
vals in the glass and, by virtue of the tensile stresses established in
6) For examples, see appended diagrams.
7) With index, if a number of similar pressure vessels are produced using one
drawing.
Page 4 A D - M e r k b l a t l N 4 . Edition 9.83

the colder surface, cooling of an abrupt nature (chilling) is a particular 11 Bibliography

threat to the glass component. In particular, glass components sub-
jected simultaneously to pressure and thermal stresses may not be [l] Lorenz, R.: T e m p e r a t u r s p a n n u n g e n i n H o h l z y l i n d e r n . V D I - Z 5 1
subjected to any sudden external cooling of their walls (water sprays, (1907) Nr. 19, S. 743/47.
c o n t a c t w i t h c o l d a n d m o i s t m a t e r i a l s ) , orto a n y s u d d e n i n t e r n a l c o o - [2] Grass, G., u. K. G. Wiirkec Zulassige Aufheiz- und Abkuhlge-
ling of their walls (inflow of colder charger material). The cooling of s c h w i n d i g k e i t e n d i c k w a n d i g e r R o h r l e i t u n g e n . A l l g e m e i n e War-
t h e s e g l a s s c o m p o n e n t s , a b o v e a l l i f t h e y a r e pressurised, must take metechnik, Jahrgang 1956, S. 211 ff.
place only slowly, e.g. by means of the natural dissipation of heat [3] E x n e r , G . , u . 0 . L i n d i g : B e s t i m m u n g d e s W i d e r s t a n d s w e r t e s d e r
into the ambient air. SpannungsriBkorrosion n an Borosilicatglas DURAN. Glastech-
nische Berichte 55 (1982) Nr. 5, S. 107/17.
10.3 Service temperatures etB > 200 “C [4] E x n e r , G . : E r l a u b t e B i e g e s p a n n u n g i n G l a s b a u t e i l e n i m Dauer-
With service temperatures 8s > 200 “C, special precautions must l a s t f a l l . E i n V o r h e r s a g e k o n z e p t aus d y n a m i s c h e n Labor-Festig-
be taken for the prevention of abrupt temperature fluctuations. The keitsmessungen. Glastechnische Berichte 56 (1963) Nr. 11.
measures to be adopted must be agreed with the manufacturer. [5] VDI-Warmeatlas 2. Auflage 1974.
 Page 5 AD-Merkblatl N 4, Edition 9.83

2,o
1
I
I I 1
1,9
CZE t?i-l?a 15
q --.
1,8 2(1-V) 2i.
da +’ 14
uada In d,-2s
1,7 ’

I I I //A//

///I /
0,8

0 36

T e m p e r a t u r e i n p i p e 6, i n “C

Fig. 1. Thermal wall stress, calculated for vertical pipes 5 m long, DN 100 to 1000, at room temperature 6, = 15 “C a n d w i t h h e a t t r a n s f e r
a , t h r o u g h n a t u r a l c o n v e c t i o n [5].
Page 6 AD-Merkblan N 4, Edition 9.99

Example 1. Pressure vessel made up from a number of glass components.

Inscription on the nameplate: (F)

Manufacturer:
Drawing: A 483-l; Year of manufacture:1981
Permissible service overpressure: 0,5 bar
C a p a c i t y o f p r e s s u r i s e d c o m p a r t m e n t : 1 4 3 0 litres
Permissible service temperature: 1 5 0 “C
Permissible temperature difference: in the wail of the
column 5 K,
in the wall of the
cooling coil 40 K.
 P a g e 7 A D - M e r k b l a t l N 4 . Edition 9 . 8 3

J 4a

ii
Example 2: Installation comprising a number of glass pressure vessels which can be operated either with an overpressure or under
vacuum.

Inscription on the nameplate: (F)

Manufacturer:
Drawing: R 759; Year of manufacture: 1982
Permissible service overpressure: -1 to 0,5 bar
C a p a c i t y o f p r e s s u r i s e d c o m p a r t m e n t : 1 8 5 0 litree
Permissible service temperature: 2 0 0 “C
P e r m i s s i b l e t e m p e r a t u r e d i f f e r e n c e i n vessel wall: 5 K
Page 8 AD-Merkblatt N 4, Edition 9.93

10-l loo 10’ 103 104 105 10s 10’ 108 109
Load-application time t in s
I I 1 I I I I I I I
10-4 10-3 10-2 10-l 100 10’ 102 103 104 105
Load-application time t i n h

10-l 100 10’

5.10-l 5,100
Load-application time t i n a

Fig. 2: Variation of the factor f for the tensile strength of borosilicate glass 3.3 in water, with n = 28, in relation to the load-application time.

Appendix 1, AD-Merkblatt N 4
Explanatory notes relating to Section 5 of
AD-Merkblatt N 4:
Strength characteristics for design
1 Special aspects of the strength of glass
When design calculations are performed for pressure vessels, pres-
sure vessel components and fittings for pressure vessels made from
glass, account must be taken of the special material properties of
the latter. In the technical sense, glasses are ideally elastic*) mate-
rials in which no yield processes take place. In the event of mecha-
nical contact being made with hard materials, this means that surface
damage occurs which takes the form of extremely small and, to some
extent, submicroscopic cracks and chips. Surface damage of this
kind, which is practically unavoidable when a glass is subjected to
normal handling, has a decisive influence on the tensile strength as
a consequence of the notch-effect with which it is associated. Accor-
dingly, the tensile strength relates primarily to the state of the surface
of the specimen that is to be tested, which means that figures for
the tensile load-carrying capacity always demand the provision of
information on the condition of the surface.
Tensile strength values for the performance of calculations for pres-
sure vessels made from glass (design characteristics) which are
derived from measurements on flame-polished specimes
have suffered no mechanical damage, with account taken of the time
over which the stress is applied and the statistical distribution of mea-
s u r e d v a l u e s , m a y o n l y b e u t i l i s e d t h e r e f o r e i f t h e occurence of sur-
face damage can also be ruled out during service (e.g. inner surface
of sealed-off vacuum vessels; surfaces with protective coatings).
If on the other hand the condition of the surface of pressure vessel
components can alter as a consequence of mechanical effects
during service, then the design characteristic applicable for such
components must relate to measurements performed on tensile spe-
cimens whose surfaces have been subjected beforehand to damage
of the maximum possible degree in accordance with practical expe-
rience.
If compressive stress is present in glass surfaces, damage to the
surface is of no significance because cracks are closed. Because
of this, the compressive strength of glass attains values that are at
least ten times higher compared with the values for the tensile
strength. Thus, it is possible for the most part to neglect compressive
stresses.
2 Influence of time
The tensile strength of glass declines with the time over which the
load is applied; in this connection, the functional relationship is affec-
ted by the contiguous medium and may exhibit marked differences
f o r d i f f e r e n t t y p e s o f g l a s s ( s e e [3]). T h e i n f l u e n c e o f t i m e m u s t b e
taken into account in particular in the case of short-term tests (see
also Sections 4 and 6).
In the presence of a pulsating load, the decline in strength with
respect to time can be equated with that which occurs in the pre-
s e n c e o f a c o n t i n u o u s l y a p p l i e d l o a d ( s e e [4]).
The permissible compressive stress is unaffected by time.
‘) The term “ideally elastic” describes a material where there is a linear
relationship between load and deformation to the point of fracture, i.e. the
material does not have the capacity. e.g. that of a ductile steel, to reduce
stresses by undergoing plastic deformation processes.
Page 9 AD-Merkblatl N 4, Edition 9.83
3 Influence of temperature
The influence of temperature on the strength of glass is negligibly
slight between room temperature and 200°C. Over the range of low
t e m p e r a t u r e s (< - 1 5 0 “ C ) , a m a r k e d i n c r e a s e i n t h e t e n s i l e s t r e n g t h
generally occurs. At temperatures between 200 “C and the trans-
formation temperature (530 “C), the tensile strength again
increases.
T h e r e a s o n f o r r e s t r i c t i n g t h e s e r v i c e t e m p e r a t u r e t o 5 3 0 0 “C (see
Table 1) lies principally in the possible thermal stresses in the glass
components.
4 Influence of the medium
When in contact with aqueous agents or steam, glass in which tensile
stresses are present undergoes stress corrosion cracking, which is
responsible for the variation of the tensile strength with respect to
time which is plotted in Fig. 2.
I n t h e a b s e n c e o f w a t e r ( e . g . c o n t a c t e x c l u s i v e l y w i t h o r g a n i c non-
aqueous agents), the tensile strengths obtained are higher than
those specified here which are applicable for worst-case conditions.
which
5 Compressive strength
The specimen configuration and the condition of the surface have
an appreciable influence on the results obtained from a compressive
strength test - for which where glass is concerned no standard
exists -, s i n c e u l t i m a t e l y a b o d y s u b j e c t e d t o a x i a l c o m p r e s s i o n o v e r
its entire cross-section is destroyed solely as a result of the tensile,
stresses which occur during the compression test at its periphery.
(The test to which reference is being made here is one which differs
from the tensile test only in respect of the sign for the force, as oppo-
sed for example to the penetration test where a sphere is forced into
the surface.) The compressive stress under discussion here is the-
refore often tangential to the surface.
As the permissible compressive stress, it is customary to specify 10
times the tensile stress. This rule is based on tests performed on
special specimen configurations and represents a conservative
approach.
6 Factor for the tensile strength
The relationship described in Section 2 between tensile strength and
load-application time is expressed by the equation:
t1 1
02 = 0, --n=ot * f
( t7 1
If the resistance value for stress corrosion cracking n is known for
the particular type of glass, on the basis of the tensile strength u,
m e a s u r e d f o r t h e l o a d - a p p l i c a t i o n t i m e t, i t i s p o s s i b l e , w i t h t h e a i d
o f t h i s e q u a t i o n , t o c a l c u l a t e t h e t e n s i l e s t r e n g t h oz f o r t h e l o a d - a p p -
l i c a t i o n t i m e t2.
T h e h i g h e r t h e r e s i s t a n c e v a l u e R, t h e s m a l l e r i s t h e r e d u c t i o n i n t h e
tensile strength.
For borosilicate glass 3.3 in contact with water, a value of n = 26
h a s b e e n d e t e r m i n e d e x p e r i m e n t a l l y ( s e e 131).
UDC 621.642.02-98-033.5:620.22:620.1:658.562:539.4.001.24:614.8 Edition June 1985

Pressure Vessels Assessment of defects in walls AD-Merkblatt

made of non- of pressure vessels N4
metallic materials Appendix 1
made of glass

‘ h e AD-Merkbldtter a r e c o m p i l e d b y t h e s e v e n t r a d e a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “ A r b e i t s g e m e i n s c h a f f Druckbehdl-
er” (AD). AD-Merkblait G 7 covers the composition and application of the AD-Regulabons and also the procedural rules.
‘he AD-Merkblltter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
Ind above the normal level being anticipated during the operation of pressure vessels. allowance must be made for such stresses by
neeting special requirements.
jhould t h e r e b e a n y d e p a r t u r e s f r o m t h e pronsrons o f t h i s A D - M e r k b l a t t , i t m u s t b e p o s s i b l e t o d e m o n s t r a t e t h a t t h e s a f e t y s t a n d a r d s embo-
liedin t h e s e r e g u l a t i o n s h a v e b e e n o b s e r v e d b y m e a n s o f a l t e r n a t i v e a p p r o a c h e s , e . g . testing o f m a t e r i a l s , t e s t s . s t r e s s a n a l y s i s , operating
txpefience.
Fachverband Dampfkessel-, Behllter- und Rohrieitungsbau e. V. (FDBR), Dijsseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sank? Augustin
Verband der Chemischen lndustrie e. V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen und
Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Dtisseldorf
V G B T e c h n i s c h e Vereimgung d e r GroRkraftwerksbetrefber e. V., Essen
V e r e i n i g u n g d e r T e c h n i s c h e n iiberwachungs-Vereme e . V . (VdTiiV), Essen.
‘ h e AD-MerkblBUer are amended continuously by the trade associations m k e e p i n g w/th t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
)e addressed to the publisher:
Vereinigung der Technischen iiberwachungs-Vereine e.V., Postfach 103834, D-4300 Essen 7.

Contents

1 Scope 4 Types of defect and defect

2 General assessment

3 Inspection 5 Bibliography

I Scope refractory lining of the furnace or constituents of the glass that have
crystallised out.
[his A D - M e r k b l a t t c o v e r s t h e v i s u a l i n s p e c t i o n o f t h e w a l l s o f p r e s -
s u r e v e s s e l s m a d e o f g l a s s t o d e t e r m i n e w h e t h e r d e f e c t s a r e pres-
4.1.2 Assessment
?nt, a n d i t e m b o d i e s c r i t e r i a f o r t h e a s s e s s m e n t o f d e f e c t s t h a t h a v e
3 considerable adverse influence on the strength. Solid inclusions which lie in the vicinity of the surface of the glass,
and which therefore deform or interrupt the line of the surface and
can thus be detected by touch, are not permissible.
2 General
S o l i d inclusions from which cracks extend into the surrounding glass
2.1 D e f e c t s m a y a r i s e i n t h e g l a s s w a l l d u r i n g t h e m a n u f a c t u r e o f are likewise unacceptable.
h e u n f i n i s h e d g l a s s p r o d u c t , d u r i n g t h e f u r t h e r p r o c e s s i n g o f t h e lat-
:er t o g i v e t h e f i n i s h e d p r o d u c t , o r d u r i n g t h e c o u r s e o f h a n d l i n g a n d Solid inclusions within the glass wall are permissible,
when In use. - if their diameter is no greater than 50% of the wall thickness, but
does not exceed 4 mm,
2 . 2 Vessels made of glass, in whose walls defects are present
Nhich h a v e a c o n s i d e r a b l e a d v e r s e i n f l u e n c e o n t h e s t r e n g t h , m a y - and if the distance between them is at least ten times the diameter
lot be employed as pressure vessels. of the smaller inclusion.

4.2 Bubbles
3 Inspection
4.2.1 Description
i/isual inspections of the walls for the presence of defects are nor- Bubbles are gaseous inclusions. They may be closed or open. Open
n a l l y m a d e w i t h o u t a n y a i d s , a n d i n c a s e s o f d o u b t u s i n g a magni-
bubbles are bubbles that have opened up at the surface of the glass
ying glass.
wall, or bubbles sited at such a short distance beneath the surface
that they can be made to collapse easily.

I Types of defect and defect assessment

4.2.2 Assessment
8.1 Solid inclusions Open, sharp-edged bubbles or bubbles which can be made to col-
1.1.1 Description lapse easily are not permissible.

Solid i n c l u s i o n s a r e n o n - t r a n s p a r e n t i n c l u s i o n s i n t h e s o l i d i f i e d g l a s s . Closed bubbles are acceptable if half the sum of breadth and length
The solid inclusions may be both undissolved constituents of the of the bubble is no greater than 13 mm, and the bubble thickness
glass batch, and also foreign bodies, e.g. particles from the is less than 50 % of the wall thickness but does not exceed 4 mm.

Carl Heymanns Verlag KG T r a n s l a t i o n : TechnIcal Help to Exporters Service of BSI

Luxemburger StraOe 449, 50939 Kdln
GutenbergstraBe 3. 10587 Berlin
Pago 2 AD-Merkblatl N 4 Appendix 1, Edition 6.65

4.3 Nodules 4.5.2 Assessment

4.3.1 Description Cracks are not permissible.

Nodules are roundish integrated inhomogeneities within the glass.

They have a different refractive index and are therefore visible. 4.6 Scratches

4.6.1 Description
4.3.2 Assessment
The term scratches is used to describe damage at the surface of the
Nodules from which cracks extend into the surrounding glass are not glass which follows a linear path, is rough, and which as a rule has
permissible. a dull appearance.

4.6.2 Assessment
4.4 Cords
Scratches which can be detected clearly by touch, and those asso-
4.4.1 Description ciated with cracking, are not permissible.

Cords are filamentary or thread-like inhomogeneities in the glass

which for the most part follow a twisting path. They have a refractive 4.7 Knocks
index differing from that of the glass of the vessel wall, and are ;-
therefore visible. 4.7.1 Description
Y
Knocks are points at the surface of the glass which have been chip- ..’
4.4.2 Assessment ped as a consequence of impacts or blows. ..^

Cords from which cracks extend into the surrounding glass are not
4.7.2 Assessment
permissible.
Knocks are not permissible

4.5 Cracks

4.5.1 Description 5 Bibliography

Cracks are breaks in the glass body which propagate rtght through Jebsen-Marwedel, H., R. Brikkner: Glastechnische Fabnkatlons-
or partly through the wall thickness. fehler. Springer-Verlag.
UDC 621.642-98.001.24 Edition January 1995

Design AD-Merkblatt
of Design of Pressure Vessels
Pressure Vessels BO

The AD-Merkbl2tter are compiled by the seven trade assoclarions specified below who together form the “Arbeitsgemeinschaft Druck-
behdlter” (AD). AD-Merkblatt G 7 covers the composition and application of AD-Regulat;ons and a/so procedural guide/ines.

The AD-MerkbWer contain safety requirements which must be adopted for normal operahng condibons. ln the eventofloadings exceeding
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any devfations from the provisions of this AD-Merkbiatt. it must be poss\b/e to demonstrate that the safety standards
embodied in these regulations have been observed by other means. e g. tesong of materials, experiments, stress analysis, operating
experience.
fachverband Dampfkessel-, Behdlter- und Rohrleffungsbau e V. IFDBR). Dijsseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e V Sankt Augustin
Verband der Chemfschen lndusrrie e.V. (VC/). Frankfurt/Ma/n
Verband Deutscher Maschtnen- und Aniagenbau e. V. (VDAIAi. Fachgeme/nschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Ma/n
Verem Deulscher Eisenhunenleute (VDEhJ. Dtisseidorf
VGB Technlsche Veremigung der GroBkraftwerksbetreiber e V Essen
Verband der Technischen Ciberwachungs-Vereine e.V. IVdTUVl. Essen.

The AD-Merkblatter are amended conWuous/y by the trade assoc!affons to keep with the state-of-the-art. Relevant proposals should be
addressed to the pubbsher

Verband der Technischen iiberwachungs-Vereine e.V.. P.O. Box 103834. D-45038 Essen.

Contents

1 Scope 7 Safety factor

2 General
3 Symbols and units
4 Design pressure
5 Design temperature
6 Stress coefficient
8 Use of the permissible design
stress level in joints
9 Allowances
10 Mlnimum permissible wall thickness

1 Scope 2 . 3 The AD-Merkblgitter contain safety requirements obli-

1.1 The AD-Merkblatter of Series B and S deal with design
rules for pressure-bearing components of pressure vessels.
Their application assumes that the AD-Merkbl8tter of Series
W and HP as well as current engineering practice were taken
into consideration for the selection of the materials and their
processing. See also AD-Merkblatt G 1.
1.2 The AD-Merkbltitter of Series 6 and S 3 apply to pre-
dominantly static stresses. AD-Merkblatter S 1 and S 2
also apply to alternating stresses.
gatory for normal operating conditions. Whenever excessi-
vely high stresses are expected in the operation of pressure
vessels, special conditions have to be satisfied to meet these
contingencies.
2 . 4 In the event, deviations from the requirements of the
AD-Merkbl2itter, it shall be ascertained that the technical
safety standards laid down in these Merkbl2itter are strictly
adhered to in another form, e.g. by material tests, experi-
ments, stress analyses and operating experience.

3 Symbols and units

2 General
lever arm in mm
2.1 This AD-Merkblatt includes the fundamental rules a
which are common to all AD-Merkblatter of Series B and S. b width in mm
The other AD-Merkblgitter of Series B and S can therefore cl allowance for minus thickness tolerance in mm
only be used in conjunction with this AD-Merkblatt. c2 wastage allowance in mm
2 . 2 Where the Merkblgtter do not give design rules for pres- diameter of an opening, flange, screw
d
etc. in mm
sure-bearing parts, then, in each individual case, proof shall
be furnished by the application of other rules or calculation da external diameter of a tube, nozzle,
methods, strain measurements, relevant operating expe- flange in mm
rience gained etc. that the components are not overstressed d, internal diameter of a tube, nozzle,
taking into due account material and service conditions. flange in mm

Supersedes Edition March 1990; ) = amendments to the previous Edition

Carl Heymanns Verlag KG Translation: Technical Help to Exporters Service of BSI

Luxemburger Strafle 449. 50939 Kbln
GutenbergstraBe 3. 10587 Berlin
Page 2 AD-Merkblatt 6 0, Editton 01.95

4 pitch diameter in mm 4 Design pressure

do average gasket diameter in mm 4.1 Generally the design is based on the permissible work-
e wide side of rectangular or elliptical ing pressure. The static pressures caused by the contents of
plate in mm the vessel during service and/or testing need not be taken
into account as long as they do not increase the stress to the
f narrow side of rectangular or elliptical wall by more than 5%.‘)
plate in mm
weld thickness in mm 4 . 2 If a wall is subject to pressure on both sides at the same
g time, the design shall generally not be based on the pressure
h height in mm difference. Design shall consider both pressures separately.
ko setting characteristic of gasket in mm Exceptions are permissible provided proof has been fur-
nished that a higher stress cannot occur in the wall than that
kt service characteristic of gasket in mm
due to the pressure difference.
1 length in mm
4 . 3 If a wall IS subject to pressure and vacuum at the same
n number -
time, the desrgn pressure is equal to the pressure difference.
P design pressure in bar This applres also to the determination of the test pressure.
test pressure in bar If there IS no reliable limitation of the vacuum, the design
P’ pressure shall be the actual pressure increased by 1 bar.
r generally radius, e.g. transition
radius in mm 4 . 4 If a test pressure is used in the pressure test which is
hrgher than 1.3 times the design pressure, calculated proof
S required wall thickness including shall be furnished that the safety factor is at least equal to_
allowances in mm S’ of table 2, taking due account of the stress coefficient at
Se actual wall thickness in mm test temperature.
V factor rndicatrve of the utrlizatron of the 4 . 5 AddItIonal static loads shall be given on the drawing, if
permrssrble desrgn stress In jornts or these Increase the stress rn the vessel wall by more than 5%
factor allowrng for weakenrngs -
(e.g. due to supports, wind, snow and brick linings’)). Astress
X decay-length zone in mm analysrs shall be carried out If the additional static loads
Influence the design of the pressure vessel significantly. It
A area In mm’
has been found that Increases in stress due to additronal
c, p design factors - loads can be expected if the criteria in the S 3 series of AD-
D shell diameter in mm Merkblatter apply.

4 outside diameter e.g. of a cylindrical

shell in mm
D, internal diameter e.g. of a cylindrical
5 Design temperature
shell in mm
E modulus of elasticity at design 5.1 The selection of the material and the determination of
temperature in N/mm2 the stress coefficient depend on the highest wall temperature
which can be expected during service at the appropriate
F force in N working pressure. The wall temperature is derived from the
J planar moment of inertia in mm4 permissible working temperature plus an allowance for the
K stress coefficient at design temperature in N/mm2 particular type of heating and is referred to as the design tem-
perature. For unheated walls the highest temperature of the
KD dimensional stability of sealant at room vessel contents may be used for this instead. For heated
temperature in N/mm2 walls the design temperature can generally be determined
K 20 stress coefficient at 20 “C in N/mm2 from table 1; otherwise e.g. in the case of brick linings the
design temperature shall be determined by calculation or
M moment in N/mm
measurement.
R radius of curvature in mm
5 . 2 If the highest expected wall temperature during service
S safety factor at design pressure is below +20 “C, the design temperature is +20 “C. For tem-
S’ safety factor at test pressure peratures of the vessel contents below - 10 “C AD-Merkblatt
W 10 shall also be referred to.
SD leak safety factor
SK safety factor against elastic cupping
at design pressure
safety factor against elastic cupping 6 Stress coefficient
at test pressure
6.1 The stress coefficients K shall be selected for the
safety factor on the permissible number
design temperature according to the stipulations of the
of load cycles AD-Merkblatter of Series W.
W section modulus in mm3
Z auxiliary value -
1’ poisson’s ratio - 1) Example: permsssible design pressure = 2 bar
height of vessel = 5 m
u stress in N/mm* contents: water
p = 2 + 0.5 - 0.05 2 = 2.4 bar
8, T temperature in “C 2) Cf DIN 28 060
 Page 3 AD-Merkbiatf 6 0. EdItIon 01.95

Table 1. Design temperatures Table 2. Safety factors against yield point, proof stress or
creep rupture strength
Type of heating Design temperature
Safety factor S
Safety factor S’
by gases, steam or the highest temperature of Material for the material
for the
liquids the heating medium and equipment at design
test pressure
temperature
by fire, exhaust gas in the case of protected
o r e l e c t r i c a l equipmenV) wails, the highest temperature 1. Rolled and
of the vessel contents plus forged steel t,5 1,J
20 “C 2. Cast steel 2.0 1.5
3. Cast iron wrth
in the case of unprotected spheroidal graphite
walls, the highest temperature to DIN 1693
of the vessel contents plus 3 1 GGG-70
50 “C GGG-60 5,O 2.5
3 2 GGG-50 4,o co
6.2 In the range of time-dependent stress coefficients, it 3 3 GGG-40 3.5 1,7
shall be verified whether the average creep rupture strength 3 4 GGG-40 3
value for 100 000 h4) is lower than the guaranteed minimum GGG-35.3 2.4 1.2
yield point value or 0.2% proof stresss) - or, where appli- 4. Aluminrum and rts
cable, for 1% proof stress. The lower of the two values shall alloys - malleable
be used in the design calculation. materrals I,5 1,1
6.3 For materials with no guaranteed yield point or proof (GGG = nodular graphite Iron)
stress, the guaranteed m i n r m u m tensile strength at the
design temperature shall be used as the stress coefficient. Table 3. Safety factors against tensile strength
In such cases the safety factors of table 3 shall be taken into
consideration. Safety factor S
jafety factor S’
Materral for the matenal
6.4 Where the weld deposit is not of the same type as the for the
and equipment at desrgn
base material the stress coefficients of the weld deposit shall test pressure
temperature
be considered in the desrgn If they are lower than those of
the base material. 1. Grey cast Iron
to DIN 1691 3.5
6.5 For fully-stressed welded joints in components which
1 .l non-annealed 9.0
are designed using the creep rupture strength, the calcula-
1.2 Annealed or
tion should be based on a stress coefficient 20% lower than
enamelled 7.0
that of the base material as long as no creep data of the weld
2. copper and Its
deposit are availabie6). alloys lncluslve
6.6 Higher stress coefficients due to work-hardening may of rolled and
be considered in the design only if their presence in the com- cast bronze 23
ponent has been proved. 2.1 with seamless and
welded vessels 3>5
2.2 wrth soldered
7 Safety factor vessels 4,o

The safety factors shall be taken from tables 2 and 3, unless

differing or additional data are given in the separate AD-
Merkblstter.
8 Use of the permissible design
stress level in joints
8.1 The use of the permissible design stress level in welded
joints is given by the factor v in the design formulae. The fac-
tor v is obtained by dividing the values for the use of the per-
missible design stress level according to synoptic table 1 of
AD-Merkblatt HP 0 by 100. If not other values are specified
for the unnamed materials by agreement according to sub-
clause 1.2 of AD-Merkblatt HP 0, v = 1 ,O.
2) Does not apply to lndlrect electrical heating (e.g. by means of 011 bath)
“) In well-substantiated cases creep rupture strengths other than for 100000 hours
may be chosen.
5) If the material does not show a yield point. then the 0.2% proof stress according
to DIN 50 145 shall be applied
6) The 20 $6 deductIon from the creep rupture strength value of the parent metal shall
be made If there are no creep data wallable either for the weld fillet or the heat-
affected zone (HAZ) of the parent metal (determmed at the transversely stressed
lolnt) However. if such values are awlable.the lowest values $n each case shall
be used (parent metal. HA2 or filler metal). For creep rupture strength values of
the parent metal. see the relevant DIN standards and VdTUV Material Speclfica-
tlon Sheets. for creep rupture strength values of the HAZ. see VdTUV Material
Speclflcatlon Sheets and for creep rupture strength values of the weldmg fillers.
see a g, VdTUV Identlfwzatlon Sheets.
8.2 For brazed joints v = 0,8 may be applied to the design
provided no lower values have been deemed necessary in
the context of process inspection and testing.
8.3 Soft-brazed longitudinal joints are not permissible.
Lapped soft-brazed circumferential joints between copper
parts are acceptable provided the lapping is at least IO s,,
and the wall thickness does not exceed 6 mm and D, . p 2
2500 mm bar. Here the factor v is equal to 0,8 for the
circumferential joint.
8.4 For soft-brazed joints between copper plates with a
continuous lappet having a width of 2 12 s, on both sides
of the joint, v is equal to 0,8 provided the wall thickness s,
does not exceed 4 mm and the permissible working pres-
sure does not exceed 2 bar gauge.
9 Allowances
9.1 Allowance to compensate for minus tolerances in
wall-thickness
9.1.1 For ferritic steels, the minus tolerance permitted in
the relevant dimensional standards shall be used as the
allowance c, in the design where this can occur on the
finished component.
Page 4 AD-Merkblatt 8 0, Edition 01.95
9.1.2 In the case of austenitic steels and nonferrous metals
minus tolerances are not taken into account. For austenitic
sheets in conjunction with DIN EN IO 029 as the dimensional
standard, this only applies to minus tolerances up to the
values of the lower deviation for class A, i.e. when using
sheets with greater minus tolerances, only the amount of the
difference from class A shall be taken into account.
9.1.3 Where the manufacturing process entails reduction in
thickness (e.g. in the case of cast or deep-drawn parts) the
minimum required wall thickness calculated with c, = 0 shall
be stated and clearly marked on the drawing.
9.2 Wastage allowance
9.2.1 For ferritic steels the wastage allowance is cp =
1 mm. It may be omitted for s, 2 30 mm or if the steel is
adequately protected against the contents e.g. by means of
lining with lead, cladding, rubber or plastics but not by elec-
troplating. In the case of lining with plastics, the suitability of
the plastics shall always be verified.
9.2.2 By derogation from subclause 9.2.1 a higher allo-
wance c2 may be agreed upon between manufacturer and
user if the contents of the vessel are severely corrosive or
if the vessel cannot be examined on the inner surface during
subsequent servrce. In these cases the amount of cp allo-
wance shall be stated on the drawing.
Some special types of corrosion attack may require in add;-
tion to the use of suitable materials and adequate design, a
reduction of stress in the walls in contact with the vessel
contents in order to avoid e.g. destruction of protective
coatings or stress corrosion cracking.
9.2.3 For austenitic steels and nonferrous metals generally
the wastage allowance is cp = 0, provided no higher wastage
allowance has been agreed between manufacturer and user
which then shall be stated on the drawing.
10 Minimum permissible wall thickness
10.1 The minimum permissible wall thicknesses specified
in the AD-Merkblatter of Series B are nominal wall thicknes-
ses which the finished pressure parts shall demonstrate as
a nomnal dimension.
10.2 By derogation from subclause 10.1, the minimum per-
missible wall thicknesses may be smaller provided that:
a) this IS required by the process or the operating conditions
and
b) the stability of the pressure vessel is not affected adver-
sely and
c) the manufacturing conditions are suitable for this.
IJDC 621.642-98.001.24:62-213.6-434.1:62-213.6-436.1 Edition June 1986

Design AD-Merkblatt
Cylindrical and spherical shells subjected
of
to internal overpressure Bl
Pressure Vessels

‘he AD-Merkblatter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
,ehtilter” (AD). AD-Merkblati G 1 covers the composition and application of the AD-Regulations and also the procedural rules.
rhe AD-Merkblatter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
md above the normal /eve/ being anticipated during the operation of pressure vessels, allowance must be made for such stresses by
neeting special requirements.
Should there be any departures from the provisions of this AD-Merkblait, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, t e s t s , stress analysis,
operating experience.
Fachverband Damp fkessel-, Behdker- und Rohrleitongsbau e. K (FDBR). Diisseldorf
Haupiverband der gewerblichen Berufsgenossenschafien e.V., Sankt Augustin
Verband der Chemischen lndustrie e.L! (VCI), FrankfurtiMain
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaff Apparatebau, FranMurtlMain
Verein Deutscher Eisenhiittenleute (VDEh), Diisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroRkraftwerksbetreiber e. V., Essen
Vereinigung der Technischen iiberwachungs-Vereine e.V. (VdTl&), Essen.
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s l y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s should
5e addressed to the publisher:
Vereinigung der Technischen iibetwachungs-Vereine e. K, Postfach 103834, D-4300 Essen 1.

Contents

1 Scope 5 Calculation
2 General 6 Minimum wall thickness
3 Symbols and units 7 Literature
4 Weakening caused by cut-outs

1 Scope 4 Weakening caused by cut-outs

The design rules below apply to cylindrical and spherical See AD-Merkblatt B 9.
shells for pressure vessel shells and pipework subject to
internal pressure, where

D 5 Calculation
2-z 1,2 (1)
Di - IThe required wall thickness s is, in the case of cylindrical
1 shells
For pipes with D, 5 200 mm these rules apply up to a ratio
Da . P
D,/D, = 1,7. For cylindrical shells with DJD, > 1,2 consult .S= + Cl + c2
AD-Merkblatt B 10. 20;.,+,

or sphencal shells
Da P
s= + Cl + c2 (3)
2 General K
4os.v+p
This AD-Merkblatt shall only be used in conjunction with AD-
Merkblatt B 0.

6 Minimum wail thickness

6.1 For the minimum wall thickness of seamless, welded
3 Symbols and units or brazed cylindrical and spherical shells, the stipulatedvalue
see AD-Merkblatt B 0. is 2 mm.

Supersedes Edition February 1964; ( = Amendments relating to previous edition

Carl Heymanns Verlag KG

Luxemburger StraOe 449,50939Kdn
GutenbergstraOe 3. 10587 Berlin
Page 2 AD-Merkblatt 6 1, Edition 6.66
6 . 2 Contrary to the stipulation made in Section 6.1, for the
minimum wall thickness in the case of cylindrical and sphe-
rical shells made of aluminium and its alloys, the relevant
value is 3 mm.
6 . 3 For exceptional cases, reference shall be made to AD-
Merkblatt B 0, Section 10.
6 . 4 In the case of heat-exchanger tubes, the minimum wall
thickness may be less than the values stipulated in Sections
6.1 and 6.2.
7 Literature
[l]Class, I., W. Jamm u. E. Weber: Berechnung der Wand-
dicke von innendruckbeanspruchten Stahlrohren. VDI-Z
97 (1955) Nr. 6, S. 159167.
[2] Schwaigerer, S., u. E. Weber: Wanddickenberechnung
von Stahlrohren gegen Innendruck; Erlauterungen zu DIN
2413, Ausgabe 1972, TO 13 (1972) Nr. 3, S. 74i78.
[3]Zellerer, E., u. H. Thiel: Beitrag zur Berechnung von
Druckbehaltern mit Ringversteifungen. Die Bautechnik
(1967) H. 10, S. 333/39.
[4] Mang, F.: Festigkeitsprobleme bei ottlich gesttitzten Roh-
ren und Behaltern. Rohre - Rohrleitungsbau - Rohriei-
tungstransport (1970) H. 4, S. 207113, u. H. 5, S. 287/79;
(1971) H. 1, S. 23/30.
IllXr 621.642-98.Dnl.24:62-213.6-434.5:614.8 Edition Januarv 1995

Design Conical shells AD-Merkblatt

of Design subject to internal and external
Pressure Vessels pressure B2

The AD-Merkbldffer are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaff Druck-
behdlter” (AD). AD-Merkblatt G 7 covers the composition and application of AD-Regulations and a/so procedural guidelines.
T h e AD-Merkbldtter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g condiUons. In t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal level expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblaft, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e.V. (FDBR), D&sseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sankt Augustin
Verband der Chemischen lndustrie e. V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaff Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Dijsseldorf
VGB Technische Vereinigung der GroOkraftwerksbebeiber e.V., Essen
Verband der Technischen Ciberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkblstter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s t o k e e p w i t h t h e s t a t e - o f - t h e - a r t . R e l e v a n t p r o p o s a l s s h o u l d b e
addressed to the publisher
Verband der Technischen iiberwachungs-Vereine e. V., P.O. Box 103834, D-45038 Essen.

Contents

1 Scope 6 Weakening due to openings

2 General 7 Allowances
3 Symbols and units 8 Calculation
4 Safety factor 9 Minimum permissible wall thickness
5 Use of permissible 10 Literature
design stress level in joints 11 Appendix: Explanatory notes

1 Scope s-c,-cp
0,001 % 5 0,l (1)
41
The design rules stipulated below apply to conical shells Equation (1) shall be satisfied for s = si and for s = ss. In the
which are connected with a cylindrical shell on the same axis case of external pressure the opening angle is limited to:
by a corner joint or knuckle (cf. Fig. 1) and which are subject
to internal or external pressure within the following limits: -70” % qT % 70” (2)

Supersedes Edition May 1991; ) = amendments to the previous Edition

Carl Heymanns Verlag KG Translation: Technical Help to Exporters Service of BSI

Luxemburger Strak 449. 50939 Kbin
GutenbergstraOe 3. 10587 Berlin
Page 4 AD-Merkblatl B 2, Edition 1.95

0.5
0.11 A 11= ‘+0,817$1365b2
A E +1,0381861882
0.3 ;; = +0,0622158210
A = +0,0096929535
0.2 -A;‘: = +0.0597195135
A22
z -0,2412593780
P’S = -0,1880642590
A32
15.K.v
A 4 2 = -0,0324536587

kb9
0.08
0.07
0.06
0.05
o.ou

0.03

0.02

0.01
00%:
.
0.007
O.OOd
0. OO?
0.001

0.00:

0.00;

0.00
0.001 I

0.001 t-

~ -_- .-
0.001 0 7
- -
0.0006
l
0.0005. x= I n [ (q - cl - c2)/Dal]
t '4

0.0002. -(--I
p.S =ez
15.K.v

0.0001 4
z c) ggr;ziL s v) Qr-QQ
ooooo-
0 iii 5:_ g_ 0. 0I .0 .0 0. 0. 2. g. . -. -. 2 2 2 2
d d d d d do000 0 0 0 0 0 F3sJ~”

SI - c, - cp
Da l

Fig. 3.1. permissible value --$-& for convergent cone with an opening angle q = 10”
 Page 5 AD-Merkblatt B 2, Edition 1.95

0.5
r
0.Y I -0,1430803135
= +0.1381824165
0.3 = -0.1765906005
= -0,0065026025
0.2 = -1.4462692977
A 22 = -0.8328006417
P’S = -0,1486033657
15.K.v A 42 = -0.0281519950
0.1
0.09
0.06
0.07
0.06
0.0s
0 . OY

0.03

0.02

0.01
oo* 0000:
0:007
0.006
0.003

0.001

0.003

0.00:

00%
0: OO(
0.001
0.001
0.001

0. OOL

o.oot
C Aij .x'-'.yi-'
i=l j=l
O.OO(
P.S = e2
15.K.v

0.001

Dal
P.S
Fig.3 . 2 . p e r m i s s i b l e v a l u e - f o r c o n v e r g e n t c o n e w i t h a n o p e n i n g a n g l e q = 2 0 "
15.K.v
Page 6 AD-Merkblatt B 2, Edition 1.95

0 . 5

0 . 1 -0.3500365835 -
A = -0,2440022374
I I I I
0 . 3 - 2: = -0.3246595673 - I I I I

A41 = -o,o190535072 I cp=30” !

0 . 2 - A 12 = -3,6181287755-
A22 w -2.6258109205
P-s 432 = -o,5453370384
15.K.v
A = -0,0635460883
42
I I
X:&l

X:Z
0 . 0 6
0.01

0 . ou

0 . 0 3

0 . 0 2

0 . 0 1
0.009
0.008
0.007
0.006
0.005

O.WY

0.003

SI - Cl - c2
Da l

P-S for convergent cone with an opening angle Q, = 30”

Fig. 3.3. permissible value -
15.K.v
 Page 7 AD-Merkblatt B 2. Edition 1.95

0.5
0.1
= co,5378481 964
0.3 t-- 4, = -0.1986665329 ,tttjt/-
= -0.0125237427 1 ,
I
0.2 A 12
= -8.8190247674
= -6,4515131511
t- A 2 2 i
P’S
~- h2 = -1,3258437675
15.K.v = -0,1177022169

%
0.08
0.07
0.06
0.0s
0.04

0.03

0.02

0.01
00%:
.
I I I
0.007 1

n I
'0,03 _ I
0,06
0,08
% A 9n

Y= I
I. ---L\-, n I t.5, - c, - c,)/D,,] -I

z= ii 2 Aii .x’-’ .yi-1

i;l j=l

P’S ez

Da l

Fig. 3.4. permissible value -P.S for convergent cone with an opening angle cp = 40"
15.K.v
P a g e 8 AD-Merkblatl B 2. Edition 1.95

0.5
0.Y

0.3 - 4, = -0.1656688432
A = -0.0118934136
0.2 -A;: = -5,0206287530
A22 = -3,5637644804
- P-s - A32 = -0,5711850721
15.K.v A 4 2 = -0,0600216109
1
i
X:h
0.06 I , .
0.07 t iii 1 !/”
0.06
0.05
O.OY

0.03

0.02

0.01
xx:
.
0.007
0.006
0.005
0.001

0.003

I I1111
x= In [ (q - cl - cd/D,11 --
y = r/D,,

z= 2 g Aii -Xi- 1 .yi-1

i=l j=l

Dal

Fig.3.5. permissible value -P.S for convergent cone with an opening angle q = 50”
15.K.v
 Page 9 AD-Merkblatt B 2. Edition 1.95

0.5
0.Y A 11
7
= +1,8694396440
I l-Ill-T I

0.9
E
.A21
4,
’
= +1,3659163860
= -0,0648173574

+0,0553080284
I I

0.2
= -0.0511260440
P.S
15.K.v
0.1
:*oo:
0:07
0.06
0.05
O.OY

0.09

I I IllIll
0.02

0.01
0.009
0.006
0.007
0.006
0.005
0.004

0.003

0.002

0.001
x*. 0088
0.000
0.000
0.000
0.000 -t-
I

0.000

0.000

o.ooc

D al
P.S for convergent cone with an opening angle Q) = 60”
Fig. 3.6. permissible value -
15.K.v
page 10 AD-Merkblatt B 2. Edition 1.95

0.5 --
I I I
0.1 --A,, = a,31 34405430
A = ‘+0.0067874373
0.3 - ,I(; = - 0 . 3 6 9 7 9 7 7 4 2 9
A = -0.0270059480
0.2 -A:: = +17.879016063
= +l 1 . 9 1 7 9 5 9 3 5 6
P.S
-.--
A22
= +2.9083873997
15.K.v A32
A 42 = +0,1924692668
0. I
0.09
0.06
0.07
0.06
0.W
0.09

0.03 -
0.02 -
--
0.01
0.009
0.006
--
0.001
0.006I _
O.W¶ I _ --
0.0011

0.003I
I -

-
-
-

--
--
O.WL I
0 . 0 0 0 19 -
o.wa lb -
o.wa It-
o.wa 16 i
o.wa ts -
o.wc
x= In [ (q - Cl - C:

Y = r/D,,
/I
&WC

Da l

Fig. 3.7. permissible value - p ” f o r convergent with an angle ql= 7 0 ”

15.K.v
 Page 11 AD-Merkblatt B 2, Edition 1.95

0.5 I
0.Y _ A ,, - +1,2759;i136iO
A = +1,0123657862
0.9 - 2 ;= - 0 . 0 2 1 5 3 5 4 6 8 1
A 41 =
+0,0003868570
= -0.0193896780
0.2 - A 12
A22 =
+0.0023390140
P.S 42 = +0,0000046173
15.K.v A*.-, = + o , O o o O O O 3 0 2 5
0.1
0.09
0.09
0.07
0.09
0.05
O.OY

0.09

0.02

0.01
t*iE
o:oo~
o.oot
0. OO!
0.001

0.00:

0.00:

0.00
0.00
0.00
0.00
0.00
0.00
Y= Ifplin"
0.00 I-H- % Aii -xi - l . y i - l - -
0.000
i=l j=l

P.S $
o.ooa
15dcv=

o.ooc

0al

P.S f o r divergentc o n e ( c o r n e r j o i n t ) w i t h a n o p e n i n g a n g l e Q = - 1 0 " t o - 7 0 "

Fig. 3 . 8 . p e r m i s s i b l e v a l u e ~
15.K.v
Page 12 AD-Merkblatt B 2. Edition 1.95
8.2.3 Stability
In addition, it shall be verified that the cone area is sufficiently
safe against elastic and plastjc buckling in the presence of
external pressure. This verification is performed according to
AD-Merkblatt B 6 by investigating an equivalent cylinder.
Fig. 4. Geometrical quantities in the case of stresses due
to external pressure
For the example shown in Fig. 4, the equivalent cylinder dia-
meter between the knuckle and stiffening shown is:
D = Da, + 42
a (9)
2 . cos cp
and the equivalent cylinder length is:
I = &I - Da2
2 (sin q (
Deoendinq on the relevant boundary condition, the equiva-
lent lengthbetween two effective stiffenings shall be re’liably
estimated within the meaning of AD-Merkblatt B 6. Angles
between a cylindrical shell and convergent cone CF 2 10” can
be considered as effective stiffening.
8.2.4 Reinforcement by stiffening rings for divergent
cones
A stiffening ring in the transfer between a divergent conical
shell and the cylindrical shell shall meet the following require-
ments:
(11)
p . D2
Aa al . tan jqj (12)
80 . $
Here I is the moment of inertia about the axis parallel to the
bisector, A the ring surface, Sk the safety factor against
elastic buckling in accordance with AD-Merkblatt B 6, and
D,, the diameter according to Fig. 1 b. Moment of inertia and
area of the shell itself can be considered to be support-
ing over a width of OS V D,, s,
The equivalent cylinder length according to equation (10)
shall be formed as the sum of the individual meridional
lengths of cone and cylinder.
9 Minimum permissible wall thickness
9.1 The minimum permissible wall thickness of conical
shells is 2 mm.
9 . 2 Dy derogation from subclause 9.1, the minimum per-
missible wall thickness of conical shells made of aluminium
and its alloys is 3 mm.
9 . 3 Exemption from the stipulations in subclauses 9.1 and
9.2 are possible within the framework of AD-Merkblatt B 0
subclause 10.2.
10 Literature
(,o) [l] Schwaigerer, S.: Festigkeitsberechnung im Dampfkes-
sel-, Behalter- und Rohrleitungsbau [Strength Calcu-
lations in the Construction of Boilers, Vessels and
Piping]; 4th Edition, Springer 1983
[2] Ciprian, J.; Wolf, H.: Bemessungsvorschlage fur kegel-
formige Boden unter innerem ijberdruck [Design Propo-
sals for Conical Ends Subject to Internal Pressure];
Chem. Eng. Proc. 18 (1984), p. 5-13.

Appendix to AD-Merkblatt B 2
11 Explanatory notes
Re 8.1.1
Figs. 3.1 to 3.8 were prepared on the basis of geometrically
and physically linear stress calculations on selected cone/
cylinder combinations of homogeneous wall thickness with
a numeric program on the basis of elastic analysis [Al].
Fig. 3.8 for a divergent cone applies to the corner joint. The
use of this figure for knuckle-shaped transitions is conser-
vative and for this reason the investigation of different r/D,,
ratios was dispensed with. Fig. Al which represents a
typical stress distribution clearly shows that the stress in
the knuckle (or corner joint) area is extremely inhomoge-
neous and that the maximum stress is concentrated in a very
narrow area. With sufficiently ductile material behaviour, this
stress distribution allows design according to an elasto-
plastic design criterion. The socalled balancing-out criterion
[A21 was selected whereby the local membrane reference
stresses (reference stresses on shell centre line) shall satisfy
the condition
0urn 5 K
and the total reference stresses (reference stresses on the
inner or outer fibre) shall satisfy the restriction:
Both reference stresses were formed in accordance with the
v. Mise criterion at the location of maximum stress within the
meaning of the balancing-out criterion and were combined
as a function of parameters q/D,, and r/D,, for the angular
range -70” 5 q 5 70” in Table Al.
The information in this table allows the use of other design
criteria; the wall thickness shall then be determined on the
basis of non-linearity s! = f (.s,iD,,) using an iterative method.
Re 8.1.2
As shown in Fig. Al, in the case of the convergent cone, the
tangential membrane stresses which determine the stress for
the unaffected cone area change sign in the knuckle area.
This makes it permissible to calculate the globally acting tan-
gential membrane stress with the reduced diameter DK using
equation (7). In contrast, in the case of the divergent cone,
tangential stresses occur which are higher compared with the
cylinder. For this reason, the maximum diameter D, in equa-
tion (6) must be used in this case.
Page 13 AD-Merkblatl B 2, Edition 1.95
Re 8.2.3
A series of numeric stability calculations [Al] with different
values of y and r/D were performed to investigate the
stiffening action of cylinder-cone connections. The behaviour
of the material was assumed to be linear and elastic and the
geometry was assumed to be free from imperfections.
Even with very small cone angles the stiffening action of the
corner joint in the case of the convergent cone was so great
that design as specified in subclause 8.2 gives safe results.
The range of cone angle for which the unstiffened corner joint
can be regarded as effective stiffening within the meaning of
AD-Merkblatt B 6 was therefore restricted to a safe estimate
of 10”.
Stability behaviour is completely different in the case of diver-
gent conical shells [A61 where the membrane circumferential
stresses which determine buckling are higher in the taper
area, a fact which can result in drastically-reduced stability
pressures. This phenomenon may be disregarded if one of
the following prerequisites is met:
- Overdimensioning (i.e. wall thickness is more two and a
half times the wall thickness required for a convergent
cone with the same cone angle).
I- A stiffening ring is fitted
Literature for Appendix
[AlI Esslinger, M.; Geier, 5.; Wend, U.: Berechnung der
Traglast von Rotationsschalen im elastoplastischen
Bereich [Calculation of Ultimate Load of Rotational
Shells in the Elasto-plastic Range]; Stahlbau 3 (1985),
p. 76-80.
WI Ciprian, J.: Ausgewghlte Kapitel aus nationalen und
internationalen Regelwerken zur Frage der Auslegung
von Druckbehtiltern [Selected Chapters from National
and International Regulations on the Design of Pres-
sure Vessels]; VT-Verfahrenstechnik 1 4 (1980).
W31 Fit-day, G. E.; Timmins, W.: Toriconical Heads: A Para-
metric Study of Elastic Stresses and Implications on
Design. The International Journal of Pressure Vessels
and Piping 1 5 (1984), p. 213-217.
[A41 Myler, P.; Robinson, M.: Limit Analysis of Intersecting
Conical Pressure Vessels. The International Journal of
Pressure Vessels and Piping 18 (1985), p. 209-240.
[A51 Richtlinienkatalog Festigkeitsberechnungen, Behglter
und Apparate [Catalogue of Strength Calculation
Guidelines, Vessels and Apparatus] Part 1, 1979.
VEB Komplette Chemieanlagen, Dresden.
WI Hey, H.: Stabilitatsfragen bei Krempen [Stability Prob-
lems with Knuckles]; TO 29 (1988) Vol. 12, p. 408-413.
 Knuckle
Cylinder 4-l f--- Cone
Taper area
CF [N/mm21
100

-5

-1 Of
s,--q-422 = 2 - aMeridional membrane
D al = 1000
i/ - - OTangential membrane

‘IDal
P
=
=
0,02
1,9 bar
i’\
I I\
II - - - - - CMeridial b e n d i n g
-I- OTangential bending
K = 200 N/mm*
I \\
1\
I \
IIII

I I I II I
I I I
100 150 200 250 5 [mm]
50

Fig. Al. Example of stress distribution in a convergent conical end

 P a g e 15 AD-Merkblatt B 2, Edition 1.95

ovm/p = eZ/10 a,,/p = eZ/10

i 41 Ai 41 42 I
1 - 2,5237969597 +1,1718103575 +0,1496835203 +0,3255543662
10" 2 -2,4153539023 +1,1474454704 -0,1879063400 +0,4167173076
3 -0,4038842551 +0,3839948118 +0,1757519735 +0,1836143406
4 -0,0330836416 +0,0389466712 +0,0081195373 +0,0313833090

1 -0,1109670044 +0,4722244664 -0,6668478808 +7,3276929901

20" 2 -0,6872551935 +1,2380603309 -0,6682163561 +5,2817367631
3 -0,0812069729 +0,5747024263 +0,1257423724 +1,1471788733
4 -030186653523 +0,0712478607 + 0,0062924567 +0,1029314310

1 +3,2299184495 -2,1818217232 -0,7114356273 + 2,9838980255

30" 2 +2,3094075681 -0,9248619254 -0,6883641503 +2,4407071076
3 +0,6933321727 +0,0619133670 +0,1576241651 +0,5202050650
4 +0,0390535194 + 0,0428255806 +0,0098584261 +0,0688575135

1 +2,5212270988 + 4,8684293849 -1,5948245200 + 3,5376927693

40" 2 +2,2581979332 + 3,4690991549 -1,3902532006 +2,6716211775
3 +0,7867433541 +0,9137634718 +0,0271632095 + 0,4076937782
4 +0,0503939512 +0,1018112152 +0,0020815324 +0,0542686188

1 +0,5185276150 + 5,2975587044 -1,3734853008 -1,9552210270

2 +1,0535897122 +3,1202522978 -1,3146451741 -1,6454698620
50"
3
4

1
+0,5934015673
+0,0405323870

-1,6579394037
+0,6808922159
+0,0805186977

+2,1641361616
! +0,0637164751
+0,0057154347

-1,6749121764
- 0,7399992942
-0,0361418824

- 3,9034124693
60" 2 -0,4569117690 +0,1821431876 -1,6979268164 -2,6358971212
3 +0,3016339649 -0,2028321051 -0,0168563536 -1,0050513413
4 +0,0225425561 +0,0042067218 + 0,0002791709 -0,0606765266

1 -0,4925617936 -17,557012809 + 0,5702782982 -17,976856691

70" 2 + 0,2774395555 -13,735107260 -0,3317074974 -11,747523095
3 +0,4841566815 - 3,3337669298 +0,2825904061 - 2,9506836442
4 + 0,0360758749 -0,2184950285
L + 0,0209348933 -0,1984557457

I Divergent cone (corner joint) (-70" 5q 5 0')

i-l
. I&

avmJp = eZ/10 a,,/p = eZ/10

i 41 42 41 42

1 -1,3900928316 +0,0214659968 -1,0710374065 +0,0135399856

2 -1,0854083891 -0,0014225617 -0,8739710331 - 0,0060753953
3 +0,0059213539 -0,0000916712 +0,0551000435 - 0,0004709124
4 - 0,0009900764 -0,0000194763 +0,0014706982 -0,0000133725

T a b l e A l . I n t e r p o l a t i o n c o e f f i c i e n t sA ,f o r t h e r e l a t i v e m e m b r a n e r e f e r e n c e s t r e s&s, , , l pa n d t h e o v e r a l l r e f e r e n c e s t r e s s
q J pa t t h e m o s t h i g h l y - s t r e s s e d p o i n t o f c o n v e r g e n t c o n e s o r d i v e r g e n t c o n e s ( c o r n e r j o i n t )
UDC: 621.642-98.001.24 Edition October 1990

Design AD-Merkblatt
of Domed ends subject to
Pressure Vessels internal or external pressure B3

The AD-Merkblatter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
behalter” (AD). AD-Merkblatt G 1 covers the composition and application of the AD-Regulations and also the procedural rules.
The AD-Merkblatter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
and above the normal /eve/ being anticipated during the operation of pressure vessels, allowance must be made for such stresses by
meeting special requirements.
Should there be any departures from the provisions of this AD-Merkblait, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis,
operating experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e. V (FDBR), Dusseldorf
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, FrankfurtMain
Verein Deutscher Eisenhiittenleute (VDEh), Dusseldorf
VGB Technische Vereinigung der GroBkrahwerksbetreiber e.V., Essen
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkbldtter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e. K, Postfach 103834, D-4300 fssen 1.

Contents

1 Scope 6 Weakening due to openings

2 General 7 Allowances
3 Symbols and units 8 Calculation
4 Safety factor 9 Minimum permissible wall thickness
5 Percentage of permissible I Appendix
stress level in joints 1: Explanations

I Scope 2 General
rhese design rules apply to domed pressure vessel ends, 2.1 This AD-Merkblatt shall only be used in conjunction with
?g. 1, of the torispherical, semi-ellipsoidal and hemispherical AD-Merkblatt B 0.
ype subject to internal pressure with the following relations’)
2.2 The length of the cylindrical part is:
2nd limits:
a) for torispherical ends h, 2 3,5 s (9)
1) Torispherical ends
b) for semi-ellipsoidal ends h, 2 3,0 s (10)
R = D, (1)
r = 0,l D, (2) However, the following dimensions need not be exceeded:
hp = 0,1935 D, - 0,455 se (3) Wall thickness Length of cylindrical part
s, - c, - cp
0,001 5 5 0,l (4) up to 50 mm 150 mm
Da
over 50 mm up to 80mm 120 mm
1) Semi-ellipsoidal ends over 80 mm up to 100 mm 100 mm
R = 0,8 D, (5) over 100 mm up to 120 mm 75 mm
r = 0,154 D, (6) over 120 mm 50 mm
h2 = 0,255 0, - 0,635 se (7)
s, - c, - c2 No cylindrical part is required in the case of hemispherical
0,001 5 D 5 0,l (4)
a ends.
:) Hemispherical ends 2 . 3 Deviating from Section 2.2, the cylindrical parts may be
D, shorter provided that the circumferential joint between the
-5 1,2 (8)
D, domed end and the cylinder shell is non-destructively tested
in the same way as a fully stressed butt weld with 100%
utilisation of the permissible design stress in accordance with
) For the tlme being this AD-Merkblatl gives design factors fl for the end shapes
described in DIN 28 011 and 28 013 and for the hemispherkal end only. AD-Merkblatt HP 0.

Supersedes Edition June 1986; j = amended compared with previous Edition

Carl Heymanns Verlag KG

Luxemburger StraOe 449. 50939 K6ln
GutenbergstraOe 3. 10587 BerIm
Page 2 AD-Merkblatt B 3. Edition 10.90
2.4 If a domed end is welded together from crown and
knuckle components, the joint shall be at a sufficient distance
from the knuckle. The distance regarded as sufficient is as
follows:
a) Crown and knuckle are of different wall thickness:
x = 0,5 q/R (s - Cl - cz) (11)
where s IS the required wall thickness of the knuckle,
b) The crown and knuckle are of equal wall thickness
fortorispherical ends x = 3,5 s (12)
for semi-ellipsoidal ends x = 3,0 s
(13)
1with a minimum, however, of at least 100 mm (see Fig. 3).
3 Symbols and units
In addition to the stipulations in AD-Merkblatl B 0, the
in mm
4 Safety factor
4.1 The safety factors are given in Tables 2 and 3 of
Section 7 of AD-Merkblatl B 0. Deviating from these Tables,
for grey cast iron the following applies:
a) unannealed 7,0
b) annealed or enamelled 6,0.
4.2 The safety factor SK against elastic buckling of the
end under external pressure shall be calculated using
formula (14)
(14)
If a test pressure higher than 1,3p is specified, the safetyfac-
tor S;, at the test pressure shall not be less than the value
4 . 3 The safety factor S is to be increased by 20% com-
pared with Tables 2 and 3 in AD-Merkblatl B 0 for all veri-
fications involving external pressure; the values for grey
cast iron and cast bronze are exceptions.
4.4 Verification of the crown against plastic instability is
carried out with a safety factor S as specified in Section 4.3
but a minimum value of 2,4 is to be used.
5 Percentage of permissible design stress
level in joints
In addition to the rules in AD-Merkblatt B 0 the following app-
lies:
( v = 1 ,O may be applied if the scope of testing corresponds
to that specified for a design stress level equal to the
permissible design stress level or in the case of one-piece
ends. v = 1,0 may also be applied in the case of welded
domed ends-except hemispherical ends-regardless of the
scope of testing provided the weld intersects the crown area
of 0,6 D,, see Figs. 5 and 6 (left-hand side).
6 Weakening due to openings
Depending on their location in the knuckle or crown, open-
ings are to be taken into account differently in accordance
with Section 8.
7 Allowances
The allowances given in AD-Merkblatt B 0 apply. In addition
to the rules in AD-Merkblatt B 0, the wall underthicknesses
given in DIN 28011 and DIN 28013 are also to be con-
sidered.
8 Calculation
8.1 internal pressure
3.1.1 Crown and hemisphere
The wall thickness of the crown of domed ends and of hemi-
;pherical ends shall be determined according to equation (3) ’
,n AD-Merkblatt B 1 where D, = 2 (R + s,).
8.1.2 Openings in crown or hemisphere
If openings are in the crown area 0,6 D, of torispherical or
semi-ellrpsoldal ends, Fig. 2, or in the entire area of hemi-
spherical ends, their reinforcement shall satisfy AD-Merkblatt
B 9.
Where disc-shaped reinforcement is used the edge of the
disc shall not extend beyond the area of 0,8 D, in the case
3f torispherical ends or 0,7 D, in the case of semi-ellipsoidal
ends.
6.1.3 Knuckle and hemisphere connection
The required wall thickness of knuckles and hemisphere
connections shall be calculated according to equation (1.5).
s= Da.P.P + c, + cp
(15)
40;. v
The design factors /j shall be taken from Fig. 7 for knuckles
of tonspherical ends and from Fig. 8 for knuckles of semi-
ellipsoidal ends as a function of:
s, - c, - c2
D,
(iterative method is necessary). In equation (15) as well as
in Figs. 7 and 8, D, is the diameter of the cylindrical body as
shown in Figs. 1 and 2. The lower curve dJD, = 0 applies
if the area outside 0,6 D, is not weakened by openings. The
design factor B = 1 ,l applies for hemispherical-shaped solid
ends in the area x = 0,5 VR (s - c, - c,) adjacent to the
welded joint. This value applies regardless of the ratio
s, - c, - cp
Da
8.1.4 Openings in knuckle area
If there are openings in the area outside 0,6 D,, these are
taken into account by increasing the design factor in the ratio
dJD, > 0 according to Figs. 7 and 8. If the ligament on the
connecting line between the centres of adjacent openings is
not entirely within 0,6 D,, the minimum width of the ligament
shall equal the sum of half the opening diameters.
8.2 External pressure
8.2.1 Limiting of permanent elongation
Verification according to Sections 8.1.2 to 8.1.4 shall be per-
formed using the increased safety factors in Section 4.3.
8.2.2 Elastic buckling
The safety factory SK in Section 4.2 shall be used to examine
whether there is adequate safety against elastic inward
buckling. This is the case where:
2
p 5 3,66 &. Se - “d - c2
( )
 P a g e 3 AD-Merkblatt B 3. Edition 10.90

8.2.3 Plastic buckling
Spherical segment shells shall also be designed to prevent
plastic instability. This is ensured by verification according to
Section 8.1 .l using the safety factor defined in Section 4.4
regardless of the quality assessment of the joint (v = 1 ,O).
9 . 2 Deviating from Section 9.1, the minimum permissible
wall thickness of domed ends made of aluminium and its
alloys is 3 mm.
9.3 The exemptions in Section 10 of AD-Merkblatt B 0
apply.

9 Minimum permissible wall thickness

9 . 4 For castings the minimum permissible wall thickness,
9.1 The minimum permissible wall thickness of domed among other parameters, is determined by the manu-
ends is 2 mm. facturing technique.

Fig. 1. Solid domed end Fig. 2. Domed end with nozzle

Fig. 3. End with knuckle and crown of unequal wall thickness

v = 0,85 or 1,0 v = l,o v = I,0 v = 0,85 or 1,0

) Fig. 4. Weld outside 0,6 D, 1Fig. 5. Weld inside 0,6 0, 1Fig. 8. End welded together f r o m
round plate and segments
Page 6 AD-Merkblatt B 3, Edition 10.90

N/mm’ A Torispherical end: 0, = 1 0 0 0 m m

.S= 7 m m
Ri = 1000 mm
fi= 100mm
s/D, = 0 , 0 0 7
t ; #? \ i P= 5,9 b a r
80

-20 Developed meridian

-40 a,,,* = Meridional stress on outer surface

or.,, = Meridional stress on inner surface
-60 qn = Tangential stress on outer surface
q, = Tangential stress on inner surface
-80
\
si,/&A I
Centre of domed end
Crown area knuckle Cylindrical part
,- I-

Fig. 1. Stress distribution in a torispherical end

 Page 7 AD-Merkblatt B 3, Edition 10.90

IO

0
0 qdo2 Oh4 ok6 O.ObS O.dlO O.dl2 O,l%b l&d16 O,Cil6

s e - C l - c 2-

Del

Fig. 2. Design factors for torispherical ends

Page 8 A D - M e r k b l a t t B 3 , E d i t i o n 1 0 . 9 0

ad10 am2 aoib airs a&r

Se-Cl+

47

) Fig. 3. Design factors for semi-ellipsoidal ends

UDC 621.642-98.001.24 Edition May 1991

Design AD-Merkblatt
of Dished heads
Pressure Vessels B4

T h e AD-Merkbl3tter a r e c o m p i l e d b y t h e s e v e n t r a d e a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e ‘Arbeitsgemeinschaft Druckbehdl-

ter” ( A D ) . AD-Merkblaff G 1 c o v e r s t h e c o m p o s i t i o n a n d a p p l i c a t i o n o f t h e A D - R e g u l a t i o n s a n d a l s o t h e p r o c e d u r a l r u l e s .
The AD-MerkblWer cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
and above the normal level being anticipated during the operation of pressure vessels, allowance must be made for such stresses by
meeting special requirements.
Should there be any departures from the provisions of this AD-Merkblait, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis,
operating experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e. V. (FDBR), D&se/doff
Hauptverband der gewerblichen Berufsgenossenschaffen e. V., Sanki Augustin
Verband der Chemischen lndustrie e. V. (!/Cl), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhijttenleute (VDEh), Diisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkraMverksbetreiber e . V., E s s e n
Verband der Technischen iiberwachungs-Vereine e. V. (VdTiiV), Essen
T h e AD-Merkblstter a r e a m e n d e d c o n t i n u o u s l y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e.V., Posffach 103834, D-4300 Essen 1.

Contents
1 Scope 7 Additional margins
2 General 8 Design calculations for internal overpressure
3 Symbols and units 9 Design calculations for external overpressure
4Safety factor 10 Minimum wall thickness
5 Exploitation of the permissible
11 Literature
design stress in welded joints
6 Weakening caused by cut-outs Appendix 1: Explanations

1 Scope 3 Symbols and units

The design rules presented in the following are applicable In addition to the definitions contained in AD-Merkblatt B 0,
for dished heads subjected to internal and external over- there are the following:
)ressures, where the ratio of the wall thickness of the b width of the flange in mm
spherical shell segment to the radius of the crown is as fol- hF height of flange in mm
ows: r radius at transition point from flange to
s, - c, - c2 spherical shell segment in mm
1,005 5 % 0,l (1) s, required wall thickness of undisturbed
R
spherical disc portion in mm
F forcing acting on flange in N
2 General M moment acting on flange inNmm
2.1 This AD-Merkblatt shall only be used in conjunction q in this context: inclination of flange in ’
Cth AD-Merkblatt I3 0. 2 auxiliary factor in mm

2.2 The wall thickness of plane heads represents the limit

:ase for the wall thickness of dished heads. 4 Safety factor
2.3 The radius rat the transition point between flange and 4.1 For the safety factor, reference shall be made to
spherical shell segment shall be at least 6 mm. In the case Tables 2 and 3 of AD-Merkblatt B 0, Section 7.
If materials whose deformation capacity is low, with fracture
As a departure from this, the values for grey cast iron are as
elongations A5 of less than 10 %, the radius rat the transition
follows:
,oint shall be made at least equal to the wail thickness of the
spherical shell segment; there is no need however for the a) unannealed 7,0
.adius r to exceed 30 mm. b) annealed or enamelled 6,0.

Supersedes Edition June 1986; ) = Amendments to the previous Edition

ci;ar, neymanns vermg nu Translation: I ecnnical neip to txporters 3ervIce or &I

Luxemburger StraBe 449. 5000 Kdln 41
Gutenbergstral?.e 3, 1000 Berlin 10
P a g e 2 AD-Merkblatt B 4, Edition 05.91

4 . 2 The safety factor &for elastic buckling of the end in the 8 Design calculations for internal over-
presence of external overpressure is calculated using equa- pressure
tion (2).
8.1 Dished heads where the wall thickness in spherical
0,002 shell segment and flange is the same (Figs. 1 and 2)
.%=3-k
I. (2)
s* - Cl - cq The required wall thickness s of the spherical shell segment
R is calculated using equation (5):
i >
Where a testing pressure greater than 1,3p is stipulated, the P.R.B
s = ----+c,+c,( s, (5)
safety factor S’k for the testing pressure shall not be less than
2o.g.v
the value:
with p = PI + CA (54
S’=S .2.2 (3)
K K 3 The design coefficient /?, can be obtained from Fig. 3 as a
function of
4 . 3 Safety factor S shall be 20 % above those in Tables 2
and 3 in AD-Merkblatt B 0 in the case of all certification for d
-L and smcR-, , or is calculated using equation (6).
external pressure with the exception of the values for grey R 1 2
cast iron and cast bronze.
4 . 4 The safety factor S according to Section 4.3 is used to
verify the spherical part against plastic instability but a mini-
mum value of 2,4 shall be adopted.

5 Exploitation of the permissible design

stress in welded joints
f
The design calculations are also applicable for dished heads -c?
which are welded together from a number of elements. In
considering the utilisation of the permissible design stress in
the weld of a composite spherical cap, reference shall be
made to AD-Merkblatt HP 0.

Fig. 1. Dished head where the wall thickness in spherical

6 Weakening caused by cut-outs shell segment and flange is the same; single-witdh
inner seal
Calculations can be performed for cut-outs in dished heads
in accordance with AD-Merkblatt B 9; in such calculations, for
the internal diameter of the sphere twice the radius of the
crown is utilised. The distance of the cut-out from the inner
edge of the flange shall correspond at least to the decay
length.

x= 2V(2RfS,-c,-CJ (se--,-cc,) (4)

Where disc-shaped reinforcements are employed, the

distance between the inner edge of the flange and the edge
of the disc shall be not less than:

1/(2R+s,-c,-cz)~ (se--,-cc,)

Cut-outs in the edge zone are possible if it is demonstrated

by other means that the permissible stresses are not exceed-
ed.

Fig. 2. Dished head where the wall thickness in spherical

7 Additional margins
shell segment and flange is the same; full-width
For additional margins, see AD-Merkblatt B 0, Section 9. seal
 Page 3 AD-Merkblatt B 4, Edition 05.91

ai

?I -

2, -

Ii

(I -
O 0.4 0.8 1.2 1.6
d,lR
Plane plate Dome

Fig. 3. Design coefficient ,8, for dished heads where the wall thickness in spherical shell segment
and flange is the same

p = 0.5 bar

20 2

E lo
E 5
.F
0”
5 10

20

40

1 I I I
1000 2000 3000 4000
d, in mm

Fig. 4. Design coefficient C, for the determination of the G-value

Page 4 AD-Merkblatt B 4, Edition 05.91

The design coefficient ,0, shall be obtained from Fig. 8 as a

/3, = 1 + 0,833 . ,/z +na.cosa (6) function of
R
4
with sin a = 2~ s a n d - - - - or over the range 0,6 5 2 5 15 calculated
(7) s-q-c,
d ’ using equation (14).
and cos a =
Jo l- gq

The expression p shall not fall below a value of 1,85.

8,=1,3,
Jzz~
sina.cosa-sin2a. (14)

The design coefficient is C, = 0 when there is a full-width

For sin a and cos a, see equations (7) and (8).
seal. When there is a single-width inner seal, the coefficient
is calculated using equation (9).
8.2.2 Design calculations for the flanges
130 d, a, C,
C,= (9) Calculations for the loose flanges are performed in accor-
R. (d,+2b) ( s -c,-c,)
dance with AD-Merkblatt S 8.
For soft seals, the design coefficient C, in mm shall be obtain-
ed from Fig. 4 as a function of db and p, or it is calculated
8.3 Dished heads with a thickened flange (Figs. 9 and 10)
using equation (10) and (11); here, the value to be employed
is the lower of the two. 8.3.1 Design calculations for the spherical-disc portion
The required wall thickness s, of the spherical disc in the cen-
tral undisturbed region (beyond the decay-length zone) shall
be calculated using equation (15).
(11)
P’ R
where or, is measured in mm and p in bar. so=-----+c,+c, (15)
2 0 g.v
The design coefficients CB are applicable for p 5 40 bar and
do 5 4000 mm. In the decay-length zone x (edge zone as defined by equation
(4)) of spherical discs, the wall thickness shall be calculated
by iteration using equation (16).
8.2 Dished heads with loose flanges (Figs. 5 and 6)
8.2.1 Design calculations for the spherical-disc portion .S= P.*-C,.B+, 3
+c _s
2<e (16)
20 ;
The required wall thickness of the spherical disc in the central
undisturbed region (outside the decay-length zone) shall be where p is determined using equation (17a) respectively
calculated using equation (15). The wall thickness of the (17b) or by reference to Fig. 12.
spherical disc in the decay-length zone x, as defined by
equation (4), and in the clamping region shall be calculated p = 2,18-0,593lgx + 0,381 (lg22-0,12 (lg$ + (17a)
using equation (12). + 0,4 (lg i)”
P.R.B
s= -----+c,+c, 2 s, for i =’ ->-‘2. I/d,. ( s -c,-c,) 5 3
(12)
20-;. v resp.
p=2
with ,l? = ,l$ . Cc UW s-c1 - cp
forx = . j/d, . (s - c, - c2) > 3 (17b)
The expression b shall not fall below a value of 1,85. R

The design coefficient Cc shall be obtained from Fig. 7 or is For designs with a weld at the transition between flange and
calculated using equation (13). spherical shell segment, C, = 1,2. In cases where at this
transition point there are internal and external radii which
4,32- 10-6. d: + 0 , 3 8 8 d , + 7 4 5
c, = comply with the conditions specified in Section 2.3, C, = 1.
d, + 742

b d, b 4
t- -I-=

Fig. 5. Dished head with loose flanges and single-width

inner seal Fig. 6. Dished head with loose flanges and full-width seal
 Page 5 AD-Merkblatl B 4, Edition 05.91

098

0.6

u”
Q4

0.2

Fig. 7. Design coefficient Cc

loose flanges d, In mm

a4 018 1.2 136 2,o

d,/R
Fig. 8. Design coefficient p2 for dished heads I I
Dome
with loose flanges Plane plate
Page 6 AD-Merkblatt B 4, Edition 05.91

Fig. 10. Dished head with thickened flange; transition point

Fig. 9. Dished head with thickened flange; transition point machined
not machined

“D

dt

da

Fig. 11. Forces acting on a dished head with a thickened flange

Fig. 12. Design coefficient p for the edge zone of the spherical-disc portion of dished heads with a thickened flange
 Page 7 AD-Merkblatt B 4, Edition 05.91

8.3.2 Design calculations for the flange The following strength conditions shall be satisfied:
The calculations are performed with reference to AD-Merk- (1) for the operating state:
blatter B 7 and B 8 and DIN 2505; as part of this procedure, I MB I 1 i<I
the seal characteristics can be obtained from the latter. I - W +5‘2n.A- S (32)
The forces and moments are as follows: (2) for the assembled state:
(1) Operating state: m<K, (33)
F -P.d:.n - w -S’
RB - 40 (18) 1(3) for the test condition:
F =P (4 - d:) = IMpI 1 IFHP1 KF
Fe 40 (19) ---@ +F.msy (34)
- -P .
FDB- ,. n . do . SD . k, PO)
9 Design calculations for external
with SD = 1.2
overpressure
P
F,,=z.n.d,~ (21) 9.1 Limitation of permanent elongation
The safety factors increased in accordance with Section 4.3
MB = FRB. aR + FF~. aF + FDB. aD T FHlj. aH (22) are used for verification of the shell in the area of the decay
Plus signs are used for FHB. aH if FHB acts below the length using equations (5), (12) and (16) and in the area of
centre of mass of the flange, and minus signs for cut-outs as specified in AD-Merkblatt B 9.
FHB. aH if FHa acts above the centre of mass (see The flange shall be calculated as appropriate according to
Fig. 11). Clause 8 using the safety factor according to Section 4.1.
(2) Assembled state: Equation (22) is replaced by equation (35).
FDv = n. dD. k, K,, or F& (23) MB = - FRB (aR - aD) - FFB (aF - aD) + FHB ’ +, (35)
where F+,, is determined in accordance with AD- The plus sign is used if FH, acts above the centre of mass
Merkblatt B 7, Section 6.1.2.2 of the flange and the minus sign is used if FHB acts below the
centre of mass of the flange. The increase in the seal face
M, = F,, . a, resp. M, = F&. a, (24) pressure as a result of the external pressure shall be borne
(3) Testing state: in mind.
if the testing pressure p’ > 1,3 . p, the force compo- 9.2 Elastic bulging
nents and flange moments shall be determined for this The safety factor SK according to Section 4.2 shall be used
load case also. to investigate whether there is adequate safety against
in order to study the influence of the horizontal force F,,, the (inward) elastic bulging. This is the case if:
effective edge cross-section shall be determined:
A = AF + AK (25)
where AF = flange cross-section, and AK = corresponding 9.3 Plastic bulging
proportion of the disc cross-section.
Spherical segment shells shall also be designed to withstand
AF = 0,5 (d, - cl, - 2 . dJ . h, (26) plasctic instability. This is achieved by verification using
equation (15) with the safety factor stipulated in Section 4.4
A,=(~.--,--c~).J(R-~).(s~-c,-c*) -2 (27) regardless of the joint factor assuming v = 1 ,O.
Here, KK is the strength characteristics for the spherical disc,
and KF the strength characteristic for the flange. A value no 10 Minimum wall thickness
higher than 1 may be substituted for KKIKF 10.1 For the minimum wall thickness of the spherical shell
The following strength condition shall be satisfied: segment of dished heads, the stipulated value is 2 mm.
F
-.-LB--<> K 1 0 . 2 Deviating from the stipulation made in Section 10.1,
2.n.A-S (28) for the minimum wall thickness in the case of dished heads
In order to study the influence of the bending moment MB, made of aluminium and its alloys the relevant value is 3 mm.
the effective flange resistance shall be determined: 1 0 . 3 For exceptional cases, reference should be made to
AD-Merkblatt 6 0, Section 10.
W=2.0,9n b’-~+~d,((s,-c,-c,)*-(So-c,-c,,‘)
[ I 1 0 . 4 The minimum wall thickness of castings is determined
I
(29) among other things by the production process.
with s, from equation (15) and
b’ = b - dfL (with d’L according to AD-Merkblatt B 8, 11 Literature
Figure 3) (30)
I [l] Hein, G.: Die Berechnung von Tellerboden. Zeitschrift
and where in order to limit the inclination of the flange; des TijV Miinchen, Nr. 7 und 8 (1955).
II,,,,, 2 2,5 S, is required. [2] Htitte Maschinenbau Teil B; 28. Auflage. Wilhelm Ernst
When R > 3 (see equation (17) and Fig. 12) the inclination & Sohn (1960).
of the flange [3] Schwaigerer, S.: Die FestigkeitflachgewolbterBehalter-
0,75 MB (da + d,) . 5733 deckel. BWK 3 (1951), S. 411 ff.
(31)
’ = Es W(hF + 0,9 d(d, + S,) s,) [4] Schwaigerer, S.: Festigkeitsberechnung im Dampf-
shall be limited to 0,5” (consult AD-Merkblatt B 8, SeC- kessel-, Behalter- und Rohrleitungsbau; 4. Auflage.
tion 6.14). Springer (1983).
Page 8 AD-Merkblatt B 4, Edition 05.91

Appendix 1 to AD-Merkblatt B 4

yield point of more than about 300 N/mm*, the inclination of

Explanations to AD-Merkblatt B 4 the flanqe shall be borne in mind having regard to the leak
tiohtnesi of the flanged joint.
ln theory, the dimensions of the spherical disc may lie bet- “a”-.---

ween the limits R = 0,5 . d, (dome) and R = 00 (plane circular Equation (32) reflects the superimposition and evaluation of
p l a t e ) . The normal dimensions of dished heads are of the the stresses acting in the flange ring in the peripheral direc-
order of d,lR = 0,5 to 1,5. tion which result from the normal force and bending moment.
In the flange ring and the corresponding proportion of the
The specified equations relating to the illustrations are valid spherical-disc cross-section, as a result of the horizontal
onlywithinthe limits represented be the particular illustration. force FHB a peripheral stress is produced of the order
a,,, = f,,/2 ;I A. Moreover, as a consequence of the external
To No. 8.1 and 8.2 bending moment MB, an internal moment with a radial vector
occurs in the flange ring which according to the calculation
For dished heads with the same wall thickness in spherical
of the flange using the yield-hinge-concept results in a maxi-
shell segment and flange, use was made of the method of mum peripheral stress of uB = Ma/W,,. Adopting the ultimate
calculation established by G. Hein [2] taking account of expe- load theory for the bending components and equation (28)
rimental results. For this calculation procedure, adequate for the normal stress components, the following strength con-
experience is available. dition is obtained for the superimposition of the stresses:
1 IFHBI
I M,l +-.-.--s- KF
To No. 8.3
,J
W-, S 2;r.A S
Calculation of the edge cross-section of the spherical disc:
where W,, is designated by W.
The design coefficient /3 was determined as the result of para-
By introducing the quantity signs into equations (32), (33) and
meter studies using numerical methods (transfer matrices).
(34), the most unfavourable combination of stressesisestab-
Design calculations for the flange: 1lished.
The design procedure corresponds to a simplified bearing-
load method (yield-hinge-concept), by analogy with the Literature
method for flanged joints which are joined to cylindrical com-
ponents, in accordance with DIN 2505 and AD-Merkblatt 6 8. [II Schwaigerer, S.: Festigkeitsberechnung im Dampfkes-
sel-, Behalter- und Rohrleitungsbau; 4. Auflage. Sprin-
The location of the yield hinge is assumed to be at the tran-
ger (1983).
sition point between the flange and the spherical disc.
PI Hein, G.: Die Berechnung von Tellerboden; Zeitschrift
For an initial rough calculation, the flange height can be found
des TijV Munchen, Nr. 7 und 8 (1955).
using equation (1):
(1) 131 Hutte Maschinenbau Teil B; 28. Auflage. Wilhelm Ernst
hF = se ’ PF
und Sohn (1960).
with pF determined from Fig. 1.
[41 Schwaigerer, S.: Die Festigkeitflachgewdlbter Behalter-
The use of this method of calculation presupposes a flange deckel. BWK 3 (1951), S. 411 ff.
height of hF I 2,5 s, in order to limit the inclination of the We/linger, K., Krsgeloh, E. u. W. Braig: Untersuchung
151
flange. Limiting the flange height in the upward direction may von Tellerboden. Technische Mitteilung GWK-Verband
be called for on account of welding considerations. More- (1965).
over, in the case of flange materials with a room-temperature

se-c, -c2
jT= d, (se-c,-c2)
R v
Fig. 1. Design cc lefficients /3F for the flange height.
 Edition Mav 1w-m

Design AD-Merkblatt
of Unstayed and stayed flat ends
Pressure Vessels and plates B5

T h e AD-MerkbLWer a r e c o m p i l e d b y t h e s e v e n t r a d e a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “Arbeitsgemeinschaft Druck-

behdlter” ( A D ) . AD-Merkblatt G 7 c o v e r s t h e c o m p o s i t i o n a n d a p p l i c a t i o n o f A D - R e g u l a t i o n s a n d a / s o p r o c e d u r a l g u i d e l i n e s .
The AD-Merkb/ZSter cover safety requirements which shall be adopted for normal conditions of operation. /n the event Of stresses over
and above the normal level being anticipated during the operation ofpressure vessels, allowance shall b e m a d e f o r s u c h s t r e s s e s b y m e e t -
ing special requirements.
S h o u l d t h e r e b e a n y d e p a r t u r e s f r o m t h e p r o v i s i o n s o f t h i s AD-Merkblatt, i t shall b e p o s s i b l e t o d e m o n s t r a t e t h a t t h e s a f e t y s t a n d a r d s e m b o -
d i e d i n t h e s e r e g u l a t i o n s h a v e b e e n o b s e r v e d b y a l t e r n a t i v e m e a n s , e . g . t e s t i n g ofmaterials, trials, stress analysis, operating experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e.V. (FDBR), Dijsseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sankt Augustin
Verband der Chemischen lndustrie e. V. (VCI), FrankfutilMain
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhijffenleute (VDEh), D&se/doff
VGB Jechnische Vereinigung der GroBkratierksbetreiber e.V., Essen
Verband d e r T e c h n i s c h e n iiberwachungs-Vereine e . V . (VdTijV), Essen.
T h e AD-MerkblStterare a m e n d e d c o n t i n u o u s l y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t h e t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents

1 Scope 5 Allowances
2 General 6 Calculation
3 Symbols and units 7 Bibliography
4 Weakenings Appendix 1: Explanations

1 Scope 3 Symbols and units

The design rules hereafter apply for flat ends and plates and In addition to AD-Merkblatt B 0 the following applies:
tube bundles of heat exchangers as far as their staying effect d,, d, design diameters in mm
is concerned. They are based on the Kirchhoff equations for l effective length in mm
plates taking into consideration the effect of the boundary 1K length over which tube is roll-
conditions and multiple openings approximately. In addition, w expanded into tube plate in mm
the C-factors also include the effect of a Poisson’s ratio of
0,3. PI? Pll design pressure within tubes,
respectively around the tubes in bar
In the case of materials where the Poisson’s ratio differs con-
D,, D2, D3, D4 design diameter in mm
siderably, and in those cases where the dimensions exceed
the limits: FA axial force in N
FK buckling force in N
s, - c, - ca , 4 PS 1 FR tube force in N
0,0087 T; D 5 T
D - v- t in this context: pitch in mm
a separate stress and deformation analysis is necessary. a slenderness ratio
For D, the relevant design diameter shall be substituted. This
distincition does not apply for tubeplates where mutual brac-
ing is provided by the tubes.
4 Weakenings
2 General 4.1 Openings in unstayed flat ends and plates
2.1 This AD-Merkblatt shall only be used in conjunction with 4.1.1 Central openings with diameter d, can be as shown
AD-Merkblatt B 0. in Figure 21 for designs as specified in 6.1 and 6.2 and as
shown in Figure 22 for designs as specified in 6.3 and 6.4.
2 . 2 When using blind flanges to DIN 2527 and blind covers
(flat covers of steel) to DIN 28 122 the requirements of this 4.1.2 The required wall thickness of the plate with an open-
AD-Merkblatt are deemed to be met, if non-metallic gaskets ing is determined from formulae (2) to (4) where the C-or C,-
(e.g. flat gaskets for flanges with a flat face to DIN 2690 to factor as specified in table 1 or figure 5 is multiplied by the
2692) are used. opening factor CA or CA,.

Supersedes Edition January 1995; 1 = Amendments to previous edition

-
tian neymanns vemg Kl3
.,^ - ^
Translation: Technical Help to Exporters service of BSI
Luxemburger StraBe 449. 50939 Koln
P a g e 2 AD-Merkblatt B 5. Edition 05.99
4 . 1 . 3 The values of CA or CA, shall be taken from curve A
or B depending on whether an opening does not have a con-
nector (design A in figures 21 and 22) or does have a connec-
tor (design B in figures 21 and 22). If the diameter ratio di/&
3 0,8, the flange design rules as specified in AD-Merkblatt
B 8 shall be applied.
4.1.4 Eccentric openings can be considered in the same
way as central openings.
4 . 1 . 5 For round unstayed plates having an equidirectional
additional peripheral moment where the ratio s, - c, - c2/dt
2 O,l, if there are several cut-outs, the cut-out correction
value AAl can be determined as follows:
where A is the cross sectional area of the unpierced plate and
AA is the sum of the cross sectional areas of the openings
in a cross section which represents the maximum weakening
effect.
4.1.6 For tube plates, the efficiency factors shall be deter-
mined in accordance with formulae (17) and (18).
5 Allowances
Please rever to AD-Merkblatt B 0, Section 9, but note that,
unlike that section, there is no c, allowance for walls thicker
than 25 mm.
6 Calculation
6.1 Unstayed circular flat ends and plates with no addi-
tional peripheral moment
6.1.1 The required wall thickness s of unstayed circular flat
ends or plates with no additional peripheral moment is
+ c, + cp
with the design factor C and the design diameter D, to
Table 1.
6.2 Unstayed rectangular or elliptical flat ends and pla-
tes with no additional peripheral moment
‘------==‘- ---= ,----
] r-/==-- --7---* -.
I I,r’,q
I/! I,’ /
; ‘L
I --f-----e-
Fig. 1. Unstayed rectangular or elliptical plate placed in front
from inside with no additional peripheral moment
6.2.1 The required wall thickness s of unstayed rectangular
or elliptical plates with no additional peripheral moment to
Fig. 1 -is
+ c, + cp
The factor CE from Fig. 2 allows for the special conditions pre-
sented by rectangular or elliptical plates. The C value shall
be taken from Table 1 in accordance with the boundary con-
ditions relative to the short side.
6.2.2 For covers as shown in figure 1 with an additional
load from U-bolts, the permissible bolt load acting in the same
direction as the internal pressure shall be taken into account.
Generally it is adequate to replacep by 1,5p in formula (3).
6.3 Unstayed circular plates with an additional periphe-
ral moment
6.3.1 The required wall thickness s of unstayed circular pla-
tes with an additional peripheral moment acting in the same
direction is
P.S + c, + cp
s = c, . do . -
10K
The C, value can be taken from Figure 5 as a function of the
ratio d,/& and the value 6. Here, the ratio of the required bolt
load and the internal pressure is
with S, generally equal to 1,2 and the gasket characteristic
k, to be taken from AD-Merkblatt B 7. C, = 0,35 if the moment
is acting against pressure load.
Fig. 3. Unstayed circular plate with an additional peripheral
moment acting in the same sense as the pressure
load Direction of
pressure load
Fig. 4. Unstayed circular plate with an additional peripheral
moment acting against the pressure load
6.3.2 Plates which are designed in accordance with the
above formulae meet the strength requirements. It is possible
however, e.g. in the case of plates made from high-strength
steels, and in the case of plates made from non-ferrous
metals or plates of larger diameter, for problems to be enco-
untered in respect of sealing and permissible bolt deflection
which are attributable to excessive angling of the plates. It
is recommended therefore, when non-metallic seals and
combined seals are used, that the inclination of the plate cp
should be kept to within about 0,5” to 1’ [I 71. It will then some-
times be necessary to make the plate thicker than would be
demanded on the basis of the strength requirements.
P a g e 4 A D - M e r k b l a t t B 5. Edition 05.99

r-
Table 4. Design factor for flat plates with stay bolts
Design factor
Design of stay bolts
C? I

6.7 Circular flat plates in heat exchangers

The design shall be in accordance with the requirements of
6.7.1 to 6.7.6. The requirements of 6.7.7 shall be noted in any
case.

6.7.1 Circular flat plates mutually stayed by the tubes

and the shell
6.7.1.1 The required wall thickness s of circular flat plates
(see Fig. 9) mutually stayed by the tubes and the shell is
P.S + c, + cp
s = 0,40 d2 . -
10K
(12)
where p is the greater of the tube or shell side pressure. The Fig. 9. Circular flat plates mutually stayed by the tubes and
design diameter d2 shall be the diameter of the greatest insc- the shell
ribed circle in the unpierced part of the plate (see Fig. 10).
6.7.1.2 In the case of tubes roller-expanded into tube plate
adequate safety against pulling out the tubes shall be avail-
able.
This is the case where the strength in the tube to tube plate
connection given by the tube force FR (see 6.7.1.4) and the
effective area A, does not exceed the values of Table 5.

Table 5. Permissible strength for tubes roller-expanded into

the tube plate

mean gasket diameter or

welded joint
The effective area is
A, = (d, - d,) . lw (13)
with a maximum of Fig. 10. Determination of design diameter d2
A, = 0,l . d, . 1, (14)
The expanded length I, shall be at least 12 mm and may be
considered up to and including 40 mm for the determination
of the effective area.
6.7.1.3 In the case of welded tube to tube plate connection
to Fig. 11 the welded joints shall be able to sustain the total
force exerted on the tube. In the shearing cross section the
joint thickness shall be at least

6.7.1.4 The calculation of the tube force F, is to be based

on the strengthened area AR corresponding to one tube. For
fully perforated tube plates the strengthened area is desig-
nated by the shaded part in Fig. 12. In the case of partially
perforated tube plates the portion of the border area shall be
taken into account. In the case of border areas in flat ends
the area of the end shall be taken into account up to the tran-
sition from flat plate to flange. In the case of border areas in
flat plates the strength of the border area may be assumed
to be taken up by up to 50 % by the direct adjoining wall of
the vessel. Fig. 11. Thickness of awelded tube to tube plate connection
 P a g e 5 AD-Merkblatt B 5. Edition 05.99

Fig. 12. Strengthened area AR

6.7.1.5 If the tubes are subjected to buckling loads, the

requirements of 6.5.3 shall also be noted. If the buckling load
is higher than the permissible buckling load to formula (8),
then the required wall thickness s of the plates is

(16)

The design factors Care to be taken from Table 1 and Fig. 5. Fig. 13. Circular fully perforated tube plates for U-tubes
The weakening factor shall be determined as follows

(17)
6.7.3 Partially or irregularly perforated flat tube plates
for U-tubes
If the tubes can be assumed to be fully load-bearing, e.g.
when DIN 28 182 is observed, the following formulae can be
6.7.3.1 The required wall thickness s of circular partially or
employed:
irregularly perforated flat tube plates for U-tubes is
t-d d
v=----1fA512
t d, ’ s = C, . D, ’ &gJ+c, i-c2 (22)
and
and
4
v=t-iifd,>j2 (18b) s = C4. D, . (23)
t d, ’
6.7.1.6 Formula (12) does not take into account the effect
In accordance with 6.7.2.1, the wall thickness shall be deter-
of the various thermal expansions of the shell, the tubes and
mined using formulae (22) and (23) with the relevant C4
the plate itself. Where the effect of different thermal expansi- design factors with the larger wall thickness being the deter-
ons has to be taken into account, the design method is to be mining factor for the design. However, the wall thickness
agreed upon between manufacturer and user. shall not fall below the required value for unpierced plate.
6.7.1.7 Where the pressure in the pipes is more than twice
the pressure around the pipes (i.e. p, > 2 x p,), it shall be The design factors C4 are to be taken from Fig. 14. For the
proven that the shell can also withstand the axial force arising weakening factor the formulae (17) and (18) apply.
from pi.
6.7.3.2 In the case of plates with tube lanes (multi-pass
6.7.2 Circular fully perforated tube plates for U-tubes heat exchangers), in the case of plates whose tubed region
6.7.2.1 The required wall thickness s of circular fully perfo- does not extend as far as the edge of the plate (e.g. rectangu-
rated tube plates for U-tubes to Fig. 13 is lar tubed region), or in cases where for the individual diame-
ters of concentric tube rows the pitches are unequal, sepa-
s = c . D, . Pi . s + c, + c,
___ rate calculations shall be performed for each distance 1
(19)
10K.v (mean distance of the centre-lines the tubes for the tube row
and under consideration to the centre-point of the plate), with the

s=C.D,. P” . s +c, +c* highest value $$ being the determining factor for the
10K.v design.
The greater wall thickness obtained from formula (19) or (20)
is decisive. Design diameter and design factors for tube and Individual tubes located outside the tubed region may be
shell side are to be taken from Table 1 and Fig. 5. For the ignored here. If it is necessary for similar untubed boundary
weakening factor the formula (17) and (18) apply. regions to be provided in front of shell nozzles, they can be
ignored.
6.7.2.2 For tubes roller-expanded into the tube plate, the
requirements of 6.7.1.2 shall be noted as appropriate with
6.7.3.3 In the case of roller-expanded tubes, the require-
F = d$.x.p, ments of 6.7.1.2 shall be noted as appropriate. FR shall be
R
40 (21) determined here according to equation (21).
P a g e 6 AD-Merkblatt B 5, Edition 05.99

bearing tubes from the existing tubed region results in a smal-

ler diameter for the tubed region, and thus in a smaller I’ and,
from Fig. 16, a larger value for C5 which is used to determine
the thickness of the tubeplate. If & < O,l, for C5 the maxi-
1
mum value in each case is applicable.

Fig. 15. Circular, flat tube plates of heat exchanger, where

tube bundle is provided with a floating head

6.7.4 Circular, flat tube plates in floating head heat

exchangers
Fig. 17. Circular, flat tube plates of heat exchangers with
6.7.4.1 The required wall thickness s of circular flat tube expansion bend in shell
plates in floating head exchangers to Fig. 15 is
PI s 6.7.4.5 The pressure p, is decisive for the buckling load on
s = C5. D , -----+ c, + c2 (24)
10K.v the tubes in the inner tube field. The loading area of a tube
and shall be assumed to be the loading area given in 6.7.1.4 and
extended by the cross-sectional area of the tube.
s = C5. D , P” . s
----+c, +c;!
10K.v
6.7.5 Circular, flat tube plates of heat exchangers with
The design diameters for the shell and tube side are to be
bellows in the shell
taken from Table 1 and Fig. 3 or 4. The greatest wall thick-
ness s obtained from formula (24) or (25) is decisive for the 6.7.5.1 The required wall thickness s of circular, flat tube
design. For the weakening factor v formulae (17) and (18) plates of heat exchangers with bellows in the shell as shown
apply. When calculating the floating head tube plate D, is to in Figs. 17 and 18 is with
be replaced by D2 as shown in Fig. 15 in the formulae (24)
and (25). (26)
6.7.4.2 The design factors C5 for the shell and tube side
shall be taken from Fig. 16. The decisive curve for the type
of design results from the boundary conditions. The decisive
curves for additional peripheral moments apply for 6 = 1,5
(see formula (5)). For gaskets having other values for 6 the The diameter D, shall be taken from Table 1 and Figs. 3 or
4 in accordance with the boundary conditions on the tube
design factor C, shall be multiplied by A. For calcula-
v- side.
tion the design factor C5 shall not be lower’than 0,15.
The requirements of 6.7.4.3 shall apply as appropriate for the
6.7.4.3 The distance 1 is the mean distance of centre-lines
determination of 1 in formula (26). The design factor C5 shall
of the outer tubes from the centre-point of the plate. In the
be taken from figure 16 in accordance with the boundary con-
case of a fully tubed plate, 1 can be taken as equal to the
ditions on the tube side. The requirements of 6.7.4.2 shall be
radius of the envelope circle. Individual tubes located outside
noted. Formulae (17) and (18) apply for the efficiency.
the tubed region may be ignored here. If it is necessary for
similar untubed boundary regions to be provided in front of 6.7.5.2 A check shall be made moreover on whether the
shell nozzles, they can be ignored. boundary tubes (roughly speaking the two outermost tube
6.7.4.4 A check shall be made moreover on whether the rows), together with their joints in the tubeplate, are capable
boundary tubes (roughly speaking the two outermost tube
of withstanding the tensile load p . 0: .G. Here, p shall be
rows), together with their joints in the tubeplate, are capable
of withstanding the buckling and compressive loading substituted in accordance with formula (26). If pi or pu are
pu. 0: . $ and the tensile load pi .Dz -$ underpressures, the boundary tubes shall also be capable of
withstanding the buckling and compressive loading p, . Df .
D2 here relates to the floating tubeplate. If the stress on the X and pu . (0; - 4 L2) . -&. If this requirement is not satis-
boundary tubes is too high, the necessary number of load- 40
bearing tubes shall be determined. Deduction of these load- fied, the procedure as outlined in 6.7.4.4 can be followed.

6.7.5.3 The pressure p, is decisive for the buckling load on
the tubes in the inner tube field. The loading area of a tube
shall be assumed to be the loading area given in 6.7.1.4 and
extended by the cross-sectional area of the tube.
Fig. 18. Circular, flat tube plate of heat exchanger with gland
in shell
6.7.6 Circular, flat tube plates of heat exchangers with
a gland sealing the floating tube plate
6.7.6.1 The required wall thickness of circular, flat tubepla-
tes of heat exchangers having a gland sealing the floating
tube plate as shown in Fig. 19 shall be calculated using for-
mula (27) taking into consideration for the fixed tube plate
P = Pi
. D:-D’4
0:
and
. 0:-D:
P = P” (29)
0:
and for the floating tube plate
0; - 41’
P = Pi ’ (30)
0:
and
0’4 - 412
P = Pu . (31)
0:
The maximum value of p obtained from the formulae (28) and
(29) and (30) and (31) is decisive for the design of the tube
plate. For the floating tube plate C5 shall be replaced by 0,45.
For the determination of 1 in formulae (30) and (31) appro-
priate reference shall be made to the provisions of 6.7.4.3.
6.7.6.2 The assessment of the tensile and compressive
stresses on the tubes, and of the buckling resistance, shall
be made through appropriate reference to 67.5 for the mean
load on the tubes.
6.7.7 Circular, flat tube plates with projecting flange
rings on heat exchangers
6.7.7.1 The required wall thickness s of circular, flat tube
plates with projecting flange rings as shown in Fig. 20 shall
be calculated for the range given by the design diameter D,
according to 6.7.1 to 6.7.6.
Page 7 AD-Merkblatl B 5, Edition 05.99
6.7.7.2 For through tube plates as shown in Fig. 20, the pro-
jecting ring shall be recalculated in cross-section C-C in
accordance with preliminary standard DIN 2505 (October
1964).
6.7.7.3 The axial stress in the shell shall be assessed as
appropriate in accordance with 6.7.1.7.
Fig. 19. Circular, flat tube plates on heat exchangers with a
sealing gland at the floating end
6.8 Rectangular flat tube plates in heat exchangers
Rectangular tube plates are dealt with in accordance with
6.7.1 to 6.7.6 depending on their shape and taking into
account the design factor CE from Fig. 2. This means multip-
lying the value for C by CE in each of the formulae concerned.
The values for C are determined in accordance with 6.4 from
the geometric conditions related to the short side of the plate.
In the relevant equations, replace the design diameter D, by
the length of the short side f of the plate.
C
--D,------ ;
Fig. 20. Circular, flat tube plates with projecting flange ring
7 Bibliography
[l] Mppl, A.: Vorlesungen ijber Techn. Mechanik; Bd. Ill,
Festigkeitslehre. Teubner Verlag, Berlin (1922).
[2] Timoshenko, S.: Theory of plates and shells. M CGRAW
Hill Book Company, Inc., New York/London (1940).
(31 Filonenko-Boroditsch: Festigkeitslehre, VEB Verlag
Technik, Berlin (1954).
141 Hampe, f.: Statik, rotationssymmetrischer Flachen-
tragwerke; Bd. 1. VEB Verlag fur Bauwesen, Berlin
(1966).
Page 8 AD-Merkblatt B 5, Edition 05.99

151 Fijpp, L., u. G. Sonntag: Tafeln und Tabellen zur Festig- illI Hijbner, F.-W.: Berechnung der Axialkraft von Ankern
keitslehre. Oldenbourg-Verlag, Miinchen (1951). und Ankerrohren zur zentralen Verankerung ebener
Miller, K.A.G.: The Design of Tube Plates in Heat- Boden. Techn. ijberwach. 9 (1968) Nr. 3, pp. 95197.
Fl
Exchangers. Proc. Inst. Mech. Engineers Series B, P21 Physikhutte 29. Auflage, pp. 240ff.
Vol.1 (1952) pp.215/31. 1131 Dietmann, H.: Spannungen in Lochfeldern. Konstruk-
[71 Sterr, G.: Berechnungsfragen von Rohrboden im tion 18 (1966) H. 1, pp. 12123.
Druckbehalterbau. Verlag Ernst & Sohn, Miinchen [I41 Nadai, A.: Die elastischen Platten. Springer-Verlag Hei-
(1967). delberg, Berlin, New York (1968).
181 Sterr, G.: Die genaue Ermittlung des C-Wertes fur die 1151 Sterr, G.: Die festigkeitsmaisige Berechnung von War-
am Rande mit einem SchuO verschweif3te Kreisvoll- metauschern mit geraden Rohren. Verlag TijV Bayer&
Platte unter Beriicksichtigung der im SchuO auftreten- Munchen (1975).
den Spannungen. Techn. ijberwach. 4 (1963) Nr.4,
1161 Hijtte I, 28. Auflage, pp. 940ff.
pp. 140143.
1171 Schwaigerer, S.: Festigkeitsberechnung im Dampfkes-
PI We/linger, K., u. H. Dietmann: Bestimmung von Form- sel-, Behalter- und Rohrleitungsbau; 4. Auflage (1983)
dehngrenzen. Materialprijfung 4 (1962) Nr. 2, pp. 41/47. Springer Verlag Berlin, Heidelberg, New York.
UOI Siebel, E.; Festigkeitsrechnung bei ungleichformiger
Beanspruchung. DieTechnik 1 (1946) Nr. 6, pp. 265/69.
 P a g e 9 AD-Merkblatt B 5, Edition 05.99

Table 1. Design factor9 for unstayed circular flat ends and plates without additional peripheral moment

Type of flat end design design factor

conditions
(principle only) c

1. knuckle radius: 0,30

a) flanged flat end

r
0, min.

upto 5 0 0 30
over 500 up to 1400 35
over 1400 up to 1600 40
over 1600 up to 1900 45
over 1900 50

and it 1,3s
2. bylindrical part h 2 3,5 s

1. knuckle radius: 0,35

b) forged or pressed flat end

r2 -$, however

at least 6 mm

2 . c y l i n d r i c a l p a r t h? s

c) flat plate welded into the shell from both sides plate thickness: s 5 3 s, 0,35
s>3s, 0,40

d) bolted flat plate with full face gasket D, 1 D, 0,35

e) flat plate with stress-relief groove’) 1. residual wall thickness at the groove: 0,40

,e ‘Elmr 1,3
aa- 2 K ’
t 1
but not less than 5 mm
and with D, > 1,2 D,, sR 5 0,77 s,

2. groove radius:
r 2 0,2 s, but not less than 5 mm, and

3. only killed steels shall be used. If plate

s, = effective wall thickness of the cylin- material is used, the plate shall show no
drical portion of the head at the junction evidence of laminations in the weld zone
with the cylindrical shell over a width of at least 3 s12).
page lo AD-Merkblatt B 5, Edition 05.99

Type of flat end design design factor

conditions
(principle only) C

f) plate welded to the shell with welds at plate wall thickness: s 5 3 s, 0,40
both sides of the latter S<3S, 0,45

only killed steels shall be used. If plate mate-

rial is used, the plate shall show no evidence
of laminations in the weld zone over a width
of at least 3 s,‘).

g) simply supported flat plate resrdual plate thickness at the gasket

circle or at the grooves: 0,40

SR 2 0.7 s

h) flat plate welded Into the shell from one stde only plate thtckness: s 5 3 s, 0.45
s>3s, 0.50

i) flat plate placed in front from the external side 1. residual plate thickness at the gasket 1,25
circle: se 2 0,7 s

Individual force 2. non-metallic gasket:

D, 5 500 mm
L

k) flat plate placed in front from inside residual plate thickness at gasket circle: 0,45
SR 2% 0,7 s

4
SR>O?S b
r 1

‘) Stress-relief grooves wth dlfferenf cross-sect!ons may be more effective in *) As a rule. this IS the case when the inspections are carned out as specified
redwng stresses and are acceptable If appropriate evidence is produced. I” Stahl-Elsen-Lleferbedlngungen SEL 072. Inspection Class 2 This can
be sttpulated at the time when the order is placed.
 Page 11 AD-Merkblatt B 5, Edition 05.99

Table 2. Design factors for circular flat ends and plates with central stay

flanged fiat end

a) with inward flange

or
2. cylindrical part h 2 3.5 s
b) with protruding stay

protruding stay
page 12 AD-Merkbiati B 5, Edition 05.99

ratio file

Fig. 2. Design factor CE for rectangular or elliptical flat plates

Elliptical plates
Rectangular plates f = short side of the elliptical plate
f = short side of the rectangular plate e = long side of the elliptical plate
e = long side of the rectangular plate

;s,A,.(;)i-’ ( 0,l < (6) I l , o

CE =
1,562 0 < (5) I 0,l 1
I A, = I,48914600
A, = I,58914600 A2 = -0,23934990
A2 = 4 2 3 9 3 4 9 9 0 A3 = -0,33517980
A3 = -0,33517980 A4 = 0,08521176
A4 = 0,08521176
 design factor cl

66’90 UO!W~ ‘s s uWWaW-aV El 3%

 ratio D,/d,
Fig. 6. Design factor CZ for central stays

A , = 0,4092%0
Central stays
A2 = -0,1073072. 10-l
D, and di = design diameters according to Table 2 from AD-Merkblatt 6 5 A, = 0.1128268. IO-’
A , = -0,1518604 lo-*
C, = ;= , A , . ( 2)i-’ / 5 5 2 5 32.5 A5 = 0,9880992 IO-“
A6 = -(I,3485928 1O-5
A , = 0,6391361 lo-’
A , = -0,4773844. lo-’
 Page 15 AD-Merkblatt I3 5, Edition 05.99

:e
applicable in accordant'LX
with boundary condition Nr
in table 1 and Fig. 5 fo

c, =0,68

Fig. 14. Design factor C4 for tube plates with U-tubes

(note: approximation functions in preparation)
 Page 16 AD-Merkblatt B 5. Edition 05.99

0,81.::.j..:I.- ::l:l::.:L::.!k:,~~.::~:...f~.~:~:;.:f~:~.:::::l
. .._ . ,. . ._,I.. . I.--f-..:,.
-... ..* .-.-,....,....,....,

applicable in accordance
with boundary conditions
in

Fig. 3 and 4
“clamped with additional
peripheral moment”

Table 1
Design type
c = 0,45
c = 0,40
c = 0,35

ratio ND,

Fig. 16. Design factor C5 for tube plates of heat exchangers with floating he ?ad

Design factor C, for tube plates with additional peripheral moment to Fig. 3 or 4
I = mean distance from plate mid-point of the tube row under consideration
D, = design diameter
or = pitch circle diameter
dn = mean gasket diameter
 Page 17 AD-Merkblatl B 5, Edition 05.99

A , , = -0,236012836.10+‘; A,2 = 0,545217668.10+‘; A,3 = -0,311489659~10+‘; A,4 = 0,308300374

A,5 = 0,168134309
API = 0,101396274 lo+‘; AZ2 = 0,109609483.10+‘; AZ3 = 0,162822737.10+‘; AZ4 = -XI,345692712
10”
A,, = 0,126083679 lo+’
A , , = -0,316517682 10+2; A32 = 0412763296.10+2;
, AD = -0,369557657.10+2; A34 = 0,248045141
10+2
A 35 = -0,727898100 lo+’
41 = 0,472852891 10+2; Ab2 = -0,522484275. IO+‘; Aa = -0,334202904.10+‘; Ati = -0,426049735 lo+’
Ad5 = 0,236709739 10’2
A 5, = XI,821294529 101”; AS2 = 0,122221210~10+3; A% = -0,167734885.10+3; AS4 = 0,166614761
10+3
A 5 5 = -0,574166821 lo+’

Design factor C, for tube plates without additional peripheral moment and where C = 0,45 to Table 1
1 = mean distance between centres of the tubes of the tube row considered from the plate midpoint
D, = d e s i g n d i a m e t e r

0 < ($ so,5
c5 = t ; A , , ($-’
i=l j=l 1
c5 L o,l’5

41 = -0,236012836. lo+‘; A,2 = 0,545217668.10+‘; A,3 = --0,311489659. lo+‘; A,., = 0,308300374

A ,5 = 0,168134309
A2, = 0,101396274.10+‘; A22 = 0,109609483.10+‘; A23 = 0,162822737.10+‘; As4 = -0,345692712.10+’
A 25= 0 13 2 6 0 8 3 6 7 9 . 1 0 ”

A31 = -0,316517682~10+2; A32 = 0,412763296.10+“; As = -O,369557657. 10+2; A34 = 0,248045141 ‘lo+’

A 35 = -0,727898100.10+’
A , , = 0,472852891. IO+‘; Ad2 = -X),522484275.10+‘; A , = -0,334202904.10+‘; A , = -0,426049735.iO+2
A 45 = 0,236709739 . 10”

A51 = -0,821294529. IO+‘; AS2 = 0,122221210-10+3; As = -0,167734885.10+3; AM = 0,166614761 . 1O+3

As5 = -0,574166821.10+’

Design factor C, for tube plates without additional peripheral moment and where C = 0,4 to Table 1
I = mean distance between centres of the tubes of the tube row considered from the plate midpoint
D, = d e s i g n d i a m e t e r

i=l
A, (;)i-’ 0 < (k) IO,5
1
c5 1 0,;5

A , = 0,399827021
A2 = 0,870316825
A3 = -0,547933931.10+’
A4 = 0,622283882.10+’
A5 = 0,747769988 . lo+’
As = -0,208753919.10+2

Design factor C, for tube plates without additional peripheral moment and where C = 0,35 to Table 1
I = mean distance between centres of the tubes of the tube row considered from the plate midpoint
D, = d e s i g n d i a m e t e r

A,. (+)i-’ 0 < (k) so,5

i=l 1
c5 2 0.;5

A, = 0,350103983
A2 = 0,426355908.10-2
A3 = -0,153280871
A4 = -0,474043872. lo+’
A5 = 0,109862460 . 1 0+2
A6 = -0,103370105~10+2
page 18 AD-Merkblatt B 5, Edition 05.99

Fig. 21. Opening factor Ca for flat ends and plates without additional peripheral moment

d = inside diameter of Opening

Type A D, = design diameter
d = inside diameter of opening f = short side of elliptical end
0, = design diameter
0<($).0.8
f = short side of elliptical end A,. ($)I-’ I 1 \
‘i 1
IS1
6 0<(+0,8 \
I
1
I , =, A..($)‘-’
1
1 c, =
.i,~, A,.($)‘-’
\ O<: ($) 5 0>8 I

I
0 < ($) I 0,8 I
A,. (+)I-’ I
A, = I,00100344
A2 = OS94428468
A, = 0,99903420 A3 = -4,31210200
A2 = I,98062600 A4 = 8,38943500
A3 = 9,01855400 A5 = -9,20628384
A4 = 18,63283000 A6 = 3,69494196
A5 = 19,49759000
As = 7,61256800
 Page 19 AD-Merkblatt B 5. Edition 05.99

dildt, and d,lf =

1.6

ratio dildo and d,lf

Fig. 22. Opening factor CA, for plates with additional peripheral moment

d = inside diameter of opening

d, = pitch circle diameter
d, = mean gasket diameter
f = short side of an elliptical end

0 < (Z) IO,8

A,, ($)‘-’ ($j-’ 0
I=1 ]=l
1,o I (2) I 1,6
CA! = I 0
0 < (S) IO.8
.i 2 A , , (;)i-’ (+)j-’ D
I I=1 JZl
1,o I (2) 5 1,6
0

A,, = 0,78361000; A,2 = 0,57648980; A,3 = - 0,50133500; A,4 = 0,14374330

AZ, = - 6,17657500;A , = 25,97413000;AZ3 = - 20,20477000;AZ4 = - 5,25115300
AZ, = - 55,15520000;As2 = -187,50120000; A , , = 151,22980000;AN = -40,46585000
A 4, = -102,76280000; Ah2 = 385,65620000;Aa = -328,17740000;A+, = -92,13028000
&I = 17,63476000;As2 = -218,65220000;As = 223,86580000; A% = -71,60025000
A 61 = 76,13799000;Ae2 = - 99,25291000;Ae3 = 46,20896000; AM = - 3,45883000
Page 20 AD-Merkblatt B 5, Edition 05.99

d = inside diameter of opening

d, = pitch circle diameter.
dD = mean gasket diameter
f = short side of an elliptical end

0 < (+) 5 0,8 '

ii=l ;j=l A,, ($)i-’ gjj- D

1,O 2 (5) -i 1,6

CA, = I 0

0 < (;) 5 0,8

0

1,0 5 (2) 5 1,6

0

41 = 1,00748900; A,, = - 0,02409278; 43 = 0,02144546; A,4 = - 0,004895828

A 21 = 3,20803500; A , , = - 1,09148900; A23 = 1,55382700; A24 = - 0,423889000
A 3, = -13,19182000; As2 = 10,65100000; AD = -13,27656000; AM = 3,525713000
A 4, = 30,58818000; A,, = -44,89968000; Ad3 = 47,62793000; AM = -11,93544OooO
A 5, = -43,36178000; A,, = - 7 9 , 5 6 7 9 4 0 0 0 ; A, = -71,67355000; As = 16,794650000
A 61 = 42,25349000; A,, = - 9 2 , 6 4 4 6 6 0 0 0 ; A,, = 74,76717000; AM = -17,856930000
 P a g e 21 A D - M e r k b l a t t B 5. Edition 0 5 . 9 9

Appendix 1 to AD-Merkblatt 6 5

Explanations to AD-Merkblatt B 5 Substituting the numerical value for v and dividing by

s, - c, - c2 gives:
W p .D4
To 1 = 0,5 = . 0,00435 (4)
se-c, -c, E . (s, - c, - c&4
The question of differentiating numerically, for plate design,
between thick plates and membranes is one that has not yet Resolution using (s, - c, - c,)lD finally gives:
been finally settled in the literature. In the present case, in
keeping with the data of Kantorowitsch [i], a wall-thickness/
diameter-ratio of I:3 has been adopted as a limit to distingu-
ish thick plates. The lower limit for defining extremely thin pla-
tes was fixed such that, in the exact design of plates com- To 6.5.2 and 6.7.1.6
pared with design in accordance with AD-Merkblatt B 5, a Allowance can be made for thermal stresses occurring in
maximum error of 5 % can occur. This error results for the accordance with AD-Merkblatt S 3/O.
worst case of the simply supported plate with a plate deflecti-
on/plate thickness-ratio of 05. To 6.5.3
From the formula for the deflection of the simply supported In order to allow buckling cases encountered in practice to
plate. be embraced in a more discriminating manner, various load
cases have been defined for buckling. In the present case,
p . R4 5+v this is done in such a way that, as the buckling length lk, a
.- multiple of the existing bar length can be substituted accord-
w= 10,64.N 1 +v
ing to the load case.
E (s, - c, - c2)3
where N = this gives: Bibliography
12(1 -t2)
[i] Kantorowitsch, S. 8.: Die Festigkeit der Apparate und
p . 04 12 (1 - I”) (5 + v) Maschinen fur die chemische Industrie. VEB-Verlag
w= F(s,-c,-c2)3’ 10.64.16.(1 +v) Technik, Berlin (1955).
UDC 621.642-98.001.24:62-213.6-434.1 Edition January 1995

Design Cylindrical shells subjected AD-Merkblatt

of
to external overpressure B6
Pressure Vessels

The AD-Merkblstter are compiled by the seven trade associations specified below who together form the ‘Arbeitsgemeinschaft Druck-
beh%/ter” (AD). AD-Merkblatt G 7 covers the composition and application of AD-Regulafions and a/so procedural guidelines.
T h e AD-Merkbltitter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . I n t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal level expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e. g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e.V. (FDBR), Diisseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e. V., Sankt Augustin
Verband der Chemischen lndustrie e.V. (KY), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, FrankfurtlMain
Verein Deutscher Eisenhijttenleute (VDEh), Diisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkraWerksbetreiber e . V . , E s s e n
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkblfitter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s t o k e e p w i t h t h e s t a t e - o f - t h e - a r t . R e l e v a n t p r o p o s a l s s h o u l d b e
addressed to the publisher:
Verband der Technischen Ciberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents

1 Scope 6 Weakenings
2 General 7 Calculation
3 Symbols and units 8 Minimum wall thickness
4 Safety factor 9 Literature
5 Exploitation of the permissible design
stress in welded joints Appendix 1: Explanations

1 Scope 3 Symbols and units

The design rules below apply to smooth cylindrical shells ser- In addition to AD-Merkblatt 6 0 the following applies:
ving as shells of pressure vessels and to tubes subjected to b double taper length in mm
external pressure having a D&ratio 5 1,2. In the case of Im length of cylinder between effective
tubes with D, 5 200 mm they apply furthermore up to a ratio reinforcements (buckling length) in mm
DJDi = 1,7. The cylindrical shells may be reinforced or I
m supporting shell length in mm
unreinforced.
Pe elastic buckling pressure of stiffening in bar
The pressure must act over the entire periphery. Additional q in this context: flattening in mm
account must be taken, e.g. in accordance with [IO], of axial U out-of-roundness in %
loads which are higher than those attributable to the external G auxiliary calculation quantity
overpressure. H auxiliary calculation quantity

2 General
4 Safety factor
2.1 This AD-Merkblatt shall only be used in conjunction with
AD-Merkblatt B 0. 4.1 The coefficients of safety for plastic deformation are
given in Table 1. The coefficient of safety S’ at the test
In the case of heat-exchanger tubes, except where special
pressure is given in AD-Merkblatt B 0.
agreements are reached between manufacturer and opera-
tor, the margin to be allowed for thinning is cp = 0. 4.2 The safety factor for elastic buckling, irrespective of
2 . 2 In the case of pressure vessels made of grey iron, the the material, is SK = 3,0 and is valid for u I 1,5%, with u
being determined in accordance with Section 7.3.4.
performance of design calculations for internal pressure
using the safety factors given in Table 1 is sufficient, for In the case of u > 1,5%, SK = 2,25 + 0,5 u. Where a
which purpose the external overpressure is substituted for testing pressure greater than 1,3 p is stipulated, S;, must
the internal pressure. be at least 2,2 S&/3.

Supersedes Edition November 1992; ) = Amendments to previous Edition

_
CarlHeymannS Verlag Kti - .--.
Translation: Technical Help to Exporters Service of BSI
Luxemburger StraOe 449, 50939 K6ln
GutenbergstraRe 3, 10587 BerIm
P a g e 2 AD-Merkblatt B 6. Edition 01.95

Table 1. Safety factors (see Section 4.1)

1
Safety factor for elastic
Material limit, yield point or
creep strength
-1
1. Rolled and forged
steels 1,6
2. Cast steel 2,o
3. Spheroidal-graphite Fig. 1. Double shell
cast iron to
DIN 1693 Yp I
3.1 GGG-70
GGG-60 50
3 . 2 GGGdO 490
3 . 3 GGG-40 3,5
3 . 4 GGG-40.3
GGG-35.3 24
4. Aluminium and its
alloys
- malleable
materials 126

Safety factor for tensile Fig. 2. Square-sectional rings as stiffeners

strength

5. Grey iron to %l
DIN 1691 60
6. Copper and its
alloys including
rolled and
cast bronze 4,O

5 Exploitation of the permissible design

stress in welded joints Fig. 3. Sectional rings as stiffeners

irrespective of the scope of testing as defined in AD-Merk-

blatt HP 0, General Table 1, when performing design CalCUla-
tions for external pressure the exploitation of the permissible
design stress in welded joints need not be considered.

6 Weakenings I
I 8
Calculations for cut-outs shall be performed in accordance
with AD-Merkblatt B 9, with p as the internal pressure. Cut- Fig. 4. Half-round heating ducts as stiffeners
outs in double shells which are braced relative to one another
by nozzles and not be considered when calculating the wall
thickness.

7 Calculation
7.1 General
7.1 .l Calculations shall be performed for elastic buckling in
accordance with Section 7.2, and for plastic deformation in Fig. 5. Square-section heating ducts as stiffeners
accordance with Section 7.3. The lowest calculated value
for p, andp, is the essential factor in establishing the permis-
sible service overpressure. forcing elements (see Figs. 2 to 5). In the case of vessels with
7 . 1 . 2 The buckling length 1 is the length of the double shell domed heads, the buckling length starts at the transition point
(see Fig. I), or the distance between a pair of effective rein- between the cylindrical rim and the end-plate flange region.

se - c, - c, 80 . +2”2-‘-2v (1)
2 Da + 12 (l-V2)
1+ “z
0 ,
 Page 3 AD-Merkblatt B 6. Edition 01.95

Pipe bends are not considered effective stiffening [9]. Simi- 7.3.4 For the out-of-roundness u expressed in %, the
larly compensators are not usually regarded as effective stif- following equations are applicable:
fening. Due to the absence of support at this side of the cylin- where the circumference is oval:
der shell, formulae (1) (4) (5) and (6) do not apply. Such
Di max - ‘i min
cylinder shells can be conservatively calculated using for- (7)
’ = 2 ’ Di max + Di min ’ loo
mula (3).
and where the circumference has a flattened portion: (see
Fig. 9)
7.2 Design calculations for elastic buckling
u=+.q.100 (8)
a
7.2.1 Calculations are performed using equation (l),

with Z = 0,5Ga
I and
a) n integral
b) nz-2
c) rJ>Z
so determined that the value for p, is a minimum. n denotes
the number of ridges produced by the buckling process which
may occur at the periphery in the event of failure. The number
of buckling ridges can be estimated using the following
approximation equation [5]: Fig. 9. Flattening q

0,” The maximum and minimum diameters D, ,,,= and D, m,n are
n = 1,63 . 4
J 12 (se-c, -c2)
(2) governed by the manufacturing conditions (for permissible
degress of out-of-roundness, see AD-Merkblatt HP 1).
7 . 2 . 2 The required wall thickness s can also be determined For tubes/pipes, the out-of-roundness can be determined
for dimensions commonly employed using Fig. 6. This illu- using equation (7) with the maximum and minimum external
stration is valid for a poisson’s ratio of v = 0,3. For poisson’s diameter. The diameters are obtained from the Technical
ratios which differ appreciably, calculations shall be perfor- Supply Conditions (Technische Lieferbedingungen) stipulat-
med using equation (1). ed in the Standards.

7.2.3 For tubes/pipes, calculations can also be performed

using equation (3): 7.4 Stiffeners
3
s, - c, - c,
( 0, )
E -. 20 7.4.1 Sealing ends, such as externally domed ends or heat-
Pl =‘s;;., --2 (3)
exchanger ends for example, that are mutually anchored by
the tubes and shell may be regarded as effective stiffeners.
7.3 Design calculations for plastic deformation This also applies to the designs in Figs. 2 and 3 if the conditi-
ons in equations (9) and (10) are satisfied in conjunction
7.3.1 For F cr 5, equation (4) is applicable: (4) which equations (11) and (12).
In order to determine geometrical quantities A,,,, W, and I,
p -20.K.Se-Cf-C2. (see Figs. 2 and 3) the supporting shell width I, must first
2
s 0.3 be determined using equation (12). The geometrical moment
, +1,5+~0,2 +.Da of inertia I, and the section modulus W, are to be referred
to the centre-of-gravity axis of the cross section that is
100 (se-c,-c2)
parallel to the shell axis (see x-x axis in Figs. 2 and 3) which
consists of the cross section of the stiffener and the suppor-
7.3.2 For commonly employed dimensions and with an out-
of-roundness of u = 1,5 %, the required wall thickness s can ting part of the shell of length 1,. D, is the relevant centre-of-
gravity diameter.
be determined directly with the aid of Fig. 7.
For the case of tubes/pipes where the out-of-roundness is p . SK < Pe (9)
greater, the required wall thickness s can also be determined
as a simplification using Fig. 8. p . I , . D, + p . 1. D,’
(10)
20 . A,,, 8000 . W,,, . 1 -SK4 p/p, zc -!G
7.3.3 For Dal1 > 5, the higher pressure obtained using
equations (5) and (6) is the determining factor for the estab- 240 . E . I,
lishment of the permissible service overpressure. (‘1)
where pe = (1 -v”) . (Da-s, + c, + c2) * 0; . 1
p2 = 20 K . Se - C I - C2
(5)
S & and I, = b, + b = 1,l . JDa * (s. - Cl - C2) + b (12)

2 whereby a length exceeding length 1 must not be used for the

Equation (6) is applicable above all where the stiffened
lengths are short (e.g. in the case of heating ducts as illustra-
ted in Figs. 4 and 5).
length f, which is also carrying the load. The strength charac-
teristic value of the stiffening ring is to be used for K.
Narrow, high stiffeners as shown in Fig. 2 may buckle; the
height of the stiffener shall therefore not exceed 8 times the
Page 4 AD-Merkblatt B 6, Edition 01.95
width. For profiles as shown in Fig. 3, the required geo-
metrical moment of inertia relative to the centre-of-gravity
h“
axis y-y depends on the profile height h and is Is? -
3000
7 . 4 . 2 In the design of the whole shelf an allowance can be
made for the effect of heating ducts (see Figs. 4 and 5). In
equation (1) the permissible pressure will then be increasing
in the ratio of moments of inertia with and without heating
ducts (referred to the relevant centre-of-gravity axis x - x or
x’ - x’) and in equation (4) in the ratio of the cross sectional
areas of vessels with and without heating ducts.
7.4.3 Where reinforcing elements are joined to the shell by
means of discontinuous welds, the fillet welds at each side
must encompass at least one third of the shell circumference.
The pitch adopted for the fillet welds in the peripheral direc-
tion must be at least 300 mm, and the number of weld discon-
tinuities must be at least 2 n. The number n of buckling ridges
is obtained as indicated in Section 7.2.1.
8 Minimum wall thickness
8.1 For the minimum wall thickness of seamless, welded or
brazed cylindrical shells, the stipulated value is 3 mm.
8 . 2 Contrary to the stipulation made in Section 8.1, for the
minimum wall thickness in the case of cylindrical shells made
of aluminium and its alloys, the relevant value is 5 mm.
8 . 3 For exceptional cases, reference shall be made to AD-
Merkblatt B 0, Section 10.
8 . 4 In the case of heat-exchanger tubes, the minimum wall
thickness may be less than the values stipulated in Sections
8.1 and 8.2.
9 Literature
[I] Hiitte I., 28. Auflage, S. 953. Verlag Ernst und Sohn,
Berlin.
PI Meincke, H.: Berechnung und Konstruktion zylindri-
scher Behalter unter AuRendruck. Konstruktion 11
(1959) Nr. 4, S. 131/38.
131 v. Mises, R.: Der kritische AuRendruck zylindrischer
Rohre. VDI-Z 58 (1914) Nr. 19, S. 750/55.
141 Schwaigerer, S., u. A. Konejung: Die Festigkeitsbe-
rechnung von Flammrohren. Konstruktion 2 (1950)
Nr. 1, S. 17123.
151 v. Reth, Th.: Unmittelbare Berechnung der Beulwellen
in Gleichung (1) des AD-Merkblattes B 6. TU 12 (1971)
Nr. 12, S. 362.
(61 BS 5500 - Specification for unfired fusion welded pres-
sure vessels, 1982; herausg. v. British Standards Insti-
tution.
(71 Link. H.: Berechnunq rinoversteifter Bohrschachtver-
rohrungen aus Stahl in den USA (Design of Ring-
stiffened Pit Pipework Made of Steel in the USA).
Structural Steel Engineering 9 (1981) p. 284/287.
PI Ebner, H.: Festigkeitsprobleme von U-Booten. Schiffs-
technik, Forschungshefte fur Schiffsbau und Schiffs-
maschinenbau 14 (1967) H. 74, S. 95/l 13.
PI Meincke, H.: Rohre in Apparaten unter AuOendruck.
Chem.-lng.-Technik 3 (1978) S. 215/17.
Deutscher Ausschu8 fur Stahlbau: Beulsicherheits-
[lOI
nachweise fur Schalen, DASt-Richtlinie 013, Juli 1980.
t111 Feder, G.: Zur Stabilitat ringversteifter Rohre unter
AuOendruckbelastung (Stability of Ring-stiffened Tubes
Subjected to External Pressure Loading). Schweize-
rische Bauzeitung, 89, Annual Set, Volume 42 (21. 10.
1971) p. 1043/1051.
 Page 7 AD-Merkblatt B 6, Edition 01.95

T
v,
Y
Q
0

01 (+b-=s)
-2
=a
Page 8 AD-Merkblatt B 6, Edition 01.95

Appendix 1 to AD-Merkblatt B 6

Explanations to AD-Merkblatt B 6

To No. 4.2 and 7.3.4 To No. 7.2.3

Available experience indicates that SK = 3,0 is adequate in
the case of out-of-roundness up to u = 15 %. The influence
associated with the out-of-roundness was determined in
accordance with the literature [4], the basis adopted being
SK = 3,0 for u = 15 %.
According to AD-Merkblatt HP 1 Table 1, out-of-roundness
may not usually exceed 15% in the presence of external
pressure stresses and where slD ratios do not exceed 0,l.
In the case of tubes to AD-Merkblatt W 4 and tubes made of
austenitic steels to DIN 2462 and 2463, the safety factor for
elastic buckling in normal cases can also be determined
directly, as an approximation, as a function of the nominal
diameter of the tube (DN in mm):
10sDNc50:SK=8,25-+
50<DN : SK = 3,25
Equation (3) is an exact expression for the cylindrical shell
of infinite length (D,/l = 0), and can be derived from equation
(1). Using equation (3), the pressures obtained are lower
than when equation (1) is employed. The differences are plot-
ted for various Da/I-ratios in Fig. l/A. For the ratios s/D,
> 0,0025 and Da/1 < 0,04, thedifferencesare lessthan 5 %.
To No. 7.3.2
Fig. 8 is an exact representation for the cylindrical shell of infi-
nite length (D,/[ = 0). For cylindrical shells of infinite length,
the pressure obtained are lower than when equation (4)
is employed. The differences are plotted for various
D,il-ratios in Fig. 2lA. For ratios of Dal1 5 0,2, the differences
are less than 5 %.

Fig. l/A. Design calculations for elastic buckling - differences

between the pressures determined using equations (1) and
(3), plotted as a function of (s, - c, - c,)lD, and Da/I.

Fig. 2/A. Design calculations for failure due to plastic deformation -

differences between the pressures obtained using equation
(4) and those obtained according to Fig. 8, plotted as a
function of (s, -c, - c,)lD,, Da/I, and the out-of-roundness u.
 P a g e 9 AD-Merkblatt B 6, Edition 01.95

To No. 7.4.1 pressure for defining the permissible working pressure can
be determined directly:
Equation (10) originated from the derived equation in the
literature [4] and [7]

p - lm . Da + P * 1. D,” .-
u= 20. A , 8000. W, 1 -;,p, (A 1)
20 . A,,,
where G = 2. Pe . I, . Da (A 3)
Equation (A 1) was modified so that safety factor S is
obtained in the purely plastic range and safety factor Sk at
least is obtained in the purely elastic range. Equation (A 1) (A 4)
modified in this way resulted in equation (10) making allo-
wance for the specified dimensions. If this is resolved and the values for pe and 1, are according to equations
according to p taking into account equation (9) the decisive (11) and (12).
 B
m
m

“I b,l 0,15 0,2 0,3 0,4 0.5 0.6 0.7 0,8 1 1,s 2 3 4 5 6 7 8 1 0 15 20 30 40 50 60 70 80 100
-.
f~ ’ sK 1o5 -)
E
Fig. 6. Required wall thickness s for designs resistant to elastic buckling
0.03 0,04 0,OS0.06 0,oa 0.1 0,15 0,2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 V 2 3 4 5 6 7 8 910

0,03 0,04 0,05 0,06 0,08 0,l 0,15 0,2 0.3 0,4 0,5 0,6 00.8
,7 0,9 1 1.5 2 3 4 5 6 7 8 910

Fig. 7. R e q u i r e d w a l l t h i c k n e s s s f o r d e s i g n s r e s i s t a n l e l a s t i cd e f o r m a t i o n 10.7-
P. s
UDC 621.642-98.001.24:621.882.2 Edition June 1986

Design AD-Merkblatt
of Boltings
Pressure Vessels I37

The AD-Merkb/&fer are compiled by the seven trade associations specified below who together form the “Arbeifsgemeinschafi Druck
3ehdlter” (AD), AD-Merkblatf G 7 covers the composition and application of the AD-Regulations and a/so the procedural rules.
The AD-MerkblWer cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses eve,
snd above the normal /eve/ being anticipated during the operation of pressure vessels, allowance must be made for such stresses b]
neefing special requirements.
Should there be any departures from the provisions of this AD-Merkblaft, it must be possible to demonstrate that the safety standard:
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis
3perafing experience.
Fachverband Dampfkessel-, Behdlter- und Rohrleifungsbau e.V (FDBR), Diisseldorf
H a u p t v e r b a n d d e r g e w e r b l i c h e n B e r u f s g e n o s s e n s c h a f t e n e . V . , S a n k t Augustin
Verband der Chemischen lndustrie e.V (VCI), Frankfurt/Ma/n
Verband Deutscher Maschinen- und Anlagenbau e. !JI (VDMA), Fachgemeinschaft Apparatebau, Frankfurt/Main
Verein Deutscher Eisenhijttenleute (VDEh), Dijsseldorf
VGB Technische Vereinigung der GroOkraffwerksbetreiber e.V., fssen
Vereinigung der lechnischen iiberwachungs-Vereine e.V (VdTiiV), Essen.
T h e AD-Merkblafter a r e a m e n d e d c o n t i n u o u s l y b y t h e t r a d e a s s o c i a t i o n s U? k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s shouk
be addressed to the publisher:
Vereinigung der Technischen ijberwachungs-Vereine e. V., Postfach 103834, O-4300 Essen 1.

Contents

1 Scope 6 Calculation
2 General 7 Allowances
3 Symbols and units 8 Minimum permissible
4 Design temperature bolt diameter
5 Safety factor 9 Literature

I Scope
This AD-Merkblatt applies to the design of bolting which as
non-positive connecting element is predominently subjec-
ted to static tension. Additional loads due to thermal influ-
ences e.g. local or temporary thermal gradients, different
thermal expansion coefficients and the like or external for-
ces e.g. from connecting pipe work are not covered by this
AD-Merkblatt and should be considered separately’) if
required.
2 General
2.1 This AD-Merkblatt shall only be used in conjunction
with AD-Merkblatt B 0.
2.2 In order to make a bolted connection as elastic as
possible, it is recommended to design it with neckeddown
bolts to DIN 2510. Neckeddown bolts should be applied if
he design temperature exceeds 300°C or if the design
3ressure is higher than 40 bar. Care has to be taken that
adequate effective bolt length is available which can be
ncreased e.g. by sleeves to DIN 2510. The length of the
oolt shank must be at least twice the thread diameter.
2.3 Neckeddown bolts are regarded to be bolts having a
shank diameter d, P 0,9 dK or having dimensions accord-
1) e.g. slmllar to preliminary standard DIN 2505 (10.64).
ing to DIN 2510. Bolts with no reduced shank are regardec
to be rigid as far as design is concerned.
2.4 For bolts to DIN 267 and DIN 2510 calculation of the
thread load is not required provided the lengths of nuts ant
engagements given in these standards are taken intc
account. Lengths of engagement may be taken from e.g
DIN 835, 938, 939 and 940 which give required lengths o
threaded ends for various materials.
2 . 5 In the case of standardized pipe flanges the bolts an
deemed to meet these requirements if number and diame
ter comply with the relevant pipe flange standard and tht
permissible service temperature for these flanges is no
exceeded. For design temperatures higher than 120°C ant
materials specified in the pipe flange standards the permis
sible design pressure is to be reduced either according tc
the decrease of the yield strength with the temperature o
to DIN 2041. This applies, however, to materials to AD
Merkblatt W 7 only. Higher temperatures can also be con
sidered by using materials with accordingly higher yielc
point.
2 . 6 For shell flanges to DIN 28032,28034 and 28038 the
bolts are deemed to meet the requirements above if they
comply with DIN 28030.
2 . 7 Bolted flange connections should have as much bolts
as possible in order to obtain optimal tightening condition:
and a pitch as small as possible (see AD-Merkblatt B E
Section 2.3).

Supersedes Edition February 1977; j = Amendments relating to previous edition

Carl Heymanns Verlag KG

Luxemburger StraOe 449. 50939 Kijin
Page 2 AD-Merkblatt B 7, Edition 6.86

2.8 The contact face of bolts and nuts should at least test pressure p’ is higher than 1,3p then the bolt load should
comply with quality grade mg, and the thread with quality also be determined for the testing condition.
grade m to DIN 267.
6.1.2 Circular bolted flange connections with the
gasket within the bolt-circle diameter
2 . 9 Consult also AD-Merkblatt A 5, Section 3 regarding bol-
ting design. Bolt hooks subjected to unilateral loads shall not 6.1.2.1 The minimum required bolt load is for the service
be used. condition
2.10 Flanges with slot and key or spigot and socket, or plain Fss = h3 + FF, + &I6 (1)
flanges with special gaskets (flanged gaskets, spiral asbe- with the components
stos gaskets with forced-in wire-mesh) shall not be used for
inflammable or toxic gases. & = P .7 d?

40
(2)

f _ p-n.(&-d*)
1_
3 Symbols and units FB - (3)
40
In addition to AD-Merkblatt S 0 the following applies:
bo effective width of gasket in mm P
f36= 10 .7. dD . SD k, (4)
C5 design allowance for rigidly connected bolts in mm
dK root diameter of bolt thread in mm where SD = 1.2.
ds shaft diameter of a bolt in mm The formulae (1) to (4) may be applied for the testing condi-
n number of bolts - tion accordingly.
AD area in compression in mm2 6.1.2.2 The minimum required bolt load is for the bolting-up
K D,Y dimension stability of gasket material condition
at the design temperature in N/mm> F Dv = ;I dD k, K, (5)
&I mean gasket crrcumference in mm
X number of grooves - If the setting load F,, is greater than F,, it may be replaced
- in the case of soft gaskets by
v in this context: auxiliary factor
F;, = 0,2 FD, + 0,8 ‘J’-, (6)
4 Design temperature
6.1.2.3 In order to keep the gasket load and the bolt load
The design temperature depends on the type of bolted con- adhered to as small as possible it is recommended to design
nection and the thermal insulation. If there is no extra proof the gasket as narrow as possible (e.g. to DIN 28040) taking
of the bolt temperature or if the bolting is not in direct contact the permissible surface pressure (e.g. DIN 3754) into
with the vessel content having a temperature higher than account. For soft gaskets and metal coated soft gaskets per-
50°C then the design temperature of the bolting may be assu- manent setting after first pressurization may occur. This is
med to be lower than the maximum temperature of the vessel to be compensated by tightening the bolts.
content by For metal gaskets the permissible load during service is
a) 30°C with thwo loose type flanges connected
b) 25°C with one integral type and one loose type flange FDa = n . dD . k, . K,, (7)
connected resp. for grooved metal gaskets
c) 15°C with two integral type flanges connected.
FDe = . z . d,, . fi . /co . KDIt (8)
These temperature differences consider the decreased tem-
peratures in the case of insulated bolted connections. Further with K,, to be taken from Table 2.
reduction without extra proof of the bolt temperature is not The bolted flange connection remains tight after several
acceptable even for bolted flange connections without insu- starts and stops only if
lation operating at lower temperatures which produce higher
FDB 2 Fss (9)
thermal stresses in the bolted connection though the bolt
temperature is lower. For permissible service temperatures If the permissible gasket load is exceeded it is recommended
below -10°C refer to AD-Merkblatt W IO. to shift to a more suitable gasket material or gasket type.
6.1.2.4 The gasket characteristics k,, k,, and KD resp.
k,, . KD are to be taken from Tables 1 and 2 taking into account
5 Safety factor that the characteristics for gases and vapours only apply for
Safety factors should be determined to Table 3 with Q; = 0,75 the service condition. Characteristics for other gasket types
for bolts with unmachined but parallel contact surfaces, eye- and shapes should be determined by tests.
bolts and hinged bolts; p = 1,O for machined or equivalent 6.1.3 Circular bolted flange connection with full-face
contact surfaces. Non parallel contact surfaces are not per- gasket
missible.
The bolt load should be determined to formulae (1) to (6).
Where the gasket diameter dD is qual to the bolt-circle dia-
6 Calculation meter dt and bD to Table 1 is equal to half the effective width
of the gasket.
6.1 Determination of the bolt load
6.1.4 Rectangular and other bolted flange connections
6.1 .l General having the gasket within the bolt-circle diameter
The bolt load should be determined for the bolting-up condi- The minimum required bolt load for the service condition is
tion prior to pressurization and the service condition. If the for rectangular bolted flange connections
 P a g e 3 AD-Merkblatt B 7, Edition 6.86

Intermediate values are to be interpolated linearly according

Fse= $[e.f+2SD(e+f).kl]
to
and for other bolted flange connections
6 5 - Z . FSB
-
fgs= +(A,,+So.UD+,) J K. n
(11) cg =
15
with So = 1,2.
The formulae (10) and (11) may be applied for the test con- For neckeddown bolts cs = 0. Deviating from AD-Merk-
blatt B 0 further allowances are not required.
dition accordingly.
The minimum required bolt load for the bolting-up condition
is for rectangular bolted flange connecGons

FDv = 2 (e + f) k. . K, (12) 8 Minimum permissible bolt diameter

and for other bolted flange connections Generally bolts smaller than M 10 or equivalent root diameter
are not permissible. For special applications (e.g. bolts for
F,” = UI, /CO . K, fittings) smaller bolts may be used, however, not smaller than
(13)
M 6 or equivalent diameter.
The values fore, f, AD and Ur, are referred to the mean contact
line of the gasket.
Formula (6) may be applied accordingly. Table 2. Deformation resistance KD and KD* of metallic
gasket materials
6.1.5 Rectangular and other bolted flange connections
with full-face gasket Gasket
material
The bolt load should be determined to formulae (IO) through
(13). The values for e, f, AD and UD are referred to the bolt
hole centres and b,, to Table 1 is equal to half the effective sofl aluminlum
copper
width of the gasket Formula (6) may be applied accordingly. soft Iron
steel St 35
alloy steal
6.2 Determination of bolt diameter 13 CrMo 44
The required root diameter dK for rigid bolts resp. shank dia- austenltic
steel
meter d, for neckeddown bolts of a bolted flange connection
with n bolts is the greatest of the following Intermediate values are to be Interpolated

dK resp. d, = Z. * + c5 (14) Table 3. Safety factor S, auxiliary factors Z and q

-\i.
for the service condition Materia!s having a yield point]
and where the safety factor
I refers to the yield point Materials havmg
FSP resp ue/1OOooO no yield point an<
&resp.d,= Z. - (15) Condition and where the safety
K20 . ”
N e c k e d d o w n I/
quality factor Bolts factor refers to th
t0e.g. tensile strength
for the testing condition bolts, DIN 2509
I D%g& / DI&3,
FDV 1 I
d,resp.d,= Z. ~ Service
Kzo . ” 5 = I,5 s = I,8 s = 5,o
condition
for the bolting-up condition
For I
I v = 025
4.s p= 1.00
1 ;I;$ / ;r;;; ; :I;;;;
with Z to Table 3 resp. Z = - ~.-.--
n.p7
Bolting- up and ’
For neckeddown bolts with bore d, is to be replaced by test condition s = 1.1 5 = I,3 5 = 3.0
__.-__ ..__-
Vd$ - d2 in formulae (14) through (16) where d is the bore
diameter. For
v = 0,75 2 = 1.37 z=1,49 ( z = 2.26
9= l,W Z = 1.18 Z=i,i9 i z = 1,95

7 Allowances
9 Literature
For rigid bolts in the service condition the design allowance
to formula (14) is [l] Trutnovsky, K.: Dichtungen; Werkstattbuch Nr. 92. Sprin-
ger Verlag Berlin, Heidelberg, New York.
[2] Schwaigerer, S.: Festigkeitsberechnung im Dampfkes-
F sel-, Behalter- und Rohrleitungsbau. 4. Auflage (1983).
c,=3mm,if Z. 2520mm (18)
K.n Springer Verlag Berlin, Heidelberg, New York.
resp. [3] Schwaigerer, S.: Die Berechnung der Flanschverbindun-
gen im Behglter- und Rohrleitungsbau. VDI-Z. 96 (1954)
c5= 1 mm,if Z.1 Ii
xr50mm (1% Nr. 7.
Page 4 AD-Merkblatt B 7, Edition 6.66

Table 1. Gasket characteristics

jacketed asbestos

1) They apply machined. flat and sound faces. Deviations are possible 4) Gas tight quality provided.
prowded adequate proof has been furntshed. 5) The valves do not apply for grooved metal gaskets wth support.
2) Where k , c a n n o t be given the product of k, K,. 6) The bolt load is to be increased by the ratio y,iy2 of the mOment arms.
3) Polytetrafluorineethylene.
ICS 23.020.30 Edition February 1998

Design AD-Merkblatt
of Flanges
Pressure Vessels B8

T h e AD-Merkb@itter a r e c o m p i l e d b y t h e s e v e n a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “Arbeitsgemeinschaft Druckbehdlter”

(AD). AD-Merkblatt G 1 covers the composition and application of AD-Regulations and also procedural guidelines.
T h e AD-Merkb&tter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . In t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e. V. (FDBR), Dijsseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e. V., Sankl Augustin
Verband der Chemischen lndustrie e. V. (VCI), FrankfurtfMain
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Diisseldorf
VGB Technische Vereinigung der GroLJkraftwerksbetreiber e.V., Essen
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-MerkbHter a r e a m e n d e d c o n t i n u o u s l y b y t h e a b o v e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iibenvachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents

1 Scope 5 Safety factor

2 General 6 Calculation
3 Symbols and units 7 Literature
4 Design strength value

1 Scope 2.3.1.1 The number of bolts shall be as large as possible

to ensure uniform and reliable tightening. Therefore, the bolt
The design rules below apply to circular flanges of pressure pitch shall not be greater than 5 c&. The number of bolts shall
vessels made from steel, cast steel, grey cast iron and non- not be less than 4.
ferrous metals up to an internal diameter of 3600 mm.
2.3.1.2 The moment arm a of the bolt load shall be as small
as possible.
2 General
2.3.1.3 The radius r between flange and tapered or cylindri-
This AD-Merkbiatt shall only be used in conjunction with cal hub shall be at least 6 mm unless standard flanges are
AD-Merkblatt B 0. used. For less ductile materials with an elongation at fracture
& below 10 % the radius r must be at least equal to the wall
2.2 Manufacture
thickness at the point of attachment of cylindrical shell, but
2.2.1 Flanges can be manufactured by forging, rolling or shall not exceed 30 mm.
casting, by bending and butt welding of sections or strips, or
by cutting from plate (see DIN 2519 and DIN 28030). 2.3.1.4 When selecting the gaskets their mechanical and
thermal load carrying capacity and where required their
2.2.2 Welding neck flanges and welding stubs (Figs. 1, 2, chemical resistance must be taken into account.
5 and 12) shall not be cut from plate in the case of circular
flanges. If manufacture from plate is envisaged then strips 2.3.1.5 Examples for weld flanges and guidelines for
shall be cut from the plate in the rolling direction such that welded joint dimensions are given by Table 1 or the stan-
one plate surface faces the flange axis. In addition, the strips dards for shell flanges listed in DIN 28030.
shall be ultrasonically tested for lamellar tearing and shall
2 . 3 . 2 For the design of flanged connections consult AD-
comply with the requirements of clause 4.351 of AD-Merk-
Merkblatl A 5, Section 3.
blatt W 9.
2.3.3 Flanges with tongue and groove or spigot and recess,
2.3 Design rules or plain flanges with special gaskets (jacketed gaskets,
2.3.1 When designing bolted flange connections the follow- spiral-asbestos gaskets, gaskets with wire-mesh insert) shall
ing shall be taken into account: be used for inflammable or toxic gases.

Supersedes March 1990 edition; 1 = Amendments relating to previous edition

Carl Heymanns Verlag KG

Luxemburger StraBe 449, 50939 Kdn
Page 2 AD-Merkblatl 6 8, Edition 02.98

3 Symbols and units When using this standard, the strenght calculation of the
flanged joint considers, in addition to the calculation of pres-
In addition to AD-Merkblatt B 0 the following applies: sure loadings, the loadings obtained from bolting-up (tighten-
& pitch diameter in mm ing), from external loadings or differing temperatures in the
& hole diameter in mm individual components. In addition, the standard covers a
total height of taper-hub flange in mm method for the control of leakage with defined leakage rates.
h/t
hE thickness of inserted (split) ring in mm 6.1.4 The greatest flange section modulus Wobtained from
flange thickness in mm formula (1) or (2) is decisive for the flange dimensions.
f”F
PF seating stess in N/mm* For the operating condition is
Sl wall thickness at transition to w- Fs0.S .,
cylindrical shell in mm K
SF wall thickness of tapered hub at and for the bolting-up conditions is
transition to flange in mm
W flange section modulus in mm3
Formula (1) may also be applied for the test condition accor-
4 Design strength value dingly.

The design strength values given in AD-Merkblatt B 0 apply. 6.2 Welding neck flanges with tapered hub
If the strength of the cylindrical shell material is lower than to Figs. 1 and 2
that of the flange material then the calculation must be done 6.2.1 A confirmatory calculation shall be made for welding
with a wall thickness s, which has been reduced by the ratio
neck flanges with tapered hub to Figs. 1 and 2 regarding sec-
of the strength values.
tions A-A and B-B For the calculation to formulae (4) and (7)
the thickness sF of the tapered hub shall not be greater than
5 Safety factor l/3 hr. Furthermore, the values obtained from formulae (3)
through (5) shall be taken. For design purposes the double
Consult AD-Merkblatt B 0, Section 7. Deviating from Table 3
of AD-Merkblatt 6 0, Sections 1 .l and 1.2 the following safety width of the flange is
factors may be used for the design of grey cast iron flanges b = d, - d, - 2 d; (3)
in the unannealed or the annealed. or enamelled condition: with d; obtained from Fig. 3. The factors are
(1) Safety factor S = 4.0’) Z = (d, + sF) s; (4)
(2) Safety factor at test pressure S’ = 3.0’)
Z, = ;. (d, + s,) s: (5)
6 Calculation do-
6.1 General
6.1.1 The strength calculation shall always consider the
-di
1
interacting parts of a bolted joint (flanges, bolts and gaskets).
The interaction of forces in the joint can be demonstrated in
stress-strain diagrams [4, 51. The flanged joint shall be
designed to withstand any forces during assembly (gasket
seating condition) and during operation. If the test pressure
p’ > I,3 p, this case must be considered, too, in the calcula-
tion.
6.1.2 Flanges to Figs. 1, 2,5,6,7, 8, and 10 shall be calcu-
lated to preliminary standard DIN 2505 (October 1964) taking
its preface into account. These flanges can also be calcu-
lated to the equations hereafter which are solved to obtain
hF and simplified, as far as possible, and which refer to appli-
cations not covered by the standards. Generally greater
flange thicknesses are obtained. Shell flanges to DIN 28030 Fig. 1. Welding neck flange with tapered hub (section A-A)
need not be recalculated provided the requirements of this
standard concerning allowable pressure, temperature and
materials for flanges, bolting and gaskets are considered.
This applies also to pipe flanges to DIN 2500 up to and includ-
ing a nominal diameters of 600 mm. Standard pipe flanges
with greater diameter are likely to become untight when using
a standard gasket and therefore a confirmatory calculation
(refer also to AD-Merkblatt B 7) is required. The bolting shall
be calculated to AD-Merkblatt B 7. The finished flange shall
show the calculated flange thickness hF. Grooves for groove
and tongue or ring joint designs need not be considered.
6.1.3 The calculation of circular, bolted, gasketed, flanged
joints may also be made in accordance with the procedure
to DIN EN 15912) taking its application limits into account.
I) These factors are based on an rwestigation on standard integral-type flanges with
lamellargraphltecast iron (MPA-Report, Stuttgart. dated21.11.1957). Thesafety
factors of other flange types are to be rncreased to S = 5, respectively S’ = 4.
2) At present available as draft standard only. Fig. 2. Welding neck flange with tapered hub (section B-B)
 P a g e 3 AD-Merkblatt B 8, Edition 02.98

All other cases must be calculated to formulae (14b) and

(14d) of preliminary standard DIN 2505 (10.64). The required
flange thickness is

hF = B . ,/1.27- (9)
V b

where the factor B is determined to either the following

formula

(10)

0 500 di lmml or to Fig. 4 using the following values

Fig. 3. Reduced bolt hole diameter d;.

The following conditions must be met:

Section A-A (Fig. 1)
The moment arms of the bolt load apply to the test and
The required flange thickness is operating condition
hF = 1.27 W-Z 0% d, - d, - s,
a=
b 2
and to the bolting-up condition
The moment arms of the bolt load apply to the test and oper-
ating condition a, to formula (8).
a = d,-d,-SF 6.2.2 Flanges with diameters greater than 1000 mm having
2 (7) a hub length h, - hF of at least 0.6 hF and a hub thickness
and for the bolting-up condition sF - s, of at least 0.25 hF may be calculated for the sections
A-A and B-B to formulae (14) and (15) which give smaller
- 64 thicknesses than formulae (6) and (9):
a, = - (8)
2
Section A-A
Section B-6 (Fig. 2).
hF = bi 1.06 Wb- 0.8 Z +
The results obtarned for section B-B apply within the (14)
following limits
Section B-5
0.5 5 hA - hF 5 1.0
hF
(15)
0.1 5 s, +
b SF < o,3
- For the moment arms of the bolt load, formulae (8) and (13)
apply.

6.3 Welding stubs with tapered hubs to Fig. 5

Tapered hubs shall be calculated to formulae (3) through (15)
where d, is replaced by d, and d[ = 0.

Fig. 5. Welding stub with tapered hub

6.4 Weld-on flanges to Figs. 6 and 7

0.6 The values obtained from formulae (16) through (19) are
0.5 ‘Jr6 0,7 B,i$!E 0.9 1
required for the calculation of weld-on flanges to Figs. 6 and
ratio
7. In the following formulae the thickness s, shall not be grea-
ter than 112. hF. The effective double width of the flange is
Fig. 4. Factor 8 to formula (10) b = d, - d2 - 2di (16)
P a g e 4 AD-Merkblatl B 8, Edition 02.98

with di to Fig. 3. If the welded joints comply with design 4 or 6.5 Weld-on collars to Fig. 8
5 to Table 1, then d, may be replaced by dr. Weld-on collars shall be calculated to Section 6.4 with dl
replaced by d, and d [ = 0 .

6.6 Reverse slip-on flanges to Fig. 9

The values obtained from formulae (21) through (26) are
required for the calculation of reverse slip-on flanges to Fig. 9.

Fig. 6. Weld-on flange

di-

Jg5Fd- 2-
Fig. 9. Reverse slip-on flange

Table 1. Field of application for someslip-on flange designs

-do-&-CID---l
Fig. 7. Weld-on flange

The factor Z is
z = (d, + s,) . s: (17)
The moment arms of the bolt load apply to the test and
operating condition
a = dt-di-sl
2
and to the bolting-up condition

The required flange thickness is

(20)

The dimensions of the reinforced cylindrical hub shall appro-

ximate those of DIN 28038.

1
da
-di _iS’p

Fig. 8. Weld-on collar

e-L,,_I The difference between g, and g2 shall not exceed 25%.
 P a g e 5 AD-Merkblatt a 8, Edition 02.98

The effective double width of the flange is 6.8 Flanges for clamp bolts to Fig. 11
Flanges for clamp bolts shall be calculated to preliminary
b = d - di - 2di (21)
standard DIN 2505 (10.64) with di = 0 and the external
with di to Fig. 3. The auxiliary value Z is diameter d,*.

Z = (d + s,) . s: (22)
The moment arms of the bolt load apply to the test and oper-
ating condition.

a=a,+a, a-1 (23)

i d:, 1

a = d-d,+% (24)
1 2

a = d-do+%
2 (25)
4
and to the bolting-up condition

The required flange thickness is

hF = 1.42 W-Z (27)

f - i - -
Fig. 11. Flange for clamp bolts
6.7 Loose flanges to Fig. 10
For the calculation of loose flanges to Fig. 10 the effective 6.9 Flanges with full face gasket to Fig. 12
double width of the flange is For the operating condition the moment arm of the bolt load is
b = da - d, - 2di (28) a = dt-d,-s, (32)
2
with d, to Fig. 3
and the moment arms for the operating or bolting-up condi- and a, = 0 for the bolting-up condition.
tion are The required flange thickness is
a=a,+2?! (2% (33)
hF=C. c

The required flange thickness is
The seating stress between collar
lated by formulae (31)
with factor C to be taken from Table 2. It is known from expe-
rience that for higher pressures and greater gasket widths
this type of flange connection is likely to produce tightening
problems.
and flange shall be calcu-

(31)

pF shall not exceed the lower strength value K

Fig. 12. Flange with full face gasket

Table 2. Design factor C for flanges with full face gasket

design factor
flange type C
welding-neck flange 0.9
all other flange types 1.1
Fig. 10. Loose flange
Page 6 AD-Merkblatt 6 6, Edition 02.96

6.10 Loose flange with inserted split ring to Fig. 13

6.10.1 The flange (loose flange) shall be calculated in t
accordance with Sections 6.7, 6.11 or 6.12.
6 . 1 0 . 2 The calculation of the ring considers shearing loads
to formula (34), bending to formula (35) and seating stresses
to formula (37). The greatest value h, obtained from formula
(34) resp. (35) is decisive for the thickness of the inserted
ring.

(34)

-4
Fig. 14. Split loose flange (one ring).

6.12 Split-ring loose flanges to Fig. 15

Split-ring flanges to Fig. 15 shall be calculated to Section 6.7.
Due to the split double ring with the gaps offset by 90” the
bolt load is to be increased by 50% which requires determi-
nation of the flange thickness from

(41)

instead from formula (30) The thickness of each flange ring

(h,, h2) must be at least -$-

Fig. 13. Flange with inserted split ring

In formulae (1) and (2) the moment arm a or aP is to be
replaced by
G-6
a* = - (36)
2
The seating stress is

pF= 1 . 2 7 . Fss (37)

d: - d2
It shall not exceed the lower design strength value.
6 . 1 0 . 3 The tube plate section marked with hR shall be calcu-
lated to withstand bending. The shoulder of the groove in
the tube plate shall be at least

(36)

The moment arm a or a, in formulae (1) and (2) is to be Fig. 15. Split-ring loose flange (two rings with offset gaps)
replaced by
d, -d
a3 = - (39)
2 6.13 Screwed flanges to Fig. 16
The same requirements apply to the shoulder of the loose For the calculation of screwed flanges to Fig. 16
flange accordingly. b = d, - dF - 2di (42)
Check the cross-section hR and the nose on the flange for applies.
shearing and seating stress.
The moment arms for the operating or bolting-up condition
6.11 Split ring flanges to Fig. 14 are
Split-ring flanges to Fig. 14 shall be calculated to Section 6.7. dt-6
a=a,---- (43)
Due to the split flange ring the bolt load must be doubled, 2
however, which requires determination of the flange thick-
The required flange thickness hF shall be determined to for-
ness from
mula (30). The thread shall be calculated to withstand shear-
ing as follows
hF = 7
2.54. b (40)
K 2 6x1 (44)
instead of formula (30). 7 z hF.n.dF
 P a g e 7 AD-Merkblatt B 8, Edition 02.98

---d----------1
Fig. 16. Screwed flange
6.14 Flange deflection
integral type flanges designed to the formulae above comply
with the strength requirements. However, flanges of high
strength materials or nonferrous metals or with large diame-
ters are likely to show tightening problems due to excessive
deflection of the flange. For non-metallic gaskets and com-
bined sealts it is therefore recommended to limit the flange
deflection p, to about 0.5 to 1” [4], Fig. 17. The flange then
becomes thicker than required by strenght calculations.
7 Literature
ill Schwaigerer, S.: Die Berechnung der Flanschverbin-
dungen im Behalter- und Rohrleitungsbau. VIII-Z. 96
(1954) No. 1, pp. 7/l 2.
PI Haenle, S.: Beitrage zum Festigkeitsverhalten von Vor-
schwei8flanschen. Forschung auf dem Gebiet des Inge-
nieurwesens 23 (1957) No. 4, pp. 113134.
[31 Btihner, H., Kopp L. u. Schwarz, E.: Das Festigkeitsver-
halten von Apparateflanschen. VDI-Z. 107 (1965) No. 10,
pp. 445155.
141 Schwaigerer, S.: Festigkeitsberechnung im Dampfkes-
sel-, Behalter- und Rohrleitungsbau 4th edition (1983).
Springer-Verlag Berlin, Heidelberg, New York.
[51 VDI-Richtlinie 2230. VDI-Verlag GmbH, Dusseldorf.

Fig. 17. Principle of integral type flange deflection

 Edition Julv 1995

Design AD-Merkblatt
Openings in cylindrical, conical
of
Pressure Vessels and spherical shells 89

‘he AD-Merkb&tter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
,ehd/ter” ( A D ) . A D - M e r k b l a t t G 1 c o v e r s t h e c o m p o s i t i o n a n d a p p l i c a t i o n o f A D - R e g u l a t i o n s a n d a / s o p r o c e d u r a l g u i d e l i n e s .
r h e AD-Merkblattercontain s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . I n t h e e v e n t o f l o a d i n g s e x c e e d i n g
he normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
,equirements.
:hould there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
:mbodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e. V. (FDBR), D&se/dot?
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sankt Augustin
Verband der Chemischen lndustrie e.V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhijttenleute (VDEh), Dtisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroRkraftwerksbetreiber e.V., E s s e n
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkbldtter a r e a m e n d e d c o n t i n u o u s l y b y t h e t r a d e associations in keeping with technical progress. Relevant proposals should
be addressed to the publisher:
Verband der Technischen iiberwachongs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents
1 Scope 4 Weakenings
2 General 5 Literature
3 Symbols and units Appendix to AD-Merkblatt 6 9

1 Scope 1.2 For conical shells AD-Merkblatt B 9 applies only if the

wall thickness is determined by the circumferential stress
1 .l The following design rules cover openings in cylindrical, (see Section 8.1.2 of AD-Merkblatt B 2).
conical and spherical pressure vessel shells and the calcula-
tion of the necessary reinforcement within the following limits:
2 General
0.002 5 se--1-c2
D <- 0.1
a 2.1 This AD-Merkblatt shall only be used in conjunction with
AD-Merkblatt B 0.
Where the wall thickness to diameter ratio exceeds 0.1. the
openings can be calculated to TRD 301TTRD 303 and the 2.2 The design rules of this AD-Merkblatt permit plastic
boundary conditions therein contained. deformations of up to 1 % at highly stressed local areas dur-
ing pressure test. Openings shall therefore be carefully
Values for the wall thickness and diameter ratios may drop designed (prevention of abrupt changes in geometry, welds
below the lower limits provided the ratio is: free from undercuts and excessive welding stresses) expeci-
ally in the case of steels having a minimum yield point
d 1
AC:- > 440 N/mm” at 20 “C (minimum yield point in compliance
4 3 with the relevant standards).

The scope of this AD-Merkblatt remains restricted to dia- 2.3 The subsequent design rules can be appropriately
meter ratios d,iD, 4 0.8 for cylinders and cones which are adopted for brittle materials in cases where the resulting
designed on the basis of long-term material properties or stresses have been reduced to a low level by the imposition
which fall within the scope of AD-Merkblatter S 1 or S 2, e.g. of larger safety factors on the tensile strength.
in cases of high-strength steels or large numbers of load
cycles. 2.4 Compensation methods
Additional external forces and moments are not covered by 2.4.1 Increased thickness of the shell
the design rules of this AD-Merkblatt and are therefore to be
considered separately. Attention is drawn to AD-Merkblatter, Openings are reinforced by increasing the shell thicknesses
Series S 3. (Figs. 1 and 2).

Supersedes Edition October 1991; ( = Amendments to previous Edition

mr, neymanns
,,^
vemg Rb 7I rans~auon.
---l-l:.-. -rI ethnical ^ , --I
Help to txponers 5ervICe 01 tw
Luxemburger Strak 449, 50939 KOln
GurenbergstraBe 3. 10587 Berlin
Page 2 AD-Merkblatt B 9, Edition 07.95

2.4.3 Tubular reinforcement

Openings are reinforced by increased nozzle thickness
(Figs. 5 and 6).

Fig. 1. Increased thickness of a cylindrical shell

Type a) Type W Type 4

Fig. 5. Nozzle reinforcement

Fig. 2. Increased thickness of a conical shell

&.-.-. J---------)--J
2.4.2 Pad and ring reinforcements Fig. 6. Necked-out opening
Openings are reinforced by means of a set-in or set-on ring
or pad (Figs. 3 and 4). 2.4.4 Pad-type and tubular reinforcements
Pad-type and tubular reinforcements may be used together
to strengthen openings (Fig. 13).

Fig. 3a. Set-in reinforce- Fig. 3b. Reinforcement

ment ring ring

Type 4 Type W
Fig. 13. Pad-type and tubular reinforcement

2.5 Design and finish of openings

25.1 Wherever possible, the openings shall be positioned
at least 3 s, away from the weld-especially where non-heat
treated parts are concerned. The vicinity of openings in or
adjacent to welded joints shall be accessible to non-destruc-
tive testing.
2.5.2 Sharp-edged openings shall be avoided.
2 . 5 . 3 Fillet weld g on a pad-type reinforcement shall have
Design to Section 43.1 Design to Section 4.3.3 a minimum thickness of 0.5 h (Fig. 4). In cases of tubular
and 4.3.2 reinforcements the load-bearing thickness of the welded joint
shall be at least equal to the required thickness of the thinner
Fig. 4. Pad reinforcement attached wall.
 Page 3 AD-Merkblatt B 9, Edition 07.95

2 . 6 The materials of the shell requiring reinforcing and the which is based on the consideration of the equilibrium
reinforcement itself shall have the same ductility, whenever between the pressurised area and the load-bearing cross-
possible. Where the strength of the reinforcement is lower sectional area. Instead of applying Figs. 7a to 7e and 8a to
than the strength of the shell requiring reinforcing, an allow- 8c, it is also possible to proceed with direct reference to for-
ance in accordance with Section 4 will then have to be made mula (1). However, the wall thickness thus determined shall
in the design calculations. If the strength of the reinforcement not be less than that of the unpierced shell. The pressurised
is higher than the strength of the shell requiring reinforcing, area A, to be inserted into formula (1) and the load-bearing
the former shall not be fully utilized. cross-sectional area A,, = AoO + A,,, + A,, are obtainable
from Figs. 9 to 122).
3 Symbols and units The maximum length of the load-bearing cross-sectional
In addition to AD-Merkblatt B 0 the following applies: area to be considered in calculation should not exceed b for
b Width of a pad and ring reinforcement formula (3) for shells and 1, for nozzles according to Sec-
or width of full shell reinforcement in mm tion 4.4.3. With inward protruding nozzles, only the portion
I’, 5 0.5 I, can be included as load-bearing in the calculation.
h Thickness of pad-reinforcement in mm The requirements of Sections 4.3.1, 4.3.2 and 4.4.2 shall be
I Ligament (web) between two nozzles in mm observed.
1, Length of nozzle reinforcement in mm
1 s. new Reduced length of nozzle reinforcement in mm
m Protruding length in mm
SA Required wall thickness at opening edge in mm
ss Wall thickness of nozzle in mm
t In this context: centre-to-centre distance
between two nozzles in mm
“A Compensation factor for the weakening
effect of openings

4 Weakenings
4.1 Calculation
The v+, values for nozzles perpendicular to the shell can be
read with sufficient accuracy from Figs. 7a to 7e and 8a to Fig. 9. Calculation scheme for cylindrical shells
8c. The wall thicknesses sA in these figures is the required
wall thickness’). Intermediate values may be obtained by If the strength value K, or K2 of the reinforcement is lower
linear interpolation between the families of curves in the indi- than that of the shell to be reinforced, then the dimensions
vidual figures and between Figs. 7a to 7e or 8a to 8c. should comply with:
In the case of cylindrical and conical shells having a diameter
ratio d,lD, 5 0.85, interpolation between Figs. 7a to 7e may
be dispensed with if the v, value is taken from the figure
having a s,lD, ratio that is less than the existing one. .Ao2+Ap
In the case of a spherical shell having a preferred opening The calculation method selected shall be indicated in the
documentation.
diameter dJ% 5 1.42, interpolation between Figs. 8a to 8c ss-c,-c,
may be dispensed with if the vA value is taken from the figure - - - - - i i - -
having a s,i-$ ratio that is less than the existing one.

If the strength value K of the reinforcement is smaller than

the strength value of the shell to be reinforced then, for pad
reinforcements, the cross section of the reinforcement and,
for nozzle reinforcements, the nozzle thickness shall be
reduced accordingly before determining the factor vA from
Figs. 7 or 8.
The vA value obtained from Figs. 7 or 8 for individual nozzles
or according to formula (9) for in-line nozzles shall be intro-
duced instead of the value v into formula (2) or (3) of AD-
Merkblatt B 1 or into formula (6) or (8) and into Figs. 3.1 to
3.8 of AD-Merkblatt B 2for the determination of wall thicknes-
ses sA required at the edge of the opening, provided v, < v.
This does not affect the determination of the wall thickness
of the cylindrical, spherical or conical shell outside the area
close to the opening.
Compensation for the openings can be traced to the gener-
ally valid relation:
D iAn l\ K
L--r_+-5- Fig. 10. Calculation scheme for spherical shells
lo\A, 21 s (1)
2) The calculation scheme for oblique nozzles and other types of reinforcement can
‘) It should be pomted out that the wall thickness sA is determmed by iteration be taken from TRD 301 or TRD 303.
Page 4 AD-Merkblatt B 9, Edition 07.95
Fig. 11. Calculation scheme for adjacent nozzles in
a sphere or in longitudinal direction of a cylinder
Fig. 12. Calculation scheme for adjacent nozzles in a
sphere or in circumferential direction of a cylinder
4.2 Increased thickness of the shell
The weakening factor vA for openings to Figs. 1 and 2 should
be taken from the lower curve in Figs. 7 and 8.
4.3 Pad reinforcement
4.3.1 If the actual wall thickness s, of the cylinder or sphere
is lower than the required wall thickness .sA at the opening
then the opening is adequately compensated it the wall-
thickness .sA is available round the opening over a width of:
b = \‘(/I + s+j - c, - c,) . (sn - c, - c,) (3)
with a minimum, however, of 3 .sA (Figs. 3 and 4).
4 . 3 . 2 In calculating the wall thickness, sA can be taken into
account only up to twice the actual wall thickness s,. The wall
thickness of external pad reinforcement should not exceed
s, (except of set-on reinforcement rings). Internal pad reinfor-
cement should be avoided as far as possible.
4.3.3 The width of the pad reinforcement may be reduced
to 6, provided the wail thickness of the pad is increased to
h, according to:
b, h, P b . h (4)
The limits given in Sections 4.3.1 and 4.3.2shall beobserved
here.
4.4 Reinforcement by increased nozzle thickness
4.4.1 For reinforcements according to Figs. 5 and 6 the
weakening factor vA should be taken from Figs. 7 and 8 for
the following wall thickness ratio:
ss-c, -c2
s&J-c,-c2
The wall thickness of protruding nozzles according to Fig. 5,
Type c, may be reduced by 20 % compared to Section 4.4.1,
if the pipe protrusion is m 2 ss.
The wall thickness sA at the opening shall extend over a width
to be calculated according to formula (3), though with a mini-
mum of 3 sA around the opening.
If, in the case of necked-out branches, the pressurised areas
A, and the load-bearing cross-sectional areas A, are deter-
mined as with welded-on or set-in branches - i.e. discounting
the neck radii, then the load-bearing cross-sectional areas A,
shall be multiplied by a factor of 0.9 to account for losses
incurred in shaping. If areas A,, and A, are determined plani-
metrically, for example, the 0.9 factor need not be applied.
4.4.2 The wall thickness ratio should be:
q-c, -cp
4 2.0 (5)
s+j--c,-c2
4.4.3 For nozzles in cylinders and cones the formula for the
load-bearing length I, is as follows:
k = 1.25 d(d, + ss - c, - c,) css - c, - c,) (6)
For openings in spheres the factor in front of the root sign in
formula (6) becomes 1.
The nozzle length may be reduced to is, new provided at the
same time the nozzle thickness ss is increased toss, subject
to Section 4.4.2 and the following condition:
Is, new .ss, P 1,. ss (7)
4.5 Reinforcement by combination of increased wall
thickness of the shell and nozzle thickness
Calculation is carried out using Sections 4.3 and 4.4 simulta-
neously.
4.6 Multiple openings
4.6.1 Multiple openings should be ragarded as isolated
openings provided the distance between two adjacent ope-
nings (Figs. 11 and 12) complies with:
12 2 . Q(D, + SA - c, - c,) . (SA - c, - c,) (8)
4 . 6 . 2 If the distance I does not comply with formula (8) it
should be checked whether the remaining cross section
between openings is able to sustain the load acting on it.
Adequate cross section is available if formula (1) or (2) is met.
4.6.3 Branches or sockets in series joined to the shell shall
be fully penetrated welds with wall thicknesses calculated
for internal pressure only may be designed with a reduced
weakening factor:
t - d,
v, = - (9)
t
For branches and sockets joined to the shell by partially
penetrated welds di should be replaced by d, in formula (9).
5 Literature
Schwaigerer, S.: Festigkeitsberechnung von Abzweig-
111
stucken unter Innendruck, Tech. iiberwach. 9 (1968)
Nr. 11, S. 372177.
121 Siebel, E., u. S. Schwaigerec Das Rechnen mit Form-
dehngrenzen. VDI-Z 90 (1948) Nr. 11, S. 335/41.
 page 5 AD-Merkblatt B 9, Edition 07.95

190

0 ,9

02
,1

Weakening factor vA for openings and branches perpendicular to the shell in cylinders and cones iSAIDi = o.o”2)
1Fig. 7a.
page 6 AD-Merkblatt B 9. Edition 07.95

.P
E

U
Diameter ratio d,lQ

vA for openings and branches perpendicular to the shell in cylinders and cones @in/D, = 0.005)
1Fig. 7b. Weakening factor
 page 7 ,QN&!rkblatt B 9, Edition 07.95

Diameter ratio d,lQ

1Fig. 7c. Weakening factor vA for openings and branches perpendicular to the shell in cylinders and cones (SA/Q = O.0’)
 ~~-~~~kbk,tt B 9, Edition 07.95
Page 8

Diameter ratio dJDi

1Fig. 7d. Weakening factor vA for openings and branches perpendicular to the shell in cylinders and cones (s,JQ = 0.05)
 Page $2 AD-Merkblatt 6 9, Edition 07.95

Diameter ratio dJQ

for openings an~ branches perpendicular to the shell in cylinders and coneS @AIDi = O.‘)
\ Fig. 7e. Weakening faCtOr VA
page 10 AD-Merkblatt 0 9, Edition (X.95

Related opening diameter diI ?$ -

Fig. 8a. Weakening factor vA for openings and branches perpendicular to the shell in cones @A/% = 0.02)
 AD-M&d,latt B 9, Edition 07.95
Page 11

@A/ 42 = 0.04)

Weakening factor vA for openings and branches perpendicular to the shell in cones
Fig. 8b.
Page 12 AD-Merkblatt B 9, Edition 07.95

Fig. 8c. Weakening factor vA for openings and branches perpendicular to the shell in cones (sA@ = 0.10)

Appendix to AD-Merkblatt B 9
Explanations to Section 1.1 of AD-Merkblatt B 9
1. Lower limit of the related wall thickness
The weakening factors according to this AD-Merkblatt pre-
sume ability of a structure to shakedown plastic deformations
in the elastic range*). Thin-walled shells with large openings
do not match with this presumption due to their high mem-
brane stresses in relation to the bending stress.
2. Upper limit of the diameter ratio
Experience has shown that in the case of great diameter
ratios stresses occur in the cross section perpendicular to
the vessel axis (gusset area) which are not covered by this
AD-Merkblatt. The results available from research work in
this field are not sufficient to establish general design rules.
Generally these stresses do not result in failure as long as
no creep occurs and damage due to cyclic loading according
to AD-Merkblatt S 1 is not expected.
‘) Translator’s note.
There is no literal translation of the term “Stljtzwrkung”. In the Anglo-Saxon litera-
ture this phenomenon is deswbed as Increase of the load due to support of the
elastic zone in a cross-section with elasto-plastic deformation.
Page 13 AD-Merkblatt B 9, Edition 07.95
Explanations to Section 4.1 of AD-Merkblatt B 9
Where materials are stressed to the same permissible
degree by the shell and branches in the case of cylindrical
shells’), the weakening factor may also be calculated using
the following formula:
The curves shown in Figs. 7a to 7e correspond to formula
(10) for s,/D, = 0.002 (Fig. 7a), 0.005 (Fig. 7b), 0.01 (Fig. 7c),
0.05 (Fig. 7d) or 0.10 (Fig. 7e).
It is on the safe side to use one of Figs. 7a to 7e as long as
the actual wall-thickness parameter s$D, is not less than that
shown in the figure.
If shells and branches are made of materials with different
permitted stress levels, the weakening factor produced and
in accordance with formula (2) is calculated as follows:
0; (A, + 2. A,,)
VA = (104
s,(2A,+A,, -2 41)
In using formulae (10) and (1 Oa), allowance should be made
for additional values c, and cl.
I) Weaklng factor vI\ for conical shells can also be deduced from TRD 303.
UDC 621.642-96.001.24 Edition June 1966

Design AD-Merkblatt
Thick walled cylindrical shells
of
Pressure Vessels
subject to internal pressure BIO

‘he AD-Merkb@tter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
)eh#er” ( A D ) . AD-Merkblai? G 1 covers the composition and application of the AD-Regulations and a/so the procedural rules.
rhe AD-MerkblBtter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
md above the normal level being anticipated during the operation of pressure vessels, allowance must be made for such stresses by
neeting special requirements.
?hould there be any departures from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis,
operating experience.
Fachverband Dampfkessel-, BehBlter- und Rohrleitungsbau e. V. (FDBR), Dtisseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e. V!, Sankt Augustin
Verband der Chemischen lndustrie e.K (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e. K (VDMA), Fachgemeinschaft Apparatebau, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Dijsseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r Groi3kraftwerksbetreiber e . V, E s s e n
V e r e i n i g u n g d e r T e c h n i s c h e n iiberwachungs-Vereine e . V. (VdTiiV), Essen.
The AD-Merkbldtter are amended continuously by the trade associations in keeping with technical progress. Relevant proposals shoulc
be addressed to the publisher:
Vereinigung der Technischen iibenvachungs-Vereine e. V., Postfach 103834, D-4300 Essen 7.

Contents

1 Scope 5 Percentage of the permissible

2 General design stress level, Weakenings
3 Symbols and units 6 Calculation
4 Safety factor 7 Literature

1 Scope
4.2 The safety factor of thermally loaded shells (ovel
The design rules presented below apply to the cylindrical 200 “C) with a diameter ratio 0,/D, > 1,35 may be reducec
shells of pressure vessels within the limits’) 1,2 < O$ to S = 1,4 after agreement with the operator (customer:
Di 5 1,5 provided they are subject to full axial load and provided the danger to personnel and the environment ha:
made of ductile material. been reduced by special measures e.g. installation in spe
cial chambers or rooms or on open fenced-in ground witt
) remote control.
2 General In this case a safety of 1 ,l against yield point at 20 “C
This AD-Merkblatt shall only be used in conjunction with during test pressure must be verified separately.
AD-Merkblatt B 0.

3 Symbols and units

In addition to AD-Merkblatt B 0 the following applies: 5 Percentage of the permissible design
stress level, Weakenings
CY in this context: coefficient of linear thermal ,
5.1 In accordance with the requirements of the HP Series
expansion in -
“C of the AD-Merkbl&ter, a 100% longitudinal weld efficiency
(v = 1) must be guaranteed in manufacture and test?
before this AD-Merkblati can be used.
4 Safety factor
5.2 If small radial bores for fittings and the like are requi
4.1 Refer to AD-Merkblatt B 0 Section 7. red in the cylindrical shell, then the stress increase at the
bore hole must be considered for the service condition:
1) For greater wall thicknesses refer to Literature e.g. [5] and the hydraulic test.

Supersedes Edition February 1977; 1 = Amendments relating to previous edition

Carl Heymanns Verlag KG

Luxemburger StraOe 449, 50939 KBln
GutenbergstraBe 3, 10587 Berlin
 Page 2 AD-Merkblatl B 10, Edition 6.66

6 Calculation The auxiliary factors A and B are determined as follows

6.1 Walls with no considerable temperature difference A=2772-1
7+ - 1 In77
6.1.1 The required wall thickness s is
B=-.L-- 1
5=
D..P + CI + c2 q’- 1 Inrl
23+-p (1)
They can also be taken from Table 1.
6 . 1 . 2 Furthermore, a check is required whether the stress
intensity due to internal pressure does not exceed the per- Table 1. Auxiliary factors A and B
missible design stress K/S on the outer (uva) and inner (u”,)
surface Irl = D . / Q ( 1.2 1 133 ( 1 8 4 1 1.5 1 (16) ( (1.8) 1
u- = PPa+%)
VI (2) A 1,rX 1.09 1,ll 1.13 1,15 1.20
23s, B - 0,94 - 0.91 -0,89 -0.87 -0-85 -0980
P(b-3.%)
%a = (3)
23s,
6.2.3 It should be checked whether the maximum stress on
16.2 Walls with considerable temperature difference the inner a, resp. outer surface a, does not exceed the per-
missible stress K/S.
6.2.1 If heating or cooling is expected to produce a heat
flow from inside or outside through the cylinder wall, the Ui = Owl + Uvj (8)
resulting reference stresses have to be added, taking
1account of their sign>). Ua = %a + &a (9)
For a,, and a,, the formulae (2) and (3) apply.
6 . 2 . 2 The thermal stresses are according to Lorenz on the
inner surface
1 7 Literature
uwi = +-q”.(iF-q’.A

and on the outer surface 111 Siebel, f.: Die Festigkeit dickwandiger Hohlzylinder.
Konstruktion 3 (1951) Nr. 5, S. 137141.
1 E
a,, = -. --a.(~?~-- rJ).B PI Class, 1.: Stellungnahme zum Aufsatz ,,Die Festigkeit
2 l-w
dickwandiger Hohlzylinder“ von E. Siebel. Konstruktion 4
where v = 0,3 for steels. (1952) Nr. 1, S. 25.
[ 3 1 Siebel, E., Schwaigerer, S., u. Kopf, E.: Berechnung
I*) Strictly speaking, the tangential, radial and axial stresses set up by the internal dickwandiger Hohlzylinder. Die Warme 65 (1942) Nr. 51/
pressure and the heat flow must each be algebraically added and the resulting 52, s.440145.
total tangential (CT,). radml (0,) and axial stresses (4) combined to form the refe-
rence stress (q): Lorenz, R.: Temperaturspannungen in Hohlzylindern.
[41
q = 0.71 \/cs- q)2 + (q - q)2 + (0, - 4)” VDI-Z 51 (1907) Nr. 19, S. 743147.
For the sake of simpliclly it has become common practice to add the tangential
stress due to the heat flow to the reference stress produced by the internal pres- [ 5 1 Buchter, H. H.: Apparate und Armaturen der Chemi-
sure. schen Hochdrucktechnik. Springer Verlag 1967.
ES 23.020.30 Edition May 1999

Design AD-Merkblatt
of Single-Ply Bellows Expansion Joints
Pressure Vessels B 13

The AD-MerkbWter are compiled by the seven trade associations specified below who together form the ‘Arbeitsgemeinschaft Druck-
behdlter” (AD). AD-Merkblatt G 1 covers the composition and application of AD-Regulations and also procedural guidelines.
T h e AD-Merkbl2tter c o v e r s a f e t y r e q u i r e m e n t s w h i c h s h a l l b e a d o p t e d f o r n o r m a l c o n d i t i o n s o f o p e r a t i o n . I n t h e e v e n t o f s t r e s s e s o v e r
and above the normal level being anticipated during the operation of pressure vessels, allowance shall be made for such stresses by meet-
ing special requirements.
S h o u l d t h e r e b e a n y d e p a r t u r e s f r o m t h e p r o v i s i o n s o f t h i s AD-Merkblatt, i t s h a l l b e p o s s i b l e t o d e m o n s t r a t e t h a t t h e s a f e t y s t a n d a r d s embo-
diedin t h e s e r e g u l a t i o n s h a v e b e e n o b s e r v e d b y a l t e r n a t i v e m e a n s , e . g . t e s t i n g o f m a t e r i a l s , t r i a l s , s t r e s s a n a l y s i s , o p e r a t i n g e x p e r i e n c e .
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e.V. (FDBR), Diisseldoti
H a u p t v e r b a n d d e r g e w e r b l i c h e n B e r u f s g e n o s s e n s c h a f t e n e . V . , S a n k t Augustin
Verband der chemischen lndustrie e.V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Dijsseldori
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkraftwerksbetreiber e.V., E s s e n
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t h e t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e. V., P.O. Box 103834, D-45038 Essen.

Contents

1 Scope 5 Allowances
2 General 6 Calculation
3 Symbols and units 7 Bibliography
4 Safety factor Appendix 1: Explanatory notes to AD-Merkblatt B 13

1 Scope Instructions for the calculafion of bellows expansion joints

outside the aforementioned scope (multi-ply bellows, geo-
The design principles specified hereafter apply to metallic’) metric parameters) may be taken from [3], for example.
single-ply bellows expansion joints with parallel-sidewall or
lyre-shaped convolutions (Figs. 1 and 2), within the following
limits:
2 General
3 5 dlh 5 100
031 5 rlh 5 OS 2.1 This AD-Merkblatt shall only be used in conjunction with
0,018 5 slh 5 0,i AD-Merkblatt B 0.
2.2 This AD-Merkblatt covers bellows expansion joints
loaded by pressure and forced movements (axial or lateral
movements, angular rotation) and subject to cyclic loading
during operation.
2 . 3 Expansion joint bellows are not suited to withstand con-
siderable forces and moments. Therefore the design shall
ensure, e.g. by guides, internals, supports, that bellows are
not subjected to these loads. As torsional moments, how-
ever, cannot be avoided in any case, relations have been
introduced in this AD-Merkblatt to consider such moments.
2 . 4 Expansion joint bellows may be connected to adjacent
components by circumferential buttwelds (Fig. 3). In the case
of differing wall thicknesses between bellows and connecting
components 2.7 and 2.9 of AD-Merkblatt HP 5/l shall be
taken into account.

Fig. 1: Bellows Fig. 2: Bellows

expansion joints expansion joints with
with parallel-side- lyre-shaped convo-
wall convolutions lutions (angle 5 8”) 1) See explanatory notes in Appendix 1 to this AD-Merkbiatt.

Supersedes Edition of January 1995; 1 = Amendments to previous edition

-Gan neymanns venag Kti Translation: Technical Help to Exporters Service of BSI
Luxemburger StraBe 449. 50939 Kbln
Page 2 AD-Merkblatt B 13, Edition 05.99

Joints other than butt welds, e.g. according to Figs. 4 and 5 d mean internal diameter of expansion
are also permitted. joint mm
2.5 Where corrosion is expected to occur, a corrosion- C,i lateral working spring rate of a bellows
resistant material shall be agreed between manufacturer or an expansion joint consisting of two
and user. It is not suitable to provide a corrosion allowance identical bellows with intermediate
for compensation of corrosive attacks on the bellows. pipe section N/mm
2.6 The distance between the expansion joint welded end fl cyclic strength factor for circumferential
joints on the bellows -
and the radius tangent of the expansion joint knuckle shall
not be less than the maximum value of the three individual f, characteristic value for partial plastic
amounts 3 s, IO mm and 0,25 . G, if the weld is to be deformation -
disregarded in consideration of the fatigue. h convolution depth m m
convolution length, measured in neutral
position mm
3b n in this connection: shape factor
nl shape factor for application of 1 %
proof stress
no.2 shape factor for application of 0,2 %
proof stress -
r knuckle radius (for different radii at
the internal and external knuckle the
arithmetical mean applies) m m
W axial movement on one side of a
convolution, measured from the neutral
position m m
Fig. 3: Butt weld W, equivalent axial movement of a
convolution for the rotation angle a mm
equivalent axial movement of the
convolution subject to maximum loading
for lateral movement i’ of the
expansion joint m m
Z number of bellows convolutions
Zl number of bellows convolutions of
an expansion joint with two identical
bellows and intermediate pipe section
E 20 modulus of elasticity at 20 “C N/mm2
Ll overall length of bellows (Fig. 6) mm
L length of intermediate pipe (Fig. 6) mm
Fig. 4: Inserted butt weld MT torsional moment acting on the bellows Nm
N here: number of cycles
N ZUI allowable number of cycles
R here: design factor
%v) design factor for axial working
spring rate
R(P) design factor for pressure loading
R(W) design factor for axial loading
S urn safety factor for circumferential stress
SV P safety factor for stress intensity
a here: rotation angle of a convolution,
measured from straight position degrees
lateral movement of an expansion joint
Fig. 5: Lap weld with one bellows or two identical
bellows and intermediate pipe section,
measured from straight position
(Fig. 6) mm

3 Symbols and units 2 . &ages effective range of total expansion %

A uvges total equivalent stress range N/mm*
In addition to the requirements of AD-Merkblatt B 0 the follow- &, equivalent stress range due to axial
ing applies: V(W)
movement, e.g. AcT,~,~ = 2u+,, for axial
b length of reinforcing collar mm movement + w N/mm2
ccl angular working spring rate of a N m/ Aqa) equivalent stress range due to angular
convolution degress rotation, e.g. AIJ,(,~ = 2u,,,, for
CW axial working spring rate of a convolution N/mm rotation f a N/mm*
 Page 3 AD-Merkblatt B 13, Edition 05.99

equivalent stress range due to lateral 6.1.4 Loading due to angular rotation
movement, e.g. ACT,(~) = 2cr,,) for The values for loading due to deflection can be determined
lateral movement F A N/mm2 by means of the axial loadings.
equivalent stress range due to alternating
gauge pressure, e.g. da,(,) = a,(,) for Equivalent axial movement of convolution for the rotation
pressure cycles 0 + p N/mm2 angle:
equivalent stress range due to cyclic d+2h
torsional moment, e.g. AU,(~) = 2 c&(T) w,= 1,J5.p-J2’a (5)

for torsional moment + MT N/mm2

mean circumferential stress N/mm2 Maximum stress intensity:
maximum stress intensity N/mm2 E
maximum stress intensity due to G,,,) = 2,l 104 . 7;- R,,, . (d + 2 h) . a 03)
angular rotation N/mm2 Angular working spring rate:
maximum stress intensity due to
torsional moment N/mm2 ~,,=2.2.10-6.(d+2h)~.c, (7)
maximum stress intensity due to
internal or external pressure N/mm2 6.1.5 Loading due to lateral movement
maximum stress intensity due to As a deviation from formulae (3) to (7) applying to a single
axial moment N/mm2 convolution, the formulae (8) to (13) apply to the complete
expansion joint.
6.1.5.1 Single-bellows expansion joint
4 Safety factor
Lateral movement of this expansion joint is only possible, if
As a deviation from AD-Merkblatt 6 0, the requirements in the bellows has at least two convolutions.
clause 6 apply.
Equivalent axial movement of the convolution subject to
maximum loading for lateral movement of the expansion
5 Allowances joint:
As a deviation from clause 9 of AD-Merkblatt B 0, allowances w -3, d+2h A ’
are not taken into account. I- ___‘-
I.2 z (8)

Maximum stress intensity:

6 Calculation
E
For the calculation against internal or external pressure and rr,(;., = 2,4 1 o-4 1 -g- R(w) I WA (9)
torsional loading the bellows minimum wall thickness, and for
the calculation against axial, lateral or angular movement the Lateral working spring rate of expansion joint:
bellows maximum wall thickness shall be used. In such cases
the minimum or maximum wall thickness shall be used in due pA+(cgLi’. ? (10)
consideration of the tolerances specified in the standards for
semi-finished products, in accordance with the AD-Merkblat- 6.1.5.2 Lateral expansion joint with two identical bellows
ter of the W series, with the wall thickness being reduced or (double expansion joint) with unguided intermedi-
increased by the thickness change due to forming, as appro- ate pipe section
priate. Equivalent axial movement of convolution subject to maxi-
In the calculation, the authorized inspector shall take into mum loading for lateral movement of expansion joint:
account the manufacturing method used by the particular
manufacturer in order to make allowance for the any change
in wall thickness occurring as a result of the forming process.
WA = d+2h
.-.- 2’
05 G 2 +2.5+45
3 2L, 22, (11)
6.1 Stresses, spring rates
6.1 .l Loading due to internal or external pressure
Maximum stress intensity: Maximum stress intensity:
a,(P) = R(P) . p (1) E
~,,,,=2,4.10-4.~.R~~).w~ (12)
6.1.2 Loading due to torsional moment I
Maximum stress intensity: Lateral working spring rate of expansion joint:

4 MT. lo3 with i T in Nm (2)

u”(T) =
,z d2 s 2
c; =
6.1.3 Loading due to axial movement
0
5L1 2
+2.2+4
3
(13)
Maximum stress intensity: Ll

q,,,) = 2,4 . IF . + . Rtwj . w (3) These relations apply to the lateral expansion joint according
to Fig. 6 where the expansion joint tie only effects parallel gui-
Axial working spring rate: dance of expansion joint ends, but, no guidance of the inter-
)c,=0,15~10-4~(d+h)~E~R~~~ (4) mediate pipe section.
 P a g e 4 AD-Merkblatt B 13, Edition 05.99

6.1.5.3 Lateral expansion joint with two identical bellows By approximation Au,,,, may be determined by addition of
and guided intermediate pipe section the individual equivalent stress intensity components Au,
The two bellows shall be calculated in accordance with 6.1.4. from :

Aa,,,,= Ao,(,) + A%.,) + Aa,(a) + da,,,, + 4,) (19)

Partial plastic deformations are taken in account by the factor

f, which is obtained from:

r,=,+c(p-2)+0,1d3 (20)

B is the greater value of _ %P,

_ _ and %!,-
K
:, . K S”r!l

and formula (20) applies to:

Auv,,,, > 2
Fig. 6: Lateral expansion joint with intermediate pipe sec- K -
tion For d < 2 is f2 = 1
K
6.1.6 Design values R The shape factors C for axial, angular and lateral movement
The design values R,,,, R,,, and Rt,,, required for formulae shall be taken from Table 1.
(i), (3) (4), (6), (9) and (12) shall be taken from Tables 2 to
25 for rated parameters. Intermediate values shall be Table 1: Shape factors C
subject to straight interpolation. See also 6.5.
I C (values in parantheses apply to deflection,
6.2 Calculation against static loading e.g. angular and lateral movement)

6.2.1 Pressure and torsional moment Material Bellows with Bellows without circumferential welds
vow circumferential in highly loaded zone
welds in highly work hardened hot formed or
%T) . s,,
-!I . 15 + d”@, 5 + K (14)
( loaded zone normalized
VP
Here uVcp, shall be determined elastically as specified in 6.1.1. Austenrte ) 0,127 (0,101) 0,105 (0,086) 0,085 (0,067)

The shape factor n shall be inserted with F e r r i t e 0,155 (0,127) 0,155 (0,127) 0,133 (0,109)

no,2 = 1,551 - 2,8 . 1O-4 . K (15)

or n, = 1,55, and with a safety factor S,, = 1,2. In the case of combined loading AUK,,,, . f2 is calculated as
follows:
In addition, the following applies to the mean circumferential Auvges f, =

1
stress due to pressure and torsional moment
(d + h) .I. p K 4~
I 40~s~(1,14r+h)~v +uV(n%Sum (16) ( ‘%P) + A0v&u V(W) + A”v(u) + A”v(l.)
+ A’J”(W, fZ(W)

I with S,, = 1,5. A”“(u, + Au”(i)

6.2.2 Proof of stability + tAuNP, + A”vl 1 Au
For an axial expansion joint the assessment of sufficient [ VW + A”v(~~) + A”v(i)

safety of the bellows against column instability (squirm) shall
be made by
3xc,
PS 22 .1
For angular and lateral expansion joints sufficient rigidity
against excessive bellows deformation due to internal pres-
sure shall be ensured additionally.
6.3 Calculation against variable”) loadings
The effective total strain range is calculated as:
. fz . f . 1 o2
2 . &ages = A&,,,
E ’
AU&J,5 is composed of the variable part of the loading due to
axial and lateral movement, angular rotation, internal pres-
sure and torsion and shall be determined from the sum of the
resulting stress components occurring at the same time.
2) The variable stress portions are identified with A.
and ho) 1
(21)
+ 4(cr) + AU”(l) fzc,,,
(77)
f2(w) are the respective factors f, with shape factors
C for axial and angular movement according to formula (20).
The effective total strain range at the point of maximum load-
ing shall be determined in connection with Tables 2 to 13 and
f, = 1,o.
For bellows with circumferential welds at the internal knuckle
the fatigue strength of the circumferential weld shall also be
assessed. In this connection, the effective total strain range
at the circumferential weld (internal knuckle) shall be deter-
mined using the design factors from Tables 14 to 25 and the
factor f, = 2 which takes into account the lower fatigue
strength of the weld.
The greater value of 2 . sages shall be decisive for the determi-
nation of the number of cycles to failure.

At elevated temperatures the effective total strain range
2 . &ages shall be multiplied with E,,-JE.
The expected number of cycles to failure (until onset of
leakage) is obtained from:
3.45
NC &- for500I NS 106 (22)
( . ages 1
The allowable number of stress cycles is obtained from:
N,,, 5 F with SL = 2,0 (23)
L
Prerequisite for SL = 2,0 is that, by representative component
service life tests in due consideration of materials and manu-
facturing processes, it is proved that the number of cycles to
failure N according to formula (22) is obtained for at least
95 % of the expansion joints. Otherwise, SL = 5,0 shall be
inserted in formula (23).
In the case of non-uniform loading (variable amplitudes) the
usage factor of the individual load cycles shall be accumu-
lated according to the linear damage rule.
D=x+ ; (24)
I
where n, is the number of load cycles of the respective load
cycles and N, the allowable number.
6.4 Elevated temperatures
Within the temperature range of the creep rupture stress
values?) the shape factor will be smaller than that at room
P a g e 5 AD-Merkblatl 8 13, Edition 05.99
temperature in the case of equal limit loads. For temperatu-
res 2 500 “C the shape factor n = 1,28 shall be inserted in
formula (14) as well as for the determination of B (see 6.3).
Values for temperatures between 300 “C and 500 “C shall be
subject to straight interpolation between n according to for-
mula (15) and 1,28.
6.5 Design values
The numerical values for R(,,, Rtw) and Rfcw) shall be taken
from Tables 2 to 13 or 14 to 25. Intermediate values shall be
subject to straight interpolation+).
7 Bibliography
VI Friedrich, W.: Festigkeitsberechnung einwandiger Balg-
kompensatoren. (Strength calculation of single-ply bel-
lows expansion joints).
Technisch-wissenschaftliche Berichte der Staatlichen
Materialpriifungsanstalt an der Universitat Stuttgart:
(1973) Heft 73-01.
PI We/linger, K.; Dietmann, H.: Festigkeitsberechnung von
Wellrohrkompensatoren. (Strength calculation of corru-
gated-tube compensators). Technisch-wissenschaftli-
the Berichte der Staatlichen Materialpriifungsanstalt an
der Universitat Stuttgart: (1964) Heft 64-01.
[31 Anderson, W.F.: Analysis of stresses in Bellows
NAA-SR-4527; USAEC, October 1964.
3) See explanatory note in Appendix 1.
“) The mterpolation equations in Appendix 1 to this AD-Merkblatt can be used.
page 6 AD-Merkblatl B 13. Edition 05.99

Irl _ . _ _. . ._ . rih
h : 0,500 0,475 0,450 0,425 0,400 0,350 0,300 0,250 0,200 0,150 0,100

03 88 .. 03 94.-04 ... ....... 04-....-. ,”04 16...04,2j...,.O

I... .L..“-. 4 .“.33
.... “.....! ...... ..04.!45...05!!!” . .....W83 . .- . ..-. .......
Q,080 ..-&i?- 34t”‘3
. ............ ................- .... .!. ..-.325
...............7. . ....310 .!...... .291.!“. . _ 277
,. . ..........8 ..“.....“..L.” 8.. ..............!..”
.271 2......304 .... . ..” 2..3.... ...$.z.!i ..
122,3 1065 93,14 81,66 72,02 57,35 47,79 42142 40,60,
0327
......... 0331
..!. ...................... 0337
0...... .._. ........... . . .._...........0346 0349
.......................... 0355
..!...................... 0379,,0427
.!.... . . . .............!.. .............. ..-? ............04,80
...................
0,090...............
366. ..................
1 3509 . . .!. ...... ..337 0 3238
.^ .........!................ 3125 . .. .!".... -29X.6
.._...! -.... .......... 311 .8<,346,9
'..". .......-....-!. .... . ..I.._-.......-.387,0
. . ..-_...I .. .......
la,2 131,1 1157 102,4 91,31 74,49 63,76 58,12 56,79i --.-* . .. . . .'
02. !. ......-,
......... 81“. ..02 84 02
..-. ............... .._ .-!. . 86,,02
. . ..-. “..A ...
..... 9;-...~2,~5....0
. .......^.2.!. .....
99..” --.03 29-,03,64
..” . !. ..... -. ...... .--....
RPI ,

0,100.3]j2fjw. . ,._.__ 360 3 348 RWI

"2.^ ....... .......... "!.."1.. . ,,336
.-...-..!.-...8 e2j_7_,f?_M,321 .._.....-...---,1 _" 351,5,,388,3
.. . ... . ".. - _".^-.-.....
178,8 158,4 141,0 126,O 113,5 94,72 8X06 77,41 R cw

Table 2: Design values

I (stress intensity at the point of maximum loading of the convolution and axial working spring rate)
 Page 7 AD-Merkblatt B 13, Edition 05.99

1
-d ..- m..-- ..-- r/h
h 3,5 0,5000,475 0,450 0,425 0,400 0,350 0,300 0,250 0,200 0,150 0,100
32,96 33,41 3495 ..&..F3692 . .@.g..f 40,14 tIzc:.,iiillI4623 ........ ..!.......... 5317
),o18 ....$.q .......... 1.,146,5.;, . .. i"$&.3""T&... 61 97 F ".g3"29" 70,91 ..a2"57"'. 84,70 1192 .............
g2 3..!.o. ..
............... .!. ..................
..!.................. ..?.. .................. ..!. ..... .............. .!..........._^..._!.. .... ,.". ......L..................!. ..............................
7,485 5,843 4,647 3,721 3,025 2,075 1,474 1,069 0,786 0,609 0,546
2859 2895 30,28 3179 .......!..... ....... 3449
. ........!..............3947 4511
......!........... .......... 5224,,5916
*................. 7251
..!...................!-.-_..........!, 9786
........,."" "A........
3,020 "25~~~~~~~"2'tj'94""'193
... ..........! ..................!....... ......... .J. ...........-."!...... . 6 ..1.7~-~3..._154.,5. , 133
.......... 4 114
"............... 8
I...", 98
......I .-.72 .
... ..88 . ...!.83
.......... .-.........?0-
104
9,123 7,203 5,784 4,672 3,826 2,649 1,891 1,374 1,018 0,805 0,741
23 6~."...."
....."..'.- 232..99 ......,.25,05..26,09.....-. 28 . ....I.24-.32 ......... 04 36'..."..
..........,"...." 28 .41 .-..!.58 ..-. .46,37..58,15......x87 ..............
3,023.-_-.? 2632 2374 2184 2035 1897 1646 1424 1226
..... ..-...-."!......... ._...... ....... .-...^. ".!................I " .... ..........--., >".-- ....L"...............!....... .-............?. ........- .!..........._..........!.... 1063.9855,,1212
11,85 9,493 7,713 6,298 5,201 3,643 2,615 1,909 1,435 1,171 1,114
2007
.. ._... ...!............ 2035
..__.! ..__... ..^.._ 2121 ..!.. ..........__ 2201 2371
-..!._...._. .......... 2670
I................ 3001 . ..............
. ........., .........L..... 3396
.. .!......"..3732 4734
L............... . !"...-5895 ..........!. ....
0,026... ...........
2703 2456
. ............... 2258
. ..!. ..... .. ............ 2117 1982
.!...... ..-.....^. ..! ..................................... 1729 . ..!........... 1498
...... "I? 1293 1136 1120
............... ..I.!.. ...................! .................. 1381
..!....... ..............!. ...
14,89 12,06 9,897 8,149 6,776 4,788 3,455 2,541 1,944 1,635 1,596
1656
,....._. 1680
"'................. I.......... ..1748 . ...... .!............. 1813
........!.......... ...1934.......?.............. 2156
........!...................2400 .L... ..I.....2671,,2885.3679
. .......!."................. .................. 4510
".!................. .........
1,030,.....".... 2771 2543 2372
..!. ....................!. .................... 2203 2071
....................!. .................... 1817
..................... .!....... 1580 1374 1231 1336 1603
. ........ - . ..!. ..... .-......... ...... ..... ........- .!.....................!. .... ............. ....
19,38 15,90 13,17 lo,94 9,163 6,540 4,757 3,544 2,783 2,429 2,433
.......1346 1366
...!.................... ..................1418 ...!. ...........-1469 1551
.... ...!................. 1708
..?....... ........ . .!............... 1879 " 2..............II 2052 2175
..!........ ..........
........L .........2785 ..!.........3395 . ...............
1,035 2834
.... ........... 2658
......................!. .......2492
. ............!...... 2323
............. . 2166
................... 1900
A..................... !.". . 1662
........... 1465 1371
...?-...............!................... 1600
..................... 1876
..!...... ......... -..-.....
25,6321,27 17,80 14,92 12,58 9,078 6,684 5,083 4,128 3,744 3,840
1123 1140 1181 12,22
D,040 ...29~~..2‘j.‘~~...25t"9"...~4i" .....1278 225 1392
.....A... ...7..... .........
1g7 3. 1513
...................... ! I......7. .-.1625
173 157...... ........ 1768 2228 26,49
1 .....$.~...g...~~..~~~ @
............. ?. .................
...!...... ..............!.................... ..!.. ................ ..!. ...... ..............!...... ............. .....................!....... ............!................... ...!..................... ......
32,5027,23 22,95 19,37 16,44 12,00 8,966 6,976 5,850 5,474 5,709
0955-2T-:;j::"'264"2"
o,045 -.L-.:~:; 0970 lo,03 ...yF$..F...23~ lo,36 1074 f11 58 12,45 13,18 1488
..~~~~,..182"5'...~~~~. 8 1822
1 8..!.o. ...................
........ g 21
2 1 .o................ 26
., 24...!.....1 3. .,
................ .................... ..!. ................... .!.................. ..!.................... ..!.. ................. .. .._._....! ....... ,."" .........?. ...
..!....... .......................
39,92 33,70 28,60 24,29 20,73 15,32 11,63 9,269 8,005 7,678 8,105
0825
........... 0838
.!. ................ ..!........., .."._0864 . ..!. .............0892 0917
..-. .! .................. 0979
A..."............. 1043
. ................. !....".........1090 1267
..A........,.-...... 1518
. ................. 1745
..!.. ............... .A........
0,050,."47,85"" 2987
. ...... .J. .._.__ 40,662838
..-!.........,, 34,71 2690
-...... .........2g,65, 2535 2386 211,9
...........!.".....2~.-&....T~-.ti~...i~~j.....~~-"~~".~f@...~ 1911 1792 204,7 2357
........
,o,42 2678
. .!......'"1.. .^......"?.
1 ,og...

0637 06‘47
o,060 .y&.....$g-$.- 0664
......... 7. 0682
275. ..........-.-..261..! ....6, 0693
. .......
248 .........2! 0727
. ............
224 ........
.!
6.. .......
208 0762I ...............
4- 220 0801. !........ 09,49 11,Oj
8.... ~~i"'2"...$.-.@. .3"
,.". ..........! . ............ "! ............_.. ..L. ..............!. .._...._._._.. L " ... ..........A.".. ,....".."......... I-.-".A . ................................!.".. .
65,16 55,99 48,32 41,76 36,28 27,92 22,35 19,03 17,60 17,73
0508
........ 0516
. .! ...... . .......... 0527
................. 0540
.?................ 0544
. ........,.__ "J.."....... ...-0562 0581
.".!.. .............. 0641
.. . ............. 0738
. .......... ,...... 0837
. ...?. ...........
. .A.........
om ,310 7 295 .!.....
.............!......."..._..." 7 ,,281............ %.2!8,6..."25
.' .... 7 0. ......239
_."..._.A.. 4 236
...I.._.!...... . ."......A. 6 ....264 .......- t.....
2 ..z!6!2...3_3_1..!8 m
84,40 73,27 63,88 55,84 49,09 38,86 32,19 28,44 27,15 27,89,
04.!...........
.. ........ 16 .04 22.........
......!.. ........ ,04.!...........
29 . ..04 39<,04
" ."!..........-.-...?. 41 ........
. .......... 04!".49..04,64_..o'j.,2_5
...........05 ......A91 "".....
3,080,........_.
3183 3049 2927 2813 2714 2578 2768 3062
...!..............._ !....., ...... .... .................!". ... ... ... ..-. L .................!...........".."".d.... .--.....-!..-......... .I.L..... 3402
105,7 92,67 81,62 72,13 64,19 52,21 44,61 40,64 39,72
.. 0350
..... "I___ ...... 03" ..!.52 0357
.............. 0364
....".&.....03
, ?............. . ,_". ....?65 0368,
..................0395
. .......... 04 38
. ........... ......... 04
. ............. 85
..... J...........
0,090,"..........
3301 3167 3052 2950 2884 2905
.I. .... _.... "...'.,"..........._J........-......."._..,......".......!.................................?.. .......3160 3471 3831
. ........!............-...!....- f
129,3 114,4 101,8 90,92 81,85 68,31 59,98 56,Ol 55,75 ........... i
0299
,......._ 0301
.!.................... 0302..... ._...-!
!“........ .........“L.. 0307 0308
_.._” ............ 0315
................... 0341
.!. ................... 0372
.! .- ................ . ......... RPI
0,100............
3443 3333
...!. .................... 3243
!" .......... ........3168
.._.......! 3123
.._.._".!..- ,."."_._ 3269
2.................. 3541
..!.................... 3871
.! ................... .!.... R WI
155,5 138,8 124,6 112,5 102,4 87,51 78,67 74,97 R@"

Table 3: Design values

I (stress intensity at the point of maximum loading of the convolution and axial working spring rate)
 Page 8 AD-Merkblatt B 13. Edition 05.99

d ,_ _. . _ _. _. . _ .
m rlh
h i 4,() 0,500 0,475 0,450 0,425 0,400 0,350 0,300 0,250 0,200 0,150 0,100
354!3,,3598
........ . I......- .....'-"....--.- 3737.3944-4264
....!...--. - ..I.... ........... .-.-.....!.... .._"4880+88 ,."-.....I. ..-... ..-.....! .I-.....I..1 6462-^I-." 7318 .-....I-- ...8962 .-..--! --...-1201 .- ..-"".A.....
0,018--....".I
229-0._2~~,8.._~.86!L.._..I__ 172 6
. ..?..... 159
._I..........!....",,."8 137
^..__..L.... 5 118
V.."..-...!. 6
, . 101
.."..I--^? 8
...- 87
."..".. A.... 41 -.....-- 78 - .A..- 71 - 9247
I-...A.,...
6,680 5,270 4,229 3,414 2,795 1,934 1,379 1,001 0,740 0,584 0,538
3079
......... 3115
..!.. ..".. .. .-....- ..!.......... - 3239 3399 3667
...."."!..............-.....!................... ..!. ......._, ...4171
.^......!. ...-........ 4743 5443
..-...!. ..--.... I....... ..-.- .- ."6093
..- ..!.. ......... ..-- 7590 .....!" I.........9819...... .!.._......
0,020_.............
2354 2120
.................... 1928
.!. .................. 1793 1668
"! .,.-.,..............?.................... 1443 1246 1070
..!...... ............ ., 2...... .._......_...!.".. .. ........._...!. ..- _ .-."." ..! 9244 8492 1038
.._-..... .._..__ .!...............^.......1."._.(
8,141 6,493 5,257 4,279 3,526 2,461 1,762 1,283 0,958 0,775 0,732
......2552 2577
.._!..-.. ..I.. ........... 2681
. ......... .......... 2793
..!. .......... .....- 3006
..-!. .................. 3388
..!..................... 3813
............ -.._- . ............. 4324
..-- 4761
. .. . ....- ^ ..__. 6011
-.!..-.-..... ..--.-. 7481
................. ..- .!...._...
0,023"...........
2430 2209
..!. ..... ............ 2009
..?.................... 1877
..!._...........-.__. .!..........1755 1527
_........!_..............._. 1321
!. ..... .._._.___! .._......1137
. ._ ...A"-.._.._._! 9964 _...__...._ 9799 1204
-. ...._.. ._....." ._..I.. ....
lo,57 8,542 6,994 5,749 4,773 3,365 2,423 1,777 1,353 1,133 1,103
2165
^....^.. . 2187 ! .!.......". ..-2272
.. ................... I.....!.-..."_. ,".2353 . ......!I_ ..- ...-.__.2525 2823
!".. ..-......-.-? .__--. .3146 ..-.-!.--__...-2 3524 -.--."..3822 ".-!.."~"...-."...!....-4849-I--_ 5893 I.
0,026... ......"...!""
2485.2272 . . _........"A......"" 2082
. .....!.... 1943
...._I.-'-."...--.!........-1- 1824 1595 1383 1197
.- --.-!..-,,.--.-A"..-._...... -".. 1067 1140
..^__
I _ A....."...""" 1369 .A--.-
13,26 lo,83 8,947 7,411 6,190 4,401 3,189 2,362 1,838 1,588 1,583
I .1787.1806
.. ... .....I._.. ..-...L. .".. ........ 1873
"..A....".. .. "...- 1935 .!__..-.. -2059 ...-! .-.-....-_.2277 ".A...-... ..-.A......"~.2510 ,^_I 2762 ..L."........2945 . .-. ..!-...--,.3734 -.-..L."..".. ._I.... 4526 ! ...". .."
0,030-.. ..-2535 -...!".. ......... 2334 2183 2031 1893 1665 1450 1270
- -.....!. ..... --..__....!. ..._, .__.__".? I_.. .- _..---.!..."... .._..I .._..L ..-.-....-- .! -..-.,I--.--.! ._I. ."... .-.A.-. ,^..._._...L." .. .__"-....!..... 1173 1349 1585
17,22 14,23 11,86 9,903 8,326 5,978 4,374 3,296 2,6442,370~2,417
1451.1468
.......!.. ..- I--.............I._...._!. 1518 1566
. ..-.......-....-! 1648
.._..-.. I".......! _.-....... ..-1800 .-L __..--....1958 .. "....!.."..- ..^. 2114
-.-.!.I ...... ..-- 2248 . ....!.....-. 2848 ..-"..A.."..-.. 3397 ..-.......!. ....- .-
0,035...-.........
2571 2420
.!.................... 2275
..!.................... 2125 1985 1730 1521 1369 1353
..!..-......."-..-.... ! ..........._.......!. ..-. . _....-......!. ..... ...--...-I !-... .. _....-_... -- ..__._........!...................... 1604 1852
.! ..-....__...- . .L..
22,6918,!35 15,94 13,42 11,36 8,259 6,136 4,741 3,945 3,670 3,819
1210 12,24..235'-&.
o,040...@...r...yT...i" 1262.."i-i'g. 1300 4" ..2tig.. 1355 14,62- .......-.
c ..l'iii;b""'i- 1571
, 6.!o_-._. 1669-i~~4~.
6 "T-."'j;"' 1845..7~~ 22,65 26,45
. ..z'i"i-s"
.....-.-.....!........-.. -.....-'-........ .. ..... !.-.....".."-....1."".._._....... .I.. .._.-_..."... ..! .^..^._._..._ .. .!,_.,,-^..."..A.... . .."." _ ...... !..".. ...._. . ._ A... . .._...._
_ I...."
2868 24 16 2047 17,35 14,79 lo,89 8,237 6,535 5,623 5,384 5,682
... 10,27,,10,39
...........-..... .........I.".. ......... lo,69
_. ......_.._....lo,99...I........._11 36 1213
..I. .... -........-_......_. "..'..-.....1289 1350-...I".1540
.I-...-.!".,........-...I . .._I.-L". ...1844 21 ...!
.... ".-.!.. ..-.-...-.-. 20..--...
0,045.............2650 2517 2384 2245 2112 1874 1690 1587
.L..."......... .-.-..!...... .-.-.""-.!....... . ..".."..".!. ..-..... ..........!-........._........'. .... .--. I...... .!.-..........-....-.!....... -. ..."...2.............. 1830 2098 2377
.._."..!...... ..-..I...-.!". ...
35,13 29,81 25,41 21,69 18,60 13,90 lo,71 8,726 7,732 7,572 8,072
.. 0886,,0896
..-.....!.................. ..?...........0919 0943 0968
.-........!.._...................!............. ........!........... 1022
_.........!. ...._....... 1076 1115
.._...!..-........... 1303
.. ..._?.................... 1531
..!..-................ ..!. .......". 1739
...........!..........
0,050.............2669,2544
..!..................... 2418
L...... ..-........ 2286
...!...................... 2160
................... 1937
......................... .!...... ._."1773
-.......1.-........1806
........"2.........2061 ..... ... ..!...... b."2339. . ._....?.......... 2637
...........!......
42,Ol 35,88 30,78 26,43 22,81 17,30 13,61 11,36 lo,33 lo,29 11,05
0680
......... ..!.............. 0688 0703
........!... ......I ......._!. 0718
.............. ..^...!.......... ..-.0727
"....!......I... ..^0756 0784
. . ..."I... ......" ...... 0832
".. .!.-....-. ............ ...- ........0968
..-..-..!.....--. ....1106 . ..-..! -.....-.
0,060.............2738 2586 2468
..!....-.................!................. 2353
. ..!. ... ........I....L... . 2244
........... ." 2. .,._,. 2062
....... . .- .. .! _.-. 2007
.........."...! 2239
.._..,--_-.? .._ _ 2511
._ ._.-.. 2812
...!......a.............L".
57,06 49,31 42,78 37,21 32,54 25,46 20,82 18,17 17,19 17,56.
...0541_..I. I..-. ..t...0547 ."...L.."" ...0556. ..I.--._.-. 0566 2--_-._-! 0568 0582 .0597
._I_I......!""...... 0660.., ...
".....A"....." ."".."A..." 0748 0839
..!~~..."~.....L.~"".
0,070... .2820 2682
. .-.._.-."~..-."~~~~~."..~.._.^ I- 2565 2460 2370 22__5_4ZJAGj-,2658 -....I- --.-."!-~--L"". 2948 3276
73,93 64,58 56,67 49,89 44,22 35,68 30,25 27,37 26,63 27,68
0441- .,.-.....A"
--.-!..- 0446 0452
..-.-.....".A." .-.,.--.- 0459 0459
L...........___.!. .--, ."0464 .._- .! ._.-_ _.-. 0483 0537
..._-.-....,.A.. _._..._- 0597 - .!."_--.. i
0,080......2959 2836 2730 2637 2575 2584. ..".""......!..-..".........'"
2798 3064...- 3375 .-"....!."... 1
~ ...!.."...~.~...." L ..-. -....."-!" - _ --.-..A...".-.._-. ..! - --...-'..
92,82 81,92 72,67 64,76 58,16 48,31 42,25 39,34 39,lO
0370
......... 0371
..!....-.............. .? ..-...... -..0375 0380 .---.!
.....!.-.._ ", .~."....L..."". 0379 .----......- 0379 .....?. 0408. ..0447
..-..-............. 0489
. ....!. ..... . .-..- . ..!.-...."
0,090.............3103 3003 2922 2854 2817 2945
..!-- .... ..--.-..."?-...... - ...".. ...!-_.. -._.-._!I ..- ..._.--.....!.-.. -.w".-~...-... I-.. L.... ---.".A..--_-....- 3177 3461 3794 .. ...!.....
114,O 101,6 91,lO 82,13 74,67 63,69 57,20 54,49 55,01<e.._.em.w .m ;
0316<0316
..........'...-... ..- - z......... ... 0317 -““! II.. . 0321 .-..-2--....-1........“. 0319 03,28.-..0351 ._^. “..! --... 0378 ... --_. .!“.... . ,. R(P)
0,100 32fi,&,m3J~,Cj_314 2 3109 3107
"..-"..! ._-,._.._-.._A----. ".-'.---.?1.....-~....--.-' 3298 354 7 384 9 R WI
137,7 123,9 112,2 102,3 94,07 82,16 75,46 73,22 cw

Table 4: Design values

I (stress intensity at the point of maximum loading of the convolution and axial working spring rate)
 Page 9 AD-Merkblatt B 13, Edition 05.99

1
h 5,O 0,500 0,475 0,450 0,425 0,400 0,350 0,300 0,250 0,200 0,150 0,100
.4031
. I. . . ..! . . . . . . . 4090
. . . . . . . . ....!. ,v.. . . . . . ..-. . . . 4200 . . . . . .!..." . . . . . 4425 . . ".!. . . . .,........ 4741
. . A..". .. . . ....!. "..".5369 .6087 .-A. ..-....6927 . . ."....!..._".-..-. ...*. . .7684
. . . . .. . ..!.. ...--!. .. . 9611 "1207 ...-.....-.?.."
0,018 ,2002
. . . . . ....!. . . . . . ...!. . . . . . . . . . . . . . . . . . . . . . . . . . .-.... 181 3 1647
. . . . . . . .* . ..-.-......!". . ,............-.! 151 0 1408 . . . ._..I 1220
. . ..-.-..!.. ....-...-...!.-.. 1051 ." 9014
-..__I -_..... I ,._...-. 7835 L . . . . ."._ . 7517
...--! . ..-...-.--_.. 9214 !..--..
5,476 4,396 3,579 2,927 2,420 1,697 1,217 0,887 0,667 0,549 0,529
..."".A...".
35 ?".35,!44. ..-3~~~~~~.-~~~-..45,9_1_.,~.,Iz.@".-5.!x!A..J?.m-...F)OA!.!". xE!
0,020,2046 . . . . . . . . 1864
. . "..".....'..... .. . . . ....!. . . . !. . . 1702 ..-.........!
. . . . . -...... . . 1558..-.b..... 1458 . . .!.. . . ..._.?..I1269
I...-... . . . !... . . . 1095 .9425
. . ...-....... ..-""A."-.....8299 ..."...A. ...-..- ..-.--.. 8526 !...."..-,_1029 .._...._.'...
6,666 5,402 4,433 3,651 3,035 2,143 1,544 1,133 0,866 0,733 0,721
2905
."..".....!
. . . . -........ . . . 2931
. . . ....--...! . . . . . . . . . . . . 3019 . . . .!. . . . . . _.,........! .3141
. . . . . ...". ..-...? . . ,I3348. .. 3728 ...._..
. . ...!..." . . . 4139
. . .._.., 4601
. .! ..-........-...... !..."... ,^....._. 4952 .?. ..-.I...-! .6244 . .7464
. . . ...-.. I,...... . . "..!.
. . . . . . 0,023 ...?. . . . . . . ..." 2094 . . . . ....!. I..". 1921 ...!. . . ..... ...?. . 1764.. . .
. .. . . . . ... . 1615 . .. ....!. . . . 1518
.. . ....!..... . .. .... 1327
...-.. ,. ...........-.! . . . .. . . . 1150.. 9983 9006
!.._".....,,..........? . .._.1008 . ......." 1189
....!_.....,........_....... ?.."
8,628 7,075 5,860 4,867 4,073 2,902 2,106 1,566 1,231 1,081 1,090
. . . . . . . . . . . .,.." . 2465. . ..! . . ... 2480 . . ....!2558
. . . . ....". . ....?.-...2645
. . . . !.... ..-...............? . . . . . . . . . .2811 . . . ...!. . . . . . ..._.3100 . . . . . . . . . . . . . ....!3399
. . . . . . . . !. . . . I._3730 ..-....... 3957 .! ,......^..4975 5941
..‘...... !.."-.....,.........,? .....
0,026 2125 1961
. . . . ....!.... . . . . . . . . . . . . . . . ._ . . . . ..^......!
. . . . . ....!. . . . ,..............! 1808 1679 1562
. . ....!. . . . . . . . . . . . _ . . !.". . . . . . . ..-. 1372 1195
. . . . . . ...-... . . .!. . . .. . . .._._.1050 ....!. . .!". . . ,.--.._. 9831
. . . .!.... ...-... .. 1159 1347
.... .,............. !...
lo,78 8,924 7,448 6,226 5,238 3,764 2,757 2,084 1,684 1,526 1,567
. . ....!,---..! . 2032. ."I.. . . . . . 2043 2105
..-.....,.-...... .! .-.....-. - .... 2161
. ...-?"...! . . _... . 2286
. . -..... ..I.. . . ..-.... . . . . 2491 . 2695
. ...-....! ...-.....!. . ...-.- .-2907 _....!..-.-,,_--._ 3084 L... .--.I. 3833 ..-!....--.. .4242 ..A. ..-.
0,030-z.!LZ.-... .!!9!4 . . . . . . ..,,. 186 . .-_ 7. ..!.?!.!5 L ..I_ . . . . . . .!.!?2;9.._ . .^ '42 ..^!..0..-.......124 . ..."..?- 8 ." ..---. 1131...-, 0 ._"" 115 ..--?
. -.... 9 . 135 7 ,_.-_...
..-.-!...".. 155. ..A... .5
13,92 11,63 9,787 8,243 6,979 5,073 3,772 2,922 2,447 2,293 2,397
..I1646 ..--. .! -..-....I ........! 1656 I.. ,..I1701
..-.. . .._.?. _... 1742 ..-.....! ,.......... . 1822 ..__L..-.......-...... 1957 L ._......II.2087 . . .".'....."..
. 2210
...." . ...!I_......I
. . . --..-. .2414. .L... . .. . . . .. 2930 L....."...,.-_. 3396 .! .-_,
0,035,....-. 2172
. . . . "...A".. 2033
. . . . .. . . . . . .!". . ....!,...,_." .. 1920 1802 1690
...-^.......!.".". ._-._.."!....". -.-......_..!.. ._.-_.....L...... 1489 1331 1237
. . .._........
. . . . .!. .,..,.. . . 1394 1600
"2.. ..-...I_..._._.!_....,. _._^......L. 1813
18,22 15,37 13,04 11‘07 9,442 6,974 5,300 4,241 3,693 3,574 3,793
o,040 -.22t'-$. 1367...$...;F".T95"5" 1375 14,08...Ti-..,".Fyyg 14,38 1490 ...&..'j" 1580."'41'-3" 16,65 .-142"5" 17,36 ,...1954 i"$..2" .sTg~f 2312 -20s-9 26,38
. . . ....!. ..I. . . . . I.... I. . . . . . . .! . . . . . . . . ....!. . ...s............. . . . ..!. . . . . . . . . ...-.....! . . . . . ....-..!. . . . . . . . ..-..,. ..I . -......
. . . '...."..._". . . . !."".., I.._I..-..!---..___......! _._.. _.._.....-..0 . . .
22,8919,47 16,64 14,23 12,23 9,191 7,153 5,906 5,315 5,268 5,649
,...w1156 . . ....?1163
. ...?.. ..I . . _.....-.......! . . . ..... . . ....!1187 . . . . . . . . . . .1209 . . . . . . . . . . . .1243 . . . '. ..1303 ...-! -..........1359 ..I. 1-....-.._1400 I.". . .!..-........1612 . ".A. ..-"....^I 1872 . 2111
..-.!. . ...--......... -L-....
0,045 . . ..--.......! 2248
. . . . . . . . . ....-.......-.! 2106
. . . . . .,...., 1980
. . . . . . . . .! .."-.........! 1877 .. .-.............! 1780
. . . . .. ....!. ...-....-......! 1611
. .. . . . . ... . .1. . 1498 1641
-.-..-.....! .. .. 1846
-.._ ...!
. . .."L
. . . . . . 2072
._"
. . . . . . .-.,,....
. . 2323
. . _ !...
27,92 23,92 20,58 17,73 15,36 11,76 9,374 7,966 7,368 7,435 8,030
. . . . . 0993 . . "..! . 0998
".. .*I... ...!. 1016
",",." -...A....-...._....... 1033 !.."..-,,-..1053 ....A.".. ..- ..,," 1094 . . .!"..U"..
. ,....._ 1131 1161 ..-
.,A...""...."."A..."....... 1353 A.".."...-..,- 1549 L."...."..,.-I. 1730 ..-.
0,050,2281
. . . . . . ....!. . .- 2150
. . ..-..........! 2031
. . . ....!. -....t..............
. . . . . . . .!. ..-.. 1920
. . . . . . . .-............? 1823
. ....!. . . .... . . .._ 1685 1673
,........_.... . . .!. -..... 1852
...-......-.!
... 2065
,..............?
..."..-.....!
. . . . . . . .. . . 2303 2575
,...........-. A...
33,31 28,73 24,88 21,60 18,86 14,71 12,Ol lo,47 9,904 lo,13 11,00
. . . . . . . . . . . . . . . . . . . ...!. 0757
. . . .I . . . ..-.0760 . . . . . . . 0770 . . . . . 0779
. . . . . ..L. . ..._....! . . . . . . . ...?. .. ...!0786
. . . . . .. . . . . . .. 0804 . . . .. . . . .. 0819 . . . . .! ..............! 0879 0995
.......... ............! 1113
......-.............! __.......
. . .0,060 . . ....!. . . .,............... . . 2372 . . . . . I....... . 2259,..............! 2161 2075
.... .,.............! . 2003
... ,..............! . . . . . .....!... . . . . .1924 . ._ . . . . . . 2066 ...-..!. . . . . . .!.. . . . .2263. . . . ..-.., . . ....-.!, ..I2494
. . . . J. .-.... . . . 2760
45,23 39,51 34,69 30,56 27,12 21,95 18,70 17,02 16,64 17,36
. . . . . . . . . . . . . . . . . . 0598 . . . ....!.-!. . . . ....?.I.0601 . . . . . . . . . . .0606 . . . _.. . .0611
. . ...-!. . ..-... . . . . . . . . . . . . ....!0611 . . . !". . . "... . . . 0617 . . . . . . . . . . ..0623 . . . .! -.,.. 0689
. .."!...^.I
. .0764
... ..-...!...._-...0842 -..."2. -..-....
0,070
. . . . . ....!. . . .."-.........? 2508
. . . . . . ... . . . . ...-..-? 2411
. .. . . . . . 2331 2270 2224
I.. . . ...-._....!".._.,^..._...."2_...... ...-... 2278 2448
. "...!.-. ...I. ..I....!. ..---.............! 2661 . . ....." 2913
. ..---. . . ...L...-. 3209
. . . . ..-.-.. . . . . !.
58,88 52,07 46,31 41,39 37,30 31,25 27,59 25,94 25,96 27,41
0486 .0488.0491
-.+....'...".-. ..I.--.!--...."..."..!..^__.....-...!.. 0494 -...,,__^ 0490 L....-.....--._.! 0491 -..--,b......... 0513-0557 L... ..".".-!. .-__ ,..-. 0608 L......... ;
0,080__._^...! 2679 .........2602 .."..-...!.......,.....-....2544 2506 250
..!.--. -.."..".".A...".,_-._. ._._..1. 2631 . . . . . .._.,,.-- 2818
..".....! -.....L... 3049
- ..-...L......."-...... 3324 L.....
74,52 66,68 60,04 54,40 49,73 42,94 39,07 37,64 38,30*
,..-"0406 .... L,._-__..^_... 0406 !. .-..0407 .._.-!...-.... 0409 --,-_!........". 0405 .w.....J-..--. 0406 ..."..".!^_.. 04 31 0462
^ .-""...L.."."....^.,_... .!..".--.0497 -...-?. ...-.....
0,090 -...,288 ...? 1
.I . ..-I._._....I..!. . ...^............282 7 280
. . . .L. . . .I.. .!".- 3, 279 1 2,s212.sJjL,.,,317 9 342
-- -....'...... ..-- -..!..-. --....A..... 9 372 8
92,43 83,63 76,20 69,91 64,74 57,40 53,48 52,50 54,06 *..em--.v-- I
0347
,....._. 0344
. ! . . . . . . . . . _. -....... !. ..-...-. ,”0344 -... “2” ..-- .0345 ..-..A .._...- 0342 -._- . ! . . . ..--. ..II. 0352 .A.. . . . . . . . 0369
.. . ..-...L.~“... 0390 . . . . -. . L... . . . RPl
0,100,._...._..__. 3128 3095
1. _.......--__...!..._.."_^-.......I..... 3078 3076
-.---A..."..-..I. 3141 3312
"2...-.--..-.. ...!....".-....".--lI-.--.--.A.-.. 3532 3802 _ R(w)
112,9 103,2 95,09 88,23 82,66 74,94 71,21 70,93 Rh

Table 5: Design values

I (stress intensity at the point of maximum loading of the convolution and axial working spring rate)
 Page 10 AD-Merkblatt B 13, Edition 05.99

A rlh
h

0,018

0,020

0,023

0,026

..
0,030 ..,

..
0,035

,.
0,040

..
0,045 . .

..
0,050

0,060

0,070

0,080 .

.
0,090 . .

0,100
L

Table 6: Design values

I (stress intensity at the point of maximum loading of the convolution and axial working spring rate)
 Page 11 AD-Merkblatt B 13, Edition 05.99

d r/h
h 10 0,500 0,475 0,450 0,425 0,400 0,350 0,300 0,250 0,200 0,150 0,100
6115
.".._-. 6177
.! _._.._....._..... 6200
.!. ......... _ .........! 6439
.......................! .............6708
^. .. ..!. .. . . ....."7251
.... ..L."..- .....^.7801 .1. . .... . .....8296
. . . ... ..--. _I..... 8749,1048 1215
.. . .........................?....... .. I......... ..!....
0,018.... ._..._.....!
1175 1092
.._ .................. 1019
.!. .............. . . . .......... 9454 8778
......................._......! 7616 6778
^........ ._.......2. .. ..-.............!. ..-. ..^ .. 6396
.. ....! 6946 7908-89,20
............ ......!.............I...... L-.................. .._.I..
2,709 2,272 1,917 1,619 1,374 1,003 0,752 0,592 0,507 0,486 0,514
5293
......... ..!. ......... .".5329
....... .!............. 5349
. ....-!...-............5527
..- .!...............5738 . . .. !. .............. 6140
. ...............".6530 6870
.......!. ..-.I ............. .! 7218,,8623
. . . ............. 9923
..!.............._ ..-.!. .................. ..!.. .......
0,020.............
1192 ..!........... 1105 1027 9583 8940 7837 7145
. ..........I..". .................!................ .!. ............-... ...! ......... ..... ..- ..?....I..........-. ...!. ......I.,.... ..-...L .." 6992 7828 8825 99,05
. . . . ... .."....!.... ......... ..-..- .!.. .... .-............... ......
3,250 2,742 2,326 1,975 1,685 1,246 0,950 0,766 0,675 0,659 0,704
4355
"...... 4365
...!. .............. 4384
."...!............."..." 4494 "....
..!......^......_...!........... 4643 4902
. .-.!. ................. ...!..... ..-_ ._.5137..... ..!-..-...5333 ..-."...!..".-. w.........!.5693 6690
................... 7598
..!.....................!.........
0,023.............
1210 1131 1058 9902
..!............_.. . . ........ "".."..!......... .......?.............. 9303 8351
........!. ..........._......_!.............. 7801
. ..- . ..! . .... 8185 9125
. .. .... ........ ..... ." ...... ....."! 1018
. . ............ 1138
..... ......!. ..-................!..-..
4,120 3,506 2,997 2,565 2,206 1,663 1,303 1,087 0,991 0,992 1,069
3657
........... 3649
.................... 3667
...?................... ...!. .......... ._3733 3840
_.......................... 4008
....................... ..... . 4148
.......... ..-...!. .............. 4262
. .....!................ 4626.... .! 5344
................. 6005
. ..!.. .................. ..!..........
0,026... ............!.
1226 1153 1087 1025 9703 8893 8608
.............. .._ ..!.................... ..!. ..................... .!. ..... .......... .! . ..".. .... .._ .......I........... ......................... 9410
. . !......! ..^."................ 1040 1153
..!.. ................. 1284
..!.................... ..!. ....
5,060 4,338 3,735 3,222 2,796 2,151 1,731 1,489 1,395 1,421 1,542
2968
o,030 .........
1 24..!. ......... 294611111.-L.::
7 'lljlj.ILz 2962...To'i"' 29,92 3062 31,55 3222
< ...~~~4"...9B,o'i""...~~ 4 3276
.1 .................. 1 3616
1 ,..!.o.................. o 7 ,I 4105
, 2..!.......... .-.......!...........
, 33 o ....... 4564
, 47... . .........8
.............
6,425 ..!. . . 5,560 . . 4,834 . . . . . . . .j.. .
..4:.$...$$. ... . .
2:92.....2,436. . ..!...... ....
2,1 _...... ..?.......
71 ............ ...!. .........
2,0g3 2,1 67 2,366 . ........!. ..... ................!.....

23 ...........
........... 57 . ..~~..3~~...23,4.~...~. 23..!. ...................
........ 45 23 ..!.88 .. 24..!. ...............
................. 29 24 ..-.. !".50 .... I. .. ..........L.....
24 65............ 27..!. ..............
63 .......!..........
30 87 ....... 3x97
..-..........
0,035....8,32g
131 0 ..1~~.,3....~.20.!5
. ..........!. ....... 7,2go 6,415 . ..5.(6~...~~~~...~~~~..3.56 .. 116 2 113 6 113,O ^. 120
.._ 1
.. ...!. .........
8 3,2g2 129
........... 6 141
....... 3,257.. 2
..-.......-.!...... .3 420. .^. 3,752155,o
.._.-......_ .^ 172to
.._.. ............
,
11938
o,040 .......... .! .....242.... ., ........
,190433 1902
, 3 o., ......
..?. ......7-. ...........!. 18@.$. .94....19 T.gj- . 20 . ....19,34
. . .19,31
j-30"5".-13'iij"4. . .. ..-.-!. 19 . 70
148 7 .".21
......... ,..-.61 .!".86 24
. ..4^ .......,-....A.."
76 128... ". ......... 2633
, g6 ..!. .......
7
...._...... ..- I....... ...... .._..... !- ....... ..-.-.... .!. .................... !. . .."........ - ..-.L" .. ..I.I.....".!.. ..... .^._.._._.L.... .. ..^".-.....! . ............... . . . . .........I ..-... ...!. ...
-%i$- 9,277 8,261 7,398 6,683 5,637 5,020 4,760 4,797 5,085 5,597
1605
. ..__ 1588
. . !.. . .................. I........... ... ..-1582 1570
....!. ....-..........-. . .!. ............... 1583 1582
.". ..!...........".........? 1568
... . .........-.....!....... 1623.1777,.1941
I............. L-... ..-.......!. .................. 2104
.!.. . ..-.. ...........!. . ..-..
0,045............ 1476 1443
...!. ...................... 1420
I...._................!. ..... ..--1414 141
......... .!. .................... 8.........
!..". ...... 1476 1563
.!...... .I... ....... ..! ... ....... ... .1675
. ... ........... 1814,1984
.
..........!. ......... -.. ......!. . .... . 222,l
-...-..............
12,92 11,56 lo,41 9,437 8,636 7,484 6,840 6,622 6,765 7,220 7,966
....1364
. ......!.. ............. 1349
........!...".. ......1340 1328
. .......!.......... ... ._..... .!............. 1332
...... ..!. ....... . ....1322
. ... ..!. ............ .1303.1365
.. . ....!..-.- .............?.._..I. .. .1477..1599_...17.!23.
... ...! ..... . .. .-.I... .!. ......
0,050.............
1593 1574 1564
..!....... .............. .!................... 1561
..!................... 157
..!. .................... 8 1644
. ..................... 173
.!. ............"...".!,.... g-,186 lXlj..,2....2199.
. ,."....?... .. . . . ........."?.... ................... 247,6 -.
15,69 14,17 12,90 11,83 lo,95 9,718 9,074 8,930 9,216 9,883 lo,92
1030
......... 1018
..!. ..................... I......._.......1008 0995
. ....!....-............... 0991 ..-.-...!....^...
. - ........."........!........... 0973 ." 0961,1012 .-.. ...! 1075
.... ...... .... . !....I ..-......... 1147
. .!...................... ...........
0,OSb 186
.... ......... 1 184 9 184 6 186 0 189
..!. ........ .-........A.." .................!. ...........".....................I......!"................ 0,,197 3 2084 222
..!.. ........_.I... ....!-.. ..... ..... ." . ..? ..I.. 6..J4~,3.....~~4,2 -
22,34 20,55 19,07 17,83 16,84 15,52 14,97 15,OB 15,78 17,03
0815
o ,070 .....2.1.2.!5
. .......!. ......... .0805
..?.$..
. ...0795
...$.$...&....215" 07,8407,775 7" ..y~b 5.. ....07 .$.55 0761 07,88 0825
T ..y.~F...25..6;l ^ ..-..!............
279,0;. 08683........,I..........
o5
................................... ...!............. . ...... ..!. ............_... ...!.._............... ...!. ................... ..!..-............. ......! ... ..-.........!.......
30,73 28,73 27,OB 25,73 24,68 23,40 23,07 23,60 24,91 27,OO
0668 0659
...........!................... 0649
..!.................... 0639
..!. ..................... 0629
. ................... ..!.......... ".0617 0624,0637
..... ..!. .... ............... . . .... ...!...........0658
..!.......... ...........!..........
0,080...............
2388 2390
....................... 2410
.................... 2447
..!. ...................... 2493
. .................. 2607
.......................... 2755
.................... 2941 L..". 3207
..!. ................................ ".!......
41,18 39,Ol 37,25 35,85 34,BO 33,68 33,74 34,88 37,04
05 62 ........
...........!.............. 05.. .............
55 0546 ........!-.- ....... 05 ..-....?.37 .......I. 05.... .......31,,05
...^.. .." ........ .!.25.....g5,25...0
............5.. ..?._...... 29....0541 ..... ...!..^.......
0,090....-265 .... 0 266
. -.-.. ,"......... 0 268 8 273
. . .. .. ._ "...^_...!..... .---.... 1."... . 3 -278
. .. . .. ..!.... - 6.29!_.~!_....3_q8,3...33 . .. . . . ... . -...... . 363,4
0 O- .... . . ...
53,97 51,69 49,88 48,49 47,52 46,73 47,36 49,31 52,58 . . . .. . . . . .
.- 04..... ...!.88 ......- .. 04,~2.04,.J~,7_5_ 04“.! I-.._.^_..._
,,.___ 69 04..!“-.. 64- ,___ 04.A”-” 56. . .04,51 . . . . . . .. ,,04,50.. . . ..... . ’ RPI
0,100....___ 291 3 293 1 296
._ '......,._".I._...L......._..._!..._.... 1 301 3 3074...3z3..je..34
. . ... . ..!^_...... . .......!-. 0 7 "369
.._-.".!...... -...".....!."". 6 R WI
69,40 67,07 65,29 63,98 63,16 62,87 64,27 6730 RN

Table 7: Design values

I (stress intensity at the point of maximum loading of the convolution and axial working spring rate)
Page 12 AD-Merkblatt B 13, Edition 05.99

A!, e.e. w.m.-.- rlh

h 1 15 0,500 0,475 0,450 0,425 0,400 0,350 0,300 0,250 0,200 0,150 0,100
I 77nc 77lQ 70CC

u,o-t I U,LII
; ...!.9.26....!..!?,92. . . . .
0,045 1 38 ,O 1 37,6.,..l,

Table 8: Design values

I (stress intensity at the point of maximum loading of the convolution and axial working Spring rate)
 Page 13 AD-Merkblatt B 13. Edition 05.99

d rfh
h 20 0,500 0,475 0,450 0,425 0,400 0,350 0,300 0,250 0,200 0,150 0,100
8916 8868 87/x QQ77 onca al nn oT)!2ll 0’11i-2 0 0 7 1 111a
.” . . . . . . . . !.... . . ... . . . . . . .1.” .-.... . . . . . . . . . . . !.
hn4e cnnn R I
Y,” I”

12,23112.012

0,035
4,u 12

.” 2644 25 !.9L
. . . . . . . ,! ..-....., ,.-....._ . . . . . . . . . ....-.Lcl..-.!
nndn 1c)l-l EI 171

0,060

0,100

Table 9: Design values

I (stress intensity at the point of maximum loading of the convolution and axial working spring rate)
 Page 14 AD-Merkblatt B 13. EditIon 05.99

T rlh
4

~ . ..
0,018 ” ..
0.723 0.653 0.595 0.546 0.506 0.449
9i40
,....-... 8$87
!. .-....., ,....-.. 2 ...." . . . . ..8i98 . . . .-. ! . . . . . . . . . . . .Si84
. . . . . . . . L..".... ..-8i21 . ...-! . . ...-.-. 8602 ,. . . ..A. . . . . . .. . .
.........!..-.-... ,. . -2 ..-....... . . . . . . . .-! . . . . . . .._. ,...-..- L......". ...-.-..! .-..-.. .6527
6250 6210 6205 6228 6300 ..-....! . ..-.- . . . .
0,885 0,808 0,744 0,691 0,647 0,589
. 7388 7242
. . .-. .! . . . . . . . . . . ,..........? . . . . . . . . . . . . . 7091 7045
. . . . . . ".! . . . ..-.... ,..........? ...-.....
. -.........! 6973 ..__...... ..-...... 6824 -'..-...- . . . .
0,023 ,. .7061
. . .! . . . . . . . . . . ,. . .7044
. . .! . . . . . . . . . . . . .7061 . . . . . . .! . . . . . . . . . . ,.._7120
. . . . . .! . . . . . . . . . . . .7215
. . . . . . . .! . . . . . . . . . . _7489. . . . . . .. I . .._.. . .
1.172 1.086 1.015 0.956 0.909 0.849
.. .
0,026 .

-
0,030 . . . . . . . . . . . . . . . . . . . ._.......: . . . . . . . . . . . . . . . . . . . . . . . . . . ..” ..-.. .- . . . . . . . . . . . . . . -.: . . . . . ..- . . . . . . . . . . ..-..... . .
2,094 1,992 1,910 1,846 1,799+1,753
_3996
. . . . . . .! . . ..-......__.3903 ...? . .3813
. . . ...-....... 3742
. . . . . . . .! . . . . . . . . . . ,.._-. ..? ..._._.... .3674 . . . . ...-.!__..-_,_-.. 3521 -.! . ..._.._. . .
0,035 . . .1026
. . . . . . . . . .! . . . . . ,. . .1033 . . . . .! . . . . .1044 . . . . . . . . . . .! . . . . . . . .1059 ...--.. .. !. _.... ...-1078 . 1125
. . ..._. !. . . . ,......-....... L.. . . .
3,013 2,905 2,823 2,761 2,722 2,703
. 3323
. . . . . . . .! .I. . . . , ,. . 3245 . . . 1. . . . . . . . . . . . .3166 . . . . . . . .! . . . . . . . . . . . 3097. . . . . . . .? . . .._.-.. . .3034 . . . . . . . .! . . . . . . . . . . ,."2890-...- L... . . ...
0,040 115.8 116.9 118.3 120.1 122.4 127.9 . . .
. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...!. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . L .._. .- . . . . . . . . . . .- ..-.

4,191 4,084 4,007 3,956 3,931 3,956

. .2837
. . . . . . .! . . . . . . . . . -. . . . .27
! . . . . . . . . . . . 71. . . . . 2700,2634 . . . . .! . . . . . . . . . . . . . . . . .! .._...... . . 2576 . . . . .-.! . . . . . . . . . -2442 . . . . . ! .._..... . . .,
0,045 . . .1291 1305 1323 1344 1368
. . . . . . . . . .! . . . . . . . . . . . . . . . . . . . . .! . . . . . . . . . _. . . ! . . . . . . . . . . . . . . . . . . . .! . ,. , .-.-.........! . . . . . ...-........... 1432 .! . .. . .
5,665 5,565 5,502 5,468 5,466 5,554
. .2473
. . .. . . .! . . . . . . . . . . ,....-....!2415 . . . . . . . . . . . . . 2351
. . . . . . . .! . . . . . .._ . . .2289 . . . . . . .? . .._...... . .2235 . . . . . . . .! ..-.-.. ."-"....L 2110 . . . . . . .. . I
0,050 _.I..........!
1424 . . . . . . . .1442 . . . .. . . . . . . .! . . . . . . .1463 . . . . . . . . . . .! . . . . . . . . . .1488
. . . . . ..-... L.. . . . . . . 1516 . . . . . . . . . . . .! . . . . . . . . 1585
. . . . . . . . . . . .? . . . . . . .
7,472 7,388 7,346 7,339 7,370 7,541
,. . .1965
. . ! . . . . . . . . . . ,. . .1919 . . .! . . . . . . . .1866 . . . . . . .! . . . . . . . . . . ,._1810 . . . . . .! . . . . . . . . . . . " 1764 1658
. . . . . . . .! . . . . . . . . . . ,...._....? . . . . . ......
0,060 ,. . .1692J716 1745 1776
. . . . ! ... . .. .. . . . . ......!.__._.. .. . . . .... ......!_.....-...............? .. . . . . . . . . . .. . . .!. . . ..._......-. .. . .! . . . . ..- 1812 1898

I
.. .
0,070 .- .

I..
0,080 I
.-.

-.
0,09c -..
I

_I .
0,lOC I
-.
51,97 152,64 153,48 I54,43 ]55,53 158,24

Table 10: Design values

I (stress intensity at the point of maximum loading of the convolution and axial working spring rate)
 Page 15 AD-Merkblatt B 13, Edition 05.99

1,018154 271543615469155291:
..__ ..-.! . . . . . . . . . . . . . . . . . . L.. . . . . . . . . .._......! . . . . . . ..- . . . . . . . . . . .! . . . . . . . . . . . . .

. . . .._.. . . ............... ..-. i. . . . .

. ......
t.020t59.60t59.84160.:

),023167 57168031687316E
......... ..! ..................... . ................... ..!. ......... ........

. . . . . __.. . . . . . . . . . . . . . . . . . . i . . . . . . . . . . . . . . . i.
I.026 I75.53t76.20 177.'

1,030 186
..__.....!. 14187 . . . . .09j88
. .. . . ....!_....._..! . . . . . . . . 29189
.. ..._... . . ..-.. . . . 67 1 .
. . ..-.....!

........Z.! ............................................
......................
. .......... ...................

0.040~1127t114.41116.3t118.41120.E

f . . . . ..___.. ,. . . . . .._....... . . .
0,045 1 126.1t128.(

. . . . . .._.... . . . . . . . . . . . . . . . . . . . I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,

0.0701
i93.5t197.0t201.0t2

0,100~2755~2810(2871~2935( .. .. . .... !- .." "..........-!...._

....._........-........!.........

Table 11: Design values

I (stress intensity at the point of maximum loading of the convolution and axial working spring rate)
 Page 16 AD-Merkblatl B 13, Edition 05.99

d r r/h
h t

0,018
I ,

. . ,

0,020
. . ,

. . I

0,023
.

0,026

0,030
. .

0,035

0,040

0,045

0,050

0,060

0,070

0,080

0,090

0,100

Table 12: Design values

I (stress intensity at the point of maximum loading of the convolution and axial working spring rate)
 Page 17 AD-Merkblatl 6 13. Edition 05.99

d _ _. _ _ _. rlh
h 100 1o,5oo~,4~510,450/0,425~0,400~0,35010,30~~50~0,100

Table 13: Design values

I (stress intensity at the point of maximum loading of the convolution and axial working spring rate)
Page 18 AD-Merkblatt B 13, Edition 05.99

d l- rlh
h 0,500 0,475 0,450 0,425 0,400 0,350 0,300 0,250 0,200 0,150 0,100
3834
_....! 4164
. .................... _ 4680
. .............. 5433
.....!..........".... .._. 6450
...... .._".........
....._....."_,,_._"9555 1505
..!._....^I... ..".." 2521I......--.
. ..!_..._.. .-"-.'...~. 4477 . 7815
"I............... 1175
.....- .............
. .........!......
1,018 ..........L....................
3375 31.....................
85 31..!.^ ........._.........?.............
85 3249 ..." 3354 3760 4162 4278 4285
. ..!...... .". ......-.... -...I............A...... ".. ..-..-.!.."....... 6279 91
. . .-. ....-..... ".(.........2 ................60
..J-........

3232 ............................
3547 4042
..................... 4766
..!..................... 5741......8724
j.. ........... . ._....!.......... 1397
. .. I'......._......_._ 2353.
.._ .!.._- .... .~"",..'.-. . 4080 6783
..I..._.! .-....... .-. 9703
. ...- !......- - .-.-..- .I.... " ..
1,020 ...4339 4145
. ._...!................ 4110
..."..!............. 4112 4145
..^....!........... ..-......?.. .._."............. 4574 4823 4799
........... ..".....".!......."....._.-..! ..-." _............! 5130 7421 1038
...... .... .!. - ..-I .-....... . ...." -........ ...! ..-.

2438 2768
......!...................... 3280
..!.............. ,_.4010
.!..I...._......... . .. I".... ..__ . .."5056
..!.- . .."-..... .."8019 1281
A.. ..^........"...." 2134
. ..!.- ........ .-..- 3547
.- J............-.- 5530
. ..!.. .......... 7471
.........!. .._I......-.....!. ........
3,023 .".......
5854 5589
................ 5457
."...?.. ............. 5343 ._5461
..^...!.".. ...... "."......!.......... 5710
........!........... ._..... 5724
. .?............... 5542
..-...!.................... 6509
. ..".!...^...... 9146
I'.....-.................. 1217
A.-................ ..-.!.....

2286
......!. 2702
........... ........... 3291
I.................... 4043
. .!................... ..!. .............. ._4988 7593
. ..!. .................. 1189
...!. ....................... 1937
..!.................... ..?.......I.....3084 4560
.............................. 5907
.............-..... ...! .........
3,026 ..........
7327 6958
....................... 6711
..................... 6661 6723
..!. .......... ,_.. ...... .!................... 6736 6535 6282 7976
..!........._ ..................................!.......... ..... .-. ..?.................... 1086
..!..........................1392
...-.................. . .....

2590
......!. 2972
.................. 3488
...?................... 4138
...!...................... 4954
....................... 7206
.........-.......1082
..._.......". ........ . .-.....!. .._"......1698 2566 ..!........... 3587
-.....'-. ..II........... 4481
-...-.. ....-I... ._........!.........
3,030 ........
9130 8613
..!...................... 8419
..................... 8331 8236
..!........... .".......!.................... 7945 7527
. ...............
..!. ..................... 7842 1001 1311 1622
-...!...-...............2... ..-........I_...._!.. ..... _...._ ......I-...- .
. . ..... .. .! .."
2871 3218
.-.._ ................
...... 3669 . ...............4228
I...... .._..... ."...!. "J...... 4925
. ........._ 6836
.!. ....."..._......_. 9699. ... ,"1437
'...."_..... .."."!._._- 2057.... .._....
I.....?. .... _.. .".....A..". 2730 .....!.-.... ..3388
. .--..! ...."...
0,036 __."
1109
_....!. .........._1065 1042
.".......!......" .._....._ ..!..... ,.__1014
"" ..A...... _-9864
......!._._..^ ....9261 8719
. ..... .._..._......._.... 1001
._- ..... .._.... 1259 1586 1904
"....'....... .-.....-_ .!m .-..........-..A.... .I-.... ..!..."

3054 .._.. . 3368

._...!......... ." ..! _............3767
._....! .._......... .._.4256 4858
..!._....... I....... 6489
. .!........".".........! -8872
-............ 1224
..A... . .....o........... 1668
2 ."....... .".-..".L ......... 2177 2651..
.."...I..-.......--"~.--.
0,040 ...............
1297 1251
....................... 1212 1168 1126
..........._..........!. ..........".............................. 1045
..!............... 1049 1228 1515 1854
."...2... ............-.. .!".. ...... ...........! .-.....-..........!. ......... 2182
. . ..... ...?...... .I... .. . e...!.. ..

h .....3154 3439
..!. ................... 3793
..!. ................... 4221I............... .....4743
..!....................... 6132
. ....... .........8110
..!. . ..... .............. 1080
.._.!....-....................
.! 1419 1791
. ..I!...-...........-...
.............. 2132
"!...-................
.........
0,045 ...............
1470 1411 1358 1302 1249
....... ........-...... I.........._".....".!.. ..-.... ._._.. .^ .!. ............... 1160
..... ................... 1247
. .!. .................. 1461 1769
..!........ .-......-.I............... 2117
"" ..!.. ......... 2457
. . .....1" .." .............
..!....

..._..3192 3448
._.........._...._3762
f..................... 4136
..!....""............ 4588
..!....-............ 5769
".!..................... ."7408
...- ........... 9568
..A....-............"..! 1219-1498
.. . ........... 1753
. .I,..!."..I. ......"...L....... ............ ........
0,050 . ..___
1620 1550
. .....!. ............. 1486
.......?" .._. ....... 1421
.._....!................. 1363
....!...........-...... 1325
...!. ..-. .......-.- ..?....-....1452
...." 1694
.....!..". .. ,." 2018 2374 2728
.... . L".... .... I.... .... ...... ,."-........L.........-. .......'..

'3140 3344
.......!. ..................... 3586
.!. .................. 3870
..!.................... 4206
.................... 5058
..!............... ....... 6188
. !. .................. 7606
..!..........-...........!. 9243
.................. 1094
..!.................. .......!. .........
0,060 '1870 1786
_____I__... ..!. .......... ........... 1712 1642 1623
.! .....................!. .......... ............!. ................... 1690
.!. .................... 1874 2156
..................... ..!. .................... 250,2 287,6
.!...... ....... ..".. .......... .......................

.....2991 3150 3335

..!............... .......!.................... 3549
..!. .................. 3797
..?.............. ...... 4412 5203
. .!............... ........!................... 6163 7242
..!..........."..........!..................... 8346
!."................
...!..."..........
0,070 .............
2084 1998
..!...... ................ 1953 1938
.. .._...... ._..... ...!........... 1953 2071
.._..... ...!............_........!...................... 2296 2606
.!. ............_....I!............. 2971,,3366
.I.....!..............."" ..!. ...................
.!..I ..
\
.....2802 2924
..!.........I................... 3063 .......
..- ." _.....!............... 3224 3407.- ... ,--^
. !. .........-. .......!........ 3854 I" 4417 . ......
.. . ... .. .-...!....-..- 5087 .A-....... ...5831
. . . ......... ;
0,080 ....2310 2265
.."..._..!.. .... ._.._ . ......*.......2249
.",."-.A.... 2258-....I..
.. ,.----..A 2296. .... . . ... .......2455 . "2.-.....2712 3043..---...........!--.
... .....!........."..-.-...!.. 3426

2601
...."2. .._........... 2694
..... 2799
..__..l.".. "."A. ."...-...... 2919 3055
.."'.. ..".....-.-".! 3383 . .-..'"...
.....-......"L.......-... 3790......-.4271 4803 ...
. .-..!......"...".
-..-'.-....-
0,090 .......2573
.._.. .,! -._,,".2549
. .......... 2555
.!...... ..-.-_
.- .!.". .... 2585
,.- .."! . ......2643 2836
..-.. ..-.A.-.. ..-- 3118 . ._..........
3469
. ..- ..L... .~..".....A.-. 3870
...-...-_-...._
. . !-..

.....2406 2476
. !. .... ................. .!. ...................2555 2644
.!. .........I .......... 2746 -I2988
I”. ... “.”... -.“!.“........... . 3288,,3641
. . !..“........ .. .. . L”“. ..- ....
...! . ..“. ..........
0,100 .............
2842 2839 2865 2914 2989 3211
..!..........-..........-- ..... .-......... !".........-..-..-I...... --.......L.....--.........'..-.. .^..... 3515 3883....
. .-.-L.-.......~..~~.""~~
I I I I I I I I I

Table 14: Design values

(stress intensity in the middle of internal knuckle of convolution)
 Page 19 AD-Merkblatt B 13, Edition 05.99

d
h
I I I I I I

..I"........1781
i?~FlnIdn17Id7nF;IF;fi~~l7nn711TJg6 .._... ...!........... 3OOg
._.__. ..........5175
......... .......... 8470
.......... 1192
..!......................
. .!. .....
-,- .- .....TV,,
.._..............I .......................
VW,"8 ......................
"l ,u I ..X.!...C..~ .155
... . ..zx!.=r"............. 4399
................. ^-..!......... ,.I4319 4709
_.....?. ...^..._ ._I.. 6728
.. ..!...................... 9230
L.". ...............
..!-........

2880
....._! 3350
..".. ....__....._I.. 4066
.. ...............
...... 5065
._...._..... ._....? 6435
. .............. ."....!. 1029
..................
..... 1674
..?. .............
...... ..! 2795
... . .............. 4649,725l
.....................
..!........
. )." . ......! ... ........9786
..... ..!.........
0,020_..__5024 4795
..!..............
.mm1.?.............4685
..""...!. ............4706 4831 5010 4993
..__ ".j........_......."...!.....".. ........... ..?.............
......... !" 4811
................. 5628 7858.1040
..-.!.......". ............. ......................
,.!................ ..!......
I I

;h’/ ,,,,i,,,,,,,,,,,,,,,,,/iiRI~~~F;11541
* n33 1I...................... . . . . . . .. ..-.....!
;; ~~~~.~~~~~.~~~~~.~~~~j~.~~t ......................
,;;; .2501 . . . 3960
. . . . . . . . . ....!_..........?
. . . ..._.....
. ..... . 5815
. ,..........?
.... 7487
..-...,...!
.....
I..58
......!...02
-I--- /..~7.!.y..~...!.!.c....~~.~.!.~.!. t.'~.r~...~...~..~..:..!.~..:...~~.~.~.~.~...~
. .....1:.....55,72
............^..... ...70,83 . . . !35,41
. . . . . . . 121,2
...... . . ..-........................
I 1 1

t3.06613,575
...................... j2'. 4...g .7i".,
260 ..75.fj'.....~..$.i
5,119 6,190 6g945
-. ......!............... 126 65".!.1422
........ 43
. ........ . 2234
. .@.A~ 3382....1'1'.....i'3'jij'-
6.. ...@.g!.gT 4734 5835l
-,--- 1......................
0.026 .-,v-
7FI 517 f”‘;j’Fi”i
....:..r 2....................
..!................... ..!. .......... .............I............
..!. ................... .. ............!..... ..-.... . ..?...................... . .. ..?. ...................
. .................... ..!.....

.......3413
. ....__..._. .....3869 4466
. J... .._........_....!. .._....... ", .."5207 6129
..?...............
.._...! 8654""............!
_......._".................... 1274 1917
..-....... ,-..... . !. ..".. ......2759 3679
........!........... ..-. 4510
".."L--..............
..........
0,030.....-....
9665 9356
......._.........._!. 9115 8844
..........._.._... .! ._ . ..".............. 8579
.!................... 8015 7492
..!. ......... .... .-....!".............-- ..! .._. I.... 8479 1062 1336 1603
.... . ....'"........--......-..!. ...........-.... ..?.... . ..^.....__.!.....

.....3699 4102
..!_ .................. 4616
".!..................... 5247
L......_" ........... I......._...... . 6025
..".!. ...."...-_......8129 1121_.......
. .."..."."...-.."...'.," 1585
"N..L.-......... 2169
..-.! -..-.. ^, ,".2785 3395
.......A-"..... .w.....- .!......I.
0,035............
1175 1127
...!. ..................... 1086
!....,......... 1042
.........._..................
J.............9996 ....... 9211 9215
.._.!. "(,"....._..!. ................ 1073 1315
... ...._..^ .._. .." ._...!.__.. .-..........-!. 1600 1876
...-............... I'....... ........-...-!......
3849
o,040 .......!.
1 34 . .g .....4207
. . . .4653 . . . .5,194
1'~~7‘...~~~~...~~~5"...~~~~-. . . . . 5,853 . . . .1 o3 7606
.!.............. 1 1009
7 ........ o ,.,".11347
1. . .2.... .._... . .3...! 3 .-....11768
o. . ........ ... .....I...
56 2228
4 . ............
1 85 7 2649
.!. ..................
214..!. ........
6
...............
. .......................
~....... ...............!......................
............._._.......! .....................
'" ... ....--.-....! ..-... ..-.......... A..-.. ...........-!....... ............... .'.....- _.. ..........
..!. .....

o,050 ...3876
, 62.3.......4153
....!..... . . . .4486 . . . .4,882
~g..~.-T.....~.~T~... . . 2" 5353
. 1..!......-
35 ........
5 ......?.
1 3g 6562
. ........-.. 8189
5. .."1 ..I-.
53 . .....-. 1026 ~1267 15,18 17,45.
4 ... .i'7~~..?'~~~...235"7".ILB'~
...............
. .......................
I....................
..!. ......................
I....................
..!. ..... ......_ .......?._.._ .._...........I.. ...................
.!.....................
!"...................
..?.....................
.....
3702’3g44 IA IZC!A AA~~A~~C~CC~A
I InfinnInnnnfn~n-~44n~ 1
. .I I Lt IQ0 9,vt.L c ...1’6’iii”5”
Y,f IU
... dUl
. . . . ...! . . . . . . . . . . . . . . . . . ...? .~5”...@..K...1’&... . ~~-.3”...~g... OOYU M,UUU Y,4YL ......................
$- ..~-.....8”....$.~~2”‘. I
284 3 I,UI
0.060
-.--- ...lR4
..L..:..!..:...1 . 17F
. .A.. . . ? -._ ................. . ...................... I. . . . ...............!..................... ..................... . !. ............................ .- ............!. ..._. ................!. .....

3446 5 ....3600
o,070 .......!..............
206 3779 3,984 4,221... .215
~~~o"..2'~~~...200'~-2'ij'2"9". 4802
..?. 5534
. ............5..-...!"....--"..
236 6 I......!6409
264.......... .2......7379
2g6
. ...! 3 8369
......I.... ......!..............
331 8.
....... .."..... ....... ............... ...................
...!. ......."........... -'...._...... ..^...... ..................
...?I-.. .-.........- ......... ..-.A...... .--......-2......... ........... J.......

.._2900
...!. .......I.........-2982
..!....-..--.....3074 3180
. ...!. .... .."- .........-? 3301 3591
I.-......-.."........................."'...-..I..... 3952 4379
.. ...!-.."...-..4852,
.......I..... .......... .." ..!.............. i
0,090 261 3 ....... 260 6 262 4 266 2 -272 2 ,, 290 5
............. ..!. ._-..........!I..........-. ...- !....... ."... -..... .! .-... ......"......I.. .... .....^....... .!....I ..3.l..lii_,l?....347,1...~36 3 .1.....
_^"........!. ;

2652 . _ 2710
....................... ....I.............. “. 2776
....!...“.......^. ..__2852 2938 ....
.I_........._..... ....I.................. 3147!.“........I. ..-3408,-3718
. !I .-.- . .... .......-..
.. ....
0,100... .........
2894 290 3 293 7 2990 306.3
...!. .........._......."?. ...... _...._. ...... . ......... ... ._... ...?.--. ........ ..-.. .!- . .." . 3269 3541,,387
. .... . . . . . .!. ..-.._I . 1.. . .
--.....!...... -._..A

Table 15: Design values

(stress intensity in the middle of internal knuckle of convolution)
Page 20 AD-Merkblatt B 13. Edition 05.99

d rlh
h 44 0,500 0,475 0,450 0,425 0,400 0,350 0,300 0,250 0,200 0,150 0,100
3231
...45 . 3881
..!. .....55..............
43.!..............
42 .....43 4846
..!. ............. 6177
14 ..:~-.A...~ 7952 12,76 20,98 3498 5789 89,62 1201
i :::: ~~:;03:~..4~70"..~~~~..~~~23"-s'l'l'ijil...j-~~~ ..-...-...-.
g2 47 !.".. ..
0,018 ....... ..!. .... .............. ..!.
.?........ ... .. ....... . ........ ...................................
.! ..^ ....... ...".
. .....!.. ....._. ... .."..... . . . . .............
I.. ......
. ...... !". ..-. ...

....3. 1.. ....105 3859

..-............ 4884
. ................. 6 ...!164
.._.!_ ................. 7..!. 740 1208
.............. ..-......!
. .................. 1973
L... ..-........... 32
..!. . ..-....... ..-.....18 51 . . 31
... . I ............ 7590
. ..... L......-.98
.... . . ...... . --......!.19
.... ....
0,020 ..........
5537 5325
. ................... 5321
..?. ..................
...!........... . 5314 5317
. .........!.................... 5258 5053 4810 6063
............ .- ..... ...!. ......... ........... ..............
..! ...................... 8164
..-. ...!........... ,._^... .A 1038
.. . ...........................

....3..!. ................
586 4.... .. 243 5.. ..!.120
................. ..6~~.14....7,56911
............... ............... .29 18........!.............
. ............ 03 28 34 42
.._.....?............. 94 ,,60,1
.........!.......... -.1..... ..............
.............. 74a81 ........
0,023 ..........
7038 6844
....................... 6731
................... 6602
...!. ..................... 6480
................... 6181 5799 5974
..! ......................
...!.,.....-.............!.................... 7549
f................ 9799
. .....!. ..................... 1204
... .-...................
..!....-.

C1,026
I 4327
, o2 7.........4,848
...--!......... @.$.....~.~....g...~ 5,517 6342 $.... .@..@.7359 y ".y...jlo,12 r...77 1449
. .....!......
8g"... go 2098
..-..L-. 2901 3734 45,26
21 ~...~lbL.~..i"~~...1585'
1,030 ........_....! ..............
...?. ...............
..-.'. .......................................
.. ..................!. ..................L...... ..... ....!...- ....-...-..'..-.--....- ...L... .--......-!. ...

..4580
..,...!.21 o.........5,033
........ 5,600 6291. ..&.<
I"i"j"o"...ri.T...yg..T. 7134 T "yrfr 9,385 .97"4812,59 ,1701
.............
, .!3..-.... ,2248
o . ........ "!........
35 ....2848
3.,..1.60L t!.....3397
. ..-..!........._.?85.!2.,,
.-.-!.. .......
1,035 ...............
............................................
...!....... ..............
.!...............!........ ...........?....................
. .........................
.!. ................. ......

4669
.......!.
, 3.............
6 o ...1'2s" 5,061 5,543
s" ...~~~ . ".i"1'6"2" 6,122 ...l"~~ 6,822.....i "&..8651 11 18 14,48
3" .-T$.Tt.Tj3m8" ...fs918,45
.4"‘"qs.3" 22,65.-.yri"'s26,45
1,040 . ........... ...!. ..... ...................................
...!. ..... ,........_.....!..................
..! ..... ..............!...................
.!...-. ..-........L...................
.! ...................
..................!..... .

4645
.......!. 4982
. ............. ...... 5390 5875
..!........ ...... .......
.................... 6453 7937
..!. ....................
!.".. ............... 9931 1246 A"".......1540
. .........................
...................... 1844
. .-...I. .............. 2120 .! ......
. .!. ..................
1,045 ....148
............ 6 140
. ..... .............. 7 133
.!................... 7 127
..!...................... 1 123 2
.!. ...................!....... -~.26,7..~.~.38.!7....15 8
..._.....-.L 3 183
..................
"! 0,,209
............... ..!. 8 237
................. 7
.! .-..

).. 4547
...,. .!.5g 7 ,...4,835
............. 5,178 5583 6060
i"~~~...~~~2"..~~o"2"...~~~ .... .7,265
1 45"5.... 'i'59"6"" 8,847 81080
...,... ...?. 206 1303
o.....6..... ....... 1531
. ..!..................
, 233 1739
I. ................
g 263 ...........
7
3,050 ............. ..!............................................
..!......................
.!. ..................
..!.................
...?... .................
..!.................... ..!. .....................!. ................
"2.....................
.!......

.....4235 4441
..!..................... 4681
...................... 4961
.................... 5285
...!.................... 6085
..!.............. ......! 7102
. .................. 8322
..!.................... 9678 1106
..!. .......................
..!.................... .L .......
0,06U' 180 5 ,, ...175
... ............!...... 6 173
. ..........?. .......... 1 172
........ ...!. ..... ............... .4..........
174 0 183
......... ..!.......... 5 200
...........
........... 7 ..~223,9..~25.1.,1~~.28
..!......
.......... ...........
...?.......
1 2

3. ...!. .............
o,070 ...208 867 4 011 4 178 4,3714.....4,592
, ...$.i65'~...$.~..~... zos"'i"'_5?..1_31.....5,804. 6 602 7 484 8,387
221 3 240 8 ..A-...~A...~~~~~...-~ "F
...............!.".. .. .............!.................. .........I.. ........... .....
...!. ....",.I.........A................! .... .,........
-.A....

..3504 3604
....! ............"..I'-__ 3719
...._..--J . .._ ........ 3852 4004
.._..._.......! 4372 4830-5373
. .................!...-........".!.."......... ....! ....5975,
.........- ... ;
0,080..............
3362 2349 2358 2385 2433
!.".. . .............?..................!.. ..... __........2...............
!""... . 2584
. ............. 2798
1.................! 3064 3375 . .
......-..... 2..."....-....A-

3170
....... 3239
.................. 3318
.1'....._............. 3409
.!...................._..............3514
...!........... 3768 4087
. .......!................. 4468
................... 4895
....................
.!-....... ..
0,090...............
2646 2648
!"..... .............. 2672
j................ 2713
...!..........__.... 2773
...!.................... 2945
. ............ 3177
......'................. 3461
.!...................? 3794--.,
..............".! :
__.__..- ..-
......2874 2973 2920
..!...................3035
L..................3107
. .................3285 3511 3784 RPI
. ....................................... .‘-. ...-..-. .......!...-...-. ......‘~~---.--~
0,100 ....._........_!
292 9..................
294 ...!....................
6 298 3..!..303 6 310 7, 329 8
................?....................!................ A.-.
. 354
.......-...7..-383.~2
.!. .... -. R(w)
L

Table 16: Design values

(stress intensity in the middle of internal knuckle of convolution)
 Page 21 AD-Merkblatt B 13, Edition 05.99

d rlh 1
h 5,() 0,500 0,475 0,450 0,425 0,400 0,350 0,300 0,250 0,200 0,150 0,100
. . . . . . . . . . . . . ....!. . . . . 4559
. . . . . . . ...?. . . . . . 5621
.*. . . . . ...!. . . . . . . . . 7016
. . . . . . . . . . . . . . . ...!8737
. ..*..........! . . . . . . . .A. . . . . . 1084
..._.... . . . . . . 1720
. . ...!. . . . . . . 2769
. 4400 .^6765
. . . I ........
........! . . . . . . . 9611
. ...?. . . .......... . . . . . . . . . . . ..1207
. ....!. .
0,018.........5571 ..!..................... 5389 ..?................... 5286 ..!.................... 5179 5084
..?................... 4857
..!.................... 4554
..!................... 4561
..!............... 5741
I...................
..-. ...!................ 7472 9214
-...... ..................... ...........

5056 6000
.......!....-............. 7235
...?.................. 8763
.._.!...................... 1064
........................ 1636
..!..................... 2572
..................... 3963
..!................ 5864
"2.................... 8018
..!.................... 9819
..?. ...................
..!.........
0,020...........!......................
6621 6365 6182
.................... 5989
...!. ..................... 5810 5429
I........... ...........!.................... 5031
..!. ............ 5386
..-.....!................... 6726
..!.................... 8526 1029
..!.......... ....................................
..! .....

5637
.......!. 6458
...................... 7519
I.................... 8830
..!.............. ....... 1045
. !....................... 1515
..!...................... 2294
..................... 3384
..!...................... 4772
..................... 6244
..!............. 7464
........?. .....................
..........
0,023...........!......................
8044 7674 7372 7059 6765
.'.......... ...........!.......... ............ .................. 6197
...!..................... 5818
.!................... 6684 8206 1008
..!.......... ...........?..............-.....!.......................... 1189
.!...................
..!.....

6,034 6,764 7,695 8,837 lo,24 14,03 20,38 28,96 39,28 49,75 59,41
0,026.........
9279 . .....8803
..!. ............ 8393
.!..............
....._ .!.............7977
.. _.....! 7590
..-.................!. 6897
.....................!. 6957
.............
......" 8020
!.............. .....-. 9672,1159J347
.! ..-....I ....... . .!.. ............... . ........-....^.!.....
...-.-?..

6327
....._.! 6959
._.........". ....... ..".7748
................ 8708
. .!....._..........._. 9876
2..."...."........ 1297
..!...... ..".. ..............?. 1737
............. 2366
.......t."...................?. 3084
. ....I._.... I ............. 3833 4542
.! ..................-...........
..!
........
0,030.............
1066 1007
..!..................... 9541 9023 8553
.!........._.......!....._._. ...........I.................... 7949 8550
..!......................?. ................... 9820
..!. .................. 1159
..?.. ......._............. 1357
..!................... 1555
...?......................
......

6419
.......!. 6944
...................... 7588
I............... ........ 8360
...................... 9288 1169
~............... .......!........_............. 1497
...!...................... 1918
!.".. ................. 2414
.................. 2930
........................ 3396
. .!. ......... .--... ...!
........
0,035.............
1206 1136
..!. ...................... 1074 1015
@....... ............... ....................... 9644 9757 1060
..........._.......!.... I.... .............................. 1206
.._....!.... ................... 1394
I._................. 1600
..!. .................. 1813 ..!.....
..?.. ..................

6313 .._6747
.......!............... 7269
. ..?.................... 7889
..!..................... 8624
.. ................... 1049
..!........................ 1296
..!........... ..-.......! 1603
.-................. 1954
..?....................
..!............2312
.......... 2638
f....................
..!.........
0,040.............
1322 1246
..!...................... 1180
..................... 1134
..!..................... 1126
..................... 1163
..!.- ................. 1266
.- .................. 1425
"!..................... 1622
.!.-. ............... 1838
..!. ..................... 2069
....-...............
..!.....

6095
.......!...... 6449
..".. ........... 6870
.................... 7366
..!. ..................... 7947
I_..................
..!..................-9401 1128
..!....................... 1357
..!.- .................. 1612
.!................ 1872
..-.!.....^ ... ...... 2111
"...!."..................
..........
0,045............
1423 1346
..!....... ............... 1313 1296
I....... ...............!...... ..-............ 1297
I....................
..!....... . 1352
. ........... 1471
..!.................... 1641
..!.................... 1846
..?.. ................. 2072
...!..................... 2323
.......................
......

5816 6104
.......!...................... 6442
.!................... 6838
..!................... 7298
..!.................... 8435
..!...................... 9882
..................... 1161
..!. ............. ......... \1353
. .?. ................... 1549
..!................... 1730
...!......................
..........
0,050.............
1535 1493
..!.................... 1469
..!. ................... 1461
..!................... 1470 1541
..!. ....................
..!.................... 1673
.!. .................. 1852 2065
..!. ..... ........... ..._!...................... 2303
. ..................... 2575
.......................
......

5203 5390
.......!...................... 5606
.!................... 5857 6147
..!........................................... 6855
..!..................... 7741
.!................... 8789
..!. ...._. .............. 9946
I...................
............ 1113
. !........... ...!..........
0,060.............
1821 1794
..! ....... .............. 1786
.!................. 1793 1817 1914 2066
...... ...............!._.............._...?....".",.,"_..... I..."....
..-!.. ..................... 2263 2494 2760
...... ......-........-.....-.!.. ...................!.......

4614
_.....!.... 4732 4869
. ._...-........?...................... .5029
........^ ..-.. 5214 5663
.".A._.......... ._....!......_..."........ . .........".....6228 6898
. ....................... 7643
.........I...........
!" ........... 8421
..............-.....
0,070..............
2108 2096 2102 2123 2159 2278 2448
J. .._......_"........'.............._.._..!..". .... ._._.. . .........._..... ... I_...................................... 2661 2913 3209
. !. ..... .........-....L.-.I... ...."...!...... ......-... . ..?......

4093
............ 4166 .^4251
_ _._....."2......_...... 4352
....!.-........",.,.? 4470
_--._"".. ..-...!. 4760
. ... -... ....... I 5130 5576 I.........--.-- 6081
....... ...". ....!................ .......!...........I"
0,080.............
2396 2396
..!..................... 2415 2447 2494 2631 281 8 3049 3324
.!.........-.."......!"... ..........-.... -........_.-._._!.--...-- _........?.. .......-..........L-.... -.................. .-"..........!......

. .._3646 3689 3741

..!........._............................... 3803 3878
..!...... ^... . ........!.................. 4066
...!. ..................... 4313
..!. .........I....4619
.!........._........ . .".?........... 4972
..........!.. ............ /
0,090...............!.....................
2680 2693 2723
..................... 2765
..!. ..................... 2822
J............. 2976
..-.....!. ..-.............- 3179
- L................. 3429
..!............ 3728
..-.-...! -.... ...............
!-....
-. . .__ .-. ...L
3268 3291 3319 3356 3402 3523 3690.3903
.......!. ................ ....... .._............ ..... .- .. ““........ “2.................. ....!. ....^....^ .......... ..-......... . .” . !. .......-.... ..” 2.. ............. . R(P)
0,100.... ...........!...".................
2960 2984 3024
....... .._........ 3076
...!. ..^........".. ......!- .... ..^3141
..".. .....t..... 3312 3532.3802
...........!. ...................
.. .............?......... ....... Rrw,

Table 17: Design values

(stress intensity in the middle of internal knuckle of convolution)
 Page 22 AD-Merkblatt 6 13, Edition 05.99

1
7,(j0,500 0,475 0,450 0,425 0,400 0,350 0,300 0,250 0,200 0,150 0,100
. 9597
. . . . . . . . . . . .._... ....!1103
. . . . . . . . ,......! . . . I . . . . . . . . . 1285
. ..._... . . . . . . . . . . . . . ....!. .1510
. . . . . '.. . . . . 1785 .2699
. . . . . .'. . . . . 3998
. . . . . . ,........... . "! .._._..... . 5770 2.._.........7957 1021 .!.. .1203
....! ._......... ._............. ..............!
.....
D,018 6626
. . . . . . . ....!. . . . . . . . 6259
. ..(........... 5951 5643
. . . . . . . . .!.. . . . . . . . . . . ...I. . . . . . . ....!,..........
. . . .'....._....
..... 5359 4842
. . .......?. . -......... 4712 5393
. . . . . . . . . . . . . . !.. . . . . . . . 1. 6498 7808 9085
......! .-.,................!.......,....^........!
.....-..

1015
........ 1143
...!. .................... 1304
.I. ................... 1503
..!...................... 1745
.!................... 2497
..!. ...................... 3588
.................... 5017
..!. .................. 6703
..?. .................. 8384 9829
..-.....! .....................
..!.............. . .........
0,020........7406 6969
...!.......... ... ......... 6592
I..............
......... 6220
.......................I 5880 .........!.............
. .............
........!.............. 5295 ...... 5489 6277
..!.......... .......... ..............7446 8785
...................... 1011
.......?..". ..........
..........
.!.....

1060 11,70 13,06 1472 1673 22,08 30,48

o,023 ..'iii3‘!~~...7~~~...~~~~...69!'68'..65'!.~~...62"3~..~~~........L.".... ...409676 o2 ..8.......5275
8..!43 64,17 75,47
._........^. . i^@.......~fF $
......... ..!....................... ..!. ........ ..............!. .................
I........... ......... ...!......................
.......-............
..!. ....................
..................
. .! -.......... . .... ... .......!.....
.... ... ...A"

1073
........ 1167
...!. .._............ 1282
..^.!. ............. 1420
.._....!......_........ 1587
"....L"..... ................ 2019
.._....-._..... 2606
.............I__ .! 3380.."....4241
..... . .. ....."...L.." ..-!"..........-5156 5979. .
. . ..L.-...... ."........L..-
0,026......_9208 8624 8111
._ !."..._.........._ .?.................... 7628 7239 7336 7912 8914 1021
..!...._............2.... .._..... _....1.....".. .. ..-."....1... ............."..!.. .._. .........., .?-- .. ..--.. ."..! 1164
........"....."....L .. . ....."....!... .,I‘1
1314

... 1056 1131

........!. .............. 1223
.......................
.......!...............1332 1461
.......L.............. 1790
...... .!..-.-- .__I. . ..? 2223
... .................!"
.... .-..... 2760 3369 -. ...I.....3990-4553
......?I...... - ..".......!. ..-....L ---. ..... .^.- !".. ..-.
0,030.............
101..!. ........
1 ........
94.a.............
. 84 89 38 86 67 85
........!.............. ....................... 97
........!........... ..8El.!.33....35,38 .. .........
106 3 ..-...-
. .^......... .119 9 135 .!.0. ..... 151
. ..-!..._...-........_ 4
...... I...........

1004 1061
...........!................... 1130
..!. .................. 1210
..!. ................. 1304
..?. .................... 1539 1841
.!......... ..........L............... 2204
..-.!......-.......... 2608 .....
..?..-.........-.......!.......... 3017
....!... ."........3394
.......! ..........
0,035, ..... ..._..!
1108 1068 1045 1032 1033
. .... [. .......... ...!......1........ ..... ..!. ..... . .... . ....... ..!. ... .I ............ 1071 1154 1273
...!.. ... .I ........... ...?- .....I..-..........!......] ......I.... .!. .." 1417
..,......-.....-!. 1578
..... . ............ 1763
..!....... ...-_.... ..L../

9378 9809
.......!...................... 1031
......".. .............. 1091
.2.......................!. ..-.......1160 1329
........!. ..... .-........_._._! 1544
.............. 1799
. ..-.!.. .. _ ..",,_." .._.I..........2079
. ... ..._.!.......... 2364 2631
-_._. ..?-..--. .............
!..".......
0,040.._........
1253 1222
...!. ................... 1205
. _ ................. 1199 1206
..!. ..... ................ _..........._... ...! 1257
_............- 1350 1477
... ...?....... _-....-....!...... ... ........... 1629 1804
L.""....-.........!................... 2010
."!...........
...." . !..."..

8683 9003
.......!...................... 9377
. ...._............... 9814
....................... 1032
............... .......... 1156
..!......_.........." 1312
2. ....... _ ...........!. 1496
......._......... - ?. ..-........1698
..-.. ...!............1906 2103
.."..-...!...................
..!....... ".,
0,045. ..........
1400 137,5
....... ............ 136,5
..........................136,6 137,9 1440 1542 1677
/.-. ..........?...... ............. ..!...... ............
I" .................... 1839
..!.................... 2028 2258
..!...... I"""""""?....... ............. ..!......
I-' r I 1 I I 1
8011
o,050 . ..g .7". ...8246 ~ .L...~...~&...8521. 8,844 ...i.53"'ij"'...154"9"'. 9,217 .1013
.......
1 62.... ...-..... 1128
o . .."..A".."
1 73 .-..-1264
o. ......,87 L"..........
3 204 .._14‘t5
-.! 1571
... .5..... -...-
224 1722
. ..?.... ..-g............
25,..!...........
g
..!.
............. .................... ..!. ..!. ..!. ^
..!........................ ...............!........................................... ..............
......... ...! ..-... . .
.... ......- !.. ,-.-... . .A... .......... ..-... . .

. . .6.816
. . . ............. 6.940 7085 . ....................
7260 .7464
................!_................... 7974 8628
................. . . ..!................... 9417
. .................
"4..... 1031
. .. . ........ 1126
...!-".... .... .................
0,060.
~183.7t"'i-ii
"._.:......t""-'.. .............
I,0 ...... I"". ................
183,7 ........... ....W2<
185,4 197,1"-- .. .-......._...-
. ......... _".....-_. 2093... ... . .......
225,7 .. ....-245,?
. ..-. . ...-...--.-......
2W
I

. . 5846
. . . .!...... . . . . . . . .5904
. . . . . . . . . .,..... . '. . 5976 . . . . 6067
!-.. .._....... .2. ."" .._ ..._6177 6465 .._......"...6850
2.. . . . ..._.."..,._._! ..A..... . .^...7331 7893,8507
L....-.."...A.
.m....
. . "..."
. . . . . . ..-.
!.".
0,070 2122 2126 2142 2168 2205 2310 2453 2632 2852 3145
. . . . . . . ...-...! . . . . . . ,..... I _..... .! . . . . . . . . . . ..-.......! . . . . . . ,..._......^,.! . . ..- _ .._..” . .._. !,..“. . . . . .._ “,...!_.... . . . . . . * ..-. ..!...”
. . . . . . . . . . ..‘..~.. . ..“-..“..!. . . ...< . ..” . . . . . . . ...!
..-..

. . . . . . . . . . . . . ..._.!. . . 5071 ,......5091 ...! .._.... 5119 . . . ...! . .. . . . 5162 ....!. . . . . . 5217
..._....._.^........!
. . .,........,.... . . . ,......5375
. . . . . . . ...".., . .!. . ...!. . . . . 5604",5906 . . . .^.. ..-L . ...!. . . . 6272,
...". . ..--.......
0,080. ... .. 2402 . . . 2415
.. . .. ...!.. ..._....! I . . . 2440
. . ,.....,,.......,.......
. . . .,...... . 2475
. . . !.... . . . 2520
...!. . . . ,.............. . . 2641
. . . . . . . . . .!. . . . . . 280
. . . . . . . . .__.,,,..." . . . . . . .!. 1. . . . .3000
. . . . ..A".". . . . 3246
." "!""...

4451
_....._! . . . . . 4448
._...,.__....,,,......, . I .... .._..........4450
. . . . . . . . . . . . 4463
. . . . . .._._..! . .._.. .!. . . . . . .._.4485
..._..!
. 4564
,...... . . . .4697
. .!.........!. ...^..... 4887
. . . . I I....,.....! . ...-.-...5131
......!.I-....--.
0,090 2676 2698
. . . . ...!. . . . . . . . . . ....?. . . . . . . . . . . ....!. . . . . . . . . . . . . . . . . 2732 2774 2827
,..............A.".... . . . .._....^
. . . ".!. .. . . .. 2964 3142
. !. ..-.--^. . . !.-.. 3362-
. . ., .". . - . . L.. 3665,
. . . .I. . . I L."..

__....!3950 . . . . . . . _. . _. . _ 3932 . . 3919

?. . . . . . . . . . .._.....^! . . .. . ..- *.3913
. .!. . . . . 3915 3944
. . . . . .!..^................. L.. . . . . . . . . .-,.4015.4133
. . . . . .!..........
. . . . . . . . . . .‘” . ...-.....
0,100 2945 2975 3017
. . . . . . ....!. . . . . . . . . . . . . . . . . . . . ....!. . . . . . . . . . . . . . . . .!. . . . . . ...-........? 3067 3128 3282 . . . . .!. . . . . . . . . . . .3719
. . . . . . . . . . . . . . ... . .._.......!
. . . . . . . . .. ..-.....-...! 3477 . . . . . .!

Table 18: Design values

(stress intensity in the middle of internal knuckle of convolution)
 Page 23 AD-Merkblatt B 13, Edition 05.99

d rlh

1918
... ........ 2107
..... .._............ ...?............. 2340 2622 2961
........!. ........ . ............!................... 3938
..!..................... 5293
.!. .................. 6941
..!. ................... 8749.1048 1215
L-............-.....!. ..-..............
..!...................... ..!......
0,018........6573 61 32 5746 5382 5067
...!. ............. .........I........... ......... ..!. ......... .... ........!. ............ 5058
...... ..!. ............. 54
.........!. ......... ...........22 6081
............... 6946, 7908 89
.._....?..... .".. ...-.....-!.-....... .__.....?. ............ 20
.. .... .!
. . .......

... '9 18 ..~~..8L..22.!79....2

........!........... 5............
..........!. 18 . .....
28 03.........,35
..!. ......... 36.......45
.!... ......... 74 58........
..!....................!. 49. 72al8.
. ._....... 86123L....._.......
9932
. . ...".. ._I................ --....
0,020...........
7057 .............. 6585 6174
........!.............. 5796 5707
......... .....-....... .._.... .............. 5803 6228
..... ...!......".. .-......-!.............. 6932 7828.8825
...... ..!....--............L- ....--.-.... ............."-....~-- 9905
.................!~. .......

l8JJ- ._....... 1997 21. . .!

. . ......... .._.._ 53 ..2339
........... "A 25
... .........- ..!. ....._58 . . ...31
.... 10. .. -2"...-.
2-..- ........ 3829,~4708-2693 6690
I ..""~.. ... .75,98
...-..L...-. . .. . ..-..... ._I.... ..-.......I...
0,023 _-..-
76.I. ..^78
.........71.,j$.....6z!23.,._^......?. 67 .._.....
88 ."........!....
67 47 69 26 .74
..._.,".......I'....I...... 26
.... ...!.... 81 A...
I -......I.... 85-... ._-
91,25~,101,8
............ __"..-... ." .. .. ..113,8
. .......I-..

...1783 18..?. ............

I.....i..."...",,__._" 86 2008 21 52
........!.. ." ......._......_.!. ....^.....2320 27
. ......!............. 39 32
.........-...- 75..~~,17.._46,26....5344.
.... .I....!.."-. . .-......L."... 60
.."......2..05
....I ..
0,026._""...8347 8069
..!.............. 7894
......... ..-..........._.. ".!.. ...........7796
.._... ...? ............7791
. . . ... .! 8043 8603 9410
.. . ...... ," . ..-. ...?. . ..^" ..... .".. . ..!.. . .. ........... 1040
. .!...........-.-.." ..! 1153
... ... .-."-....t"... 1284
. ---......!......
1649
........... 1724
. ......I .............. ...... 1811
................. 1914
.... .._............ 2033
...!.................... 2327
..!. .................. 2697
...!............... 3135 d........- 3616.4105
..-...!....-.............. 4564
.....-2..... ." ...........L ..-... ........
.....!.........
0,030...........
9552 9317 9187
. .......... ...........J. .._.................!_............ 9135 9175
........!I.......... .._.......!............. 9510 1014 1101 1207 1330-1478
.. ........!....... ..--...-....! --......-..I.....!..........-...."..!.....
...... ..!.......-...... ...... ..............

... 14 79 15
........!. ............. 28 ...........!.
.._.....I........... 15 85 ......... 16 52 17........!.31.............. 19
........... .!............. 23 ....."
..-... ........... -21 64..~~,49.._27.,63....3...0.....
...!. ................ 87 . ." .....33,97
.................
0,035.............
llO4...._?~8,6....~.e7,9....10
..!................. 7
..!. 9 ..-108 ...!. 8 .113 ...!.
. ........ ...... ................ .......... 0 120
..-....".!.. '-,I29
........ ..... .J.._... 6
..-. 141
"..... 2..155,0.
...!...... ....I._"....... - 172,O
...........
.._......

1321
........... 1353
. ......_........ 1390
"..-*...................... 1435
..................... 1486 1614 .!............1776
..!.......... ._........!..................... 1970 2186 2412
..... . ....."..-"....L.."".....-.....L-.......... 2633
-..~..-. ........"......!
..........
0,040...............
1251 1238
....................... 1236
.I. ................... 1241
..! ....................... 1254
I....... ............... 1305
.................... 1384
...!.................... 1487
..!. .................. 1614
. .?. ................. 1768 -.~....... 1967
-..L............... --~--~~L~~~

"883 12,03 ...12,27

o,045 ......................
, 3g 6 ".l'~jij;8..
...............
. .......................
8..................
i'39"o"'..~.~.,56....1.2.!9013476
14o o 141 8 .. ...i;4y6"...~-.... 14t88j ..............
16 523 .,....
167......."...... 17 4 77
. .!. .............
81 . ,."g8 '94'
..A.......... 2' 04
4 ...........!....
222 ,..-..
.._.! ..................
.... I....... ............
...!. ..... .....................................
.!.....................
L"................
..!....... ...............t
...................
..! ......

'0 65
... ........!.
..............'0
....... .!.76 '0 .........
...................!. 9' ...11__1..~~~~.._?.~.~32~..... '1 90 ....'2
.................. 68.... .. .!?..@.....~.4.t77~...".....^............
.... ... ....." '59 ..............
'723 __I.
0,050....."1538
..^............ ..".."1535 1542
_.....L _.... "............. 1556 . .I....1578
... .._.. ........."2..... .. .^......1644 1739.-..1861
I -.--?.-.-........"..!-.".. 2012~,2199a2476
..- -."..L...--.-A-.. I.". ..^_. A.". ""....."...!...
..

8 ...^......-
.......!. 760 ...8.782...8.!820....8 ......?882
-..--..-.....8..! ..".
968 ..........,9 224.. _9. ... A.-.--..
. ..^..! .._-..._ 608 .. .-...'0".A 12
... . ... . ... ..-'0.- !....."-.
75 . . .....-...I.."..._.
"97
0,060.... .......
1817 1823
...!. .........""..... 1839
".I.. ..... __ ........ 1860
...!. ..........""...... 1890
A..."..............!
..... * 1973 2084
..... .....A..... -. ............ 2226.2403,,2642
!................
-J..-... " ..........!......"
. _...............

.....7370 7345
.... .!. ... .._...... ".7329
..!. ................. 7329
.. ..!. ............. ........ I.........._.. .._7345
.................7434
. ..! ... L.. .............7612,,7885
.".!.. ............ ".... .I_.......... 8249 ."" ..! . 8688
............. ..--?.......I......
0,070 209
.... ......... 0
..!. ..... ..~.104....2.12.!8 215..?.7.... ...219
................. 5 229
. ......... ............?.3........242
..!........... 3 258
........_ ..!.. ............ . . .....!..... 6.. .279
.." "..!..- ...0I__."_"
31015
. .... ... .

6324 6275
.......!......................
................ 6231 6200
I.....!............_.........? 6178
^..........._ .......!.. ..^.......... ..."6176 6238,,6372 6580
...-..... ..-..?- ...... _I........
..!............. . ..!....A". ..!"
............
0,080 235 7 ,,237
.I............!............ 9 241. ..........0..!..-,244
..-. ...?.. ....... -249
I - ..._"......L .-..7 -- ..-..-.!. ...............
3"..~60,7...275,5...29 ..A."............... 4 1 320..!.-. 7, 1

o,080 ...5262 518

. .... ......... 5457 5399 5,350 5,308
o ..~~~~...~~~-.lij""..273"3".^~~~
...... 5254
..._6 ........
2g1.!............
7 ........
308 5248
.! .. .".......
3 330 5298
........ . 5407,
..--o ............
..!.-...".4. ....
363 ;
...""..._... I _....._._...... ..1."... ".....^......!.."...._..._._...?..........
..............
. . ....".I...... . . ........ ..- .-..'..... . .--...-L... - ."_.".......!.. ....
.._e.m.-.e .:
4882
.......!. .....-.. .... 4815
4751 4,693 ...4640 4556
. ...!.........".... .......,!.... 4508
. .- ..". ....... 4504
. ..........
.!....... .!.............. RPI
0,100...............
287 . .......................
9 "$-iii"$i~~ "%-i-$i-
I....... ............ ...!...................... 307 4
..... I ...............!........ .~~~.,1.....340,7 .. 369 ..?6......
............ Rrw)

Table 19: Design values

(stress intensity in the middle of internal knuckle of convolution)
 I.
Page 24 AD-Merkblatt B 13. Edition 05.99

_..___.._ T- rlh
1 5 3,5000,475 0,450 0,425 0,400 0,350 0,300 0,250 0,200 0,150 0,100

.I . . . . . . 38 04 40 56 4354 47,03 . ,. . . .55

..35. . . . . .! . . . .91 . .! . .69
. . . . . ....66
.. . . . . . . .! .74
. . . . . . . . . ,,79 94 .."94
..^. . . . ...! I........ . . . . -! . . . 50,..109,2....~.22.,7.,
. . . ..^
1,018 .58
. . . "...! . . .54 . . . . . . . . ,.-&?--55'$- . . . . . . . . . .? . . ..I . . . . . . . . . . . . . .! . . . . . . . . . . ..55,99..,.59,56. , . . . . 2. . . . . . ."-....--! . .22
. . . . . 0 . . . . . . . . . . . . . . . . . . . . .! . . . . . . . . . . . "54"$8""54"4"j;' 64 77 71 78 .._,......
. . ."._ ,..........? 70 ..-......
87 .! _..."
50.. I

.3395
. ...-.! . . . .I_. .3563
64,67 3760 39,94 4265 4933 57,76 .^._
..~zls~..~i.83"".61".2a".6~137'-,"~~27'".~~:i5"' 6774 . . . . ..._"65. 7870
"272 7g..._..._.45.8981
...".! . .87,46
"...A
. ._.-.. . .g7,1 1002
. . . ..."-... !......
o
1,020 _ ..__......." .__. I...........,.......... I...................... 1. . . . . . . . . . L . . . . . . . . . .1. . . . . . . . . A. . . . I..-....- .! . . . . . . . . I..........." . . . . . . . . .I.-.-- .I.. j..". . ..!. . . . . . ./.."" . . . . . . . . . . .j...".." . . . . . . ...-. \

. 3090 3207
......... .................... J.. ............3344
......... .............3505 3692
........ .!. ...-- ... ..-... ...!......... .."4152 4728 .
.-.... ........... ----..L..-. 5409.6157
..---'-...." 6923
-.--..- .! ^_.... ."..-...! 7651
.- .- ... .-.-..".! _..._I .
1,023 ........................................................
7373 7224 7147 7121 7157 7396 7830 8425 9164,,1005
. . . . ......- ^.. .._-.-!. ..- .....
. ........................................... ..!_.....................! ............... ..- . !. ...- ....... "_". ...
. I. ..- .. III
..I_ _. ....-!.5..-. 4

2801
82. !. 63
........ ..........., 2881
8I..?.43
...... .............2975
8.... ..o. !. g4 3087 3217 35,38 39,43- g5
.............~~~~...~i"!56"'...84'43"...~~iI .".4423 4956
. .._ .!. ....66.._" .."-"...!. 7 ,5509
,03.......... .._ . ...?.
I3.._^5... ..6043
..-..-
, 25.! -... 8I.. .
3,026 ....... "J ........... ..................................
I ..............................._ ........... ..!....._ ............... .!. ......... ..... ..- . !. .......... .."......~ .......... .. ..-...-...!..........-.......-.L- .. -----J~~~~~~~

? ..2459 .............25,06
........!. 28
g4 25,62 2631 2712 29,14
93'45"...~;5‘30"'...~~~5"...~~!.~~...9'ij"'o'j-' 3175
... . ..-o3
., . !. ......... , , o 6.. .....3844
5.. ..34!!8 ,..- ,..! g 6. -_4220
......... 7 _...4592
,.-3. ?. o.......... .... ..!........^
I44 8
0,030 ......... !. . .............
. .I........... .. !........................
. .......... . . .I. ... . . . ............
. .. .....................
. . . .. !. .......... . . ..! .._ ......... ....... .!. ......... ....... . .!. ..... ............... . ...............! .- ...
.......

21 .....................
............ 06 21 28 21 56 21,92 22,36 2351 ..!I........... . -2506,27,00
...!. .....- - 29,26,31,71 34,20
1 08 ........
0,035 ................ 5 -[-~,1:: -;j;j~:;i;: ...............
"l'os"'i"' "'i"l'o"5" I 14 7 I 20 9
........ ..... ..__......! ...................... .. ...... ................ . . . . -j-i$:;j;:: -:j:jj:;j:; -j-i-%-;6:: -;j:-:~:;j:;

.......... ..1~..33....~.8.!44 .... 18 61 18 83 , 19,47 2Ot41 ... ..-21... . .!. 64

18 . !. 26
... ...... 23. ..!
.... ." .. ^._.. 12....--
........ 24 79 ....2633
. ...?........... ..-.-....- ...
0,04c ..............
I 22 .!. 5..... .._1~~.,5....1.23,~ .. ...............
?$i-3"-l"i‘?kti-
.I....... ............. "!. ................... . !. ....... ..- .......... !". .......-....... ...! -....-....I.. ... . !. ...... ..- ..... ...!.. - ............... . !. I....
"'i"3'i;"'l"'"'i'38"-i"' 147 3 158 8 173 2 I94

I636
... ,...... 022 , ,I6
. !. ............ 006 ... .I6
.......36.I . .......... 01
..!. .........
,....37 I6 07 I6 I6 16,49 17,04 I7
7 ...~~~~...~~~j.~..i4'i."'2"...~~~-~- ....83
.. .".I65 , 78 , . . , 94 ..4..-.._
2". 3... -.-_?ji~~.18,..j.~~jj 212I..!..."...
g24o.
0,04t ...............! ..._ .....".I.............. .............. !. ...... ..-.-.-.... .!. .............. .....!. ............. - ..- ..? --.. ."I-. ...A...... .-"...-"L. - - ....... . . . ..._....... .. . ..- .. " -.- .."..t.... .

_....._1421. !. ........... 1415 1410

. _. . .!. ..- .. ..- ._....._ .!. ..............1408
.._ ... L . I..........1409 1422
".. ..!................... 1452 . .. !.."..... .. 1502
. 2.................... ...... . ... "I1569‘
..-. .! .-...!...... ......1651
..-......L.... .-. ...........
1743 !...".".
o,oa I.........
1497+1505 1520 1539 1564 1630
_. . . !. ..... t...............!. .....I............ . .!. .... .I". . .._ ...A.. .... /...%.-.!..""~.............~......t 171 9 183,2 197,4
. ....... "2". ... . . ... . ...... I"+ ^- ...... t-....-". 216,6 2440
.... .I I......... ... .I ....
I I

, .
0,060 . --l--
! . ! . ! . % . . . Y . i 40
. . . . . . . . . . . . 1129
'9
. . . . . . . .! . . . . . . . _^ .1120
1802
. . . . . . . . . . L.... . . . II
1828
. . . . . . . . . .! .I2
1861
. . . . . . . . . .1104
. . . . . . . . .? . . . . . . . . - 1107
1943
. . . . . . . . . .! . . ." ._..II
2050
,......_.^22
2185
._... II
L.... ..-.-..-! .51
2355
. . . . . . . . . .1192
. . . . . . .! ..a.......
2617
. . 176.4
. . . . . . . . . . . . . . . . . . . . . .177
. . . . . . . . . . . .! . . . . . . . . . . . . . . . . .-.! . . . . . . . . . . . . . . "..A . . . . . . . . . . ^....,.....! .._._ ,.........._...?......_ . . . . . . . . . . . . . .! . . . . . ..-.. "I . . -?. . _ I..-..-... !.."........." . . .-.L-.. .

" .9640
. . .! . . . . . . . . . . . . . . ,. .9501
._. I................ .9367
. . . .! . . . . . . . . . . . . . . . . 9244
. . . . . I . . . . . . . . . . . . . . .9133
. . . . . . !." . . . . . I- . . .8952
. . . . . .! . . . . . . . . . . . . . . .8846,*8831
-...A.. . . ...-... . . . . . L..".. . . . . . . . _8913<,.9,F1_9.3..
-2." . . . . . . . . . .
0,070..._..........,E
2025 ., . _, ,. . . . . 2048 2078
"...A . . . . . ...._..._. ,..-! . ..._....._....-. 2112 "A . . . . . . 2152 ..-.........! . . ... t. . . 2251 . . . . . . . .! . . . . . . ."..."_2377 . . . 2535
. . ..I."".. 2769
. . . . . . "- ?. . -. ...-....-"L".
. 3070
-----'---
I I

. . .8262
. . .! . . . . . . . I . . . . . ,_8120 . . .! . . . . . . . . . . . . . . . . .7979
. . . .! . . . . . . . . . . . . . . ;...s. . .7846(7,72017,4961
L..... _ . .~r/fzFf~255
. ., . . . . . . . . . . . . . . . . . 5’~i
. . . . . . . . . ...! . . . . . . . . . . . . .
0,080 p...
228.3 231.3 235.0 239,'
. . . . . . ...! . . . . . . ;.....- . . . . . . . L .,.... . . . . . . . . . . . . . . . . . . . . . . . . .-....- _.. .I . . . . . . . . . . .! . . . . . . ” . . . . . . . . . . . . .! . . . . . . . . . . . . . . . . . . . . . . ! . . . . . . . . ..-...-... .! -....
I

....!. . .7. 217 ... .. .. ..... . 6.!937

. . . . . . ,,..L!?.?? . . . . . . ...!. 6. 673 .6. ..._.............
. . . . ...?. . . . . ... .. . 6. .803 . . . . . . ....6...!
...?
430 . . . . ,.............
. 223
. . . . . . ....!. . . ,,. .6. . 063
. . ...!. . . . . 5 g60
0,090 ,._..........._!
253 . 8. . . . .,_.257
. . . _. . 5I.......
. 261
..._......... !. 9. . . .,..266
. _..-...? . .7. . . . .. .272
. . . . . . . . . . . .! . .3,,285
. . . . . . . . . . . . . . . . . .! . .5. . . . 303
. . . . . . . . "...! . .3,,329
. . . . ._._..._... "? ...^Im..3G&2..,
,._.mwv.... -'
6399
_,.,,,,! 6264
,__..,.,,.....,,......? ............... . 6129 5997
. . . . I . . . . . . . . . . . . . . .-.A ..^...... _... .5868 5620
..-.. I. ... . . ... . ... . -...A. 5397.,5208
. . . .- . . . ...I--"L--.- .--.? .....--- ..
279,0
,O,lOO _....,,.." 283,3 .._288,4
..,,..._.__,)...................... 294,0 ..._300,3
. . . . . . ...-........ ._.................... ..-..... -..-.., .I".....315,4 339,4,,367,9
. . . . . . . . . - -...I-.......-.... .__".._ . . . .. . .

Table 20: Design values

(stress intensity in the middle of internal knuckle of convolution)
 Page 25 AD-Merkblatl 6 13, Edition 05.99

d r rlh
h 3,5000,475 0,450 0,425 0,400 0,350 0,300 0,250 0,200 0,150 0,100
5086
. ......-.....5272 5489
. I....!-..-..... .._.- 5746
_ .!.............-.-....! ..........6044 6776
.-....!......I ......""....! 7694
.. .!"......... 8778
........ . ......... . . ....... . ....9971 1119
- 2..... ." ........... 1236
. ......!-..................
..!.....
5796 5681 5621 5600 5625 5802 6125 6572 7131 7808
0,018 .............._.. ._..."....!...".. ......... "! _.....". .. .._.. .._.!. ... .._._._..,..!,"..... .."..-..-.I____".........!.".. ........."".L...."......" ".A."...... .-........!................8653
.... .....-...
4665
.........
63 I..8g 4798 4955 51,42 5359 5895 6572 73,75 82,66 91,91 100,9i'
...........8~92....gzl~~...~~~~..~~~~...~~~~..~~$';j"...~~~~-."~~~~.~~~e"i-..~~~
0,020 ....... ..!. ......... ........... ......................
........................
.................
." ..!...................
.......... ........I.
L.....".....".....L........
.. . . . . .... .-.. ......L-...........-...!. ........
41
....... 03
72..!.6.........
o . .41 82 42 77 43‘92
.~~~~...~i"!~~...~~~ 45,28 ........
. ..7.gg. 48 69. 553-;~_9...08!f?J
75"!..........
og 7g o7 .. 84 4 1.. - ......... g64,42 70,77 ...i'-i"r
1 1 ..4 ..... g3".gij-- 77,05 .$
0,023 ...._... f.. ................. . I....................
..! .....................
......................
. .......... .._.......I.. ....................
I"........ ......". ..!......I.......... L. .- ..- .-........I..... .."......- ....- ..L..

3629
81 ,4
.......... ,, 8 3674
. ..................
o..!.7..-...... 83728
o ...........!.
o 77 3798
81......!.
. ........... 21 .-.. 3882
.....^ .....82 og... ..-&.4102
.. ....... 4394 47,58 51,77
..- ...e s!5Z"'.-~r4~...~..@... 56,31 60,89
g ...~~$...$-.....'i"i'~ j
0,026 ................................
.......................!. .......... ........... ..................... ..!.....................................
.._....!..............
".... ..........
.! - .............
I. ..-................
...-.. I... _. ..... ..!.....
31 3 217
g 2 .........
..........!. 31,32..~~~
".B'i"'z~ 31‘54 ..g3!3q. 31 87 3229
...g4!.$..y. ".~a"'~~ 33,49 ...i'o'$ 35,21 37,47 ...rT~
.-$ i"'~~ii' 40 17 43,19
$.-...i"z.z 46831
.. ...Tay 7
0,030 ..................................
............ ...................................
.......................
........... ............ ........................
..!.........................
. ............................................
..!......................
......
26
, o626 o 26
..........!............ .........!
,06,3 22 26,07,,
.............
...... 22 .J!.,.28....2gj4J
..!. ......... 1 o8 2 1 og ...8 . ..~$..$......~g....
26 91 27 .$. 78 29,03 30064
.....i"zs"'ti"'...~3F .-$- ..T$...32,53 y ..~ 34,56
..y
0,035 ............. . ....... ......................
.....................................
.......................
. ......................
.....................
..!. ...................
..!.....................
.!....... ...-..._.....!......... ..I._.......!......

..-22
1 g....56
1 .....!. 224 1 22 F..
5......... .j'.&.F...T$.. 29. .i"2;i-"'&.....?'2';j;"'
22,22 22,19 iii"' Z,~~..X2,.22,~8
1 3 o o . 1 36 g.. .....2336 i45"8'..j..~70~ 2432 .. _____" 25,52
l 7 l 3 ." _.._ .26,66
. .........
1 g2 7- ..
0,040 .............!............-.......!. ...... -..- .........!...................... !..". .. ..-.............. ..._.........?.- .............
....!...".. .._...-.......! -.......
.. ....." ..!........ ..-..".- ..!-.-................
.!......

f 1970
,._"....I." __.,_1950 -..-J _...._. .._.". 1931 1916
. .... I I................ 1905
"?I.................... 1894
. ..................... 1902
...............
.._...! 1934
.......... ,._.".. ..L 1989
... ............... 2065
. !.. ........... .2155
_. ...JL....-.........
. .! ........
0,045 . 132 8 133 9 135 4 137 3 139 6 145
..".._........... ................I....... .. ............!....... _ ............. I.............-.... ..!.. ........ 6 153 5..._?~3,5....~.76.!.1....
"!. ..................... .-. .............
. ..........!.- ................ 193 4 217..!-4...

.. 1744
,............. 1721...T.L$.
46 .o........ 'i;4Tc 1699 16,80 ."1'5';j;"3""
y ".i;'51"'6" 16,64 ..... 1639
1 ..6..!.1........l . ....11630
..-6g 1638
. ..!...-g. ........18t"l" ...i..$~ 1666 17,12 17,72
1"" ..;i"i"5"6"-242"' i"
0,050 ........_..... ......................
....................
..!.......................
....................
..!_ ..... ...............I...... ............_.! ....... . ...........
.'L.. ........." ,'...."....".-.A"-.......
....
. . . .!.....
1413 1389
............................. 1365
...?.......... .......... 1343
..!........_,....._ 1321..!. .......... _1284
............... ._...... 1256
.-..... .................................1239 1236
..-. ...I " -...I..-..".."!. ....-I.....1246
- ...- I....." ...
0,060 .. ............!.
1721 ........1742
. ..........I.........1768 1798
......^.... . ......... 1833 1918
... -. .....!.........^"........!........ 2025
.....................2159
..-...... ...!.......... ........."?..^...2351.2602
. . . .........!............
. .......L"....

1184
. .........!. 1161
................... 1137
. J.. ................. 1114 1092
...!. ......._............!...................... 1051
!".................... 1015
.!.............-.. 9862
...!.. ..............
.........
. ..... 9672
? ......... 9589
. ...............
"2.. .............
0,070 ..............
1979 2006
....................... 2040
j................... 2077
...!.........._...........! 2119
...................... 2221 2347
..................... ..!.................... 2523 2760
..!........ .-..-. .. ...?.................... 3050
..!.. ..................
..!.......
1018
....... 9954
...!................. 9729
.I. .................. 9508
. . .................... 9290
..!. ................... 8869
..!..................... 8481
..?................... 8143
..!..................... 7873
..t...................
..! .............. ;
0,080 ..............
2233 2268
. ...................... 2308
I...................... 2352
...................... 2402 2520
.....................!...................... 2680
.!................... 2902
..!.-.................. 3171
.!....... "............l......

8914
....... .............. 8705
.......I.. 8494 8284
... .!. ................
................ 8074....!.............. 7663
.....I................. 7270
........................ ....L............ 6911 6599,
.......?.................
. ...!. ........... i
0,090 ................
2485 2526
_................. 2573
...?................... 2624 2681 2826
. . .."......... ...................-.I.......!.. .......
,."...............
.......!. ..... 3035 3284
.!..".... _ ..".-....2 3585
..........
. ..^...!. ..-..
_...__..._ _
. . 7. ..!. 925
......-......- 7,7~~-.J.~3_2-. ..-.7‘........- 334... . 7.A..-.. 136."6 . 740 - - 6 - ......354,,5,989-
..” . . .“... .. .. . . ..".... RPI
0,100 .-..-.-
273 .-!.....4 2'J~._..283,5 366,7.. -.--..."L.... 289 3 ..... 296 5 .316
. . . .. ..A-.. . . . ..-....1. ..... . . I....-..--..
339‘2 .._...........".... . Rm,

Table 21: Design values

(stress intensity in the middle of internal knuckle of convolution)
Page 26 AD-Merkblaft B 13, Edition 05.99

d . . . ... . . . rlh
h 30 0,500 0,475 0,450 0,425 0,400 0,350 0,300 0,250 0,200 0,150 0,100
7524...........!.. 7610 .....- .. __7717 7855
.I.. . . . . _. " ..I.-8023
.......!................... ..L ........._._.....8464 9056
..!...._" ... ..""."9796
. I................. .!..--I.. ..-....".... 1065,,1158
.! .-... .... .. . .. ..! .-.. _.._1252
..... ...!
.. . .
3,018 -ss’!‘iiii” 5595 5597
. ...?........... ...........
...........!. ................ 5624 5680
.!. ....-... ...........
. ...................... 5877
. ...................... 6175
.................. 6574 7080 77 . .L.........
..___!.._.........-......!. ...-............. ...... .-.... .-...... 19 8546 ..--.-A.-......

67..........
............ 25 ,67 65 68,20 .......... .!.,68
......_. ...99 70
. .......!.......... 01 ...~~.,~.....76.!86-..-....-.82 07" -!.88
L...." ........ .-- .... I29,,95 I ...-102,3
..- ..A.... ......19 ..........I ...
3,020.........61..!. ......................
85 -sl'!'s<"61""iii6" 62
1........... ........ ...!. .................... 28 63
.!. .................. 00 65 27 68 59 72 98 78 56 85
. ... .. ..-- ............?. ..._. .........."...!.. ...........
..!. .................
..!.- ................ 64 94. ..!..".
.... ..?...... -. .-.... 83. ...

57 .61. .... ..... ....._

........... 57n60-..-.........57
..... ..._68
.!. ......... .~~~,92....58.!3~~...~~,68...6~~!90~ .... ..--
652..01 . .._..... .-.
68"" 2.
.... . . _......
94
... 73148.._.................
?8,30 ..........
w3 ..........
70.! .08 . ..........E.!~..5...7.!.!55 . ..... .71!.20.... .72.!!.5.. 74
.......... . .....
89.._. ...78
. ._ . ...!.74
..... ...... ._...... 77 90. . ..!.1. ........
83 ................ ._._................
5 .I g8t27 .....109,0 . ..........I...

50..!.14
......... ......... ,,49 89 49,70...49,63...~9.!67...5 0 ...16... .........
..........!. 51.._..!.30,
......... ".53 13.....55,63,
.... . I'..._...... 58a67
._.......^..... ... ...... ...".... ....62102
."...............
A026 ......... . . . . . . .
78..!. 19 :Z~~~::::7y:II!Ij::...BOIQPI.....!.L.Z.....84.fto.....@.!!?O... ..........I... 94 4-i' .
...................... .
101 .!.7..... ..^"...-.
1 10. .........
19 ....123 ........
.........
I4

4254
3,030 ...........!.
88 8g 4212
...........-.A. 4175 4146 4123
$ 1111 9i31:42::...91.!.59...9.~!~ 41,06
. ..$.- 6'. ..4135
i'b2 1 4215
....!. ......... 1o8 7 4347 7 o 'I 4525
...............................
1 1 ..!.......... .......... 4735
127.!. ..-..6.............
142,8 .! ... ......
...........!. ................... ..!. .......... ... _,___,,_! ...................... . ....... ............ 2....... ...............
~........... ............... . ...... .__......2....... ..... .................

.......35.........
..!. 60 ... ,,35,1 1 34,63...~4,2_11.....33,83~..3 ..........3.. ..........
24." ........
32 96 33
. .................... ...!.. .... _..04.. . ^-.33..!..........
51 ._34 ........L".
36............
35...!50 ... . ..
0,035...........
102. ...........
1 -i-@-i--""i"o4"4"
................ ...................
..!. 105
........
. g
........... 107
I....... ..^ 8
........
...! . 112
......... 5
........... 118
......... 6
.._...........! 126
..-...,.-. ..... . 3
A...... 136
. .... .._......! 0
^.... 148,8
.__^...^.."" 167,0
-......
. .‘. ......
-.....

30
1 ,5. ..-53
o,040 ...........!. .3001 . .. 2951
2......T$.g...11‘$"2"',... . . .$g....~.~~~~ 2903. . 28,58 . . .2780 127 g 2722
..?._ ........ .^_.-134
..! g".._2_Ij_!jj-.
...... 143 8'-154g" 2c2.8_!.27 17018
..........? ---.7"". . _-2774
lgl ..! ......3 .
............. ..!. ..... ...............!..........._...... ...!........._._.......I..._.. .. .._.........! ........... .!. ...... .._. ...I... ..!.,...........-... I .._It............ .!. ......... "..... "...!.-..
. ........ ...!.._.. ." ...........

...26 68 26 ...17
. ....-.! . ..................... . . .... 25
.... 66 25 ........17
...... ..!............. 24........!......_
. .............. 70 .....23,83....23.!~.0...2 .. . .. 2..L.."
..... 56..... -22 25 ,,22
.._.L......... ..^...I. 19 ...".."_
L."....... .22,38 -........
0,045._ ............I..
1283 1299
..__.._..._.....__..! .._. 131. . ..........9 .....................
................... 1342.._..........!1368 1432 ..........
........... 151
...................... 2,,161
..!. ........... 2 1742,
..-....L. - ............ 192,s
......!..-.. ^......... 215,7
^"............................

2367 2318
.. .._......!................... 2268
..?.................... 2219
..!..................... 2172
.................... 2081..!. ........ ......2001
...!.................... 1934
.... ..!. ......... ............ 1885,,1857
t - ..........-- ..... ...........-..!.. ........ 1851
. ....! .... .......!. ........
0,050.... ...........!.
1412 1432
.......
..... ...... .... ..!. 1455
.............
...!. 1482
..".
....... . ..... ...!. 1512
................ 1584
".A...-.............
. L... ... . . . 1674,,1785.1942,,214,5
.......... ..!. . ... ..-. ..." .A...........I .".... !."... _.-............. .." _240,2
". .......I..."..

......1929 1883
.._.!. ..................... 1837
..................... 1792
..!. ....-._ ............. 1747
................... 1658 1573
..!........ ... - ..I..
..!.................... 1495....!.........1428.1376
... !". ..-.... _...... -....-. ..!..I..... ...".".L..........
0,060.....1669 169
. ..-... ..!...................... 5 1726
. .. .................. 1759
..!. . .................... 1797, 1886
.!. ...... .....".......!.....................
........ ..j.!l>5....214 .._" .."....?. .........._..... ...!.5,,258,6
8 234 . .........^.-...". ....

1625
........... 1584
....................... 1543
. ......._. ......... 1501
..!...................... 1459
..................... 1375
..!................... 1292 1213
..!........... . . . ........!.............. 1140T,1077
.......!..............
........!....................!...........
0,070.............
1923 1956
..!...................... 1993 2034 2079 2184 2334 2522
.......................!. .....................!.......... ............!. ...... ............ ...!.....................
.'.......... ............ 2749,303,0
J.............".. ... ..!. ..... ......... -...........

14..!.04
......... ......... .... .I..?.!?......!.3.!29.. .. 1231 1?,52.............. 11 .!...................
74 10..!. ......................
96 10 ........... l8 -.g,444 ^......._........
0,080....217 . 5 221.......... 4 225
...........!...................... ......... 8 "%i6"'5""235"'ilj
...!. ...... ............. !."" .. * .2504
..!. .................... ..!.......
......... ..228i4 ...... 289
.........
. .!.
.7 315
......
.......... 6
. .!.......

1235
........... 1201
!."................... 1167
I.... .! .."......... .._1132
0............... ... 2. ...........I.1096 1024
... "1............. 9501 8763...... . . ...8038
....I........ .-....!
....... -.. ..- ."....! ..A."......-...
0,090_...........
2425 2470
"!. ........ 2520 258_8_--~~-,3.~
. ... ...... L...... ._--.".....!.... .... ......."..? 2834
_.___A.. 3035
.._^.......
... . 3275
._............
. 356,5
..A.-.--.-I.. . ..I...
.*.-.--.-.-I
1102
..,....-.-! 1071
.-..-............. .!... . . .....1039 . ...... 1007
. ..-.! 9746. ..-.!.”
.... .. ..“...!.........“-
t...-.-.! 9075. ..... 8385,_7685
..- . . L..- . .A............ . RPI
0,100.......
2675 2742... _ .......2815
..-...!_..... ,."2892
_...._"L.... ..2976
. ....... . . ...........3166 3389 3654 ... R (WI
..-....!..... ...............L ..^..... L ..-.. ....
. . .J....".--.-"-.~--

Table 22: Design values

(stress intensity in the middle of internal knuckle of convolution)
 Page 27 AD-Merkblatt B 13, Edition 05.99

d _. . . .
-r rlh
I

h 45 0 1,500 0,475 0,450 0,425 0,400 0,350 0,300 0,250 0,200 0,150 0,100

,. . 1,05.0 104.4 103.9 103.7 103.6 104,4 1065 110,l 115,'

),018 . .&I.
I

cjg. .!................... 1000 1048

..I. 3304
.... 4 o 5g 9217. .!. . 91 . .39 . . .9079
. .6~~~..6‘i'lo'jij"'..62"04"...~4"57"'.
75.... .... 90,35
. . .90,09 . . . 9086 g5 9280
67..!.._._I.....".
72. ..!.28 9590
......... ,, .._...-.
77 L." 78..... ..-...-.^.
84 "!."... ........-...
8, g4 22 ..!...".
1,020 . . .c. .._...! ......I .. ........_..! .....................
.!.".... .._..."^....!.........
...... .... ............. ...-?......................
. ......!................. !.-.... . ,- .."...~.............. I. .. .!.-. ...........-. ..?^.....^..

,. . i79
......!.20 78 . .. ..-.!.14...
......" ..... ........ .77i_?.f?.....76,25v .. 75147 74%' ..............!.
73 ..........
88 3,30~,75 ._"-...!-...-.-.
61 ......-...!
77 78 ....... . ,,80,59
..... _..............
1,023 ,. . I 37 36 67
......... .......................93
..............68
. ....... ...73 69...... ..!.70
............ ......... .:~~0:~~~::17319:!:. . 77 86 82
. . . . _......!.................... 88 89 22
..!. ..................... 97 ..!.......... .... .........!.6......
......-.............32 108

. .t5878 6766
....... .!. .................. 6657
..!. .................... 6556 ..!. ..... ..-.. 64,61 63,00
.!. ..... ............. 6190 6142
..!........... .._.......I."
.......... 6166
. ..".. . ."....." .?^. ..".... I..6260
. ." . ..!. ..........6414
. .... ...!...".. ....
3,026 ,. . 75 26 76 05
..... ..!....................
..!........... .~~.,07.....7.!26....7~~~..~~~~ .
............ ....................... 87
. ................ 72 93
.._ ..!.. .._.............. 43
..!..-........... 100
. ......!. 6 109
... .................. ..!. 8,,122
......... 9
. ..".....?.......
1 54,08 52,19 5063
. ! 51340
35'7....86'!80".5728 "sFf7.. 56,17....&....-$ 55,ll g....9'f..31"'..$.cg f ............. 8 4950
, o.o...................
, o7..!.......... 4888
4 .........
, ,. .?.5. ........ 4882
8. .........
, 26 g 4930
. .......... ..........!
,42. .,...-..
D,030'I,.. ........I...................... I.................................................
. ....................... I...........
_._.___.(._! ...................... ..!. ..... ....... ..--. L.." .. ..... . . .... ..!. ...... .............
..- ................. ..!. .....

,. .4 1904 4798
._ .. ...!... .._............... 4692
. ....................... 4587 ............ 44,84
I...................... .... ..__.............4286 41 .06
" ......... . ..................... 3953
.... ...-..-....- 3835
. . -2.. . ..--..3759.37
..!...._" ....... .. . . ......-.-.- t-...-..!.29
. .........
i I
0,035 . , .........
9877 ..............._loo,2 101 0........ 8 _._......_
................................1037 .!........... 1058 1108
_....... ..!.-.-. ........ 1171
. . ... ........ -...-..- 1249. _.^.I ..1346.1485..jjl.~~
. ..!.... ............. .".-.-.. L..". ....__......! ..-.. ...

42 ..23
,. ........L. 41..!.24
-- .. .-..- ......... 40-....- .?.24 39. ...-.24
....--..... .I...........,.~~.,25..36,30...344 .. . ..I.._ 32-
4 .. ..-....! 75 31 ..
. . ... ".-I-'- 30
. .... I30,16,
-...-.... ..29,40 . . ..."...."...
0,04c1 . . ...........
1117 1134
..?. ................. 1154 1176 1201
...!. ..... ......_....-.1.~" ..........".. . ..!. .............. 1260
..- ...!. ..... . ...........
..!. .. . 1332
... ._...._.!..
." 1422
_.__^_, ..!..-. 1543
.-...... .
A..... 1702,1903
.." ..-.....
. !.... . ......
..-!.......

t 37 06 36
...... ..!. .................. 14 3521
.._! .................... 34
..?.............. 27 3333
. ... ..!...................... 3146 29 62 2789,,2631- . .. ..!-...-... .^.......!... ...........
..!............ ..-......................
L................... 24 . . .. ...--
96,,.2?,,$_4_m
. .I
0,04ci " ............
1246 1267 1290
...!. . ...............
. .. ................ 1316
. .!. ...............
. . .._ .!..... . . 134,4 141 1 1493 1597 1741
. . ...!........._.._.."... ..? . ..... ... ..-.-.- ..!........... .... ..-..?
................................... 1919
..-.... . -. .. . !..". ...... 2145
..........L....

3301
.........
,375 3216
! . ..................
13g8",425 3129
..!. ................... 3041
........... .........
,454 2953 2774
..!.......... ....T$$....T.! y....25,97 2424
"...........-..." 2262
i"65'4-.,78,'",g40 2117
_._,_!,...- ..............
2,37.'2388 1998
..!..... ." ............!..........
o,os _........... I... ... .............
..!......................
.!. ..... ............... .............. ..!. ............
..^.. .!. .................. L..... .- ............!- ..... -........"...!...."...
"".."2. ..-................ . . ... .....?......

2707
.......... 2633
I........... ......... 2558
..!. ......... .......... 2481
...!. ........... ..".2403
..?._ .._. ........... ..... !. ......... _ -2243 2081
.... ...!. .............
........!. 1918,,1758 1607
..!....--. ...._. ...!. . .._..............
.................. ..!..........
0,06t ...........
1630 1659
..!. ............. 1693
..".. ..! .................... 1729
.!.. ................. 1768
..!. .................... 1860
..................... 1992
..!............ 2149,,2339
..!.
_........?- ....................-. ............ ".! 2575
..................
..!. .....

2293
-........ 2229
I........... ......... ... 2162
..!. .................. 2094
....................... 2025 1882
. ...................
. ..................... 1735
..!. ................... 1584,,1433
..?. ................... 1285
..!..-..........I......-.......... .......!..........
0,07( ...........
1883 1918 1958 2001
..!. .............._......!....... ............... .I. ................... 2055
..!. .................... 2185 2338 2520
..!. ..... ...............f....... . ..-
. ................... 2741
..........!..........
..^...._.?....I. 3016
..,......... ...!.......

1989
2,
....... 1931
..?.3..-.3........2,
...... 1872 1812
..!.7.... g......... $.~$....gL 17,50 "1621
T -.36:;j...25, 1487
-.....!.........., . ............!. 1349
268...^_5 .. ....^.....!"
28g 1207.
....3. .........
., 3,4".!........
5 i
0,08r ... ......... .!. ..... _ .........._ .! _....................
.! ..-............-. ..!. ...... . -_........ !..". .... ,." . ..-.".....!...".. ..-..... . ."! ."..
......L......

.. 1755
.-.-. --.- . 1704 .. . . . .1650
. . ..... .! . . . . . .1596
... . ."? . ..^.......!."..-1540
^ -....-_ 1.".1424
. "_..-.-"..!..1302.1174 .1_Fl$42
. .. .I.. .".-"...L."- .- ...!""-. . . :;
_."2406
__. ...?_.^_J(2465 .. . .. 2530
___._.. .!I..... 2598'267 2 2838'3034
....... "~--~---"-"l""-----"t-- ..-.L""~"-..+"-" 326 A7'355 1
.-.. 4" .... .2.-j ;

. . . I.1570
. 1524
. _ _ . . ...^....! . . . ..._._. ,. ._.1475 1426
^. 1. .. _ “... .._.......! 1375
. . . .. ,._-. 1269
‘....“..” .-“.“...! 1157 . . .1039
^...... . . ..-..‘......-.. .--.‘.--
. 2688
.._......... .. 2754
?... ...!
. 2825.!-.....I2901
_ . . . ..-. .2.. .2983
..-.......---- .I ..-I. ..-3158
.-..._ !-....3385-3644
...-"......!....- -.-. -.!......

Table 23: Design values

(stress intensity in the middle of internal knuckle of convolution)
 Page 28 AD-Merkblatt B 13. Edition 05.99

rlh
h 1 6Q 0,500 0,475 0,450 0,425 0,400 0,350 0,300 0,250 0,200 0,150 0,100
. 1322 . . . . 1303
. . _..............! . . . ....?.. .. ..1285.1268
. . . ....!._....,,............_.? . .. .. . . . . . . 1254 !... 1231
. ..^......... .)....... 1219
..L.. . ."..-,. 1221
.I !......,,.._...........! . 1238,,1269
. . . . ..!. .. ..-.
... ..-...-.. . . ... .." . . 1311
. ._......
. . . .L- ..
. . . . . . . . . . ....!0,018
. . . . . . . . 52 . . 56 . . . . . . . 5302
I........... . . . . . . . . 53 . . 66 5443
. . . "..,.! ,..........A..".. . .55
.." . . .37,
.!. .--.. . "... . 57. . . L..‘.
74
. . .. 60 .."L-..- 83,,64 . . 74. . .-"...l~-....
. . ."..A.""... 69 70,_776~L~O-~~84,55~~

.1171
..._.._.........! ..1151
. . . . . . ..... . . . . . 1132
. . . ...!. . ... . .,..............? . 1114
. .. .. .. .. .. * . . . . . . . .!.. . . 1098 !.......,......1069 . . 1048
. . ... . ...._._"
I^....! 1038 -.-.. . 1039
I....-,, .-...._.__? ..-.. ...!-...,-.-1053-1077
".......L... -" . ...!
_.^.
0,020 . 57
. . ......_! . 83 . . ....!. 5843
. . ....... . . . 59
. . . ,.........,,...........! . . . 22 .6013
. . ....!._I . . 61
. . . L..". -.... . 22, . . 63
. -.,. . .-... . . .93.."-6740,,71
. . . ..t .-... 78...~2;30.,.84,35_94,06
. . . .!". . ...-....!..._..I -----..,

o,023 ."..99 ...!

65. 7.83 97 89 95 96 94,lO 92,330.. .88
..^....,..~~5‘i'".'67'!.~i""6'ij;16~~.'"~9"96 __....._!
. 73 97 .1 786,186,.,..84$j..
. . ...-... . 77 23 .) 82 30.82 88 88
"-.....!...-. 82 63 83,29
68 .~j..$.$g---5
. . . . . . . . . . ....!. . . . . . . ...?. . . . . . . . . . . . . . _._.,,.._,
. . . . __........! ...!
. ."-..'..-"~~ -........I." "..!-....
....!. . ..... . . . . . . . . . . . . . . . . . . . . . . ..!. . . . . . . . . . .!- . . . .-. . .!----.......-..-.L.-..-..
. . . . . . . . .

86
o,026 .........
73..!54 ..^91...... ,, .~~.,04....83.!~.7
74 55 75 76 ...77".~~...~....~ .. 81,33 7933g..76 07 72 94 70~318'.....68
... 82:3~...87'!.~~...92"7 ..^.,!.. ...32
1oo o. .... _........
67. ^.......
1og 6'. ........
09 m65
122.._.........7
...........
. ......................
I...............
.._..! ....... ._. ................................
..!. ......... ................................ ...... .I...... .-............!..........._"......!. ......
..!.......... ........A..................

7405 72,31 70,56 6881

. .......................
........... ...........6707
............ 6365
. ....................... 6040
~........... ......... . !5744-5490,5292
"."!. ....... . -".--..! .I..._. ...-.....?-. ...". ..5161
.... ............. . . .... . !....._....
0,030...........
83......................
96 "85'23"86"~~.~~.,35....90,2~
.....................
..!. ......... .. ............
94........................
59 100..!............ 0 106 . .-.... .!.7.. . .....--......
115,l ".--,,126 8 141
.._....._.L.... ..".-...."!8.-..

o,035 ._6245
..... ...! ..........
g6 g2 ..g.. 6087.....T.&.. 5927 57,67 56,05 5281 49,62 4656
$. ....i"^d'~~-.i~~~...~~~~...~i61'. . ....1 .4375
. ..1.. 24. ".....-
1 34 6 . ,,4132
I !....".. . ..--_?
148-...I3.......
3942
.1 .65
. ....--..
8
........".!.....................1... ............. .....................
.._.......! ...........
.!. ..... _....._......L....". I.. ........
." ...
. ... . !......" .-.."-..L"....... .. .." I. .... .----. ... ...I .^I_..._! .....

53..!. .....I..
......... 96 ,,.~?_,5~~.~5~.,08~,,49 . ..-.....!.....--.61.. ....-A...-
48 12....45 .".-2....!!...42,.!6..~3 ~~.~~.L..."..
9 07. "....36 20 .... .33
""!".."..." "2 . . "............"
. .59. 31 38 .....
0,040...............
1098 1117 1139
. ...... ................ I...................... 1162
....................... 1188
I.................... 1249 1323 1417
..!....-.. ..............!. .........-.-.......!." .......... 1543,1699 1898
-....... .L.-.-..-...'~~". ......_.._..L................... .!--.,

i 4750
"......... 4620
........................ 4487
I........... ........... 4352
!."................... 4215
.................... 3934
..!. ...-................ 3648
."..!.....""...-....3361
......_.......... .. .I..._^ L...........".."..!".......
3079-,2813.2578
. ".*"..--...-.."..!---
0,045 1227
............... 1249
. ....................... 1274
I....... ............ 1301
...!. ................ 1331
..A................... 1399
.! .............-.....?. 1483,,1599
-...... .-.-..-...!-.... .-...-.-.A..... .I-.._1740,w1916 2139
- .A..-.. -...-_..... ........_I........!.
. ..

.. 4241
.........!. .......... 41,22 40,OO 3876 3750
.,".. ...... !. ............ 3489 .! .-- ....3221
. ......!...-..-............. .- . .I ... L.."....2948..2675..2 4 .!..........
,w...... . .... .. -......!....."....-._- 11 21 ..-......72
2.......
0,050 "135 5 -i-%-b-"'l';j;o"'iii"
_......._..!..._...............................
L.... 143
,!...-.. ..... .......... g 147
...^...... 2
........... !-.". l5j.~ ..... 165
._..__ ... 3
!."..
. ,, 178
_-.--. "L..2 . 19jz.8_.....293>j ... 238,l
._"-. .........
-.

3492
......... 3390
..?.. .........".3286
..!. ................... 3180 3071
. ...............
...... ..!. ..................... 2 845 .I ..._.... ..-..-2609*,2365
.... ..!. ..-..... ........... 2114,,1865
. .. !"."..... -_....^!... -..... I...... ..!..... . .-......!,........
0,060...............
1609 ..... 1641
...... ........... 1675 1712
.I.. ..... ....................................! 1756 1866 ?. .... 1995,2149
...!-..... .. .- .........................
...... ............ 2337,,257,0
.^..............-.!..-.... . .... ".I...... ...............
I.....

29
o,070 .........
1 86 66
..!. ......... 28 79 27 88 2625 26.1 .-00
1 .....~~~2"...i~~~...2004"..~~ .._24
1..... ....21 01g 23321..!..................
. ..!. 8................... 92 251 g 273 7 .. ...3Eg2z
g ......~.~,73....~.7,4_6_ 15 ..!..........
15 ...
............... . .......................
u....... .. .._..".. ...! .................
...... ...... .. .._......-
.! ..................................".. .. -.L- )^I....- -.~...... --..."..".~..-..

25 ........
. . .........!. 78. ...........
25 .I. ...................
01 24 ..!.21 23 .A...........
.......... ......... 39 22 54 20
..I................ 77 .. l8,l8j-.~,l693-
...........L-".. .. ..".....! .^..... 14
^ . . "- 87
..!
..........
0,080"......._....
2134 2186 224 3 2303 2368 2514 2685",289O
* " ._......_......-'.."..... .-..-. .......-....-..- ...?. .... I ... .... .! -- ... .-"--.-~-..... .. -.-~..- . . ..-..Lm..... 3140
.-."...! .....I

22!..-".79
" ._._ ... .^..._2210A..._ ... .21-! ._.....38 2065
.. ^..--2" .. . . ...-."1989 1830 1662J483
.!.. ... ...... "..2.".""...".."."..!-" ".-.."L". 2_9,4.,
0,090.. .._.._
2414 2472
.....!.. .._....-._-. 2536 2604
. ..-...-....!.......""....-...J".... ... 2676 2840 3033_,3263_-3544
. .. _...._.-- "L.....""--I _-..-"A. -..........I....-.
... . . . ....
2042 1979 1915 1848 1780 1636 1482 1319
........._!. .....................j....._._. -.._._I .._...-. ..- ...... .- . ..- . ..... . ..--I.. ..- ..“2.. ......-. ..---2.“-- .... .--‘-.- ..
0,100 269 ..!..4........
............. 276.!......0 _^..._
.......... 283 . .....!. .....1 ...._.-.....?
,290^ ........ . . .... - .
6 .....298 .
6"_3_!,~8....~~~,3_~~~63,9 . .
1
Table 24: Design values
(stress intensity in the middle of internal knuckle of convolution)
 Page 29 AD-Merkblatt 0 13. Edition 05.99

d ...-..--- e r
h 100 t

.” 2023
5..........
o 48 1975 1927
..!..........~r;g....~~ 188,O 183,2<1739
1!2"' ..53"o.....5'~f 1650 156,9 1500
.. ..-.... . . .....-..1447
..~~~~...~~~~:~~~~~~:..g~~~ ...".I..
75... 4g 1412
..!. ..^...
. .........".! ^.......
..,84~~~
),018 . . . ........!. ....................
!.".. .. ..............!........... _........1....................
A."..."............!................"-.!"."".... .. ..-..I'...........

. . . 1800 1756
.._ _.... ..!.............._...... ..........171
..".. ...... !......0," _...........!.......
1665 . ._.......".!.
1620 1529
. ....a............... 144-....1,........1358
A"... ---....-2. 1283
. ....?-- ... . . 1220--11.~J!,2,
. .. . . . ... ..-..-....-~
."
1,020 55~70,,,~~~59~57 61 58 72 59 98,.62 93 66 56 71 05.~~~~~...~3,97_93.8
5
““A..“.. . .-“..,A.. ........
..^ ......!“. ....... ._ .......!
I . . _....“. .... . ..!
...............L-.”
. ..““..--- -

1544
......._....! 1504
_................... 1463
.!.. ........_...... 1422
...!................_...? 1380 .._............!
. .. ._. ...............!....... 1295 _.......1210 1127
.-......... . -.... ,...-. ..."A.........1049
. I.....!" ^... ..9786 9203
. "2.-.I .....
. .... ..!.-.......
3,023 . , .63 52 64
....................... 59 65
........!.............. 82 67 14 68
........!.............. ....................... 62 72
...... ..!............. 08 76 ............................. d............._.......-1..!...".
........?.............. 30..8_?,5r?1~_87.!97....9 6 74 108

1352
.I ,____,_,,,___! 1316
...................... 1278
...................... 1240 1202
.................................. 1123
.._._____..!..................... 1043
..................... 9626 8846
..!. .................!................... 8116
I.....!....... ",7481
..!.............. .......-.!.. ........
3,026 . . ,,.,.,.,_!
7132 7258
...................... 7400
....................... 7554
........................ 7725
............... 8120
..__...!...................... 8602
..................... 9192 9951
..!............................................! 1095 .!.......1223
....... ................. . . ....... ..!......

. . . 1159 1127 1094

.._.........! ..........._.........d..................... 1060
............ 1025
.._... ...?................... 9535 ......-...!.
...!....... .._.......!.......- 8799 8049
..-........-
......I 7298
. ......... 6572
. . ... ......_. ..t.......
... .! -..." 5912
-.-..-
. ..!.........
D,030 ._ .......
81..!. ..........
68 . 83..!. .............
. ....... 19 84 89 .-.....................
. _... ..!.-...-... 86 70 88 70 ..~~.,33_..98,93...10
..-....!........... .._..-...?5"-....
8 115 1 126 6......
.".."!.I_..w.."......-!.".. 141
...... . .4...

9840 9556 ..__.?_._. .......9264

. . _....-!.............. .__....! 8965
_......-..m-.... 8659
.!....-.............. 8024
..!...... ..-..-...... ...7362
.?.. .......... 6677...d....".. ...5978
. ...-- ...... .-..... 5283
..-"!....-........ . .4627
."...~...-..... .-.!.. ........
0,035 . . .-._...!
9460 9642
_.............._.._?.
........... 9844 1006 1030 1084 1150
.._.....!..."..........._ .."....L..- ........-...!...... ..-. ..I....... .......
....." 1239
............ ..-.".-..1'-......1347 1481
. ..............* ...-.."..."L.. 1652
. "................

8545
...... 8294 8034
...!...................................... 7769 7495
..".. ..!............................................. 6927 6329
.!...._..... ,.".......L........... ..^. ......... " .. ,I^5705 5058
..-...!....- .., .....-...! 4403
^...."... ..__I . ..L..."......3769
..-..!....".. ..
0,040 .....................................
1075 1096 1119 1144
....... .._...........!.............. 1172 1235 1318 1420 1543 1696 ""..L........1892
..__ .!....... ._............!. ............._.......!. ......... ........ ..!"".... ..".. .... ..?...-. ..... .-.I.....!...". .......... .......-!".-..

7551
....... 7326
..! .................... 7093
..!. ................... 6854
..!. ..................... 6608
I................ 6094.........
..__.! ......- .................... 5551
. ....!....._."....4980 4382
... ..L ..".. ... .... 3769..I?....-.-. _."3164
...!...........-... ..--!......".,
0,045 ..................................
1203 1227 1254
..?................
.._..!..... . 1282 1313
. ._....... ...!................... 1392
...........
..!...... ... .L.-. _.1487
.._. ".-!. .._. 1601
. ........ ...^ ..!
---.. .1739
..........
......
... . .... . 1911 2132
"...L....... .-........!
..

6764 6559 6349

...._....!........................................... 6132 ."........!.......-............!......................
..!.......... ...............-...... 5908 5440 4944 ......^I, ...4418 3865. ............
...........-..- ..........!""". 3292 2717
"L..""......
" " ..!.. .... ".
0,050 ..............
1330 1358 1388
. ..... .._...._......!.. .................... 1422
................ 1462 1552
......L...... .-...........!...................... 1657
.!.. ........-....."..! 1783 1937 2128 2373
..... "...^. ....... . ......"".....!..................A""......."".A.....

5596
..........!. 5424
..................... 5247
d..................... 5064
.. .................. 4875
..!.................... 4479
..!.................... 4057
..!.................... 3607
..!. ......... ........... 3128
.....I ..... .I.. 2625
. .....!......................
.!...... ...
0,060 ..............
1592 1631
............ 1672 1717 1764 1872 1998 2149 2333.2563
......... ..!......................!. ....................?......................!........... ...........?......................!. .........._...^...?................... ...! ....................
.!. .....

4770
....... 4623 4470
...!............................................ 4312
..!......................... 4150
. .-............... 3807
..!...................... 3440 3047
..!........... ........
I.................... 2627 2181
. ...... !"..................
................. .L.. ........
0,070 I . 1868 ..!. 1913
............
. 1961
............ .......... ................... ..!.......... 2013
............!. 2068
........
............!....... ..-2193
............
!...
. .....
. 2341
.-. 2517
........................... ..?..-
- 2732,-3000
.............
.!.I ..........
" ....i......

0,080 I .

__-.3682 ..!._......I ,,.."3567

_.....'-.._......3447
..""....!........... 3324
.--- '"w....s.... 3196 2927
...-L..... . . . . ..-.. . --..-..2638 ........ 2336 1991
.-........!-..-........--.f.-......
0,090 I ._._..___.
2423 2481 2544 2610 2681 2842
!......, .....___..L..__.._..._!.._.,_"". .._..A".-.."..".."...!.... ,_I---...L...--.. ..."..!-....-."....."?1-."..... 3032 . 3258 3536
."."..".-A."..
...-......-.
3304 3200 3093 2982 2867 2624 2362 2080
,. . _. . .! ._..._..,,” ........!_..,...-” .__...._. !” . . . ..-. ,.” ...-.. !. . . . . ...-.. . . . _. . . . . .!. . .. ... . . . . . .. ! . ..-..-. -.-..-! . . . . . . . . . . . . ...I. --.-.. _ RPI
0,1oa ,_.............
I 2703 2768
I ._..., ...." ._._....? 2837
... ._......_..... !..."., 2911
............- . . ...!. . . .2990
. . . .L...".. . .I 3169
. . . . . .... . .3380
. ,..............? ..A-.....3632
...-.."."--~--" Rm

Table 25: Design values

(stress intensity in the middle of internal knuckle of convolution)
 P a g e 31 A D - M e r k b l a t t B 13, Edition 0 5 . 9 9

Appendix 1 to AD-Merkblatt 6 13

Explanatory notes to AD-Merkblatt B 13
This edition of AD-Merkblatt B 13 is based on the dissertation
“Festigkeitsberechnung einwandiger Balgkompensatoren
(Strength calculation of single-ply bellows expansion joints)”
by Dr. Friedrich of MPA (Institute for theTesting of Materials)
in Stuttgart. The results determined ‘especially on the basis
of 150 expansion joints are supported by a numerical calcula-
tion procedure (transfer matrices). With the aid of the finite
element method the correctness of the transfer matrices
method is confirmed.
The mathematical formulation of the method is based on a
toroidal shell element.
of the maximum distortion energy theory. The individual
stresses are combined to form a stress intensity u+), and
uVCw, respectively. Because of the way in which they can be
represented, the four variables d, r, s and h of an expansion
joint shall be reduced to three by dividing d, r, s by h as follows
z,i and $. The results were evaluated with the following
values:
h = 50mm
E2 0 = 2,l 1 0 5 N/mm2
= 0,3
CL
The convolution depth h was selected to be h = 50 mm, since
most of the investigated expansion joints were constructed
with this convolution depth. Here the linear connection
between external load and stress distribution of geometri-
cally similar components was utilized. Here it can be noticed
that all geometrical parameters refer to the centre of the shell.

The design values R(,,, R,,, and RCcwI refer to the following:

= stress intensity at 1 bar gauge pressure

merit
= stress intensity at 1 mm axial displace-

where:
d.s.r = axial load per mm of mean circumfe-
UQZ = membrane stress R(c,) ( jy>7;,7; 1 rence in the case of 1 mm axial displace-
%b = bending stress ment.
tQ = shear stress
V = displacement in direction of shell normal
W = axial displacement of one bellows convolution Explanation of formula (3)
I (displacement in meridional direction) Since the design value RCw, refers to a convolution depth
X = torsion of the shell normal h = 50 mm and a modulus of elasticity of 210 000 N/mm2,
The notation of these displacement and stress symbols the exact formula is written as follows:
refers to the calculation model of half the bellows convolution
shown above. The symbols and units used here are not 50 ~. E
%4 = 7 . 210 000 R(w) . w
derectly related to the symbols and units used in the Merk-
blatt itself.
The term 50/210000 was reduced to a factor 2,38 . 1 O-4 -
On the basis of this element, a system of linear differential 2,4 . 10-4.
equations can be formulated with the aid of equilibrium condi-
tions, the geometrical relationship between strains and dis-
placements as well as Hooke’s law. This system is principally Explanation of formula (4)
soluble, however, not as an integral solution, but asan appro- Since the design value R,,, refers to a modulus of elasticity
ximate solution, with the differential equation being trans- of 210000 N/mm*, the exact formula is written as follows:
formed into a difference equation. The system of linear diffe-
rence equations is solved with the aid of a matrix method. The
c,=n.(d+h).&. %w)
method of transfer matrices is subject to the type of rotation
and thin wall of the component. These conditions are met I
by expansion joints. It was ascertained that at a ratio where n. (d + h) is the mean circumference of the bellows
convolution. The term 7c/210000 was reduced to the factor
v + $1 0,15. 10-d.
L 2 4 no influence on the accuracy of calculation can
s
be noticed.
Explanation of formula (5)
At each point (step i = 0 to n) the stresses uqz, a@ and ~~ The relationship between rotation angle a, in degrees, and
are determined both for strain’) and internal pressure*). The an axial displacement w is
maximum value in the shape is to be determined with the aid
360/n. w
a= d+2h
‘) Loadings other than those mentioned in 2.2 of the AD-Merkblatt will not be
taken into account for the calculation. This procedure is not applicable pafti-
cularly to lateral deflection. The term 360/n approximates to 1 ,15 . 1 Oz.
Page 32 AD-Merkblatl 6 13, Edition 05.99

Explanation of formula (6) 4 =(d+2h-2r).2r+2r.(d+2r)

= 4 r. (d + h)
Formula (6) is determined by insertion of
w=&(d+2h).a 4, = (h-2r+4+8.+s

from formula (3).

E Ia,, = 14h-4q:‘,jd2_+~~,s.v.Pwithpinbar
u,,(~) = 2,4 . 1O-4 h. Rcw) .&.(d+2h).a

The term 2,4 . 1O-4 . n/360 gives the factor 2,l 10-6. 1. (d + h)
O”rn = p [N/mm’]
40-s~[1,14r+h)'v I
Explanation of formula (7)
The following generally applies
M
c, = a
w h e r e M = 0 , 1 2 5 . ( d + 2 h)2 . a c, Explanation of formula (18)
This formula is Hooke’s law where partial plastic deformation
With a = &. a0 the following is obtained is taken into account by the factorf, and the weld by the factor
M . & . (d + 2 h)2 . c, . a f,. The significance of the effective total strain range
M 2 &ages is shown by Fig. 41 of the dissertation. It can be
c, = a= &. ( d + 2 h)2. c, measured directly.
Here, variable stress compoments A mean the start-up and
= 2,2 . 103 . (d + 2 h)2 . c, [Nmm/‘]
shutdown conditions, e.g. from 0 bar to the maximum allow-
or expressed in [Nm/“]. able working pressure. Pressure fluctuations (as in AD-
c,=2,2.10-6.(df2h)2.cw Merkblatt S 1 or S 2) may be taken into account by formula
(24). A further condition is that only stress components
Explanation of formula (14) occurring at the same time can be included in the calculation.
L.K=1,5.$.~ The addition of stresses (Formula 19) is justified since tests
%P) = s
VP , I
have shown that at the location of maximum loading (internal
=-
”. K knuckle) the stresses from pressure and axial movement or
12 deflection act in the same direction and therefore are com-
with S,, = 1,2 and S = 1,5. The effective shape factor then bined. If one of the components p, w or a is constant, the rele-
becomes vant stress portion A is equal to zero.
g= 1,25 when n = 1,5.
12
w=-5mm
Explanation of formula (15)
The shape factor n depends on the shape and material. 038
The dependency on shape is expressed by the factor 1,55
which is increased compared to the case of a beam (with n
= 1,5) (see figure 33, page 44 of dissertation). The depen- Q4
dency on the material-here in particular high-strength mate-
rials are meant - is expressed in the second portion of the 2
formula. With an increase in yield strength the shape factor .E 0
decreases for equal plastic strain. The formula applies up to ici
a temperature of 350 “C. If this value is exceeded, 6.4 shall
be taken into account. - 0.4

Explanation of formula (16)

- 0,8

+.------ Expansion joint No. 19 (DN 1200)

The mean circumferential stress according to the area
method is Strain curve for elastic loading in circumferential (subscript “)
and meridional (subscript m) direction under internal pressure
(5 “Ill d!iLp
A, . v (subscript p) and axial compression (subscript w).
 Page 33 AD-Merkblatl 6 13, Edition 05.99

Explanation of formula (20) Where axial displacement and deflection are combined, for-
mula (21) is to be used. Here the stress component Aov,(,) has
The factor f, takes into account partial plastic deformation been proportionally added to the stress component Au,(,)
and is only determined if the loading da,,, has exceeded
and Aq,) respectively.
twice the yield limit - i.e. the elastic portion. This is taken into
account in the formula in the second term by subtracting 2. The factor f, is explained on page 54 of the dissertation and
The third term of the formula 0,i B takes into account a pro- takes into account the surface and the structure of the weld.
gressive distortion (incremental plastic strain or incremental For design reasons, the weld is located in the middle of the
collapse) in meridional direction. The letter C (in the second external knuckle and/or of the internal knuckle. The tests
term indicates that the factor f, is only determined in the case revealed that the centre of the internal knuckle is subject to
of axial displacement or deflection (see table). the greater loading. For this reason, Tables 14 to 25 were
established which contain design values for this location and
thus make a separate examination of this location possible.
Graphical representation of formula (20) Tables 2 to 13 contain the design values for the location of
maximum loading of the shape. Where acircumferential weld
is provided both locations (location of maximum loading and
I,4 - 2 E(,& location of weld) shall be examined. The higher value of 2 .
f* = &,ges is decisive.
2 4$es
1-3 -
Explanation of formula (22)
12 This formula represents the equation for the straight line in
the log-log diagram (see Figures 70 and 71 of the disserta-
tion) thus establishing a relationship between the number of
1.1 load cycles N and the effective total strain range 2 . &,ges.
range of empirically
determined C values A figure below this number of load cycles is outside the zone
1 .o I I I of experience covered by the literature. The aim of the lower
0 1 2 3 4 5 6 limit for the number of load cycles is to
A0 vge# - limit the reduction in stiffness from the deflection with
regard to stability,
where - ensure that formula (11) that strictly speaking only applies
2 ’ E(e)ages = effective strain range, applied for the failure of to the elastic behaviour of the bellows also applies in the
bellows subject to cyclic loading elasto-plastic range.
2 . 4ges = fictitious strain range according to the theory
of elasticity
Explanation to 6.2.2, 2nd sentence
The relationship between 2 . ~(0,~~~ and 2 E @Iages can be The bellows of an angular or lateral expansion joint is subject
represented graphically as follows: to deflection due to angular rotation or lateral movement
which under the simultaneous influence of internal pressure
may lead to a lateral offset of the bellows along with exces-
sive deformations.

Explanation to 6.4
The shape factor n = 1,28 at elevated temperatures was
determined by means of tests as can be found on page 65
of the dissertation.
For the calculation procedure indicated here only results of
various short-term tests are available for the elevated tem-
perature range. It is intended to gain experience with these
values. Additional surveillance measures are required.

Materials
For the tests, expansions joints made from the following
materials were used :
MRSt 34-2 1 .0108
2 fF& HI 1.0345
H II 1.0425
16CrMo4 1.7242
Due to the scatter range of C values determined in the tests, XlOCrNiTi 189 1.4541
an average value of 0,l was selected for the third term of
formula (20). The C values given in Table 1 refer to these materials.
Page 34 AD-Merkblatt B 13. Edition 05.99

Interpolation equations
R; = R:, + (R:, - R:,) A +
The numerical values for RtpJ, R,,, and f&,) are taken from
Tables 2 to 13 and 14 to 25 respectively. Intermediate values
shall be subject to straight interpolation in accordance with R: = R:, -t (4, - R:,) A +
the following model :

4 = R:, + (R:, - R:,) A +

R: = R:, + (R:, - R:,) A ;

-S - % -
A + = =
-so - s,-
h h
11 R= R”+ (R’-R”1.A:
- r - r”-
A+==
-To - r”-
h h

d
--2d
A+==
d d
-2-2
h h
ICS 23.020.30 Edition May 1998

AD-Merkblatt
Special Simplified analysis
cases for cyclic loading Sl

The AD-Merkblatter are compiled by the seven associations specified below who together form the “Arbeitsgemeinschaft Druckbehdlter”
( A D ) . AD-Merkblatt G 1 c o v e r s t h e c o m p o s i t i o n a n d a p p l i c a t i o n o f A D - R e g u l a t i o n s a n d a / s o p r o c e d u r a l g u i d e l i n e s .
T h e AD-Merkblatter c o n t a i n safety r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . In t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied i n t h e s e r e g u l a t i o n s h a v e b e e n o b s e r v e d b y o t h e r m e a n s , e . g . t e s t i n g o f materials, e x p e r i m e n t s , s t r e s s a n a l y s i s , o p e r a t i n g
experience.
Fachverband Dampfkessel-, Behalter- und Rohrfeitungsbau e. V. (FDBR), Dusseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sankt Augustin
Verband der Chemischen lndustrie e.V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhijttenleute (VDEh), Dusseldorf
VGB Technische Vereinigung der Groflkraffwerksbetreiber e.V., Essen
Verband der Technischen iiberwachungs-Vereine e. V. (VdTi&), Essen.
T h e AD-Merkb&tter a r e a m e n d e d c o n t i n u o u s l y b y t h e a b o v e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen ijberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents
1 Scope 8 Consideration of special operating conditions
2 General 9 Measures to be taken when the design lifetime
3 Symbols and units has been reached
4 Determination of allowable number of 10 Additional requirements
load cycles Annex 1: Explanatory notes on AD-Merkblatt S 1
5 Design Annex 2: Example of calculation
6 Manufacture Annex 3: Preliminary rules for a simplified analysis for
7 Test and inspections cyclic loading for vessels made of Aluminium
AlMg 4.5 Mn (in course of preparation)

1 Scope The number of load cycles to be withstood may attain a mul-

1.1 The rules below governing a simplified calculation for
cyclic loading’) apply for pressure parts of pressure vessels
made of ferritic and austenitic rolled and forged steels manu-
factured and tested according to the AD-Merkblatter of the
series W and HP.
1.2 The calculation only applies for components dimen-
sioned on the basis of non-time-dependent design strength
values (see AD-Merkblatt B 0, sections 6.2 and 6.3) and sub-
jetted to cyclic loads only in the form of pressure fluctuations.
Additional cyclic loadings, for example loads due to rapid
changes in temperature during operation or from external for-
ces and moments, are to be assessed within the framework
of the calculation according to AD-Merkblatt S 2.
1.3 The analysis for cyclic loading shall only be considered
a lifetime expectancy calculation to reasonably determine
test and inspection intervals so that fatigue cracking which
may occur can be detected in time.
1) The term “cyclic loading” is meant here in a comprehenwe
over time of a loading regardless of the magmtude and arithmetic sign of the mean
value.
tiple of the design load cycle number if the scatter band of
the fatigue values is taken into account and in the case of
boundary conditions for design, manufacture and loading
that are more favourable than those on which design appro-
val is based.
1.4 If the following two conditions are satisfied, AD-Merk-
blatt S 1 need not be applied.
a) The number of load cycles with pressure fluctuations
between pressureless condition and allowable working
pressure p (start-ups and shutdowns) is N 5 1000
and
b) the range (Ei -0) of any number of load fluctuations does
not exceed 10 % of p.
The limit value for the pressure fluctuation range oj - 0) of
10 % may be increased to 20 % of p if the following additional
conditions are satisfied:
- the number of load cycles with pressure fluctuations
between pressureless condition and allowable working
pressure p (start-ups and shutdowns) is N 5 1000
sense as the variation - steels with tensile strenghts 5 300 N/mm* at 20 “C, as
specified by the standards, are used

Supersedes September 1995 edition; 1 = Amendments relating to previous edition

Carl Heymanns Verlag KG

Luxemburger StraOe 449, 50939 Kdln
Page 2 AD-Merkblatt S 1, Edition 5.98
- wall thicknesses of up to 25 mm
- governing design temperature r‘ 5 200 “C
- geometries with a shape-dependent stress factor r) 5 3 to
Table 3 of this AD-Merkblatt.
1.5 Regarding an intended operational lifetime of 20 years
(365 operational days) this AD-Merkblatt need also not be
applied if the following conditions are satisfied:
^ I
- the range of pressure fluctuations y referred to
i 1
p does not exceed the values to Figure 2
- steels with tensile strengths 5 300 N/mm2 at 20 “C, as
specified by the standards, are used
The curves in Fig. 2 apply to
- N 4 1000 load cycles with pressure fluctuations between
pressureless condition and allowable working pressure
(start-ups and shutdowns)
- wall thicknesses of up to 25 mm
- governing design temperature T* 5 200 “C
- welded joints of weld class K 2 and geometries with a
shape-dependent stress factor r) 5 3 to Table 3 of this
AD-Merkblatt.
For fillet welds for the connection of nozzles only 4/s of the
referred pressure fluctuatron range to Fig. 2 are beyond the
limits of application.
In the case of more than 1000 start-ups and shutdowns, the
ranges of pressure fluctuations to Fig. 2 shall be reduced
P-P
to obtain - with F, taken from Fig. 3.
i P i - Wall thickness,
1.6 In lieu of the allowable working pressure p the ranges
of pressure fluctuation (J? - p) may also be referred to the
design pressure p, (fictitious pressure).
1.7 If the number of pressure fluctuations to be expected
during operation exceeds the allowable number of load cyc-
les calculated according to this AD-Merkblatt it is necessary
to change the design or conduct a detailed calculation
according to AD-Merkblatt S 2 to satisfy the cyclic loading
conditions.
1.8 This AD-Merkblatt assumes that there are no influen-
ces from the fluid which may reduce the fatigue life (see
section 8).
2 General
2.1 This AD-Merkblatt shall only be applied in combination
with AD-Merkblatt B 0.
2 . 2 The criterion for failure due to cyclic loading is an inci-
pient crackz).
2 . 3 A measure for cyclic loading in this AD-Merkblatt is the
stress range (double load amplitude) arising from the action
j of the repeatedly fluctuating pressure (see Figure 1).
2 . 4 The allowable number of load cycles calculated accord-
ing to AD-Merkblatt S 1 is influenced by the dimensioning and
design of the pressure vessel. In the case of frequent load
cycles with considerable cyclic loading, calculations accord-
ing to AD-Merkblatt S 2 would be more practical, however,
to assess appropriate modifications measures. As a rule, this
yields a greater allowable number of load cycles than the
calculation to AD-Merkblatt S 1.
2) An mclplent crack is a crack-type material discontinuity which can be detected
by optical means or non-destructive testmg.
2.5 Of special importance are fluctuations between the
unpressurised state and the allowable working pressure p
(start-ups and shutdowns). The pressure fluctuations can
also be superimposed, however, with low amplitude on the
working pressure (e.g. in surge or storage vessels) or can
arise with varying amplitude in the range between 0 and p
with irregular sequence and differing frequency (operational
load regime). Where the vessel is under vacuum, this proce-
dure shall be applied accordingly.
2 . 6 The number and level of pressure fluctuations which a
pressure vessel can withstand during its probable lifetime
without damage to the pressure parts depend on a large
number of drfferent influences, e.g.:
- Desrgn,
e.g. configuration of component with regard to the avoi-
dance of high peak stresses;
- Manufacture,
e.g. avoidance of damaging residual stresses and weld
imperfections;
- Material,
softer steels are for example normally less notch-sensitive
than harder ones. With the notch-sensitive steels it must
be noted that the probability of failure is greater if a manu-
factunng defect is not noticed or the operating conditions
are unfavourable. The strength of the weld metal should
be equal to or just little higher than that of the base metal;
- Surface condition,
design with minor surface roughness (machining, grinding
of welds) for high lifetime requirements;
with equal stress range, an increase in the wall thickness
will reduce the component lifetime because of the
influence of size;
- Temperature,
higher temperatures reduce the cyclic strength of the
materials and hence the component’s lifetime.
2 . 7 Corrosion arising during operation can reduce the num-
ber of load cycles which can be withstood, especially in
notch-sensitive materials. Operational measures (see sec-
tion 8.1) and inspection during the operating period (see sec-
tion 7.3) are of special importance here. Where a protective
(magnetite) layer forms, this should be considered when
dimensioning and designing in order to prevent the protective
layer from tearing up.
2 . 8 For the calculation the following is defined as the gover-
ning temperature during any load cycle under consideration
(see Fig. 1):
r‘ = 0.75 . i + 0.25 i (1)
All temperature-related factors shall be related to this gover-
ning temperature T* of the relevant load cycle.
2 . 9 To determine the allowable number of load cycles for
the whole vessel, the calculations according to section 4
must be performed for the various sections of the vessel. The
smallest value is the relevant one for the vessel.
3 Symbols and units
The following symbols apply beyond the provisions of AD-
Merkblatt B 0 and in deviation from it:
temperature influence factor
fatigue strength reduction factor for
welded ioint classes
 Page 3 AD-Merkblatl S 1, Edition 5.98

fL load cycle increase (fatigue strength
extension) factor for pressure fluctuati-
ons
w -0) < Pr
k number of intervals of differing pres-
sure fluctuation ranges which together
form the load regime
Pr pressure which can be calculated for
the whole vessel or also as fictitious
pressure only for sections with full utili-
sation of design stress K&S and the
planned dimensioning according to
AD-MerkbUter of the B series
(under certain circumstances, the for-
mulae shall be broken down to obtain
P)
pressure fluctuation range (double
amplitude; see also Fig. 1)
‘=d correction factor to take account of the
influence of the wall thickness
N here: operational number of load cyc-
les
N ZUI here: allowable number of load cycles
with pressure fluctuation ranges (p-0)
N 100 Allowable number of load cycles for
pressure fluctuation ranges @, - 0) at
temperatures T* 5 100 “C
r governing calculation temperature
during one load cycle
2d, fictitious pseudo-elastic stress ampli-
tude
%I, fictitious endurance strength values
stress factor (shape-dependent)
‘I
Superscript - = maxlmum value, e.g. p
Superscript ” = minimum value e.g. p
Subscript k = number index e.g. Nk
4.1.3 To take account of the cyclic load strength-reducing
influence of the component size a correction factor Fd shall
be taken for wall thicknesses s, > 25 mm according to
,Cd
( or from Figure 4. The factor Fd shall be limited to F, = 0.64
-
with wall thicknesses of s, L 150 mm maximum. In the case
of forgings, the governing heat treatment diameter according
to DIN 17243 shall be taken as the wall thickness.
4.1.4 With load cycle temperatures of T* > 100 “C up to
temperatures of nori-time-dependent design strength values,
a temperature influencing factor fT. shall be considered. The
correction factor fy shall be determined for ferritic material
according to
in bar f,.= 1.03-1.5.10-4.r-1.5.10-6.T** (4)
and for austenitic material according to
in bar
f,. = 1.043 - 4.3 104 . 7-+ (5)
- 1 or shall be taken from Figure 5.
4 . 2 The allowable number of load cycles shall be calculated
- within the scope 103 I N 4 2 . 106 as a function of the stress
amplitude 2d, according to section 4.1 from
-
(‘3)
- where m = 3 for welded joints and m = 3.5 for unwelded
component areas with rolling skin surface, or shall be taken
( from Figure 6. The notch effects from weld seams or surface
in “C roughness and the greatest possible influence of residual
welding stresses or mean stresses from working pressure
. ^
In N/mm‘ have already been taken into account here.
in N/mm’
4.2.1 The values of the calculation constants B can be
-
found in Table 1. The class K 0 here applies to unwelded
component areas. The other classes relate to welded jolnts
allocated to classes K 1, K 2 and K 3 in Table 3 in accordance
with their notch effect.

Table 1. Calculation constants B

4 Determination of allowable number of load Class B [N/mm*]

cycles 103~N~2~106

4.1 To determine the allowable number of load cycles the KO 7890

fictitious pseudo-elastic stress amplitude 20, shall be calcu- Kl 7940
lated according to K2 6300
K3 5040
(2)
4.2.2 The fictitious endurance limit is fixed as N = 2 . 106.
4.1 .l Here the fictitious pressure pi shall be determined as With stress amplitudes 2d, below the values 20,~ according
allowable pressure with full utilisation of the design stress to Table 2, endurance may be assumed.
K2dS for a point under consideration on a pressure vessel
from the dimensioning formulae of AD-Merkblatter B series. Table 2. Endurance limit values 20,~
For this purpose, these dimensioning formulae may have to
be broken down to obtain p. Class 2~ [N/mm21
In this case, only 50 % of the minus tolerances (c,) and wear Nr2.106
I allowances (c,) need be taken into account.
4.1.2 The stress factors q can be found in Table 3 as a
function of the component geometry3)4). These stress factors
represent the upper limit of the stress factors for dimensio-
ning conditions of a certain component geometry arising in
practical situations. 4 . 3 For the special case of welded pressure vessels with
Where lower stress factors q are selected, they shall be ver- geometries to correspond to a stress factor q 5 3.0, at tem-
I ified. peratures T* % 100 “C, wail thicknesses s, % 25 mm and
pressure fluctuations between 0 and Pr, the allowable num-
3) See Annex 1
ber of load cycles within the range 1000 c: N,,, 5 2 . 1 O6 can
“) See also aectm” 5.2 be determined by means of
 Page 4 AD-Merkblatt S 1, Edition 5.98
N,,, = NlOO ’ fN fL (7)
with
1.854.10~0
N (8)
loo = (K&s)3
(9)
and
(10)
The values Nloo and f, can also be taken from Figures 7
and 8.
The pressure fluctuation range related to ,u,, that can be with-
stood under fatigue strength considerations by the vessel,
shall be taken from Fig. 9 as a function of K&S.
The curves are described by
2@-Ph = %D (11)
Pr 3. K&S
with 2aaD from Table 2.
4 . 4 If pressure fluctuations of differing range and frequency
occur (operational load regime), the allowable fatigue life
shall be determined using the linear damage accumulation
law.
; * = (2 + * +.... 3) 5 1.0 (12)
j 4.4.1 N,, N, ._. NI, are the numbers of load cycles to be
expected in operation, with the load cycles with the same
pressure fluctuation range @ - 0) being comprised to form
one load regime. The related allowable number of load cycles
N ZUll, NzulP . . . N,,,, shall be taken from Fig. 4 with the relevant
stress amplitude 2c$ according to equation (2) in the corres-
1 ponding load cycle curves to Fig. 6 or shall be calculated
according to equation (6).
j 4.4.2 If an operational load regime gives rise to stress amp-
litudes 2a*, which are smaller than the latigue limits 20,~ given
in Table 2 for N > 2 . 106, the related allowable numbers of
load cycles N,,, = 2 106 shall be taken. The damage porti-
ons of load regimes whose stress amplitude 24 is smaller
than 50% of the 2~ values can be neglected here.
5 Design
5.1 The fatigue life of cyclically loaded components largely
depends on the dimensioning and design. Special care must
be taken here to ensure that designs with high stress or strain
concentration are e.g. due to abrupt wall thickness transiti-
ons, are avoided. Table 3 contains an assessment of fre-
quently used weld details in pressure vessels. In the case of
rigorous requirements regarding component lifetime, the
weld designs of class K 1 are recommended. If necessary,
more rigorous requirements shall be imposed on the design
than are given in AD-Merkblatt HP 1 (compare stress factors
rj in Table 3). By appropriate designs testing and inspection
to Section 7 shall be made possible.
5 . 2 To assess the life expectancy of designs not given in
Table 3, the anticipated q value shall be fixed by means of
corresponding estimates on the stress concentration factor
(see AD-Merkblatt S 2, section 4). In such cases, however,
it is practical to conduct a detailed calculation according to
AD-Merkblatt S 2. This applies as a rule for example to cam
closures and clasp-bolted joints.
5.3 The life expectancy can be increased within the frame-
work of design evaluation according to Table 3 by, for
example, the following design measures:
(1) Hemispherical or torispherical head instead of semi-
ellipsoidal head;
(2) Conical shell with knuckle instead of cone with corner
joint;
(3) Avoidance of inclined nozzles and pad reinforcements;
(4) Tapered transition between tubesheets, flanges etc. and
the vessel shell;
(5) Avoidance of rectangular openings.
Over-dimensioning for predominantly static loading also
leads to a greater number of allowable load cycles. Similarly
a greater number of load cycles can normally be permitted
by applying AD-Merkblatt S 2 (see Annex 2 of this AD-Merk-
blatt).
6 Manufacture
For the manufacture of pressure vessels the AD-Merkbl$tter
of the HP series apply. For vessels calculated according to
this Merkblatt the following requirements shall additionally
be met:
6.1 In the case of cyclic loading, defects arising during
production have a more unfavourable effect than with static
loading. The component lifetime can be considerably
reduced by notches or unfavourable residual stresses.
6.2 For the components special requirements shall be
imposed on the form of welds. Rating group 6 according to
EN 25817 shall be observed. With regard to heat control
during welding and welding sequence, special attention shall
be paid to the welding residual stresses. All heat treatments
shall be properly performed to meet the material and wall
thickness requirements.
Annealing temperatures, holding time and cooling conditions
shall be fixed as far as possible such that considerable elon-
gation and notched bar impact toughness are ensured. In
many cases the yield point and tensile strength will set in at
the lower limit of the allowable range. Stress relief shall be
performed such that the residual stresses are reduced to a
low level and the above material properties are maintained
(see the corresponding standards and material data sheets).
Stamping shall not be performed at locations subject to high
loading.
7 Testing and inspection
For the testing and inspection prior to, during and after manu-
facture, the following sections shall be observed in addition
to TRB and AD-Merkblatter of the HP series:
7.1 Initial inspection - Design approval
Within the context of the design approval according to TRB
511, the authorised inspector shall establish the locations
which shall be tested in particular with regard to cyclic loading
in the tests described under sections 7.2 and 7.3.
7.2 Tests during production and final inspection
7.2.1 The tests to be performed during production by the
manufacturer or within the final inspection by the authorised
inspector shall ensure that there are no defects present in the
pressure vessel or pressure vessel component which may
grow rapidly in size under cyclic loading and which may result
in failure of the pressure parts before the allowable number
of load cycles has been reached (see AD-Merkblatt HP 5/l).

7.2.2 For the non-destructive test, the provisions of AD-
Merkblatt HP 5/3 in conjunction with the general table for
HP 0 shall be observed. If according to this, the method of
non-destructive examination is left open, the ultrasonic
examination should be given preference. Locations subject
to high loadings during operation such as welded-in nozzles,
hole edges or cross sectional transitions, shall as far as prac-
ticable be subjected completely to non-destructive testing.
The visual examination for surface defects and external
visible welding defects shall be performed with appropriate
care.
7.3 Inspections during operation
7.3.1 According to Annex II number 15 of the pressure ves-
sel ordinance (DruckbehV) each pressure vessel for which
the number of allowable load cycles (cycle number N) has
been fixed shall undergo an internal inspection at the latest
when half of the load cycles fixed has been reached.
If shorter intervals are prescribed for the internal inspection
under Article 10, para 4 of DruckbehV or other regulations
in Annex II of DruckbehV, or because of a special agreement
with the authorised Inspector, the shortest inspection inter-
vals of these shall be observed.
The user is obliged to record the number of load cycles ari-
sing by suitable means and, if necessary, to arrange for the
internal inspections.
7.3.2 If the operating conditions assumed in the calculation
under section 4 deviate in terms of a greater cyclic loading
or if damage to the pressure-bearing wall IS to be expected
before the end of the inspection intervals owing to other op-
erational influences, the inspection intervals shall be shorte-
ned by agreement with the authorised inspector.
Longer inspection intervals will possibly result from calculati-
ons according to AD-Merkblatt S 2.
7.3.3 In the case of pressure vessels subject to cyclic load-
ing, in-service inspections are of particular importance; they-
permit early detection of incipient damage. For this purpose,
the internal inspections shall be supplemented by non-
destructive tests on highly loaded locations. Surface crack
tests and ultrasonic tests are the methods to be considered
here. For the examination of readly accessible areas, the out-
side surface of the vessel can also be subjected to ultrasonic
testing.
7.3.4 If no cracks are detected during an internal inspec-
tion, the next internal inspection shall be performed within the
shortest interval laid down in 5 10, clause 4 of DruckbehV or
another regulation of Annex II to DruckbehV or on account
of a special agreement made with the authorized inspector,
however at the latest, when half of the fixed number of load
cycles has been reached. This also applies if the allowable
number of load cycles is exceeded.
7.3.5 The inspections prescribed under clause 7.3.1 to
7.3.4 for cyclic loading during operation may be waived if the
component is designed to withstand an operational load
cycle number of 2 . 106.
8 Consideration of special operating
conditions
In the case of corrosion-induced crack formation (fatigue
crack corrosion, strain-induced crack corrosion), hydrogen-
induced crack formation in compressed hydrogen, or the
presence of a magnetite protective layer, the provisions of
AD-Merkblatt S 2, section 13, shall be applied accordingly.
Page 5 AD-Merkblatl S 1, Edition 5.98
In cases of doubt a calculation according to AD-Merkblatt S 2
shall be conducted.
9 Measures to be taken when the design
lifetime has been reached
9.1 If the allowable number of load cycles for a component
or the allowable value for cumulative damage according to
section 4 has been reached, non-destructive tests according
to section 7.3 shall be performed as completely as possible
at a certain number of highly loaded locations to be laid down
with the authorised inspector.
9 . 2 If no cracks are found in the tests conducted under sec-
tion 9.1, continued operation is permitted. The prerequisite
for this is that no fatigue damage is found in the non-destruc-
tive tests conducted in the inspection intervals which corre-
spond to 50 % of the operating time according to section 9.1.
After this operating time has been reached, further measures
shall be agreed for each individual case with the authorised
Inspector.
9 . 3 Should cracks or crack-type defects for the purpose of
AD-Merkblatt HP 513 section 5.2 or 5.4 or other more exten-
sive damage be found in the tests conducted under section
9.1 or 9.2, the component or the structural element con-
cerned shall be replaced, unless continued operation is
deemed to be permitted by virtue of appropriate measures
to be agreed with the authorised inspector.
9 . 4 The following design, manufacturing and process-rela-
ted measures can be considered to allow for continued oper-
ation:
(1) Removal of cracks by grinding. If as a result of grinding
too thin a wall thickness is obtained repair welding shall
only be applied in collaboration with the manufacturer
and the authorised inspector;
(2) Grinding the welds to remove all notches;
(3) Removal of restraints to expansion: e.g. replacement of
cracked rigid stiffeners by joints not restraining expan-
sion;
(4) Change in mode of operation.
10 Additional details
10.1 In all cases where the conditions for waiving applica-
[ tion of this Merkblatt according to sections 1.4 an 1.5 are not
met, this shall be indicated to the manufacturer and to the
authorised inspector for the purpose of design approval. In
such cases, measures adapted to operational needs shall be
provided for and, if necessary, agreed between the manufac-
turer, user and authorised inspector. These measures shall
be included in the design-approved drawing and in the certifi-
cate of the final inspection, making reference to AD-Merkblatt
Sl.
10.2 The following items shall be indicated in conformity
with the scope given in section 1 (internal pressure fluctuati-
ons only):
- Number of pressure fluctuations between unpressurised
state and allowable working pressure (start-ups and shut-
downs) ;
- Pressure fluctuations of constant amplitude which are
superimposed on the working pressure, and their number
of operational load cycles;
- Pressure fluctuations of various load cycle groups and
their number of operational load cycles for a specified
operational load regime;
- Minimum and maximum temperature during a load cycle
or, in the case of load regime, in the individual load cycle
groups.
 P a g e 6 AD-Merkblatl S 1, Edition 5.96

l o a d c y c l e ------+

time

Fig. 1. Pressure curve and load cycle (schematic)

Design stress
i-C,& [ N / m m * ]

m Start-ups and shutdowns N S 1000

Wall thickness s, 5 25 mm
’
CL
G o v e r n i n g t e m p e r a t u r e T 5 2 0 0 “C
B 038 Welded joint class K 2
9
l% 0.7

091 j I I I II I I
1 10 100
I Number of daily load cycles

I Fig. 2. Delimitation between design against predominantly static loading and design against cyclic loading for pressure
vessels with an operational lifetime of up to 20 years (365 operating days)
 Page 7 AD-Merkblatl S 1, Edition 5.98

Start-uos and shutdowns

099

100 120 140 160 180 200 220 240

Design stress K&S [N/mm*1

Fig. 3. Reduction factor for pressure fluctuation ranges to Fig. 2 with more than 1000 start-ups and shutdowns

1 I I
1 i I I I /
0,95

099

0,85
038
0,75

097

0,65

096
0,55 1 1
! 1
jI ! / ( i
0,5 /
20 30 40 50 60 70 80 90 100 110 120 130 140 150

Wall thickness s [mm]

1Fig. 4. Correction factor fd to take into account the influence of the wall thickness
 P a g e 8 A D - M e r k b l a t t S 1, E d i t i o n 5 . 9 8

1
0,95

0,9
0,85

0,8
0,75
077
0,65
1
036
0,55
0.5 /

100 150 200 250 300 350 400 450

Governing temp’erature T [“Cl

1Fig. 5. Correction factor f,. to take into account the temperature influence
 800

600

400

200

0
103 104 105 10s

allowable number of load cycles &,I

Fig. 6. Allowable number of load cycles for design temperatures 5 100 “C and wall thicknesses 5 25 mm
Page 10 AD-Merkblatt S 1. Edition 5.98

20000

governing temperature r ‘_ 100 “C

\ structures wall thickness with s,
5 3 5 to 25 Table mm 3

lOOOO-

5000

2000

1000.
100 150 200 250 300
Design stress K&S [N/mm21

‘ig. 7. Allowable number of start-ups and shutdowns with pressure fluctuation ranges (~3 - p) = @, - 0)

0,3 0,4 0,5 0,6 0,7 0,8 0,9 1

referred pressure f l u c t u a t i o n r a n g e @ - p) / (pi - 0 )

:ig. 8. Load cycle increase factor for pressure fluctuation ranges (~3 - 0) < (pr - 0)
 Page 11 AD-Merkblatt S 1, Edition 5.98

o’25 -j
0,20
g o v e r n i n g t e m p e r a t u r e T 5 1 0 0 “C

0,15

0,lO
100 120 140 160 180 200
Design stress K&S [N/mm21

rig. g. pressure fluctuation ranges (~3 -P)&,- 0), related to pr that can be withstood under fatigue strength considerations
Page 12 AD-Merkblatt S 1, Edition 5.98

Table 3. Examples of structural forms and welded joints with the corresponding classes (K 0, K 1, K 2 and K 3) and
corresponding stress factors 7 (cracks drawn in as examples)

ierial Illustration Description Requirements Class 7

No.
1. Cylindrical and conical shells, dished heads

l o n g i t u d i n a l or c i r c u m f e r e n t i a l welded from both sides Kl 3.05)

weld in walls of equal thickness

1.1

welded from one side with Kl

backing weld

1.2

welded from one side without K2

backing weld

1.3

longitudinal or circumferential welded from both sides Kl 1.5”)

=2-s weld in walls of unequal
R thickness
1.4
.j&-&
*
+

Kl

1.5

Kl

1.6

welded from both sides, edge- Kl

offset the same inside and
outside
1.7
//4

Kl

1.8
,
fi

Kl

1.9

5) For allowable peaklng and flattening. see AD-Merkblatf HP 1. If no peaking or flattening IS present, 7 = 1.5 can be assumed.
6) For allowable wail thickness ratios and allowable mismatch, see AD-Merkblatt HP 5/l. The values for longitudinal welds apply.
 Page 13 AD-Merkblati S 1, Edition 5.98

Table 3. Examples of structural forms and welded joints with the corresponding classes (K 0, K 1, K 2 and K 3) and
corresponding stress factors TJ (cracks drawn in as examples)

2. Nozzle-to-plate welds

full-penetration welded from o n e

side with backing weld

: left-hand version)

side without backing weld or

without machining of root

nozzle with pad reinforcement. K3

weld: on the outside diameter of
2.7 reinforcing pad

nozzle with pad reinforcement. Full-penetration welds for Kl

weld: nozzle-to-plate weld connection of nozzle to basic
2.8 shell and pad reinforcement
Page 14 A D - M e r k b l a t t S 1, Edition 5 . 9 8

Table 3. Examples of structural forms and welded joints with the corresponding classes (K 0, K 1, K 2 and K 3) and
corresponding stress factors q (cracks drawn in as examples)

Description Requirements Class 17

. Flanges and build-up pads

full-penetration welded from one

side with backrng weld

full-penetration welded from o n e

side with backing weld

Ily only necessary if the bolts are frequently

cases the values in brackets K 0 and TJ = 5 . 0

.-e.

4. Bolted, simply supported or clamped flat plates with openings

Application and additional requirements:
- The stress factors r) apply to heads with central openings, if the following conditions for the opening are met (notations see
AD-Merkblatt B 5 or B 9): di / D, 5 0.2 and s, /s 2 1.25 . di / D, + 0.1 for reinforced openings and d, / D, S 0.2 for unreinforcec
openings
- Reinforced openings: weld form and assignment to class as serial Nos. 2.1-2.6, 3.3-3.7
- Unreinforced openings ( f l a t p l a t e s w i t h o u t w e l d ) : c l a s s K 0
 Page 15 AD-Merkblati S 1, Edition 5.98

Table 3. Examples of structural forms and welded joints with the corresponding classes (K 0, K 1, K 2 and K 3) and
corresponding stress factors 1 (cracks drawn in as examples)

5. Connecting welds of flat plates

Application and additional requirements:
Classes K and stress factors q a l s o a p p l y t o h e a d s w i t h c e n t r a l openings i f t h e f o l l o w i n g c o n d i t i o n s f o r t h e o p e n i n g a r e m e t ( n o t a t i o n s
see AD-Merkblatt B 5 or 6 9): d, / D, 5 0.2 and s, / s 2 1.25 d, / D, + 0.1 for reinforced openings and d, I D, 5 0.2 for unreinforced
openings
Page 16 AD-Merkblatt S 1, Edition 5.98

Table 3. Examples of structural forms and welded joints with the corresponding classes (K 0, K 1, K 2 and K 3) and
corresponding stress factors 17 (cracks drawn in as examples)

erial Requirements Class

VO.
Illustration Description v
I

4
flange head, connecting weld knuckle radius and flange depth KllK2 1.5
act. to AD-Merkblatt B 5, Tab-
l e 1, t y p e a , w e l d d e s i g n a n d
5.9 class assignment as serial
no. 1.1 - 1.3

flanged head, knuckle unwelded K O 2.0

5.10
forged or pressed head, knuckle radius.and flange depth Kl/K2 1.5
connecting weld act. to AD-Merkblatt B 5, Tab-

-I
l e 1, t y p e b , w e l d d e s i g n a n d
5.11 class assignment as serial
no. 1.1 - 1.3

forged or preesed head, unwelded KO 4.0

5.12
knuckle

5. Jackered shell-connecting welds

T

with shaped sealer ring full-penetration welded from one K2 3.0

The evaluation applies to both side
t h e Inner v e s s e l w a l l a n d t h e
connecting weld

with separate sealer ring full-penetration welded from both Kl 3.0

The evaluation applies to both sides
the inner vessel wall and the
weld connecting the sealer ring &I-penetration welded from one
and vessel wall. side with backing weld
(The connecting weld between
sealer ring and external jacket is
evaluated as per serial no. 1.3
with K 2)

7. Welded attachments, general

Prerequisite: external findings of attachment welds, to EN 25817, quality level 8, e x c l u d i n g w e l d r e i n f o r c e m e n t a n d w e l d s a g a n d
unequal leg fillet welds

7.1
-
T Welded attachments without
application of alternating additio-
nal forces and moments
full-penetration welded from both
sides

fillet-welded from both sides

Kl

K2
2.0

7.2

full-penetration welded from both K 17)

sides
fillet-welded from both sides K 27)

Reinforcing plate, backing plate s2 I 1.5 . s, K2

connected with fillet weld. No rz2d,
application of alternating additio-
nal forces and moments

The evaluation refes to the rib centre. For the rib end the evaluation is made for a lower class in each case
 P a g e 1 7 A D - M e r k b l a t t S 1, Editlon 5 . 9 8

Table 3. Examples of structural forms and welded joints with the corresponding classes (K 0, K 1, K 2 and K 3) and
corresponding stress factors q (cracks drawn in as examples)

erial Requirements Class 7

illustration Description
IO.

w e l d e d a t t a c h m e n t s w i t h applica- full-penetration welded from both K 1 3.0

tion of additional forces and sides
7.6
moments

welded from both sides, but not K 2

fully penetrating
7.7
-A

3. Welded attachments without application of alternating additional forces or moments. Examples

prerequisite: external findings of attachment welds to EN 25817. quality level 8, e x c l u d i n g w e l d r e i n f o r c e m e n t a n d w e l d s a g a n d
unequal leg fillet weld

vessel wall with support foot

(with or without backing plate)

vessel wail with lifting lug welded from one side

(with or without backing plate)
Page 18 A D - M e r k b l a t t S 1, E d i t i o n 5 . 9 8

Table 3. Examples of structural forms and welded joints with the corresponding classes (K 0, K 1, K 2 and K 3) and
corresponding stress factors 1 (cracks drawn in as examples)

Serial Illustration Description Requirements Class I)

No.
vessel wall with bracket welded from one side K2 2.0

8.9

Annex 1 to AD-Merkblatt S 1
Explanatory notes on AD-Merkblatt S 1.
The AD-Merkblatt S 1 constitutes a simplified fatigue analysis
on the basis of new AD-Merkblatt S 2, “Analysis for cyclic
I loading”, edition May 1998.
The following explanatory remarks refer only to the simplifi-
cations with regard to the procedure according to AD-Merk-
blatt S 2. Concerning the basis of fatigue analysis as deve-
loped further, reference is made to AD-Merkblatt S 2, Annex 1.
The following simplifications are determined in this AD-
Merkblatt as against AD-Merkblatt S 2:
1. Calculation only to establish cyclic loading from internal
pressure fluctuations below the creep range.
2. Approximate calculation of stress amplitude 2d,viaglobal
component-specific stress factors q and utilisation of the
design stress according to AD-Merkblatt 6 0 instead of a
detailed stress analysis.
3. No correction factors for plastic strain concentration
(k, factors) and mean stress influence (fM factors).
4. No correction factors f, to take into account the surface
influence in the case of unwelded components. Load
cycle curve for unwelded components limited to rolling
skin surfaces.
5. Uniform and load cycle independent correction factor f,,
to take into account the wall thickness influence for
welded and unwelded components.
6. Simplified calculation of damage accumulation with ope-
rational load regime without indication of fictitious load
cycle curves in the endurance range (e.g. modification
according to Haibach).
Explanatory note on section 1.2
With most pressure vessels, temperature changes during
operation or external loads in terms of cyclic loading play a
subordinate role as against operating load from internal pres-
sure. For reasons of simplification, only the cyclic loading
from internal pressure fluctuations is therefore taken into
account.
In the dimensioning of creep strength characteristics (e.g. for
100000 h), the damage fraction from cyclic loading is in most
cases very small as against creep damage.
Conversely, for the sake of simplification application of this
AD-Merkblatt is excluded for higher temperatures at which
time-dependent strength values are crucial for dimensioning.
Explanatory note on section 1.4
The abandonment of a simplified calculation for cyclic load-
ing with the sole action of internal pressure fluctuations below
1000 load cycles and/or pressure fluctuations of not more
than 10 % or 20 % of the allowable operating pressure (or the
fictitious pressure p,) is a practical solution for pressure ves-
sels with geometries and welded connections less suited for
cyclic loading, or for pressure vessels designed for predomi-
nantly static loading (e.g. simple pressure vessels to EC
Simple Pressure Vessel Directive.
Here, it is assumed that fatigue cracking, if any, can be detec-
ted in time during periodic inspections in accordance with
5 10, Sect. 4 of the Pressure Vessel Ordinance (DruckbehV).
Page 19 AD-Merkblatt S 1, Edition 5.98
1Explanations to section 1.5
The curves in Fig. 2 and 3 have been determined with respect
to further renounce to the application of AD-Merkblatt S 1 to
obtain
-P-P B
P q.KIS.Nlt3
1and
- (NABIAN - 1000) .
i
where
B = 6.300 to Table 1 for class 2
7j =3
N = 20 365 . number of daily pressure fluctuations
NABiAN = number of start-ups and shutdowns
1For the reduction factor F,, only 90 % of the full pressure fluc-
tuation range were considered for start-up and shutdown and
the 1000 start-ups which are negligible according to section
1.4 were deducted.
Explanatory note on section 4.1.2 and Table 3
The stress factors q are regarded as geometry coefficients
which relate to calculated stresses in accordance with the
dimensioning formulae according to AD-Merkblatter
Series B (limit load stresses). The stress factor q of a compo-
nent structure generally has a smaller range than the structu-
ral stress concentration factor cz, which is used, for example,
in a detailed analytical stress analysis.
The 1 values in Table 3 are figures established by calculati-
ons, estimates and experience. They normally constitute the
maximum of 1 factors for the parameter ranges arising in
practice for every component structure. For related compari-
sons see BR-E 2 [3].
Example 1: Cylindrical shell with perpendicular branch
Conversion of formula (2) according to AD-Merkblatt B 1,
where c, = cZ = 0 and v = vA as ligament efficiency yields:
- (Da-s)‘P = ,,“m;pv
u= 2o.s.v* . A
Structural stress iT related to mean stress intensity in a cylin-
drical shell without discontinuities
Dm P
.--
5=a 2o.s
Stress factor
Il+a.v,
Figure A 3 of this Annex shows the stress factors q for this,
which are calculated from v, values according to AD-Merk-
blatt B 9 and structural stress concentration factors a accord-
ing to XIE and LU [6] (cf. [7], Fig. 7).
Corresponding calculations for spherical shells with a branch
yield somewhat higher 1 values. In Table 3, a value of 17 =
3.0 was fixed for nozzle-to-cylinder welds (no. 2) in shells.
Example 2: Conical shell with corner joint
Conversion of the dimensioning formula in AD-Merkblatt B 2,
section 8.1.1, according to
 Page 20 AD-Merkblatt S 1, Edition 5.98
K P
-=a= ,&Lj.ezt zl P z act. to Figs. 3.1 to 3.7 in
S determination of allowable load cycles), the semi-logarithmic
AD-Merkblatt B 2
according to clause 8.1.2
K
-c-o=
S 20 . s
according to Annex to AD-Merkblatt B 2
P ez2
z2 A z act. to Table A 1
u = UP3 = lo
I r 1.5. e*l , e*z 1
2 . ez2
II= g=tnax
D
K .++1
cosq
I 1
For parameter calculations for this, see Fig. A 4.
Excluding the shallow conical shells (q = 60-70”), which are
hardly used in practice, for pressure vessels under cyclic
pressure loading, a stress factor of 7 = 2.7 was fixed accor-
dingly in Table 3, No. 1 .l O/l .l 1.
Explanatory note on section 4.1.3, Formula (3)
In order to take into account the cyclic-strength-reducing
influence of the component size, the correction factor f, was
taken for welded joints in the endurance range according to
AD-Merkblatt S 2, section 7.2.6. Dependence on the number
of load cycles according to AD-Merkblatt S 2, formula (17),
was dispensed with.
The fd factor is also used by way of simplification for unwel-
ded components.
I Explanatory notes on section 4.2 and Figure 6
To plot a load cycle curve for unwelded components (surface
condition: rolling skin), calculations were conducted accord-
ing to AD-Merkblatt S 2 for different materials taking account
of the influence of plasticity and maximum mean stress
kJ = 4l0.2).
According to Figure A 1 of this Annex, it is possible to indicate
by approximation a “mean value” curve with constant gra-
dient exponent m = 3.5 on a double-logarithmic scale. This
load cycle curve class K 0 is almost identical with the load
cycle curves for unwelded component areas according to the
British Standard BS 5500: 94 [4] or, as the case may be,
BS 7608: 1993 [5] (curves of class C).
For welded joints, the load cycle curves of classes K 1, K 2
and K 3 from AD-Merkblatt S 2 were taken.
To check the influence of plasticity in the range of low num-
bers of load cycles, calculations were conducted (conservati-
vely) according to AD-Merkblatt S 2 for the low-strength
material H II. Figure A 4 shows that the reduction through the
k, factors (k, > 1) is relatively small from 1000 load cycles
on and only takes effect in classes K 1 and K 2. In view of
the scope (N r lOOO), a global stress increase in elastic-
plastic range through k, factors was therefore dispensed with
for reasons of simplification.
For reasons of practicability (easier readability for faster
presentation was chosen for the cyclic load chart as in the
previous AD-Merkblatt S 1 (Edition 3.90), Figure 2 (N,oo
curves).
Explanatory note on section 4.3 and Figure 7
In compliance with the former representation of the Nloo and
f, curves, similar curves for pressure vessels of certain
design and operational boundary conditions were taken over.
Formula (8) is obtained from Formula (6) with B = 7.940 from
Table 1 for class K 1 and 7) = 3.0.
Explanatory note on section 4.4
To simplify the procedure with damage accumulation in the
case of an operational load regime, no ficititious load cycle
curves according to the Haibach modification as in AD-
Merkblatt S 2 are contained in the endurance range
(N > 2 106).
As compared with the base values of allowable stress ampli-
tudes 2u, according to AD-Merkblatt S 2, Table 4 in the range
N = 2 106 to 108 and in accordance with the procedure
according to AD-Merkblatt S 2, section 9.2, stress amplitudes
with N 2 2 106 at a level of 50 % of the endurance values
2~ according to Table 2 of this AD-Merkblatt are regarded
as negligible.
Literature
j [l] AD-Merkblatt S 2: Fatigue analysis, Edition May 1998
Heymanns Verlag, Cologne; Beuth Verlag, Berlin
[2] AD-Merkblatter, Series B.
I Heymanns Verlag, Cologne; Beuth Verlag, Berlin 1998
[3] Richtlinienkatalog Festigkeitsberechnungen (RKF), Be-
halter und Apparate Part 5.
Edition 1986. Linde-KCA-Dresden GmbH
[4] British Standard BS 5500/l 994: Specification for unfired
fusion welded pressure vessels
[5] British Standard BS 760811993: Code of practice for
fatigue design and assessment of steel structures
[6] Duan-Shou Xie and Yang-Gou Lu: Prediction of Stress
Concentration Factors for Cylindrical Pressure Vessels
with Nozzles.
Int. J. Pressure Vessel & Piping 21 (1985)
[7] Gorsitzke, B.: Vorhersage der Ermtidungsfestigkeit
druckftihrender Komponenten im Energie- und Chemie-
anlagenbau, Part 1 and Part 2
Z. Tij 30 (1989) No. 2 and No. 3
[8] Gorsitzke, B.: Neuere Berechnungsvorschriften zur
Ermiidungsfestigkeit von Druckbehaltern.
Z. TO 36 (1995) No. 6 and Nos. 7/8
[9] Gorsitzke, B.: Eriauterungen zum neuen AD-Merkblatt
S 1 ,,Vereinfachte Berechnung auf Wechselbeanspru-
chung und erganzende Hinweise“.
Z. TO 37 (1996) No. 6 and Nos. 7/8.
 Page 21 AD-Merkblatt S 1, Edition 5.98

10000

influence of plasticity and maximum mean stress Zr = R, 0.2

ADS 1, Class KO

100

‘i
1 I,
10 T’
103 104 105
allowable number of load cycles N,,,

Fig. A 1. Allowable number of load cycles as a function of the stress amplitudes according to AD-S 1 and AD-S 2 for unwel-
ded components with rolling skin surface at ambient temperature and wall thicknesses 5 25 mm

1) P 265 GH according to DIN EN 10028-2

2) P 500 Q. P 500 QH or P 500 QL according to DIN EN 10026-6 (at present still prEN)
 1000 -
- I--T -
- with k, factor -
material l-l II -
x).2 = 265 N/mm*
-
- t - t + - -
.
-

100 -
. -
-
.
- - Class
-
4
-
: Kl
-
- K2
-
- K3
-

10 -

103 104 105

allowable number of load cycles A!,,,

Fig. A 2. Allowable number of load cycles as a function of stress amplitude according to AD-S 2 for welded joints at ambient temperature and wall thicknesses < 25 mm
taking into account the influence of plasticity (k, factors)
 Page 23 AD-Merkblatt S 1, Edition 5.98

?j = VA . cl
vA values according to AD B 9
a values according to [6]
/ r-
l I
A (
7f-r-
n n
t-

1 0 r
4

t
I

0
/ ( ‘4
t
+ 6 in

+
n
n
n
n

A sA/Q = 0,5

5s _ l s,/s,=l,o -I
t
. s,/s,=1,5
-, -
n sA/sZ = 28
4l
t
A--.-.-.’ .
i

t
4 6 8
1 2 3

parameter 6 =
(2)‘J&

Fig. A 3. Stress factors q for cylindrical shells with perpendicular branch

Page 24 AD-Merkblatt S 1, Edition 5.98

23 -, I I - I I I

294

22

50”

1,4

12

14
0 0,005 0,010 0,015 0,020 0,025 0,030 0,035 0,040

s I 0,

Fig. A 4. Stress factors q for convergent conical shells with corner joint
 Page 25 AD-Merkblati S 1, Edition 5.98

Annex 2 to AD-Merkblatt S 1

Example of calculation 255

2d,=2+- = 247 N/mm2
1.5
Pressure vessel for pulverised coal injection installation
= 16593
1. Design Details
see Figure A 5 3.3 Conical shell, upper knuckle connection according to
cylindrical shell, conical shell, torispherical head, closure and AD-Merkblatt B 2, conical shell outside the die-out length for
nozzle plates made of H II pr decisive
nozzle tubes made of St 35.8 I
flanges of C22.8, nominal pressure PN 16
blind flange with full-face gasket PI =
design of the welded joints of pressure-bearing walls
(longitudinal, circumferential and nozzle connection welds)
in accordance with weld class K 1, of welded-on parts Class DK = 2847 mm from the calculation according to AD-Merk-
K 2. blatt B 2
1 wear allowance cp = 2 mm for shells and heads.
I 20. +85(18-l)
Pr = = 1 6 bar
2847
2. Operational Data -----+ 1 8 - 1
cos 20”
allowable operating 1Table 3, NO. 1 .lO => K1,‘1=2
pressure 16 bar
Table 1, K 1 3 6 = 7940
operating temperature 50 “C
internal pressure 12 255
amalitude
mode of operation
p-p=l2-0=12bar
3 cycles/h, 3-shift
I 26”=2.-‘--
1.5
= 255 N/mm*

= 30188
operation

3. Stress amplitudes and allowable numbers of load

cycles according to AD-Merkblatt S 1, Section 4. 3.4 Conical shell, nozzle region
temperature influence according to AD-Merkblatt B 9 with cylinder substitute dia-
factor for T* 5 100 “C f,. = 1 meter D, = 2200 mm
=> pI = 26 bar
wall thickness correction
factor for s, 5 25 mm F,, = 1 Table 3, No. 2.1 3 K I, ‘I = 3
yield strength at 20 “C K2,, = 255 N/mm2 Table 1, K 1 3 I3 = 7940
safety factor s= 1.5 12 255
21$=3.~.~ = 235 N/mm*
3.1 Cylindrical shell, longitudinal weld area with peaking
fictitious pressure in accordance with AD-Merkblatt B 1 = 38571

3.5 Torispherical head, knuckle region

Pr = according to AD-Merkblatt B 3 3 p,=18bar
I Table 3, No. 1 .I5 => KO,q=2
20. +0.85(18-l) Table 1, K 0 => 6 = 7890
Pr = = 16.5 bar 12 255
3000-(18-l) 2d,=2. -ijj-.- = 227 N/mm2
1.5
according to Table 3, No. 1 .l => Kl,q=3
according to Table 1 for K 1 => 6 = 7940 N/mm” = 247559
Stress amplitude according to formula (2)
3 12 255 3.6 Torispherical head, nozzle region item 6 decisive
2a”,=-.-.-----‘--- = 371 N/mm2 pr = 22 bar
1 . I 16.5 1.5 according to AD-Merkblatt B 9 =>
allowable number of load cycles according to formula (6) Table 3, No. 2.1 => Kl,r/=3
Table 1, K 1 => 6 = 7940
= 9803
12 255
2a’=3.=.- = 278 N/mm2
1.5
3.2 Cylindrical shell, bracket area
7940 3
pr = 16.5 bar
Table 3, No. 6 . 5
(see 3.1)
=> K2, q=2
i J
&“I = 278 = 23298

Table 1, K 2 + 6 = 6300 N/mm2 Blind flanges are not relevant with regard to fatigue life.
 Page 26 AD-Merkblatt S 1, Edition 5.96

4. Overall result and evaluation I N,“, = 49000

The allowable number of load cycles for the vessel is with an inspection interval of approx. 1 year
obtained as the smallest value from the allowable values for
the locations considered at
0.5 .49 000
1N,,, = 9803. = 340 days
Ii 3 .24 1
The wall thickness dimensioning for static loads (AD-Merk-
blatter Series B) leads to an unacceptable number of load A clearly more favourable result can be achieved, however,
cycles or inspection intervals. if the calculations are carried out according to AD-Merkblatt
The number of load cycles can, for example, be increased S 2. For this, see calculation example for the same pressure
by increasing the wall thicknesses. An analogous calculation vessel with s, = 30 mm in AD-Merkblatt S 2, Annex 3.
with wail thicknesses of 30 mm for cylindrical shell, conical
shell and head leads to N,,, = 250000, Inspection interval 5 years.
 Page 27 AD-Merkblatt S 1, Edition 5.98

11

.8
-

-1

Fig. A 5. Pressure vessel for pulverised coal injection installation (sample)

ICS 23.020.30 Edition May 1998

AD-Merkblatt
Special cases Analysis for cyclic loading
s2

T h e AD-MerkblWer a r e compiled b y t h e s e v e n a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “Arbeitsgemeinschafi Druckbehtilter”

‘AD). AD-Merkblatt G 1 covers the composition and application of AD-Regulations and also procedural guidelines.
T h e AD-Merkblatter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . I n t h e e v e n t o f l o a d i n g s e x c e e d i n g
‘he normal level expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
squirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
:mbodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e.V. (FDBR), Dijsseldod
H a u p t v e r b a n d d e r g e w e r b l i c h e n B e r u f s g e n o s s e n s c h a f t e n e . V . , Sank? Augustin
Verband der Chemischen lndustrie e.V. (VU), FrankfurtlMain
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, FrankfurtlMain
Verein Deutscher Eisenhtittenleute (VDEh), Dijsseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkraftwerksbetreiber e. V., Essen
Verband d e r T e c h n i s c h e n iiberwachungs-Vereine e . V . (VdTiiV), Essen.
T h e AD-Merkblgtter a r e a m e n d e d c o n t i n u o u s l y b y t h e a b o v e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents

1 Scope 10 Design requirements

2 General 11 Manufacturing requirements
3 Symbols and units 12 Testing and inspection requirements
4 Basis of stress calculation 13 Consideration of special operating conditions
5 Equivalent stress range and equivalent mean 14 Measures to be taken when the design lifetime has been
stress in the case of uni-axial and multi-axial reached
fluctuating stresses 15 Additional requirements
6 Principal equivalent stress range for elastic-plastic Annex 1: Explanatory notes on AD-Merkblatt S 2
conditions Annex 2: Comments on the assessment of cyclic
7 Allowable stress range with a known number of loading on the basis of fatigue tests
load cycles Annex 3: Notes on the conduct of stress evaluation
8 Allowable number of cycles with a known stress Annex 4: Alternative calculation method for higher allowable
range stress ranges or load cycle numbers at reduced
9 Consideration of operational load regime inspection intervals

1 Scope 2 General
1.1 The design rules presented below apply to the design 2.1 This AD-Merkblatt shall only be used in conjunction with
of pressurized components of pressure vessels made from AD-Merkblatt B 0.
ferritic and austenitic rolled and forged steels, manufactured
and tested in accordance with the AD-Merkblatter of the 2 . 2 The analysis for cyclic loading requires a knowledge of
Series B in conjunction with those of Series W and HP. These the loadings and their changes over time, see Section 15.
rules consider the cyclic loadings’) occurring at the most The loading conditions of the component are determined by
highly loaded points as a result of internal pressure and tem- the mode of operation of the pressure vessel and must be
perature differences or additional external forces and known either from the process in question or from the oper-
moments (see Annex 1). ating conditions.
1.2 This specification need not be applied if the conditions
in accordance with AD-Merkblatt S 1 are satisfied. 2 . 3 The stresses or strains can be determined either expe-
rimentally or mathematically. Their history is assessed in a
‘) The term “cyclic loading” is meant here in a comprehensive sense asthe variation fatigue analysis, with a distinction being made between uni-
over time of a loading regardless of the magmtude and arithmetic sign of the mean
value. axial, bi-axial or tri-axial states of stress.

Supersedes February 1995 edition; ) = amendments relating to previous edition

Carl Heymanns Verlag KG

Luxemburger StraOe 449, 50939 Kdln
 Page 2 AD-Merkblatt S 2, Edition 5.98

2.4 The criterion for failure due to cyclic loading is an 4l design lifetime for creep loading in h
[ incipient crackz). N in this context: number of operational
load cycles
2 . 5 The calculation of the loadings shall be based on the
Rn minimum tensile strength at 20 “C for
most unfavourable deviations from shape according to the
the section with the smallest wall thick-
AD-Merkblatter unless the deviations from specified shape
ness in N/mm*
are known. In such cases, the actual dimensions are introdu-
ced in the calculations. As far as wall thicknesses are con- R po.zfr proof stress at elevated or design tem-
cerned, the nominal wall thickness s, can be used in the perature 0.2 % T' for the section with
design approval. Minimum wall thicknesses shall be conver- the smallest wall thickness in N/mm*
ted to obtain a mean wall thickness. T temperature in “C
T* governing design temperature for
2 . 6 For the purpose of calculation, the governing tempera- cyclic loading in “C
ture during the load cycle under consideration is defined as:
0, equivalent stress in N/mm2
r‘ = 0.75 . t + 0.25 . f (1) 6, reduced equivalent mean stress in N/mm*
All temperature-dependent variables shall be related to this 2 aa pseudo-elastic stress range in unnot-
governing temperature 7 of the load cycle under considera- ched bar specimens and welded joints in N/mm2
1tion”). 2 %a equivalent stress range in N/mm*
2 %vap equivalent stress range from
2 . 7 The equivalent stress range and mean stress can be
mechanical load in N/mm’
determined by means of the von Mises criterion (maximum
distortion energy theory) or according to Tresca’s shear 2 %w equivalent stress range from thermal
stress theory, the former being the more exact method and load in N/mm2
the latter the more conservative one. In addition to the gen- 2 L7$ principal pseudo-elastic equivalent
eral definitions, the formation of the equivalent stress range stress range in N/mm*
and the equivalent mean stress according to Tresca’s shear AC7 principal stress difference in N/mm2
stress theory are shown for the sake of simplicity and greater
clarity in the application of Section 5.2.
Superscripts and subscripts:
2 . 8 If it is intended to deviate from the fatigue curves and Superscript * = corrected value, e.g. 2 G,
correction factors of this AD-Merkblatt, the procedure for
Superscript ^ = maximum value, e.g. 6, A&,*
determining the allowable stress range or allowable number
of operating cycles from fatigue tests on test coupons or com- Superscript ” = minimum value, e.g. ir, Ab,2
ponents shall be agreed in each specific case with the autho- Superscript - = mean value, e.g. 6
rised inspector with regard to type, parameters, number of Subscript i, k, j = number index, e.g. A+ Nk, t,
test specimens and safety factors (see Annex2).

2 . 9 Welded joints which cannot be tested shall be designed

beyond the endurance limit. Other procedures shall be 4 Basis of stress calculation
agreed with the authorised inspector. In this case Section 4.1 Structural stress verification
14.2 shall not be applied.
In the case of welded components, the principal stresses are
determined by means of verification of structural stresses.
3 Symbols and units The structural stresses (equivalent stress, if any) reflect the
basic loading arising from applied external loads (forces and
Over and above the AD-Merkblatt B 0, there are the follow- moments) and the reciprocal mechanical influence of the
ing : individual structural parts which results in linearly distributed
e here: cumulative damage fatigue index stresses across the section thickness. They can be determi-
(usage factor) - ned according to the theory of plane load bearing structures
fo surface finish correction factor (e.g. theory of plates and shells), to finite element analysis
wall thickness correction factor - or experimentally. Structural stress includes the effects of
fd
gross structural discontinuities under loading, however, ex-
f temperature correction factor
cludes the notch effects of local structural discontinuities
f; mean stress correction factor -
which have already been considered in the load cycle num-
f*M mean stress correction for welded, ber curves for welded joints (see Fig. 12).
stress-relieved components
fN fatigue strength reduction factor for In the case of FE calculations or strain measurements using
taking into account the medium of the strain gauges, the maximum structural stress value shall be
pressure vessel determined approximately for the location of the weld transi-
ke plasticity correction factor for stress tion by linear extrapolation of the structural stresses on the
due to mechanical loading j component surface with a sufficient distance4) from the seam
plasticity correction factor for stress (see Fig. 1). When interpreting measured structural stresses
k
due to thermal loading as linearly distributed membrane and bending stresses,
attention must be paid to the possibility of non-linear stress
t in this context: operating time under
distributions across the section thickness, e.g. as a result of
creep loading in h
thick walls and/or local applications of force (see Annex 1).

) *) An incipient crack is a material discontlnulty which can be detected by optical

means or non-destructwe testing.
1 3) Materlal data in accordance wth VDI-Richtlinie 3128 1 4) See e.g. lida [94]
 Page 3 AD-Merkblatt S 2, Edition 5.98

4.2 Notch stress verification stress range 2 a,, is obtained from equation (5) as follows
(see also Fig. 4):

I1
In the case of unwelded components, the stresses shall be
determined on the basis of notch stress verification. The AC+,,-A;,,
notch stress takes account of the notch effect of local structu- 2 uva = max. A&-A& (5)
ral discontinuities in addition to the respective structural
A;,, -A&,
stress.
Stress concentration factors may be determined according The mean equivalent stress ti, related to the equivalent
to the notch stress theory, be means of special analytical stress range 2 uva shall be determined from those two stress
methods or, alternatively, using strain gauges in the notch or histories u, and q from which the principal stress differences
by means of FE analysis. Abi, and Ac?,~ have been determined, which are the deter-
mining factors for the equivalent stress range. Then the varia-
In special cases, notch stress verification may also be perfor-
tion with time of the sum of principal stresses shall be deter-
med for welded joints using FE calculations; provided the fine
mined according to
structure of the weld seam is covered by a sufficiently small
grid subdivision and the applied notch configuration parame- 25, = (4 + a,) @a)
ters (shape, thickness, root and residual gap of the weld) will
and the maximum value x6,, and minimum value x4i, are
be realised in practice.
to be determined. The mean equivalent stress 6, is then
For details regarding the calculation of structural and notch obtained from
stresses, see Annex 3.
a, = ; (Cb,, + Cc,,) (6b)
A simplified procedure for the effect of only one type of load-
5 Equivalent stress range and equivalent ing and ignoring shear stresses is described in Annex 3.
mean stress in the case of uni-axial and In the case of a tri-axial tensile stress state, the requirements
multi-axial fluctuating stresses I of AD-Merkblatt S 4 shall be met.
The equivalent stress range of a load cycle at a point under
consideration is the difference in stress intensity between
two stress sensors in the same system of co-ordinates, 6 Principal equivalent stress range for
whose points of time within a load cycle are to be selected
such that the equivalent stress becomes a maximum. elastic-plastic conditions
For this purpose the load condition must be known for every 6.1 Mechanical loads
major point of time during a load cycle. This definition applies In the case of mechanical loadings, the principle pseudo-ela-
in general and regardless of the equivalent stress hypothesis stic equivalent stress range shall be determined according to
used. For unwelded components or component areas, the 2 u w v v a p = 2 a,,, k, (7)
related equivalent mean stress shall also be determined. The
The plasticity correction factor k , takes account of the defor-
following calculations apply for a,,,, from mechanical and cr,,,
mations in the elastic-plastic range and shall be taken from
from thermal loads according to Tresca’s theory with con-
stant principal stress directions. Fig. 5.
The k , curves of Fig. 5 can be described in the range
For cases where the location of the principal stress directions 1 .O < u,,dRpO W. 5 1.5 by the equation
varies over time, reference should be made to Annex 1 of this
AD-Merkblatt. k,=Al. 03)
Je+l
5.1 Uni-axial stress state
and in the range u&R~~,~ > 1.5 by
In the case of uni-axial stress as depicted in Fig. 2, the
equivalent stress range is 2 ~7~~ according to Tresca’s theory k,=A2+A3$= (9)
p 0.2/f
2 uva = (c?- 6) (2) The values Al, A2 and A3, which are dependent on the
and the equivalent mean stress according to material structure, shall be taken from Table 1.

a,+?+ 6) (3) Table 1. Values Al, A2 and A3

Material Group ( Al ( A2 1 A3 1
5.2 Multi-axial stress state with principal stress directi-
ons constant ferritic, R, = 800 to 1000 N/mm2 0.518 0.718 0.432
In order to form the equivalent stress range according to ferritic, R, 5 500 N/mm2 and 0.443 0.823 0.327
Tresca’s theory, first the variations with time of the principal austenitic
stresses a,, C+ and a3 must be determined for a tri-axial stress
state as shown diagrammatically in Fig. 3. For ferritic materials with R, between 500 and 800 N/mm2
Then the variations with time of the three principal stress linear interpolation is permitted.
differences Au,,, Aq,, Ag, shall be established using equa-
tion (4):
Aalp = a, - a,
Aq, = 02-a. (4) 6.2 Thermal loadings
A+, = Q-U, In the case of thermal loadings through the material thickness
For each of these three variations of the principal-stress the principal pseudo-elastic equivalent stress range is calcu-
differences, maximum and minimum values must be found lated from
by taking the arithmetic signs into account. The equivalent 2 c$,, = 2 uvaw .k, (10)
Page 6 AD-Merkblatt S 2. Edition 5.98
the factor f, being limited to f, = 0.64. The factor f, can also
be found in Fig. 8. In the case of welded forgings, the provisi-
ons of Section 7.1.3 shall apply. For the correction factor fT
I ponents shall be determined according to
the equations (24) or (25), or Fig. 10 apply.
7 . 2 . 7 In the case of stress-relieved components, the fatigue
strength is increased by a reduction in the residual weld
stresses compared to the weld condition. The allowable
stress range can thus be determined by including the correc-
tion factor f, to take account of the mean stress influence
from the loading according to Section 7.1.4 from
2 2 a, . fd . fy . f*M (28)
%ZUI =
0.4343 In N - 4 699
with fM = 1.3 1.602
fM (284
where no value smaller than 1 .O need be taken into account.
7.3 Alternative calculation method
Alternatively to the methods described in 7.1 and 7.2, the
allowable number of load cycles may also be determined by
means of the procedure in Annex 4. Here, higher allowable
stress values are obtained with reduced test intervals.
8 Allowable number of cycles with a known
stress range
As in Section 7, distinction shall be made between welded
and unwelded component areas when determining the allo-
wable number of load cycles N,,,.
8.1 Unwelded components
The allowable number of cycles shall be calculated from
equation (29) or taken from Fig. 11.
4.104
2 times etc. The related allowable numbers of load cycles N,,, ,,
N ZUI =
2~: - 0 . 5 5 R, + 1 0
Here the equivalent stress range is 2 ai, which shall be deter-
mined from the equivalent stress range 2 uva according to
Section 5 or 2 4, according to Section 6 and the correction
factors f,, f,, f, and f7 according to Section 7.1 from
2 %a
2 @ = f. . f, . f, fT.
The correction factors f, (N, R,) and f, (N, s), which are
dependent on the number of cycles, shall be determined ite-
ratively for N = N,,,.
With values for 2 C$ under the curves according to Fig. 11
intherangeN?2.106orwith2~~~2u,forN?2.106
according to Table 2, endurance limit exists.
8.2 Welded components
The permissible number of load cycles is calculated accord-
ing to
with the constants 61 from Table 4 and the stress range 2 r$
from
2 4a (32)
26 = fd . f,.
or from Fig. 12. where 2 uva shall be inserted according to
Section 5 and 2 @zz according to Section 6 and the correction
factors fd and fF according to Section 7.2.6.
If the boundary conditions according to Sections 7.2.4, 7.2.5
or 7.2.7 apply, the procedures stated there shall apply accor-
dingly in which case the stress range for stress-relieved com-
(see section 7.2.7).
8.3 Alternative calculation method
Alternatively to the methods described in 8.1 and 8.2, the
allowable number of load cycles may also be determined by
means of the procedure in Annex4. Here, higher allowable
numbers of load cycles are obtained with reduced test inter-
vals.
9 Consideration of operational load regime
9.1 With differing applications of loading and for each type
of loading, the load condition, the equivalent stress range,
and if necessary, the principal equivalent stress range shall
be determined in the plastic range and, with unwelded com-
ponents, also the equivalent mean stress.
The following calculation shall only be used if the greatest
stress range exceeds the endurance limit.
The damage due to cyclic loading is determined with the
linear cumulative damage rule
1 N,= $+Z+...$) 51.0 (34)
k NM
Here, N,, N, NI, are the numbers of load cycles to be expec-
ted during operation, the load cycles which cause the same
stress range 2 a,, or 2 &;, being combined in each case.
Therefore, the stress range 2 uva, or 2 c&, occurs N, times
during the entire operating period, 2 a,,> or 2 ea2 occurs N,
N ZUI 2 “’ Nm, k can then be taken from the relevant load cycle
curves for unwelded and welded components with the
respective stress range 2 @,; in the range of N > 2 1 06, the
fictitious load cycle curves shown as a dotted lines in Fig. 11
or Fig. 12 apply. The fictitious load cycle curves can be des-
cribed for unwelded componznts according to eq. (35)
N
zulk =
and for welded joints according to eq. (36)
N ml k =* (36)
with the constants 6 2 indicated in Table 4.
9.2 If an operational load regime contains loadings with
stress ranges 2 a,, (2 u&J which are smaller than the values
given in Table 2 or, as the case may be, Table 4 for N 2 1 08,
the fractions of damage of these load regime stages can be
ignored in formula (34).
9.3 If a component is operated in the high-temperature
j ranges), the fatigue phenomenon due to cyclic loading is
accompanied by an additional creep damage, whose portion
of the damage shall be determined with
(37)
The creep damage fractions + + +- . . . 4 are deter-
mined analogously to the fatic$e dai2age f:ctions from
appropriate creep diagrams, using the minimum values of the
scatter band as a basis (see, for example, EN 10 028-2:
1992, Table A.1 footnote 1).
1 6) Temperature range wIthin which design is governed by time-dependent design
strength values !n accordance with AD-Merkblfatter, Series 6

With regard to fully stressed welds, AD-Merkblatt B 0 Section
6.5 shall apply.
9.4 For an estimate of the superposition of fatigue and
creep damage with regard to the tests in accordance with
Section 14.5, it is possible to make use of a modified linear
cumulative damage rule. Here, the damage fractions accord-
ing to equations (34) and (37) are combined to give a cumula-
tive damage fatigue index (usage factor)
e= + 1; Il.0 (38)
i mi
If need be, for specral applrcations the permissible value of
e shall be determined (see Section 14.5).
10 Design requirements
10.1 The fatigue of cyclically loaded components largely
depends on the dimensionrng and design. Special care must
be taken here that structures with high stress and strain con-
centrations are avoided, e.g. by designing cross-sectional
transitions such that stresses can be properly distributed. An
assessment of weld details customary in the pressure vessel
industry is presented in Table 5. Where long service lrves are
required, the weld forms of class K 1 are recommended. If
necessary, higher requrrements than given in AD-Merkblatt
HP 1 shall be imposed on the design. By appropriate designs
testing and inspection to Section 12 shall be made possrble.
1 0 . 2 Fatigue life can be Increased by the followrng design
measures, for example.
(1) Hemispherical or tonsphencal heads instead of semi-
ellipsoidal heads
(2) Conical shell with knuckle instead of a cone with corner
joint
(3) Overdimensroning of the flat head of an unstayed head-
to-shell corner joint (in the load case internai pressure)
(4) Increase in the wall thickness of nozzles in cylindrical and
spherical shells but not above a wall thickness ratio of
s,ls, = 2. It has to be noted that the structural stress on
the outside of the nozzle joint connection can reach or
even exceed that on the inside
(5) Avoidance of inclined nozzles and pad-type reinforce-
ments
(6) Tube sheets, flanges and similar items with a tapered
transition to the shell
(7) Backing plates for support columns or the like with roun-
ded corners
(8) Avoidance of rectangular openings
1 0 . 3 By taking further special measures, e.g. the applica-
tion of residual compressive stresses, or through mechanical
or thermal treatment of surfaces, the service life of a compo-
nent can also be increased. The allowance to be made for
these measures in the determination of the surface finish cor-
rection factor or the allowable stress ranges in accordance
with Section 7, shall be settled from case to case with the
authorised inspector.
I
11 Manufacturing requirements
For manufacture, the AD-Merkblatter Series HP apply. Addi-
tionally, the following requirements shall be fulfilled for pres-
sure vessels designed according to this AD-Merkblatt:
11.1 In the case of cyclic loading, defects arising during
manufacture have a more unfavourable effect than with static
loading. The component lifetime can be reduced conside-
rably by notches or unfavourable residual stresses.
P a g e 7 AD-Merkblatt S 2, Edition 5.98
11.2 For the components special requirements shall be
imposed on the form of welds. Rating group 6 according to
EN 25817 shall be observed. With regard to heat control
during welding and the welding sequence, special attention
shall be paid to the welding residual stresses. All heat treat-
ments shall be performed properly to meet the material and
wall thickness requirements.
Annealing temperatures, holding time and cooling conditions
shall be fixed as far as possible such that good elongation
and notch toughness is ensured. in many cases the yield
point and tensile strength will set in at the lower limit of the
allowable range. Stress-relief annealing shall be carried out
to reduce the residual stresses to a low level and maintain
the aforementioned materiai properties (see the appropriate
DIN Standards and Materials Sheets).
Stamping shall not be performed at locations subject to high
IoaOing.
12 Testing and inspection requirements
For the testing and Inspectron prior to, during and after manu-
facture, in addition to the AD-Merkblatter of the Series HP
and TRB, account shall be taken of the following Sections:
12.1 Initial inspection - design approval
Within the framework of tne design approval according to
TRB 511, the authonsed inspector must fix the locations
which shall be tested in partrcular with regard to cyclic loading
in the tests described under Sections 12.2 and 12.3.
12.2 Testing during production and final inspection
12.2.1 The tests to be carned out during production by the
manufacturer or within final inspections by the authorized
inspector shall ensure that the pressure vessel or its compo-
nents are free from defects which may increase rapidly in size
under dynamrc loading and result in a failure of the pressure-
bearing components before the ailowabie number of load
cycles has been reached (cf. AD-Merkblatt HP 511).
12.2.2 Non-destructive testing is covered by the regulati-
ons in AD-Merkblatt HP 513 in conjunction with the synoptic
table in HP 0. If it is not strpulated there whether testing is
to employ radiography or the ultrasonic method, as a rule
ultrasonic testing shall be preferred. Locations subject to high
loadings during operation, e.g. nozzle welds, edges of holes
or cross-sectional transitions, shall, as far as possible, be
subjected completely to non-destructive testing. The visual
examination for surface defects and visible external weld
defects shall be carried out with appropriate care.
12.3 In-service inspections
12.3.1 According to No. 15 of Appendix II of the Pressure
Vessel Ordinance (DruckbehV), each pressure vessel for
which the number of allowable load cycles (number of load
cycles N) has been laid down shall undergo an internal
inspection at the latest when half of the load cycles fixed has
been reached.
If shorter intervals for the internal inspection are prescribed
under 5 10, Para. 4 of DruckbehV or other regulations of
Appendix II of DruckbehV or as a result of a special agree-
ment with the authorised inspector, the shortest of these
inspection intervals shall be observed. The user is obliged to
record the number of load cycles occurring by suitable means
and, if necessary, to arrange for the internal inspections to
be carried out.
Page 10 AD-Merkblati S 2, Editlon 5.98

Fig. la. Stress distribution across wall thickness

notch stress effect

i nozzle 1
wall 1

-ve of stress linearised

I
structural 3 component surface

I
stress,
max. value
; (hot spot)
I
--a---.
--
I component surface

Fig. lb. Maximum structural stresses at weld transition

Fig. 1. Examples of stress curves

 P a g e 11 AD-Merkblatt S 2, Edition 5.98

Fig. 2. Stress curve for uni-axial load

(diagrammatic)

Fig. 3. Stress variation for tri-axial load with principal

stresses out of phase (diagrammatic)
Page 12 AD-Merkblatt S 2, Edition 5.98

Fig. 4. Curve for differences between principal stresses and equivalent stress range 2 ava according to Fig. 3
 Page 13 AD-Merkblatt S 2, Edition 5.98

2,6

for ferrites between 500 and 800 Nimm2,

2,4 linear interpolation is required

mechanical ,

1
I
#
,
l
l
4
/
l
2 1,8
s" ferrite R, I 500 N/mm”
l
I austenite
I
l
.
1,6

ferrite and austenite

1 185 2 23 3 3,5 4

ova 1 RpO.2P

Fig. 5. Correction factors k, and k,, to take account of the elasto-plastic strains when twice
the proof stress is exceeded
Page 14 AD-Merkblatt S 2. Edition 5.98

0,5-

0,4

102 10s 104 105 106 2 10’

Number of load cycles N

Fig. 6. Correction factor f, to take account of the surface notch effect from rolling skin
 Page 15 AD-Merkblatl S 2, Edition 5.98

1
40
Or9 50
60
80
03 100
li 120
150

c /

104
I 1 I1111l1

105
1

106 2

Number of load cycles N

Fig. 7. Correction factor f, to take account of the influence of the wall thickness in unwelded components
 Page 16 AD-Merkblatt S 2. Edition 5.98

h-ml
l-
30
089 40
50
60
03
80

100
," or7 120
150

0,6 -

-
0.5 I

0,4 P -

102

Number of load cycles N

Fig. 8. Correction factor fd to take account of the influence of the wall thickness in welded joints
 Page 17 AD-Merkblatt S 2, Edition 5.98

600
INkl2. I
038 \ 80(

N 1000

0 200 400 600 800

-800 -600 -400 -200

Mean stress 5, [N/mm’]

Fig. 9. Correction factor fM to take account of the influence of the means stress for the endurance
limit range (N 2 2 . 106)
Page 18 AD-Merkblatt S 2, Edition 5.98

0,9

0,8

0,7

Cm

k a5

0,4

0,3

02

O,l

0
100 150 200 250 300 350 400 450 500 550 600

Governing temperature T* [“Cl

Fig. 10. Correction factor f,-. to take account of the influence of temperature
 Fictitious number of load
cycles, taking account of an
F4- operational load regime
E
E
t
-mm-

i i!il
, I/I

il
@J
II
b” 1000
N [N/mm21
a,
F
it 1000
800

600

100

Allowable number of load cycles N,,,

Fig. 11. Allowable numbers of load cycles as a function of the stress range for unnotched test bars of high-temperature ferritic and
austenitic rolled and forged steels at room temperature and Cr = 0
 w-t-t-t-tt iii/ ----II II
I II I I
Fictitious number of load
cycles, taking account of an

1000 1llll I
Ill,, 1
operational load regime
.-

Class

KO
Kl
K2
K3

10
102

Allowable number of load cycles N,,,

Fig. 12. Allowable numbers of load cycles as a function of the stress range for welded joints of high-temperature ferritic and austeni-
tic rolled and forged steels at room temperature (independent of (J)
 Page 21 AD-Merkblatl S 2, EdItIon 5.98

T a b l e 5. Examples of welded joints with the assigned weld classes K 1, K 2 and K 3, dependent on the kind of stress analysis
(typical cracks indicated as examples)

Weld class
for stress
Jo. Illustration Description Requirements analysis 1 or 2

1 2

I. Cylindrical and conical shells, dished heads

Longitudinal or circumferential Welded from both sides Kl Kl

weld in walls of equal thickness

1.1

Welded from one side with Kl Kl

back-up weld

Welded from one side without K 2 K2

back-up weld

Longitudinal or circumferential Welded from both sides Kl Kl

weld in walls of unequal thickness

VT
4
K27) Kl

1.5

K3 Kl

1.6

Welded from both sides, Kl’) Kl

edge-offset the same inside
and outside
1.7

Kl Kl

1.8 ,
A

K2 Kl

1.9

1 ‘) For allowable wall thickness ratios and allowable mismatch see AD-Merkblatt HP 511. The values for longitudinal welds apply
Page 22 AD-Merkblatt S 2. Edition 5.98

Table 5. Examples of welded joints with the assigned weld classes K 1, K 2 and K 3, dependent on the kind of stress analysis
(typical cracks indicated as examples)

Weld class
for stress
No. Illustration Description Requirements analysis 1 or 2

1 2

Cone with corner jotnt Welded from both sides or from - Kl

one side with back-up weld
1.10

Welded from one side without - K3

back-up weld
1.11
- 6J

Head-to-shell weld for dished Stress analysis 2:

heads with cylindrical flange For descriptron of welded joints,
depths according to prerequisites and the assigned
C
1.12 AD-Merkblatt 6 3 weld classes see example
Nos. 1.1 to 1.9

2. Nozzle-to-plate welds

Set-through or Full-penetration welded from both - Kl

Set-in nozzle sides
2.1 or
full-penetration welded from one
side with back-up weld
Full-penetration welded from one - K2
side without back-up weld
2.2

Set-in nozzle (in the illustration, Welded from both sides, but not - K2
l e f t h a n d versron) full penetration welded
2.3

Set-in nozzle (in the illustration, - K3

right hand version)
2.4

Set-on nozzle Full-penetration welded from one - Kl

side (without residual gap),
nozzle bored out
or root ground over
2.5

Full-penetration welded from one - K2

side without back-up weld or with-
out machining of root

2.6

Nozzle with pad reinforcement - K3

Weld: on the outside diameter of
2.7 reinforcing pad

Nozzle with pad reinforcement Full-penetration welds for connec- - Kl

Weld: nozzle-to-plate weld tion of nozzle to basic shell and
2.8 pad reinforcement
 Page 23 AD-Merkblatt S 2, Editton 5.98

Table 5. Examples of welded joints with the assigned weld classes K 1, K 2 and K 3, dependent on the kind of stress analysis
(typical cracks indicated as examples)

Weld class
f o r stress
10. Illustration Description Requirements analysis 1 or 2

1 2

3. Flanges and built-up pads

AD-Merkblatt B 8, table 1

full-penetration welded from one

side with back-up weld

full-penetration welded

full-penetration welded from one

side with back-up weld

weld on inside
the illustration: left

Set-on pad, weld on outside

the illustration: right

$. Jacketed shell - connecting weld

With shaped sealer ring: Full-penetration welded from one - K2

side
The assessment applies both to
the inner vessel wall and the
connecting weld

With separate sealer ring: Full-penetration welded from both - Kl

sides
The assessment applies both to or
the inner vessel wall and to the
weld between the sealer ring and Full-penetration welded from one
4.2 the vessel wall. side with back-up weld
(The weld between sealer ring
and outer shell (jacket) is asses-
sed as K 2 according to No. 1.3)
Page 24 AD-Merkblatl S 2. Edition 5.98

Table 5. Examples of welded joints with the assigned weld classes K 1, K 2 and K 3, dependent on the kind of stress analysis
(typical cracks indicated as examples)

Weld class
for stress
No. Illustration Description Requirements analysis 1 or 2

1 2

5. Connecting welds for flat heads

sides but not fully penetrating

dimensions according to

sides or full-penetration welded

from one side with back-up weld

Welded from one side

of the welded joints,

nd assigned weld classes see
mple Nos. 1.1 to 1.3.
 Page 25 AD-Merkblatt S 2, Edition 5.98

Table 5. Examples of welded joints with the assigned weld classes K 1, K 2 and K 3, dependent on the kind of stress analysis
(typical cracks indicated as examples)

Weld class
for stress
Jo. Illustration Description Requirements analysis 1 or 2

1 2

5. Welded attachments8)

Welded attachments without app- Full-penetration welded from both K 1 -

lication of additional forces and sides
3.1 moments

Fillet-welded from both sides K2 -

- &
5.2

Full-penetration welded from both K 2 K 19)

sides
9.3

,
Fillet-welded from both sides K3 K2 9 )
+kYFx4-&
6.4

Fielnforcing plate, backing plate s2 5 1.5 s, K2 -

c o n n e c t e d wrth f i l l e t w e l d . N o rs2.s,
application of alternating additio-
nal forces and moments
UT
&F

t-

6.5

\\h

Weld-on parts with transfer of Full-penetration welded from both - Kl

changing additional forces or sides
6.6 moments

Welded from both sides but not - K2

fully penetrating
-
6.7 <A

7. Weld-on parts without transfer of changing additional forces or moments, example@)

Vessel with connected skirt sup- Welded from one side K2 -

Pan

7.1

8) Requirement. External fmding according to EN 25817, quality level BK, excluding the features weld reinforcement and sag and unequal leg fillet welds
9 The assessment refers to the rib centre. For the end of the rib. the assessment IS a class lower in each case.
Page 26 AD-Merkblatt S 2. Edition 5.96

Table 5. Examples of welded joints with the assigned weld class K 1, K 2 and K 3, dependent on the kind of stress analysis
(typical cracks indicated as examples)

Annex 1 to AD-Merkblatt S 2
Explanatory notes on AD-Merkblatt S 2
The new edition of the AD-Merkblatt S 2 represents a further
development of this specification which takes account of the
growth in knowledge gained during the last years in the field
of “fatigue” and other international regulations on fatigue
evaluation (e.g. Eurocode No. 3, [76]).
As compared with the edition 3.90, the following specific
aspects have been revised or newly incorporated.
1, Separate presentation of fatigue curves for unwelded and
welded components, including austenitic materials.
2. Calculation of the principal stress range in the fully plastic
range by the use of plasticity correction factors k, and k,
for mechanical and thermal loads.
3. Change or supplementation of correction factors to take
account of the influence of surface, mean stress, size and
temperature.
4. Consideration of the influence of pressurised hydrogen on
the fatigue behaviour.
Explanatory note on Section 1
The curves for the number of load cycles and the incorpora-
ted coefficients for number of load cycles and stress safety
factor are adjusted to ductile rolled and forged steels for the
purpose of the AD specifications, displaying as they do a
linear stress-strain behaviour, with sufficiently homogenous
and isotropic properties. In the case of high-strength steels
with a large elastic ratio, special care should therefore be
taken to ensure strict adherence to all material requirements
laid down by the material sheets (see also explanatory notes
to equation (14)). This AD-Merkblatt cannot be applied to
cast steel or other metallic materials, e.g. non-ferrous metals,
since such materials display different fatigue strength proper-
ties.
Application of this Merkblatt in the low-cycle range is not a
substitute for any safeguard which may be necessary against
brittle fracture failure when high-strength steels are used.
Explanatory note on equation (1)
In the lifetime prediction for load cycles with changing tempe-
ratures, it is assumed that the results obtained in isothermic
fatigue tests can be transferred to nonisothermic loading
processes. Tests conducted by Wellinger and Idler [28] have
shown that, in fatigue tests with changing temperatures, the
numbers of load cycles obtained lie between the points attai-
ned with constant load cycle temperatures. In no case was
it observed that the number of load cycle up to fracture or inci-
pient crack was lower with changing temperature than with
constant maximum temperature with the same amplitude in
each case.
The temperature taken as the determining temperature of a
load cycle for fatigue by fluctuating stress is therefore one
between the upper and lower temperature limit. Until further
knowledge is available, equation (1) of this Merkblatt will be
used for the calculation.
Explanatory note on Section 4.1
In the case of local application of forces, non-linear stress dis-
tribution over the cross-section may occur in accordance with
the St. Venant principle. This applies all the more, the closer
the location under consideration is to the point of force appli-
cation.
Page 27 AD-Merkblatt S 2, Edition 5.98
This St. Venanf principle says that, when the force acting on
a small area of the surface of an elastic body is replaced by
an equivalent system of forces, this redistribution of loading
causes major changes in the local stresses, but has a negli-
gible stress effect with those distances which are large com-
pared with the dimensions of the surface subject to loading.
Explanatory note on Section 5
In Section 5 of the Merkblatt, the Tresca hypothesis (shear
stress theory) is given preference, since the calculation rules
given in the B Series of the AD-Merkblatter are based for the
most part on the Tresca hypothesis. Under Section 2.7 of this
Merkblatt, the user is also free to use the Mises hypothesis
(maximum distortion energy theory). On the one hand, the
calculation of the equivalent stresses according to the maxi-
mum distortion energy theory yields somewhat more favou-
rable results than the shear stress theory. On the other hand,
however, the application of the shear stress theory may,
especially with multi-axial loading, be more advantageous on
account of its simpler structure.
Where the directions of principal stress change over time,
[2] indicates a method for determining the equivalent stress
range in order to establish the principal stress range.
The calculation rule for determining the equivalent stress
range according to [2] yields the same result as Section 5 of
this Merkblatt if the directions of principal stress are constant.
Explanatory note on equations (8) and (9)
If the equivalent stress range 2 a,, is calculated in a purely
linear-elastic mode and if double the yield point is exceeded,
the disproportionate strain increase in the fully plastic range
has to be taken into account by determining a global plastic
stress range (principal stress range 2 d\;,).
Instead of the Neuber rule applied hitherto, which overesti-
mates the total strain with large notch stresses calculated in
a linear-elastic mode [63, 641, plasticity correction factors k,
and k, were introduced for mechanical and thermal loading,
as in the procedure described in the ASME Code.
For this purpose characteristics of the cyclic material beha-
viour obtained in numerous series of tests from the material
data collection of Boiler and Seeger [69] were evaluated,
using approximation formulae according to DixonlStranni-
gan and KdhnapfeUTroost [65]. The two k, curves given in
Fig. A 5 of this Merkblatt which can be described by the equa-
tions (8) and (9) correspond approximately to the upper limit
of the scatter band of the k, curves determined accordingly
for the various material groups. The elastic-plastic behaviour
of some materials below the “static” yield point (material sof-
tening) was ignored and the lower limit was fixed pragmati-
cally at cs,,&o.m = 1 .O for a correction of the stress calcula-
ted linear-elastically. The k, factors calculated according to
this are also comparable with the fz factors to be determined
using the equation (12) in AD-Merkblatt B 13 to take account
of elastic-plastic deformations.
Further details are given in [92].
Explanatory note on equation (11)
With the equation (11) the global stress increase for thermal
loading in a cross the wall thickness is calculated for stress
ranges above twice the yield point. The equation was taken
Page 28 AD-Merkblatt S 2. Edltion 5.98
from [80] and is based on consideration of thermal strains in
the elastic range and in the elastic-plastic range and a simpli-
fied assumption of an ideal elastic-plastic material behaviour.
Explanatory note on equation (12)
Equation (12) contains an approximation solution for super-
imposing mechanical and thermal loadings.
Explanatory note on equation (14)
For the sake of easier handling, load cycle curves are given
in this new edition which incorporate safety factors for num-
ber of load cycles and stress.
The basis of the equation (14) is provided by the curves for
number of cycles to incipient cracking given in previous
editions of this Merkblatt (see Fig. A 7 of this Annex). This
figure is based on strain-controlled and stress-controlled
fatigue tests under tension or bending compression con-
ducted by a number of instrtutes the results of which were
published in [4] to [26]. The fatigue life was determined here
mainly for the failure criterion of fracture. The results of fati-
gue tests ander incipient cracking are within the scatter band
of the numbers of load cycles to fracture for corresponding
material specrmens. In the case of small, unnotched speci-
mens, fracture is imminent after an incipient crack has appe-
ared (N, = 0.8 NBruch). It IS therefore appropriate to consider
fatigue curves of a component (normally with greater dimen-
sions than the specrmens) plotted on the basis both of frac-
ture fatigue values and incipient cracking fatigue values in
small specimens as fatigue curves up to Incipient cracking,
especially since the components display greater or smaller
micro-notch and macro-notch effect and are thus more sus-
ceptible to cracking.
In order to ensure optimum utrlrsatron of the material (e.g. in
the dimensioning of unwelded high-pressure vessels) the
rise in fatigue strength In the range of higher numbers of load
cycles with increasing tensile strength was taken into
account by introducing R, as a parameter for the number of
load cycles. The number of load cycles at which the load
cycle curves start to follow a horizontal path has been taken
consistently as 2 106 (fictitious endurance limit). There is
adequate statistical corroboration 1261 of a figure of 0.46 for
the mean ratio between fatigue strength under tension/com-
pression and tensile strength for unnotched smooth speci-
mens of steels with tensile strengths up to 1300 N/mmz.
Using an overall reduction factor of 1 .15 for any endurance
strength parameter, if any, to be considered, for the endu-
rance stress range with a mean stress of zero 2 ova =
0.8 . R, has therefore been adopted to date.
In the endurance strength range the curves shown in
Fig. A 7 can also be assessed as mean-value curves.
Within the revision of this Merkblatt, additional evaluations
were conducted of test data for unnotched test bars from the
data collection of Boll& and Seeger [69]. The evaluations
showed that curves for number of cycles up to incipient crak-
king according to Fig. A 7 can also be used on the basis of
current knowledge as the basis for design load-cycle curves
and austenitic materials can also be assessed according to
this. Fig. A 8 of this Annex shows, as an example, a compari-
son between test data for high-strength ductile steels with
allowable load cycle numbers for R, = 1000 N/mm2 accord-
ing to this Merkblatt.
For further details see [92].
To establish design load cycle curves, safety factors have
been fixed according to statistical considerations.
The load-cycle safety factor SN is calculated on the assump-
tion of a Gaussian distribution for the load-cycle scatter band
as a function of the scatter coefficient l / T , and the failure pro-
bability PA from
where z = f (PA) according to the following table
PA Z
50 % IO
10 % 1.28
1 % 2.33
0.1 % 3.09
0.01 % 3.72
Statistical evaluations relating to the life scatter band for
smooth bar specimens, welded joints, pipes and cylindrical
vessel courses with branches over the load cycle range from
about 10“ to 106 [6. 25, 39, 52 et al.] have shown that as a
first approxrmatron a Gaussian distribution can be assumed
for the measured values, and that forthe prediction of the ser-
vice life of components in the range from 2. 104 < NA < 106
(depending on the magnitude of the stress ranges) scatter
coefficients of T, = 1 : 3 to 1 : 6 have to be expected (see
Fig. A 3 of the Annex). With reference to the life curves in
Fig. A 7. which can be regarded as mean values, and adop-
) ting a failure probability of P, = 0.01 % to 0.1 % which is
appropriate for many pressure vessels, on the assumption
of a Gaussran distrrbution one obtains, for example for the
scatter coefficient TN = 1 : 5, astatisticallysubstantiated mini-
mum load-cycle factor of SL = 10 (see Fig. A 5b of this
Annex). Similar considerations for the scatter of the stress
range in the endurance limit range lead to a stress scatter of
T,, = 7 : 1.4 between P, = 10 and 90% and, adopting the
above-specrfied failure probability of 0.01 %, to a minimum
safety factor against stress of 1.63 for the endurance limit
(see Fig. A 5a of this Annex).
Consideration of the above safety factors, elimination of the
overall reduction factor of 1.15 in the endurance limit range
and smoothing out of discontinuities leads to design load-
cycle curves which can be described with adequate accuracy
using the approximation equation (14). In relation to a mean
endurance limit 2 a, = 2 . 0.45 . R, according to the esti-
mated equation of Schijtz et al 1681, one obtains according
stress safety factors with N 2 2 106 of S = 1.5 to 1.57, which
corresponds to an increase in the failure probability of
I approx. 0.1 % (see Fig. A 5a of this Annex).
Explanatory note on equations (15) and (16)
In view of the lack of details on surface fineness in most
descriptions of fatigue tests, the results from individual series
of tests largely depend on unknown influences, which in turn
leads to a relatively wide scatter band of test results.
The surface correction factors given in edition 3.90 of AD-
Merkblatt S 2 were oriented on approximation equations and
diagrams on the estimation of the notch effect of roll scale
in the endurance limit range from R, = 400 to 1000 N/mm’
as given in various publications and technical Rules [6, 16,
32 to 351. In this edition, the surface influence in the endu-
rance strength range according to [54] was adopted with
equation (16). According to this, one obtains somewhat lower
correction factors, but a better adaptation to the fatigue cur-
ves of the welded joints.
Strain and stress-controlled fatigue tests in the endurance
strength range show that the surface influence becomes
smaller as the number of load cycles decreases and is no lon-
ger present in the range below approx. 1 O2 load cycles [6,11,
36 to 381. Starting from these investigations, a linear load-
cycle dependence was postulated on the double-logarithmic
scale with equation (15).

Explanatory note on equations (17) and (18)
Equation (18) is based on a literature evaluation in [85]
relating to the problems of the reduction in fatigue strength
with increasing component size. With equation (17) the same
law was assumed for load cycle dependence as with (15).
Explanatory note on equations (19) to (21)
The influence of the mean stress on the fatigue strength has
to date been considered according to the Gerber equation,
which, on the basis of more recent knowledge, does not cor-
rectly give the strength dependence (R,) and cannot be used
for mean compressive stresses. In equations (19) to (21)
therefore calculation proposals of SchOrzlHaibach and Mer-
tens [70] are incorporated, describing these influences more
realistically.
Explanatory note on Section 7.1.4.2
If the yield point is exceeded at the most highly loaded point
of the component, it has to be taken into account that the
strain no longer reacts proportionally to the stress. As a result
of the stress redistribution, the mean stresses are reduced.
Figure A 1 of this annex shows for a uniaxial stress state under
the simplified assumption of an ideally plastic material behaviour
how the mean stress 0 relating to the elastically calculated
principal stresses b and is is reduced to a,, = Rp0,21T. - uVva in
the case R,,,ur < 2 ova < 2 RpO,PT. (cf. equation (23) of this
AD-Merkblatt). In the case 2 ova > 2 I?,,,~ the strain cycle
CDEFC corresponds to the elastically calculated stress cycle
ABA in Fig. A 2 of this annex. Thus a,, = 0 (cf. Section 6 of
the Merkblatt). With multi-axial stress state, the equivalent
stresses have to be considered here accordingly.
Explanatory note on equation (24)
The equation (24) to take account of the influence of tem-
perature on the fatigue strength corresponds to equation (15)
in the previous edition 3.90. The correction factor fT is essen-
tially based on the isothermic fatigue tests of We/linger/Luff
[21] and Sautter [7] and corresponds approximately to the
lower limit of the scatter band of fatigue strength reduction
for unalloyed and low-alloy ferritic rolled and forged steels in
the range of approximately IO* to 105 load cycles. They do
not contain any influences from time-dependent deformation
(creep, relaxation). The increase in fatigue strength 1311
occurring partly with ferritic, and in particular unalloyed steels
in the temperature range from approximately 250 to 350 “C
(blue brittle range) was not considered here.
Explanatory note on equation (25)
The evaluation of a large amount of test data from strain cycle
tests for unwelded austenitic specimens at room temperature
and temperatures up to 600 “C from [69] have shown that,
for austenites, a fatigue-strength-reducing temperature
influence factor corresponding to the temperature-related
reduction in the elasticity modulus can be included in the cal-
culation. Taking account of these facts, the equation (25) was
derived on the basis of the details of elasticity modulus for
austenites [58].
Explanatory note on Section 7.2.1
The fatigue life of welded joints is no longer evaluated as pre-
viously on the basis of curves for number of load cycles to
incipient cracking for specimen bars and of weld seam cor-
rection factors fK, but with reference to the European steel
construction regulations Eurocode No. 3 [76]. Under this, the
fatigue life of welded joints is assessed according to standar-
dised stress number curves in which the weld seam notch
effect and the greatest possible influence of residual welding
Page 29 AD-Merkblatt S 2, Edition 5.98
stresses have already been taken into account (nominal
stress number curves).
Fig. A 9 of this annex describes, in accordance with this code,
the diagram of parallel stress number curves allocated to
welded joints typical of steel construction. The curves are
graded according to the standard number series R 20; the
weld classes are described in accordance with the numerical
value of the stress range for 2 106 load cycles. The endu-
rance limit is taken as N = 5 . 106. For damage accumulation
calculations, the stress number curves are continued with
reduced slope up to a limit value of N = lo*.
The fatigue curves are based both on stress-controlled and
strain-controlled tests, the allowable stresses being fixed at
a distance of twice the logarithmic standard deviation of scat-
ter distribution of test results from the mean values and hence
corresponding to a survival probability of P Ij = 97.7 %. With
regard to the magnitude of the standard deviation of load cyc-
les to incipient cracking or fracture, values of sN = 0.22 to
0.29 have become evident, which are within the usual scatter
of i/T, = 3 to 6 (cf. Fig. A 6 of this annex). Details of the stan-
dard deviations of stress ranges in the endurance limit range
and mean values on a data basis are unfortunately not avail-
able and must if necessary be taken from other sources as
an empirical value [70].
The fatigue curves as per Fig. 12, equation (27) and the con-
stants in Table 4 of this Merkblatt have been derived from the
Eurocode in accordance with the following considerations:
The weld seam configuration groups K 0, K 1, K 2 and K 3
according to Table 5 were allocated to the Eurocode classes
112, 90, 71 and 56 with comparable welded joints.
For the purpose of adapting to the survival probability usually
taken as a basis for pressure vessels, namely P, = 99.9 to
99.99% (PA = 0.1 to 0.01 %), the curves in the fatigue
strength range were transformed by a factor of 2.5 of the
“base number of load cycles” N = 5. 106 as a transition to
the endurance limit range according to Eurocode to the cor-
responding endurance limit load cycle number N = 2 . lo6
according to this AD-Merkblatt, while maintaining the stress
ranges at N = 5 106 according to Eurocode. The load cycle
reduction factor of 2.5 can be justified on the basis of a mean
value for the above standard deviations of sN = 0.25 from the
relationship between the standard deviation and scatter (cf.
Fig. A 6 of this annex) and from the linking of safety factor,
scatter and failure probability (cf. Fig. A 5b of this annex).
The fatigue curves derived in accordance with the above
from the Eurocode weld classes 112, 90, 71 and 56 for the
configuration groups K 0, K 1, K 2 and K 3 run along almost
the same course in the fatigue strength range as the fatigue
curves of classes 80, 63, 50 and 40, as proposed among
others by Maddox in CEN TC 54 WG C SG-Design Criteria,
on the basis of Eurocode 3. For the purpose of consistency
with this CEN standard, the stress curve constants given
there in for the fatigue strength range have been taken over
as constants Bl in Table 4.
Any further lowering of the allowable stresses to the break
point 5 106 load cycles is not considered necessary or even
practical further to the results of investigations by a number
of German institutes [71, 771. The break point in the endu-
rance limit is fixed uniformly for unwelded components at
2 . 106 load cycles.
Explanatory note on Section 7.2.5
It is known from fatigue tests on welded specimen bars that
the fatigue life can be increased by dressing the welding
beads [16, 25, 27, 69, 881. The test results show, however,
a considerable scatter in the possible increase of fatigue life
or fatigue strength because of fatigue-strength-reducing
 Page 30 AD-Merkblatl S 2. Edltion 5.98
weld influences, which cannot be eliminated or only to a very
limited extent by dressing (e.g. material composition, form of
weld, micro-defects). It is only admissible to upgrade to class
K 0 if freedom from defects is verified for weld seams ground
flush on both sides by means of a 100 % nondestructive
examination.
Explanatory note on Section 7.2.6
The fatigue-strength-reducing influence of component size in
the case of welded joints (exponent Z = 4) was taken from
the Eurocode No. 3.
Explanatory note on Section 7.2.7
The fatigue life curves for welded joints according to Sec-
tion 7.2 cover the conceivably least favourable case for
superposition of load and residual welding stresses, so that
an effective upper stress sets is summarily on the level of the
yield point. Consequently, however, it must also be possible
to consider that only very low residual welding stresses are
present after stress relief and only mean load stresses are
effective. On the basis of corresponding test results, it is
recommended in [71, 781 that an allowance of 30% be
applied in the calculation. Based on this maximum allowance
of 1.3 and in relation to the load cycle dependence of the
mean stress correction factor fM as an upper limit to take
account of the possible influence of welding residual stres-
ses, a linear dependence of the correctron factor f; from the
load cycle number was laid down pragmatically on a double-
logarithmic scale in accordance with equation (28a).
So that, in the equation (28) for high-strength steels (e.g.
R, = 1000 N/mm2), the allowable values do not fall below
those for the case without annealing, in spite of the stress
( relief, the value fi is limited downwards to 1 .O.
Explanatory note on equations (29) to (33)
The equations (29) to (33) given in Section 8 have been deve-
loped by an appropriate reformulation of the equations from
Section 7.
Explanatory note on equations (34) and (37)
The linear damage accumulation rule given in equation (34)
for the superposition of various load cycles with different
stress states, both in the temperature range of non-time-
dependent and time-dependent deformations, was selected
for reasons of plausibility and ease of handling. It is not pos-
sible at the present time to make a generally valid statement
on the reliability of this rule, especially in the high temperature
range. Its significance in the prediction of fatigue life has
rather to do with the determination of a “warning point” from
which special tests have to be taken according to the provisi-
ons of Section 12 of the Merkblatt.
In order to take account of the damage portion of stress amp-
litudes below the endurance limit, the allowable stress ran-
ges 2 o, in the endurance limit range are continued by a fictiti-
ous extension of the load cycle curves up to IO* load cycles,
on the basis of the modified linear damage accumulation rule
according to Haibach [62].
Explanatory note on equation (35)
Equation (35) describes the linear decline in the load cycle
curves on a double logarithmic scale in the range of 2 lo6
to 108 load cycles. The equation was derived from (14) and
N = 2 106, taking account of a curve slope m = 10, which
was taken from the previous edition 3.90 of the AD-Merkblatt
s 2.
Explanatory note on equation (36)
In the case of welded joints, the slope of the load cycle curves
was taken for the damage accumulation calculation from the
Eurocode as m = 5. Equation (36) was developed accor-
dingly from (27). The calculation constants were determined
taking account of the endurance limit values N = 2 . 106 and
2 a, = const. according to Table 4.
Explanatory note on equation (39)
According to test results in [87] the numbers of load cycles
to fracture for high-strength hydrogen transport vessels are
lower than lower limit curves from reference tests (incipient
crack) with oil by a factor of 6.5, and according to other
unpublished results they are lower than laboratory air by a . .
factor of 10. The beginning of cracking is indicated in [86] on
average as 81 % of the number of load cycles to fracture
achieved in the test. Statistical evaluations have yielded scat-
ters of TN = 1 : 3.5 to 1 : 4. When risk factors are included
because of the relatively small amount of data (cf. Annex 2,
Section 3). this leads to necessary safety margins of S,, = 8
to 10 against the mean values, if an allowable failure probabi-
lity of PA = 0.01 % is assumed.
The fracture-fatigue life line (mean values) runs almost paral-
lel to a mill scale design curve according to Section 7.1 of this
Merkblatt adjusted to the strength characteristics of the test
pieces. It also lies slightly below the design curve for air
medium. According to this, it is therefore permitted to conduct
an evaluation of the fatigue life of these vessels on the basis
of the procedure for vessels where there is no influence from
the medium and to reduce the numbers of load cycles via a
reduction factor. The size of this factor is set pragmatically
at f, = 1110 and, according to current knowledge,
corresponds to a crack failure probability of approx. 0.1 %,
which is still regarded as acceptable.
Explanatory note on Section 13.3
For welded joints of fine-grained structural steels under the
influence of hydrogen, there are only very few usable and
comparable test values from [SS]. The mean values formally
calculated using a statistical procedure are therefore only to
be rated as rough guidance values for 50 % values of a larger
totality.
The striking thing is the slope characteristic of the mean crack
curves as compared with the “air” curves. The reference test
data under air with specimens from the same batch are only
a little above a corresponding design curve for weld class Kl
according to Section 7.2 of this Merkblatt. It can be concluded
from this that the test values both for air and for hydrogen are
to be allocated to the lower range of the scatter band for butt
welds of class Kl and the “mean value curve” is to be alloca-
ted to a smaller failure probability P, < 50 %. It seems to be
therefore justified to set a safety margin for calculation purpo-
ses of only 5 (fN = l/5) against the mean test values. With
reference to a calculation according to Section 8.2, it is thus
possible to derive a simple approximation for the fatigue-
strength-reducing hydrogen influence for materials with
strength coefficients of K20 5 355 N/mm2 (StE 355) in
accordance with equation (40). According to this, the fatigue-
strength-reducing influence of compressed hydrogen begins
above an equivalent stress range of 2 ava = 215 N/mmz.
A comparison of the test data for flush-ground weld speci-
mens of StE 460 in hydrogen and air environment does not
reveal any significant differences between hydrogen and air.
A design curve calculated according to Section 7.2.5 of this
Merkblatt (weld ground/K 0) runs with a margin of approxima-
tely four to eight times the number of load cycles below the

formal mean fracture curve for hydrogen. It is therefore advi-
sable to conduct the calculation for air medium according to
Section 7.2.5 with flush-ground seams as well and to reduce
the number of load cycles as a precaution via a constant
reduction factor of fN = 112.
It is evident from a number of comparable test results for weld
specimens of StE 355 and StE 460 as well as from crack
findings obtained in hydrogen storage tanks that the higher-
strength fine-grained structural steel is more sensitive to
hydrogen. It is regarded as realistic to reduce to half the
values calculated for steels with K2,, 5 355 N/mm*.
For further details, see [92]
Literature
[l] Technische Regeln fur Dampfkessel, here: TRD 301
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[2] KTA-Regel 3201.2: ,,Komponenten des Primarkreises
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[5] Betz, U.: Zur RiObildung wechselbeanspruchter glatter
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[6] Ma//, G.: lnnendruckschwellverhalten von Hohlzylin-
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Techn.-wiss. Ber. MPA-Stuttgart (1970) Issue. 70-03.
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Techn.-wiss. Ber. MPA-Stuttgart (1971) Issue. 71-04.
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Techn.-wiss. Ber. MPA-Stuttgart (1973) Issue. 73-01.
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[I l] Grubisic, V., and C. M. Sonsino: Festigkeitsbeurteilung
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[I 21 Saal, H.: Der EinfluO vom Formzahl und Spannungsver-
haltnis auf die Zeit- und Dauerfestigkeiten und RiOfort-
schreitungen bei Flachstabchen aus St 52.
Published by Inst. f. Statik und Stahlbau der TH Darm-
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[13] Klee, St.: Das zyklische Spannungs-Dehnungs- und
Bruchverhalten verschiedener Stable.
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[l4] Schijtz, H.: Schwingfestigkeit von Werkstoffen.
VDI-Report No. 214, pp. 45147.
[15] Just, E.: Beabsichtigte Einflusse der Fertigungsver-
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ohne Randschichtbehandlung. VDI-Report No. 214,
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1161 Broichhausen, J.: Beeinflussung der Dauerhaltbarkeit
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metallurgische Kerben.
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[17] Schmidt, W.: Werkstoffkennwerte bei Dauerfestigkeits-
untersuchungen.
DEW-Techn.-Rep. 11 (1971), pp. 8/21.
(181 Pomp, A., and M. Hempel: Wechselfestigkeit und Kerb-
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Archiv Eisenhuttenw. 21 (1950) Issue. l/2, pp. 53/66.
[19] Hempe/, M.: Dauerfestigkeit von unterschiedlich er-
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spruchung.
Mitt. VGB (1964) Issue 92, pp. 342157.
[21] We/linger, K., and G. Luft: Wechselverformungsverhal-
ten van Stahlen.
Mitt. VGB (1968) Issue 1, pp. 33145.
[22] Degenkolbe, J., and H. DiBelmeyer: Schwingverhalten
eines hochfesten wasserverguteten Chrom-Molybdan-
Zirkonium-legierten Feinkornbaustahles mit 700 N/mm2
Mindeststreckgrenze im geschweinten und unge-
schwei8ten Zustand.
SchweiOen und Schneiden 25 (1973) Issue 3,
pp. 205107.
[23] Hailbach, E.: Schwingfestigkeit hochfester Feinkorn-
baustahle im geschweil3ten Zustand.
SchweiBen und Schneiden 27 (1975) Issue 5,
pp. 179181.
[24] We/linger, F., and M. Liebrich: Kerbempfindlichkeit von
Stahlen im Gebiet der Zeitfestigkeit.
Z. Konstruktion 20 (1968) Issue 3, pp. 81189.
1251 Internal test report by the company Thyssen Nieder-
rhein AG.
[26] Hempel, M.: Dauerfestigkeit von Stahl. Merkblatt
No. 4574.
Beratungsstelle fur Stahlverwendung, Dusseldorf.
[27] Hempel. M.: Zug-Druck-Wechselfestigkeit ungekerbter
und gekerbter Proben warmfester Werkstoffe im Tem-
peraturbereich von 500 bis 700 “C.
Archiv Eisenhtittenw. 43 (1972) Issue. 6, pp. 479188.
[28] We/linger, K., and R, Idler: Der EinfluO wechselnder
Temperaturen auf das Zeitfestigkeitsverhalten von
Stahlen.
Archiv Eisenhuttenw. 48 (1977) Issue 6, pp. 347/52.
1291 Schieferstein, U., and W. Wiemann: Anwendung von
Bemessungsregeln auf Bauteile mit gleichzeitiger
Kriech- und Dehnungswechsel-Beanspruchung.
Chem.-lng. Tech. 49 (1977) No. 9, pp. 726/37.
[30] Zenner, H.: Niedriglastwechselermijdung bei hohen
Temperaturen.
VDI-Report No. 302 (1977), pp. 29/44.
[31] VDI-Directive 2227, 1974 version ,,Festigkeit bei wie-
derholter Beanspruchung”.
Page 32 AD-Merkblati S 2, Edition 5.98
[321 Siebel, E., and M. Gaier: Untersuchungen tiber den
EinfluO der Oberflachenbeschaffenheit auf die Dauer-
schwingfestigkeit metallischer Bauteile.
VDI-magazine 98 (1956) pp. 1715123.
I331 Hanchen, R., and H. Decker: Neue Festigkeitsberech-
nung fur den Maschinenbau.
Carl Hanser-Verlag, Munich 1967.
[341 Wellinger-Dietmann: Festigkeitsberechnung.
Alfred Korner-Verlag, 3rd edition (1976).
I351 Buch, A.: Einige Bemerkungen iiber das EinfluOfak-
torenverfahren zur Berechnung der Dauerfestigkeit von
Maschinenteilen.
Material test 19 (1976) No. 6, pp, 194/99.
1361 Unveroffentlichte Diskussionsbeitrage der MPA-Stutt-
gart zur Aufstellung der TRD 301 Anlage 1 (1974).
I371 Zirn, R.: Schwingfestigkeitsverhalten geschwei8ter
Rohrknotenpunkte von Rohrlaschenverbindungen.
Techn-wiss. Bericht MPA-Stuttgart (1975) Issue 75-01.
t381 Kloos, K.-H.: EinfluO des Oberflachenzustandes und
der ProbengrbOe auf die Schwingfestigkeitseigenschaf-
ten.
VDI-Report No. 268 (1976), pp. 63176.
[391 Haibach, E.: Schwingfestigkeitsverhalten von SchweiO-
verbindungen.
VDI-Report No. 268 (1976), pp. 179192.
t401 Nowak, B. among others: Ein Vorschlag zur Schwing-
festigkeitsbemessung von Bauteilen aus hochfesten
Baustahlen.
Der Stahlbau 44 (1975) Issue 9, pp. 257168 and Issue
10, p. 306/l 2.
[411 DIN 15018 Teil 1 ,,Krane, Grundsatze fur Stahltrag-
werke, Berechnung”, Edition 4.74.
[421 DASt-Richtlinie 011 ,,Hochfeste schweif3geeignete
Feinkornbaustahle StE 460 and StE 690, Anwendung
fur Stahlbauten“, Edition Feb. 1979,
Deutscher AusschuO fur Stahlbau, Cologne.
t431 Issler, L.: Festigkeitsverhalten metallischer Werkstoffe
bei mehrachsiger phasenverschobener Schwing-
beanspruchung.
Diss. Uni Stuttgart 1973.
[441 El-Magd, E., and S. Mielke: Dauerfestigkeit bei iiber-
lagerter zweiachsiger statischer Beanspruchung.
Z. Konstruktion 29 (1977) Issue 7, pp. 253/57.
[451 Nowak, B., Saal, H., and T. Seeger: Ein Vorschlag zur
Schwingfestigkeitsbemessung von Bauteilen aus hoch-
festen Baustahlen.
Der Stahlbau 44 (1975), p. 257/68.
1461 Troost, A., and E. N Magd: Allgemeine Formulierung
der Schwingfestigkeitsamplitude in Haighscher Darstel-
lung.
Test material 17 (1975) No. 2 pp. 47/49.
[471 Neuber, A.: Uber die Berticksichtigung der Spannungs-
konzentration bei Festigkeitsberechnungen.
Konstruktion 20 (1968) Issue 7, p. 245151.
[481 G o r s i t z k e , B . : Betriebsfestigkeitsuntersuchungen zur
Lebensdauerabschatzung, Bericht tiber das Kollo-
quium Sicherheitstechnische Bauteilbegutachtung“
des TUV Rheinland am 27. 05. 1975 in Cologne-Poll.
Verlag TUV Rheinland GmbH, pp. 77193.
1491 Krageloh, E.: Uberlagerung von thermischer und
mechanischer Beanspruchung bei Stahlen - Einflu8
von Kerben und SchweiOungen.
VDI-Repot-t No. 301 (1977), pp. 45/52.
1501 Kloos, K.-H.: Einflu8 des Oberflachenzustandes und
der ProbengroRe auf die Schwingfestigkeitseigenschaf-
ten.
VDI-Report No. 268 (1976), pp. 63176.
t511 Tauscher, H.: Dauerfestigkeit von Stahl und GuOeisen.
VED Fachbuchverfag Leipzig (1969).
Hailbach, E.: Dauerfestigkeit von SchweiOverbindun-
1521
gen bei Grenzlastspielzahlen grol3er als 2 . 106.
Archiv Eisenhuttenw. 42 (1971) Issue 12, pp. 901108.
I531 Expert Committee Report 5.016: ,,Hohere Zuverlassig-
keit im Schwermaschinenbau (Beitrag der Betriebs-
festigkeit fur die Verfugbarkeit von Huttenwerksanla-
gen) 2.
Verein Deutscher Eisenhuttenleute (VDEh) Dusseldorf,
AusschuO fur Anlagentechnik, Gemeinschaftsaus-
schuR Betriebsfestigkeit, 1974.
[541 Bericht der Arbeitsgemeinschaft Betriebsfestigkeit
beim VDEh Nr. ABF 19: ,,Leitfaden fur eine Betriebs-
festigkeitsberechnung”.
Verlag Stahleisen mbH, Dusseldorf 1985,2nd Edition.
Hailbach, E., Ostermann, H., and H.-G. Kijbler: Ab-
[551
decken des Risikos aus den Zufalligkeiten weniger
Schwingfestigkeitsversuche.
Lab f. Betriebsfest. Darmstadt, TM No. 681’73.
Uebing, D., and P. Jaeger: Bedeutung der Druckpru-
1561
fung und des Sicherheitsbeiwertes fur die Lebensdauer
von Rohr-Fernleitung.
3 R international, Issue 3 (1973), pp. 137139.
[571 Uebing, D.: Neue Wege der Sicherheitsbetrachtung bei
Pipelinesystemen.
3 R international, Issue 1 (1976), pp. 7/10.
1581 Richter, F.: Physikalische Eigenschaften von Stahlen
und ihre Temperaturabhangigkeit. Stahleisen-sonder-
bericht, Issue 10.
Verlag Stahleisen mbH, Dusseldorf 1983.
[591 Dengel, D.: Einige grundlegende Gesichtspunkte fur
die Planung und Auswertung von Dauerschwingver-
suchen.
Material testing 13 (1971) No. 5, pp. 145/80.
WI DIN 50 100 ,,Dauerschwingversuch”, Edition 2.78.
VDI-Directive 2227: ,,Festigkeit bei wiederholter Bean-
WI
spruchung, Zeit- und Dauerfestigkeit metallischer
Werkstoffe, insbesondere von Stahlen”, version 4.74.
WI Hailbach, E.: Modifizierte lineare Schadens-Akkumula-
tions-Hypothese zur Beriicksichtigung des Dauerfestig-
keitsabfalls mit fortschreitender Schadigung.
Lab f. Betriebsfest. Darmstadt, TM No. 50/70.
1631 Neuber, H.: Theory of Stress Concentration for Shear
Strained Prismatical Bodies with Arbitrary Non-Linear
Stress-Strain Law.
Trans. ASME, J. of Appl. Mech. 1969, pp. 544/50.
I641 Saal, H.: Naherungsformeln fur die Dehnungsformzahl.
Z. Materialpriif. 17 (1975) No. 11, pp. 395/98.
[651 Kiihnapfel, K.-F,, and A. Troost: Naherungslosungen
zur rechnerischen Ermittlung von Kerbdehnungen und
Kerbspannung bei elastoplastischer Beanspruchung.
Z. Konstruktion 31 (1979) issue 5, pp. 183190.
WI Dahl, W.: Das Verhalten von Stahl bei schwingender
Beanspruchung; Bericht aus Kontaktstudium ,,Werk-
stoffkunde Eisen und Stahl Ill”.
Verlag Stahleisen mbH, Dusseldorf 1978.
B71 Hoffmann, G., and F. Huba: Sichere Dimensionierung
geschwei8ter Radialltifter.
VDI-magazine 122 (1980) No. 5, pp. 177/81.
 Page 33 AD-Merkblatt S 2, Edition 5.98

WI Schlitz, W. amongst others: Berechnung von Wijhler- I831 Sonsino, C.M. and D. Hanewinkel: Schwingfeste Bau-
linien fijr Bauteile aus Stahl, StahlguO ur,d Graugul3 - teilbemessung mit hiiherfesten Stahlen.
Synthetische W6hlerlinien. VDEh-Arbeitsgemeinschaft Teil 1 : Hinwege zu Konstruktion und Bemessung.
Betriebsfestigkeit, Report No. ABF 11, Dijsseldorf Z. Stahl u. Eisen 112 (1992) No. 1.
(19831.
t841 D i t f m a r , S.: Lebensdauernachweise nach deutschen
WI Boiler, Chr., and T. Seeger: Materials Data for Cyclic Regelwerken fijr druckbelastete Bauteile; Vorgehens-
Loading. Parts A, 9, C, D and E. weise, LOcken, AbhilfemaOnahmen.
Elsevier 1987. Paper,1 8th MPA Seminar, October 1992.
1701 Haibach, E.: Betriebsfestigkeit. Verfahren und Daten
zur Bauteilberechnung. 1851 Bucak, 8.: Ermtidung von Hohlprofilknoten.
VDI-Verlag GmbH, Diisseldorf 1989. Dissertation Univers. Karlsruhe,
Fak. f. Bauing.- u. Vermessungswesen, 1990.
1711 Olivier, R., a n d W . Ritter: WGhlerlinienkatalog fijr
SchweiOverbindungen aus Baustahlen; Teil 1 bis 5. F361 Kerkhoff, H. and others: Untersuchungen zur wasser-
Deutscher Verlag ftir SchweiOtechnik (DVS) GmbH, stoffinduzierten RiObildung im SchweiOnahtbereich von
Diisseldorf 1979. Feinkornbaustahl bei low-cycle-Beanspruchung unter
dem Einflul3 von Druckwasserstoff.
(721 Gurney, T. R., and S.J. Maddox: A re-analysis of fatigue
data for welded joints in steel. VdTijV Research Project No. 250,
Welding Research International, Volume 3 (1973) Num- Final Report SB 2000185, TiiV Rheinland 1990.
ber 4. P71 Schlegel, D. and others: Sicherheitstechnisches
1731 Maddox, S. J.: Third Draft (June 1994) of proposed Gutachten zum Betrieb von Wasserstofftransportbehgl-
Detailed Fatigue Assessment Method based on Draft tern und -Druckgasflaschen.
Eurocode 3. CEN TC 54 WG C SG-DC. TijV Rheinland 1981.
[741 British Standard BS 5500/l 994: Specification for unfi-
WI Maddox, S.J.: Fatigue Aspects of Pressure Vessel
red fusion welded pressure vessels. Design. Extract from: Pressure Vessel Design Philoso-
t751 British Standard BS 760811993: Code of Practice for phy; a Short Course.
Fatigure Design and Assessment of Steel Structures. Univ. Strathclyde, 1992.
[761 Eurocode Nr. 3: Bemessung und Konstruktion von
Stahlbauten, German version of the Draft European WI Niemi, E.: Recommendations Concerning Stress Deter-
mination for Fatigue Analysis of Welded Components.
standard ENV 1993-l -1. IIW Dot. X111-1458-92, Version 15. 08. 1994.
t771 Seeger, T. and others: Zultissige Spannungen ftir den
Betriebsfestigkeitsnachweis bei wetterfesten Baustah- PO1 Radaj, D., H.D. Gerlach, and B. Gorsitzke: Experimen-
len nach sechsjahriger Bewitterung. tell-rechnerischer Kerbspannungsnachweis fiir eine
Z. Stahlbau 60 (1991), Issue 11. geschweil3te Kesselkonstruktion.
Z. Konstruktion 40 (1988), Issue 11, p. 4471452.
t7a Seeger, T. and R. Olivier: Neigung und Abknickpunkt
der Wijhlerlinie von schubbeanspruchten Kehln%hten. WI Gorsitzke, B.: Vorhersage der Ermijdungsfestigkeit
Z. Stahlbau 61 (1992), Issue 5. druckfiihrender Komponenten im Energie- und Che-
r4 Autrosson, B. i.a.: Simplified Elastoplastic Fatigue Ana- mieanlagenbau. Teil 1 u. Teil 2.
lysis. Z. Tij Vol. 30 (1989) No. 2 and No. 3.
Int. J. Pres. Ves. & Piping 37 (1989).
WI Gorsitzke, B.: Neuere Berechnungsvorschriften zur
PO1 Grandemange, J.M. and others: Corrections de plasti- Ermijdungsfestigkeit von Druckbeh2ltern.
cite dans les analyses de fatigue. 2. Tij Vol 36 (1995) No. 6 and No. 7/8.
AFIAP-Conference, October 1992, Vol. 2, 109.
1811 Htibel, H.: Plastic Strain Concentration in a Cylindrical WI D i e t m a n n , H . , and H. Kockelmann: Verwendung der
Gestaltsanderungsenergiehypothese im Anwendungs-
Shell Subjected to an Axial or a Radial Temperature
Gradient. bereich der KTA-Regeln.
Transactions of the ASME, Vol. 109, May 1987. VGB Kraftwerkstechnik 74 (1994), Issue 6, p. 4981508.
[82] Hiibel, H.: Erhiihungsfaktor K, zur Ermittlung plasti- [94] lida, K.: Application of hot spot strain to fatigue life pre-
scher Dehnungen aus elastischer Berechnung. diction.
Z. Tii Vol. 35 (1994) No. 6. IIW-Dot. XIII-941-80.
page 34 AD-Merkblatt S 2. Edition 5.98

;+

: co
t?
N I r----i
I
Id
;
I lb t?
J / cu
>b t E

I
I

Fig. A 1. Reduced mean stress ir,, for Rp0.2 5 2 a,, < 2 &O.Z

u
A B

/ /
/
tb
I Rpo.2
- .-

iN.
c?w
>b t?
1
/3p02
_.-. -. -. -.- -.

Fig. A 2. Reduced mean stress Ovr = 0 for 2 a,, 2 2 R,,p

 Page 35 AD-Merkblatt S 2. Edition 5.98

4 106 2.106
103 104 105
Number of cycles to incipient crack NA -

qm = IO%]
Scatter TN = 1:
N(, = 90%)

Ua. D(W = 10%)

Scatter T,, D = 1:
(J,. D(Ai = 90%)

Fig. A 3. Example of a statistically supported component

stress-number curve and scatter ranges (diagrammatic)

103 104 105 106 Z-106

Number of cycles to incipient crack NA

Fig. A 4. Example of a component stress-number curve not

supported statistically (diagrammatic)
Page 36 AD-Merkblatt S 2, Edition 5.98

Failure
probability
PA WI
23 0,Ol

286

2,4
or1

I / /
22

/
‘0 2 A’
5
1 1
s
% 1,8
cn 2,3

1,6 5

1,4

1 12 1,4 13 13 2

Scatter l/T

Fig. A 5a. Determination of a statistically supported safety factor with known scatter
 Page 37 AD-Merkblatt S 2. Edition 5.98

Failure
probability
PA WI

1
5
23
5
3

I I I I I

3.5 4 4,5 5 5,5 6

Scatter l/T

Fig. A 5b. Determination of a statistically supported safety factor with known scatter
Page 38 AD-Merkblatt S 2, Edition 5.98

!
0,35
t-

0,25
u)
.-f;j5
‘5
%-0 a2
t-3
zs 0,15
(I)
f

1 2 3 4 5 6 7 8 9 10 11
Scatter l/T

Fig. A 6. Relation between scatter and standard deviation with logarithmic normal distribution
 ( [N/mdl 1
I ,I,,(
1000
800

600

400

2 107
104 105 106

Number of cycles to incipient crack NA

Fig. A 7. Number of load cycles to incipient crack (scatter mean) as a function of the stress range for unnotched specimen bars of
high-temperature ferritic rolled and forged steels at ambient temperature and 0 = 0 (AD-Merkblatt S 2, Edition 3.90)
 -

I
-
-

Test data act. to BollerlSeeger

AD-S 2 (Edition 3.90) ferritic steels
unnotched smooth specimens

I
R, = 900-1500 N/mm2
A , > 15%,Z>45%
-

)
7
L L
-
- -
I .
-

I
- -

100 2
103 104 106
102

Number of load cycles N

Fig. A 8. Comparison of test data and AD-Merkblatt S 2

 Page 41 AD-Merkblatt S 2, Edition 5.98

1000 -

‘llll I Constant amplitude I I l/l/

for e ndurance limit I lllil

[ / Weld
:: 100 - 1 1 class
z??
72

160
140
125
112
100
90
80
71
63
56
50
45
40
36

10 -
104 106 2 5 107 108 109

Number of load cyCleS AI

Fig. A 9. Fatigue curves for welded joints under normal stresses act. to Eurocode N O. 3
 Page 42 AD-Merkblatt S 2, Edltion 5.98

I I

Annex 2 to AD-Merkblatt S 2

Comments on the assessment of cyclic tal evidence for only one loading level is sufficient, so that
loading on the basis of fatigue tests in fatigue tests it is possible to dispense with the expensive
determination of a component service-life curve. However,
if the numbers of load cycles for crack initiation determined
1 Establishment of the test load in the tests are only available for a few components of the
The test loads shall match the particular conditions of oper- same size, it cannot be assumed that the mean value obtai-
ation. If a component that is at elevated temperature during ned from these individual results will correspond to the mean
operation is tested at room temperature, the reduction in fati- value for all the remaining untested components of the same
gue strength of the material occasioned by the temperature kind (e.g. in a production series).
shall be considered when establishing the test load. To this There is the danger that, on the basis of coincidentally very
.
end, one can use as an approximation: f times oper- favourable test results, the fatigue-strength safety factors will
ating load. T be overestimated. Over and above the load-cycle safety
factor S, = IO relative to the mean value for the test results
If the results of the tests are to be applied to components that N Versuch (TeStIr it is therefore recommended that a risk factor jN
are geometrically similar but larger, or to components with [55] shall be taken into account which defines the risk of an
higher surface-roughness values, then it is necessary to erroneous estimation based on results that are above aver-
consider the influence of the component size and surface age because of random influences.
condition when determining the test load. In the case of fati-
gue tests performed with higher numbers of load cycles On the assumption of a Gaussian distribution for the scatte-
(approx. above 105), in addition to determining the number red number of load cycles to initiate a crack, and on the basis
of load cycles for crack initiation, tests must be carried out of a statistical certainty of 95 %, the risk factorj, can be obtai-
with 1.5 times the relevant test load for the operating conditi- ned as a function of the number n of components tested
ons and applying the same number of load cycles as the (number of test results) and of the scatter range l/TN to be
number experienced during operation, in order to verify the expected from Fig. A 10 of this annex, or can be obtained
safety factor of S = 1.5 in accordance with Section 7.1.1 of from :
this Merkblatt.
2 Determination of a component stress number curve
If for a component the allowable stress amplitude or operatio- by calculation.
nal load amplitude is to be plotted for different numbers of
operational load cycles, it shall be considered, when establis- The permissible number of load cycles N,,, from just a few
hing the testing programme, that the degree of scatter asso- test results, which are insufficient for a statistical evaluation,
ciated with stress number curves is generally considerably is then determined from:
high.
For the quantitative definition of this scatter band with the aid
of statistical methods of evaluation, there must be a suffi-
ciently large number of test points covering the scatter band
for the life distribution, as illustrated diagrammatically in Fig. 33 1
A 3 of annex 1. At a number of load horizons, at least seven 28 c
to eight components should be tested in order to be able to v)
2-4 . zi
carry out a structural evaluation for the particular test load / P
value, bearing in mind the failure probability. Component
stress number curves established with the number of test
points shown in Fig. A 4 of annex 1 (diagrammatic) cannot
provide any information on the amount of scatter by virtue of
the random factors governing the location of the test points.
The ,,mean-value” curve which passes through the points,
plotted perhaps by means of compensation calculations, can
at best be said to represent a survival probability of PO =
50%.
In the case of fatigue tests in the endurance-strength range,
or when an operational load regime is being taken into consi-
deration (strength test under service load), it will be advisable
to make reference to further literature because of the testing
techniques required [59 to 611.
1 3 4 5
3 Estimation of the risk when only a few test results are SEaher l/T, -
available
In a large number of cases, for the assessment of the compo- Fig. A 10. Risk factorj, on the basis of a statistical certainty
nent subjected to cyclic loading, mathematical or experimen- of 95%
 Page 43 AD-Merkblatt S 2, Edition 5.98

Annex 3 to AD-Merkblatt S 2

Notes on the conduct of stress evaluation In the case of calculations with direct determination of the
equivalent stress (without use of stress components), the
maximum equivalent stress 6,. the equivalent stress range
Contents 2 uva and the mean equivalent stress ?I, are evaluated
1 General according to the general equations (2) and (4) assuming
2 Symbols and units negligible shear stresses and with the action of only one type
of loading.
3 Recommendations for stress verifications
i
3.1 Cylindrical shell with openings
3 . 2 Connection between cylindrical shell and stiffening ring
~a,,=
(*
B.as~--B.as~
1
.G

3.3 Cylindrical shell with deviations from shape

3.4 Connection between cylindrical and conical shell (3)
3.5 Dished heads with openings
3.6 Connection between cylindrical shell and spherically
domed head with corner ring or reinforced flange
3.7 Connection between cylindrical shell and unstayed flat Where
head s, s are extreme values for a load factor, e.g. internal
3.8 Circular unstayed flat plates with openings pressure p
3.9 Bolted joints %a? %B are structural stress concentration factors
4 Sample calculation assigned to the load factors B and E? (with linear
5 Literature dependence of load and stress czs~ = use).
G is a special function dependent on geometrical
factors, e.g. mean equivalent stress related to p
1 General according to the shear stress theory for cylindrical
The notes below give simple, engineering-type calculation shells
methods which can be used to determine structural and G E- % -
notch stresses for vessel structures which are frequently built 20 s
and are relevant with regard to operational lifetime. The equations (4) and (6) according to AD-Merkblatt S 2,
The calculation procedures are limited to the effect of internal Section 5.2 for the formation of the equivalent stress range
pressure only. For calculations with regard to other types of 2 u,, and the related mean equivalent stress 5, will then not
loadings, such as non-steady-state thermal strains, refe- be used. If there is a combined loading state consisting of a
rence is made, for instance, to the literature [l] and [4]. number of types of loadings, other calculation methods nor-
mally have to be applied, from which the proportionate stress
The term structural stress is used here to describe the stress components for superposing and forming of equal stresses
calculated on the surface according to theories of plane load can be determined. The corresponding references to the lite-
bearing structures (e.g. theory of shells, plates, beams), not rature can be found in the following sections.
taking into account the notch effect (micro-notches). The
structural stress concentration factor a, expresses the ratio The recommended calculations below are based on the
of the structural stress u, to the nominal stress a,, which is linear elasticity theory (pseudo-elastic stresses) and apply
normally identical to a mean stress in the cross-section of a for the special case v = 0.3 and the same Young’s moduli
location under consideration. The notch stress ok is the maxi- of parts connected with one another.
mum local stress in the notch base beyond the structural
stress. Using the notch sensitivity ratio a, the ratio of elastic
notch stress ak to the structural stress us is defined. In order
to link the structural stress concentration factor and the notch
sensitivity ratio, a multiplicative superposition law is applied
by approximation. The following therefore applies: 2 Symbols and units
UK = Clk . a, = ‘q . a, . CT” (1) In addition to the provisions of AD-Merkblatt 6 0 the following
It is not always possible to make a sharp delimitation between apply:
structural stress and notch stress. d branch diameter in mm
When assessing weld seam areas according to AD-Merkblatt f” out-of-roundness factor
S 2, Section 7.2, the weld notch effect is already taken into h height of edge offset, peaking
account in the fatigue curves. In unwelded component, locati- orflattening in mm
ons remote from discontinuities ok corresponds to the sur-
S nominal wall thickness less wear
face finish correction factor fo. allowance in mm
In the case of sharp notches, a support effect arises in the D diameter of the main body in mm
notch which is dependent on the stress distribution and the bending stress concentration factor
cLb -
material, and which leads to somewhat reduced notch stres-
ak notch sensitivity ratio
ses as compared to those calculated with equation (1). How-
ever, this support effect is ignored in the approximation calcu- as structural stress concentration factor -
lations indicated here. aso membrane stress concentration factor -
Page 44 AD-Merkblati S 2, Edition 5.98
Subscripts:
a outside
I inside
k conical shell, spherical shell
m mean value
z cylindrical shell
A branch
6 head, e.g. dished head, plate
D gasket
3 Recommendations for stress verifications
3.1 Cylindrical shell with openings
In the case of cylindrical shells with openings with tubular
reinforcement within the scope of the AD-Merkblatt B 1 and
B 9 respectively, the stress maximum is, in many cases, at
the inside edge of the nozzle-cylinder penetration in the longi-
tudinal section plane. With relatively large openings and/or
large nozzle reinforcement, the location of greatest stress
can be shifted to the exterior of the penetration in the direction
of the cross-sectional plane. The relevant stress concentra-
tion factor equations known from the literature make it pos-
sible to calculate roughly the highest value of structural
stress, but not to determine its position and direction. If not
verified by other calculations, the equivalent stress to be cal-
culated, for example, according to [3] is to be taken as princi-
pal structural stress both for the interior and exterior of the
cylindrical shell, regardless of the type of nozzle weld con-
nection at the penetration point (set-on or set-through
nozzle).
If the openings are located in the area of elliptical geometrical
deviations (out of roundness U), a bending stress term f, . cr,
is to be considered on the basis of [l] in addition to the mem-
brane stress concentration factor a,,.
In the case of nozzles in inclined position in cylindrical direc-
tion, the stress concentration factor a,, is to be corrected on
the basis of [2].
In the case of elliptical tubular openings, e.g. for access and
inspection openings, with a ratio of large axis to small axis
5 1.5 it is possible to proceed analogously to circular ope-
nings. The principal mean nozzle diameter d, shall be deter-
mined from the opening axis lying in longitudinal direction to
the cylindrical shell.
For other opening geometries, such as rectangular charging
openings or oblong inspection glass inserts, no sufficiently
accurate analytical calculation methods are known for deter-
mining the stress concentration factor. Known solutions for
disks or plates with openings, e.g. according to [4, 51 cannot
be applied to shells, because additional structural bending
stresses are superimposed on the structural membrane
stresses on account of the curvature in the shell.
In the case of butted flanges (pads) or thick-walled weld-in
rings (cf. AD-Merkblatt B 9, Figures 3 a./3 b) which meet the
conditions
SA 2 2 . s,, b . sA 2 cl, s, (5)
at least a,, = 2.5 must be taken.
For combined tubular and pad-type reinforcements no self-
enclosed analytical approximation approaches are known. A
component-specific calculation of the stress concentration
factor with diagrams is given in [4].
In the case of unreinforced circular openings, the structural
stress can be determined according to [4].
3.2 Connection between cylindrical shell and stiffening
ring
In the case of cylindrical shells with stiffening rings (cf.
AD-Merkblatt B 6, Figs. 2 and 3) or support rings (e.g. for
internals) connected to the inside or outside wall, these wel-
ded-on parts give rise to bending stresses through restraints
to expansion and these bending stresses are superimposed
on the membrane stresses from internal pressure. The maxi-
mum equivalent stress arises on the inside and can assume
double the value of the membrane stress in the location
remote from discontinuities. In the case of rings welded on
the inside combined with a notch-intensive weld configura-
tion, such “subordinated” component areas can therefore
also be a determining factor for fatigue life. The equivalent
stress on the outside is always below the membrane stress
at locations remote from discontinuities.
The calculation can be conducted according to [12]
3.3 Cylindrical shell with deviations from shape
In the case of cylindrical shells, production-related deviations
from shape with the additional stresses they cause, can have
effects which are relevant with regard to fatigue (cf. AD-
Merkblatt HP 1 and AD-Merkblatt HP 511). This applies in par-
ticular for cylindrical shells without any other discontinuities
(e.g. without openings) whose dimensioning is adjusted to
plane cylindrical shells and the location of maximum deviati-
ons from shape coincides with a fully stressed weld (longitu-
dinal weld).
For oval deviations from shape, the procedure to be adopted
can be analogously to [l], taking a,, = 1 and ab = 1.
In the case of edge offsetment in the longitudinal weld, the
calculation according to [4] is recommended.
In the case of peakings and flattenings, the structural stress
can be determined conservatively in accordance with AD-
Merkblatt HP 1 Annex 1.
Where it is not intended to conduct more precise calculations
in individual cases, calculations to the 2nd order theory can
be performed [9], i.e. taking account of the deformation set-
ting in under pressure loading and hence the reduction in
bending stresses. Mention should be made of the need for
a sufficient number of Fourier amplitudes (support points) to
achieve real stress values.
3.4 Connection between cylindrical and conical shell
The transition from conical shell to the cylindrical part can
either be in the form of a corner weld or of a torus. The maxi-
mum structural stress arises in the corner weld or knuckle.
The corner-welded conical shell is very unfavourable with
respect to fatigue loading, because in this design the highest
structural stresses occur and additional weld notch stresses
act also at the point of maximum structural stress.
The calculation can be conducted on the basis of the Annex
to AD-Merkblatt B 2.
In the case of direct connection of heads, especially flat
heads, clearly higher stresses can be expected as compared
with this calculation because of the reciprocal influence.
Conical openings are to be calculated analogously to Sec-
tion 3 of this Annex, taking AD-Merkblatt B 2 Section 6 into
account.
3.5 Dished heads with openings
In the case of dished heads with openings, both the knuckle
and the spherical part with openings can be a determining
factor with regard to fatigue life. Both areas are therefore sub-
ject to a stress calculation.
 Page 45 AD-Merkblatt S 2, Edition 5.98

The notes given in Section 3.2 for openings of cylindrical In the case of dissimilar loadings of bolts and nuts (bolt ten-
shells also apply basically for openings in the spherical part sion, nut compression), the most highly loaded areais gener-
of dished heads. The local stresses, however, act here on the ally in the area of the first load-bearing thread. The extreme
entire edge of the opening. stress intensification at this point is caused by the notch effect
The structural stress at the head knuckle can be determined of the thread and the application of force into the thread flank,
according to [4] or via the a-curves in Figs. 2 and 3 in Annex 1 as well as by the additional bending stress caused by the
to AD-Merkblatt B 3. flank load. The load distribution in the thread engagement
and the thread notch effect depend essentially on the form
The spherical part with tubular reinforced or unreinforced of the thread and the yield of the thread carrier (dimensions).
opening can be calculated according to [6]. However, the cal- The stress intensity factors (notch sensitivity ratios CQ) are
culation does not apply for openings in the knuckle region lowest with the usual thread carrier dimensions for regular
(outside 0.6 . D,, cf. AD-Merkblatt 6 3, Section 8.1.4 and Fig. 2).
thread (metric IS0 thread, Whitworth thread). For buttress or
In the case of butted flanges or thick-walled weld-in rings, a acme thread values of two to three times those for regular
stress concentration factor a, = 2.0 can be expected, pro- thread may arise.
vided the conditions are met analogously to equation (5).
For the analytical calculation of the thread load distribution
Detailed analytical calculation procedures which also make and the notch sensitivity ratio ak reference should be made
it possible to determine the structural stresses in the nozzle to the literature [I 61 to [19]. To optimise a bolted joint, detailed
at the penetration are given in [4] and [7]. calculations with considerable calculation effort are required
on account of the many different influencing factors [20].
3.6 Connection between cylindrical shell and spherically
domed head with corner ring or reinforced flange
The structural stresses for spherically domed heads connec- 4 Sample calculation
ted via a corner ring or a reinforced flange with a full face gas- Pressure vessel for pulverised coal injection installation
ket can be calculated according to [4]. It is assumed here that
the flange joint is sufficiently prestressed and will not become 1 Details of design
detached in the cycle of the alternating load. Stress maxima
See Fig. A 11
arise on the inside, in the transition area of spherically domed
Cylindrical shell, conical shell, torispherical head, closure
heads or cylindrical shells to the corner ring or to the flange
and nozzle plates made of H II
rings, where in many cases the connecting welds are also
located. Nozzle tubes of St 35.8 I
Flanges of C22.8, nominal pressure PN 16
3.7 Connection between cylindrical shell and unstayed Blind flange with full-face gasket
flat head Configuration of welded joints of pressure-bearing walls
(longitudinal and circumferential welds and nozzle connec-
The connection area between a flat head and a cylindrical
tion welds) in accordance with configuration class K 1, of
shell is also a critical area with regard to fatigue. In the case
weld-on parts class K 2
of a head without opening with s&, > I the maximum equi-
Wear allowance 1 mm for shells and heads.
valent stress always occurs in the cylinder wall (inside) at the
connection area, which can for example be determined
2 Operational data
according to [l I]. More detailed calculations can also be per-
formed according to [4]. The calculations assume that the flat Allowable working pressure 16 bar
heads are fully penetration welded or welded in (cf. AD- Operating temperature 50 “C
Merkblatt B 5, Table 1, Designs c, f and h). Internal pressure range p-p = 12-O = 12bar
Number of operating load cycles N = 250.000
3.8 Circular unstayed flat plates with openings (equivalent of 3 cycles/h, 3-shift operation, 10 years)
Normally the opening area is to be regarded as critical as far
as fatigue in plates with openings is concerned. In the case 3 Allowable stress ranges according to AD-Merkblatt
of reinforced openings, the stress maximum may be located S 2, Section 7
in the nozzle tube or in the plate, depending to the respective 3.1 Unwelded area, rolling skin
dimensions. H II => R, = 410 N/mm2
If the prevailing dimensional boundary conditions are accord- R PO.PK = 255 N/mm’
ing to equation (6),
Stress range, polished surface according to equation (14)
0.05 5 -$ 5 0.3, 0.1 5 -$- 5 0.3 (6) 4.104
+0.55.410-10=296N/mm2
2 ua = X'250,OOO
the maximum-equivalent stress is always at the location of
connection of the nozzle tube on the plate, so that the Surface finish correction factor according to Table 3, equati-
nozzle tube is a determining factor with regard to the fatigue ons (15), (16)
life of the plate. A calculation method is given in [4]. F, = 1 - 0.056 . (In 2 o o y . 6 4 . In 410 +
To calculate flat plates for other load cases and load combi- + 0.289 . (In 200)0.53 = 0.72
nations, reference should be made to the literature [4], [13] 0 . 4 3 4 3 In 2 5 0 . 0 0 0 - 2
and [14]. 4.301
f.= (0.72) = 0.77
3.9 Bolted joints
Wall thickness correction factor according to equations (17),
Bolted joints as detachable connecting elements of pressure (18)
vessel pans can be subject to stresses which are relevant
with regard to fatigue life, if high alternating bolt forces
Fd = ($@ = 0.967
become effective with varying service loadings, e.g. with non-
pretensioned or inadequately pretensioned bolted connecti- 0 . 4 3 4 3 . In2 5 0 . 0 0 0 - 2
4.301
ons and if the bolt connection is frequently loosened. f, = 0.967 = 0.97
Page 46 AD-Merkblatl S 2, Edition 5.98

Mean stress factor according to equations (19) to (21) Stress range

~v=2uva= 119N/mmz (see 4.2.1) 2 u = a . tR, + sK/2) . P
“a 5
6” = 59.5 N/mm’ 20 . SK
M = 0.00035 . 410 - 0.1 = 0.0435 (2400 + 29/2) . 1 2
= 2,0 = 100 N/mm2
20 .29
_ 0.0435 (2 + 0.0435) 59.5 _ o.g8
< 2 u,,,:K, = 122
1 + 0.0435 148
4.3 Conical shell
Temperature correction factor fT. = 1 4.3.1 Knuckle on upper conical shell course
Allowable stress range according to equation (13) for rolling Stress range according to AD-Merkblatt B 2, Annex
skin surface (WH) ez
- = 6.83
2 %zul/WH = 296 .0.77 ‘0.98 ‘0.97 . 1 = 217 N/mm2 10
2 a,, P a,, = s . p
3.2 Welded area, classes K 1 and K 2
Stress ranges according to Table 4, equation (27) = 6.83 12 = 82 N/mm* < 2 uUUliK, = 122

4.3.2 Opening in middle conical shell course, nozzle item 8

2u+, = (&)’ = 126 N/mm2 Structure stress concentration factor according to [3] taking
] into account a cylinder substitute diameter D, = 2200 mm
2~~,~ = (2~~,$f~i~ = 100 N/mm* according to AD-Merkblatt B 2.
a, = 2.61
Wall thickness correction factor In this special case no deviation from shape is taken into
account (a, = aso).
/= d = 25 $ = 0,955 Stress range
( 301
0.4343 250,000 - 2
f, = 0 . 9 5 5
4.301
= 0.97 2 a,, = a , $$
K
Allowable stress ranges according to equation (26) for clas- 2229 12
z 2.6, = 120 N/mm2
ses K 1 and K 2 20 .29
2 uazul/K1 = 126 .0.97 = 122 N/mm* < 2 %,,l/Kl = 122

2 %zzul/KP = 100 ‘0.97 = 9 7 N/mm’ 4.4 Flat plates

4 Equivalent stress ranges Blind closure item 9 with nozzle item 10
With purely swelling load and the effect of internal pressure Structural stress concentration factor from BR-El3 [4]
only, the equivalent stress ranges can be evaluated in a a, 4 KS = 2.85
simplified manner according to the general equation (2) with Stress range
8. aso = 0
P
4.1 Cylindrical shell with deviations from shape (peaking) 2U”, ; u, = 0.31 . . fi. as

Stress range according to [8] 2

. g = 118 N/mm2
+6. ~
Di’h.P
20 . s?
< 2u.az”,,K, = 122
= 2942.12 +6, 2942.5.12 = 124 N/mm2
20.29 2 0 292
4.5 Cylindrical shell with bracket support
= 2 a, Z”,,K, = 122
Bracket design with reinforcing plate, webs and support plate
4.2 Dished head with openings regarded conservatively, with a view to the strain-inhibiting
effect for the cylindrical shell, as a rectangular “core” in disk
4.2.1 Head knuckle under two-axial tensile load.
Structural stress concentration factor according to AD- Calculation of stress concentration factor according to [5],
Merkblatt B 3, Annex 1. Section 2.4, equations (51) to (54) with polynomial coeffi-
cients according to Table 4 or from Fig. 36.
a, P a = 3.9
Structural stress concentration factor a, = 2.1
Stress range
Stress range
2 a,, = a, -$$
’ K 2 P = . D,.P
a,, a, a,
2942.12 20z .
= 3.9 . = 119 N/mm2
40 .29 = 2.1 2g42 ’ l2 = 128 N/mm2
20 .29
< 2 u=“,/wH = 217
> 2 %ul/KP = 97
4.2.2 Spherical part of head with opening, nozzle item 6
The allowable stress range is exceeded. The acceptability of
Structural stress concentration factor according to 161, Sec- the design envisaged may, if necessary, be verified by more
tion G.2.5.2 precise stress calculation. Otherwise a change of design is
a, =A s.c.f. = 2.0 necessary.

5 Literature
ill TRD 301 Annex 1: Berechnung auf Wechselbeanspru-
chung durch schwellenden lnnendruck bzw. durch kom-
binierte Innendruck- und Temperaturanderungen.
Edition April 1975. Cologne: Heymanns Verlag
Berlin: Beuth-Verlag
121 KTA 3211.2: Druck- und aktivitatsfiihrende Komponen-
ten von Systemen au8erhalb des Primarkreises.Teil
Auslegung, Konstruktion und Berechnung, 6/l 992
t31 Duan-Shou Xie and Yong-Guo Lu: Prediction of Stress
Concentration Factors for Cylindrical Pressure Vessels
with Nozzles.
Int. J. Pressure Vessel & Piping 21 (1985)
t41 Richtlinienkatalog Festigkeitsberechnungen
Behalter und Apparate Teil 6.
Edition 1986. Linde KCA Dresden GmbH
El Raday, D. and G. Schilberth: Kerbspannungen an
Ausschnitten und Einschlussen.
Deutscher Verlag fur SchweiOtechnik, Dusseldorf 1977
161 BS 5500: 1991 Unfired fusion welded pressure vessels.
British Standards Institution: London 1994
[7] Varga, L.: Bestimmung der in der Umgebung der
Ausschnitte von innendruckbeanspruchten Druckbe-
halterdeckeln auftretenden Spannungen.
Forsch. Ing.-Wes. 29 (1963)
[8] Schmidt, K.: Beanspruchung unrunder Druckbehalter.
VDZ-Z. (1960) No. 1, p. 1 l/15
[9] Pith, R.: Der Zusammenhang zwischen der Unrundheit
von Kesseltrommeln und den zugehorigen Biegezu-
satzspannungen.
Mitt. VGB (1966), Issue 103, p. 270/279
[lo] John H. H., L%sig G. and D. Niedermeyer:
Ursache fur RiOschaden im Langsnahtbereich von
zylindrischen Apparatemanteln.
Chem. Techn. (1990), Issue 6, p. 2421245
Page 47 AD-Merkblatt S 2, Edition 5.98
t111 Sterr, G.: Die genaue Ermittlung des C-Wertes fur die
am Rande mit einem SchuO verschweif3te Kreisvoll-
Platte unter Berucksichtigung der im SchuO auftreten-
den Spannung.
Techn. Uberwach. 4 (1963), No. 4 p. 140/143
[la Zellerer E. and H. Thiel: Beitrag zur Berechnung von
Druckbehaltern mit Ringversteifungen.
Die Bautechnik 44 (1967), Issue 10 p. 333/339
2:
t131 Warren C. Young: Roark’s formulas for stress and
strain.
McGraw-Hill Book Company 1989, 6th Edition
t141 DIN 3840 ,,Armaturengehause - Festigkeitsberech-
nung gegen Innendruck”.
August 1989 version , Beuth-Verlag GmbH, Berlin
(RKF),
[I51 VDI-Richtlinie 2230 ,,Systematische Berechnung hoch-
beanspruchter Schraubenverbindungen”
VDI-Verlag GmbH, Dusseldorf 1986
tl61 Maduschka, L.: Beanspruchung von Schraubenverbin-
dungen und zweckmal3ige Gestaltung der Gewinde-
trager. Forschung Vol. 7 (1936), Issue 6, p. 299-304
t171 Hase, R.: Verformung der Gewindegange bei Bela-
stung der Gewindeverbindung. Werkstatt und Betrieb
1 1 1 (1978) 12, p. 813-815.
tl81 Neuber, H., Schmidt, J., Heckel, K.: Ein dauerschwing-
festes Gewindeprofil. Design
27 (1975) H. 11, p. 419-421.
1191 N e u b e r , H . : Kerbspannungslehre.
3rd edition, Springer-Verlag BerliniGottingeniHeidel-
berg 1985
PO1 G o r s i t z k e , 6.: Kerbspannungsberechnung von
Schraubverbindungen.
lnterner Berechnungsbericht des RWTUV (1994).
pl] Zeman, J. L.: Aufdachung an Langsnahten zylindri-
scher Schusse.
Techn. Uberwach. 34 (1993) No. 718 p. 292/295.
Page 48 AD-Merkblatt S 2, Edition 5.90

30
-

-1
800

I
10
I
9

Fig. A 11. Pressure vessel for pulverised coal injection installation (sample calculation)
 Page 49 AD-Merkbiatt S 2, Edition 5.98

Annex 4 to AD-Merkblatt S 2

Mternative calculation method for higher allo- unnotched polished test bars is to be determined by means
nable stress ranges or load cycle numbers at of equation (A 1) in the range 102 5 N 5 5 106 or from
Fig. A 12.
reduced inspection intervals
Compared to the mean load cycle curve to incipient cracking
I Scope the curves contain a load cycle safety factor of SN = 3 to 5
and a stress safety factor of approx. S, = 1.5.
The alternative calculation method below can be applied if
ihe inspection intervals for in-service inspections and after
6.7.104
the design lifetime has been attained in accordance with sec- 2& = - +0.55.R,-10 (AlI
tions 12.3 and 14.2 of this AD-Merkblatt are reduced from LN
50% of the fixed load cycle number to 25%.
The stress range 2u, for the endurance range (N 2 5. 106)
2 General can also be taken from Table A 1.
The load cycie number curves to figures 11 and 12 have been
raised, under economic aspects and with the assumption of Table A 1. Stress range 2~~ in the endurance range for
a smaller load cycle safety factor SN or greater failure proba- unnotched test bars
bility PA, to obtain higher allowable stresses or load cycle
numbers, with the allowable stress ranges in the endurance Tensile strength 2cr, = const. [N/mm’]
range being marntarned.
R, [N/mm’] Nr5.106 NzlO8
The load cycle number at whrch the load cycle number curves at load regime
are plotted horizontally (“end-of-curvature load cycle num-
ber”) were uniformly displaced from 2 106 to 5 IO6 (Figures 400 240 178
Al2 and A13). 600 350 259
Nith a view to the early detectron of rncrprent cracking, if any,
:his alternative calculation method may be considered to be 800 460 341
equivalent to the calculation in the main part of this AD- 1000 570 422
\/lerkblatt with respect to safety.
iNhere the effective material properties are located unfavou-
rably in the scatter band of the fatigue life curves, the service 3.2 Welded component sections
life may be reduced if the design lifetime is exceeded. The allowable stress range 2u,,,, shall be calculated accord-
Unless otherwise specified in this AD-Merkblatt, all rules of ing to equation (26) in which case the stress range 2~~ is to
the main part apply. be taken from Fig. A 13.

3 Allowable stress range at known number of load
cycles
3.1 Unwelded component sections
The allowable stress range 20,,,, shall be calculated accord-
ing to equation (13) in which case the stress range 2~~ for
By application of equation (27) and use of the constants of
Table A 2 the curves of Fig. A 13 are within the range
102 5 N % 5. 106.
The load cycle number curves are based on a failure probabi-
lity of PA = 2.3%.

Table A2. Constants Bl, 82 and stress range 20, in the endurance range for welded joints

Constant Stress range

Bl B2 20, = const. [N/mm”]
Class lo* % N 5 5. 106 5. 106 5 N 5 IO8 N~5.10~ NzlO8
at load regime
KO 2,56 1012 1.64. 10’6 80 44
Kl 1.25. 10’2 4.96 . 10’5 63 35
K2 6.25 . 10” 1.56 . 1015 50 28
t1 K3 3.2 . 10” 5.12. 1014 40 22
Page 50 AD-Merkblatt S 2, Edition 5.98
4 Allowable load cycle number at known
stress range
4.1 Unwelded components
The allowable load cycle number shall be calculated by
means of equation (A 2) or be taken from Fig. A 13
6.7 . lo4 2
(A 2)
24-0.55.& + 1 0
where 24 is the stress range to equation (30).
In the case of 2d, values below the curves to Fig. A 12 in the
rangeofN~5~106orif20*,=2o,forN~5~106toTable
A 1, endurance strength is obtained.
4.2 Welded components
The allowable number of load cycles shall be determined by
means of equation (31) using the constants 81 from Table
A2 and the stress range 24 to equation (32), or from
Fig. A 13.
I 5 Consideration of operational load regime
The calculation shall be performed accordingly to AD-Merk-
blatt S2, section 9 in which case the respective load cycle
number curves from Fig. A 12 or A 13 shall be used. The ficti-
tious load cycle number curves may be described for unwel-
ded compoponents by means of equation (A3)
and for welded joints by means of equation (36) using the
constants B 2 of Table A 2.
6 In-service inspections
The inspection intervals for the inspections to AD-Merkblatt
S 2, section 12.3 shall be reduced from half to a quarter of
the fixed number of load cycles.
7 Consideration of special operating
conditions
7.1 For steel cylinders and seamless pressure-gascylin-
ders made from tempering steel for the transport of cold com-
pressed hydrogen AD-Merkblatt S 2, section 13.2 shall apply
accordingly in which case the reduced number of load cycles
N;,, to equation (39) shall be calculated with N,,, to equation
(A2) und f, = l/10.
7 . 2 For welded hydrogen storage tanks according to AD-
Merkblatt S 2, section 13.3 the number of load cycles calcula-
ted by means of equation (31) using the constants 8 1 to
Table A2 shall be reduced with the reduction factor to equa-
tion (40).
For unwelded components or welds ground flush without not-
ches on the hydrogen-exposed side of the wall, the allowable
load cycle number can be determined in accordance with
section 3.1 or 3.2 using equations (39) and (40), respectively
in which case no value smaller than 0.5 need be taken into
account.
For hydrogen storage tanks with design strength values K,,
of 355 < K20 5 500 N/mm’ only 50 % of the number of load
cycles determined by means of equation (49) shall be taken
as allowable number.
8 Measures to be taken when the design
lifetime has been reached
If during the tests according to AD-Merkblatt S 2, section 14.1
no cracks are detected, continued operation is permitted until
the attainment of five times the design load cycle number N,,,
or the accumulated damage according to equation (34). The
precondition for this is that during the non-destructive tests
to be performed at inspection intervals corresponding to
25 % of N,,, no fatigue damage is found. Further steps to be
taken are subject to the requirements of sections 14.3 to 14.5
of this AD-Merkblatt.
 --- - Fictitious number of load
cycles, taking account of an
operational load regime
I I llllll

Rm
[N/mm]
1000
800
600

400

100
IO2 IO3 IO4 lo5
Allowable number of load cycles N,,,

Figure A 12. Allowable number of load cycles as a function of the stress range for unnotched test bars of high-temperature ferritic and
austenitic rolled and forged steels at room temperature and Cr = 0
 10000

I I I bI,LII
t - i i iii/iii I I llllll

1000

Weld
100 class
KO

z
K3

lo2 103
Allowable number of load cycles N,,,

Figure A 13. Allowable number of load cycles as a function of the stress range for welded joints of high-temperature ferritic and
austenitic rolled and forged steels at room temperature (independent of 5)
.-- --------- Edition Mav. 1999

General verification of stability AD-Merkblatt

Special for pressure vessels
cases s 3/o
Basic principles

The AD-Merkbltitter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
behsilter” (AD). AD-Merkblatt G 7 covers the composition and application of AD-Regulations and also procedural guidelines.
The AD-MerkbWter cover safety requirements which shall be adopted for normal conditions of operation. In the event of stresses over
and above the normal level being anticipated during the operation ofpressure vessels, allowance shall be made for such stresses by meet-
ing special requirements.
Should there be any departures from the provisions of this AD-Merkblatt, it shall be possible to demonstrate that the safety standards embo-
diedin t h e s e r e g u l a t i o n s h a v e b e e n o b s e r v e d b y a l t e r n a t i v e m e a n s , e . g . t e s t i n g o f m a t e r i a l s , t r i a l s , s t r e s s a n a l y s i s , o p e r a t i n g e x p e r i e n c e .
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e.V. (FDBR), Dijsseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sankt Augustin
Verband der Chemischen lndustrie e. V. (VU), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Vetfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhfittenleute (VDEh), Diisseldorf
VGB Technische Vereinigung der Grob’kraftwerksbetreiber e. V., Essen
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
The AD-Merkbldtter are amended continuously by the trade associations in keeping with the technicalprogress. Relevant proposals should
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents

1 Scope 5 Bibliography
2 General Appendix 1: Specimen of a certificate in accordance
3 Symbols and units with 2.7
4 Specifications for a strength verification with
the inclusion of stability

1 Scope S 313 -, Vessels with dished ends on feet

The S 3 series of the AD-Merkbi&ter provides information on
allowing for the additional forces in pressure vessel walls;
see also 4.5 of AD-Merkblatt B 0. They also provide informa-
tion for those cases where the verification of the stability is
also to include the effects on the retaining and supporting
structures as well as on those components of the pressure
vessel itself which are subject to pressure stresses. The pro-
cedures for these are regulated in this AD-Merkblatt. Pos-
sible solutions for some of the structural shapes which fre-
quently occur are also given.
2 General
2.1 The S 3’series of the AD-Merkblatter
in conjunction with AD-Merkblatt B 0.
2 . 2 The S 3 series of the AD-Merkbltitter
ing parts:
S 3/.. -, General verification of stability for pressure vessels
S3/0 -, Basic principles
S 3/l -, Vessels on skirt supports
S3/2 -, Horizontal vessels on saddles
S314 -, Vessels with support brackets
S3/5 -, Vessels with ring supports
S 316 -, Vessels with supports subject to additional loading
S 3/7 -, Consideration of thermal stresses in heat exchan-
gers with fixed tube plates
2 . 3 If requirements regarding strength and stabilityverifica-
tion in addition to the verifications in accordance with the
B series of the AD-MerkblBtter are specified for a vessel, the
following procedures can be used. The possible solutions
given in AD-Merkblatter S 3/l to S 317 take into account
these specifications.
2 . 4 4.1 of this AD-Merkblatl contains the loadings essential
for stability verification together with information on determin-
shall be used only
ing the load variables. The appropriate loads for the particular
application case can be determined from these. The corres-
include the follow- ponding, jointly-acting loads are summarised under load
cases in accordance with 4.2, allowing for their significance
for the pressure vessel. The level of the permissible stress
during the strength verification then depends upon the type
of load. 4.3 contains information on strength verifications inc-
, luding the specifications necessary for the permissible stres-
ses where these exceed those in AD-Merkblatt B 0.

Supersedes Edition of January 1995; 1 = Amendments to previous edition

ldan neymanns venag KC, Translation: Technical Help to Exporters Service of BSI
Luxemburger StraOe 449. 50939 Kdln
P a g e 2 AD-Merkblati S 3/O, Edition 05.99

2 . 5 If there are standards which give specific dimensions, A Number of platforms

connecting geometries and details of permissible loads (for 4 Projected area in mm2
example bracket supports to DIN 28 083 Parts 1 and 2) for B Live load deduction in %
pressure vessels or parts of pressure vessels, no additional C Total live load to be taken into account in %
strength verifications are necessary. It is then sufficient to
compare the loads which occur with those which are permis- D Diameter of vessel in mm
sible. Gd Maximum possible total weight oft the
vessels in service in the section plane
2 . 6 The connecting parts of supporting elements on frame- under consideration in N
works, platforms etc. shall be designed such that it is possible
GZ Minimum possible total weight of vessel
for the force to be introduced without slippage, tilting or lifting. in service in the section plane under
If platforms are fitted which do not comply with DIN 28 017, consideration in N
the stability of these shall be separately verified.
H Height of vessel above ground in mm
2 . 7 The verifications in accordance with the S 3 series of M Total moment of the supporting
the AD-Merkblatter do not include steel or solid structures elements in the section plane under
which serve to transfer the load. To describe the common consideration, resulting from external
interface it is necessary to document the maximum loads and loads in Nmm
anchor forces as well as the number, quantity and quality of
N Fd Compressive force on supporting
anchor bolts and the maximum compressive stress exerted elements in N
by concrete used in the calculation, for each type of load (see
4.2.1) in a separate certificate, e.g. in accordance with NFI Maximum tensile force on supporting
elements in N
Appendix 1.
Sh4 Coefficient of safety for installation
2 . 8 When using materials in accordance with the W series cases -
of the AD-Merkblatter for the manufacture of supporting and -
ss Coefficient of safety for special cases
attaching elements, the certification in accordance with 2.2
of EN 10 204/DIN 50 049 can be used for the verification of
the material, instead of the specifications contained in the
AD-Merkblatter. 4 Specifications for a strength verification
with the inclusion of stability
Materials of identical type are to be used for parts that are
welded to the pressure vessel wall. If materials are used 4.1 Loads
which are not of identical type, approval for the deviations is
to be certified. 4.1.1 Loads means the influences acting on the pressure
vessel and its attaching and supporting structures which
2 . 9 The B and S series of the AD-Merkblatter can be used cause stress in the vessel.
for the verification of stability in accordance with regional
building regulations for the vessel itself as well as for the sup- 4.1.2 When determining the loads, constraining forces
porting and attaching elements. and moments due to restrictions on deformation (for
example due to supporting structures, components fitted
on and inside as well as pipe connections) shall be taken
into account.
3 Symbols and units
4.1.3 The specified number of load reversals shall be
The following apply in addition to, as a deviation from, the
taken into account for load cases which are to be included
specifications of AD-Merkblatt B 0.
in the fatigue analysis.
a Factor for coefficient of safety in accordance
with 4.3.4.1 (3) or (4) - 4.1.4 For each load case, it shall be checked whether
Coefficient of wind force - the following loads occur and whether yet further loads
Ct
also occur. Examples of such loads are as follows.
cfkorr Corrected coefficient of wind force
d Diameter of vessel including insulation in mm 4.1.4.1 Dead load
6 Reference diameter of supporting This includes the dead load of the pressure vessel and of
elements in mm the components attached to it, the charge of the pressure
e The wall thickness to be used as vessel and other loads which are constantly present.
a basis for the calculation after 4.1.4.2 Pressures
substraction of the wall thickness
allowances c,, c2, . . . in mm This includes pressures related to place and time includ-
ing local pressure application (for example when closing
ez Wall thickness of skirt supports in mm
and opening valves).
f Permissible calculation stress in
accordance with 4.3.4 in N/mm* 4.1.4.3 Temperatures
fP Permissible calculation stress for This includes temperature patterns which vary with loca-
the test case in N/mm2 tion and time including temperature fields limited to speci-
fbl Permissible calculation stress for fic areas (e.g. during charging and discharging processes)
the installation case in N/mm’ as well as temperature gradients in the component cross
Permissible calculation stress for section. The effect of thermal insulation shall be allowed
fs
special cases in N/mm2 for.
n Number of supporting elements - 4.1.4.4 Static and dynamic loads from components fitted
W Clearance between vessels and/or on and inside as well as from pipes (e.g. due to pressure
between vessels and building in mm surges, thermal expansion) and charging loads.

4.1.4.5 Live loads
Live loads can act on platforms or components fitted on or
inside. The loads for components fitted on or inside are deter-
mined in accordance with DIN 1055 Part 3, and for platforms
and walkways in accordance with DIN 4133.
If more than three platforms are fitted to one vessel, the live
loads for the global stability verification can be reduced in
accordance with 9 of DIN 1055 Part 3 in accordance with the
following rules: The live loads of the three platforms (walk-
ways) which most frequently place a load on the component
are calculated using the full amount. Live loads of other plat-
forms (walkways) may, where there are uneven loads, be
reduced according to the loads in descending order by an
amount increasing in steps of 20 %. The reduction of the ove-
rall live load shall, however, not exceed 40 %. The following
deductions and overall platform loads result where the plat-
form live loads are the same.
A l-3 4 5 6 7 8 9 z 10
5 0 20 40 60 80 80 80 40
c 0 95 88 80 71,4 65 60 60
The individual verification for single platforms (walkways) as
well as the local introduction of the load into the pressure ves-
sel wall is carried out in each case using the total live load
associated with the platform.
4.1.4.6 Wind loads
The wind loads shall be determined in accordance with DIN
1055 Part 4, or where there are higher narrower vessels with
a height H of at least 20 m above ground where HID > 10
such as for columns in accordance with DIN 4133. The pro-
jected area (vertical to the direction of the wind) of the particu-
lar pan under consideration is used for assessment. For ves-
sels with a height to diameter ratio of less than 4,0, the wind
roof load shall be taken into account. The magnitude and line
of effect can be determined in accordance with DIN 4119.
For adjacent vessels or vessels close to buildings the coeffi-
cient of wind force ct shall be chosen relative to the clearance
of the vessels in accordance with DIN 1055 Part 4. For
simplification, the following can be used in accordance with
DIN 18 914 Supplement 1 (9/85) where the clearances are
d + w 5 2d:
7 >ackings in particular, if they are located in the upper part of
Cf korr = 1-r . Cf
100 (1 + F-90,2
!
When determining wind loads, access ladders, platforms and
connected pipelines etc. may be taken into account in one
lot using an allowance. Unless otherwise specified and the
additional projected area is less than 15 % of the vessel pro-
jected area, the increase in wind load in accordance with
5.2.2 of DIN .I055 Part 4 can be calculated by an overall
increase of 25 % in the static pressure.
As an alternative to the aforementioned calculation, the wind
loads of access ladders, platforms and connected pipelines
can be determined in accordance with the following.
(1) The coefficient of wind force cf is
cf is 0,7 for cylindrical vessels and the pipes running
parallel to them, provided the average clearance
between the pipeline and cylinder is equal to or
greater than I,2 times its diameter, including the
insulation.
ct is 1,5 for the adjacent pipes provided the average cle-
arance between the pipeline/cylinder is less than
1,2 times its diameter including insulation
P a g e 3 AD-Merkblatl S 3/O, Edition 05.99
cr is 1,2 for steel structures such as ladders and tubular
framework
c, is 1,4 for steel structures such as platform and walk-
ways.
(2) The following projected areas A, are to be used
- Round solid platforms (angle at circumference
360”):
Platform external diameter x 0,5 m. For columns the
platform external diameter where there is an effective
platform width of 1000 mm (standard width in accord-
ance with DIN 28 017 Pan 1) is the diameter of the
column with its insulation plus 2,4 m.
- Platforms with an angle at the circumference of more
than 100 ‘:
as for solid round platforms
- Round platforms, with an angle at the circumference
of not more than 100”:
(vessel diameter with insulation plus single width of
platform) X 0,5 m
- Platforms, polygonal:
Diagonal dimension x 0,5 m
- Walkways:
Length x 0,5 m
- Ladders with safety fittings:
Vertical height of ladder x 0,33 m
A detailed determination of the wind loads in accordance with
DIN 1055 Part 4 can be used instead of the simplified deter-
mination of the wind loads using the foregoing parameters.
4.1.4.7 Vibrations resulting from wind load
In the case of vessels with a natural oscillation period of
Tr 1 set, account shall be taken of vibrations in the wind
direction resulting from the dynamic effects of gusts of wind,
eg. in accordance with [1] or [2]. This is generally the case
with very tall or very slender vessels. Fatigue analysis need
not be carried out for this type of loading.
Vibrations transverse to the wind direction as a result of eddy
shedding are not to be expected even in the case of tall slen-
der vessels, e.g. columns, if platforms, ladders, parallel pipe-
work, lateral manhole nozzles etc. are distributed over the full
height. Internal fittings such as fluid distributor ends or filler
(1)
.he column, also counteract transverse vibrations.
n the case of very slender and tall chimney-like vessels with-
,ut any significant fittings outside or inside, if transverse
Jibrations are to be expected, fatigue analysis shall be
:arried out for this loading. This can also apply to columns
leing assembled depending on the type of assembly and
state of manufacture where other temporary or permanent
design measures to prevent transverse vibrations are pos-
sible. These measures may also be required if transverse
vibrations are observed during operational stoppages
[column with no fluid charges, fillers internals etc.).
In cases of doubt, the possibility of transverse vibrations
occurring can be determined in accordance with [l] or [2]. For
information on this, see also [3].
14.1.4.8 Snow loads
Snow loads are determined in accordance with DIN 1055
Part 5. As a rule, the projected area at right angles to the ver-
tical is used as a basis for the loaded area. For platforms and
walkways the snow loads can be allowed for in accordance
with DIN 4133.
 P a g e 4 AD-Merkblati S 3/O. E d i t i o n 0 5 . 9 9
14.1.4.9 Other dynamic loads (for example, earthquakes,
processes with rapid pressure rises).
Details of the tracing point excitation during earthquakes can
be obtained from DIN 4149. Information from the operator is
necessary regarding possible processes involving rapid
pressure rises and associated stresses.
4.2 Load cases
The load cases to be taken into account are the states in the
pressure vessel and/or in the system which includes the
pressure vessel. They are to be given regardless of the instal-
lation point, the process conditions and, if necessary, regard-
less of the legal and regulatory basis applicable to the requi-
rements and to be classified in accordance with the details
in this subclause.
The load cases in this case represent a combination of simul-
taneously-acting loads or corresponding load patterns. The
individual loads shall be determined in accordance with the
details in accordance with 4.1 and combined to form load
cases in accordance with the example in Table 1. In doing
so only those loads which occur jointly with respect to time
need to be combined. In special cases the loads acting jointly
shall be combined in each case with only one special load.
For all load combinations the superposition shall always be
chosen which determines the maximum possible internal
force in this combination.
All the stresses and load cases to be taken into account shall
be given.
4.2.1 Types of load cases
Load cases can be:
- Operating cases (OC)
- Test cases (TC)
- Installation cases (IC)
- Special cases (SC)
4.2.1.1 Operating cases (OC)
Operating cases are those load cases for which the plant
with the system in a functional state (undisturbed state) is
designed and suitable. Other operating cases are load cases
which occur during malfunction of parts of the plant or sys-
tems (disturbed state) provided this does not stand in the way
of continued operation for safety reasons.
4.2.1.2 Test cases (TC)
Test cases are pressure and tightness testing. This includes
tests in the manufacturing works or by the operator after
installation, and also recurrent tests, taking account of the
particular supports and locally occurring pressure.
4.2.1.3 Installation cases (IC)
The stresses which occur during installation, transport and
erection (for example‘inertia forces, wind loads) are to be
taken account of as installation cases for the particular instal-
lation condition.
4.2.1.4 Special cases (SC)
Special cases are events during the occurrence of which the
plant cannot be continued to be operated for safety reasons,
but which shall be kept in check when they occur.
14.3 Verifications of strength an stability
4.3.1 General
The type and scope of the necessary strength verifications
depend on the type of component for which the verification
is to be carried out and the loads to be taken into account (see
4.1) and/or the stresses caused by these.
For the load cases given in 4.2, the strength verifications con-
tained in the B and S series of the AD-Merkblatter shall nor-
mally be used, taking into account the permissible calculation
stresses contained in 4.3.4. Verifications going beyond this
shall be carried out in accordance with AD-Merkblatt G 1 (4.2
and 4.3).
The stresses found during the stress analyses are assessed
in accordance with AD-Merkblatt S 4.
4.3.2 Type of component
4.3.2.1 Pressure-stressed components
The B and S Series of the AD-Merkblatter apply (as appli-
cable) to all pressure parts and to all parts firmly connected
to the pressure vessel. For welded support structures, the
part which is integrally joined to the pressure vessel shall be
calculated in accordance with the Band S (where applicable)
series of the AD-Merkblatter. The boundary between the inte-
gral retaining part and the support structure is decided using
the condition over the run-out length, for example for skirt
supports (Fig. 1) where
I
Fig. 1.
4.3.2.2 Supporting elements
Supporting elements can be verified in accordance with the
S 3 series of the AD-Merkblatter.
4.3.2.3 Anchor bolts
The minor diameter area of the bolt (Ad3 in accordance with
DIN 13 Part 28) is the determining factor for dimensioning.
4.3.3 Type of load
4.3.3.1 Components subject to compressive load
For components subject to compressive load the stresses
which occur during individual loads (see 4.1) shall be deter-
mined separately according to membrane and bending stres-
ses, in addition to the dimensioning in accordance with the
B series of the AD-Merkblatter, particularly for areas where
forces are applied as well as for the essential load bearing
cross sections. The stresses determined for the individual
loads are then totalled according to the signs, separately
according to membrane and bending stresses, in accord-
ance with the defined load cases (see 4.2) for each location
under consideration and are then compared with the permis-
sible calculation stresses in accordance with 4.3.4. In this
case, the global membrane stresses resulting from mechani-
cal loads shall not exceed the stress limits specified in 4.3.4.
The higher stress limits may be used for superposed stresses
resulting from mechanical and thermal loads. For membrane
stresses in severely restricted local areas, such as points
where loads are applied, and for the total stresses resulting
from membrane and bending stresses, the permissible cal-
culation stresses can be increased corresponding to the
details in AD-Merkblatt S 4.
 P a g e 5 AD-Merkblatt S 3/O, Edition 05.99

Table 1. Example of assignment of loads and load cases to the stress stages and permissible design stress

accordance

1) The load cases given here are examples of allocations and are to be accordingly given for the particular application case.
2) The associated temperature is generally decisive for determining the permissible stresses. Additional thermal stresses shall be allowed for the load case:
shown with a cross in this column.
3) The details for load superposition contained in the relevant DIN standards can be taken into account.

If compressive membrane stresses occur for the stresses
determined outside local points, the stability shall also be
verified for this load case. Stability verification in accordance
with DASt Guideline 013 or DIN 18 800 is a possibility in
these circumstances, in addition to the 6 series of the AD-
Merkblatter.
4.3.3.2 Supporting elements
For supporting elements of shell-shaped components the
constructions for components subject to compressive load in
4.3.3.1 apply in principle.
For supporting elements of rod-shaped components the
stresses (tensile, compressive, bending and their combi-
nations) shall be determined for the individual combinations,
starting from the load combination, and shall be limited to the
permissible calculation stresses in accordance with 4.3.4
depending on the load case and load combination. If com-
pressive or bending stresses occur in these components
under the individual load combinations, these shall be limited
in accordance with DIN 4114.
If verifications are made either completely or partially in
accordance with standards for steel construction, the main
load H load case corresponds to operating case OC and the
main load and additional load HZ case corresponds to the
installation and test case and the main and special load case
HS corresponds to the special cases.
4.3.4 Permissible design stress
The permissible design stresses depend on the load case
and type of component. They are included in Table 1 by way
of example. The following bases are used.
4.3.4.1 Pressure vessels
(1) The permissible design stress f is determined from the
material characteristic value K and the coefficient of
safety S in accordance with AD-Merkblatt B 0 or in
accordance with the corresponding calculation sheets to
obtain
f = KIS.
(2) For the test cases, the coefficient of safety S’ is used,
instead of (1) to determine the permissible design stress
fp = KIS’.
(3) For installation cases, a distinction is made between
installation loads which act for short periods (e.g. setting
down during transportation) and longer-acting installa-
tion loads.
The permissible design stresses
fM = K&,
are in this case derived from the coefficients for the
operating case and test case by adapting the coefficient
of safety in accordance with AD-Merkblatt B 0 to obtain
SM = S - a . (S - S’), (3)
 Page 6 AD-Merkblatt S 310. Edition 05.99
where.
a is to be regarded-as I,0 for short-term stress and
a is to be regarded as 0,5 or long-term stress.
(4) For special cases the permissible design stress
f, = KIS,
is established as for installation case taking a to be equal
to i,25. In this case, however, .Ss shall be not less
than 1,O.
4.3.4.2 Supporting elements
(1) The permissible design stress for operating cases
f = KIS
the strength characteristic value K with the coefficient of
safety for the design case in accordance with AD-Merk-
blatt 6 0 can be used as a basis for materials given in the
W series in the AD-MerkbUtter.
(2) The coefficient of safety may be reduced by a factor of
1,l for the installation and test cases.
(3) For special cases the coefficient of safety can be reduced
by a factor of 1,5.
(4) The required safety with respect to stability depends on
the type of verification on which it is based, whereby a
reduction in the necessary coefficients of safety in
accordance with the specifications for supporting ele-
ments under (1) to (3) can be taken into account as
necessary.
If stability verifications are carried out in accordance with
DIN 4114, the o values for all tough (ductile) materials
in accordance with the W series of the AD-Merkblatter,
whose tensile yield strength Rp0,2 at room temperature is
5 240 N/mmzcan be used. For such materials with aten-
sile yield strength at room temperature of between 240
and 360 N/mm2 the (r) values for St 52 can be used.
(5) As a deviation from AD-Merkblatt B 0, the ambient tem-
perature can be used for parts of the supporting element
if these are outside the thermal insulation of the vessel.
If steels contained in DIN 4133 are used for supporting ele-
ments, the K values contained in it can be used as the design
temperature.
4.3.4.3 Anchor bolts
For anchor bolts for strength classes 4.6 and 5.6 and also
anchor bolts made of St 37-2 and St 52-3 materials, the
strength characteristic value K for the operating load cases
at ambient temperature is the yield strength given in DIN
I 28 082 Pat-l 2. For higher temperatures the characteristic
values given in the W series of the AD-Merkbltitter for these
materials apply.
In the operating load cases the coefficient of safety S is 2,2
with respect to the yield strength. Furthermore, the appro-
priate regulations in 4.3.4.2 (2), (3) and (5) apply.
4.3.5 Checking the stability verification
A prerequisite for checking the stability verification is check-
ing the dimensioning of the pressure-containing vessel com-
ponents (cf. 4.2.1 and 4.2.2 of TRB 511).
A description of the complete static system, the necessary
design drawings and the required calculations including cal-
culation against internal pressure shall be submitted for
checking the stability verification.
A test report shall be prepared on conclusion of a successful
check and the evidence checked shall be given a check note.
If a check of the stability verification is not carried out during
the preliminary testing, because this test is arranged by the
operator or if it is not required because the vessel installa-
tions fall outside the scope of the Pressure Vessel Code, for
example, the pressure vessel manufacturer shall inform the
preliminary testing agency of this.
The Model Building Code contains exceptions to the check-
ing of the stability verification.
4.4 Load distribution where there are several
supporting points
If a vessel is supported on several feet or lugs equally
spaced, then, where the division is equal, the maximum com-
pressive force at each individual element can be calculated
as follows:
An anchorage against lifting is necessary where
fi > 0,7 G,
dF
The following shall be used as the maximum tensile force for
determining the anchor bolt forces.
for n 2 4.
For n = 3 columns, the maximum tensile force is given by
The individual anchor bolt forces are determined as a func-
tion of the structural relationships in the point of the foot (see
6.2 of AD-Merkblatt S 313).
Where an even load distribution cannot be guaranteed by
ensuring a uniform support, the maximum value of n that can
be used for the calculation is 3. Where two support points are
used a stable supporting state is not generally guaranteed.
Account is to be taken of this if necessary by using additional
supports in the horizontal direction.
The rotational axis through the centre of the vessel should
be used when determining the bolt force components due to
the instantaneous loading.
The calculation bolt forces shall be increased by IO % to
allow for bolt pretensioning.
4.5 Taking into account longitudinal forces
As part of the stability verification, the longitudinal forces in
the pressure vessel wall due to external loads and gravitatio-
nal loads shall be checked to determine whether these lead
to an increase in the overall stress and therefore require an
increase in the wall thickness. If in this case compressive
forces occur in the longitudinal direction in the vessel wall,
a stability verification, e.g. in accordance with DASt 013 or
DIN 18 800, is also necessary.
4.6 Assessment of welds on supporting elements
The formation of welds shall be in accordance with DIN 8558.
Fillet welds need not be verified if the weld thickness is at
least 0,7 times the smallest wall thickness of the welded pla-
tes and the weld is formed on both sides. The weld thickness
g and a weld factor v of 0,6 shall be used as a basis for the
calculation of fillet welds welded on one side. Butt welds
welded on one side shall be assessed using v = 0,7 where
there are tensile membrane stresses.
For butt welds welded on both sides v = 0,85 shall be used
for assessment where there are tensile membrane stresses.
The weld factors v shall only be taken into account when
verifying membrane stresses.
 P a g e 7 AD-Merkblatt S 3/O, Edition 05.99

15 Bibliography
[l] DIN 4133 Steel stacks, November 1991 edition
[2] Eurocode 1: Basis of design and actions on structures -
Part 2-4: Actions on structures-Wind actions (currently
ENV 1991-2-4)
[3] Richtlinienkatalog Festigkeit RFK (Catalogue of Strength
Guidelines): Part 3: BR-Kl (No. 5.2 Transverse vibra-
tions), 3rd edition 1981, VEB Komplette Chemieanlagen
Dresden (now Linde-KCA-Dresden GmbH)
P a g e 8 AD-Merkblatt S 3/O. Edition 05.99

Appendix 1 to AD-Merkblatt S 310

Specimen of a certificate in accordance with 2.7

Connecting loads of vessel, relative to system axis and

[ ] lower edge of skirt supporWring support, level of bracket support
[ ] lower edge of profile/tubular supports
[ ] lower edge of saddle support
in kN and kNm:

External loads

Wind

Loads per support

- maxV

Wind

Snow

Maximum anchorage force [kN]

Maximum surface pressure [N/mm*]

 Edition May 1999

General verification of stability AD-Merkblatt

Special for pressure vessels
cases s 3/l
Vessels on skirt supports

The AD-Merkblgtter are compaed by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
behdlter” (AD). AD-Merkblatt G 1 covers the composition and application of AD-Regulations and a/so procedural rules.
T h e AD-Merkblatter c o v e r s a f e t y r e q u i r e m e n t s w h i c h s h a l l b e a d o p t e d f o r n o r m a l c o n d i t i o n s o f o p e r a t i o n . I n t h e e v e n t o f s t r e s s e s o v e r
and above the normal level being anticipated during the operation of pressure vessels, allowance shall be made for such stresses by meet-
ing special requirements.
Should there be any departures from the provisions of this AD-Merkblatt, it shall be possible to demonstrate that the safety s t a n d a r d s embo-
diedin t h e s e r e g u l a t i o n s h a v e b e e n o b s e r v e d b y a l t e r n a t i v e m e a n s , e . g . testjng o f m a t e r i a l s , t r i a l s , s t r e s s a n a l y s i s , o p e r a t i n g e x p e r i e n c e .
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e.V. (FDBR), Dijsseldorf
H a u p t v e r b a n d d e r g e w e r b i i c h e n B e r u f s g e n o s s e n s c h a f t e n e . V.. S a n k t Augustin
Verband der Chemischen lndustrie e.V. (WI), FrankfurilMafn
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA). Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhtittenleute (VDEh), Dtisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkraftwerksbetrefber e. V., Essen
Verband der Technischen iiberwachungs-Vereine e. V. (VdTCiV), Essen.
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s l y b y t h e t r a d e a s s o c i a t i o n s IR k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the pubksher:
Verband der Technischen iibetwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents

1 Scope 6 Verifications of stability at skirt-to-vessel junction

2 General 7 Verification of stability of skirt support
3 Symbols and units 8 Verification of slip resistance and safety against
4 Design variants for skirt-to-vessel junction overturning
5 Sections and section values 9 Bibliography

1 Scope is 0.7 times the wall thickness of the thinnest of the plates
involved and is welded from both sides or full-penetration
This AD-Merkblatt can be used to provide verification of sta- welded. If verification of welds is required this can be carried
bility of skirt supports on vessels. The verification shall be out in accordance with AD-Merkblat& S 3/O.
carried out separately for the local loadings at the skirt-to-
pressure vessel junction, for the skirt itself and its anchoring The loads shall be uniformly applied on the base ring; peak
in the foundation. stresses shall be avoided.
Stress intensifications within the meaning of 4.5 of AD- The load cases specified by the purchaser in accordance
Merkblatt B 0 in the pressure-retaining shell are to be with 4.2 of AD-Merkblatt S 310 shall be verified in which case
expected, particularly in the case of low pressure loading (el the allowable stresses given in AD-Merkblatt S 3/O shall be
D < 0.005) as well as in the case of high additional moments, used. The allowable design stresses and stress resultants
for example due to wind loads (H/D > 5). Below these limits are a function of the particular load case. However, to limit
it may be necessary to perform a stress analysis if additional the number of indices and thus improve clarity these are not
loads are extreme (e.g. due to additional weights, high-den- indexed in the following text.
sity filling weights or high eccentricity in the event of trans-
verse acceleration) or if the design principles do not match 3 Symbols and units
the design variants dealt with in this AD-Merkblatt.
The definitions in AD-Merkblatt B 0 are supplemented by:
a Lever-arm eccentricity (cf. Fig. 2) in mm
2 General b Width of base ring in mm
e Actual wall thickness less any wall
This AD-Merkblatt shall be applied only in conjunction with thickness allowance e = se-Xc, with s,
AD-Merkblatt S 3/O. in accordance with AD-Merkblatt B 0 in mm
The support skirt shall be designed to DIN 28 082 Part 1 and f Allowable stress as a function of the
Part 2 or in conjunction with these standards. Attention shall load case in accordance with AD-
be paid to the presence of inspection openings. Merkblatt S 310 in N/mm*
The design of the welds shall be compatible with DIN 8558. F Section force relative to axis of
The verification of welds may be omitted if the weld thickness symmetry in N

Supersedes Edition of February 1998; 1 = Amendments to previous edition

Larl neymanns “erlag Kc2 Translation: Technical Help to Exporters Service of BSI
Luxemburger StraBe 449, 50939 Kdn
Page 2 AD-Merkblatt S 3/l, Edition 05.99

9 Projecting length of base ring at Flange or base ring

non-anchbred end in mm Section for which verification is provided
h Height of support ring (cf. Fig. 6) in mm (possible values 1 to 5)
i Width of support plate or ring Support ring
girder in mm Anchor bolt hole circle or diameter of bore for
k Distance between skirt and bolt anchor bolt
circle in mm Gauge pressure or vacuum pressure as nega-
1 Projection of the base ring on tive gauge pressure (without hydrostatic pres-
the anchored side in mm sure)
M Resulting section moment, rela- Skirt support relative to non-weakened shell
tive to axis of symmetry in N/mm
n Number of anchor bolts -
4 Design variants for skirt-to-vessel junction
r Cut-out parameter in rad
This AD-Merkblatt allows verifications of stability at the junc-
t Distance between two web
tion of support skirt and pressure-loaded shell for the design
plates ” in mm
types A, B and C shown below.
T Distance between two brackets in mm
W Section modulus of ring accord- 4.1 Design type A (skirt support connection via sup-
ing to Fig. 1 in mm3 port ring at cylindrical shell)
a Stress intensification factor from Cylindrical or conical support skirt with an angle of inclination
AD-Merkblatt B 3 Appendix 1 - 5 7” to the axis.
Y Connecting or limiting angle in”
AF Vessel dead load beneath
0,
section 2-2 in N
AM Moment increase due to change
of centre of gravity in area of
cut-out in N/mm
6 Half opening angle of cut-out
(cf. Fig. 4) in mm
& Displacement of geometrical
centre of gravity by cut-out in mm
(3 Stress N/mm2
Indices
a External shell surface, i.e. side facing away
from axis of symmetry -
b Concrete
bcsuperscript) Bending portion
B Vessel
D Support plate or ring girder
F Filling
ges(superscrlpt) Total stress, i.e. membrane and bending
portion
G Portion of vessel weight including internal and
external attachments, without filling
H Hydrostatic column
i Internal shell surface, i.e. side facing towards
axis of symmetry
K Minor-diameter area of anchor bolt
FF+AFG
rn(superscnp0 Membrane portion t
FG+ FF t
n Verification point (possible values p and q),
defines the sign of the moment portion of Fig. 1. Design type A- skirt support connection via support
section force ring at cylindrical shell (section values from inertial
forces)
Shell surface (possible values i and a)
Verification point where the moment portion 4.2 Design type B (connection of skirt support in
with positive sign enters into the section force knuckle area)
(i.e. side facing away from the wind - wind-
Cylindrical or conical skirt support with an angle of inclination
ward)
9 7” to the axis and welded directly onto the domed end in
Web plate the area 0” 5 y 5 20”.
Verification point where the moment portion
Wall-thickness ratio
with negative sign enters into the section force
(i.e. side facing away from the wind - 0.5 5 2 % 2.25
leeward)
 Page 3 AD-Merkblatt S 3/l, Edition 05.99

Section 4 - 4

See Clause 8 for details

Fig. 4. Schematic diagram of support skirt - sections and

Fig. 2. Design type B-skirt support connection in knuckle
area of torispherical and semi-ellipsoidal ends
(section values from inertial forces)
4.3 Design type C (skirt slipped on vessel shell)
Cylindrical skirt slipped over vessel shell and welded on
directly.
It is assumed that, on either side of the attachment weld the
shell is free from discontinuities such as openings, attached
ends, vessel circumferential welds, etc. on a length of 3eB.
The risk of crevice corrosion shall be taken into account.
FG - A FG
section values
6 Verifications of stability at skirt-to-vessel
junction (sections l-l, 2-2, 3-3)
For the junction area sections 1 to 3 defined in Figs. 1 to 3
have to be verified. The membrane stresses and total stres-
ses shall be verified separately with only the respective longi-
tudinal components being taken into account.
The section force F, in the support skirt of the junction
depends on the position (n), i.e. whether the moment streng-
thens (q) or weakens (p) the load component:
Fz,=--F,-AFG-FF?D (1)
Z (n = P, 4).
Here F, is the resulting perpendicular force and M, is the
resulting moment due to external loads in section l-1 above
the junction of pressure-loaded shell and skirt.

6.1. Membrane stress analysis

The verification of membrane stresses is the same for design
types A, 6 and C. The membrane stresses at verification
point n in section l-l are:
6 = Fzn + AFG + fF PI O .DB
I” n. DB. eB 40 . eB (2)
(n = P, 9).
The strength condition is:
l&(5fB (n = P, 4). (3)
The wall thickness in section l-l in accordance with equa-
tion (3a) can be determined from equation (3) by equating
t FG + F~ with (2).
Fig. 3. Design type C - slipped-on skirt (section values em _ 1 F,, + AF, + fF PO. DB
from inertial forces) in---’ JC. DB + - x i -i (34
fB
The calculation of this wall thickness is requred for design
5 Sections and section values me A.
If a?” is a compressive stress, verification of stability shall be
The shell section values Fs, H, and M, on the respective sec- carried out according to [l] and taking [2] into account. This
tion 1 to 5 dealt with are determined as a function of the com- may be omitted if the longitudinal stress component is less
bination of all the loads to be taken into consideration for this than 1.6 times the value of the resulting meridional mem-
load case (cf. Fig. 4). brane compressive stress in the vacuum or partial vacuum
Further stability verification of sections may be necessary if load case and this load case was verified according to
the wall thickness at the support skirt is stepped. AD-Merkblatt B 6.
P a g e 4 AD-Merkblatt S 311, Edition 05.99

This applies accordingly to other sections in the cylindrical 6.2.2 Design type 6 (cf. Fig. 2)
part of the shell. The eccentricity a of the shell centre lines causes a bending
Regardless of the verification point, the membrane stress in moment at verification point n:
section 2-2 is: M, = a . F,,, (n = P, q) (10)
~=um=um= + AF, PO.
I DB
a 2P 27. D,.e, 40 . e, (4) with a = 112 1,’ ei + es + 2 es . e, . cos y

The strength condition DB+eB-DZ+ e,

and cos ‘/ = 1 -
2 (f + eB) ’
(4q’fB (5) that produces the corresponding bending stress portions in
shall be satisfied. sections 1 to 3
The required analysis wall thickness in section 2-2 in accord- OS& (a) = C 6 Mn
-7’ DB.ei (S = 1,2; n = P3 4) (11)
ance with equation (5a) for compliance with this strength con-
dition can be determined from equation (5) by equating with
equation (4).
1 AF, + F, + PU DB (12)
(n = P, 4)
eF=-i-’B ;I. DB 40
Within the range of validity,
The calculation of this wall thickness is necessary for design
0.5 5 2 5 2.25
type A.
In section 3-3 of the support skirt, the membrane stresses the correction factor C can be calculated by approximation
at verification point n reach the value: to obtain:

djl, = Fzn (6) C = 0.63 - 0.057 12)’

;I D, e, (n = p- 4).
This relationship was determined from numerical calcula-
The strength condition tions using the finite element method. Because of the large
number of parameters, a simplification had to be made
I &I 2 fz (n = p, 4). (7) which, under certain circumstances, can lead to significant
shall be satisfied. over-dimensioning, e.g. in the case of semi-ellipsoidal ends.
The required analysis wall thickness in section 3-3 in accord- This bending stress component is superimposed in the
ance with equation (7a) for compliance with this strength con- region of sections 1 and 2 by a bending stress portion caused
dition can be determined from equation (7) by equating with by the internal pressure (,o) in the knuckle
equation (6).

For torispherical ends, substitute ya = 45”, for semi-ellipsoi-

The calculation of this wall thickness is necessary for design dal ends, substitute ya = 40”; the stress concentration fac-
type A. If o& is a compressive stress, the stability verification tor a is to be taken from Appendix 1 to AD-Merkblatt B 3 for
that is then necessary may also be carried out according to the relevant end type.
[l] taking [2] into account.
6.2.3 Design type C (cf. Fig. 3)
6.2 Bending stresses The eccentricity of the shell centre lines causes a bending
moment at verification point n
6.2.1 Design type A (cf. Fig. 1)
Verification shall be made according to DIN 2505. M
”
zz k&k F,,
(n = P, 4). (14)
2
The local bending moment at verification point n is: that results, in sections 1 and 2, in the bending stresses

d,= ,.“,t?D B B (S = 1, 2; n = p, q) (15)

and, in section 3, results in the bending stress:

Using the required analysis wail thickness determined in
accordance with equdtions (3a), (5a) and (7a), the total sec-
tion modulus of the support ring at verification point n can be (n = p, q) (16)
calculated as follows: Bending stresses caused by pressure are ignored, i.e.:
Wn=$ [(DZ+eZ-D,- eB).hz (9) S(P) = 0
+ (2ei--e$-e?‘).D,
6.3 Total stresses and strength conditions
+ 0.5 (e: - e,“,‘) . DA (n = P, 4).
6.3.1 Design type A
Here, the factor 0.5 in the third summand takes into account
the type of transition from the skirt to the support ring as At each verification point n, the strength condition
shown in Fig. 1.
( n = p , q ) (18)
If the allowable stresses of vessels (fB) and/or of the support
skirt (f,) are less than that of the support ring (f,), the second has to be checked with M, being determined according to
and/or the third summand in equation (9) shall be reduced equation (8) and W, being determined according to equa-
with the respective ratio of the stresses fdfT and/or fz/fT. tion (9).
 P a g e 5 AD-Merkblatt S 3/l, Edition 05.99

6.3.2 Design types B and C the cut-out parameter is restricted to:

The total stresses on the inner (i) and outer (a) surfaces at
verification point n in section l-l are: F=6 (26)

@esIIll = u;“, - at” (a) + u: (p) (19i)

or, in the case of cut-outs where, 6 5 0.8 (i.e. there is an
a+ opening angle 5 90”) there is an additional safety factor
1na = ~3:” - a:, (a) - u! (p) (n = P, q)
(194
of 2 against the allowable stress f, with verification being
with the individual components in 6.1 and 6.2.2 or 6.1 and provided according to [I] using the cross-section values
6.2.3 for design types 6 or C. of the non-weakened cross section.

Accordingly, the total stresses in section 2-2 are:

Verification of slip resistance and safety
u L$f = c$m + a& (a) + c$ (p) (20i) against overturning (section 5-5)
ages = 0: - 4, (a) - 4 (1.4 (204 The section values in section 5-5 are used for verification of
2na
(n = P, q) the components of the skirt support.
and in section 3-3 the total stresses are:
8.1 Verification of slip resistance
ages
3n1 = u3; - a;, (21 i) The slip resistance may be verified according to DIN
18800 Part 1. Load cases with a high horizontal-to-vertical
uw = (214 load ratio are critical.
3na 4” + 4”
(n = P, q)
The strength condition in the case of ductile material be- 8.2 Anchor bolts
haviour is as follows:
Load cases that cause tensile stresses in the bolt are critical;
as a rule, the load case that results from minimum weight and
maximum tensile force due to the moment (verification point
p, generally in windward direction) is decisive. The force for
each anchor bolt is:
(S = 1, 2, 3; n = p, q; 0 = i, a)
1 ‘4
It shall be adhered to for all total stresses in accordance with fKp = y- D - 0 . 9 F5 . (27)
equations (19) to (21). i t i

Anchoring to ensure safety against overturning is necessary

7 Verification of stability of skirt support where FKp > 0.
(section 4-4) The anchor bolts shall be dimensioned in accordance with
AD-Merkblatt S 310.
The residual surface area A, and the section modulus W, of
the residual cross section shall be determined in section 4-4, In exceptional cases initial prestressing of the anchor bolt is
the cross section with the maximum strength due to maxi- higher than the service level loading. In such cases, substi-
mum section value and/or maximum weakening. With the tute the pre-stressing force in equation (33) to (35) for FKp.
section values F4 and iM, that are present in the area of this
section and the moment AM, = &F, that increases the stress The allowable anchor bolt forces may also be taken from DIN
due to the displacement of the centre of gravity, the stress 28082 Part 2 for the materials St 37 and St 52.
in the region of the opening is
8.3 Application of load in base ring
um -+M,+4 F4
--
4” - - A structural design with a single base ring which shall comply
W, A4
with DIN 28082 Part 1 is sufficient for load cases with a low
The strength condition: overturning moment. The verification of the design may be
Id&l fz (24) provided in accordance with 8.3.1.
shall be satisfied. For higher overturning moments, a design as defined in DIN
28082 Part 2 shall be provided. Verification of the base ring
For the sake of simplification, the strength can be reliablyver-
may be provided in accordance with 8.3.2.
ified using the cross-section values A’, and kY4 for the non-
weakened shell in the case of tubular-reinforced or unrein-
forced openings as long as the resulting stresses are cor- 8.3.1 Single base ring
rected by applying the efficiency factor V, in AD-Merkblatt 4
B 9 for nozzles on spherical shells, i.e. the following relations- Geometrical conditions
hip has to be satisfied:
gsl+b
++-$}l (25)
IaLl=/ j- 4 4 ] VA ISfz
(n = P, 9).

If a:, is a compressive stress, a stability verification shall be

carried out. If this verification is performed according to [3],
the allowable stress f used has to be reduced by 20%.
For the sake of simplification, the verification to [3] may be
omitted if the edge of the opening is reinforced by a nozzle
to prevent radial strain and either: Fig. 5. Single base ring for low-moment loading
 P a g e 6 AD-Merkblati S 3/l, Edition 05.99

The maximum concrete .compression is The thickness of the support plate or ring girder e, is:
1
a, = flh =
JC. Oz. b i
eD
The thickness of the base ring shall satisfy the following 2 FK~
(35)
requirements: 12 fD

where a, is to be taken from equation (28) and fkp is to be
taken from equation (27).
8.3.2 Base ring with brackets or double ring with webs
The maximum concrete compression a, from equation (28)
gives the necessary base ring thickness eR for T/l 5 3:
(32)
where K = 1.145 . Tll - 0.5.
Verification is carried out using equation (29) for T/l > 3.
The web-plate thickness ep has to satisfy the following requi-
rement :
In addition to the stress analysis in accordance with equation
(33), if necessary, verification of stability shall be carried out
based on 7.3 of AD-Merkblatt S 314 for the thickness ep of
1 the web plates.
-
The influence of the shear moment from FKp. k on the skirt 1. ;I
support shall be verified. For brackets, this can, for example, .c
be performed with reference to AD-Merkblatt S 314 (where
ap = k - ez12; NF = F,,). The double ring with webs can, for
example, be verified using corresponding ring supports
under n radial loads R, in accordance with [4] or [5]; where ‘.
._
R, = F,, k divided by [h - 0.5 . (e, + ea)].
._,
9 Bibliography -
[1] Deutscher AusschuB fur Stahlbau: Beulsicherheitsnach-
weise fur Schalen (German Structural Steel Engineering
Association: Verification of Safety against Buckling of
Shells) DASt-Directive 013, July 1980.
[2] Hinweise auf die Schalenbeulrichtlinie in: Mitteilungen
des IfBt (Guidance on Shell Buckling Directive) 4 (1981)
p. 116.
[3] Knodel, P., a. U. Schulz.: Zur Stabilitat von Schornsteinen
mit Fuchsoffnungen (Stability of Chimney Stacks with
Smoke Flue Openings). Stahlbau 57 (1988), Vol 1,
p. 13-21.
[4] Petersen, Chr.: Stahlbau. [Steel construction] Verlag
Friedrich Vieweg & Sohn, Braunschweig 1988.
[5] Stahlbau Handbuch Band 2. [Steel construction Manual
Vol. 21 Stahlbau Verlagsgesellschaff, Cologne 1985.

Geometrical conditions

1.5 %I
S-- s3
ez
5, ~3. e,

1.5 e, 53. ep

9 s-.b
:
t s 1.4 T

0.5 5 1.0

Fig. 6. Base-ring design for high-moment loading

ICS 23.020.30 Edition February 1998

AD-Merkblatt
Special Verification of load-carrying capacity for
cases horizontal vessels on saddle supports S 312

T h e AD-Merkbldtter a r e compi/ed b y t h e s e v e n a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “ A r b e i t s g e m e i n s c h a f t Druckbehtilter”

(AD), AD-Merkblatt G 7 covers the composition and application of AD-Regulations and a/so procedural guidelines.
T h e AD-Merkblatter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . I n t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt. it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e. V. (FDBR), Diisseldorf
Hauptverband der gewerb/ichen Berufsgenossenschaften e. V., Sankt Augustin
Verband der Chemischen Industfie e. V. (VU), Frankfurt/Main
Verband D e u t s c h e r M a s c h i n e n - und A n l a g e n b a u e . V . ( V D M A ) , F a c h g e m e i n s c h a f t V e r f a h r e n s t e c h n i s c h e M a s c h i n e n
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhijttenleute (VDEh), Dtisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroRkraftwerksbetreiber e.V., E s s e n
Verband der Technischen iiberwachungs-Vereine e.V. (VdTCiV), Essen.
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s l y b y t h e a b o v e associattons In k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents

1 Scope 5 Verification of cylinder load-carrying capacity

2 General in the saddle region
3 Symbols, units and sketches 6 Verification of the load-carrying capacity of the saddle
4 Verification of the load-carrying capacity 7 Literature
in the cylinder (general) 8 Diagrams

1 Scope positioned horizontal vessels with intermediate supports. For

such vessels, special calculations are required, e.g. in
1 .l This AD-Merkblatt is intended to provide strength calcu- accordance with [2].
lations for horizontal vessels supported on saddles, i.e.
- calculation of local stresses in the vessel wall at saddle
support regions 2 General
- calculation of cylindrical vessel acting as a beam over sup-
2.1 The basis for determining the allowable forces on the
ports
saddle is the calculation of the local limit load of a beam of
- calculation of load-carrying capacity of the saddle. rectangular cross-section cut from the shell in accordance
1 . 2 The verification of local stresses at the saddle support with [2] and [3]. For this section the allowable local bending
region is especially required for vessels stress asr shall be determined to limit the local bending stres-
- with e l D < 0.005 ses resulting from local membrane stresses and the degree
of utilization by the general membrane stresses.
- made of non-ferrous metals
- of large length to diameter ratios
2.2 The support reaction forces, transverse shear forces
- under high additional loads and moments shall be calculated for a circular beam simply
- with high btilization of vessel wall stresses due to internal supported over saddles.
pressure
- with included saddle angles < 120 2 . 3 For the calculation in accordance with this AD-Merk-
blatt the following requirements shall be met.
or in the case of vacuum.
1.3 The calculation of the vessel acting as a beam over sup- 2.3.1 Transitions from the saddle support to the vessel wall
ports is only required for the mid-span between supports if (location 3 in Figure 2) shall be smooth to avoid peak stres-
Wm.span ’ Msupport ses. This especially applies to unstiffened cylinders with
e/D < 0.005. In the case of rigid saddle design - especially
Regarding the design of saddles refer to [4]
at the horn of the saddle (e.g. concrete saddles) - this
1 . 4 This AD-Merkblatt shall only be applied in conjunction AD-Merkblatt shall not be used. For such a case the local
with AD-Merkblgtter B 0 and S 310. It does not apply to super- stresses may be calculated e.g. in accordance with [I].

Supersedes September 1995 edition; / = Amendments relating to previous edition

Carl Heymanns Verlag KG

Luxemburger Strak 449. 50939 Kbln
 Page 2 AD-Merkblatt S 3/2. Edition 2.98

2.3.2. Welds or nozzles adjacent to saddle supports shall Fi actual reaction force at saddle support i N
be avoided. The distance from the reinforcing plate weld to ~~ allowable axial force from stability
any nozzle weld shall be > 1 .l G, or to the next circum- condition N
ferential weld or next support or between longitudinal weld S total weight pertinent to the respective
and saddle horn shall be at least fi. This condition does load case N
not apply to the circumferential weld of the dished head. Here
the distance from reinforcing plate weld to head circumferen- K, to K t4 factors
tial weld shall be 2 3 . eb, but at least 50 mm. L length of cylinder including h, mm
resultant moment above support i Nmm
2.3.3 The equations given hereinafter apply if the following 2
conditions are met: I resultant transverse shear force above
support i N
60”s 6, 5 180”
elD 5 0.05 W section modulus mm3
e I e, % 1.5 e IP factor for width of support rad
for saddle supports with reinforcing plate 6
b3 2 0.1 D 1 included angle of saddle support degrees
I 62 included angle of saddle plate degrees
2 . 3 . 4 fv 2 f (see AD-Merkblatt S 3/O, Section 2.8)
stability factor for plate instability accord-
2 . 3 . 5 The densities of fluids contained and test fluids shall ing to equation (19)
be taken into account. factor for determining Fi in accordance
2 . 3 . 6 The saddle supports shall principally be welded to the with Figure 9
vessel. Where, for certain reasons, the saddle supports are ratio of local membrane stresses to local
not welded to the vessel (fabrication, assembly, high thermal bending stresses
expansions, dissimilar materials) it shall be ensured that the degree of utilization for shell due to
vessel is uniformly supported on the saddle. general membrane stresses at location i
2 . 3 . 7 Where thermal expansions are to be expected in lon- circumferential buckling strain
gitudinal direction, one saddle shall be designed as rigid sup- factor for distance to the outermost fibres
port and the other as loose support at the base to provide free at the bottom of the vessel
horizontal movement. Saddle supports being flexible in axial general membrane stress resulting from
direction may be designed as rigid supports if they are bending in longitudinal direction N/mm2
capable of withstanding the thermal expansions.
allowable bending stress N/mm2
3 Symbols, units and sketches partially included angle in accordance
with Figure 8 degrees
3.1 Notations
In addition to or deviating from the stipulations of AD-Merk- indices
blattitter 6 0 and S 3/O the following notations apply: b vessel head
a1 distance from saddle support to p plastic
adjacent end of parallel lengths of r ring stiffener
cylindrical part (Figure 2) m m
s saddle
a2 distance from neutral fibre of reinforcing
ring to vessel wall; see Table 3 m m v reinforcing plate
distance from saddle support to length A Section A - A
a3
of extended equivalent cylinder (Figure 1) m m
3.2 Sketches
4 axial width of saddle support (Figure 2) mm
width of reinforcing plate (Figure 2) m m The figures shown hereinafter are basic layout sketches only
bz
to illustrate the dimensions required for the design.
b3 width of reinforcing plate portion extend-
ing the saddle plate to Figure 2 m m
I be actual width of plate (Figure 6) m m 4 Verification of the load-carrying capacity
e, equivalent wall thickness mm in the cylinder (general)
e,t effective wall thickness calculated in
accordance with equation (11) mm 4.1 Approximate calculation of the load-carrying
capacity
I e2 thickness of saddle plate m m
f nominal design stress in vessel wall in For vessels supported on twin saddles in accordance with
accordance with AD-Merkblatt S 3/O N/mm’ support type A of Figure 1 the calculations according to
effective length of cylindrical wall accord- Sections 4.2 to 5 can be omitted if the following conditions
ing to Figure 2 mm are satisfied :
length of saddle support plate mm L 5 L,, (see Figure 3)
number of saddle supports P 10
allowable external pressure bar f z 130 N/mm*
radius from vessel axis to neutral fibre a, % 0.5 D
of support ring m m b, 2 1.1 V$%
t thickness of ring support welded to v 2 0.8
shell (Figure 2) mm
D internal diameter of cylindrical shell mm bz 2 KI, .D+ 1.5b, for saddle supports with
e, 2 e > reinforcing plate
FC? equivalent axial force from local
membrane stresses acting on support i in density of fluid contained % 1000 kg/m3
accordance with equation (6) N K,, see Section 5.2.2.1
 P a g e 3 A D - M e r k b l a t t S 312. Edition 2.98

A
Vessel resting on two symmetrically
placed saddle supports

B
Vessel resting on 3 or more symmetrically
placed saddle supports

C
(Example)
Vessel resting on supports not symmetrically
placed (except for A and B)

Fig. 1. Types of support

4.2 Actual forces and moments Mid-span moment

The actual support reaction forces F,, support moments M,
M=Mn/r,+F,.(~-a,)-4.(C+2h,)2
and transverse shear forces Q, above the saddles as well as 2 2 2 3
the mid-span bending moments between the supports shall Support type 6:
be determined on a beam with circular cross-section (see
Figure 4). This can be done by means of the asymptotic solu- Support moment
tions and/or in accordance with the rules of structural mecha- M = max(q,lf/8;q.a$/2- M , } i = 1,n
nics. ’ i q.lTl8 i=2...n-1
The load is found to be
Transverse shear force
G
4= Qi = F, I 2
L+$h,
Mid-span moment not governing
Support type C:
The support moments, transverse shear forces and mid-
4.2.1 Support reaction forces span moments shall be determined in accordance with the
For support types A and B (see Figure 1): rules of structural mechanics.
w, G 4.3 Verification at mid-span between supports
F, = n
The following verifications for mid-span moments between
1 .O for n = 2 vessel supports are only required if
(II, =
according to Fig. 9 for 3 5 n 5 8
I ‘hid-span 1’ 1Msupport 1.
For the support type C the support reaction forces shall be
determined according to the rules of structural mechanics. 4.3.1 Vessels subject or not subject to internal
pressure
4.2.2 Moments and transverse shear forces Proof of strength
The moments shall be determined above the supports as well pD+ 4 I ‘%,d-span 1 64 < f
as the moments at mid-span between the supports. 40 . e v .z.Dz.e.v - (1)
Support type A: VSl if circumferential weld is located at point of
Support moment calculation
V,Y5V%l in accordance with AD-Merkblatt B 9 if an
opening is located at point of calculation
K 14 see Section 8
Transverse shear force The proof of stability for the pressurized section shall be
Q, = (L - 2a,) / (L + 4. h2) . F, made in accordance with_.I.51 or I61 with
-_ p = 0
P a g e 4 AD-Merkblatt S 3/2, Edition 2.98

plate

a) Support region. Cylindrical shell not stiffened by rings

(illustrated with reinforcing plate; also valid without reinforcing plate)

b) Support region: Cylindrical shell stiffened by rings

Fig. 2. Saddle designs

4.3.2 Vessels subject to external pressure Fl s min { bdmi F3,adrn >

Proof of stability shall only be made for the pressurized sec- where
tion of the vessel under combined loading in accordance with F2 adm admissible support reaction force resulting from
[51 or P31. loading in longitudinal direction (Location 2 in
Figure 2) in accordance with equation (3)
F 3,adm admissible support reaction force resulting from
loading in circumferential direction (Location 3 in
5 Verification of cylinder load-carrying Figure 2) in accordance with equation (4)
capacity in the saddle region
To determine the F,,adm the following parameters shall be
it shall be demonstrated that calculated:
 P a g e 5 AD-Merkblati S 312. Edition 2.98

20 28
i I I I I I I I i I I I II II km.
mm

22

201 / 20

18 18

16 16

1L 1L

12 12

10 10

a 0

6 6
c

2
0
LOO a00 1ZCE 1600 2000 2Lcc 2800 3200 LOO 800 1200 1600 2000 2100 2aoo 3200 Dulmrn
ommm
6,=120"
6, = 90 -

Vessel without reinforcing plate

- - - Vessel with reinforcing plate

Fig. 3. L,,, for vessel on twin saddles

Fig. 4. Beam model for calculation

5.1 Allowable bending stress 5.2 Verification of load-carrying capacity without stif-
The allowable local bending stress asr shall be calculated in fening rings
accordance with equation (2): The limit load shall be determined at location 2 (longitudinal
K,.f.S direction) and location 3 (circumferential direction) of the sup-
ugr = ___ (2) port region shown in Figure 2.
K2

K = 1.2 for the service condition with S = 1.5

2 5.2.1 Cylindrical shell without reinforcing plate
1 .O for the test and assembly conditions with S’ = 1 .l
5.2.1.1 Proof of strength
K, = Coefficient depending on 6, and a2 according to clause
521.1
F 2 , a d m = 0.7 ffgr;2. aiT& (3)
3 5

I
with K, Z 0 f o r )I ? , , f 0 :

F3 , a d m= 0.9 ' ugr;,. m K, . K" . K (4)

9 10
K, = (l+33yfi2) [* Jm-j

act. to equation (2) and Table 1.

for 6, = 0 : Here K, shall be calculated with the
agr;z
quantities 17, and 19~ to Table 1.
1.5 (1 -IYz2) and That value for L?$ (&, , or 19~. 2)
ogr;3 shall be taken which leads to
If iY2 < 0, then 19~ = 1tY2 1and the sign of 19, shall be reversed. the smallest value of as,.
The service and test condition, the pressureless condition
with filling as well as the given assembly and special condi- 4 Mi
urn, =
tions each shall be verified by way of calculation. I ,T.D2.e I
Page 6 A D - M e r k b l a t t S 3/2, E d i t i o n 2 . 9 8

Location 61 t?2. 1 6 2. 2

0.23 . K6 . KS K2 - @
2 - fflm
.
s. f 4 0 e - %x
.K,
S.f
KS . Kz i

0.53 . K4 P,D
-.- K2
3 0
K, . KS . Klo. sin (0.5 6,) 20e S.f

Table 1. I$, fi2,, and fi2,2 values for determining usl, 2 and u,,,~ as a function of K, and K2
K2, S as in equation (2)
K3, K4, Klo effect of width of support b,
4, KG K, effect of included angle 6,
KB> Kg effect of distance to outermost fibres at vessel bottom a,

Factors for 1.5 operational weight

- distance to outermost fibres at the vessel bottom and y = 1.3 test condition
y = 2,83 .2 . E 1 .15 assembly, special conditions.
$
- width of support 5.2.2 Cylindrical shells with reinforcing plate
5.2.2.1 Simplified strength calculation
p = 0,91 . b,
5G If the condition
2,718282-f . sin,B b2>K,,.D+1.5b,
K, = max ; 0,25
B is met, the verification shall be made according to equa-
tion (8).
1 -2,718282-p. cos/!I Fi 5 1.5 min {F~.~dk F3.adm) (8)
K, =
P F ‘=wm
2,admy according to Section 5.2.1.1
K = 1,15 -0,1432 8, 5
5
sin (0,5 6,)
K,, =
max 1,7 - __ 1 0
231 & The proof of stability shall be made in accordance with clause
n I
K, = 5.2.1.2 in which case the thickness of the reinforcing plate
sin (0,5 6,) shall not be considered.
K,= 1,45 - 0,43 8,
5.2.2.2 Proof of strength
srn (0,5 6,)
If the condition according to equation (8) has not been met,
K, = min 130 ; 098 v/;;+6y the verifications shall be made according to clause 5.2.1 .l
for the following two cases:
8,
(1) The reinforcing plate shall be considered to be a support
K, = l- plate with the width b2 and the included angle S2. In all
equations and figures b, shall be replaced by bp, and 6,
by a2. e is the wall thickness of the shell, the thickness
of the reinforcing plate shall not be considered.
(2) The reinforcing plate shall be considered as reinforce-
ment of the vessel wall. In all equations and figures e
5.2.1.2 Proof of stability shall be replaced by the equivalent wall thickness
With equation (6) I 2

e, = e. 1+ ;
Fe = F, . $ %. K, . K,
J (6) J (1
The proof of stability shall be made in accordance with clause
the following shall be verified
5.2.1.2 in which case the reinforcing plate thickness shall not
be considered.
(7)
5.3 Verification of load-carrying capacity with
stiffening ring
For p > 0 then p = 0 shall be taken
5.3.1 For vessel wall
This proof of interaction may be made in accordance with [5] 5.3.1.1 Subject or not subject to gauge pressure
or [6]. Then, according to [6] , Section 2.2.4.1 - Proof of strength
P.D + umx 5 f
- (9)
40 e
I: ax ;t(D
= 4Mi + <,(DF;.e) e a,, according to clause 5.2.1.1, equation (5).
+ e)2e
 P a g e 7 AD-Merkblatt S 3/2, Edition 2.98

- Proof of stability according to Table 2

According to clause 5.2.1.2 with p = 0 and Fe = 0. V weld efficiency of welded joint on ring

5.3.1.2 Under vacuum (11)

The verification shall be made according to clause 5.2.1.2
with Fe = 0 l,=t+4G (12)
5.3.2 Verification of stiffening ring with t = { t, te, b, } from Table 3 where for f the respective
It shall be demonstrated that I value of t, t, or b, shall be taken.
Where sections are used that are not shown in Table 3, M,
F, 5 K12.4. v (10) shall be determined by means of equation (13).
0.5 D i: a2
(+) external rings M, = W, f, (13)
t-1 internal rings W, = plastic section modulus of cross-sectional area of the
4 allowable bending moment from limit load to Table 3 section to include the area 1,. e,.The neutral axis to
with L, in accordance with equation (12) and e,, in determine a2 separates the total area into two portions
accordance with equation (11) of equal magnitude.

t6 (h-a2j2 i t6 a; + ( 2 h - 2 a 2 i f,) be “,

2 t6 h + b4 f,-i, eef

Table 3. Cross-sectional dimensions of stiffening rings

P a g e 8 AD-Merkblatt S 3/2, Edition 2.98

42

I 60” I
20

28

I 180” I 103 I
Table 2. Factor Klz

Support plate

I I- Normal shape
Web plate
II- Shape for high
axial loads
Design A

II

I b)
I I
Design B

II b)
,
i 1

Fig. 5. Forms of saddle support

 P a g e 9 AD-Merkblatt S 312, Edition 2.98

6 Verification of the load-carrying capacity 6.1.2 Bending of saddle support

of the saddle For support type B the proof may be omitted.
Principally the allowable forces are derived from the limit load
of the vessel wall (see Section 5). The equations in Section 6 (1‘3
are approximate equations giving conservative results. They
refer to saddle types A I; reference is made in the pertinent Iw,= mrnrmum
” section modulus in Section A - A
sections to the particularities of the other saddle types.

6.1 qllowable forces on the saddle

The verification is made according to equation (14).
Fi s min { F4,adrn; kadrn; FG.adrn > (14)
F+a,,“, stability of web plate act. to equation (15)
F 5,adm bending of saddle act. to equation (16) Section A - A

16i.adm bending of saddle plate act. to equation (17)

6.1.1 Stability of web plate
Forthe support types A II and 6 II the proof may be omitted.
F 4. adm = l2 ’ es ’ fS ’ q (15)

Fig. 8. Bending of saddle support

I 6.13 Bending of saddle plate

f, ’ 103
Es = E, 1.4 f, . D es . sin (0.5 6,)
b, [I71
2 fs . 6, e2 . sin (0.5 6,)
1st term = bending of web plate
2nd term = tensile stress of shell
If 6 > FG.adm this does not mean that the limit load of the
saddle support is obtained because in that case yielding of
I the saddle plate will effect a redistribution of the forces
directly on the web plate. Section 5, however, assumes that
6 5 FS.adm.

Fig. 6.
7 Literature
[II British Standard 5500: ,,Specification for unfired fusion
welded pressure vessels - Appendices A and G”.
ElE British Standards Institution.
3P /=I f ; l/r i PI Richtlinienkatalog Festigkeit RKF, Teil3, BR B 2: ,,Behal-
63 ter auf Sattellagern, 3rd edition 1981.
Linde-KCA-Dresden GmbH.
2P
-!--be ,/ I31 TGL 32903/l 7, edition June 1982: ,,Behalter und Appa-
rate. Festigkeitsberechnung, Schalen bei Belastung
/ durch Tragelemente”.
'P
I41 DIN 28080, edition January 1986: Saddle supports for
horizontal vessels“.

0 [51 DIN 18800 Parts l-4, November 1990: Steel construc-

be tions”.
0 02 Of 016 'P
T ISI DASt Guideline 013, edition July 1980; ,,Beulsicherheits-
Fig. 7. Factor K13 nachweise fur Schalen”.
Page 10 AD-Merkblatl S 3/2, Edition 2.98

8 Diagrams

i i :I I I ! i I
I

0 OJ q2 0,3 03 0,s 0x6 07 008 9* ‘0

Factor K,

I I I I

II (
221 ( 2x1 (2.6) (28) (3.0) (3.2) (3,4 (3.6) (LPI

Factors KS, K4
 Page 11 AD-Merkblatt S 312, Edition 2.98

Z?
‘18
V
‘3
‘,I
VJ
I I Ill\1
OB K7
016
03
O?
0
60 90 la0 150 6, [“I 180
Factors KS, K6, K7

0 q1 0,2 Y o,L

Factor K8

‘P
Kg
o!J
087
‘45

0,5
0:
0,3
02
OJ
0

Factor Kg
Page 12 AD-Merkblatl S 312, Edition 2.98

O?

II I I I Ill I I I
4
0,15 432 0,25 083 0,35 o&L5
-ii-
Factor K,,

2u 50 r 100 xl0 !m D2oaY

e
Factor K,,
 Page 13 AD-Merkblatt S 3/2. Edition 2.98

15
D
44
-=I
e
1.L
1000
600

0.9
1

Factor&,

z = 1 . 6 - 0 . 2 0 9 2 4 ( x - 1 ) + 0 . 0 2 8 7 0 2 x ( x - 1 ) + 0 . 4 7 9 5 . 1 0 - S y ( x - l ) - 0 . 2 3 9 1 l o -x6y ( x - I)-

0.29936 . 1W . (x - 1) x2 - 0.85692 . lo-6 (x - 1) y2 + 0.88174 . 1W x2 (x - 1) y -

0.75955 . 1W y2 (x - 1) x + 0.82748 . lo" . (x - 1) x3+ 0.48168 . 10-g (x - 1) y3

y=+ ,=L K,4 = max { 2;l.O }

D

E q u a t i o n st o d e t e r m i n e K,,

I I I I I I I I I 1 I I I I I I
1 I I n-3 I I I In-2 I I I rip51 I

‘12
‘P
OP I I I I I/l I I
\,’ -
/ /
W / /

0.c .~ ._.- ---..-- .--. -- _-.

n 96 n -7 r-8
012
0
0 o,l 0,2 0,3 0,c 0 q1 q2 q3 0,c 0 Od 42 q3 Ok q5
a3
T
Fig.9. Factor w,
ICS 23.020.3 Edition May 1999

General verification of stability AD-Merkblatt

Special for pressure vessels
cases s 313
Vessels with domed ends on feet

The AD-MerkblBtter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
behdlter” (AD). AD-Merkblatt G 1 covers the composition and application of AD-Regulatjons and also procedural rules.
The AD-Merkblatter cover safety requirements which shall be adopted for normal conditions of operation. In the event of stresses over
and above the normal /eve/ being anticipated during the operation ofpressure vessels, allowance shall be made for such stresses by meet-
ing special requirements.
Should there be any departures from the provisions of this AD-Merkblatt, it shall be possible to demonstrate that the safety standards embo-
diedin t h e s e r e g u l a t i o n s h a v e b e e n o b s e r v e d b y a l t e r n a t i v e m e a n s , e . g . tesffng o f m a t e r i a l s , t r i a l s , s t r e s s a n a l y s i s , o p e r a t i n g e x p e r i e n c e .
fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e. V. (FDBR), Dijsseldoi?
Hauptverband der gewerblichen Berufsgenossenschaften e V., Sanki Augustin
Verband der Chemischen lndustrie e. V. (VCI), Frankfurt/Ma/n
Verband Deutscher Maschinen- und Anfagenbau e. V. (VDMA), Fachgemeinschafl Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Diisseldorf
VGB J e c h n i s c h e V e r e i n i g u n g d e r GroBkraftwerksbetreiber e. V , Essen
Verband der Jechnischen iiberwachungs-Verelne e. V. (VdJtiVj, Essen.
The AD-MerkblBtter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s in keeping with technical progress. Relevant proposals should
be addressed to the publisher:
Verband der Technischen iiberwachungs- Vereine e. V., P. 0. Box 103834, D-45038 Essen.

Contents
1 Scope 5 Connection between domed end and support feet
2 General 6 Design of support foot
7 Bibliography
3 Symbols and units
Appendix 1: Formulae for the section forces and section
4 Loads moments in a spherical shell

1 Scope Appropriate measures have to be taken to ensure uniform

support by all feet (see 4.4 of AD-Merkblatt S 310). This app-
This AD-Merkblatt is be used for the design of domed ends lies especially if the behaviour of the material of which the
of pressure vessels subject to local loads due to tubular ves-
sel feet (see Fig. la) uniformly spaced on a pitch circle
0.7 5 dFiD, < 0.8 as well as for the design of the vessel feet
including the base plates themselves.
With the above preconditions, the calculation is valid within
the limit e/R, > 0.003 in order to exclude the possibility of
stability failure. No account is taken of forces due to inclina-
tion of the vessel. Verification of stability for the end and all
components of the foot structure has to be provided for all
relevant load cases in accordance with 4.3 of AD-Merkblatt
S 3/O. A simplified limit load method is used as a dimension-
ing criterion for thin-walled spherical shells with local points
where the load is introduced.

2 Genera!
This AD-Merkblatt is to be used only in conjunction with AD-
Merkblatt S 3/O.
The selection of foot dimensions and the arrangement of the
feet shall preferably be according to DIN 28081. In the case
of small stresses (see 5.1), reinforcement plates on the end
need not be provided.
Vessel feet in the outer knuckle area of domed ends and on
the cylindrical shell cannot be calculated using this AD-
Merkblatt. They shall be dimensioned according to other sui-
table methods (e.g. DIN 28081 Part 4). Fig. la. Domed end on feet

Supersedes Edition of February 1995; ( = Amendments to previous edition

-
GXl neymanns vermg KC,
.-
Translation: Technical Help to Exporters Service of BSI
Luxemburger StraOe 449, 50939 KBln
Page 2 AD-Merkblatt S 3/3, Edition 05.99

end is made is not ductile or if the strain is limited, moment at the fixing point at the surface of the foundation is
e.g. due to coating. calculated as follows:
The design, suitable for welding, is based on DIN 8558 MF = FF. hF, (1)
Part 2. where it is assumed that the total horizontal load F,, is
uniformly transmitted by all the feet involved.
3 Symbols and units
(2)
The following symbols and units apply in addition to those in
AD-Merkblatt B 0:
a External surface of shell, i.e. side facing 5 Connection between domed end and
away from axis of symmetry (Fig. la) - support feet
b In this context: Spacing of
5.1 Domed end
anchor bolts in mm
Thickness of end without allowance in mm The maximum loads Nrd as specified in 4.4 of AD-Merkblatt
e
S 3/O are increased by 15% in order to take into account
f Permissible stress bending effects due to the non-radial introduction of loads.
(see to AD-Merkblatt S 3/O) in N/mm2 This gives a resulting substitute foot load
i Internal surface of shell, i.e. side
facing towards axis of symmetry F = 1,15.NFd (3)
(Fig. la) This shall be inserted in Figure 2 for determining the dimensi-
1 Length of base plate in mm onless section forces and moments (N, . e/F), (NY. e/F),
m In this context: Eccentrity in mm (M, . e/F) and (MY. e/F), as a function of the shape factor
ns Number of bolts per foot -
- U= q+e (4)
9 In this context: Auxiliary quantity
r. Substitute radius in mm
and in table 1.
ii Length of projection of base plate in mm
Z In this context: limit load factor The substitute radius in this equation is given by r, = &$.
A Cross-sectional area in mm2
FV Force relative to axis of symmetry in N For vessel feet without a reinforcement plate, make Dv equal
M Section moment in Nmm or to OF.
Nmmimm The formulae given in Appendix 1 may be used instead of
N In this context: Section force in N/mm Fig. 2.

r
or N
In this context: Average radius of
the crown in mm
u Auxiliary quantity -
W Bending section modulus in mm3
a In this context: Auxiliary quantity -

Indices
b - Bending proportion
d - Compressive load relative to support foot
h - Horizontal
m - Membrane proportion
X - In x-direction
&
y - In y-direction
Z - Tensile load relative to support foot FF
B - Concrete
F - Foot I ::
I NFz ) ‘Fd
K - Anchor bolt
P - Foot plate
V - Reinforcement plate

4 Loads
The prevailing total vertical force per foot NF is calculated at
the level of the joint between the domed end and the support
foot from all the horizontal and vertical loads in accordance
with the load case under consideration (see Fig. 1 b) as
defined in 4.2 of AD-Merkblatt S 3/O.
Each support foot is subjected to an additional bending load
by the horizontal load FF. The resulting maximum bending Fig. lb. Foot geometry and load quantities
 P a g e 3 AD-Merkblatt S 313, Edition 05.99

The stress due to the internal pressure that is present at the 6.2 Loading of anchor bolts
joint between-the foot and end in the load case under consi-
deration is to be superimposed according to Table 1. The tensile force for one bolt Fk is calculated for a circular
and square base plate as follows:

Table 1. Calculation procedure 4. MF

Circular: fK = !YL. t -
-A ,ls . “t
(9)
“S
No. Stresses (N/mm*) Internal External
j with n, 5 4
1 ump = R~.P/(20.8) +
N \!‘I? ’ MF
s q u a r e : FK=T+ 2.(1-2.D) (10)

(4 bolts)
The anchor bolts shall be dimensioned in accordance with
4.3.2.3 and 4.3.4.3 of AD-Merkblatt S 3/O.

6.3 Thickness of base plate

The dimensions of the base plate are determined by the
loads and the concrete compression that occurs.

6.3.1 Simplified verification

The application of 6.3.2 with the exception of equation (24)
can be dispensed with, if within the “radiation area”

A = 5, (DF+ 2.ep)2-(DF-2.eF-2’ep)2
i (11)
4

the compression caused by the normal force and the moment

14 (U, + ub)“*“, = 1s 2 f F ‘!.I%$
OB = x + A (D, - eF)
For lined vessels, allowance is to be made for the ductility of
the lining material. does not exceed the permissible concrete compression.

In this case the conditions

5.2 Reinforcement plate
DF + 2. ep 5 Dp or 5 1 (13)
The required plate thickness is given by the inequation:
for circular ring plates and/or for square plates and
1.0.e I e, = a. - NFd
,.3.f”5’.5~e (5) ep 2 e3 in accordance with equation (24) shall be met. (14)

where e shall, if appropriate, be increased so that the 6.3.2 Verification using the circular plate theory
inequation is satisfied.
The maximum bending moments that are decisive for dimen-
sioning are determined according to circular plate theory
The factor a depends on the ratio DJDF and is given by:
assuming that the region of the plates outside the support
foot is a cantilever plate strip.
a=2.+-0.543. (6)
F
Concrete compression:
This equation is valid within the limits 1.25 I 2 i 1.5. The concrete compression that occurs is calculated for a
F
circular and square base plate as follows:

6 Design of support foot Circular plate: oB = t..:i .(I++

P
6.1 Verifi&tion of stress and stability
6.rn.n
General verification of stress is provided as follows: Square plate: a, = +. 1 + I
!

(W Eccentricity: m = F (17)
Fd

ki 4 . MF
9 = +
x’eF’(DF-eF) 2-r. eF . (DF - eF)2 Square plate:
Required plate thickness ep = (e,, e2, e,) max. (18)
Verification of stability may be provided in accordance with
j DIN 18800 Part 2; it may be omitted if the following condition
External: e, = 0.5 . \\T2 . I -DF j . 7 (19)
is satisfied: v--

N, < 0.22 . EF . IF
h2 Internal: e2 = 1.11 . (9). *
F
P a g e 4 AD-Merkblatt S 3/3, Edition 05.99

Circular plate: 7 Bibliography

Required plate thickness ep = (e,, e2, e3) max. (*l) [l] Wichmann, K. R., A. G. Hopper a. J. L. Mershon: Local
Stresses in Spherical and Cylindrical Shells due to
External: e, = (v).iw (22) External Loadings. WRC Bulletin 107 (Rev. March 1979).
Editor C. F. Larson, New York.
[2] Timoshenko, S., a. S. Woinowsky-Krieger: Theory of
Internal: ep = 1.11 (23) Plates and Shells. McGraw-Hill, 2nd Edition, 1959.

Lift-up case:
F
e3 = 1.71 . f (2.4)
fP
 P a g e 5 AD-Merkblatl S 3/3, Edition 05.99

4 My
-.- e
N,. -$ ; NY.?
F ’ F F
10 -10
6
6

IlIIIllI
11111111111111 IIIIIIII
2 I I 1 I
I I I

1,o -1.0
006
‘336

0,4

02

0.1
tiiiiiiiiiiiiiiiit
0,06

I I , Illllllllllr Iilll

O,WZ-----------------------------------------------~-

0.001 0,001
0,0006

tiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii ii ii
I
0,0002 , . 1
IIIIIII II-
tiiiiiiiiiiil
O.oool L-
0 0.5 1.0 1,5 24 2.5
0.0001

r0

YqT

Fig. 2. Section forces N,, N, and section moments M,, M, in a spherical shell caused by a radial force F
(corresponding to Fig. SR-2 in [l]).
P a g e 6 A D - M e r k b l a t t S 3/3, E d i t i o n 0 5 . 9 9

Appendix 1 to AD-Merkblatt S 3/3

Formulae for the section forces and section range. The datum points have closer spacing at the extremi-
moments in a spherical shell caused by a ties of the range than in the centre. An even and adequate
radial force Fin accordance with Fig. 2 accuracy is therefore provided over the whole of the range
of the function by a polynomial of the 7th degree in T.
Function values are plotted logarithmically in Fig. 2 of AD-
Merkblatt S 3/3. For this reason, only a logarithmical function The function values @ are given by:
can be considered for representing the curves mathemati-
cally. r$ = lO@
A linear transformation has been carried out for the abscissa i=7
U: T = -1.095238095 + 0.952380952 U. The functions where A , = 1 a , . T '
given are valid for the range 0.10 2 U 1 2.20. In the I=0
transformed region, this corresponds to -1.00 2 T
z + 1 .OO. The functions should not be used outside this The function values a , are given in Table 1.

Table 1. Function values a. for AD-Merkblatt S 3/3 Fio. 2 and WRCB. Fia. SF?-2

ai T’ 4 T’ ai . T’ ai T’

- I,253591 954 - 1,547 988505 - 1,733477011 - 2,067 959 770

- 0 , 5 0 0 7 4 3 2 9 2 .T -0,556978513. T - 0,565479303. T - 0,539315607. T
+0,202 885672 p + 0,237166411 p + 0,227 666485 p + 0,327914948. p
- 0,244594962. p - 0,349080831 73 - 0,062 135964 p - 0,562600476. p
- 0,154634027. T4 - 0,118395784. T4 - 0,049 666 123 T4 - 0,290641394. T4
+ 0,401018423. p + 0,542020509 ’ P - 0,106841035. p + 0,933201262 fl
+ 0,104621919. T6 + 0,180079948 T6 + 0,062229523. T6 + 0,327094263. T6
-0,213151433. T' - 0 , 3 9 4 5 8 1 8 5 4 .T ' + 0,057 444808 T' - 0,646227707. T'

i=7
A,= cai. T i
I=0
T = - 1 , 0 9 5 2 3 8 0 9 5 + 0 , 9 5 2 3 8 0 9 5 2. l J

-1.00 5 T I + 1.00
ICS 23.020.30 Edition May 1999

General verification of stability AD-Merkblatt

Special
for pressure vessels
cases
s 3/4
Vessels with support brackets

The AD-Merkblstter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschafi Druck-
behdlter” (AD). AD-Merkblatt G 7 covers the composition and application of AD-Regulations and a/so procedural guidelines.
T h e AD-MerkbWter c o v e r s a f e t y r e q u i r e m e n t s w h i c h s h a l l b e a d o p t e d f o r n o r m a l conditions o f o p e r a t i o n . In the event of stresses over
and above the normal /eve/ being anticipated during the operation of pressure vessels, allowance shall be made for such stresses by meet-
ing special requirements.
Should there be any departures from the provisions of this AD-Merkblatt, it shall be possible to demonstrate that the safety standards embo-
d i e d i n t h e s e r e g u l a t i o n s h a v e b e e n o b s e r v e d b y a l t e r n a t i v e m e a n s , e.g. testing o f m a t e r i a l s , t r i a l s , s t r e s s a n a l y s i s , o p e r a t i n g e x p e r i e n c e .
fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e. V. (FDBR), Dtisseldorf
H a u p t v e r b a n d d e r g e w e r b l i c h e n B e r u f s g e n o s s e n s c h a f t e n e . V . , S a n k t Augustin
Verband der Chemischen lndustrie e. V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhijttenleute (VDEh), Dijsseldori
VGEI Technische Vereinigung der GroBkraMverksbetreiber e.V., Essen
Verband d e r T e c h n i s c h e n iiberwachungs-Vereine e . V . (VdTiiV), Essen.
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iibetwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents

1 Scope 6 Verification of pressure vessel wall

2 General 7 Verification of support brackets
8 Bibliography
3 Symbols and units
Appendix 1: Formulae for the section forces and
4 Designations section moments in a cylindrical shell
5 Load Appendix 2: Explanatory remarks

1 Scope In the case of a design having a reinforcement plate, the joint

between the reinforcement plate and wall of the vessel shall
This AD-Merkblatt may be used to provide verification for ver- be executed as a complete-penetration fillet weld having a
tical, cylindrical vessels on support brackets. Verification is thickness of at least 0.7. e. Verification of such a weld is not
carried out separately for the local additional stress in the necessary.
pressure-vessel wall in the region of the support bracket and
for the support bracket itself. Verification of welds may be dispensed with if they are com-
plete-penetration welds or if, in the case of double-sided fillet
Substantial increases in stress within the meaning of 4.5 of welds, the thickness of both fillet welds is at least 0.7 times
AD-Merkblatt B 0 are to be expected in the region of the brak- the smallest wall thickness involved.
kets, particularly in the case of thin-walled vessels (e/D,
< 0.005) and in the case of high bracket forces due to large It is assumed that the horizontal forces exerted on the
filling or additional weights, wind in the case of very slim ves- brackets due to wind and transverse acceleration are so
sels (HID, > 5) as well as high transverse accelerations. small that the resulting stress may be ignored.
The calculation is valid for values e/D, 2 0.003. Outside this
range, special investigations taking into account stability are
to be performed, e.g. according to [6]. 3 Symbols and units
The use of this AD-Merkblatt assumes that the edges of the
reinforcement plates are located at least I,‘= from the The definitions in AD-Merkblatt B 0 are supplemented by:
ends of the cylinder. ab Spacing of web plates (cf. Fig. 1) in mm
a, Eccentricity of perpendicular force in
web plate (cf. Fig. 6) in mm
2 General Eccentricity of load application into
aP
This AD-Merkblatt is to be used only in conjunction with cylinder wall (cf. Fig. 1) in mm
AD-Merkblatt S 310. a, Eccentricity of load application into
The support brackets shall be designed according to DIN web plate (cf. Fig. 6) in mm
28083 Part 1 or be based closely on it. ba Width of support plate (cf. Fig. 1) in mm

Supersedes Edition of December 1996; ] = Amendments to previous edition

Lari neymanns vermg Kb Translation: Technical Help to Exporters Service of BSI

Luxemburger StraBe 449. 50939 K6ln
:.. ^.

Page 2 AD-Merkblatt S 314, Edition 05.99

bs Width of substitute web plate (cf. Fig. 6) in mm 5 Load

bv Width of reinforcement plate (cf. Fig. 1) in mm Taking into account the load cases specified by the
Plate thicknesses without allowances: customer in accordance with 4 of AD-Merkblatt S 3/Q verifica-
e Cylinder wall thickness without allowances in mm tions are to be carried out with the bracket force that causes
e, Thickness of support plate (cf. Fig. 1) in mm the maximum stress in the component under consideration.
es Thickness of web plate (cf. Fig. 1) in mm For calculation of the bracket force NF, see 4.4 of AD-Merk-
e, Thickness of reinforcement plate (cf. Fig. 1) in mm blatt S 3/O.
h, Height of bracket (cf. Fig. 1) in mm
hv Height of reinforcement plate (cf. Fig. 1) in mm
k Auxiliary quantity
1s Length of substitute web plate (cf. Fig. 6) in mm
- 6 Verification of pressure vessel wall
n, Number of webs per support bracket
4 Depth of bracket (cf. Fig. 1) in mm The pressure vessel is loaded in the region of a support
Auxiliary quantity - bracket by the load moment
CL

c!J Plate dimensioning value

ML = NF . ap (1)
FS Anchor-boltforce in N
H Height of vessel in mm and internal pressure pges as specified in 4 of AD-Merkblatt
Auxiliary quantity - B 0.
KL
M Section moment in Nmm
in Nmm The coefficients
ML Load moment
N Section force in N p= w-z
in N (2)
NF Bracket force 2 Rnl
NS Perpendicular force in web plate
(cf. Fig. 6) in N y=+
Ril Average radius of the cylinder in mm
Inclination angle of web in ’ shall first be formed.
p” Coefficient
Finally, the auxiliary quantities C,, Cb, K,, and KLx have to
a Auxiliary quantity be determined from Table 1 as a function of h,lb, and yand:
Coefficient
x Slenderness ratio hq = B . K, (4)
Indices (5)
LL=8.KLX
a Support plate
b Bending proportion for stresses have to be calculated.
d Compression The dimensionless section forces and moments
m Membrane proportion for stresses (N, . R; . p/M,), (N, . R&. p/ML), (M+ . R, . /.$.,+/Ma and
S Web (M, . R, . &./ML) are taken from Figs. 2 to 5 and applied to
V Reinforcement plate the calculation procedure according to Table 2 (example for
X In longitudinal direction a load case). The equations in Appendix 1 may be used
Tension instead of Figs. 2 and 5.
1: Concrete
V Comparative-
+ In circumferential direction

4 Designations
Table 1. Auxiliary quantities C,, CLx, KL,+ and KLx as a
Reinforcement plate function of h,lb, and y

Fig. 1. Cylinder with support brackets

 P a g e 3 AD-Merkbiatt S 3/4, Edition 05.99

Table 2. Calculation procedure where C, = 0.5 for dimensions similar to DIN 28083 Part 1
and C, = 0.71 for other dimensions.
I-
If the bracket is anchored for the tensile force A&, the follow-
NO. Stresses (N/mmz)
ing condition also applies to the thickness of the support
plate:
l ump@ = R, . p/(10 . e) A=B +

2 ompw = R, . p/(20 . e) A=B + e, 2 0,72 (8)

where d, = hole diameter.

7.2 Anchor bolts

If anchoring in accordance with 4.4 of AD-Merkblatt S 310 is
necessary, the stress verification of the anchor shall be
carried out in accordance with 4.3.2.3 and 4.3.4.3 of
AD-Merkblatt S 310 using

A F = max
6 umx = ompx + Cnx
B
! , I
f, = prestress of bolt
n = number of bolts per bracket

7.3 Webs of support bracket

For the verifications, the web is idealised as a 1, long and b,
wide rectangular plate that is inclined at an angle a with
respect to the horizontal plane (Fig. 6). The straight line
through points 1 and 2 is defined as a datum line. The angle
u IS the enclosed angle between the datum line and the hori-
zontal plane. Width b, is the smaller of the values of the
distances between points 3 and 4 relative to the datum line.

A A i-7
1 1 UX = u,,+ubx
B
A
12 (Jges v =J u;+u; -U,$‘Ux B
1 I

A
1 3 q+
B

14 z = 1,5-0,5.q’ NF NS
Ns b
-L!b
15 zutu@/ = 1,5 .z, f

I
For lined vessels, allowance is to be made for the ductility of
the lining material. Fig. 6. Web of support bracket

With n, webs per support bracket, in each substitute web

plate a perpendicular force that acts eccentrically at

7 Verification of support brackets a, = a, . sin u (9)

7.1 Support plate of support bracket N, = -!%.- (10)
n, . sin c(
The support plate is to be designed and, if applicable, stif-
fened to prevent any unacceptable bending stress occurring. is generated.
The greatest stress at the free edge of the web plate is given
1 With maximum unit soil load
by:
3 . NF
a6 = b, . i: (6) rnaxu=--$+~+6.~)5f, (11)
whose value depends on the clearance ap the neccessaty In addition to verification of stress, a verification of stability
thickness of the support plate is obtained from: is to be carried out. The upper edge of the web where the
maximum compressive stress occurs is idealised by a 7 wide
e, 2 C, . eb )y (7) bar fixed at both ends
 Page 4 AD-Merkblatt S 3/4, Edition 05.99

the wall thickness of the reinforcement plate may be cal-

culated as:

c e, = 0,67. -!%- (1%

v--
k . fv
z

where k = ym

For all other cases, see G.3.1.5 of BS 5500. Extremely reli-

\ able dimensioning can be provided with the aid of a beam
\ model. For the length of the beam, assume the height h, of
‘I:.:NSK
the reinforcement plate and h, for the load length.
j Fig. 7. System of stability for the web of support brackets
The following limits apply to the thickness of the reinforce-
that is loaded with the force ment plate:
NsK = 1 . e, . max u (12) e i e, 5 1,5. e
In the slender region

(13) 8 Bibliography
the permissible buckling force is: [Al Wichmann, K. R., A. G. Hopper a. J. L. Mershon: Local
Stresses in Spherical and Cylindrical Shells due to Exter-
/zulN,,=i,.e, [1-i.k--3J] (14) nal Loadings. WRC Bulletin 107 (Rev. March 1979).
Editor C. F. Larson, New York.
where SK = 3 for the operating case, and
.S;, = 2,25 for the test case. PI Ciprian, J.: Ausgewahlte Kapitel aus nationalen und
internationalen Regelwerken zur Frage der Auslegung
See 4.2 of AD-Merkblatt S 3/O for details of SK for other load- von Druckbehaltern (Selected Chapters from National
ing cases. For greater slenderness ratios ,I, the permissible and International Regulations on the Subject of Design
buckling force is: of Pressure Vessels). Verfahrenstechnik Vol 14 (1980)
7r2 . E ez issue 1, p. 49ff.
ZUI NsK = (15)
3. SK 1: 131 NBdai, A.: Die elastischen Platten (Elastic Plates). Berlin
1968.
7.4 Reinforcement plate
[41 DIN 18800 Part 3: Steel Structures; Stability cases;
With reinforcement plates that satisfy the condition Buckling in Plate.
1 ,O 5 + 1,3 and (16) [51 Young, W. C.: Roark’s Formulas for Stress and Strain,
Y McGraw-Hill Book Company.
b=
2 0,8 and (17) El Richtlinienkatalog Festigkeit RKF (Collection of Direc-
b, tives on Strength (RKF)), Part 2, BR-A 61, - Support
hp brackets-, 3rd edition 1979. VEB Komplette Chemieanla-
L 0,8 (18) gen Dresden. (Now. Linde-KCA-Dresden GmbH).
n,
 Page 5 AD-Merkblatt S 314, Edition 05.99

N, . R2, ./3/M,
10;
8
7

i i ii ii i ii i i i

7
6
5
4

0.1
;
7
6
5
4

0.001 L --1
0 0,05 0,lO 0.15 0,20 0.25 0.30 0,35 0.40 0.45 0,50
B

Fig. 2. Section force N, in the circumferential direction of a cylindrical shell caused by an external moment
in the longitudinal direction ML (corresponding to Fig. 3 B in [l])
Page 6 A D - M e r k b l a t t S 3/4, E d i t i o n 0 5 . 9 9

N, . R$, . B / M ,
100
i
7
IIIIIIIIIIIIIIIIIII
6
5
4

3
111111111111111111IIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
IIIIIIIIIIIIIIlIIlIllllllllllllllllll
2

10
;
7
6
5
4

1.0
9
8
7
6
5
4

/
0.1
+--,j-: : : : : : : : : ; : : : : : [ I
i
7 111 11111111111111111 ll”“““““““t
I I I I I I I I I I I I I I I I l I:
ll/lllllllllllilllllllll IllillllllJlll~~~~
6
5
4

3
I

2 I I IIII llllrllll
IIIIIIIIIIIII,I,,,,,,,l,,,,,,,l,,,ll,~,,,~~,r,~~~
IIIIIIIIIIIIIllllllIIIIIIII IIll I II III I IIII I) II I I I I

0.01
B'
7
6
5
4

1 I t I
2

0,001
( 0,05 0.10 0.15

Fig. 3. Section force A$ in the longitudinal direction of a cylindrical shell caused by an external moment
in the longitudinal direction ML (corresponding to Fig. 4 B in [I])
 Page 7 AD-Merkblatt S 3/4. Edition 05.99

M, . Rm - ,Q,&,
100
z
7
6
5
A

I I I I II I I
III II I I I I I I I I I I I I I I I I I I I I I I
I I I I Ilrlrlllrllrrrlllllllllllrllllrll

0 0.05 0,lO 0.15 0.20 0,25 0,30 0.35 0,40 0.45 0.50
ib@

Fig. 4. Section moment M, in the circumferential direction of a cylindrical shell caused by an external
moment in the longitudinal direction ML (corresponding to Fig. 1 B-l in [l])
Page 8 AD-Merkblatt S 3/4, Edition 05.99

Mx . Rm . t%P,
100
i
7
6
5
4

I , ,
2 I I I I I I I I I 1IlIIII IIIIIII I
III I

3 Y-
15
2 25
35
50

tiiiiiiiiiiiiiiiiiiiiiiit

0.10 0.15 0.20 0.25 0,30 0,35 0,40 0,45 0.50

0
?Mx

Fig. 5. Section moment M, in the longitudinal direction of a cylindrical shell caused by an external moment
in the longitudinal direction ML (corresponding to Fig. 2 B-l in [l])
 P a g e 9 AD-Merkblatt S 314, Edition 05.99

Appendix 1 to AD-Merkblatt S 3/4

Formulae for the section forces and section side the function range. Since the curvature is quite marked
moments in a cylindrical shell caused by an at low /j values, it appears useful to place the datum points
closer together in this range of values. The logarithmic trans-
external moment in the longitudinal direction
formation was the result.
in accordance with Figs. 2 to 5
The function values 9 for the prescribed parameters j3 are
The function values are plotted logarithmically in Figs. 2 to 5 given by:
in AD-Merkblatt S 3/4. For this reason, only a logarithmical
function can be used for a mathematical representation of cp = 10Aq
the curves. 1-7
A logarithmic transformation has been undertaken for the where A,, = c a, T'
abscissa p: ,$

T = + 1.462756426 + 0.667616401 In p. If interpolation of ;’ is necessary, it is proposed that the

v a l u e s A , , s h o u l d b e i n t e r p o l a t e d l i n e a r l y a n d o n l y t h e n expo-
The functions given are valid for the range 0.025 9 /; nentrated. This gives a logarithmic interpolation over y.
5 0.500. This corresponds to -1 .OO 5 T I + 1 .OO in the
transformed range. These functions should not be used out- The function values a, are given in Tables 1 to 4

Table 1. Function values a, for AD-Merkblatt S 3i4 Fig. 2 and WRCB, Fig. 3 B: N, . Ri fi/ML

y = 15 y = 25 y = 35

aI .Ti
ai .T' aI T'

N,. R$./3
+ 0,069770408 + 0 , 3 7 7 168367 + 0 , 5 5 8 163265 G=
•t 0 , 6 3 7 0 3 7 3 6 2 .T + 0 , 4 7 9 5 8 4 4 9 5 .T + 0 , 3 2 0 121289. T ML
- 0 , 4 3 9 4 7 8 4 6 0 .T 2 - 0,738848546'T' - 0,757256239.T2
- 0 , 4 0 0 3 7 8 3 7 9 .T 3 - 0,193872872. T 3 - 0,051107294. T 3 c#J = lOA@
•t 0 , 0 7 6 5 9 8 6 4 6 .T 4 + 0,511443598. T 4 + 0,284013614. T 4
+ 0,267297811 T5 - 0,316573360.T5 - 0,306517629. T 5 1-7

- 0 , 0 9 3 2 4 2 6 3 4 'T 6 - 0,312390970. T 6 - 0,094104314. T 6 A, = cai. T’

- 0 , 0 5 8 0 3 8 4 2 6 .T ' •t 0 , 2 8 4 9 4 3 3 7 0 .T ' + 0,184442410. T’ i=O

T = + 1,462756426 + 0,667616401 . In p
y = 50 y = 75 y = 100
- 1,00 5 T 5 + I,00

ai .T’ ai
.T’
ai
.T’
I
p = 3,‘b . h2
t 0,769515306 + 0,950765306 + 1,052295918 2.R,
t 0,098219319. T - 0,041551678. T - 0,178524175. T
- 0 , 9 3 8 3 3 8 7 8 4 .T 2 - 0,980465592.T2 - 0,851073714. T2 0,025 s /3 5 0,500
t 0 , 3 8 3 5 4 4 1 2 0 .T 3 •t 0,200085414. T 3 + 0,379669811 T3
t0,636444925.T4 + 0,729151877. T 4 + 0,489955835.T4
- 1,075963926. T 5 - 0,601270693. T 5 - 0,801123346 T5 y+
- 0,311371446 T 6 - 0,360931184. T 6 - 0,212351509. T 6
t 0,640118854. T 7 + 0,365185936. T 7 + 0,461202199. T '
15 5 y I300
y = 150 y = 200 y = 300

ai .T’ .T’ .T’

ai ai

t 1,183545918 •t 1,264795918 + 1,421045918

- 0 , 3 3 6 2 7 5 4 0 5 .T
- 0,748412407 T2
t 0 , 3 4 9 6 5 9 0 8 7 .T 3
t 0 , 4 4 6 2 5 7 6 2 8 .T 4
- 0,546806942. T 5
- 0 , 2 3 3 5 5 9 5 0 7 .T 6
t0,260974280. T7
- 0 , 4 4 0 4 5 4 6 7 5 .T
- 0 , 4 8 3 8 3 6 6 2 0 .T *
+ 0,445481571 T3
- 0,083184019. T 4
- 0,715802843 T5
+ 0,060898189. T 6
+ 0,402612682. T 7
- Og528440463.T
- 0 , 5 8 4 9 6 6 8 7 2 .T 2
+ 0 , 2 2 0 5 3 4 8 6 3 .T 3
+ 0,133472046. T 4
- 0 , 2 6 2 5 3 5 7 7 5 .T 5
- 0,033199051 T6
+ 0,153094435. T 7
Page 10 AD-Merkblatt S 3/4,
Table 2. Function values ai for AD-Merkblatt S 3/4 Fig. 3 and WRCB, Fig. 4 B: N, . Rz p/M,
y = 15
.Ti
ai
- 0,513110997
+ 0,770 753 790 T
- 0 , 3 0 0 7 5 8 5 3 2 ,T 2
- 0 , 1 9 0 2 5 1 1 1 0 .T 3
- 0 , 0 0 0 9 8 3 0 5 8 .T 4
- 0 , 0 2 5 6 4 1 4 5 9 .T 5
+ 0 , 0 0 7 4 4 4 2 3 8 .T s
+ 0 , 0 2 6 6 0 5 1 7 4 .T '
y = 50
.Ti
ai
+ 0,238289206
+ 0 , 4 0 1 1 4 7 7 8 1T
- 0 , 5 0 9 4 3 7 4 0 8 .T 2
+ 0 , 0 1 0 0 3 3 5 7 5 .T 3
+ 0 , 0 0 8 9 6 3 9 5 6 .T 4
- 0 , 3 0 5 9 5 2 1 5 2 .T 5
tO,O23895041.T6
t 0 , 1 3 9 1 6 9 9 8 1T '
y = 150
.Ti
ai
+ 0,795952138
- 0 , 0 7 0 3 4 8 3 6 9 .T
- 0 , 9 0 2 9 7 2 7 0 4 .T 2
+ 0 , 2 2 8 5 2 0 0 4 5 'T 3
t 0,542930331.T4
- 0 , 5 5 1 0 5 3 8 0 0 .T 5
- 0 , 2 6 8 2 6 7 2 0 0 .T 6
+ 0 , 2 5 5 4 0 7 5 8 2 .T 7
Edition 05.99
:y=25
.Ti
ai
- 0,178080448
+ 0 , 5 4 4 8 1 3 4 0 6 .T
- 0 , 4 2 2 8 1 9 4 1 0 .T 2
+ 0 , 4 8 2 8 4 6 9 3 1 .T3
- 0 , 0 7 2 6 8 2 3 0 0 .T 4
- 0 , 9 6 8 0 6 4 2 4 7 .T 5
+ 0 , 0 2 8 0 8 8 2 6 8 .T "
+ 0 , 4 1 5 9 6 3 9 9 2 .T 7
y = 75
.Ti
ai
+ 0,461812627
+ 0 , 2 2 9 3 5 1 2 9 4 .T
- 0 , 5 0 8 6 3 9 2 0 3 .T 2
+ 0 , 1 7 1 9 9 1 8 1 8 .T 3
- 0,152290131T4
- 0 , 6 2 5 9 0 9 5 8 2 -T 5
t O , 1 1 5 1 0 4 4 8 7 .T 6
+ 0 , 3 3 0 4 7 2 7 8 3 .T '
y = 200
.T'
ai
t 0,911405295
- 0 , 1 9 9 5 6 1 3 0 3 .T
- 0 , 9 4 3 1 5 6 9 1 4 .T 2
t O , 1 7 1 5 9 9 9 6 9 . T 3 + 0 , 4 0 7 9 9 2 9 9 0 .T 3
+ 0 , 5 9 7 2 9 1 5 1 6 .T 4 + 0 , 6 9 1 1 2 6 8 7 3 .T 4
- 0 , 3 2 2 4 5 31 2 6 . T 5
- 0 , 3 0 5 8 6 5 7 6 3 . T 6 - 0 , 3 6 2 9 9 1 5 7 4 .T 6
+ 0 , 1 2 6 3 8 1 8 7 3 .T 7
y = 35
.Ti
ai
+ 0,027367617
+ 0,485009916'T
- 0 , 3 3 2 7 3 7 0 3 2 .T 2
+ 0 , 0 6 8 8 7 1 8 6 2 .T 3
- 0 , 2 5 5 3 5 3 0 5 8 .T 4
- 0 , 4 0 7 8 8 8 1 4 2 .T 5
+ 0 , 1 5 5 2 9 9 8 6 6 .T 6
+ 0 , 1 9 7 1 8 3 5 5 4 .T 7
T = + 1 , 4 6 2 7 5 6 4 2 6+ 0 , 6 6 7 6 1 6 4 0 1. I n p
y = 100 - 1,OO 5 T 5 + 1,00
.T' yb.h2
ai
fi=-
2.R,
+ 0,600178208
t 0 , 0 9 5 6 1 1 5 1 7 .T 0,025 5 j3 5 0,500
- 0 , 6 5 8 2 7 3 7 5 0 .T 2
+ 0,242952891 T3
+ 0 , 2 0 1 9 0 8 8 2 6 .T 4
- 0 , 7 1 1 2 6 6 7 8 5 .T 5
- 0 , 1 0 8 8 0 8 1 9 2 .T 6
15 5 y I300
+ 0 , 3 6 5 5 7 4 0 6 8 .T '
y = 300
.T'
ai
+ 1,042515275
- 0,445126721 T
- 0 , 9 4 5 2 4 3 2 4 1 .T 2
- 0 , 5 4 7 8 6 6 4 4 7 .T 5
+ 0 , 2 0 2 1 0 8 1 2 1 ~T 7
 Page 11 AD-Merkblatt S 3/4, Edition 05.99

Table 3 . Function values a, for AD-Merkblatt S 314 Fig.4 and WRCB, Fig. 1 B-l: M, . 13,. pMJML

y=l5 y = 25 y = 35

ai
.T’
ai .T’ ai .Ti

- 1,261479591 - 1,305229592 - 1,346428571

- 0 , 2 1 7 4 8 3 6 5 8 .T
- 0 , 2 3 0 0 8 3 6 3 6 .T2
- 0 , 1 1 7 3 2 7 1 1 3 .T3
- 0 , 0 1 9 9 5 3 1 7 1 .T4
+ 0 , 0 0 2 7 0 1 6 0 9 .T5
- 0 , 0 1 9 3 5 0 9 4 6 .T6
- 0 , 0 1 2 7 8 8 7 9 7 .T7
y = 50
- 0,243665549. T -
- 0 , 3 9 7 4 6 0 6 1 3 .T2
- 0,529729402. T3
+ 0 , 2 1 9 9 3 2 8 6 0 .T4
+ 0 , 7 3 2 2 8 6 4 6 3 .T5
- 0 , 1 0 7 1 6 6 1 2 5 . T6
- 0 , 3 5 1 7 4 8 6 5 5 .T7
y = 75
0 , 3 3 5 5 0 3 3 2 7 'T
4 = lOA@
- 0 , 4 1 4 2 8 7 4 8 3 .T2
- 0 , 4 4 1 4 1 7 2 1 8 .T3
i=7
+ 0 , 1 1 6 3 3 1 8 3 6 .T4
A , = Cal. T’
+ 0 , 5 3 4 7 6 5 1 1 4 .T5
i=O
+ 0,004078096 Ts
- 0 , 1 9 8 6 6 0 8 9 5 .T7
T = + 1 , 4 6 2 7 5 6 4 2 6+ 0 . 6 6 7 6 1 6 4 0 1 1 . I n p M +
y = 100 - I,00 5 T I + 1 , O O

ai
.T’ .Ti .T’ PM, = B . KL@
ai ai

- 1,395025510 - 1,470663265
- 0,492458278. T - 0 , 6 0 9 8 1 6 3 2 2 ,T
- 1,537882653
- 0,723942664. T
B-3m
2.R,
- 0 , 4 4 8 9 5 1 3 2 2 .T2 - 0,359885739. T2 - 0,396240247. T2
- 0 , 0 2 1 1 7 7 8 7 2 .T3 + 0 , 1 3 1 0 6 0 9 6 1T3 + 0 , 2 4 7 1 0 5 4 6 7 . T3
0,025 I j&, 5: 0,500
4k 0,235629477. T4 + 0 , 0 5 3 1 2 6 6 0 6 .T4 + 0 , 1 5 7 0 8 8 0 8 6 .T4
- 0 , 0 2 5 4 6 6 8 7 0 .T5 - 0 , 2 0 4 1 7 3 5 4 3 .T5 - 0 , 2 7 5 8 7 0 7 6 2 'T 5
- 0,087698563. T6 + 0 , 0 1 0 8 4 0 7 6 6 .T6 - 0,059827432. T6
I 0 , 0 4 6 2 4 5 8 7 8 'T7 + 0 , 1 2 1 7 0 4 4 1 4 .T7 + 0 , 1 2 5 1 5 6 9 3 9 . T7

y=150 y = 200 y = 300 15 I y I300

ai
.T’
ai .Ti .Ti
ai

- 1,648596939 - 1,740816327 - 1,895408163

- 0 , 7 9 1 3 2 8 2 0 1T
- 0 , 1 5 5 5 3 3 7 6 5 .T2
b O , 2 7 2 6 1 4 4 6 2 .T3
- 0,232378298. T4
- 0 , 2 9 3 5 0 3 4 1 8 'T5
~ 0 , 1 4 8 1 1 6 1 4 4 ~T6
I . 0 , 1 3 5 6 8 6 5 4 4 .T 7
- 0 , 8 4 2 0 0 2 0 4 5 .T
- 0 , 1 0 3 5 4 2 7 1 7 .T2
+ 0 , 1 6 8 9 9 8 2 9 9 . T3
- 0 , 2 1 3 8 6 1 6 4 5 .T4
- 0 , 0 6 4 8 5 2 0 5 7 .T5
+ 0 , 1 1 5 3 6 3 5 4 6 .T6
+ 0 , 0 1 3 3 6 6 0 0 8 .T7
- 0 , 9 3 8 3 7 1 6 0 8 .T
+ 0 , 1 9 2 5 0 6 1 1 0 .T2
+ 0 , 2 2 8 6 8 5 6 0 7 .T3
- 0 , 6 5 3 0 2 8 5 3 4 .T4
- 0 , 0 8 1 9 5 1 2 4 6 .T5
+ 0 , 3 5 6 4 4 0 7 9 1 -T6
+ 0 , 0 1 4 0 8 6 2 2 6 .T7
page 12 AD-Merkblatl S 314, Edition 05.99

Table 4. Function values ai for AD-Merkblatt S 314 Fig. 5 and WRCB, Fig. 2 B-l: M, . R,,, . P&ML

d
y = 15 y = 25 y = 35

ai
.T’
ai .Ti ai .T’

- 1,053896761 - 1,110703441 - 1,154099190

- 0 , 2 3 0 6 5 5 6 5 2 'T -0,347813274. T - 0 , 4 3 3 1 9 2 0 5 5 .T
- 0 , 2 3 9 7 8 0 6 8 8 .T * - 0 , 2 3 9 9 7 9 0 2 8 .T * - 0 , 2 6 5 2 8 2 6 7 2 .T 2
- 0,083516978. T3 + 0,033891510. T3 + 0 , 0 9 9 7 6 8 9 2 3 .T 3 i=?
+ 0,065495911 T4 + 0 , 0 7 7 2 2 4 5 3 3 .T4 + 0,095443157. T4 A, = cai. T'
- 0 , 0 2 0 3 4 4 7 6 6 'T 5 - 0 , 0 4 3 7 9 3 3 9 0 .T 5 - 0,092650141 . T5 I=0
-0,062557328. T6 - 0 , 0 5 2 8 3 2 5 5 0 .T 6 - 0 , 0 4 4 7 3 5 3 8 4 .T 6
- 0,001514990. T7 - 0,013742336. T7 + 0,011093516 T7
T = + 1,462756426 + 0,667616401 . In BMx
I - 1 ,OO 5 T 5 + 1,00
;
y = 50 y = 75 y= 100
I

ai
.T’ .Ti .T’
Bux = B K,
ai ai
I
- 1,216599190 - 1,320344130 - I,401189271 ~i?-G
p=-
- 0,607402914. T - 0 , 7 7 0 6 6 0149. T - 0,928194135 2.R,
- 0 , 3 7 3 3 7 3 7 0 3 .T 2 - 0,286894393. T2 - 0,289980 196
+ 0 , 3 8 5 5 4 4 8 9 4 .T 3 + 0,686616998. T3 + 0,940404008 0,025 s BMx s 0,500
+ 0 , 3 5 8 9 8 7 5 0 6 .T 4 + 0 , 3 3 4 3 6 7 3 8 9 .T 4 + 0,393319939
- 0,348108413 T5 - 0,601557360. T5 - 0,795981822
- 0 , 1 8 8 0 4 2 9 5 3 .T 6 - 0 , 1 8 5 1 2 4 8 1 8 .Ts - 0,201417881
+ 0,108427972. T7 + 0 , 2 0 1 7 9 4 8 4 3 -T 7 + 0,274662637

y = 150 y = 200

I
ai
.T’
ai .T' ai
.Ti
I
- 1,519736842 - 1,630187247 - 1,742 029 352
- 0 , 9 8 4 4 9 5 6 3 7 'T - 1,011284848.T - 0 , 8 2 2 8 6 5 2 9 2 'T
- 0,029213477 T* t0,356533233' T* + 0,413690111 T*
t 1,000543891 T3 t 1,135622496 T3 + 0,373711878. T3
t 0,012741645. T4 - 0,738628039. T4 - 0.586212035. T 4
- 0,794741953. T5 - 1,111087702. T5 - 0,199464464 T5
- 0,013892540. T6 t 0,423592781 T6 + 0 , 2 6 2 6 0 2 8 9 5 .T "
+ 0,230110703. T7 + 0,410839122 T7 + 0,036269700. T7

Appendix 2 to AD-Merkblatt S 3/4

Explanatory remarks
Equation (19) is derived from the equation stated in [5], The equation is transferred, as an approximation, to a square
Table 24, case 21 for the maximum stress in a fixed circular or rectangular plate in accordance with [II, Appendix A,
Plate loaded by a moment. The value 0.8 is substituted as 4.2.2.
the ratio of the diameter of the loaded inner region to the The value 1.5 . f v is permitted for the StreSS at the SUrfaCe of
outside diameter of the plate. the reinforcement plate.
UDC: 621.642-g&001.24:62-219:003.62:614.8 Edition Februarv 1995

General verification of stability AD-Merkblatt

Special for pressure vessels
cases s 315
Vessels with ring supports

The AD-Merkbltitter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
behdlter” (AD). AD-Merkblatt G 7 covers the composition and application of AD-Regulations and also procedural guidelines.
T h e AD-Merkb&tter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . I n t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadrngs by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testjng of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behslter- und Rohrleitungsbau e.V. (FDBRJ, Diisseldorf
H a u p t v e r b a n d d e r gewerb/ichen B e r u f s g e n o s s e n s c h a f t e n e . V . . S a n k t Augustin
Verband der Chemischen lndustrie e.V. (VCIJ, Frankfurt/Ma/n
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA). Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhijttenleute (VDEh), Dtisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GrooBkraftwerksbetrelber e . V., E s s e n
Verband der Technischen liberwachungs-Vereme e.V. (VdTiiV). Essen.
The AD-MerkblBtter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e.V., P.O. Box 103834. D-45038 Essen.

Contents
1 Scope 6 Permissible section values for ring
2 General 7 Global verification of load-bearing capacity of ring
3 Symbols and units 8 Local verification of load-bearing capacity
4 Calculation 9 Literature
5 Prevailing total force Annex 1: Explanatory notes

1 Scope - The load over the circumference of the ring is not inforced
to be constant, e.g. by non-rigid support of the vessel;
This AD-Merkblatt shall be used for the design of support
- The supports are evenly divided and each bears a uniform
rings and ring supports. Support rings are permanently
load;
welded to the vessel and the wall of the vessel takes part of
the load. Ring supports are self-supporting rings that are not - The design types are equivalent to Fig. 2;
joined to the vessel. The vessel is supported on a number - The materials are ductile;
of uniformly distributed supports or over the entire periphery - The amount of the specific lever arms /3, 6 (equations (4)
of the ring. and (5)) is ‘: 10.21.

2 General
This AD-Merkblatt shall be used only in conjunction with 3 Symbols and units
AD-Merkblatt S 310. The definitions in AD-Merkblatt B 0 are supplemented by:
The method of calculation given in this AD-Merkblatt is d,, d, Inside, outside diameter of vessel in mm
extracted from [l]. Global and local calculation possibilities d3, d, Inside, outside diameter of ring in mm
are stated for ffie ring. Because of the wide variety of possible
6 Diameter to transverse force mid-point in mm
designs for ends of segments and bolted connections in the
case of ring supports, only the distributions of moments and d6 Diameterto line-load in mm
shearing forces are stated. 6 Diameter to supporting force in mm
Wall thickness of vessel in mm
Calculations according to this AD-Merkblatt are based on the e1
following preconditions: e3, e4, e5 Wall thicknesses of ring in mm
- The profile is constant over its circumference; e6 Wall thickness of stiffening rib in mm
- With open profiles. ribs are used in order to preserve the f Permissilbe stress
cross-sectional shape (see Subclause 8.3); (refer to AD-Merkblatt S 310) in N/mm’
- The profiles are thin-walled with the exception of the f~ Permissible stress of vessel material in N/mm’
solid rectangular section, i.e. b/e > 5 and h/e > 5; fR Permissible stress of rib material in N/mm*

Supersedes Edition November 1993; 1 = amendments to previous Edition

Carl Heymanns Verlag KG Translation: Technical Help to Exporters Service of BSI

Luxemburger StraRe 449. 50939 Koln
Gutenbergstrak 3. 10587 Berhn
Page 2 AD-Merkblatt S 3/5, Edition 2.95

fT Permissible stress of ring material in N/mm2 Q Transverse force in ring cross section in N
fi Reduced permissible stress of ring ZUI Q Permissible transverse force (for
material in N/mm2 ring cross section when subjected to
Thickness of weld in mm transverse load only) in N
g
wb Section modulus against bending in mm3
*b Permissible unit bending moment
(Table 1) in Nmm Wt Torsional section modulus in mm3
zo, z1 Coefficients, parameters -
Permissible unit torsional moment
(Table 1) in Nmm Aperture angle between two supports in ’
ns Numberof supports ; Specific lever arm of supporting force -
Prevailing line load in N 6 Specific lever arm of line-load
4

Permissible unit transverse force & Strain value for buckling verification -
91
(Table 1) in N T Angular coordinates (Fig. 1) in degrees
to Clearance in mm
u Width of rib in mm 4 Calculation
W Height of rib in mm 4.1 Strength verifications for the ring
Y Ratio of rib height to rib width For the profile selected and all relevant load cases, it has
AT Cross sectional area of ring to be verified that the prevailing hypothetical total force F
(Fig. 2) in mm2 according to Clause 5 is less than the permissible force
F Prevailing total force depending on according to equation (3).
load case in N
4.2 Local verifications
zul F, Permissible force per support The welds, ribs and any bolted connections are to be verified
depending on load case in N according to Clause 8. Equations (6) to (9) indicate the distri-
G Dead load of vessel depending on bution of section values between the supports. Verification
load case in N may be provided using these quantities. If more detailed
M Bending moment in vessel resulting determination of section values is dispensed with, the local
from external loads at height of ring, verifications shall be carried out using the permissible section
depending on load case inNmm values according to equation (2).
M, Torsional moment in ring cross
section depending on load case inNmm 5 Prevailing total force
zul M, Permissible torsional moment (for
The prevailing hypothetical total force F, according to AD-
ring cross section only when subject
Merkblatt S 310, Subclause 4.4 is given by:
to torsion load) inNmm
F = NFd.
Mb Bending moment in ring cross section inNmm
zul Mb Permissible bending moment (for For uniform support:
ring cross section only when subject F=G+ti
to bending load) inNmm

support

support ring Ring support

0 Mid-punt of transverse force q Line-load Fs Support force

Fig. 1. General principle

 Page 3 AD-Merkblatt S 315, Edition 2.95

The permissible section values in the ring are obtained by

multiplying the permissible unit quantities according to
Table 1 by the permissible stress or the permissible reduced
Square stress
solid
section ml. M, = fT. m, or G. m,
zul. M,,= f,.m, o r fT.rn, (2)
zul. Q = f,. qt or f; or
Box
section 7 Global verification of load-bearing capa-
city of ring
The permissible force as a single load on the support is
obtained as the minimum value of the permissible bending-
U-section
moment load and the permissible transverse-force load:
4 . n . zul M,

d, . Z; + Z: . (zul M,/zul M,)’

zul F, = min (3)
L-section
i 2 . ZUI
J 0
Where support is uniform
4 x. zul. Mb
(Hatched area is equivalent to the cross-sectlonal area AT of the ring) (34
“I/= = I/S-bl.d4

Fig. 2. Design types for support rings The values for Z, and Z, may be taken from the following
table. The use of these values leads to conservative results.
The permissible forces can be more accurately determined
using the values for ZO and Z, given in Annex 1.

6 Permissible section values for ring *, zo Z1

For type I ring supports and support rings the permissible 2 1.8 1.1
stress of the ring is f,, and for type II support rings the 3 1.9 0.7
permissible reduced stress of the ring, is 4 2.1 0.7
6 2.7 0.7
r; = f,. 1 -,“,‘.;‘p; (1) 8 3.5 0.7
T T

Table 1. Permissible unit section values

I mr I mb 4t t0
Page 4 AD-Merkblatt S 35, Editton 2.95

The specific lever arms /3and 6 are calculated using formulae 8.2.2 Radial welds in the ring
(4) and (5) with the diameters in Fig. 1: At locations of joints in ring segments, the required welds for
weld joint factors less than 1 are to be verified as follows:
- 0.2 5 p = 2z+ 5 0.2 (4)
C&-J
-0.2 5 6 = + 5 0.2 (5)
f; >; [[As]‘+3 [q+y]‘]* (11)
4
For externally fitted rings: where v is the weld joint factor.
d, = d3 + e4 + 2 . t,
8.2.3 Welds all the way round the ring
and for internally fitted rings:
For welds all the way round rings on individual supports
d, = d4 - e4 - 2 . to having a box cross-section (Fig. 3), the relationship in equa-
tion (12) has to be verified for welds 1, 2 and 3.
For closed cross-sections, t, is to be taken from Table 1.
For open ring cross-sections, to = 0. I 2$ 3

d-l 5
8 Local verification of load-bearing capacity ! c e5 f;= *
For verifications of load-bearing capacity at individual points
(12)
of the ring or the ring cross-section, the welds and any bolted 1
% c
connections, for instance, shall be verified.
Fig. 3. Welds
8.1 Section value distribution
The distribution of section values between the support points For welds 4 and 5. the following conditions has to be satisfied:
can be determined for a finite number of supports by using
equations (6) to (8). Depending on the angle T (see Fig. i), G 2 g-“.
bV I 2. IQi. e,
(13)
with g = ,7/n,, this gives the following section values: b . h ’ h . (e, + e,)

where i is equal to 4, 5.
Mb= A- (1 + /?) cos(r) - (1 + 6) For open profiles and rings that are evenly supported,
L sin -(9) g 2 0.5 em,” is recommended as the minimum value.

)I 8.3 Verification of buckling

Ribs are provided in order to preserve dimensional stability
and to introduce the support loads. These are evently distri-
buted around the circumference. If, in exceptional cases,
(1 + 8) . sin(t) + t f (1 + ng . 6) there are no ribs over the supports, the region where loads
are introduced must be verified in a manner similar to that in
AD-Merkblatt S 3/l.
(7)
8.3.1 Verification of ribs
The ribs are verified with regard to buckling due to the
sin(ns . t) support force. If equation (14) is satisfied, there is no risk of
“, . F&
i buckling.

Q 5 fR. u. e, C$ (14)
The section values according to equations (6) to (8) are each
to be calculated for the positive and negative sign in the where
expressions in parentheses and their respective maximum @= (15)
value is to be used as a basis for subsequent calculation.
For uniform support, the quantities are to be determined
according to equations (9) and (10). (g) J&q
M, = (is - (5) F &
and Q from formula (8) as well as e6 and u from Fig. 4. For
M, =Q=O (10) ribs above the supports Q = Fin,.
For simplification, the permissible quantities according to
The strain value E is
equation (2) may be taken as a basis for calculation.

8.2 Welds (16)

8.2.1 Welds to join the vessel and ring In this case E is to be determined at room temperature.
The strength verification described in Clause 7 verifies the
joining weld between the vessel and ring if the g dimension (17)
is equal to or greater than the thinnest attached ring wall-
the factor C2 for box profiles gives:
thickness and equal to or less than the vessel wall-thickness.
If these conditions are not satisfied, detailed verification is y 5 1 C2 = 6 . (y •t l/y)’
necessary. y> 1 C, = 24
 Page 5 AD-Merkblatt S 315, Edition 2.95

For open profiles 8.3.2 Verification of girth plates

yl 1.64 Cp = 6 (0.56 + (l/y)’ + 0.13 . y2)
y > 1.64 C2 = 7.7;
where u = rib width and w = rib height (Fig. 4). Ribs over
the supports are to be verified making Q = Fin,.
The upper and lower girth plates of the ring are to be verified
with regard to buckling due to bending. If equation (18) is
satisfied, there is no risk of buckling.
+o. $D
E (18)
3

D is 24.0 for box profiles and

D = 7.7 for open profiles.

9 Literature
[l] Richtlinienkatalog Festigkeit RKF (Collection of Direc-
tives on Strength (RKF)), Part 2, BR-A65, (Ring supports
and supporting rings) 3rd impression 1979. Komplette
Chemieanlagen Dresden (now Unde-KCA-Dresden
Fig. 4. Ribs GmbH).
Page 6 AD-Merkblatt S 315, EditIon 2.95

Annex 1 to AD-Merkblatt S 3/5

Explanatory notes for AD-Merkblatt S 315
Re Clause 7
The following simplification was adopted, compared with [I]
for a verification of the global load bearing capacity.
- Any existing load portion carried by the vessel wall was not
taken into account in the calculation for the support ring
(using the designation in accordance with [l] : K2 = 1).
- The Z,, and Z, values depend not only on R, but also on
fi and 6. The table gives only the maximum values which
occur in the -0.2 IS /3 5 0.2 and -0.2 5 6 5 0.20 para-
meter range. The results obtained using these values is
usually very conservative. The precise values of Z0 and Z,
can be determined from Fig. 1lA to 4lA, which were taken
from [l].

2.00
1,80 z,
1.80
1.40
1.20
1800
-0.20 -010 0 +0,10 B +w
2.00 &
ii= +0.20 1.80
t0.15
l O,l 0 1,60
+o.os la40
0,oo
-0,os I20
-0,lO
-0,lS 1800
-0.20 0190
0.80
0.70
0.60
I I I I I I I I
-0.20 -0JO 0 +o#lo ' +q&"'50
B
2.50
6~ +am zl
415
410
%t
l QOS 1.60
om 140
-a05 1120
-0,lO
1,oo
-0,lS 0190
-0,m 0,80
0.70
0160

I I I ,
I I I
-420 -910 0 +OJO +q20°'40
B

Fig. i/A. Parameter Z, where n, = 2, 3 and 4

 Page 7 AD-Merkblatt S 315, Edition 2.95

3.00
6= 4.20
+Q15 2.50
a.10

*&OS
0,oo 1.60
-0,os 1.40
1.20
-0,lO
1.00
-0,15 0.90
0.80
-0,20 0.70
On60
OS50

0,40

4.00
6= +Q20 &I
+a15 3,oo
l q10
2.50
+qos

QOO
:leooo
-qo5 1:60
1,40
-0,lO 1.20
1.00
-035 080
o,w
-a20 0170
0,60
Ol50

0.40

0.30

Fig. 2/A. Parameter Z, where n, = 6 and 8

 138 If8
LOO
#j
,
4
LOO I
090 090 t==k-i i !-! L 1
1 I g
OBO w 1 I I
I I -
I
--
_
0,ao
oao on t
I I

---c--l--t--c---c--
I
I 070

060 0,60 0,60

09 050

0,LO OPO

Q30 (230 03
0,25 025 0,25

020
%: 8: O,tb
0;s 0:lS 0,16
0,14 0,14 0,lL
0812 a12 032
0,lO OS0 OS0

0.08 a08 ON
I I I I I I I
I I
0,06 0,06
OD5
. 0‘05

QW a,04

Ox)3 0,03

0,02 0,02
I I I -- I I , I ,
l I - I - I I I I
I 1 I
1 I
_

Fig.3/A. Parameter Z, where n, = 2, 3 and 4

 Page 9 AD-Merkblatt S 315, EditIon 2.95

Q70 0,70
z,
060 OS0
050 OS0

0,40 Q10

030
OS25 025

020 020
0818 018
0816 0.16
0,14 QU
0.12 a12
OdO ala
am cb39
0.08 ale
a07 cl07
a06 006
905 a05

OlO4 uu

403 003
Qo25

002

a015

0 %
0,008
Q007
QOoS
IO005
-420 -910 0 +o,lo ~0.20 -0JO OJO 0 +q10 l q20
B B

Fig. 4iA. Parameter Z, where n, = 6 and 8

ICS: 23.020.30 Edition February 1998

General verification of stability

for pressure vessels AD-Merkblatt
Special
cases Vessels with nozzles . S 316
subject to additional loadings

T h e AD-Merkblatter a r e c o m p i l e d b y t h e s e v e n a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “ A r b e i t s g e m e i n s c h a f DruckbehBlter”
(AD). AD-Merkblatt G 1 covers the composition and application of AD-Regulations and also procedural guidelines.
T h e AD-Merkblatter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d fornormaloperating c o n d i t i o n s . I n t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behblter- und Rohrleitungsbau e. V. (FDBR), Diisseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sankt Augustin
Verband d e r C h e m i s c h e n lndustrie e . V . ( V C I ) , F r a n k f u r t / M a i n
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
u n d Apparate, F r a n k f u r t / M a i n
Verein Deutscher fisenhiittenleute (VDEh), Dijsseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GrooBkraftwerksbetreiber e.V., E s s e n
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkbltitter a r e a m e n d e d c o n t i n u o u s / y b y t h e a b o v e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p;ogress. Relevant proposals should
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e. V., P.O. Box 103834, D-45038 Essen.

Contents
1 Scope 5 Strength condition
2 General 6 Literature
3 Symbols and units Annex 1: Explanatory notes
4 Individual stresses

1 Scope - The number of start-ups and shutdowns does not exceed

the permissible number given in AD-Merkblatt S 1, sub-
This AD-Merkblatt applies to the calculation of local static or clause 4.2.
quasi-static stresses in pressure vessel walls in the vicinity
of nozzle-to-shell-junction due to pressure loading and addi-
tional external forces and moments. The position of the nozz- 2 General
les is generally assumed to be vertical to the basic shell
(radial nozzle). For nozzles located in the area of spherical This AD-Merkblatt shall be used only in conjunction with
part or knuckle of domed ends, the axis of the nozzle may AQ-Merkblatt S 310.
be parallel to the axis of the vessel. If nozzles on vessels have External loads on nozzles are frequently caused by piping
3 supporting function for the vessel, more detailed considera- reactions. To obtain realistic piping reactions the main
:ions may be necessary. flexibilities of the vessel, particularly in the area of the
4 verification is not required if each of the following conditions nozzle under consideration shall be taken into account in
s complied with: the calculation as flexural stiffness of the piping system.
- The nozzle is a attached to the basic shell by a through- The flexibility of nozzles can be calculated in accordance
penetration weld. with [l] for spherical shells and in accordance with [1] or
- The minimum nozzle wall thickness complies with [3] for cylindrical shells.
DIN 28115 for ferrous materials and with DIN 28025 Irrespective of the method selected to determine addi-
Part 1 or 2 for austentic materials. tional stresses, the design to withstand internal pressure
- The support intervals and flexural behaviour of the con- or external pressure loadings shall be based on AD-
nected piping shall comply with the support interval table Merkblatt B 9 and B 1 or B 3 depending on the position of
or the flexibility nomogram of TRR 100. the particular nozzle.
- The diameter d, of the support shall not exceed 0.3 times Irrespective of the source selected to determine the indivi-
Q. dual stresses, the application limits given in the particular
- The design to withstand internal pressure in accordance sources shall be complied with.
with AD-MerkblBtter B 3, B 9 and B 1 shall be based on
a 10% increase in internal pressure in which case the
basic shell and/or nozzle is to be reinforced, if required. 3 Symbols and units
- The design does not include a verification against failure The definitions in AD-Merkblatt B 0 are supplemented by
due to excess of creep rupture strength. the following:

Supersedes April 1996 edition; 1 = Amendments relating to previous edition

Carl Heymanns Verlag KG

Luxemburger StraOe 449. 50939 Koln
P a g e 2 AD-Merkblatt S 3/6, Edition 2.98

a WeA) Formula symbol 4.2.2 Stresses due to additional loadings

b (eden) Formula symbol The stresses can be determined in accordance with clause 4
Cl (i = 1.2) Wall thickness allowances of [2] or [3], provided the following conditions are satisfied.
in accordance with
AD-Merkblatt B 0 in mm eA-; -c2 ~0.0017
di Internal diameter of nozzle in mm a
eA Wall thickness at edge of opening 53 2 0.5
of the basic shell without allowances in mm eA
Wall thickness of nozzle Outside these limit values the stresses shall be determined
without allowances in mm
in accordance with [3].
Fictitious remaining strength for
additional nozzle loads in N/mm2 The equivalent stresses in the form of membrane and total
stresses shall then be determined for each of the eight points
4 Internal diameter of pipe run in mm
under consideration in each of the two sources and may be
a Stress intensification factor - carried out using the equivalent stress theory of Tresca or
e Utilization of strength by pressure - van Mises.
v Stress concentration factor -

4 Individual stresses
4.1 Nozzles in spherical shells
The resulting maximum stress component can be deter-
mined as equivalent stress intensity in accordance with [l],
subclause G.2.5 taking into account the stresses resulting
from pressure and additional loadings.
4.1.1 Stresses due to pressure loadings
Individual stresses resulting from internal or external pres-
sure loadings can be determined using the methods menti-
oned in the literature. The annex contains concrete referen-
ces to literature.
Subclause 5.3 allows a formulation without an explicit deter-
mination of these stresses.
4.1.2 Stresses due to additional loadings
The stresses can be determined, depending on their location
of application, in accordance with clause 3 of [2]. The equiva-
lent stresses shall be determined in accordance with the von
Mises or Tresca’s theory both for the membrane stresses
and the total stresses at each of the eight locations, with the
correct signs being used.
4.2 Nozzles in cylindrical shells
The maximum equivalent stress intensity resulting from inter-
nal pressure and additional loadings can be determined in
accordance with [l], subclause G.2.3.
4.2.1 Stresses due to pressure loading
Individual stresses resulting from internal or external pres-
sure loadings are, forexample, given in [4] or [5]. [4] is pre-
ferred provided the application limits of this method permit.
The curves for the stress intensification factor due to pres-
sure, given in [5], can be approximated in accordance with
[6] using the following equations.
a = 2.2 + ea(es’e,) @e&J
where a (es/e,) = -1.14 . (es/e,)2 - 0.89 (es/e,) +1.43
b (es/e,) = 0.326 . (es/e,)* - 0.69 (es/eA) +I.08
and ye = [(d, + es) I (D, + e,)] . [D, + e,) / 2 . eJO.5
The stress intensified by the factor a, resulting from the global
stress due to internal pressure (membrane stress) produces
the total stress at the intersection. It comprises the global and
also all local stress components.
5. Strength condition
In addition to the verifications of the tube cross section, based
on global stresses from internal pressure (membrane stress)
and external forces and moments (as a beam-shaped com-
ponent) a verification of the local stresses in the vicinity of
nozzle-to-shell junction is also required.
5.1 Complete verification in accordance with [l]
If the complete verification in accordance with subclauses 4.1
or 4.2 is performed in accordance with [l], the stresses can
also be evaluated in accordance with the corresponding
subclauses G.2.6 or G.2.3.5 of [l] with fin accordance with
AD-Merkblatt S 310.
5.2 Superposition of all individual stresses
The different stress components resulting from pressure and
additional loadings shall be superimposed locally in which
case the membrane stresses and the total stresses are to be
considered separately. These stresses can be evaluated in
accordance with AD-Merkblatt S 4. The safety factor shall be
chosen in dependence of the respective load case in accord-
ance with subclause 4.3.4 of AD-Merkblatt S 310.
5.3 Interaction between stresses resulting from
pressure and additional loadings
For the sake of simplification and conservatism, the determi-
nation of stresses resulting from pressure loading in accord-
ance with subclauses 4.1 .l and 4.2.1 can be omitted where
the loads are predominantly static. Using the verifications of
stresses from internal pressure and external pressure in
accordance with AD-Merkblatt B 9 and B 1 and referring the
existing pressure p or p’ to the allowable pressure pZu, we
obtain the utilization factor
a= -P
c
Pzul
The fictitious remaining strength that can be derived there-
from is
K=K.(l-Q)
and can be used to include the stresses from additional loa-
dings in accordance with subclauses 4.1 .l and 4.1.2. This
presumes that the stiffness limits in accordance with [1] are
complied with and the opening is not reinforced exclusively
in the nozzle. The stresses can also be evaluated in this case
like in subclause 5.2 by using K as the design strength value.
 P a g e 3 AD-Merkblatt S 316, Edition 2.96

6 Literature [4] Sicherheitstechnische Regel des Kerntechnischen Aus-

[l] British Standard 5500: Unfired Fusion Welded Pressure
Vessels.
British Standards Institution
[2] Wichmann, K. R., A. G. Hopper and J.L. Mershon: Local
stresses in spherical and cylindrical shells due to external
loadings.
WRC Bulletin 107, Rev. 3.79
[3] Mershon, J. L., K. Mokhtarian, G. V. Ranjan and E.C.
Radabaugh: Local stresses in cylindrical shells due to
external loadings on nozzles.
WRC Bulletin 297, Rev. 1, 9.87 (Supplement to WRC
Bulletin 107)
schusses; [Safety Standards of the Nuclear Safety Stan-
dards Commission]: KTA 3211.2.
Carl Heymanns Verlag KG, Cologne, Berlin, 1993
[5] &c/tell, M. B., and C. Ruiz: Pressure Vessel Design and
Analysis.
Macmillan and Co., London 1967.
[S] Becker, M.: Beriicksichtigung von Kraften und Momen-
ten auf Behalterstutzen nach WRC 107 und WRC 297
und die Uberlagerung mit Innendruck.
[Consideration of forces and moments on vessel nozzles
in accordance with WRC 107 and WRC 297 and the
superposition of internal pressure]
RWTUV e.V., Essen
Page 4 AD-Merkblatl S 3/6, Edition 2.98
Annex 1 to AD-Merkblatt S 3/6
Explanatory notes
Re Clause 1
The exception criteria given reflect the positive operating
experience made up to now with the component nozzle on
vessels where the nozzle and the piping have been designed
and built to the state of the art. They shall in future provide
a practical method for the design and design approval.
In extreme cases, for example, where nozzles have to with-
stand unit shear forces and moments when expansion joints
are installed, verification of the nozzles and if necessary the
complete vessel including its supporting elements is advi-
sable, even though none of the exception criteria is violated.
Re Clause 4
Clause 4 provide only references to sources for the calcula-
tion of nozzles in spherical sections of ends and cylindrical
shells. No sources are known for determining the stress com-
ponents at nozzles in the knuckle region of domed ends. If
verification in this area is necessary, for example because
the exception criteria in accordance with clause 1 are vio-
lated, this verification must be carried out using numerical
methods.
Re Clause 4.1.1
Stresses due to internal pressure loadings on nozzles in
spherical shells can, for example, be taken from [Al].
Re Clause 4.1.2
If various moments act on one nozzle, then for simplification
these moments can be vectorially combined in relation to the
section of the nozzle, to form a resulting bending and torsio-
nal moment in each case.
Re Clause 4.2.1
Because it is not possible to separate the stress components
in [5], the author [6] suggests that components without stress
intensification are used to determine the equivalent mem-
brane stresses, i.e. only the global membrane stresses
resulting from internal pressure be used. The local mem-
brane stress components are then included in the total stress
and evaluated only for verification of membrane and bending
stresses. This procedure is based on conservative total
stress values which even contain components classifiable as
secondary stresses.
Re Clause 4.2.2
Experience has shown that a transition from 121 to [3] causes
an intensification of the indicated stresses. [A21 offers a
complete procedure for determining stresses resulting from
pressure loadings and additional loadings for cases where
the wall thicknesses of the basic shell and nozzle are the
same.
Re Clause 5.3
The calculation in accordance with clause 5.3 is conservative
because the formulation can be interpreted such that all
stress components resulting from additional loadings at each
point under consideration are superimposed on the most cri-
tical stress condition due to pressure loading, regardless of
where this occurs and how the stress tensor is developed.
Literature
[Al] Varga, L.: Bestimmung der in der Umgebung der
Ausschnitte von innendruckbeanspruchten Druckbe-
haltern auftretenden Spannungen [Determination of
stresses occurring in the vicinity of openings in pressure
vessels subject to internal pressure].
Forschung im Ingenieurwesen, 29 (1963), p. 115-122.
[A21 Deco&, J.: Stresses in cylindrical shells with nozzles
submitted to external loading and internal pressure.
Report MT 156, 8 (1983), Univ. Gent.
KS: 2 3 . 0 2 0 . 3 0 Edition April 1996

General verification of stability

for pressure vessels AD-Merkblatt
Special
cases Allowing for thermal stresses in heat s 3/7
exchangers with solid headers

The AD-Merkbl&ter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
beh2lter” (AD). AD-Merkblatl G 1 covers the composition and application of AD-Regulations and a/so procedural guidelines.
T h e AD-Merkbl&tercontain s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . I n t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal level expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e. g. testing of materials, experiments, stress analysjs, operating
experience.
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e. V. (FDBR), Diisseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e. V., Sankt Augustin
Verband der Chemischen lndustrie e. V. (VU), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Diisseldorf
VGB Technische Vereinigung der GroBkraftwerksbetreiber e.V., Essen
Verband der Technischen iiberwachungs-Vereine e. V. (VdTiiV), Essen.
T h e AD-Merkbltitter a r e a m e n d e d c o n t i n u o u s l y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher;
Verband der Technischen iiberwachungs-Vereine e. V., P.O. Box 103834, D-45038 Essen.

Contents
1 Scope
2 General

1 Scope 2 Calculation of thermal stresses

The determination of stresses due to thermal stresses stated Assuming rigid tube ends, the thermal stresses can be calcu-
in this AD-Merkblatt applies to heat exchangers with solid lated as follows:
headers as specified in AD-Merkblatt 6 5 Fig. 9.
2.1 Thermal stress in the shell
Heat exchangers with solid headers (without compensator)
may be subjected to loads due to differing thermal expan- aM = aT . l?R - q,J . i?M (1)
sions between the shell and the tubes. Substantial thermal f44
stresses are to be expected, particularly with a thermal EM + AR.&
expansion difference between the shell and the tube of
2.2 Thermal stress in the edge tubes
~aM~$.J-cz~~lgR~~5~10-4 uM . i& - aR . i&
c7R = (2)
being exceeded during operation. AR
++-
R AM . EM
Taking o as the coefficient of longitudinal thermal expansion
in l/K and the indices M and R to represent the shell and the ignoring the deflection of ends, these thermal stresses are
edges tubes (the two outer rows of tubes) respectively, the to be superimposed on the values found form AD-Merkblatt
calculation in Clause 2 can be carried out for simple heat B 5. If compressive stresses occur in the edge tubes, the
exchangers having diameters up to 1200 mm and permis- buckling loads for the edge tubes shall also be checked
sible working gressures up to 10 bar. including these stresses.

Supersedes Edition October 1991; / = Amendments compared with previous Edition

Larl Heymanns Verlag KG Translation: Technical Help to Exporters Service of BSI

Luxemburger Strak 449. 50939 Kbln
GutenbergstraBe 3. 10587 S&in
ICS 23.020.30 Edition Februarv 1998

Evaluation of stresses determined AD-Merkblatt

Special
Cases
by way of calculation and
experimental stress analysis s4

The AD-Merkblatter are compiled by the seven associations specified below who together form the “Arbeitsgemeinschah Druckbehdlter”
(AD). AD-Merkbfatt G 1 covers the composition and application of AD-Regulations and also procedural guidelines.
T h e AD-Merkblatter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . In t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e. g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behalter- und Rohrleitungsbau e. V. (FDBR), Dusseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sankt Augustin
Verband der Chemischen fndustrie e. V. (VCI), FrankfurtlMam
Verband D e u t s c h e r M a s c h i n e n - u n d A n l a g e n b a u e . V . (VDMA). Fachgemeinschaff Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhuttenleute (VDEh), Dusseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkraftwerksbetreiber e.V., E s s e n
Verband der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s / y b y t h e a b o v e a s s o c i a t i o n s rn k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iibetwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents
1 Scope 5 Superposition and evaluation of stresses
2 Symbols and units 6 Limitation of equivalent stresses and equivalent
3 General requirements stress ranges
4 Stress analysis, stress categories 7 Literature

1 Scope 1.4 The stipulations of this AD-Merkblatt apply to steels

allowed for the construction of pressure vessels. Where the
1.1 This AD-Merkblatt contains criteria for the evaluation of stipulations are to be applied to other metallic materials, e.g.
stresses and can be used in those cases where the com- non-ferrous metals, the specific properties of such materials
ponent loading condition has been calculated on the basis shall be taken into consideration.
of a linear-elastic stress-strain relationship. This AD-Merk-
blatt also applies to the evaluation of measured loading con- 1.5 The component temperatures (wall temperatures) shall
ditions if - apart from locally restricted partial yielding over be in the range of non-time dependent design strength
the cross-section -a linear-elastic behaviour becomes appa- values.
rent especially after repeated loading. These criteria shall be
used unless the AD-Merkbltitter contain other pertinent rules, 1 . 6 The requirements of the AD-Merkblatter regarding the
see for example AD-Merkblatt B 0, clause 2.2. This does not materials used, manufacture, workmanship as well as first
exclude other possibilities of verification. and periodic inspections shall be met.
In the case of stresses determined on the basis of elasto-
1.7 Modes of failure
plastic analyses these criteria cannot be commonly used for
the evaluation of the stresses. 1.7.1 Where the criteria for the limitation of stresses laid
down in this AD-Merkblatt are satisfied, the following modes
1 . 2 The stress evaluation criteria in this AD-Merkblatt apply of failures will be avoided:
to components of pressure vessel systems, boiler plants,
- ductile fracture and gross distortion of materials due to
tank farms, and piping systems if they can be represented
mechanical overload
as plane or curved load-bearing structures (consisting of iso-
tropic disks, plates or shells) or as 3-dimensional rod structu- - progressive distortion (ratcheting) due to cyclic loading
res (consisting of pipes or bars with full rectangular or circular - fatigue fracture where the creep rupture or fatigue strength
cross-sections). is exceeded (in conjunction with AD-Merkblatt S 1 or S 2).

1.3 The stresses may be caused e.g. by gauge pressure 1.7.2 Adherence to the stress evaluation criteria laid down
or vacuum, external forces and moments, mass forces as in Section 4 does not safeguard against the following modes
Well as restraints on thermal expansion. of failure which shall be considered additionally:

Supersedes September 1995 edition; j = Amendments relating to previous edition

UP,, nrylllcllllls
va,,‘iy nu
Luxemburger StraBe 449, 50939 Kdn
page 2 AD-Merkblatt S 4, Edition 2.98

- instability 3.2 Welds

- brittle fracture
- creep rupture
- high temperature fatigue
- stress corrosion cracking
- corrosion fatigue.
2 Symbols and units
e calculated wall thickness at the point
under consideration (cf. AD-Merkblatt
s 3/O)
f allowable design stress
(cf. AD-Merkblatt S 3/O)
F peak stress
P primary stress
stresses due to restraints, e.g. mem-
p,
brane and/or bending stresses due to
restraint to thermal expansion
Pb primary bending stress
p, local primary membrane stress
p, general primary membrane stress
Q secondary stress
R smallest radius of curvature of shell at
the point under consideration
R p 0.2 31 Rp,oa 0.2 or 1 .O % proof stress
(minimum values)
principal stresses
normal stresses
highest principal stress
smallest principal stress
equivalent stress according to
Tresca
equivalent stress according to
v. Mises
shear stress components
3 General requirements
The allowable stress in welds shall be determined in due
consideration of the weld efficiency in accordance with
AD-Merkblatt B 0.
3.3 Claddings
3.3.1 When determining the required wall thicknesses and
sections, claddings, if any, shall not be considered to be
contributing to the strength. Deposition welds made on the
base metal with equivalent materials are not considered to
be claddings.
3.3.2 If the cladding thickness exceeds the wall thickness
m m by more than 10 %, the cladding shall be taken into account
when analysing the forces and moments.
N/mm2
N/mm2 3.4 Loadings
N/mm2 Loadings are assumed to be all effects on the component
which cause stresses in such component. The loadings shall
be comprised to form load cases in accordance with AD-
N/mm2 Merkblatt S 3/O. The loadings to be considered shall be
N/mm* indicated.
N/mm2 3.5 Stresses
N/mm2
35.1 The stresses consist of normal and shear stresses or
N/mm2 a combination of normal and shear stresses and are eva-
luated as equivalent stresses.
In the case of a linear-elastic stress analysis there is a linear
relationship between the stresses and strains. This proportio-
N/mm2 nal ratio even when in excess of the yield strength or proof
N/mm2 stress of the material shall be the basis of analysis (fictitious
N/mm2 stresses). In the case of elastic-plastic analyses the effective
N/mm2 stress-strain relationship shall be taken into account.
N/mm’ 3.5.2 The stresses are (predominantly) static loadings,
cyclic loadings or dynamic loadings. Pulsating loads are
N/mm2 considered to be a specific case of cyclic loading.
3.5.3 The stresses due to static loadings shall be limited
N/mm’
within the stress analysis according to Section 6 on the basis
N/mm2 of the stress analysis and classification of stresses as well
as the derivation of equivalent stress in accordance with
Sections 4 and 5. The limitation of cyclic loadings shall be
made in accordance with AD-Merkblatt S 2.

3.1 Objectives
3.1 .l It shall be demonstrated by means of the stress analy- 4 Stress analysis, stress categories
sis comparison with the allowable stresses that the compo- By means of a stress analysis along with a classification
nents are capable of withstanding all loadings occurring in of stresses and stress limitation it shall be demonstrated
the various load cases (service, test, assembly, and special that no inadmissible distortions occur and that deformations
loading cases) in accordance with AD-Merkblatt S 3/O. are admissible and limited if in the plastic range.

3.1.2 Within the analysis the stresses and, if required, the
forces and moments as well as deformations due to loadings
of the component to be analysed shall be determined by
satisfying the boundary conditions and taking into account
the mutual influence of adjacent components. The determi-
nation may be effected by way of calculation or experiments,
or a combination of calculation and experiments.
3.1.3 The stresses determined according to clause 3.1.2
shall be examined for acceptability in accordance with Sec-
tions 4, 5 and 6. Here, it shall be taken into account that the
exactness of the determined forces and moments depends
on the ideal geometric shape of the component, the exact-
ness of assuming loadings, boundary conditions and mate-
rial properties as well as the features and performance of the
calculation method selected.
4.1 Classification of stresses
4.1.1 Stresses shall be classified in dependence of the
cause of stress and its effect on the mechanical behaviour
of the structure into primary stresses, secondary stresses
and peak stresses [4] and be limited in different ways with
regard to their classification.
4.1.2 Where in special cases the classification into the
aforementioned stress categories is unclear, the effect of
plastic deformation on the mechanical behaviour shall be
determining where an excess of the intended loading is
assumed.
4.2 Primary stresses P
4.2.1 Primary stresses P are stresses which satisfy the
laws of equilibrium of external forces and moments (loads).

4.2.2 Regarding the mechanical behaviour of a structure
the basic characteristic of this stress is that in case of (an
inadmissibly high) increment of external loads the deforma-
tions upon full plastification of the section considerably
increase without being self-limiting.
4 . 2 . 3 Regarding primary stresses distinction shall be made
between membrane stress (P,, P,) and bending stress (P,,)
with respect to their distribution across the cross-section
governing the load-bearing behaviour. Here, membrane
stresses are defined as the average value of the respective
stress component distributed over the section governing the
load-bearing behaviour, in the case of plane load-bearing
structures the average value of the stress component distri-
buted across the thickness. For the purpose of this AD-
Merkblatt, bending stresses are defined as stresses distri-
buted linearly across the considered section and proportio-
nally to the distance from the neutral axis, in the case of plane
load-bearing structures as the portion of the stresses distri-
buted across the thickness which is distributed linearly.
4.2.4 Regarding the distribution of membrane stresses
across the wall distinction shall be made between general pri-
mary membrane stresses P, and local primary membrane
stresses P,. Rotationally symmetric primary membrane stres-
ses in discontinuity regions, which differ from the general
membrane stress, are considered to be local if the equivalent
stress intensity does not exceed 1 .l times the allowable
general membrane stress in a region remote from the discon-
tinuity and with a length 1 .O Vn in the meridional direc-
tion. Two adjacent regions of local primary membrane stress
intensities shall not be closer than 2.5 . fi in the meri-
dional direction where R is the minimum midsurface radius
of curvature and e the wall thickness according to Section 2.
Discrete regions of local primary membrane stress intensity
resulting from concentrated loads (e.g. skirts, nozzles) shall
be spaced so that there is no overlapping of the areas in
which the membrane stress intensity exceeds 1 .l times the
allowable general membrane stress.
4.2.5 While general primary membrane stresses are distri-
buted in the structure such that no essential redistribution of
stress occurs as a result of yielding, yielding in the case of
local primary membrane stresses will cause such redistribu-
tion of stresses.
4.3 Secondary stresses Q
4.3.1 Secondary stresses Q are stresses developed by
constraints due to geometric discontinuities and by the use
of materials of different elastic moduli under external loads,
or by constraints due to differential thermal expansions. Only
stresses that are distributed linearly across the cross-section
are considered to be secondary stresses.
4.3.2 With respect to the mechanical behaviour of the struc-
ture the basic characteristics of secondary stresses are that
they lead to self-limiting plastic deformation when equalizing
different local distortions in the case of excess of the yield
strength.
4.3.3 Stresses in piping systems developed due to con-
straints in the system or generally due tofulfilment of kinema-
tic boundary conditions are defined as P,. Under unfavou-
rable conditions regions with major distortions may develop
in relatively long systems, and the constraints thus occurring
will then act as external loads. In addition, it may be neces-
sary to demonstrate for these locations that no inadmissible
deformation of material occurs.
P a g e 3 AD-Merkblatt S 4, Edition 2.98
4.4 Peak stresses F
4.4.1 Peak stress F is that increment of stress which is addi-
tive to the respective primary and secondary stresses. Peak
stresses do not cause any noticeable distortion and are only
important to fatigue and brittle fracture in conjunction with
primary and secondary stresses.
4.4.2 Peak stresses also comprise deviations from nominal
stresses at hole edges within tubehole fields due to pressure
and temperature in which case the nominal stresses shall be
derived from equilibrium of forces considerations.
5 Superposition and evaluation of stresses
As shown hereinafter, for each load case the stresses acting
simultaneously in the same direction shall be added sepa-
rately for each stress category or for different stress catego-
ries (e.g. primary and secondary stresses) be added jointly.
Tables 1 to 3 give examples for the classification of stresses.
From these summed-up stresses the equivalent stress for
the primary stresses and the equivalent stress range each
for the sum of primary and secondary stresses or the sum
of primary stresses, secondary stresses and peak stresses
shall be derived (for further details see [6]).
5.1 Equivalent stresses
5.1.1 Having chosen a three-dimensional set of coordi-
nates the algebraic sums of all normal and shear stresses
acting simultaneously and having the same direction of axis
shall be calculated separately for
(a) the general primary membrane stresses or
(b) the local primary membrane stresses and
(c) the sum of primary bending stresses and either the
general or local primary membrane stresses.
These stresses shall be taken to derive the equivalent stress
according to the v. Mises’ maximum distortion energy theory.
51.2 When deriving the equivalent stress in accordance
with Tresca’s maximum shear stress theory, the principal
stresses shall be determined for each of the three cases in
subparagraphs 5.1 .l a) to c) taking the respective primary
shear stresses into account unless the primary shear stres-
ses disappear or are negligibly small so that the effective nor-
mal stresses are the principal stresses. In each case the
equivalent stress then equals the difference between the .
maximum and minimum principal stress.
For the three cases in clause 5.1.1 (a), (b) and (c) thus the
equivalent stress is obtained from P,, P, and P, + Pb or
P, + Pb.
5.2 Equivalent stress ranges
To avoid failure due to
(a) progressive distortion (ratcheting) due to cyclic loading
(b) fatigue (cf. AD-Merkblatt S 2)
the pertinent equivalent stress ranges shall be determined
from the various stress categories and be limited in different
ways.
5.2.2 In the case of subparagraph 5.2.1 a) the required
stress tensors shall be formed taking the simultaneously act-
ing stresses from primary and secondary stress categories,
and in case (b) taking the simultaneously acting stresses
from all stress categories.
 P a g e 4 AD-Merkblatl S 4, Edition 2.98
6.2.3 From the number of service loadings to be considered
two service loadings shall be selected by using one fixed
coordinate system so that the equivalent stress derived from
the difference of the pertinent stress tensors becomes a
maximum in accordance with the stress theory selected. This
maximum value is the equivalent stress range.
5 . 2 . 4 Where the loading conditions to be considered show
no change in the direction of principal stresses it will suffice,
upon application of Tresca’s maximum shear stress theory,
to form the maximum value of the differences of any two prin-
cipal stress differences of equal pairs of principal stress
directions. This maximum value then is the equivalent stress
range (according to Tresca’s maximum shear stress theory).
6 Limitation of equivalent stresses and
equivalent stress ranges
6.1 General
6.1.1 For each load case (service, testing, assembly, spe-
cial load cases) according to AD-Merkblatt S 3/O the equiva-
lent stresses and equivalent stress ranges shall be limited in
dependence of the mechanical properties of the material.
The limits fixed for these cases apply to full rectangular sec-
tions, as they are based e.g. on the considered distribution
of stresses in shell structures. For other sections the shape
factors shall be fixed in dependence of the respective load
behaviour.
6 . 1 . 2 In the case of equivalent stresses derived from pri-
mary stresses and equivalent stress ranges from primary and
secondary stresses the limitation shall be based on the nomi-
nal design stress f (allowable stress under static loading)
according to AD-Merkblatt S 310.
6.1.3 When deriving the allowable stress f in accordance
with AD-Merkblatt S 3/O the respective local temperature at
the point under consideration versus time may be used for
the various load cases (operating, testing, assembly and
special cases).
6.1.4 The equivalent stress ranges derived from primary
stresses, secondary stresses and peak stresses shall be
limited by means of a fatigue analysis performed in accord-
ance with AD-Merkblatt S 2.
6.2 Limitation of primary equivalent stresses
The primary equivalent stresses shall be limited for all load
. cases in accordance with AD-Merkblatt S 3/O to obtain
P, 5 f
P, 5 1.5 f
(P,+P,)or(PI+P,)s1.5f
P, 4 1.5 f
The classification of P, shall be decided as a function of the
arrangement of the areas under consideration in the compo-
nent, see Section 4.3.3.
6.3 Limitation of equivalent stress ranges resulting
from primary and secondary stresses
The equivalent stress range resulting from primary and
secondary stresses shall be limited for all load cases accord-
ing to AD-Merkblatt S 3/O to obtain
(P, + Pb + Q) or (P, + Pb + Q) 5 3 f
P,53f
For cast steel the equivalent stress range may be limited to
4 f instead of 3 f.
It depends on the location of the point under considera-
tion in the component whether the classification of P, as
secondary stress is acceptable.
6.4 Deviating limitation of equivalent stresses and
equivalent stress ranges
Except for the general primary membrane stress deviations
in the limitation of equivalent stresses and equivalent stress
ranges are possible if it is proved by other means that the
component meets the requirements (e.g. by tests on the
component, plastic analysis, or the like).
6.5 Limitation of stresses in case of tri-axial state of
stress
Where the stress analysis leads to a tri-axial state of stress,
the following condition shall be satisfied additionally when-
ever the smallest tensile stress exceeds half the highest
tensile stress to avoid brittle failure caused by the limited
ductility in this case:
max (u,; 9; 4 5 R,o.28
R p ,,0 B may be used instead of R, 0,2 B if the allowable stress
f under static loading according to AD-Merkblatt S 3/O has
been determined on the basis of this value.
7 Literature
111 KTA 3201.2: Auslegung, Konstruktion und Berechnung
von Komponenten des Primsrkreises von Leichtwasser-
reaktoren.
Beuth Verlag, Berlin (3/84).
PI KTA 3211.2: Auslegung, Konstruktion und Berechnung
von Komponenten der %uOeren Systeme von Leichtwas-
serreaktoren.
Beuth Verlag, Berlin (6/92).
t31 Criteria of the ASME Boiler and Pressure Vessel Code
for Design by Analysis.
The American Society of Mechanical Engineers, New
‘fork 1969.
[41 Kroenke, W.C.: Classification of finite element stresses
according to ASME Section III stress categories.
Technical paper presented to ASME 94th Winter Annual
Meeting. Detroit, Michigan. November 1 l-l 5, 1973.
151 VdTijV-Merkblatt 803: Richtlinien zur Durchfuhrung und
Auswertung von Dehnungsmessungen mit Dehnungs-
me8streifen (DMS), Edition March 1993.
Verlag TijV Rheinland GmbH, Cologne.
Dietmann, H. and H. Kockelmann: Verwendung der
El
Gestaltsanderungsenergiehypothese im Anwendungs-
bereich der KTA-Regeln.
VGB Kraftwerkstechnik 74 (1994), Issue 6.
 Page 5 AD-Merkblatt S 4, Edition 2.98

Table 1. Classification of equivalent stress intensity in vessels for some typical cases

Vessel part Location Origin of stress Type of stress Classifi-

cation

;ylindrical or Shell plate remote Internal pressure General membrane stress pill
jpherical shell from discontinuity Gradient through plate thickness Q
Axial thermal gradient Membrane stress Q
Bending stress Q
Junction with head or Internal pressure Membrane stressis) PI
flange Bending stress 0’)
4ny shell or Any section across External load or General membrane stress, averaged p,
lead entire vessel moment or internal across full section (stress component
pressure2) perpendicular to cross section)

External load or Bending stress across full section pill

moment2) (stress component perpendicular to
cross section)

Near nozzle or other External load or Membrane stress3) PI

opening moment or internal Bending stress Q
pressure2) Peak stress (fillet or corner) F

Any Temperature diffe- Membrane stress Q

rence between head Bending stress Q
and shell
3shed or Crown Internal pressure Membrane stress p,
:onical head Bending stress Pb
Knuckle or junction to Internal pressure Membrane stress WI
shell Bending stress Q

Flat head Centre region Internal pressure Membrane stress p,

Bending stress Pb

Junction to shell Internal pressure Membrane stress PI

Bending stress Q
Perforated Typical ligament in a Pressure Membrane stress p,
head or shell uniform pattern (averaged through cross section)
Bending stress pb
(averaged through width of ligament,
but gradient through plate)
Peak stress F

Isolated or atypical Pressure Membrane stress (as above) Q

ligament Bending stress (as above) F
Peak stress F

Nozzle Cross section Internal pressure or General membrane stress, averaged pill
perpendicular to external load or across full cross section
nozzle axis moment2) (stress component perpendicular to
cross section)

External load or Bending stress across nozzle cross p,

moment2) section
(continued on page 6)
P a g e 6 AD-Merkblait S 4. Edition 2.98

Vessel part Location Origin of stress Type of stress Classifi-

cation

Vozzle Nozzle wall Internal pressure General membrane stress p,

[cont.) Local membrane stress pi
Bending stress Q
Peak stress F

Differential expansion Membrane stress Q

Bending stress Q
Peak stress F

Cladding Any Differential expansion Membrane stress F

Peak stress F

fw Any Radial temperature Equivalent linear stress@) Q

distribution5) Non-linear portion of stress F
distribution

Any Any Any Stress concentration through notch F

effect
1) I f t h e b e n d i n g m o m e n t a t t h e e d g e i s r e q u i r e d t o m a i n t a i n t h e b e n d i n g s t r e s s i n t h e m i d d l e o f t h e h e a d o r p l a t e w i t h i n a c c e p t a b l e l i m i t s
t h e e d g e b e n d i n g i s c l a s s i f i e d a s Pb
2) T o i n c l u d e a l l p i p e e n d f o r c e s r e s u l t i n g f r o m d e a d w e i g h t , v i b r a t i o n s a n d r e s t r a i n t t o t h e r m a l e x p a n s i o n a s w e l l a s i n e r t i a l f o r c e s .
3) O u t s i d e t h e a r e a c o n t a i n i n g t h e d i s c o n t i n u i t y t h e m e m b r a n e s t r e s s i n m e r i d i o n a l a n d c i r c u m f e r e n t i a l d i r e c t i o n o f t h e s h e l l s h a l l n o
e x c e e d 1 .l . S, a n d t h e l e n g t h o f t h i s a r e a s h a l l n o t e x c e e d 1 .O X6-e.
1) C o n s i d e r a t i o n s h a l l b e g i v e n t o t h e p o s s i b i l i t y o f w r i n k l i n g a n d e x c e s s i v e d e f o r m a t i o n i n t h i n - w a l l e d v e s s e l s ( l a r g e d i a m e t e r - t o - t h i c k n e s s
ratio).
;) Consider possibility of thermal stress ratcheting.
‘) T h e e q u i v a l e n t l i n e a r s t r e s s i s d e f i n e d a s t h e l i n e a r s t r e s s d i s t r i b u t i o n w h i c h h a s t h e s a m e n e t b e n d i n g m o m e n t a s t h e a c t u a l s t r e s s
distribution.
 Page 7 AD-Merkblatt S 4, Edition 2.98

Table 2. Classification of equivalent stress intensity in piping for some typical cases

Piping Location Origin of stress Type of stress Classifi-

component ’ cation
Straight pipe or Location remote from Internal pressure Average membrane stress p,
:ube, elbows, discontinuities
and reducers,
ntersections Sustained mechani- Bending stress across section Pb

snd b r a n c h cal loads incl. dead (stress component perpendicular to

:onnections, weight and inertial cross section)
except in forces
:rotch regions Location with discon- internal pressure Membrane stress PI
tinuities (wall thick- (through wall thickness)
ness transitions, con- Bending stress c?
nection of different (through wall thickness)
piping components)
Sustained mechani- Membrane stress p,
cal loads incl. dead (through wall thickness)
weight and inertial Bending stress Q
forces (through wall thickness)
Restrained thermal Membrane stress p,
expansion Bending stress p,
Axial thermal gradient Membrane stress Q
Bending stress Q

Any Any Peak stress F

Branch con- In crotch region Internal pressure, Membrane stress PI
sections and sustained mechanical Bending s t r e s s Q
tees loads, including dead
weight and inertial
forces as well as
restraint to thermal
expansion
Axial thermal gradient Membrane stress Q
Bending stress Q

Any Peak stress F

Flanges Remote from Internal pressure, Average membrane stress pill
discontinuities gasket compression, Bending stress Pb
bolt loads
Wall thickness Internal pressure, Membrane stress PI
transitions gasket compression, Bending stress Q
bolt loads

Axial or radial Membrane stress Q

thermal gradient Bending stress Q
Restrained thermal Membrane stress p,
expansion Bending stress PC?

Any Peak stress F

Any Any Radial thermal Equivalent portionz) of bending F

gradient’) stress through wall
) Peak stress I F
) Consider possibility of thermal stress ratcheting.
!) T h e equivalent linear stress is defined as the linear stress distribution which has the same net bending moment as the actual stress
distribution.
P a g e 8 AD-Merkblatt S 4, Edition 2.98

Table 3. Classification of equivalent stress intensity of integral areas of component support structures for some typical cases

Type of Location Origin of stress Type of stress Classifi-

component action
support
structure

Any shell Any section through Force or moment to General membrane stress, averaged pill
the entire component be withstood across full section (stress component
support structure perpendicular to cross section)

Force or moment to Bending stress across full section Pb

be withstood (stress component perpendicular to
cross section)

Near discontinuity’) Force or moment to Membrane stress pill

or opening be withstood Bending stress Q2)

Any Restrained thermal Membrane stress p,

expansion3) Bending stress p,
Any plate or Any Force or moment to Membrane stress p,
disk be withstood Bending stress Pb

Near discontinuity’) Force or moment to Membrane stress pll7

or opening be withstood Bending stress W

Any Restrained thermal Membrane stress p,

expansion3) Bending stress p,
1) Discontinuities mean essential changes in geometry such as wall thickness changes and transitions between different types of shells
Local stress concentrations, e.g. on fillets and corners are no discontinuities.
2) Calculation not required.
3) These are stresses resulting from restraints of free end displacements or different displacements of component support structure:
or anchors, including stress intensifications occurring at structural discontinuities, but excluding restraint due to thermal expansiol
of piping systems. The forces and moments from restrained thermal expansion of piping systems are considered to be “forces o
moments to be withstood” by the component support structure.
UDC 621.646.88:621.642-98 Edition January 1995

Equipment Safety devices against AD-Merkblatt

of excess pressure
Pressure Vessels Bursting safety devices A l

The AD-MerkbWer are compiled by the seven trade associafions specified below who together form the ‘Arbeitsgemeinschaft Druck-
behdlter” (AD). AD-Merkblatt G 1 covers the composition and application of AD-RegulaBons and a/so procedural guidelines.
T h e AD-Merkbldtter c o n t a i n saferyrequirements w h i c h m u s t b e a d o p t e d fornormaloperating c o n d i t i o n s . I n t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of maferials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behllter- und Rohrleitungsbau e.V. (FDBR), Dijsseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sankt Augustin
Verband der Chemischen lndustrie e.V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhijttenleute (VDEhj, Diisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r Grol3kraftwerksbetreiber e.V., E s s e n
Verband der Technischen iiberwachungs-Vereine e. V. (VdTiiV), Essen.
T h e AD-Merkbldtter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s t o k e e p w i t h t h e s t a t e - o f - t h e - a r t . R e l e v a n t p r o p o s a l s s h o u l d b e
addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents

1 Scope 6 Materials
2 General 7 Design of bursting safety devices and
3 Types of bursting elements and vacuum feed lines
connections 8 Manufacturer’s test
4 Clamping devices 9 Marking
5 Utilization, use and arrangement of 10 Cross sections and lines
bursting safety devices
I

1 Scope 2.2 Bursting safety devices comprise a bursting element

and a clamping device’). Vacuum connections, knife-edge
This AD-Merkblatt applies to bursting safety devices as devices and trapping devices can also be component parts
safety devices against excess pressure. of a bursting safety device. The bursting elements are ruptu-
red by their response and this results in sudden release of
the relief cross-section. In contrast with safety valves, the
2 General relief cross-section remains open after the response of the
bursting safety devices.
2.1 Bursting safety devices according to this AD-Merkblatt
For design reasons, bursting discs may be ejected or retai-
shall automatically prevent the permissible working pressure ned by the clamping device.
being exceeded by more than 10 %.
Bursting safety devices shall operate reliably on the basis of 2.3 The use bursting safety devices will be considered
the individual mode of operation of the pressure space and if, e.g.
especially the charge material, the pressure and the tem- (1) a rapid pressure rise has to be taken into account,
perature and shall be able to remove the mass flow to be (2) the operating conditions can result in deposits and jam-
eliminated in an emergency. ming which might impair the efficiency of other safety
The reliability as regards correct operation can be establis- devices against excess pressure,
hed by a type test in accordance with the “Guidelines for type (3) there are increased seal requirements,
testing of bursting safety devices” (see Appendix 1 to this
AD-Merkblatt”)) for the proposed pressure range. (4) large relief cross-sections are necessary.

1) Bursting safety devices as defined in this AD-Merkblatt are only the components
‘1 In preparation Uesignated as integral by the manufacturer.

Supersedes Edition May 1992; 1 = amendments to the previous Edition

Carl Heymanns Verlag KG Translation: Technical Help to Exporters Service of BSI

Luxemburger StraBe 449, 50939 K6ln
GutenbergstraRe 3. 10587 Berlin
Page 2 AD-Merkblatt A 1, Edition 01.95
3 Types of bursting elements and vacuum
connections
3.1 Dished bursting discs
3.1 .l Concave-dished bursting discs
In this type of bursting disc, the concave side is on the pres-
sure side of the system being protected. The disc fails when
the response pressure is reached.
3.1.2 Convex-dished bursting discs
(reversing bursting discs)
In this type of disc, it is the convex side which is on the pres-
sure side of the system being protected. The dished surface
deflects and becomes concave when the response pressure
is reached. The disc is ruptured, e.g. by striking knife-edges
or by being ruptured by protrusions.
3.2 Plane bursting discs
3.2.1 Plane bursting discs made of a tough ductile
material
This type of disc, installed plane, deforms and ruptures when
the response pressure is reached as a result of its tensile
strength being exceeded.
3.2.2 Plane bursting discs made of a brittle non-ductile
material
This type of disc, installed plane, breaks when the response
pressure is reached as a result of its flexural and shear
strength being exceeded.
3.3 Bursting discs with a vacuum connection
The bursting discs mentioned in Sections 3.1 and 3.2 may
also be fitted with a vacuum connection. Vacuum connec-
tions which are not destroyed when the bursting disc
responds allow the pressure of the system being protected
to act on the bursting elements through apertures. If the
vacuum connection remains undamaged when the bursting
safety device responds, it can be reused with an element of
the same type once the destroyed bursting element has been
replaced. However, first of all an inspection to ensure that the
connection is undamaged and that the fit between the
connection and bursting element is satisfactory shall be per-
formed.
Vacuum connections which are destroyed when the bursting
disc responds extensively relieve the flow cross-section.
3.4 Other bursting elements
Other bursting elements include e.g. breaking caps, ruptu-
ring bolts and buckling rods.
4 Clamping devices
Clamping devices may have a substantial effect on the mini-
mum pressure of response of the bursting element. Conse-
quently, bursting elements should be installed in clamping
devices specified by the manufacturer oi in the type test in
order to guarantee safe functioning.
Structural measures shall be taken to design bursting ele-
ments which might compromise correct operation if they are
fitted the wrong way round in the clamping device in order
to ensure that it is impossible to fit them in the clamping
device the wrong way round, e.g. by designing the clamping
surfaces so that they are asymmetrical or positive locking.
5 Utilization, use and arrangement of
bursting safety devices
5.1 General
The manufacturer shall supply written instructions for the
transport, storage, installation and operation of the devices.
5.2 Utilization
52.1 Response pressure and operating pressure
The response pressure lies within a tolerance range having
maximum and minimum limit values specified by the manu-
facturer. The maximum response pressure shall be selected
so that the permissible working pressure of the pressure
space being protected is not exceeded by more than 10%
(cf. Section 7). To ensure the service life, the minimum
response pressure shall be adequately in excess of the maxi-
mum pressure obtained during operation (maximum working
pressure’)).
5.2.2 Service life
The service life of the bursting element is a function of the
type of bursting safety device, the creep strength of the bur-
sting element and the operating conditions. Fluctuating load-
ing, temperature influences and corrosion will significantly
reduce service life. As the service life can only be predicted
approximately, the bursting safety device should be renewed
at appropriate intervals.
5.2.3 Temperature influence
Bursting elements are characterized by a material-specific
dependance of the response pressure on the temperature.
They shall be designed for a specific pressure taking tem-
perature into account.
If there is more than one operating state to be protected, e.g.:
- a single given pressure at different temperatures, or
- different pressures between bursting elements and pres-
sure vessel space to be protected,
- the effect of ambient temperature, room temperature or
temperature due to the weather on the bursting element,
allowance shall be made for these factors.
5.2.4 Rapid rise in pressure
In the case of bursting safety devices used to safeguard
against a possible rapid rise in pressure, the parameters of
importance in designing the bursting safety device, e.g.
increase in pressure over time and flow of material to be
disposed of, are to be determined-where applicable through
suitable measurements carried out on test vessels. In the
absence of reliable data in this connection and if no other
measures are possible, the cross section shall be increased
appropriately.
The arrangement, response characteristics, geometry and
maximum pressure response influence the relief from press-
ure. It is permissible to subdivide the required relief cross-
section over more than one bursting safety device. The
objective should be to ensure that the bursting elements are
struck perpendicularly by any pressure wave which may
occur.
2) For definitions see DIN 3320

52.5 Stressing by backpressure or vacuum
If a bursting safety device may also be stressed by backpress-
ure or vacuum, the bursting safety device shall be designed
for this stressing or a type which has a vacuum connection
shall be used. The edges of the apertures in the vacuum con-
nection shall be machined in such a way as to prevent
damage and thus any premature response of the bursting
discs. In determining the necessary cross section, allowance
shall be made for the decrease in the free flow cross-section
due to the remaining part of the vacuum connection after
bursting.
5.3 Arrangement of bursting safety devices
5.3.1 Any fragments formed on rupture of the bursting ele-
ment shall not cause any hazard. Any leaking medium shall
be disposed of safely.
5.3.2 Bursting elements shall be easily renewable. They
shall be protected against damage and other external factors
(e.g. deposits, precipitation).
5.4 Combinations of safety valves and bursting safety
devices
Combinations of safety valves and bursting safety devices
are used to protected the safety valve from negative influen-
ces, e.g.
- for mediawhich are inclined to stick, encrust or cause dirt;
- for media with solid particles;
- for corrosive media;
- if particular sealing is required for a medium and/or empty-
ing of the system is to be prevented.
5.4.1 Examples of combinations
5.4.1.1 Bursting safety devices can be arranged either
before or after the safety valve. A bursting device-safety
valve-bursting device arrangement is also possible.
5.4.1.2 Parallel arrangement of safety valve and bursting
safety device
This arrangement is chosen, for example when the possibility
of a rapid pressure rise in accordance with Section 5.2.4 has
to be allowed for. The safety valve serves as a primary
response safety device. The nominal response pressure of
the bursting element is normally higher than that of the safety
valve.
5.4.2 Requirements for the combinations
5.4.2.1 Where possible non-fragmenting bursting elements
shall be used for bursting safety elements before safety
valves.
Suitable measures (e.g. capture devices) shall be used for
fragmenting bursting elements to ensure that the safety valve
cannot be rendered inoperative by fragments of the bursting
element.
The clearance or volume between the bursting safety device
and safety valve shall be chosen such that a correct opening
of the bursting element is ensured. The recommendations of
the manufacturer shall also be observed.
It shall be possible to draw off any condensate which forms
between the bursting disc and safety valve.
5.4.2.2 Feed lines and bursting safety devices before
safety valves shall be designed in accordance with
AD-Merkblatt A 2 such that the pressure loss in the feed line
at the maximum drawn off mass flow does not exceed 3 %
of the pressure difference between the permissible working
pressure and the external backpressure.
Page 3 AD-Merkblati A 1, Edition 01.95
The influence on the pressure loss by parts of the bursting
elements which remain in the clamping device after the
element has responded is allowed for if the cross-section of
the clamping devices corresponds to the following conditions
and the bursting element is mounted directly before the
safety valve.
A geom . a > I,5 . A0 . a,
Bursting disc Safety valve
A geom Geometric cross-section of bursting ele-
ments (restrictions in the cross-section,
e.g. due to sealing devices or non-destruc-
tible vacuum connections are allowed for;
restrictions in cross section, for example
due to parts of the bursting element which
remain after the bursting safety device has
operated, are not allowed for)
a Outflow coefficient in accordance with
Fig. 2
Ao Narrowest flow cross section of safety
valve
a, Outflow coefficient of safety valve
5.4.2.3 If the applicant wishes, an outflow coefficient for a
specific combination of bursting safety device and safety
valve can be determined by testing.
5.4.2.4 If a bursting safety device is positioned before or
after a safety valve, a special devrce shall be provided (e.g.
free release, alarm pressure gauge) to detect any leak or
response of the bursting element, since any backpressure in
the space between both safety devices would change the
response pressure of the bursting safety device or safety
valve.
The bursting pressure of the bursting safety device on the
outlet end of a safety valve shall be substantially lower
than the response pressure of the safety valve and shall be
selected such that the response behaviour of the safety
valve is not disturbed by a build up in back pressure between
the safety valve and bursting safety device (due to leakage
or the onset of blow-off). In this case the flow loss in the
blow-off line shall not exceed the permissible backpressure
of the safety valve specified by the manufacturer.
54.3 Combinations of safety valves with other bursting
elements shall be treated as appropriate in accordance with
Section 3.4.
6 Materials
6.1 The bursting safety device shall only be made of materi-
als suitable for the operating conditions at the installation site.
6.2 The strength properties of the materials used for the
bursting elements shall be as independent as possible of the
nature of stressing (static, fluctuating), temperature and the
duration of the stressing (creep strength).
6 . 3 The initial materials used to manufacture the bursting
elements (foil, block) shall have homogeneous mechanical
and technological properties, e.g. through heat treatment.
6 . 4 The risk of corrosion of the bursting elements due to the
contents of the vessel or the atmosphere shall be count-
ered by the use of corrosion-resistant materials, coatings or
protective foils.
Page 4 AD-Merkblati A 1, Edition 01.95

7 Design of bursting safety devices and Where:

feed lines Ao required narrowest flow cross-section
of the bursting safety device in mm2
7.1 Bursting safety devices shall respond by suddenly re-
9m mass flow to be discharged in kg/h
leasing at least the narrowest required cross-section. They
shall be designed on the basis of the pressure losses in the Rl gas constant
feed lines and blow-off lines and the possibility of back pres-
sure to ensure that the permissible working pressure of the
pressure space being protected is not exceeded by more Ro universal gas constant
than 10%. The design shall allow for the fact that the con-
figuration of the feed line to the bursting safety device and M molar mass i n -!?L
kmol
the consequent reduction of the stream can gradually
influence the blow-off line. T absolute temperature of the medium
in the pressure space in K
7.2 Gases and vapours Z real gas factor of the medium in the
7.2.1 The general relation for dimensioning the minimum pressure space
flow cross-section is: PO absolute pressure in the pressure
Qm space in bar
A= (1) V specific volume of the medium in the
pressure space in m3lkg
outflow function -
Y
Where: a combined outflow coefficient of the
connection and bursting safety device
A narrowest flow cross-section
according to Sections 7.2.4 or 7.2.5 -
9m mass flow to be discharged
PO absolute pressure in the pressure space The outflow function w can be calculated according to Sec-
V specific volume of the medium in the pressure space tion 7.2.1 or be taken from Fig. i as a function of the
pressure ratio and the isentropic exponent. Material values
a outflow coefficient
for several important gases and vapours at standard tem-
v outflow function perature and pressures are listed in Table 1. These values
In the case of subcritical pressure ratios: can generally also be used for conditions which deviate from
standard temperature and pressure.
However, the isentropic exponent k may differ from the
values stated in Table 1 at higher pressures and temperatu-
res other than 273 K. For example, at 100 bar and 293 K the
value of k for air is 1,60 and ymax changes from 0,484 to
k
0,507.
(2)
In the case of the gases listed in Table 1, the value Z for the
In the case of supercritical pressure ratios: real gas factor at standard temperature and pressure only dif-
1
fers slightly from l,O. On deviation from the standard tem-
k - l perature and pressure the values can differ from 1,0 (e.g.
(3) Z = 0,8 for ethylene at 30 bar and 20 “C).
The values of the isentropic exponent and the real gas factor
Where: can be taken for the calculations from VDI 2040 Part 43),
PO absolute pressure in the pressure space in bar at present drawt January 1990, or from the Data Book on
Pa0 absolute backpressure (beyond the Hydrocarbons4) example.
narrowest required cross-section) in bar
Dimensioning for steam may also be performed according to
k isentropic exponent of the medium in DIN 3320 Part 1 Section 3.
the pressure space -

7 . 2 . 2 In the case of industrial gases and vapours the speci- 7.2.3 The free flow cross-section shall 2 Ao. Allowance
fic volume is calculated from the general equation shall be made for any reductions in cross section, e.g. caused
v= R,.T.Z ~ by vacuum connections, trapping devices or by parts which
(4) remain after the bursting safety device has responded.
PO
Introducing this expression into equation (l), we get the 7 . 2 . 4 The outflow coefficient according to Fig. 2, column 2
following numerical-value equation: caused by the flow reduction shall be used to calculate the
A0 = 0,001964 . qm required narrowest flow cross-section at supercritical pres-
YR,+T.z
w. a.Po sure ratios for bursting safety devices having a free flow
cross-section exceeding 0,5 x the cross section of the feed
R, = 2 gives: line AL. If the free flow cross-section of the bursting safety
device exceeds the cross section of the feed line, the latter
A0 = 0,1791 . 9m . (6) is decisive in terms of the flow cross-section.
v*a-P0

or
3) VDI 2040 Part 4, draft January 1990; Principles of calculations for flow measure-
A0 = 0,6211 . 9m (64 ment wng restrictor devices, values for materials
4) Data Book on Hydrocarbon by J. Maxwell; D. van Nostrand Company Inc..
Toronto/New York/London
 Page 5 AD-Merkblatt A 1, Edition 01.95

Table 1. Gas constant, molar mass, isentropic exponent 7.4 Boiling liquids

Gas Isentropic Molar mass There are currently no generally accepted design ruless)
constant exponent k M for boiling liquids and other liquids which give off gas on
RI for STP’) expansion to the back pressure.

I I 1 8 Manufacturer’s test
Acetylene 318.82 1,23 26,040
8.1 For bursting safety devices which are fittings of pres-
Ammonia sure vessels which are subject to inspection by the autho-
rized inspector, inspection is performed by the authorized
inspector. For bursting safety devices which are fittings of
pressure vessels which are subject to inspection by the
expert, inspection is performed by the expert who
generally relies on the manufacture’s data.
8 . 2 Bursting elements are tested according to production
batch. This covers checking of dimensions, establishing
the actual response pressure on selected bursting ele-
ments by bursting tests in the clamping device concerned
and ascertaining whether the response pressure thus
determined are within the tolerance range quoted by the
manufacture. Guide values on the number of bursting
tests to be carried out per production batch from the same
semi-finished product are given in Table 2.
Table 2. Guide values for the number of bursting tests

No. of bursting elements No. of bursting

of a production series’) tests

upto 8 2
9to 15 3
16 to 30 4
31 to 100 6
101 to 250 8
251 to 1000 10
7 . 2 . 5 Where an outflow coefficient c( has been determined 1) Production series does not include the number of test samples
experimentally for a specific configuration or design of a feed
line having a bursting safety device, the value used in the If the manufacturer shows, over a relatively long period, that
equation shall be reduced by 10%. the tolerances quoted by him for the bursting pressure are
always complied with by bursting elements of identical type,
the number of bursting tests based on the guide values in
7.3 Liquids
Table 2 may be reduced in accordance with Table 3. The
figure obtained shall be rounded off to a whole number of
7.3.1 For liquids which do not boil (liquids which no not
tests.
undergo a phase transition when entering the blow-off line)
the following applies:
Table 3. Guide values for reduction for the scope of testing
A0 = 0,6211 4m
(7)
a ILiF-F No. of parts Reduction of No. of
Class manufactured tests according to
Where: of identical type Table 2
.:
A0 required’narrowest flow cross-section
of bursting safety device in mm2 1 50 to 249 75 %
2 250 to 999 50 %
q,,, mass flow to be discharged in kg/h
3 1000 to 4999 30 %
e specific gravity inks 4 5000 to 9999 20 %
m3 5 over to 10000 10 %
j Ap p0 - pa0 pressure difference in bar
a outflow coefficient according to Fig. 2,
column 3 8.3 Testing of the bursting elements shall be performed
using a suitable neutral test medium. The pressure system
7.3.2 The free flow cross-section shall 2 AO. Allowance shall have a sufficiently large capacity, particularly in the case
shall be made for any reductions in cross section, e.g. of reversing bursting discs.
caused by vacuum connections, trapping devices or by
5) VdTilV-Merkblatl on safety valves 100/Z entitled “Dimensioning PrOpOSal for
parts, which remain after the bursting safety device has safety valves for gases in the liquid state”, Edition January 1973 can be used as
responded. a source of information.
-
Page 6 AD-Merkblatt A 1, Edition 01.95
8 . 4 If the bursting element is exclusively designed for tem-
peratures above or below room temperature for process rea-
sons, the tests shall be carried out at this temperature. Tests
at room temperature will be sufficient, however, if the bursting
pressures in the temperature range concerned are identical
or the deviations are known and demonstrated. Process
records of the manufacturer can be used by way of demon-
stration.
8 . 5 A certificate concerning the tests carried out shall be
completed, giving the test temperatures, the response pres-
sures determined, the marking required in accordance with
Section 9 and the clamping device used during the test (e.g.
type mark, DIN designation of the flange used).
9 Marking
9.1 Each bursting element shall be legibly and permanently
marked to indicate the following:
- manufacturer,
- type mark,
- number of production series,
- free flow cross-section,
- material No. or material designation,
- maximum response pressure at room temperature and
operating temperature if applicable,
- minimum response pressure at room temperature and
operating temperature if applicable,
- relevant clamping device, e.g. type mark, DIN No.,
- blow-off side.
If the size of the bursting element is insufficient for the entire
required marking to be applied, a suitable fully-identifiable
packing shall be used which shall remain sealed until the time
of fitting and be retained until testing or until the last bursting
element is used (disassembled).
For bursting elements having no special clamping device, the
correct direction of flow shall be marked so that it is externally
apparent when the bursting element is fitted.
9 . 2 Type tested bursting safety devices shall also be mar-
kedwith the component mark.
9 . 3 Each clamping device shall be marked to indicate the
following:
- manufacturer’s mark,
- type mark,
- nominal pressure,
- nominal width,
- material No. or material designation.
9.4 On clamping devices of bursting safety devices, the
proper direction of flow shall be apparent at any time in the
fitted state, e.g. durably affixed arrow pointing in direction of
flow. For bursting elements which are constructed so that
they do not require any special clamping device, e.g. one-
part graphite bursting elements fitted directly between pipe-
line flanges, the proper direction of flow shall be indicated on
the clamping collar of the bursting element.
10 Cross sections and lines
10.1 It shall be impossible for bursting safety devices to be
made ineffective by shut-off devices. The installation of repla-
ceable fittings or locking devices is permissible if it can be
ensured that the required blow-off cross-section is released
at all times, even on switchover, and if the replaceable fitting
does not affect reliable operation of the bursting safety
device.
1 0 . 2 Bursting safety devices shall be located as close as
possible to the system being protected. Generally, lines are
required for hazard-free removal of the charge material. All
the lines shall be suitable for the pressures and temperatures
arising and be dimensioned and shaped so that the blow-off
volume can be discharged and effective operation of the bur-
sting safety device is ensured.
1 0 . 3 The lines and the bursting safety devices shall be se-
cured on the basis of the local operating conditions to that
the possible static and dynamic loading (reacting forces) are
effectively absorbed.
1 0 . 4 Accumulation of liquids and separation of solid sub-
stances in the feed line and blow-off line of the bursting safety
device shall be prevented in so far as these can impair the
effective operation of the bursting safety device.
 Page 7 AD-Merkblatt A 1, Edition 01.95

outflow function
Fig. 1

1 ) No. (Cannectionv:iFss h a p e r ) liquids )

!
0,68 OS
Extended
1

i
I /I’:
B u t t - j o i n t e d or
flush-mounted
pipe and com-
pensating 0,62
0,73
flange with
high drag
factor I

Compensating
flange with l o w
drag factor
w i t h r o u n Gig’ ^ -n n_,_.80
U,U”
or tapered inlet
edges and
flared
connection

I I

Fig. 2 Outflow c o e f f i c i e n t a w i t h v a p o u r s , gases and liquids

ICS 23.020.30 Mav 2000 edition

Equipment Safety devices against AD-Merkblatt

of excess pressure
pressure vessels - Safety valves - A2

T h e AD-MerkbWer a r e c o m p i l e d b y t h e s e v e n a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “ A r b e i t s g e m e i n s c h a f t Druckbehdlter”
(AD), AD-Merkblatt G 1 covers the composition and application of AD-Regulations and also procedural guidelines.
T h e AD-Merkblatter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . In t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal level expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, BehBlter- und Rohrleitungsbau e. V. (FDBR), Diisseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sankt Augustin
Verband der Chemischen lndustrie e. V, (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhtittenleute (VOEh), Dijsseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GrooBkraftwerksbetreiber e. V., Essen
Verband der Technischen iiberwachungs-Vereine e. V. (VdTiiV), Essen.
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s l y b y t h e a b o v e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents
1 Scope 8 Manufacture, testing and marking of
2 General valve bodies
3 Grading of safety valves 9 Marking component-tested safety
4 General requirements for safety valves valves
5 Special requirements for controlled 10 Dimensioning
safety valves and necessary measures 11 Tests
6 Installation, lines and cross-sections 12 Special designs and applications
7 Materials 13 Safety shut-off valves

1 Scope consideration influences resulting from chemical properties.

This AD-Merkblati applies to safety devices guarding against
excess pressure for pressure vessels in which an unaccept-
able excess pressure is prevented by the opening of safety
valves or closing of safety shut-off valvesl).
2 GeneraP)
2.1 Safety valves shall comply with the latest technology
and be suitable for the intended use. This means that they
shall satisfy the applicable requirements as regards materi-
als and design, function reliably taking into consideration the
method of operation of a given pressure chamber - particu-
larly as regards the medium, pressure and temperature- and
be able to draw off the mass flow to be diverted in the event
of a fault, while complying with the requirements of TRB 403.
As a rule, reliability as regards proper function and mass flow
is determined by a component tests) for the proposed range
of use (pressure, temperature, medium) without taking into
‘) See also Footnote 11
2, For definitions see DIN 3320
Y For the methods and extent of the component test see VdTLWMerkblatt 100 on
Safety Valves. obtainable from the TOV-Verlag GmbH, P.O.Box 903060,
D-51 123 Cologne.
During the acceptance test of the pressure vessel, the correct
dimensioning, adjustment, layout and suitability for the
intended operating conditions and for the working medium
shall be tested, as well as reliability in the case of safety val-
ves not having been subjected to component testing.
2 . 2 Safety valves shall be so dimensioned and adjusted in
accordance with TRB 403 that exceeding the highest permis-
sible working pressure by more than 10 % is prevented.
2 . 3 Safety valves shall open at a pressure which does not
differ from the response pressure by more than 10 %. In the
case of response pressures < 1 bar, the difference in the
opening pressure can be up to 0,l bar. This should be taken
into consideration when specifying the response pressure in
accordance with 2.2.
2 . 4 Safety valves close at a pressure which is not more than
10 % below the response pressure in the case of compres-
sible media and 20 % in the case of incompressible media.
In the case of safety valves having a response pressure of
up to 3 bars, the reduction in pressure below the response
pressure can be up to 0,3 bar in the case of compressible
media and 0,6 bar in the case of incompressible media.
2 . 5 The response pressure and time between reaching the
response pressure and reaching the degree of lift necessary

Supersedes September 1998 edition; ( = Amendments to previous edition

Lao neymanns veriag KG

Translation: Technical Help to Exporters Service of BSI
Luxemburger StraRe 449. 50939 Kdln
page 2 AD-Merkblatt A 2, Edition 05.2000
for diverting the mass flow shall be adapted to the maximum
rate of change of pressure in the system being protected, par-
ticularly in the case of controlled safety valves. For controlled
valves the period of time is to be indicated, which is required
after reaching the response pressure, before the necessary
lift to divert the indicated mass flow is reached. It shall further
be indicated for which state of aggregation of the medium in
the control system the data apply.
3 Grading of safety valves
3.1 Grading of safety valves according to their opening
characteristics
3.1.1 Standard safety valves
These safety valves reach the degree of lift necessary for the
mass flow to be diverted following response within wlthi a pressure
rise of
of not
not more
more than
than1010%%(see
(see2.32.3for forexceptior
exception). No further
requirements
requirements areare made
made ofof the
the opening
opening A-*-, characteristics.
3.1.2 Full lift safety valves
Full lift safety valves, following response within the 5 % pres-
sure rise, open suddenly up to the full lift as limited by the
design. The amount of lift up to the sudden opening (propor-
tional range) shall not be more than 20% of the total lift.
3.1.3 Proportional safety valves
Proportional safety valves open more or less steadily in rela-
tion to the increase in pressure. No sudden opening occurs
unless the pressure increases beyond the range of more than
10% of the lift. Following response within a pressure
increase of up to 10 %, these safety valves achieve the lift
necessary for the mass flow to be diverted (see 2.3 for excep-
tion).
3.2 Classification of safety valves according to their
me
3.2.1 Direct-acting safety valves
Direct-acting safety valves are safety valves in which a direct
mechanical loading (a weight, a weight and lever or a spring)
acts as a closing force against the opening force acting on
the underside of the valve disc.
3.2.2 Controlled safety valves
Controlled safety valves consist of the main valve and a con-
trol device. They also include direct-acting safety valves with
supplementary loading in which, until the response pressure
is reached, an additional force increases the closing force.
The closing force and additional force can be applied mecha-
nically (e.g. by a spring), by outside energy (e.g. pneumati-
cally, hydraulically or electromagnetically) and/or by the
internal medium. If the response pressure is exceeded, the
force is automatically lifted or so reduced that the main valve
is opened by the pressure of the medium acting on the valve
disc or by some other force acting in the direction of opening.
The main valve can be operated here according to the
principle of loading or unloading, and control devices can
operate according to the principle of rest or operation.
The loading principle is characterized by the fact that the
main valve opens when the load is applied.
The unloading principle is characterized by the fact that the
main valve opens when the load is removed.
The rest principle of control is characterized by the fact that
on failure of the control energy the control device effects load-
ing or unloading. Control devices with an internal medium are
allocated to the rest principle.
The operation principle of control is characterized bv the fact
that on failure of the control energy the control deiice does
not effect any loading or unloading.
4 General requirements for safety valves
4.1 Protection against shift of adjustment
Safety valves shall be secured against unauthorized altera-
tion of the set pressure or response pressure and the method
of operation. Safety valves shall be secured to prevent their
mode of operation being altered, e.g. by means of a lead seal
between the valve body and spring pipe or by means of a
positive connection between the disc and the stem of the
valve (not rigid).
4.2 Guidance of the moving parts
Safety valves are to be so designed that movement of the
moving parts is not hindered even with unequal heating.
Where deposits are to be anticipated (e.a. dust) as a result
>-
of the operating med ,_... _. _. ____ :rnal influence, LI IL, yu’“‘.L
shall be so designed, or sufficiently protected against depo-
sits, that the function of the safety valve is not impaired.
Packings which might hinder the working of the valve by
causing friction are not permissible.
4.3 Lifting ability
4.3.1 It shall be possible for safety valves to be made to
open without external aids in the range 2 85% of the
response pressure.
4 . 3 . 2 The requirement according to 4.3.1 can be dispensed
with if this is necessary for operational reasons4) or if the ser-
viceability of the safety valve can be checked in some other
way (e.g. by means of change-over valves).
4.3.3 Safety valves which are able to be opened in the
I unoressurized state shall be speciallv constructed for this
p&pose (e.g. by positive connection between the disc and
stem of the valve).
4.4 Loading weight
In the case of safety valves which are loaded by a weight
through a lever, the loading weight shall be made in one
piece. In the case of safety valves having more than one
valve disc, the individual discs shall be independently loaded.
4.5 Design of the coil springs
Coil springs of spring-loaded safety valves shall be made so
that all the coils of the spring still remain at a distance one
from the other of 0,5 times the diameter of the wire or at least
2 mm at the required lift. If springs and sliding or rotating
metal parts are protected by diaphragms, bellows, covers or
the like against dirt or corrosion, smaller distances can be
permitted.
4.6 Requirements of the valve body
If necessary, it shall be possible to fit discharge pipes to the
safety valve bodies. It shall also be possible to fit the bodies
with a special means of fastening if the reaction forces arising
during discharge cannot be transmitted by the branch pipes.
It shall not be possible for condensate to collect in the valve
body.
4.7 Functional tests
Tests on the response pressure and checks on the smooth
running of moving par&s within the guides shall be carried out
at regular intervals (see also 4.2). The intervals for regular
4) For example in the case of installations operating with inflammable or poisonous
gases and in the case of refrigerating plants

tests shall be stipulated by the user in accordance with the
operating conditions, using as a basis the recommendations
of the manufacturer and the authorized inspector. These
tests and checks shall be carried out at the latest on the occa-
sion of the external or internal tests on the relevant pressure
vessel.
5 Special requirements for controlled safety
valves and necessary measures
5.1 Each control line is to be so dimensioned that the rele-
vant main valve still operates reliably in the case of failure of
the other lines. With the principle of loading the failure of one
control line shall not affect the serviceability of the others.
5 . 2 It shall be possible to open the main valve by manually
overriding the control. This requirement shall be satisfied
even in the case of failure (e.g. during testing) of a control
line. The facility for opening the main valve manually can be
dispensed with in the cases in 4.3.2.
5.3 At least three separate control lines, i.e. three pulse
transmitters and three control elements each with an inde-
pendent pressure sampling5), pulse6) and control line’), shall
be in operation for the purposes of control. A control line can
be temporarily taken out of service for purposes of testing
and repair. At least two control lines shall comply with the
principle of rest. With such control, more than one main valve
can be controlled.
When operating the main valves according to the unloading
principle, two control pipelines are sufficient. One control
pipeline is sufficient with the principle of unloading if a
blockage of the pipeline can safely be excluded. Prerequisi-
tes for this are outside medium control, the installation of fine
filters and a clear diameter of the control pipeline of at least
15 mm without any constriction.
It shall be possible to test on the installation that there is satis-
factory interaction between the control and the main valve.
Only those media with which fouling or corrosion of the con-
trol system is not anticipated may be used for control purpo-
ses. The accumulation of condensate in the control system
shall be prevented if this affects operational reliability.
5 . 4 Two control lines per main valve are sufficient if,
- should both control lines fail, the main valve ist fully open
by the time 1,2 times the permissible working pressure is
reached or
- the mass flow to be discharged is divided over a number
of main valves and each valve is separately controlled, if
on failure of one of the main valves the others can still dis-
charge at least 2/3 of the required mass flow.
5 . 5 When the main valve is operated according to the prin-
ciple of loading, two independent energy sources and energy
supply lines shall be available for loading. On the failure of
one energy source or energy supply line, the serviceability
of the main valve shall not be affected. Even failure of only
one of the two energy sources shall be indicated in such a
way that it is certain to be noticed immediately. This can be
dispensed with if the main valve opens automatically on the
failure of an energy source. A second energy source is not
necessary when an internal medium is used.
5 . 6 In the case of main and control valves where the system
pressure or control medium pressure acts on the valve disc
in the direction of closing, the opening force shall be designed
so that the main valve still opens fully even at 2 times the per-
missible working pressure or 2 times the maximum working
pressure of the control medium.
3 Line to pulse transmitter
“1 Line between pulse transmitter and control element
‘) LIIW between control element and main valve
P a g e 3 AD-Merkblatt A 2, Edition 05.2000
5 . 7 It shall be possible to test in operation each control line
from the pulse transmitter up to and including the relevant
control elements without it being necessary for the main
valve to trigger. It shall be ensured by means of suitable
equipment that only one control line can be put out of action
in each case for purposes of testing the pulse elements and
the control elements. Pressure measuring points shall be
available to the extent necessary for assessment of operatio-
nal reliability. Pressure measuring lines in control systems
shall be as short as possible.
5.8 Control valves for internal media with associated
pipelines and fittings
58.1 Control valves for internal media shall have a mini-
mum flow diameter d,, of at least 10 mm. The lift occurring
in each opening procedure shall be three times the minimum
lift at which the main valve starts to open (and in any case
at least 2 mm). This lift is to be specified within the terms of
the component or individual test.
5.82 Control pipelines shall be installed so as to be short
and to facilitate flow. Accumulation of condensate in the con-
trol lines and freezing of the control lines shall be prevented.
To enable condensate to be drawn off, pipelines shall be
given a gradient of at least 15 %. In the case of any variation
from the above, proper function of the controlled safety val-
ves shall nevertheless be ensured.
5.8.3 Control pipelines for media with which the possibility
of fouling or corrosion cannot be excluded are to be made
with a clear diameter of at least 15 mm, and shall not have
any constrictions.
5.9 Regular functional tests are necessary on controlled
safety valves.
As a deviation from the requirements of 4.7, an annual test
is required. The functional test shall be carried out in such
a way that in addition to the performance of the main valve
the serviceability of the individual lines can also be assessed.
A test shall be carried out to see whether the criteria of open-
ing, e.g. the size and timing of the loading and unloading for-
ces, ensure satisfactory performance up to the time the main
valve is fully open.
6 Installation, lines and cross-sections
6.1 Installations and lines
6.1.1 It shall not be possible for safety valves to be put out
of action by means of shut-off devices. It is permissible to
install changeover fittings or blocking devices if the design
of the devices ensures that the necessary discharge cross-
section is left free even during change-over. In the case of
installations which are equipped with more than one indepen-
dent safety valve, when one safety valve is being tested the
others may be blocked with correspondingly reduced perfor-
mance by the installation.
6.1.2 Direct-acting safety valves are generally installed in
an upright position taking the direction of flow into considera-
tion. The supply line shall be short and as far as possible
straight.
Branches to safety valves shall not be positioned opposite
other branch pipes.
The supply lines and discharge pipes of safety valves shall
be routed to facilitate flow.
Safety valves shall be protected against harmful external
influences such as atmospheric exposure, which could
impair their function.
The transfer of vibrations to the safety valve shall be avoided.
Page 4 AD-Merkblatt A 2, Edition 05.2000

Discharge pipes of safety valves shall discharge safely. No
liquid shall be able to accumulate in the discharge system.
If there is any risk of freezing up, the pipe shall be suitably
protected.
The pipes shall be dimensioned and routed, taking the local
operating conditions into account, in such a way that the sta-
tic, dynamic (reaction forces) and thermal loadings can be
safely absorbed.
In the case of safety valves where gas-evolving and vaporiz-
ing liquids such as hot water are expected to escape as well,
pressure release devices of sufficient size shall be fitted in
the immediate vicinity of the valve. These pressure release
devices shall have outlets with an adequate cross-section
both for drawing off the unpressurized vapour (gas) and for
drawing off the liquid.
Suitable protective devices shall be fitted to safety valves
when escape of the medium (e.g. even through the open
cover) might directly or indirectly endanger persons or the
environment.
In the case of controlled valves the requirements for the pres-
sure loss in the supply line only apply if they also function as
direct-acting safety valves in the event of failure of control.
For example for a pressure loss of 3 % in the supply lines to
safety valves, with the aid of the diagram in figure 2 it is pos-
sible to determine the permissible coefficient of resistance cZ
of the supply line and thus its maximum length LE. Using the
sum of the coefficients of resistance 5, (table 2) of the indivi-
dual pipeline parts and fitted parts and the coefficient of the
resistance of the straight pipe h k it is possible to deter-
DE
mine the permissible pipeline length LE with h from table 1:
If the calculated supply line length L, is less than that
required, reliability of operation shall be confirmed by test
under the existing conditions of installation and the actual
pressure loss in the supply line shall be taken into considera-
tion when dimensioning the safety valve.

6.2 Cross-sections
6.2.1 The cross-section of the supply line shall not be smal-
Explanation of symbols
ler than the cross-section of the inlet to the safety valve. The
cross-section of the discharge pipe shall not be smaller than DE = Diameter of supply line
the cross-section of the outlet of the safety valve. AE = Cross-section of supply line
The diameter, the length of the discharge pipes, elbows, LE = Length of supply line when
silencers etc. determine the level of built-up inherent back straight
pressure. These parts shall be dimensioned and positioned A, = fi = minimum cross-
in such a way that the permissible back pressure specified 4 section of flow
by the manufacturer for the safety valve is not exceeded. k = isentropic exponent
6.2.2 The pressure loss in the supply line shall not exceed a,= allotted outflow coefficient
3 % of the difference in pressure between the response pres- A zz coefficient of pipe friction
sure and the extraneous back pressure in the case of the
5, = permissible coefficient of
maximum mass flow discharged. A precondition for proper resistance
functioning in the event of such pressure loss is that the diffe-
rence in closing pressure of the fitted safety valve shall be 5, = coefficient of resistance for
pipeline parts and fitted parts
at least 5 %. With a difference in closing pressure of less than
5% the difference between the pressure loss and the diffe- K = equivalent roughness
rence in closing pressure shall be at least 2%. Figure 1

Table 1 Coefficients of friction for K = 70 (rm (standard values)

DE [mm1 20 50 100 200 500

A PI 0,027 0,021 0,018 0,015 0,013

 c

P a g e 5 AD-Merkblatt A 2, Edition 05.2000

PaO’PO +

Figure 2 Permissible coefficient of resistance c, (for k = 1,3) for 3 % pressure loss (continuous line: vapours and gases,
broken line: also applies to liquids, regardless of the pressure ratio k = 1,3)
P a g e 6 AD-Merkblatt A 2, Edition 05.2000

Explanatory note to figure 2

where

AP, = 0 03 . 1-2
PO ’ ( 1

and
k
k-1

and

k
k - i k-l
k+l
k

Limiting curve for Pao + 1:

PO

&%I the ratio of pressure loss to absolute pressure before the inlet into the system to be protected
PO=

F = the ratio of the absolute extranelous back pressure to the absolute pressure before the inlet into the system to be
protected
 Page 7 AD-Merkblatt A 2, Edition 05.2000

able 2 Coefficients of losses 5, (standard values)

Pipe bends Deflection losses for 6 # 90” and K = 70 tirn

20 50 100 200

170 0,42 0,33 0,27

0,23
0,24 0,19
1,25 0,35 0,28 0,20 0,16
I,6 0,29 0,23 0,19 0,17 0,14
2 0,25 0,19 0,16 0,14 0,12
2s 0,22 0,17 0,15 0,13 0,lO
3,15 0,20 0,15 0,13 0,ll 0,lO
for 6 f 90” 4 0,18 0,14 0,12 0,lO 0,lO
5 0,16 0,12 0,lO 0,lO 0,lO
63 0,14 0,ll 0,lO 0,lO 0,lO
5ua = (“90 ’ & 8 0,12 0,lO 0,lO 0,lO 0,lO
$ 10 0,14 0,ll 0,lO 0,lO 0,lO

well rounded O,l

Supply line nozzles
edge cut off normally 0,25

edge sharp or pierced pipe OS0

Progressive cross-sectional
constriction

relative to the constricted cross-section 0.1

Right-angled T-pieces Connection pieces in the gate 0,353)

sharp-edged
case-hardened
in the branch 1,283)

Connection pieces necked out or 0,231

0,753)

Change-over valve/blocking devices ‘1

1) Standard extended T-pieces for the high pressure lines
2) Determination of 5 value required
3) Relative to the dynamic pressure in the pipe going out to the safety valve

6.3 Back pressures on the outlet side, which affect the
response pressure and the opening forces or the mass flow,
are to be taken into account. The manufacturer shall specify
up to which back pressure pa the correct functioning of the
safety valve is ensured and the mass flow to be discharged
(see 2.2) is reliably achieved.
If the discharge pipe of a safety valve discharges into a mains
system installed after it, then the safety valve shall be
adjusted and dimensioned so that at the maximum super-
imposed back pressure pa it begins to discharge in good time
and at the highest possible back pressure paf it is able to dis-
charge the required mass flow.
6 . 4 Safety valves shall be accessible for the purposes of
testing their serviceability and for maintenance.
6.5 The manufacturer’s installation instructions shall be
followed.
7 Materials
The materials of all parts stressed by the medium shall be
selected in accordance with the relevant generally accepted
technical rules in such a way that they are suitable for the
pressures and temperatures arising. This also applies to
supply, discharge and condensate drainage pipelines. Mate-
rials for bodies shall comply with TRB 801 No. 45.
Safety valves shall be designed so that their serviceability is
not impaired by baking. This can be achieved for example by
.the use of different types of material for the valve disc and
 n

page 8 AD-Merkblatt A 2, Edition 05.2000

the valve seat, such as martensitic and austenitic materials, If necessary, where there are relatively large differences in
or corrosion-resistant hard alloys such as stellite. This is the pressure in the upstream and downstream pressure sections
case in particular when using safety valves in systems with of the safety valve bodies, the pressure test can be carried
steam, condensate, hot water and feed-water. out separately for the two sections, taking into account the
ruling pressures.
8 Manufacture, testing and marking of valve
bodies 9 Marking component-tested safety valves
The parts of the valve body which are subjected to pressure 9.1 Component tested safety valves shall also bear perma-
are to be manufactured, tested and marked in accordance nently and legibly the allotted component identification mark-
with TRB 801 No. 45 with: ing. Adhesive films are not permissible. By applying the com-
- nominal size, ponent identification marking, the manufacturer provides a
guarantee for the conformity of the safety valve with the com-
- nominal pressure or permissible working pressure and ponent test report including its appendices, for the correct
permissible working temperature at inlet (if required),
setting according to the pressure data in thecomponent iden-
- material, tification marking and for security against change of setting.
- manufacturer’s trademark, 9 . 2 The component identification marking is composed of
- arrow indicating direction of flow. the following details:

TijV . SV 00 . xxx xx . D/G:F . o.xx . x

FIWS

TijV s y m b o l

Safety valve

Year of component test, e.g.

Component test number 4

Min. flow diameter d, before 4

valve seat in mm

Identification letters 4
D indicating vapours
G indicating gases
F indicating liquids
F/KS indicating stationary pressure vessels
and vehicle tanks for liquid, granular and powdery products

Allotted outflow coefficient ct, t -I

or outflow in t/h or kg/h or I/min
Pressure setting p in bars 4 J

In the case of safety valves which are tested for different media, more than one identifying letter can be shown.

10 Dimensioning 10.4 Gases and vapours

10.1 The required minimum cross-section of flow before
10.4.1 The general relation for the dimensioning of the
the valve seat A, is to be calculated from the formulae in 10.4
minimum cross-section of flow is as follows
or 10.5.

1 0 . 2 The minimum flow diameter before the valve seat shall

be at least 6 mm (that of control valves according to 58.1 (2)
however shall be at least 10 mm), and in the case of pressure where:
vessels containing greasy or powdery media or media inc- A0 is the
minimum cross-section of flow
lined to coalesce it shall be at least 20 mm.
om is the
mass flow to be discharged
p. is the
absolute pressure in the pressure chamber
1 0 . 3 In the case of full lift safety valves the outflow coeffi-
is the
specific volume of the medium in the pressure
cient shall not be less than the value a, = 05 - except for v
valves which have restricted lift- and in the case of standard chamber
or proportional valves it shall not be less than the value a, is the the outflow coefficient allotted in the framework of
a, = 0,08 for D/G or the value a,., = 0.05 for F. Design limits the component test (often designated as CQ also)
for lift shall allow lift of at least 1 mm. q is the outflow function
 Page 9 AD-Merkblatt A 2, Edition 05.2000

k R. is the universal gas constant

For subcritical pressure ratios k-l
= 8314.3&

M is the molar mass

T is the absolute temperature of medium

*=J& J/hi” _ (&g (3)
in pressure chamber
Z is the compressibility factor of medium
in K

in pressure chamber -
p. is the absolute pressure in pressure
chamber in bar
For supercritical pressure ratios
V is the specific volume of medium in
pressure chamber in m3fkg
(4) ~1 is the outflow function -
cr, is the allotted outflow coefficient
where The outflow function IJI can be calculated as in 10.4.1 or
pa,, is the absolute back pressure in bar obtained from figure 3 as a function of the pressure ratio and
k is the isentropic exponent of the medium in the pressure the isentropic exponent. The physical characteristics for a
chamber few important gases and vapours in the standard state are
listed in table 3. They can also generally be used for states
10.4.2 In the case of industrial gases and vapours, the varying from the standard state.
specific volume is calculated from the general relation
The isentropic exponents can, however, vary from the values
v= R, .T.Z given in table 3 at higher pressures and at temperatures other
(5) than 273 K. For example, the value k for air at 100 bars and
PO
293 K is 1,60, so that vrnax changes from 0,484 to 0,507.
If this expression is substituted in equation (2), the following
numerical value equation is obtained For the gases mentioned in table 3, the value Z for the com-
pressibility factor in the standard state differs only slightly
from 1 ,O. With deviation from the standard state, the values
A,, = 0,001964 . lct qm
~&v’Po . jm ( 6 ) can differ from 1 ,O (e.g. for ethylene at 30 bars and 20 “C,
Z = 0,8).
For the purposes of calculation the values for the isentropic
With R, = $-this gives
exponent and the compressibility factor can be taken from,
= for example, VDINDE 2040 Part 4, September 1996
A , = 0,179i 9m (7) 1 editions) and Data Book on Hydrocarbons.
v ‘a, ‘PO’ J M-
For physical characteristics for refrigerants, see UVV
where: “Refrigerating plants” (VBG 20).

A0 is vminimum cross-section of flow in mm2

do is the minimum flow diameter in mm
q, is the mass flow to be discharged in kg/h 8) VDUVDE 2040 Part 4. September 1996 edition: Calculation principles for the
measurement of fluid flow using orifice plates, nozzles and venturi tubes - Fluid
R, is the gasconstant properties
I
 Page 10 AD-Merkblatt A 2, Editlon 05.2000

Table 3 Gas constant, molar mass, isentropic exponent

Gas constant Isentropic exponent k molar mass

Rl for the standard state’) M
~JJ, = 1,013 bar,
J-- k g
kg . K T= 273 K) kmol

Acetylene 318,82 1,23 26,040

Ammonia 488,151 1,31 17,031

Argon 208,15 1,65 39,940

Ethylene 296,36 1,25 28,050

Chlorine 117,24 1.34 70,910

Helium 2076,96 1,63 4,003

Carbon dioxide 188,91 1.30 44,010

Air 287,09 1,40 28,964

Methane 518,24 1,31 16,031

Oxygen 259,82 1,40 32,000

Sulphur dioxide 129,77 1,28 64,063

Nitrogen 296,76 1,40 28,016

I

Hydrogen 4124,ll 1,41 2,016

8) For further physical characterisfics as well as physical characteristics for states varying from the standard state, see VDI Heat Atlas and footnotesB) and 9,

1 0 . 4 . 3 For steam, the specific volume v and the isentropic 10.5 Liquids
1 exponent k can be obtained from the literatureg). 10.5.1 Non-boiling liquids
With the aid of the pressure medium coefficient x, which For non-boiling liquids (liquids which do not change phase
takes into account the properties of the outflowing steam and when flowing into the discharge pipe), the following applies
conversion of the non-coherent units, the following is
obtained for steam from formula (8)
A, = 0,621l . in mm’ (9)

A, = xq, in mm2 (8)

%.Po in which

in which density in kg/m3

P

JPO . v in h . mm2 bar AP=Po-P, pressure difference in bars

x=0,6211. -
* kg The units according to 10.4.2 are used for the remaining vari-
ables.
The pressure medium coefficient x is shown for supercritical
pressure release in figure 4. 10.5.2 Boiling liquids
For subcritical pressure release and for pressures < 2 bars, Dimensioning rules are being prepared for boiling liquids and
the pressure medium coefficient x shall be determined by for liquids which release gas during pressure release to the
computation (see also 7.3 of VdTijV-Merkblatt 100 on Safety counter pressure. See VdTijV-Merkblatt 10012 on Safety
Valves). Valves.
The units according to 10.4.2 are used for the remaining vari- 9) State variables of water and steam:
ables. Springer Verlag, Berlin, Heidelberg: 1969 edition
 Page 11 AD-Merkblatt A 2. Edition 05.2000

Pressure ratio p&J

Figure 3 Outflow function

Figure 4 Pressure medium coefficient x for SteatTI

11 Tests
11 .l Operational reliability, pressure setting range and
mass flow of the outflow shall be determined by means of
component testing or individual testing.
1 1 . 2 Component testing shall be performed in accordance
with VdTUV-Merkblatt 100 on Safety Valve@). It usually
takes place using neutral test media. Other media and tem-
peratures may be decided upon if they have comparable
physical properties or if deviations can be taken into account.
11.3 In the case of safety valves which have not undergone
component testing, operational reliability, pressure setting
and mass flow shall usually be determined by means of indi-
vidual testing within the context of acceptance testing based
upon VdTUV-Merkblatt 100 on Safety Valves.
11.4 The response pressure of each safety valve shall
be determined. This may be achieved using neutral media.
A certificate specifying the response pressure, the test
medium, the test temperature and the marking shall be
issued in respect of this. This is done by the authorized
inspector in the case of safety valves which are accessories
for pressure vessels which are required to undergo accept-
ance testing by the authorized inspector.
12 Special designs and applications
12.1 Safety valves for hydraulic fluids
Subject to the proviso that non-corrosive, self-lubricating and
ageing-resistant hydraulic fluids (e.g. hydraulic oils H-L
according to DIN 51524 and H-LP according to DIN 51525)
are used, that adequate purity of the hydraulic fluid is ensured
(by changing the fluid at appropriate intervals of time and by
filtering) and that the temperature of the medium does not
exceed approx. 60 “C, the following relaxation of require-
ments are permissible.
12.1 .l As a deviation from 5.8.1 and 10.2, the minimum
flow diameter at main valves and control valves shall be at
least 4,0 mm.
12.1.2 As a deviation from 5.4, two control lines are suffi-
cient when these are installed in accordance with the prin-
ciple of rest.
Page 13 AD-Merkblatt A 2, Edition 05.2000
12.1.3 For the safeguarding of pressure vessels for hydrau-
lic fluids where the product of the volume in litres and the per-
missible operating pressure in bars is 5 6000, notwithstand-
ing 5.4 and 5.5, one control line is sufficient if the main valve
reliably opens on reaching the response pressure should
nozzles, narrow bores and the like in the control system
become clogged.
12.2 Foil type safety valves
Owing to the special design of these safety valves, the
requirement specified in 2.4 does not apply.
1 2 . 3 Safety valves for oxygen are additionally to be marked
“Oxygen! Keep free from oil and grease!” or with the relevant
symbol according to the UVV on “Oxygen” (VBG 62).
I 13 Safety shut-off valveslo)
13.1 Safety shut-off valves are controlled valves with an
opposite direction of action to the main valve (see DIN 3320
Part 1, clause 2). They are installed on the supply side of a
system to be safeguarded and are open in normal operation.
In the case of an unacceptable increase in pressure, they
automatically shut off the flow of medium. Clauses 2.4, 4, 5,
6, 7, 8, 10 and 11 shall be applied as appropriate in such
cases. Dimensioning according to DIN 3320 Part 1 is not
required.
1 3 . 2 Devices such as perforated discs or screens which
safely prevent larger foreign bodies reaching the seat of a
valve are to be installed before the main valves in the direc-
tion of flow.
1 3 . 3 In spite of protective devices within the meaning of
13.2 being installed on the supply side, foreign bodies of the
diameter of the largest screen opening can prevent complete
closing of the main valve. The system to be safeguarded
which is installed after the safety shut-off valve shall therefore
additionally be equipped with a safety valve. This shall be so
dimensioned that the leakage flow possible according to sen-
tence 1 can be discharged.
1 ‘0) DIN 3380 Pari 3 applies in respect of safety shut-off valves of pressure vessels
in gas pipelines of the public gas supply system. The use of safety shut-off valves
according to clause 13 for pressure vessels intended for other purposes is sub-
ject to an exemption approval of the institution responsible on behalf of the opera-
tor for the statutory accident insurance.
UDC 621.642-98.005:62-774:621.646-l Edition Julv 1995

Equipment Openings, closures AD-Merkblatt

of and
Pressure Vessels closure elements A 5

The AD-MerkblAtter are compiled by the seven trade associations specified below who together form the ‘Arbeitsgemeinschaft Druck-
behdlter” (AD). AD-Merkblart G 7 covers the composition and application of AD-Regulations and also procedural guidelines.
T h e AD-Merkblstter c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . I n t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e.V. (FDBR), Diisseldorf
Hauptverband der gewerblichen Berufsgenossenschafn e. V., Sankt Augustin
Verband der Chemischen lndustrie e. V. (VU), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, FrankfurtlMain
Verein Deutscher Eisenhiittenleute (VDEh), Dtisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkraftwerksbetreiber e. V., Essen
Verband d e r T e c h n i s c h e n iiberwachungs-Vereine e . V . (VdTiiV), Essen.
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s l y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen ilbetwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents

1 Scope 3.2 General requirements

2 Openings 3 . 3 Additional requirements for yoke closures, quick-acting
closures and covers with special closure elements
2.1 General requirements
4 Closure elements
2.2 Nature and dimensions of openings
4.1 Clamp-bolts
2.3 Siting and accessibility of openings 4.2 Hinged bolts
3 Closures 5 Materials, calculations and manufacture of closures and
3.1 Definitions closure elements

1 Scope 2.1.2 Manholes and inspection ports are not necessary if

1.1 This AD-Merkblatt applies to openings, closures and
closure elements of pressure vessels, It contains require-
ments for the nature and dimensions of openings to enable
inspections to be carried out. Requirements regarding the
number and siting of openings are presented in Appendix 1
to this AD-Merkblatt.
Requirements for closures and
given.
1.2 Where other regulations apply to particular pressure
vessels, these are given in the TRB 800 series.
the tests can be carried out in some other manner, e.g. via
nozzles, pipe adaptors or other detachable parts.
2.1.3 Manholes and inspection ports are not necessary if
they are unviable or unsuitable due to the type of construction
of the pressure vessel (e.g. tube apparatus, plate heat
exchangers, heating and cooling jackets, pipe arrange-
closure elements are also ments), the method of operation or charge material.
2.1.4 Where necessary, attention is drawn to Annex V
No. 1.2.1.3 of the Hazardous Substances Order (GefStoffV)
as well as the Guidelines for Working in Containers and Con-
fined Spaces (Order Number ZH l/77 obtainable from Carl
Heymanns Verlag, Cologne).

2.2 Nature and dimensions of openings

2 Openings
The minimum dimensions specified in the following Table 1
2.1 General requirements
for the effective size of openings may be reduced by 20 mm
2.1 .l Pressure vessels shall be provided with openings - at most on account of the presence of coatings or linings only
the nature, dimensions, number and siting of which shall in the case of easy-access and restricted-access openings.
enable inspections to be carried out. These are manholes The nozzle height or ring height specified for openings repre-
(easy-access and restricted-access openings) and inspec- sents the maximum distance to be negotiated and maximum
tion ports (head holes, hand holes and peep holes). height restricting the view of the inside of the vessel.

Supersedes June 1986 edition; completely revised

Carl Heymanns Verlag KG Translation: Technical Help to Exporters Service of BSI

Luxemburger StraBe 449, 50939 Kdn
GutenbergstraRe 3. 10587 Berlin
Page 2 AD-Merkblatt A 5, Edition 7.95

Table 1. Overview of requirements and dimensions of openings

Inside diameter/ I Definitions and

Type
nominal width/ Nozz’e
ring Or I requirements
of
opening DN minimum I height
I
Round 1 Oval 1 Maximum
(mm) (mm) (mm) ;
I I
! 1 Access into thevessel shall be possible with the
Easy-access /
,.
opening 1 help of aids and personal protection gear.
I
normal ~ DN 600 / - I - ;
minimum / DN 500 ~ - 250 ~ Only when indispensable for design reasons
I, I
Restricted- 450 i 350 x 450 1 150 e.g. act. to Annex V No. 1 of the Hazardous
access I Substances Order and Guidelines for Working
I
openings in I in Containers and Confined Spaces (Order
I
special cases / I No. ZH 1177 obtainable from Carl Heymanns
I I Verlag, Cologne) for containers up to 10 m3
I
I capacity and when at least one additional vent
iDN 100 is present
I
Restricted- I I ! It shall be possible to move about within the
,
access openings ~ vessel without personal protective gear or aids;
normal ( 420 1320 x 420 I 150 straight , conical designs shall not be allowed to impair
420 320 x 420 / 175 tapered i accessibility.

minimum 1 400 ~ 300 x 400 1 150 straight / Only when indispensable for design reasons;
400 / 300 x 400 175 tapered ) restrictions due to coatings or linings are not
I I / permissible.

Head hole I 320 I 220 x 320 I 120 ~ Opening through which a head, an arm and a
I ~ light source can be introduced into the vessel
simultaneously.

Hand hole 120 ~ 100 x 150 65 straight ~ Opening through which a hand-held lamp and
120 ~100 x 150 ~ 100 tapered a hand can be introduced into the vessel
I simultaneously. If the maximum dimension of
1 the nozzle or ring height is exceeded for design
reasons, the opening shall be enlarged in such
a manner that the field of view afforded is
preserved.
Peep hole I 50 1 - 50 ~ Opening through which the inside of the vessel
can be inspected with the aid of special lighting
~ equipment. Smaller diameters or greater nozzle
~ heights are only permissible if they are
, indispensable for design reasons and the field
i ( of view afforded is preserved and/or the inspec-
tion is made possible by additional means
I (provision of suitable inspection equipment).

2.3 Siting and accessibility of openings
2.3.1 The positioning of the openings in the vessel shall be
governed by practical considerations and shall allow the
openings to serve their intended purpose; it is also neces-
sary for the space required inside vessels to be available to
permit a person to climb inside, to move about within the
vessel, or to enable inspections to be carried out, or, when
necessary, to enable persons to be rescued from the vessel.
In the case of an oval opening in a largely perpendicular wall,
the major axis should generally be horizontal.
2.3.2 If special aids (e.g. ladders, platforms, hand-holds)
are required for climbing into the vessel, moving about inside
it, or carrying out inspections through the openings, it is
necessary either for provision to be made in the design for
such aids, or it is for the operator to make them available at
the time of the inspection. This also applies for the removal
of closure covers which are difficult to manipulate.
3 Closures
3.1 Definitions
3.1.1 Closures are, for example, blanking flanges, covers
which are located on the inside, covers with special closure
elements, yoke closures and quick-acting closures. They
form a direct closure between the pressure vessel and the
surrounding atmosphere.

3.1.2 The term quick-acting closure describes all forms of
closure, with the exception of yoke closures, which - compa-
red with closures where the closure elements have to be
operated individually - have shorter opening and closing
times.
3.1.2.1 Interlocked quick-acting closures are those where
the opening process and/or the pressure application is inter-
locked in such a way that unwanted functional processes are
not possible.
3.1.2.2 Non-interlocked quick-acting closures are those
which do not meet the requirements for interlocked quick-
acting closures.
3.1.3 The term yoke closure describes an externally app-
lied cover mounted on the pressure vessel at one side and
closed by means of a closure element, e.g. aclamping bolt.
3.1.4 Covers with special closure elements have at least
two closure elements to be operated individually without the
use of a tool.
3.2 General requirements
3.2.1 Closures shall be designed so that they are suitable
for their intended purpose and cannot fail under operating
stress, i.e. automatic opening under pressure is not possible.
3.2.2 Parts of closures in accordance with Sub-clause3.1 .l
which are subject to pressure form part of the initial inspec-
tion in accordance with TRB 511 and TRB 512. Closures in
accordance with Sub-clause 3.1 .I are subject to inspections
by the manufacturer and the inspector if they are used on
pressure vessels of test group I for combustible, caustic or
toxic gases, vapours or liquids or on pressure vessels of
group II.
3.2.3 If there is a danger due to delay in boiling of the
charge material, e.g. when sterilizing liquid-filled containers
in pressure vessels, it shall be ensured that the pressure ves-
sel cannot be opened until the temperature of the liquid has
dropped sufficiently below the boiling point at atmospheric
pressure. A thermal safety device, for instance, meets this
requirement.
3.2.4 Covers located on the inside shall not be used on
pressure vessels with a dangerous charge material, e.g. sub-
stances in accordance with the Hazardous Substances
Order.
3.2.5 In the case of covers which are located on the inside
and which are secured by means of a yoke and a central bol-
ting arrangement, the clearance relative to the edge of the
hole - uniformly distributed all the way round - may not
exceed 3 mm in the case of vessels with operating pressures
up to and including 32 bar, and may not exceed 2 mm in the
case of those with operating pressures in excess of 32 bar.
The seal, shall be prevented from being forced out. This
requirement is regarded as having been satisfied if metal
seals or metal braided seals are used, or if covers of the
type in question have a bead, a shoulder, or are of convex
form on the low-pressure side. In the case of pressed plate
components with a bead or a convex profile, the latter shall
be at least 5 mm higher than the thickness of the seal.
3.3 Additional requirements for yoke closures, quick-
acting closures and covers with special closure
elements
3.3.1 Yoke closures shall be designed so that the cover is
positively ventilated before the closure element releases the
cover. This requirement is, for instance, fulfilled by yoke
Page 3 AD-Merkblatl A 5. Editjon 7.95
closures in accordance DIN 28 126. Yoke closures for open-
ings whose maximum aperture dimension exceeds 500 mm
shall meet the requirements for quick-acting closures.
3.3.2 Quick-acting closures shall be designed so that open-
ing under pressure is not possible.
An interlocking device is necessary for closures which due
to the geometry can exert a force from the internal pressure
on the closure in the opening direction. This shall be design-
ed so that opening is securely prevented even without a self-
locking device. In the case of non-interlocked quick-acting
closures the pressure warning device in accordance with
Sub-clause 3.3.4 shall be connected to the locking device.
For non-interlocked quick-acting closures the locking device
in accordance with Sub-clause 3.3.7 shall be included in the
lock.
3.3.3 The suitability and reliability of quick-acting closures
shall be verified. In the case of interlocked quick-acting closu-
res on pressure vessels where the inspection before com-
missioning is to be carried out by an inspector, the interlock
shall be tested by an individual test or type test. The func-
tional testing of quick-acting closures shall be carried out as
part of the acceptance test in accordance with TRB 513 or
TRB 531.
3.3.4 Non-interlocked quick-acting closures shall have a
pressure warning system which is connected to the closure
system in such a manner that the quick-acting closure cannot
open until the pressure warning device is open.
It shall not be possible for the pressure warning device to
close until after the quick-acting device has closed comple-
tely.
The closure of the cover or of the closure elements with the
pressure warning device closed shall be precluded.
The pressure warning device shall have an internal diameter
of at least 8 mm. If there is a danger of obstruction, special
measures are required. It shall be possible for a clearing
device to be pushed through the pressure warning device
and any discharge shall not constitute a hazard. Where a dis-
charge pipe is connected this shall not incorporate any shut-
off device or have the effect of constricting the cross section.
The route adopted for the discharge pipe shall not incorpo-
rate any bends which appreciably impede the flow. The outlet
of the pipe shall be in the field of view of the operating person-
nel, or it shall be possible to see the flow through the pipe.
3.3.5 Non-interlocked quick-acting closures shall be
designed so that a gap is formed on opening through which
the pressure in the pressure vessel can be safely discharged
before the cover is opened further.
Where the charge material has a tendency to adhere, a posi-
tive gap shall necessarily be formed on opening.
When designing the restraining device which limits the gap,
dynamic forces such as those produced when the cover is
opened shall be allowed for.
3.3.6 Where non-interlocked quick-acting closures are
used, manual means only shall be employed for opening and
applying pressure.
3.3.7 In the case of interlocked quick-acting closures it shall
be ensured that the closure cannot be opened until the pres-
sure is equalized with atmosphere.
During closing it shall be ensured that the vessel can be pres-
surized only after the closure is fully sealed.
In the case of electrical components of interlocks, the require-
ments are considered to be complied with, for example, if the
P a g e 4 AD-Merkblatt A 5. Edition 7.95
specifications of DIN VDE 0116 are met. This also applies
as appropriate to non-electrical components.
3.3.8 Covers with special closure elements shall be design-
ed so that a gap is formed on opening through which the pres-
sure in the vessel can be safely released before the cover
is opened further.
Where the charge material has a tendency to adhere this gap
shall be produced in a positive manner.
3.3.9 It shall be possible to detect whether all the closure
elements have reached their terminal positions.
3.3.10 In the case of quick-acting closures fitted to pressure
vessels, where the charge material is of a caustic, extremely
toxic or combustible nature, leaktightness shall be ensured
through the adoption of special design measures such as the
application of pressure from an external source to the seal.
When pressure from an external source is used to effect a
seal, there shall be no possibility of the charge space being
pressurized until after the external pressure has been applied
to the seal.
3.3.11 All safety devices on quick-acting closures shall be
designed and fitted so that:
(1) they cannot be rendered ineffective by the charge mate-
rial;
(2) the functional safety is not impaired by environmental
influences;
(3) functional inspections and maintenance work can be
carried out at suitable intervals.
4 Closure elements
4.1 Clamp-bolts
Clamp-bolts which clamp the closure cover to the mating
flange shall be design-tested or subject to individual tests
[Guidelines for component testing of clamp-bolts, see
Appendix 2). They shall be secured to prevent them from
slipping off, and shall be attached to the vessel in such a
manner that when they are swung away they cannot drop off.
4.2 Hinged bolts
Hinged bolts which are let into the closure cover slots, e.g.
eye bolts according to DIN 444, shall be secured against
unintentional slipping. Nuts and washers shall be fully seated
outside the slots.
5 Materials, calculations and manufacture of
closures and closure elements
5.1 The requirements for closure covers, flanges, bolts and
other closure components subjected to pressure, in respect
of materials, calculations and manufacture, are satisfied if
the relevant AD-Merkblatter are employed.
5 . 2 The permissible surface pressure Kg, e.g. at the projec-
tions of bayonet-type closures made from rolled steel, can be
assumed to be 1.0. In the case of unmachined surfaces or
surfaces which have not at least been finished to give a
smooth fit, it shall be assumed that the surfaces are load-
bearing to the extent of no more than 75%.
5 . 3 Allowance shall be made for any weakening of the clo-
sure components due to wear or corrosion by increasing the
calculated dimensions through the addition of appropriate
margins.
5 . 4 In the case of closures with several locking elements,
the closure components shall be designed and machined so
that the individual components are subjected to uniform load-
ing during service.
5 . 5 In the case of closures with more than three locking ele-
ments, the theoretical load on a locking element determined
on the basis of the prevailing conditions in the case in point
shall be increased by at least 20% when carrying out cal-
culations.
UDC 621.642.02.00598:62-774:614.8 Edition December 1983

Equipment AD-Merkblatt
Directives for the arrangement
of
of manholes and inspection ports A5
Pressure Vessels Appendix 1

The AD-Merkbltilter are compiled by the seven trade associations specified below who together form the ‘Arbeitsgemeinschaft Druck-
5ehBlter” (AD). AD-Merkblaft G 1 covers the composition and application of the AD-Regulations and a/so the procedural rules.
The AD-MerkblS-ter cover safety requirements which must be adopted for normal conditions of operation. In the event of stresses over
snd above the normal level being anticipated during the operation of pressure vessels, allowance must be made for such stresses by
neeting special requirements.
Should there be any departures from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
smbodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis,
operating experience.
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e. VI (FDBR), Diisseldorf
H a u p t v e r b a n d d e r gewerblichen Berufsgenossenschafien e. V., Bonn
Verband der Chemischen lndustrie e.V. (VCI), Frankfurt/Main
Verband De&chef Maschinen- und Anlagenbau e.% (VDMA), Fachgemeinschaff Apparatebau, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDEh), Dijsseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkrafiwerksbetreiber e . L!, E s s e n
Vereinigung der Technischen iiberwachungs-Vereine e.V. (VdTiiV), Essen.
T h e AD-Merkbltitier a r e a m e n d e d c o n t i n u o u s l y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
5e addressed to the publisher:
Vereinigung der Technischen ijbetwachungs-Vereine e.V., Postfach 103834, D-4300 Essen 1.

Contents

1 General observations 2.4.5 Air receivers for air brakes (e.g. to DIN 74281)
2 Nature, number and arrangement of openings in motor vehicles

2.1 Cylindrical vessels (see Table 1) 2.4.6 Compressed-air tanks for braking systems in rail
vehicles
2.2 Spherical vessels (see Table 2)
2.4.7 Permanently sited pressure vessels made of steel
2.3 Conical vessels
for propane, butane and mixtures of the latter,
2.4 Special types of pressure vessel which are installed at ground level in accordance
2.4.1 Cylindrical high-pressure accumulators with with DIN 4680
seamless shells 2.4.8 Pressure vessels made of steel for water supply
2.4.2 Hydraulic accumulators with an elastic diaphragm installations to DIN 4810
2.4.3 High-pressure feed heaters in power stations 2.4.9 Compressed-air tanks which comply with
VDMA-Einheitsblatl 3111
2.4.4 Compressed-air tanks for starting combustion
engines to DIN 6275 2.4.10 Rotating steam-heated cylinders

1 General observations 2 Nature, number and arrangement of openings

1.1 Manholes and inspection ports must above all permit an 2.1 Cylindrical vessels
assessment to be made of the longitudinal and circumferential
Nelds, a n d o f p o i n t s w h e r e t h e r e a r e p a r t i c u l a r l y h i g h s t r e s s concen- As a rule, for cylindrical vessels the openings stipulated in Table 1
:rations and points at risk, at the inner faces of pressure vessels. are adequate.
P o i n t s w h e r e s t r e s s e s a r e p a r t i c u l a r l y h i g h c a n b e r e g a r d e d a s inclu-
jing c o r n e r w e l d s , e n d - p l a t e f l a n g e r e g i o n s , a n d t h e a r e a s surroun-
jing large cut-outs. Points at risk include, for example, the liquid 2.2 Spherical vessels
j u m p and.vessel bottom, the region in the vicinity of the surface of
: h e l i q u i d , a n d p o i n t s w h i c h - a s e x p e r i e n c e h a s s h o w n - a r e par- As a rule, for spherical vessels the openings stipulated in Table 2
:icularly subject to corrosion and erosion. are adequate.

1.2 I n s p e c t i o n p o r t s m a y b e n e c e s s a r y i n a d d i t i o n t o a m a n h o l e
n those circumstances where, for example, as a consequence of
: h e p r e s e n c e o f i n t e r n a l s , m o v i n g a b o u t i n s i d e t h e v e s s e l i s insuffi-
:ient o n i t s o w n t o p e r m i t a n a s s e s s m e n t t o b e m a d e . T h e i n s p e c t i o n
z~orts provided in accordance with Section 2 may be replaced by
smaller openings; in the event of this being done, such openings
nust then be provided in larger numbers and at suitable points.
2.3 Conical vessels
I n g e n e r a l , i t w i l l s u f f i c e t o m a k e p r o v i s i o n for’ i n s p e c t i o n f r o m t h e
end with the larger diameter, with the stipulations to which attention
i s d i r e c t e d i n S e c t i o n 2 . 1 a g a i n b e i n g o b s e r v e d w h e r e t h e l a r g e r dia-
meter is concerned.

Supersedes edition September 1975

Carl Heymanns w&g KG

Luxemburger StraBe 449, 50939 Kdln
GutenbergstraRe 3. 10587 Berlin
Page 2 AD-Merkblatt A 5, Appendix 1, Edition 12.83

Table 1. Restricted-access manholes and inspection ports in cylindrical vessels

nside Shell length Nature, arrangement and number of openings

jiameter in mm
nmm

2 300 - Subject to special agreement.

Position and size to be agreed in each individual case.

> 300 2 Peepholes.

5 1000
5 450

d 1500 1 Hand hole in central third of cylindrical length.

> 1500 At least 2 hand holes, one in each instance either in the cylinder end-regions or in the
vessel heads, with a maximum permissible distance between the hand holes of 2000 mm.

> 450 1 Hand hole in central third of cylindrical length.

2 1500
5 800

> 1500 1 Head hole in central third of cylindrical length or 2 hand holes, one in each instance
s3000 either in the cylinder end-regions or in the vessel heads, with a maximum permissible
distance between the hand holes of 2000 mm.

> 3000 Number of inspection ports to be increased appropriately.

Maximum permissible distance between head holes in cylinder is 3000 mm, and that
between hand holes 2000 mm.
One hand hole in each instance to be sited in the cylinder end-regions or in the vessel
heads.

> 800 5 2000 1 Head hole in central third of cylindrical length or 2 hand holes In the cylinder
% 1500 end-regions or in the vessel heads.

> 2000 1 Manhole’) or arrangement of Inspection ports as for inside diameters up to 800 mm
and cylindrical lengths greater than 3000 mm

> 1500 - 1 Manhole’)

2.4 Special types of pressure vessel has been made, peepholes or sultabie pipe connections with an
Inside diameter of at least 60 mm should be provided. On the subject
2.4.1 Cylindrical high-pressure accumulators with seamless shells of the nozzle height, attention is dlrected to AD-Merkblatt A 5.
2.4.1.1 High-pressure accumulators are charactensed by their Section 2.4
l a r g e l e n g t h / d i a m e t e r - r a t i o ( e . g . a c c u m u l a t o r s In hydraulic mstalla-
I n regions w h e r e It p o s s i b l e t o m o v e a b o u t Inside t h e v e s s e l wlthout
IS
tions, compressed-air starting cylinders, separators, reservoirs for
wIthdrawIng the bundle, manholes should be provided.
compressed-air locomotives).

2.4.1.2 There is no need for inspection ports to be provided In
s h e l l s . W h e r e c y l i n d r i c a l l e n g t h s a r e 5 m a n d m o r e , a n opening must
be provided in each end. In the case of cylindrical lengths of less
than 5 m, an opening at one end will suffice which must allow the
v e s s e l t o b e i n s p e c t e d i n t e r n a l l y , a s d e f i n e d i n Sectlon 1 .l A s a r u l e .
special aids need to be used for this purpose.
2.4.2 Hydraulic accumulators with an elastic diaphragm
Up to internal diameters of 300 mm, the connection openings of
h y d r a u l i c a c c u m u l a t o r s w i t h a n e l a s t i c d i a p h r a g m a r e sufflclent for
c o m p l i a n c e w i t h S e c t i o n 1 .I.
2.4.3 High-pressure feed heaters in power stations
In order, when an inspection is made through nozzle connechons
or special inspection ports without the tube bundle being withdrawn,
to be able to arrive at a judgement which is valid for all wall sections
in respect of damage produced during the course of operation, it
should be possible for an adequate assessment to be made at least
of those parts of the wall in the zone where the water level fluctuates
a n d t h e b o t t o m r e g i o n , a n d a l s o o f t h e b a f f l e p l a t e s a t t h e s t e a m Inlet
and any tube-bundle suspension structures which may be present
inside the feed heater. To this end, at the points to which reference
2.4.4 Compressed-air tanks for starting combustion engines to
DIN 6275’)
In the case of compressed-air tanks for starting combustion engines
to DIN 6275, the openings specified in the latter are sufficient.
2.4.5 Air receivers for air brakes (e.g. to. DIN 74281) in motor
vehicles>)
In the case of welded compressed-air tanks for air brakes in motor
vehicles t o D I N 7 4 2 8 1 , t h e o p e n i n g s s p e c i f i e d i n t h e l a t t e r a r e a d e -
quate. During the course of manufacture, the adoption of other
methods is assumed to be possible for making an assessment of
the longitudinal and circumferential welds. Similar considerations
apply for air receivers for air brakes which do not fully comply with
DIN 74281, provided that the stipulated requirements are met.
1) For defmltlOn of differences between “easy-access” and “restricted-access”
manhole. reference shall be made to AD-Merkblatl A 5. Section 2.3.
2) When utilised for other applications not conformtng to the Standard specified (e.g.
in the case of Section 2.4.5 applications in installations at permanent sites, and
I” the case of Section 2.4.7 applications other than for the gases named), these
openings are not as a rule adequate for the purposes of this AD-Merkblatt.
 P a g e 3 AD-Merkblatl A 5, Appendix 1, Edition 12.83

2.4.6 Compressed-airtanksfor braking systems in rail vehicles*) Table 2. Restricted-access manholes and inspection ports in
spherical vessels
As a departure from AD-Merkblatt A 5, Section 2.4.3, peepholes in
compressed-air tanks for braking systems in rail vehicles can be pro-
duced with an inside diameter of 30 mm, if the product of pressure Inside diameter
Natureand numberof openings
x capacity for these tanks is p. I Z 1 0 0 0 . H o w e v e r , p r e s s u r e v e s s e l s in mm
intended for applications of this kind which have a product of pres-
sure x capacity of p I > 1 0 0 0 m u s t b e e q u i p p e d w i t h t h e p e e p h o l e s 5 800 Subject to special agreement.
defined in Section 2.4.3 of AD-Merkblatt A 5. Position and size to be agreed in each
individual case.
2 . 4 . 7 Permanently sited pressure vessels made of steel for pro-
pane, butane and mixtures of the latter, which are installed at ground
l e v e l i n a c c o r d a n c e w i t h D I N 46802) > 800
1 Handhole
5 1500
In the case of permanently sited pressure vessels made of steel for
propane, butane and mixtures of the latter which are installed at > 1500 1 Manhole’)
ground level in accordance with DIN 4680, the openings specified
in the latter are adequate.

2.4.8 Pressure vessels made of steel for water supply installations

to DIN 48102)
In the case of pressure vessels made of steel for water supply instal-
lations to DIN 4810, the openings specified in the latter are adequate.
2.4.10.1 Where the inside diameter of cylinders is greater than
2.4.9 Compressed-air tanks which comply with VDMA-Einheits-
400 mm, but is no more than 800 mm, a peephole must be provided
b l a t t 3111”)
at each end-face.
I n t h e c a s e o f c o m p r e s s e d - a i r t a n k s w h i c h c o m p l y w i t h VDMA-Ein-
heitsblatt 3111, the openings specified in the latter are adequate. 2.4.10.2 Where the inside diameter of cylinders is greater than
800 mm, but is no more than 1400 mm, a hand hole must be provided
2.4.10 Rotating steam-heated cylinders at each end-face. A hand hole at one end-face will suffice however
In the case of rotating steam-heated cylinders in accordance with if it enables an adequate inspection to be made of the inside.
item 29 of Appendix II of 5 12 Druckbehllterverordnung, as a depar-
t u r e f r o m S e c t i o n 2 . 1 t h e f o l l o w i n g i n s p e c t i o n p o r t s a n d restricted- 2.4.10.3 When cylinders have an inside diameter in excess of
access manholes are adequate: 1400 mm, a restricted-access manhole must be provided.
ICS _.._
.__ 71 -n6n.10:23.020.30
--..-,-- _---.-- Frlitinn .IIIIV
--...-.. ““.J IQQS
.““..

Equipment Guidelines for AD-Merkblatt

of component testing A5
Pressure Vessels of clamp-bolts Appendix 2

The AD-Merkblstter are compiled by the seven trade associations specified below who together form the “Arbeitsgemeinschaft Druck-
behtilter” (AD). AD-Merkblatt G 1 covers the composition and application of AD-Regulations and also procedural guidelines.
T h e AD-Merkbl.Wer c o n t a i n s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l o p e r a t i n g c o n d i t i o n s . I n t h e e v e n t o f l o a d i n g s e x c e e d i n g
the normal /eve/ expected during the operation of pressure vessels, allowance shall be made for such loadings by meeting special
requirements.
Should there be any deviations from the provisions of this AD-Merkblatt, it must be possible to demonstrate that the safety standards
embodied in these regulations have been observed by other means, e.g. testing of materials, experiments, stress analysis, operating
experience.
Fachverband Dampfkessel-, Behdlter- und Rohrleitungsbau e.V. (FDBR), Dtisseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e.V., Sankt Augustin
Verband der Chemischen lndustrie e.V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Verein Deutscher Eisenhiittenleute (VDfh), Dtisseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r GroBkraftwerksbetreiber e.V., E s s e n
Verband der Technischen iiberwachungs-Vereeine e. V. (VdTiiV), Essen.
T h e AD-Merkblstter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Verband der Technischen iiberwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents

1 General 3 Certification of test

2 Test procedure 4 Calculation for clamp-bolts

1 General
AD-Merkblatt W 7 is applied where appropriate to the manu- 5Ps) as variation of the mean value of the
%,, = ~
facture, materials and verification of material properties. ,n loads up to discernable permanent
deformation

2 Test procedure P,m,n = ps - 3 s (Ps) as probable minimum mean

value of the group loads for
2.1 The clamp shall be tested in its normal operational load P,
bolted position so that the tensile forces are applied at the
(2) PB as a load in N at the point where failure of a
same points of the clamp components at which they would
clamp component, bending of the screw bolts
act in service. The test shall be carried out with the maximum
and/or clamp hooks or slippage of the clamp
utilizable length of bolt.
occurs
2 . 2 Initially a sufficient number of clamps shall be tested
P, as mean value of the loads P, at failure of the
from each type of clamp as determined by dimensions and clamp
material as is necessary for a clear establishment of the form
factor in accordance with paragraph (4), but in any case at sip,) as variation of the loads P, at failure of the
least five clamps each for the tests in accordance with para- clamp
graphs (1) and (2) or (3). The following shall be determined as variation of the mean value of the loads
SFBB,
by the tests. PB at failure of the clamp
(1) ps as the load in N at which substantial permanent
deformation occurs on the clamp or on one of its pB min = Fs - 3 S (Fe) as probable minimum mean
components value of the collective for
load PB
ps = q as mean value of the loads up to discer-
(3) as, uB and 6 of the screw bolt material, and:
nable permanent deformation
8s and i& as mean value of the yield point and
as variation of the loads of the breaking strength
% = JC up tod;formation
nent dlscernable perma- s@J and SC+ as variation of the yield points and
breaking strengths

-..,A ““y”1Y”“a “r,,my

Luxemburger Strak 449, 50939 Kdln

,,”

I ranswon: I ecnnlcal Help to Exporters Service of 9.9

Gutenbergstrak 3, I 0587 6er11n
page 2 AD-Merkblatt A 5 Appendix 2, Edition 7.95

scaS) and S(Q as variation of the mean value of the 3 Certification of test
yield point and breaking strength 3.1 The certification of the component test shall in particular
as ma = Bs + 3 S(,$ as probable maximum mean contain the following details:
77s mm = 77s + 3 S(Q values of the collective
(1) Manufacturer, type, size, dimensional drawing, material
(4) q as form factor of the connection and marking of clamp.
In this case q is the minimum value of the following (2) Result of tests in accordance with Sub-clause 2.2.
according to the results of the tests in paragraphs (3) The value for the load of a clamp, permissible for calcu-
(1) to (3) lating the closure, taking account of the specific form
factor in accordance with Sub-clause 2.2 (4).
P, mm
*s = ,,’ .7 or vii3 = (4) The minimum test loads, specified for delivery, until per-
-I!.-.- *.-
OS max 4 %I max manent deformation is reached or the clamps fail in
4
accordance with Sub-clause 2.3.
q denotes the relationship of the load compared to (5) Assessment of the design and confirmation thatthere are
that of a standard screw bolt subjected only to ten- no objections to the use of the tested type for closures
sile stress as a function of the design of the clamp. fitted to pressure vessels, if necessary stating under
Connections where $J I 0.7 are not permissible. what conditions.
2 . 3 Each delivery of clamps shall be subjected to random 3 . 2 The certification of the tests of the deliveries shall parti-
inspection, whereby at least two shall be tested from delive- cularly contain the following details:
ries of not more than 500 clamps and also at least one clamp
from each further 500, with a maximum total of four being (1) Manufacturer, type, size, material and marking of
tested. The following is specified as the minimum loads until clamps.
permanent deformation is reached: (2) The load determined up to permanent deformation and
up to failure of the clamps and a statement that these
d$ Jc
Ps 2 4. OS 7) where us is the guaranteed yield point. values correspond to the minimum requirements speci-
fied in the component test.
The following is specified as the minimum load up to failure
of the clamp:
cf$ n 4 Calculation of clamp-bolts
PB 14. qJ. * with u, as minimum guaranteed ten-
sile strength. AD-Merkblatt B 7 with a design allowance c of 3 mm applies
for the calculation. The safety factors are given in Table 3 as
2.4 Time point, place, type, scope and other regulations for solid shank bolts (S = 1.8 for the service state, S = 1.3
for carrying out the first test and random retesting of new for the installation and test state). However, the value de-
deliveries shall be agreed between the manufacturer or termined for the form factor q is used in place of the quality
supplier and the inspector. value q.
UDC 621.642.02-98:621.646.8:614.8:620.1 Edition June 1986

Equipment Safety devices against AD-Merkblatt

for excess pressure
Pressure Vessels MCR-safety devices A6

T h e AD-Merkblaffer a r e c o m p i l e d b y t h e s e v e n t r a d e a s s o c i a t i o n s s p e c i f i e d b e l o w w h o t o g e t h e r f o r m t h e “‘Arbeitsgemeinschaft Druck-

behalter” ( A D ) . AD-Merkblan G 1 c o v e r s t h e c o m p o s i t i o n a n d a p p l i c a t i o n o f t h e A D - R e g u l a t i o n s a n d a / s o t h e p r o c e d u r a l r u l e s .
T h e AD-Merkblatter c o v e r s a f e t y r e q u i r e m e n t s w h i c h m u s t b e a d o p t e d f o r n o r m a l c o n d i t i o n s o f o p e r a t i o n . In the event of stresses over
and above the normal /eve/ being anticipated during the operation of pressure vessels, allowance must be m a d e for such stresses by
meeting special requirements.
Should there be any departures from the provisions of this AD-Merkblatt, it m u s t b e p o s s i b l e t o d e m o n s t r a t e t h a t t h e s a f e t y s t a n d a r d s
ambodied in these regulations have been observed by means of alternative approaches, e.g. testing of materials, tests, stress analysis,
operating experience.
Fachverband Dampfkessei-, Behalter- und Rohrfeitungsbau e.V (FDBR), Dusseldorf
Hauptverband der gewerblichen Berufsgenossenschahen e.K, Sankt Augustin
Verband der Chemischen lndustrie e. V (VCI), Frankfurt/Main
Verband D e u t s c h e r M a s c h i n e n - und A n l a g e n b a u e . V . ( V D M A ) , F a c h g e m e i n s c h a f t A p p a r a t e b a u , F r a n k f u r t / M a i n
Verein Deutscher Eisenhiittenleute (VDEh), Dusseldorf
V G B T e c h n i s c h e V e r e i n i g u n g d e r Groflkrahwerksbetreiber e . V, E s s e n
Vereinigung der Technischen iiberwachungs-Vereine e.V (VdTiiV), Essen.
T h e AD-Merkblatter a r e a m e n d e d c o n t i n u o u s / y b y t h e t r a d e a s s o c i a t i o n s i n k e e p i n g w i t h t e c h n i c a l p r o g r e s s . R e l e v a n t p r o p o s a l s s h o u l d
be addressed to the publisher:
Vereinigung der Technischen lbefwachungs-Vereine e. V., Postfach 103834, D-4300 Essen 7.

Contents

1 Scope 4 Oesignation and documentation

2 General 5 Performance of tests
3 Requirements for MU&safety 6 Servicing and reports
devices

1 Scope - Shutting-off the heating system;

- Bringing into operation an emergency-cooling system;
This AD-Merkblatt is applicable for systems of automatically
controlled safety devices for the prevention of unwanted - Introduction of reaction inhibitor;
overpressures in pressure vessels of process plants, in cir- - Opening of suitable pressure-relief devices, e.g. dischar-
cumstances where the use of safety devices in accordance ging the vessel contents into a blowdown system, where
with AD-Merkblatt A 1 or AD-Merkblatt A 2, or of pipe gauges, necessary accompanied by the additional operation of gas
is not possible or would not meet the intended purpose. scrubbers (e.g. absorption columns).
Systems of this kind are characterized by the fact that, by
making use of measurement, control and regulation techno-
logy, they operate in such a manner that the service over-
pressure does at no time exceed the permissible value by
more than 10% (MCR-safety devices’). 3 Requirements for MC&safety devices
3.1 General requirements
The MCR-safety devices shall be suitable for preventing the
2 General permissible service overpressure from being exceeded by
more than 10%. To this end, the system comprising these
MCR-safety devices encompass in particular those devices arrangements shall be designed to suit the possible pres
necessary for the logging of measured data, conversion of sure-generation conditions at the process plant. The initiatior
measured data, and the initiation of measures. Examples of of measures shall be indicated by optical or acoustic means.
possible measures, individual or combined, include the fol-
lowing: 3.2 Use of fail-safe, self-monitoring, or redundant
- Isolation or shutdown of the pressure generator; MCR-safety devices
- Shutting-off the admission of substances that contribute MCR-safety devices and their components shall either:
to the elevation of the pressure; - be fail-safe,
- be designed in accordance with the redundancy principle,
I) Such arrangements may be uttlized. in accordance wth TRB 403 Section 3.7 or
together with Sectvan 3.8. only If safety dewces I” accordance with TRB 403 Sec-
tlon 3 1 .l are not possible or do not meet the Intended purpose. - shall be of the self-monitoring type.

Carl Heymanns Verlag KG

LuxemburgerStraf3e 449.50939 Koln
GutenbergstraOe 3. 10587 BerIm
p a g e 2 AD-Merkbiali A 6. Edition 6.86
in single-channel form, the self-monitoring type may be con-
sidered only if a pressure increase at the plant can take place
so slowly that sufficient time is available for the correction of
the unsafeguarded state.
In the case of electrical components of MCR-safety devices
the requirements are satisfied for example if the stipulations
of DINNDE 0116 Section 8.7 are met. This also applies
where appropriate, for non-electrical components.
3.3 Safe position in the event of failure of energy
supply
The MCR-safety devices shall, in addition to the require-
ments of Secticn 3.2, in the event of the failure or the unac-
ceptable fluctuation of the energy supply, assume a defined
safe position that ensures the safety of the plant. The supply
of energy necessary to this end shall be available in such a
form that, even in the presence of a fault, the safe position
is still realized, e.g. by means of spring tension, stored pres-
sure. If, in the event of the failure or unacceptable fluctuation
of the energy supply, the safe position cannot be assumed
or a safe position of an unequivocal nature cannot be defined,
the energy supply shall be safeguarded through the imple-
mentation of special measures, e.g. by means of a standby
power supply.
3.4 Safeguards to prevent resetting
The MCR-safety devices shall be safeguarded to prevent the
unintentional resetting of the limit values relevant to safety
devices, e.g. by restricting access to the resetting device, by
using tools.
4 Designation and documentation
The MCR-safety devices shall be given designations, and the
designations shall be incorporated in a suitable documenta-
tion system - e.g. RI-flow diagrams (DIN 28004, Part l),
MCR-classification schedules, device lists - in such a man-
ner that their unequivocal identification is possible. The func-
tion, the limit values relevant to safety, and the technical data
for the devices, shall be distinguishable. it shall be possible
for reference to be made to the documentation in the
acceptance-testing certification procedure (see Section 5).
5 Performance of tests
Verification of the suitability of the system of MCR-safety
devices is undertaken in conjunction with the acceptance
testing required by the Pressure Vessels Ordinance. This
process includes the examination of the documents relating
to the system and its components. The documents to be
examined include in particular a description of the operation
of the MCR-safety device, and the documentation as speci-
fied in Section 4.
With reference to the documents examined, functional
testing of the system or - where this is not possible - of the
individual components is carried out in conjunction with an
assessment of the effectiveness of the safety measures
achieved with the system.
Any modification of the system of MCR-safety devices, which
in keeping with 0 11 (1) Pressure Vessels Ordinance can be
viewed as an essential modification of the mode of operation,
and also any alteration of the limit values of the MCR-safety
devices relevant to safety devices, necessitate repeated
testing in accordance with 9 9 Pressure Vessels Ordinance.
6 Servicing and reports
Through servicing, i.e. regular inspections, maintenance and
corrective measures, the serviceability of the MCR-safety
devices should be ensured. For the execution of careful
inspections, maintenance and corrective measures, the ope-
rator is required to employ individuals with specialized know-
ledge. The latter, in addition to their general specialized
knowledge, are required to have been familiarized with the
special operational conditions.
The corrective measures to be implemented are governed,
in terms of their nature and scope and intervals between
them, by practical experience. There is a particular need for
regular functional tests by the operator. Irrespective of the
latter tests, the tests prescribed by the Pressure Vessels
Ordinance are still necessary. The intervals between tests
should be fixed by the operator in keeping with the operatio-
nal conditions, the recommendations of the manufacturer
and of the Expert Authoritiy being adopted as a basis here;
however, at least one functional test per annum is deemed
necessary.
It is the responsibility of those individuals with specialized
knowledge to produce a report on the functional tests and
corrective measures. The following particulars at least
should be included in the report:
- Pressure vessel/plant concerned;
- Designation of MCR-safety device with reference to the
documentation specified in Section 4;
- Nature of measures implemented;
- Results of functional tests, verification of limit values;
- Details of any devices replaced;
- Date, name and signature.
The reports should be retained until the next in-service test
at least, as prescribed by the Pressure Vessels Ordinance.
 b

Edition June 1986

31. Amendment and Supplement

AD-Merkblatt
to AD-Merkbktter

The “Arbeitsgemeinschaft Druckbehtier” (AD) has approved the following amendments and supplements of existing
AD-Merkbliitter.

Nithdrawal of AD-Merkblatter BP 0 and BP 1 To AD-Merkblatt A 5 Appendix 1 - Edition 12. 83

The associations forming the status group “Pressure Ves-
;els (AD)” have decided to withdraw the two AD-Merkbfatter
3P 0 and BP 1, October 1977 edition, which have been de-
:lared obsolete at the direction of Bundesminister fiIr Arbeii
rnd Sozialordnung (BMA) (Technische Regeln Druckbehal-
er - TRB of the 500 Series).
31. AD-Amendment 6.1986)
Section 1.1 is worded as follows:
1.1 Manholes and inspection ports shall primarily permit
evaluation of longitudinal and circumferential welds, and
severefy stressed and threatened areas on the inside of
pressure vessels. For example, comer welds, flanges and
the immediate vicinity of large openings may be exposed to
severe loading. Danger points are e.g. the sump, the vessel
bottom, the area at the liquitigas(water/steam)-interface
and any zones, experience has shown to be susceptible to
preferential corrosion.
(31. AD-Amendment 6. 1986)

‘:

Cad Heymanns Vet-tag KG

Luxemburger StraOe 449.50939 Km
GutenbergstraBe 3.10587 Berlin
 Edition November 1987 I May 1988

33. and 34. Amendment and Supplement

AD-Merkblatt to AD-Merkbhtter

The “Arbeitsgemeinschaft Druckbehllter” (AD) has approved tie following amendments and supplements of existing
AD-MerkbMter.

To AD-Merkblatt W 8 - Edition 7. 87:

1. Footnote 4 is deleted.

2. In Figure 2, the standard mentioned in the test set-up

has been changed:
Test procedure
according to DIN 50 111

(33. AD-amendment 11.87)

io ADMerkblatt B 1 - Edition 6.66: To AD-Merkblatt B 10 - Edition 6.86:

. In Sections 2 and 6.4, add a footnote after the words 1. The text in Section 6.1.2 is replaced by the following:
“heat exchanger tubes”: 6.1.2 The reference stress on the inner fibre G or on the
outer fibre a,, originating from the internal pressure is:
! General
P(& + se)
his AD-Merkblatt shall only be used in conjunction with Q = 23s (2
0Merkblatt B 0.
~ = Pa>-se)
n the case of heat exchanger tubes’) the wastage factor (3
*
:2 = 0 unless special agreements have been made
mtween the manufacturer and user.
2. Replace KIS by K in the first sentence of Section 62.3
i.4 In the case of heat exchanger tubes’), the minimum
vail thickness may be less than the values stipulated in 62.3 It should be checked whether the maximum stress 01
$&ions 6.1 and 6.2; the inner q resp. outer surface a, does not exceed the per
missible stress K.
!. The footnote reads as follows: q=l&i+a;i (8
) lnadd~~~mecasescweredinOIN28183andOIN28184.heatexchanger
%=a,+% (9
tub%areautubeswialctlareusadb3tramterhaat. For G and a, the formulae (2) and (3) apply.
34. AD-amendment 5.88) (34. AD-amendment 5.88)

‘:

C a r l H e y m a n n s Vedag K G
Luxemburger StraSe 449,50939 KBln
GutenbergstraOe 3. 10587 Berlin