Safety Standards

of the Nuclear Safety Standards Commission (KTA)

KTA 3211.1 (6/00) (incl. rectification from BAnz 132, 19.07.01) Pressure- and activity-retaining components of systems outside the primary circuit Part 1: Materials (Druck- und aktivittsfhrende Komponenten von Systemen auerhalb des Primrkreises; Teil 1: Werkstoffe)

A previous version of this Safety Standard was issued 6/91

If there is any doubt regarding the information contained in this translation, the German wording shall apply.

Editor: KTA-Geschaeftsstelle c/o Bundesamt fuer Strahlenschutz (BfS) Willy-Brandt-Strasse 5 38226 Salzgitter Germany Telephone +49-5341/885-(0) 901 Telefax +49-5341/885-905

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KTA SAFETY STANDARD

June 2000 Pressure- and activity-retaining components of systems outside KTA 3211.1 the primary circuit; Part 1: Materials
CONTENTS
Fundamentals.............................................................................................................................................................. 5 1 2 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 4 4.1 4.2 4.3 4.4 4.5 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 Scope .............................................................................................................................................................. 5 Definitions........................................................................................................................................................ 5 General principles............................................................................................................................................ 6 Selection of materials ...................................................................................................................................... 6 Appraisal of the materials ................................................................................................................................ 6 General quality-assurance requirements ......................................................................................................... 6 Requirements to be met by the manufacturer .................................................................................................. 6 Design approval............................................................................................................................................... 7 In-process inspection by the authorized inspector to 20 of the Atomic Energy Act ....................................... 7 Verification of quality characteristics ................................................................................................................ 7 Marking............................................................................................................................................................ 7 Repairs ............................................................................................................................................................ 7 Material characteristic data for design analysis................................................................................................ 7 Generally applicable stipulations for materials and material tests .................................................................... 7 General............................................................................................................................................................ 7 Allowable materials.......................................................................................................................................... 7 Requirements for the materials and their product forms .................................................................................. 7 Testing and examination of materials and product forms................................................................................. 8 Re-examinations............................................................................................................................................ 11 Product forms of ferritic steels of material group W I...................................................................................... 12 Sheets and plates .......................................................................................................................................... 12 Dished or pressed product forms made from plate ........................................................................................ 13 Forgings, bar steel and rolled rings................................................................................................................ 15 Seamless pipes larger than DN 50 ................................................................................................................ 19 Seamless pipe elbows larger than DN 50 ...................................................................................................... 20 Seamless fittings larger than DN 50............................................................................................................... 22 Castings ........................................................................................................................................................ 23 Product forms of ferritic steels of material group W II..................................................................................... 24 Sheets and plates .......................................................................................................................................... 24 Dished or pressed product forms made from plate ........................................................................................ 25 Forgings, bar steel and rolled rings................................................................................................................ 26 Seamless pipes larger than DN 50 ................................................................................................................ 28 Seamless pipe elbows larger than DN 50 ...................................................................................................... 29 Seamless fittings larger than DN 50............................................................................................................... 30 Castings ........................................................................................................................................................ 31 Product forms of austenitic steels .................................................................................................................. 33 Sheets and plates .......................................................................................................................................... 33 Dished or pressed product forms made from plates....................................................................................... 34 Forgings, bar steel, rings and extrusions ....................................................................................................... 35 Seamless pipes larger than DN 50 ................................................................................................................ 36 Seamless pipe elbows larger than DN 50 ...................................................................................................... 38 Seamless fittings larger than DN 50............................................................................................................... 39 Castings ........................................................................................................................................................ 41

(Continued next page) PLEASE NOTE: Only the original German version of this safety standard represents the joint resolution of the 50-member Nuclear Safety Standards Commission (Kerntechnischer Ausschuss, KTA). The German version was made public in Bundesanzeiger No. 194a on October 14, 2000. Copies may be ordered through the Carl Heymanns Verlag KG, Luxemburger Str. 449, 50939 Koeln (Telefax +49-221-94373-603). All questions regarding this English translation should please be directed to: KTA-Geschaeftsstelle c/o BfS, Willy-Brandt-Strasse 5, 38226 Salzgitter, Germany Page 3

CONTENTS
(Continued)
8 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 9 9.1 9.2 10 10.1 10.2 10.3 10.4 10.5 Bolts and nuts................................................................................................................................................ 42 Scope ............................................................................................................................................................ 42 Materials........................................................................................................................................................ 42 Additional requirements for the materials ...................................................................................................... 42 Bolts and nuts made by machining from ferritic bars ..................................................................................... 43 Bolts and nuts made by machining from solution-annealed and quenched austenitic bars............................ 43 Bolts and nuts made from ferritic bars by hot or cold forming and subsequently heat-treated ....................... 44 Bolts and nuts of strength classes ................................................................................................................. 45 Marking ......................................................................................................................................................... 45 Verification of quality characteristics.............................................................................................................. 45 Product forms of steels for special loads ....................................................................................................... 51 Forgings, bar steel and rolled rings................................................................................................................ 51 Castings ........................................................................................................................................................ 51 Heat-exchanger tubes ................................................................................................................................... 53 Seamless straight heat-exchanger tubes of ferritic steels with wall thicknesses smaller than or equal to 4 mm and with outside diameters smaller than or equal to 38 mm ................................................................ 53 Seamless bent heat-exchanger tubes of ferritic steels with wall thicknesses smaller than or equal to 4 mm and with outside diameters smaller than or equal to 38 mm ................................................................ 54 Seamless straight heat-exchanger tubes of austenitic steels with wall thicknesses smaller than or equal to 3.6 mm and with diameters smaller than or equal to 42.4 mm................................................................... 55 Seamless bent heat-exchanger tubes of austenitic steels with wall thicknesses smaller than or equal to 3.6 mm and with diameters smaller than or equal to 42.4 mm....................................................................... 55 Longitudinally welded straight heat-exchanger tubes of austenitic steels with wall thicknesses smaller than 2 mm and with diameters Da smaller than or equal to 38 mm ............................................................... 56 Material characteristic data..................................................................................................................... 58 Reference data on physical characteristics ............................................................................................ 85 Non-destructive examinations of steel castings...................................................................................... 87 Production welds of steel castings.......................................................................................................... 92 Procedure for determining the delta ferrite content................................................................................. 96 Non-destructive examinations of heat-exchanger tubes ......................................................................... 98 Performance of manual ultrasonic examinations .................................................................................. 100 Performance of surface crack detection by magnetic particle and liquid penetrant methods ................ 110 Additional stipulations for non-destructive examination of forgings, bar steel, rings and extrusions..... 112 Regulations and literature referred to in this Safety Standard............................................................... 119 Changes with respect to the edition 6/91 (informative) ......................................................................... 123

Annex A: Annex AP: Annex B: Annex C: Annex D: Annex E: Annex F: Annex G: Annex H: Annex I: Annex K:

Comments by the editor: Taking into account the meaning and usage of auxiliary verbs in the German language, in this translation the following agreements are effective: shall shall basically indicates a mandatory requirement, is used in the case of mandatory requirements to which specific exceptions (and only those!) are permitted. It is a requirement of the KTA that these exceptions - other than those in the case of shall normally - are specified in the text of the safety standard, indicates a requirement to which exceptions are allowed. However, the exceptions used, shall be substantiated during the licensing procedure, indicates a recommendation or an example of good practice, indicates an acceptable or permissible method within the scope of this safety standard.
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shall normally should may

KTA 3211.1

Fundamentals (1) The safety standards of the Nuclear Safety Standards Commission (KTA) have the task of specifying those safety related requirements which shall be met with regard to precautions to be taken in accordance with the state of science and technology against the damage arising from the construction and operation of the facility (Sec. 7 para 2 subpara 3 Atomic Energy Act) in order to attain the protection goals specified in the Atomic Energy Act and the Radiological Protection Ordinance (StrlSchV) and which are further detailed in the Safety Criteria for Nuclear Power Plants and in the Guidelines for the Assessment of the Design of PWR Nuclear Power Plants against Incidents pursuant to Sec. 28 para 3 of the Radiological Protection Ordinance (StrlSchV) - Incident Guidelines. (2) In the Safety Criteria, Criterion 1.1 ("Principles of safety precautions") requires, among other things, extensive quality assurance in manufacturing, erection and operation, while Criterion 2.1 ("Quality guarantee") requires, among other matters, the application, establishment and observance of design, material, construction, inspection and operating specifications as well as documentation of quality monitoring. Criteria 4.2 ("Residual heat removal in as-specified operation"), 4.3 ("Residual heat removal after loss-of-coolant accidents"), 5.3 ("Equipment for nuclear-reactor control and shutdown") and 8.5 ("Heat removal from the containment system") set forth further design and fabrication requirements for safety systems. KTA safety standards series 3211 define provisions to be made to meet these requirements within their scope of application. For this purpose it also draws upon numerous individually cited rules from conventional engineering, especially DIN Standards. (3) The scope of application defined here covers the pressure- and activity-containing systems and components located outside the pressure boundary (KTA safety standards series 3201) but having relevance specifically to reactor engineered safety per the Reactor Safety Commission (RSK) Guideline (Section 4.2). (4) KTA 3211.1 specifically defines the requirements to be imposed on: a) organizations involved in manufacturing, b) manufacture of materials and product forms as well as their chemical composition, mechanical and technological characteristics, physical characteristics, heat treatment and further processing, c) verification and inspection methods for achieving and maintaining the required quality of materials and product forms, such as destructive and non-destructive examinations, d) provision of documents for documentation of the test and inspection results.

basis with consideration of the multiple design (e.g., redundancy-type, diversity-type). b) Considerable energy is released in the event of failure of the plant section, and the consequences of failure are not limited by structural provisions, spatial separation or other safety provisions to an extent that is acceptable for nuclear safety. c) Failure of the plant section can lead directly or via a chain of conceivable subsequent events to an accident as defined by 28 Par. 3 of the Radiation Protection Regulation. (2) The following components fall within the scope of application of this safety standard: a) pressure vessels, b) piping systems and piping-system parts, c) pumps and d) valves and fittings including the integral zones of the component support structures. (3) This safety standard shall not apply to: a) piping systems and to valves and fittings of DN 50 size or smaller, b) internals of components (that are not part of the pressurecontaining wall) and accessories, c) systems and plant sections that perform auxiliary functions for the systems in question here, d) system parts in which the system pressure is determined exclusively by the geodetic pressure head in the suction zone, e) parts for force and power transmission to pumps and to valves and fittings as well as inspections for verification of functional capability, f) weld filler metals and welding consumables, g) small parts.
Note: Small parts are subject to the stipulations of Section 10 and of Table 2-3 of KTA 3211.3.

Definitions

(1) Loading temperature, lowest The lower of the pressure-test temperature or lowest operating temperature is designated the lowest loading temperature. (2) Test groups A1, A2 and A3 The components in the scope of application of this safety standard shall be classified in test groups A1, A2 or A3 depending on design data and dimensions, with consideration of the planned materials and stresses. KTA 3211.2 defines the criteria for classification of a component. The plant supplier shall decide upon the classification by consultation with the authorized inspector. (3) Repairs Repairs are deviations from the planned production flow during manufacture of product forms. Production welds to castings shall not be considered as repairs in the context of this safety standard. (4) Authorized inspector An authorized inspector for the tests and examinations for the purpose of this safety standard is a cognizant person or organization who or which shall be consulted on the basis of legal requirements, guidelines, directives or orders or who or which has been called in on behalf of licensing or supervisory authorities.

Scope

(1) This safety standard shall apply to the materials and product forms of the pressure-retaining walls of pressure- and activity-containing light-water-reactor systems and components that do not belong to the reactor-coolant pressure boundary but have relevance specifically to reactor engineered safety. This definition shall include systems and components meeting one of the following criteria: a) The plant section is necessary for accident control by means of shutdown, maintenance of long-term subcriticality and direct residual heat removal. Requirements for components in systems involved only indirectly in residual heat removal - in other words the closed cooling-water systems and secondary cooling-water systems which do not carry activity - shall be established on a plant-specific

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KTA 3211.1

(5) Material groups W I and W II The ferritic materials for manufacturing components within the scope of application of this safety standard shall be classified in material groups W I or W II according to their quality features, especially chemical composition and toughness characteristics. The allocation of materials to test groups is defined in KTA 3211.2.

(4) Mechanized or automated facilities to be employed for the non-destructive examinations required by this safety standard shall undergo an appraisal by the authorized inspector. (5) Lists of necessary procedure instructions for the production and testing facilities shall be compiled. (6) Through quality monitoring with corresponding recordings, the manufacturer shall ensure proper manufacture and processing of the materials and product forms as well as adherence to the governing technical rules. (7) The manufacturer shall employ skilled personnel capable of performing the tests and examinations properly. (8) The test supervisory personnel for the non-destructive examinations shall be part of the staff of the manufacturers works. It shall be organisationally independent from the fabrication department and shall be named to the authorized inspector. (9) The test supervisory personnel shall be responsible that the test procedures are applied in accordance with the requirements under the product-form related Sections and that the individual steps of performing the tests are applied in accordance with the corresponding regulations. The operators shall be employed by the test supervisory personnel. This also applies to the employment of works-external personnel. The test supervisory personnel shall analyse the test results and sign the test report. (10) The NDT operators carrying out the non-destructive examinations shall be part of the staff of the manufacurer's works. They shall have sufficient basic technical knowledge and shall be capable of performing the examinations in accordance with the requirements. These abilities shall be demonstrated to the test supervisory personnel. The NDT operators shall have sufficient visual capacity which is to be checked by an ophtalmologist, optician or another medical person in conjunction with DIN EN 473. A capacity of 1.0 (to DIN 58 220-3 and DIN 58 220-5) is required for the evaluation of radiographs and the evaluation of tests by means of magnetic particle and liquid penetrant methods at a distance of 0.33 m with or without visual aids. The operators visual capacity shall be checked yearly. NDT operators from outside the manufacturer's works may perform examination tasks only when the radiographic method is being employed, but when the ultrasonic examination method is being employed they may perform such tasks only in addition to inspectors of the manufacturer's works. (11) The manufacturer shall be entitled to issue acceptance test certificates only if he employs a works' inspector qualified in accordance with the conditions of DIN EN 10 204. The name and stamp of the works' inspector shall be announced to the authorized inspector. (12) If welding work is performed on the product forms in the course of manufacture, the manufacturer shall employ his own supervisory staff and welders qualified to DIN EN 287-1 in conjunction with AD Merkblatt HP 3. Only qualified welders shall be used for the welding jobs. The welding supervisor shall be a member of the staff of the manufacturer's works and be named to the authorized inspector. (13) A procedure by which all deviations from the quality requirements observed during production are reported to the responsible agency shall be set forth in writing. (14) The manufacturer shall have a quality department that is independent of the production department. (15) The organizational classification and assignment of duties of the works' inspector, test supervisory personnel, NDT operators and quality department and, if applicable, the welding supervisory personnel, shall be set forth in writing.

3 3.1

General principles Selection of materials

(1) Materials appropriate for the intended use shall be selected, with consideration of the mechanical, thermal and chemical loadings as well as the design conditions to KTA 3211.2. (2) The materials shall safely withstand the loadings during the pressure test, during operation and all specified plant conditions. Any materials on which welding is to be performed shall be suitable for welding.
Note: The selection of material shall be made by the purchaser, if necessary after consultation with the material manufacturer.

3.2

Appraisal of the materials

(1) The materials shall be appraised to determine whether they are suitable for the intended use and the planned processing conditions. (2) Ferritic steels for service in material group W I shall be appraised in consultation with the authorized inspector. (3) As regards nature and scope of appraisal tests, all other steels shall be treated as steels for conventional pressure vessels subject to supervision. If these steels for use in conventional pressure vessels subject to supervision have already been approved, they shall qualify as appraised. (4) If in individual cases a material is used outside the scope of validity of its approval, or if a different material is used, a special appraisal shall be required. The special appraisal shall be mentioned in the acceptance test certificate. 3.3 General quality-assurance requirements

The stipulations in KTA 1401 shall apply to the general qualityassurance requirements. 3.4 Requirements to be met by the manufacturer

(1) The manufacturer shall possess facilities that permit proper and state-of-the-art production of materials and product forms. (2) The manufacturer shall possess test and inspection facilities that permit testing and inspection of the materials and product forms in accordance with the applicable DIN standards or other rules pertinent to the conduct of materials testing and inspection. The test equipment shall correspond to DIN 51 220 and be inspected in accordance with DIN 51 220. Within the measuring range of the test equipment, the permitted measuring inaccuracy of the forces measuring equipment shall not exceed 1 %. Upon request, the test reports to DIN 51 220 shall be submitted to the authorized inspector. If test facilities of other agencies are employed, they shall be subject to the same stipulations. (3) The manufacturer shall have access in its own works or at other agencies to facilities with which the non-destructive examinations required by this safety standard can be performed.

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KTA 3211.1

(16) The authorized inspector shall review whether the requirements have been met before production can be started. The review shall be repeated at intervals of about one to two years, unless the authorized inspector can be convinced by other means that the conditions are still being met. 3.5 Design approval

the material characteristics shall be verified on sufficiently large test coupons in the heat-treatment conditions required for the particular purpose. (2) The products shall have smooth surfaces consistent with the forming method employed. Impermissible surface defects shall be eliminated. The resulting depressions shall be ground flush. The wall thickness shall not be less than the allowable minimum nominal wall thickness. 4.2 Allowable materials

Unless otherwise stipulated in the following sections, material testing and sampling plans shall be required only for product forms for production of components from ferritic steels of material group WI. In fact, such plans shall be required only if sampling is not clearly defined in the Sections relating to product forms. They shall be submitted to the authorized inspector for design approval. 3.6 In-process inspection by the authorized inspector to 20 of the Atomic Energy Act

Materials shall be allowable if they fulfill the prerequisites of Section 3.1 and their suitability has been established in accordance with Section 3.2 of this safety standard. 4.3 4.3.1 Requirements for the materials and their product forms Ferritic steels of material group W I

The authorized inspector shall have the right to be present during the manufacturing processes. However, he shall not impair the manufacturing operations. 3.7 Verification of quality characteristics

(1) The quality characteristics of the materials and product forms shall be determined by tests and examinations, which shall be performed in the manufacturer's works. (2) The quality characteristics of the materials and product forms shall be verified by material test certificates to DIN EN 10 204. The governing stipulations for the required type of quality verification shall be those in the following Sections relating to product forms. Confirmation that the requirements of this safety standard have been met shall be required in the certificates. 3.8 Marking

The product forms shall be clearly and durably marked, if at all possible without notching, in accordance with the stipulations in the following Sections relating to product forms. The use of code characters is permitted. The complete text of the marking shall be indicated in the test certificates. A clear correlation between the test certificates and product forms shall be possible at all times. 3.9 Repairs

Ferritic steels of material group W I shall meet the following conditions: a) In the notched-bar impact bend test on Charpy V-notch transverse specimens at the lowest operating temperature (including accidents) or at the temperature at which the primary membrane stress is higher than 50 N/mm2, the smallest individual value of energy absorbed of the base metal, weld metal and heat-affected zone shall not be less than 68 J, and the smallest individual value of lateral expansion shall not be less than 0.9 mm. b) The smallest individual value of upper shelf energy, determined on Charpy V-notch transverse specimens, shall not be less than 100 J. This only applies to the base metal. c) The energy absorbed, determined on Charpy V-notch transverse specimens, shall not be less than 41 J at the test temperature of 0 C. Only one individual value below the required mean value shall be permitted, and it shall not be smaller than 29 J. This requirement applies to the base metal, the weld metal and the heat-affected zone. For cast steel the specimen direction is not specified. 4.3.2 Ferritic steels of material group W II

(1) Any necessary repairs shall be reported to the authorized inspector. Further action shall be determined in consultation with the authorized inspector. (2) Repairs by welding shall be subject to the stipulations of KTA 3211.3. 3.10 Material characteristic data for design analysis

The characteristic data critical to strength design analysis shall be taken from Annex A, from the appropriate DIN standards or, in the case of special steels, from the authorized inspector's appraisal.

4 4.1

Generally applicable stipulations for materials and material tests General

Ferritic steels of material group W II shall meet the following conditions: a) The values of the chemical composition determined in the ladle analysis shall not exceed 0.020 % P and 0.015 % S. In addition, the processability shall be considered when defining the chemical composition, especially the permissible contents of microalloying elements. b) In the notched-bar impact bend test on Charpy V-notch transverse specimens, the mean value shall not be less than 41 J ba) at the test temperature of 0 C if the lowest loading temperature is lower than 20 C, or bb) at the test temperature of 20 C if the lowest loading temperature is higher than or equal to than 20 C. Only one individual value below the required mean value shall be permitted, and it shall not be smaller than 29 J. The requirement applies for the base metal, the weld metal and the heat-affected zone. For cast steel the specimen direction is not specified. 4.3.3 Austenitic steels

(1) The requirements for material characteristics shall apply to the final condition of the components after the in-process inspection and pressure test. On the basis of the tests and examinations to be performed on materials and product forms,

Austenitic steels shall meet the following conditions: a) The steels shall be resistant to intergranular corrosion in the production conditions in question.

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KTA 3211.1

b) Steels for hot (operating temperature 200 C) reactor water containing product forms and components in boiling water reactor plants shall be resistant to IGSCC. Details are specified in the product-form related Sections. c) The chemical composition shall be defined such that hot cracks do not develop during welding. d) In the case of steels for product forms with a wall thickness greater than 16 mm or DN greater than 150 mm, the energy-absorbed value of the base metal, weld metal and heat-affected zone, determined on Charpy V-notch transverse specimens at the test temperature of 20 C, shall not be less than 70 J (mean value of three specimens, smallest individual value not less than 60 J) in the solution-annealed and quenched condition, or 55 J (mean value of three specimens, smallest individual value not less than 40 J) in the annealed condition. e) For parts on which welding work without weld filler metal will be performed during further processing, the deposited base metal shall have a delta ferrite content of 2 % to 10 % (ferrite number 2 to 11) to Annex D. For sheets on which welding work with weld filler metal will be performed during further processing, the deposited base metal shall have a delta ferrite content of 1 % to 10 % (ferrite number 1 to 11) to Annex D. A close ferrite lattice structure is not permitted in either case. Deviations are permitted if the characteristics of the welded joint satisfy the stipulations of KTA 3211.3. f) For rolled and forged product forms made of austenitic steels as well as parts made from such forms, the required ultrasonic examinability, the further processability and the specified mechanical and technological characteristics shall not be impaired by coarse-grained microstructural zones.
Note: Based on available experience, every effort should be made to achieve a grain size corresponding to a characterizing number larger than or equal to 4 to Euronorm 103-71.

impact specimens, the notch axis shall be in the main forming direction. b) Designation based on direction relative to product geometry: Axial specimens (A): Longitudinal axis of specimen parallel to the axis of rotational symmetry; for notched-bar impact specimens, the notch axis shall be perpendicular to the cylindrical surface. Tangential specimens (T): Longitudinal axis of specimen in the circumferential direction; for notched-bar impact specimens, the notch axis shall be perpendicular to the cylindrical surface. Radial specimens (R): Longitudinal axis of specimen perpendicular to the cylindrical surface; for notched-bar impact specimens, the notch axis shall be in the main forming direction. 4.4.2 Location of specimens in product forms

The specimen location shall be identified as follows: as regards depth below the surface, by the location of the specimen axis; as regards distance from the edge, by the location of the cross section to be inspected. Further particulars are defined in the following Sections relating to product forms. 4.4.3 Size of test coupons

(1) The quantity of material to be taken shall be large enough to provide an adequate quantity of material for substitute specimens in addition to the material for verification of mechanical and technological characteristics. (2) If further specimen quantities are needed for additional tests, the number and dimensions of the additional test coupons shall be specified in the purchase order. In the case of castings, additional test plates from the heats used for these coupons shall be kept available if required.

4.3.4

Steels for special loads

If special loads such as erosion, corrosion and wear are present, materials matched to the requirements of the particular application shall be employed. The conditions for such materials shall be defined on a case-by-case basis in consultation with the authorized inspector. 4.4 4.4.1 Testing and examination of materials and product forms
3

Designation of specimen direction in product forms

HUR

The following designations shall be used to describe the direction of specimens in product forms (see Figures 4-1 and 4-2): a) Designation based on direction relative to fibre: Longitudinal specimens (L): Longitudinal axis of specimen in the main forming direction; for notched-bar impact specimens, the notch axis shall be perpendicular to the plane of the transverse and longitudinal directions. Transverse specimens (Q): Longitudinal axis of specimen transverse to the main forming direction; for notched-bar impact specimens, the notch axis shall be perpendicular to the plane of the transverse and longitudinal directions. Perpendicular specimens (S): Longitudinal axis of specimen perpendicular to the plane of the transverse and longitudinal directions; for notched-bar Page 8

2 3 1 1

1: Perpendicular specimen 2: Longitudinal specimen 3: Transverse specimen HUR: Main forming direction
Figure 4-1: Designation of specimen directions for flat products

KTA 3211.1

4.4.6 4.4.6.1
ia ax l

Tests and test methods to be employed General

HU

(1) The stipulations of clause 4.4.6 shall apply if performance of the tests cited in the following is required in the Sections relating to product forms and if nothing to the contrary is expressly stipulated there. (2) The particulars needed for materials testing and taken from the classification into test and material groups per KTA 3211.2 shall be announced to the material or product-form manufacturer in the purchase order. 4.4.6.2 Chemical analysis

HUR tangential

(1) The elements indicated for the corresponding material in Annex A shall be determined during ladle and product analyses. (2) Specimen taking and preparation for product analysis shall be governed by SEP 1805 [Steel and Iron Test and Examination Data Sheet 1805]. (3) In case of doubt the chemical composition shall be determined by the test method developed by the Chemists Committee of the Association of German Ferrous Metallurgists (VDEh) (see Manual for the Ferrous Metallurgy Laboratory [1]). 4.4.6.3 Hardness test

Specimen direction relative to Specimen No. 1 2 3 Figure 4-2: Product geometry radial axial tangential Main forming direction (HUR) tangential perpendicular transverse longitudinal axial perpendicular longitudinal transverse

(1) Hardness tests shall be performed to DIN EN ISO 6506-1 or DIN EN ISO 6507-1. (2) Other hardness test methods may also be used, subject to approval of the authorized inspector. 4.4.6.4 Tensile test

Designation of specimen directions for rotationally symmetric parts

4.4.4

Marking of test coupons and specimens

Tensile tests shall be performed to DIN EN 10 002-1 and DIN EN 10 002-5, using specimens to DIN 50125. 4.4.6.5 Notched-bar impact bend test

For the acceptance tests, the test coupons shall be marked legibly and clearly before removal from the product form, and the specimens shall be marked likewise before specimen removal from the test coupon. The specimen marking shall permit exact correlation with its location in the product form. 4.4.5 Heat-treatment conditions of specimens

Notched-bar impact bend tests shall be performed to DIN EN 10 045-1 on Charpy V-notch specimens. One set consisting of three specimens shall be tested. 4.4.6.6 Energy absorbed vs. temperature curves

(1) All test coupons shall be heat-treated on and together with the product form (normalizing, quenching and tempering, solution annealing and quenching). (2) If the product forms are not delivered in the heattreatment condition governing establishment of the characteristics, but receive this heat treatment only in the course of further processing, the material manufacturer shall perform tests on specimens from test coupons subjected to corresponding heat treatment.
Note: Unless otherwise stipulated in the appraisal, stress-relief annealing shall not constitute the heat treatment governing establishment of the mechanical and technological characteristics.

(1) Notched-bar impact bend tests to clause 4.4.6.5 shall be tested at a minimum of four temperatures to plot energy absorbed vs. temperature curves. (2) The temperatures shall be chosen such that they encompass the upper shelf energy, characterized by a dull fracture surface representing a proportion of about 100 % of the total fracture surface, as well as the transition to brittle fracture behaviour, characterized by a dull fracture surface representing a proportion of about 50% of the total fracture surface. (3) A set of three specimens shall be tested at each test temperature. For all notched-bar specimens of ferritic steels used to plot energy absorbed vs. temperature curves, the lateral expansion to DIN 50 115 and the proportion of dull fracture surface as a percentage of total fracture surface shall be determined.

(3) Should simulated stress-relief annealing be required in Annex A or in the authorized inspectors appraisal, it shall be performed in accordance with the conditions stipulated therein.

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KTA 3211.1

4.4.6.7 Technological tests on pipes The technological tests on pipes shall be performed to: DIN EN 10 233 - Flattening test DIN EN 10 234 - Drift test DIN EN 10 236 - Ring expanding test DIN EN 10 237 - Ring tensile test 4.4.6.8 Metallographic examinations

4.4.7 4.4.7.1

Non-destructive examinations General

(1) The stipulations of clause 4.4.7 shall apply unless other stipulations are made in the Sections relating to product forms.
Note: Deviations from the requirements of clause 4.4.7 are permitted by agreement with the authorized inspector.

(2) The nature, extent and date of the examinations are stipulated in the Sections relating to product forms. (3) Depending on machining location, the non-destructive examinations shall be performed by the product-form manufacturer or component manufacturer. The ultrasonic examination shall take place after the last forming step and heat treatment and in general shall be performed by the productform manufacturer. If non-destructive examinations are not performed completely by the product-form manufacture, a corresponding note shall be made in the acceptance test certificate. (4) Stipulations for automated or mechanized examination methods can be found in the respective Sections relating to product forms. (5) Where automated or mechanized non-destructive test methods are used, test instructions shall be prepared on the basis of an evaluation of the test systems which demonstrate the equivalency of the test results with those obtained with the described manual methods. The test instructions shall be submitted to the authorized inspector within the course of the design approval procedure. (6) Where weld edges and nozzles are dressed, these dressed areas shall be subjected to an ultrasonic examination prior to dressing the fusion faces. In this case, the conditions of testing prior to welding shall be considered. In the case of wall thicknesses or sections at the point of connection equal to or greater than 30 mm a section width equal to the wall thickness plus 10 mm is considered the weld edge or nozzle area, in the case of greater wall thicknesses or sections at the point of connection, a section width equal to the wall thickness plus 20 mm adjacent to the fusion face or nozzle hole. 4.4.7.2 4.4.7.2.1 Method-related stipulations Manual ultrasonic examinations

(1) The microstructural condition shall be determined by preparing micrographs at a magnification that permits an unequivocal evaluation. (2) The grain-size characterizing number shall be determined to Euronorm 103-71. 4.4.6.9 Determination of delta ferrite content

(1) If required in the Sections relating to product forms, the delta ferrite content of products of austenitic steels or austenitic cast steel as well as of composite pipes pressureclad with austenitic cladding layers shall be determined by one of the following methods: a) metallographic determination in the as-delivered condition, b) metallographic determination on the bead-on-plate test specimen, c) theoretical estimation from the chemical composition, using De Longs method [2]. (2) The Sections relating to product forms specify which of the methods indicated under (1) a) to c) is to be employed. Other methods are also permitted, subject to agreement by the authorized inspector. One such example is the physical measurement method to DIN 32 514-1. (3) If the theoretical estimate yields ferrite numbers lower than 3, the delta ferrite content shall also be determined metallographically on the bead-on-plate test specimen. (4) Details on how to perform the methods cited under (1) a) to c) are described in Annex D. (5) The particular method to be employed shall be indicated in the quality certificate. 4.4.6.10 Corrosion-resistance testing

The resistance to intergranular corrosion shall be verified to DIN EN ISO 3651-2. 4.4.6.11 Materials identification check

(1) The general stipulations of Annex F as well as the requirements of the Sections relating to products shall apply. (2) The root mean square roughness index Ra to DIN EN ISO 4287 shall not exceed 20 m on the examination surface. (3) Should it be impossible to maintain the boundary conditions for examination by the distance-gain-size method (DGS method) to Section F 4.2 or the DGS method cannot be applied due to the sound attenuation of the material, the reference-echo method to Section F 4.3 shall be employed. (4) When the DGS method is employed, the recording limits given as a function of nominal wall thickness or of bar or rod diameter in the Sections relating to product forms shall apply. (5) When the reference-echo method is employed, all indications with echo amplitudes equal to or greater than 50 % of the echo amplitude of the reference reflector shall be registered. (6) If in manual examination the coupling cannot be checked by other means (e.g., by observing a back-wall echo), the gain shall be increased until the noise background becomes visible. (7) The echo amplitudes to be registered and the acceptance limits are defined as a function of product form and dimensions in the Sections relating to product forms.

(1) Materials identification checks shall be performed by a suitable method. Comparison of stamp markings shall not be adequate. (2) For pieces that have undergone a product analysis, it is permitted to acknowledge that analysis as the materials identification check. 4.4.6.12 Dimensional check

Before shipment of the products, the dimensions and tolerances specified in the purchase order shall be checked. 4.4.6.13 Visual inspection

During the acceptance procedure, the products shall be subjected to a visual inspection of their external finish.

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Should the permissible findings be exceeded, the further actions shall be determined by agreement between productform manufacturer and authorized inspector. (8) If indications can exhibit a longitudinal or areal extension, the reflector extension shall be given, unless otherwise stipulated, by that probe displacement for which, depending on wall thickness: a) the echo amplitudes correspond to the recording limit for wall thicknesses equal to or smaller than 10 mm, or b) the echo amplitudes have dropped 6 dB below the recording limit for wall thicknesses greater than 10 mm and equal to or smaller than 40 mm, or c) the echo amplitudes have dropped 12 dB below the recording limit for wall thicknesses greater than 40 mm. (9) Should the noise background be reached in this process, reflector extensions shall be reported until they disappear in the background. The accuracy in measurement of reflector extension shall then be improved by additional investigations if these dimensions alone are critical for evaluation of acceptability. Reflectors with extensions smaller than 10 mm shall qualify as local indications. 4.4.7.2.2 Surface-crack detection

check the sensitivity adjustments and whether the procedure is performed as stipulated in the initial appraisal (4) The authorized inspector shall participate at random to the extent stipulated in (2), in the surface-crack detections to be performed in general by the manufacturer. (5) When the ultrasonic-examination method is employed, the authorized inspector shall check the test reports. The results of the ultrasonic examinations performed by the manufacturer shall be randomly checked by the authorized inspector to the extent stipulated in (2). (6) When the radiographic-examination method is employed, the authorized inspector shall check the performance of the examinations at random and shall evaluate the results on the basis of the test report and the radiographs. (7) If the authorized inspector has participated in the nondestructive examinations performed by the manufacturer, he shall include confirmation to this effect in the manufacturers certificates. (8) If the authorized inspector has performed his own examinations, he shall check the manufacturers examination results for agreement within the error inherent to the examination technique. Should agreement exist, he shall confirm this in the manufacturers certificates. (9) If substantial differences from the results of the manufacturers examinations are found, the authorized inspector and manufacturer together shall perform and document additional checks. 4.5 Re-examinations

(1) The general stipulations of Annex G as well as the requirements of the Sections relating to products shall apply. (2) The root mean square roughness index Ra determined in accordance with DIN EN ISO 4287 shall not exceed the following values depending on the process of surface treatment: a) unmachined surfaces b) machined surfaces Ra 20 m Ra 10 m

(3) Examination for surface crack detection shall basically be performed by the magnetic particle method unless specified otherwise by the product form-related sections. (4) When subjecting large areas to a magnetic particle examination, the yoke magnetization method shall preferably be used. Small parts shall be examined, if practicable by means of the auxiliary or coil technique. (5) Methods other than magnetic-particle or liquid-penetrant examination are permitted, subject to approval by the authorized inspector. They shall preferably be mechanized methods such as eddy-current examination or magnaflux method with probes for detection of surface defects. 4.4.7.2.3 Radiographic examination

(1) Test results that are based on incorrect taking or preparation of the test specimens (test specimen sets), on incorrect performance of the test or on a random narrow flaw location in one test specimen are invalid. The examination shall be repeated. (2) Should the results of a properly performed examination fail to meet the above requirements, the following actions shall be taken: a) Lotwise examination aa) The test coupon from which the unsatisfactory specimen (or specimen set) was taken shall be excluded from the lot. It shall be replaced by two further test coupons from the lot, and the required examinations shall be repeated on those coupons. ab) The examination shall qualify as passed if the results of the re-examination meet the requirements. ac) The lot shall be rejected if any result of the two reexaminations fails to meet the requirements. However, a check examination of the characteristic found to be out of specification is permitted on each individual piece of the lot. b) Individual examination ba) For each unsatisfactory specimen (or specimen set), two further specimens (or specimen sets) from the same sampling location shall be examined. bb) The results of both examinations shall meet the requirements. (3) Should it be impossible by appropriate heat treatment to eliminate the reason for the unsatisfactory result of an examination, a new heat treatment shall be required, after which the test unit shall be submitted again for examination. (4) The cause of the unsatisfactory result of the first examination shall be investigated.

The general stipulations of Annex B as well as the requirements of the Sections relating to products shall apply. 4.4.7.3 Organization of non-destructive examinations

(1) The manufacturer shall perform and verify all nondestructive examinations to the extent specified by this safety standard. (2) The authorized inspector shall perform or participate in the non-destructive examinations to the extent specified by this safety standard. The scope of random non-destructive examinations by the authorized inspector shall be 25 % in test group A 1 and 10 % in test group A 2. Examination by the authorized inspector is not required in test group A 3. (3) When equipment for mechanized or partly automated examination is used, the authorized inspector shall participate at random in the examinations and in the process and shall

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5 5.1 5.1.1

Product forms of ferritic steels of material group W I Sheets and plates Materials

(1) The following steel grades may be used: a) steel grades to Section A 1 b) other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspectors appraisal. (2) The toughness requirements of clause 4.3.1 a) for the lowest operating temperature shall be considered in selecting materials. 5.1.2 Additional requirements for the materials

b) For plates with nominal thicknesses between 5 mm and smaller than 10 mm, specimens with a width equal to the plate thickness shall be taken. The rolled surfaces shall be ground. Dressing of the specimens is permitted, in which case specimens 5 or 7.5 mm wide are preferable. c) For plates with nominal thicknesses equal to or larger than 10 mm up to and including 40 mm, specimens shall be taken at the rolled surface. d) For plates with nominal thicknesses larger than 40 mm, specimens with their axis at one quarter of the plate thickness under the rolled surface shall be taken. (5) Transverse specimens shall be used for the tensile and notched-bar impact bend tests. (6) Specimens for determination of the reduction of area at fracture on perpendicular specimens shall be taken and be prepared in accordance with the stipulations in DIN EN 10 164. (7) Standard specimens shall be used for determination of the room-temperature yield point or 0.2 % proof stress and tensile strength on specimens perpendicular to the plate surface. 5.1.3.2 Extent of tests and examinations

(1) Plates with nominal thicknesses equal to or larger than 10 mm subjected to loading perpendicular to the rolled surface shall at least meet the requirements of quality class Z 35 to DIN EN 10 164. This shall be specified in the purchase order. (2) For plates with nominal thicknesses equal to or greater than 150 mm, the smallest individual value of energy absorbed (Charpy V-notch transverse specimens) at the middle of the plate thickness at 80 C shall not be less than 68 J. (3) The requirements of (1) shall apply when plates are used for tubesheets. In addition, the same requirements as for specimens longitudinal to or transverse to the main rolling direction shall apply for the room-temperature yield point or 0.2 % proof stress and tensile strength of standard specimens perpendicular to the plate surface. This shall be specified in the purchase order. (4) The surface finish shall satisfy the stipulations of DIN EN 10 163-2 Class B Subgroup 3. Elimination of surface defects by welding is not permitted. 5.1.3 5.1.3.1 (1) Tests and examinations Sampling and specimen preparation

(1) The chemical composition shall be determined by performing: a) One ladle analysis per heat. b) One product analysis on one sampling location in each of two rolled plates per heat. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per sampling location. b) One elevated-temperature tensile test per heat, dimensional range and at most 30 metric tons. The test temperature is defined in Section A 1 or in the authorized inspector's appraisal. c) Three room-temperature tensile tests to DIN EN 10 164 at one sampling location per rolled plate for plates with nominal thicknesses equal to or larger than 10 mm, in order to determine the reduction of area at fracture, whenever the requirement of clause 5.1.2 (1) is applicable. d) One notched-bar impact bend test to clause 4.4.6.5 per sampling location at 33 C or at the lowest operating temperature, whichever is lower, for plates with nominal thicknesses equal to or larger than 5 mm. Notwithstanding the foregoing, the energy absorbed for steel grade 15 MnNi 6 3 shall be determined at 0 C. e) Notched-bar impact bend tests at one sampling location for determination of the energy absorbed vs. temperature curve to clause 4.4.6.6 per heat, dimensional range and identical heat treatment for plates with nominal thicknesses equal to or larger than 10 mm and equal to or smaller than 38 mm, and per rolled plate for plates with nominal thicknesses larger than 38 mm. At least four test temperatures shall be used, of which two shall be 0 C and the lowest loading temperature. This test may be waived for plates of steel grade 15 MnNi 6 3. f) One notched-bar impact bend test to clause 4.4.6.5 at one sampling location per rolled plate, to determine the upper shelf energy for plates with nominal thicknesses larger than 16 mm. This test may be performed during determination of the energy absorbed vs. temperature curves. In general, 80 C shall be selected as the test temperature. The test shall be performed only in test group A 1, and may be waived if the value of energy absorbed determined per d) is equal to or greater than 100 J. g) One notched-bar impact bend test to clause 4.4.6.5 at 80 C at one sampling location in the middle of the plate thickness of each rolled plate for plates with nominal

The sampling locations are stipulated in Section A 1.

(2) The following specimens shall be taken for the tensile test at room temperature: a) For plates with nominal thicknesses equal to or larger than 40 mm, flat tensile-test specimens containing both rolled surfaces. Round tensile-test specimens may also be used. b) For plates with nominal thicknesses larger than 40 mm, flat tensile-test specimens at least 40 mm thick containing at least one intact rolled surface. Round tensile-test specimens with the specimen axis at one quarter of nominal thickness under the rolled surface (test diameter equal to or larger than 10 mm) may also be used. (3) The following specimens shall be taken for the tensile test at elevated temperature: a) For plates with nominal thicknesses smaller than 12 mm, flat tensile-test specimens or round tensile-test specimens. b) For plates with nominal thicknesses equal to or larger than 12 mm up to and including 40 mm, round tensile-test specimens. c) For plates with nominal thicknesses larger than 40 mm, round tensile-test specimens with the specimen axis at one quarter of nominal thickness under the rolled surface (test diameter equal to or larger than 10 mm). (4) The notched-bar impact bend test shall be subject to the following requirements: a) For plates with nominal thicknesses smaller than 5 mm, a notched-bar impact bend test is not required.

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thicknesses equal to or greater than 150 mm, unless otherwise stipulated in the appraisal. (3) The non-destructive examinations shall be subject to the following requirements: a) Each plate with nominal thickness equal to or larger than 10 mm shall be subjected to an ultrasonic surface examination to SEL 072 by the manufacturer. If the examination is not performed with automated examination systems, 10 % of the delivery shall additionally be examined by the authorized inspector. b) The requirements of Class 3 to SEL 072 shall apply to the surface examination. (4) Each rolled plate shall be subjected to a materials identification check. (5) Each plate shall be subjected to a visual inspection of its external finish. (6) 5.1.4 The thickness of each rolled plate shall be measured. Marking

class Z 35 to DIN EN 10 164. This shall be specified in the purchase order. (2) For product forms with nominal thicknesses greater than 150 mm, the smallest individual value of energy absorbed (Charpy V-notch transverse specimens) at the middle of the product-form thickness at 80 C shall not be less than 68 J. 5.2.3 Starting plates

(1) Starting plates shall be subject to the stipulations in Section 5.1. (2) If the finished parts are tested individually in accordance with clause 5.2.4.2, the tests to clause 5.1.3.2 (2) as well as the corresponding verifications can be omitted. (3) For the tests to clauses 5.1.3.2 (4) to (6), an acceptance test certificate 3.1.B to DIN EN 10 204 will suffice.
Note: The stipulations of KTA 3211.3 shall apply to welded joints made with the starting plates and remaining in the finished parts.

(1) Each plate shall be marked with the following information: a) manufacturers symbol, b) steel grade (for steels with guaranteed reduction of area at fracture perpendicular to the product surface additionally quality class to DIN EN 10 164), c) heat number, d) specimen number, e) authorized inspectors mark. (2) The marking shall be applied such that it appears upright when viewed in the main rolling direction of the rolled plate. 5.1.5 Verification of quality characteristics

(4) If it is agreed in the purchase order that an ultrasonic examination will be performed on the starting plates, this examination shall be performed to clause 5.1.3.2 (3) in the agreed delivery condition. 5.2.4 5.2.4.1 Tests and examinations of dished or pressed product forms made from plates Sampling and specimen preparation

(1) For product forms with a diameter or length equal to or smaller than 3000 mm, the tests or examinations shall be performed on one part per rolled plate and heat-treatment lot. The maximum permissible lot size shall be 10 parts.
Note: Correlation of parts with the rolled plate can be achieved, for example, through the specimen number of the starting plates.

(1) The results of the ladle analysis, product analysis, materials identification check and ultrasonic examination performed by the manufacturer shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204, and the results of the visual inspection and dimensional check with an acceptance test certificate 3.1.C to DIN EN 10 204. The delivery condition shall be indicated in the acceptance test certificate 3.1.B. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificate as an acceptance test certificate 3.1.C to DIN EN 10 204. 5.2 5.2.1 Dished or pressed product forms made from plate Materials

(2) For product forms with a diameter or length greater than 3000 mm, each part shall be tested. For lengths or diameters exceeding 6 m one test coupon each shall be taken at two opposite sides. (3) One test coupon shall be taken from each part to be examined regardless of its diameter or length. (4) The test coupons shall be taken such that transverse specimens can be machined. Deviations up to 20 degrees from the theoretical transverse direction are permitted for heads (ends) and similar parts. If this is not possible, a different way of sampling shall be agreed with the authorized inspector. (5) Round tensile-test specimens with a test diameter equal to or larger than 10 mm shall be made for both the roomtemperature and elevated-temperature tensile tests. For nominal thicknesses larger than 40 mm, the specimen axis shall be located at a distance of one quarter of the productform thickness under the rolled surface. For product-form thicknesses that do not permit a test diameter of 10 mm, the largest possible diameter shall be chosen. (6) For nominal wall thicknesses equal to or smaller than 40 mm, one side of the specimens for the notched-bar impact bend test shall be as close as possible to the rolled surface. For nominal wall thicknesses larger than 40 mm, the specimen axis shall be located at a distance of one quarter of the product-form thickness under the rolled surface. 5.2.4.2 Extent of tests and examinations

(1) The following steel grades may be used: a) steel grades to Section A 1, b) other steel grades that the meet the prerequisites of Section 3 in combination with the stipulations in the authorized inspectors appraisal. (2) The toughness requirements of clause 4.3.1 a) for the lowest operating temperature shall be considered in selecting materials. 5.2.2 Additional requirements for the materials

(1) Product forms with nominal thicknesses equal to or larger than 10 mm subjected to loading perpendicular to the rolled surface shall at least meet the requirements of quality

(1) The mechanical and technological characteristics shall be determined by performing:

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a) One room-temperature tensile test per sampling location. b) One elevated-temperature tensile test per heat, dimensional range and at most 30 metric tons. The test temperature is defined in Section A 1 or in the authorized inspectors appraisal. c) Three tensile tests (three perpendicular specimens to DIN EN 10 164) at one sampling location per rolled plate for product forms with nominal wall thicknesses equal to or larger than 10 mm subject to loading perpendicular to the rolled surface, in order to determine the reduction of area at fracture. This test may be waived if it has already been performed on the rolled plate and documented with an acceptance test certificate 3.1.C to DIN EN 10 204.
Note: Correlation of parts with the rolled plate can be achieved, for example, through the specimen number of the starting plates.

a) If agreed in the purchase order, the starting plates or the finished parts with nominal wall thicknesses equal to or larger than 10 mm shall be subjected to an ultrasonic surface examination per clause 5.1.3.2 (3). b) The flange and knuckle of each head (end) shall be subjected to a surface-crack detection in the finishmachined condition after the last heat treatment. The acceptance criteria are defined in Table 5.2-1. (3) Each product form shall be subjected to a materials identification check. (4) Each product form shall be subjected to a visual inspection of its external finish. (5) Each product form shall be checked for accuracy regarding dimensions and form. 5.2.5 Marking

d) One notched-bar impact bend test to clause 4.4.6.5 per sampling location at 33 C or at the lowest operating temperature, whichever is lower, for nominal wall thicknesses equal to or larger than 5 mm. Notwithstanding the foregoing, the energy absorbed for steel grade 15 MnNi 6 3 shall be determined at 0 C. e) Notched-bar impact bend tests at one sampling location for determination of the energy absorbed vs. temperature curve to clause 4.4.6.6 per heat, dimensional range and heat-treatment lot for product forms with nominal wall thicknesses equal to or larger than 10 mm and equal to or smaller than 38 mm, and per rolled plate for product forms with nominal wall thicknesses larger than 38 mm. At least four test temperatures shall be used, of which two shall be 0 C and the lowest loading temperature. This test may be waived for product forms of steel grade 15 MnNi 6 3. f) One notched-bar impact bend test to clause 4.4.6.5 at one sampling location of each part to be tested to determine the upper shelf energy for product forms with nominal wall thicknesses larger than 16 mm. This test may be performed during determination of the energy absorbed vs. temperature curve. In general, 80 C shall be selected as the test temperature. The test shall be performed only in test group A 1, and may be waived if the value of energy absorbed determined per d) is equal to or greater than 100 J. g) One notched-bar impact bend test to clause 4.4.6.5 per sampling location at 80 C in the middle of the productform thickness for product forms with nominal wall thicknesses equal to or greater than 150 mm, unless otherwise stipulated in the appraisal. (2) The non-destructive examinations shall be subject to the following requirements:

(1) Each product form shall be marked with the following information: a) symbol of the manufacturer of the product form, b) steel grade (for steels with guaranteed reduction of area at fracture perpendicular to the product surface additionally quality class to DIN EN 10 164), c) heat number, d) specimen number and e) authorized inspector's mark. (2) In the case of lotwise examination, the product form from which the specimens were taken shall additionally be marked. (3) The marking shall be applied such that it appears upright when viewed in the main rolling direction of the rolled plate. 5.2.6 Verification of quality characteristics

(1) The results of the ladle analysis, product analysis, materials identification check and non-destructive examinations performed by the manufacturer, and of the heattreatment condition shall be documented with an acceptance test certificate 3.1.B and the results of the visual inspection and dimensional check with an acceptance test certificate 3.1.C to DIN EN 10 204. The delivery condition shall be indicated in the acceptance test certificate 3.1.B. (2) The forming method shall be indicated in acceptance test certificate 3.1.B to DIN EN 10 204. (3) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificate as an acceptance test certificate 3.1.C to DIN EN 10 204. Allowable length of nonmetallic inclusions 1) in the main forming direction in mm Maximum allowable frequency per 10 x 10 cm2

Material group

Inspection on

Allowable actual extension of defect in main forming direction, in mm for wall thicknesses 10 mm 1,5 for wall thicknesses > 10 mm 1,5

Steels with specified yield point > 370 N/mm2

Steels with specified yield point 370 N/mm2

Starting product Formed product Starting product Formed product

10

1,5 1,5

3 3

6 10

10 10

1) For several similar indications, verification by a specimen randomly taken from the test coupon is permitted.

Table 5.2-1:

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KTA 3211.1

5.3 5.3.1

Forgings, bar steel and rolled rings Materials

(1) The following steel grades may be used: a) steel grades to Section A 2, b) other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspectors appraisal. (2) The toughness requirements of clause 4.3.1 a) for the lowest operating temperature shall be considered in selecting materials. 5.3.2 Additional requirements for the materials

smaller than or equal to 1000 mm; from two sampling locations separated by 180 degrees for Di between 1000 mm and 2000 mm; and from three locations separated by 120 degrees for Di larger than 2000 mm (see Figure 5.3-3). (4) For plates such as tubesheets, tube plates or blankingoff covers with heat-treatment weights lighter than 1000 kg, specimens shall be taken from one sampling location. If permitted by the forging method employed, this location shall be in the top or bottom zone (see Figure 5.3-4). (5) For plates with heat-treatment weights equal to or heavier than 1000 kg, specimens shall be taken from two sampling locations. If permitted by the forging method employed, these locations shall be in the top and bottom zones (see Figure 5.3-4). (6) For forged bars, specimens shall be taken at one end as a function of the diameter D of the bars: from one sampling location for D smaller than or equal to 500 mm; and from two sampling locations separated by 180 degrees for D larger than 500 mm. (7) At the opposite end, specimens shall be taken from one sampling location for normalized or air quenched and tempered bars having a finished length longer than 5000 mm and for liquid quenched and tempered bars having a finished length longer than 2000 mm. For bars having diameters smaller than or equal to 500 mm, this location shall be offset by 180 degrees relative to that at the other end. 5.3.3.1.3 Sampling depth

For products with heat-treatment thicknesses greater than 150 mm and heat-treatment weights heavier than 500 kg, the smallest individual value of energy absorbed (Charpy V-notch transverse specimens) at the middle of the wall thickness at 80 C shall not be less than 68 J.
Note: Heat-treatment thickness and heat-treatment weight designate the wall thickness and piece weight of the product forms in the condition in which the heat treatment governing establishment of the mechanical and technological characteristics is performed.

5.3.3 5.3.3.1 5.3.3.1.1

Tests and examinations Sampling and specimen preparation Test units

(1) Unless otherwise required in clause 5.3.3.2, the following is required: a) Pieces with heat-treatment weights lighter than or equal to 100 kg may be grouped as test units of 1000 kg each. b) Pieces with heat-treatment weights heavier than 100 kg and equal to or lighter than 500 kg from the same heat, with similar dimensions and from the same heat-treatment lot shall be grouped as test units containing at most 10 parts. c) Pieces with heat-treatment weights heavier than 500 kg shall be tested individually. 5.3.3.1.2 Sampling locations

(1) For normalized and air quenched and tempered parts, the specimens shall be taken from at least one quarter of the governing heat-treatment thickness but at most 80 mm under the heat-treatment surfaces. (2) For liquid quenched and tempered parts, except for plates with heat-treatment thicknesses larger than 320 mm, the specimens shall be taken from at least one quarter of the governing heat-treatment thickness but at most 80 mm under the governing heat-treatment surface and at least from the middle of the governing heat-treatment thickness (s/2) and at most 160 mm under the other surfaces. (3) For liquid quenched and tempered plates with heattreatment thicknesses larger than 320 mm, the specimens shall be taken from at least 80 mm under the heat-treatment surfaces. (4) For parts with a governing heat-treatment thickness larger than 150 mm and a heat-treatment weight heavier than 500 kg, samples shall be taken additionally at one location from the middle of the governing heat-treatment thickness (s/2).
Note: In the case of plates for tubesheets, the question of whether this requirement is met shall be verified in the appraisal by the energy absorbed at the middle of the wall thickness.

(1) For forged hollow parts, e.g., for shell courses, nozzles or valve bodies, specimens shall be taken from one end as a function of inside diameter Di as follows: from one sampling location for Di equal to or smaller than 500 mm; from two sampling locations separated by 180 degrees for Di between 500 mm and 2000 mm; and from three sampling locations separated by 120 degrees for Di larger than 2000 mm. (2) At the opposite end, specimens shall be taken from one sampling location for normalized or air quenched and tempered forgings having a finished length longer than 5000 mm and for liquid quenched and tempered forgings having a finished length longer than 2000 mm. For pieces with inside diameters smaller than or equal to 500 mm, this sampling location shall be offset by 180 degrees relative to that at the other end (see Figures 5.3-1 and 5.3-2).
Note: Finished length designates the length of the product form during the governing heat treatment, less the length of the test coupons.

5.3.3.1.4

Specimen direction

(1) Transverse specimens shall be taken for tensile tests and notched-bar impact bend tests if geometrically possible and nothing to the contrary is stipulated in Section A 2 or in the authorized inspector's appraisal. (2) Notwithstanding the foregoing, longitudinal specimens or axial specimens may be taken from bars, specifically for tensile tests if the diameter or greatest length of a crosssectional edge is smaller than 160 mm, or for notched-bar impact bend tests if the diameter or the greatest length of a cross-sectional edge is smaller than 68 mm.

(3) For seamless rolled or forged rings or flanges, specimens shall be taken from the circumference or end of the flange. They may also be taken from the end of the welding end, if the heat-treatment wall thickness of the welding end is equal to that of the flange. Specimens shall be taken as follows: from one sampling location for inside diameters Di

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5.3.3.2

Extent of tests and examinations

(1) The following procedures shall be performed for the chemical analysis: a) One ladle analysis per heat. b) One product analysis on one sampling location in each of two separately manufactured pieces per heat. c) One product analysis on each piece for piece weights equal to or heavier than 5000 kg. (2) The mechanical and technological characteristics shall be determined by performing: a) One hardness test per piece to verify uniformity for pieces grouped together in test units.
Note: Verification of uniformity shall be acknowledged if the difference between the highest and lowest hardness values in a test unit does not exceed 30 HB units.

as the test temperature. The test shall be performed only in test group A 1, and may be waived if the value of energy absorbed determined per d) is equal to or greater than 100 J. This test may be waived for pieces of steel grade 15 MnNi 6 3 with wall thicknesses smaller than or equal to 150 mm. g) One notched-bar impact bend test to clause 4.4.6.5 at 80 C at one sampling location in the middle of the thickness for products with heat-treatment weights heavier than 500 kg and heat-treatment thicknesses larger than 150 mm, unless otherwise stipulated in the appraisal. (3) Each piece shall be subjected to a non-destructive examination to Annex H. (4) Each piece shall be subjected to a materials identification check. (5) Each piece shall be subjected in the as-delivered condition to a visual inspection of its external finish. (6) 5.3.4 A dimensional check of each piece shall be performed. Marking

b) One room-temperature tensile test per sampling location. c) For pieces of similar dimension, one elevated-temperature tensile test per heat and heat-treatment lot. The test temperature is defined in Section A 2 or in the authorized inspectors appraisal. d) One notched-bar impact bend test to clause 4.4.6.5 per sampling location at 33 C or at the lowest operating temperature, whichever is lower. Notwithstanding the foregoing, the energy absorbed for steel grade 15 MnNi 6 3 shall be determined at 0 C. e) Notched-bar impact bend tests for determination of the energy absorbed vs. temperature curve to clause 4.4.6.6. ea) per heat and heat-treatment lot for pieces with heattreatment weights equal to or lighter than 500 kg eb) per piece, at one sampling location, for pieces with heat-treatment weights equal to or heavier than 500 kg. At least four test temperatures shall be used, of which two shall be 0 C and the lowest loading temperature. This test may be waived for pieces of steel grade 15 MnNi 6 3 with wall thicknesses smaller than or equal to 150 mm. f) One notched-bar impact bend test to clause 4.4.6.5 at one sampling location per test unit to verify the upper shelf energy for pieces with heat-treatment weights equal to or heavier than 150 kg in the normalized or air quenched and tempered condition and equal to or heavier than 50 kg in the liquid quenched and tempered condition. It shall be demonstrated that the smallest individual value of upper shelf energy is equal to or larger than 100 J. This test may be performed during determination of the energy absorbed vs. temperature curves. In general, 80 C shall be selected

(1) Each piece shall be marked with the following information: a) manufacturer's symbol, b) steel grade (for steels with guaranteed reduction of area at fracture perpendicular to the product surface additionally quality class to DIN EN 10 164), c) heat number, d) specimen number, e) authorized inspector's mark and f) mark of the non-destructive examinations performed. (2) In the case of lotwise examination, the piece from which the specimens were taken shall additionally be marked. 5.3.5 Verification of quality characteristics

(1) The results of the ladle analysis, product analysis, materials identification check and non-destructive examinations performed by the manufacturer, and if necessary of the hardness test shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204, which shall include an indication of the delivery condition. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificate as an acceptance test certificate 3.1.C to DIN EN 10 204.

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KTA 3211.1

No.

Finished length Normalized and air quenched and tempered pieces: L 5000 mm Pieces quenched and tempered in liquid: L 2000 mm

Inside diameter Di

Examples for sampling

s/4

500 mm

for normalized and air quenched and tempered pieces: x = s/4

Di

s/4

> 500 mm up to 2000 mm

for pieces quenched and tempered in liquid: x = s/2

x
s/4

> 2000 mm
s

Pieces quenched and tempered in liquid: L > 2000 mm > 500 mm up to 2000 mm

s/4

Normalized and air quenched and tempered pieces: L > 5000 mm

500 mm

Di

Di

s/4

x
s/4

> 2000 mm
s

Figure 5.3-1: Examples for sampling from forged hollow parts

s/4
x

s
s/4

x HUR

HUR

L Example 3 s s/4
x

Example 1 x
s/4

HUR: Main forming direction

HUR HUR
s

L Example 2 Example 4

for pieces quenched and tempered in liquid: x = s/2 for normalized and air quenched and tempered pieces: x = s/4 Figure 5.3-2: Examples for sampling from forged valve bodies Page 17

Di

Di

Di

KTA 3211.1

s1 s1 /4 s1 /4

s1

s1

s1 /4

s2

Example 1

Example 2

Example 3

For parts quenched and tempered in liquid: x = s1/2 For normalized or air quenched and tempered parts: x = s1/4 a) Examples for sampling

Di 1000 mm

1000 mm < Di 2000 mm

Di > 2000 mm

b) Distribution of sampling locations on the circumference or at the end as a function of inside diameter
Figure 5.3-3: Examples for sampling from seamless rolled or forged rings or flanges

80 80

s/2

s/4

80

80

Di

Di

Di

s/2

s/4

s/2

80

80

For plates quenched and tempered in liquid: x = s/2 (max. 160 mm) For normalized or air quenched and tempered plates: x = s/4 (max. 80 mm)
x

80

Sampling at s/2 only for s 150 mm a) Sampling for plates with s 320 mm Contour for quenching and tempering

Sampling from top and bottom zones possible b) Sampling for plates with s > 320 mm Delivery contour Test coupon

80

Sampling from top and bottom zones not possible c) Sampling for plates with s > 320 mm

Figure 5.3-4: Examples for sampling from forged plates Page 18

KTA 3211.1

5.4 5.4.1

Seamless pipes larger than DN 50 Scope

(1) The stipulations of this Section shall apply to seamless, rolled or pressed pipes larger than DN 50.
Note: For forged pipes Section 5.3 shall apply.

(2) The stipulations of this Section shall also apply to pipes equal to or smaller than DN 50 if pipe elbows larger than DN 50 are made from such pipes. (3) The stipulations of this Section shall not apply to pipes for vessel shells. 5.4.2 Materials

(1) The following steel grades may be used: a) steel grades to Section A 3, b) other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspectors appraisal. (2) The toughness requirements of clause 4.3.1 a) for the lowest operating temperature shall be considered in selecting materials. 5.4.3 Additional requirements for the materials

Pipes with nominal wall thicknesses equal to or larger than 10 mm and subject to loading perpendicular to the surface shall at least meet the requirements of quality class Z 35 to DIN EN 10 164. This shall be specified in the purchase order. 5.4.4 5.4.4.1 (1) Tests and examinations Sampling and specimen preparation

The pipes shall be tested in manufacturing lengths.

(2) Specimens shall be taken from the ends of manufacturing lengths. (3) Transverse specimens shall be taken for tensile tests and notched-bar impact bend tests. If this is not possible, it is permitted to take longitudinal specimens. (4) Notched-bar impact bend tests shall be performed only for pipes with nominal wall thicknesses equal to or larger than 10 mm. (5) Specimen forms to DIN EN 10 002-1 and DIN EN 10 002-5 may also be used for tensile tests. (6) For tensile tests other than those to DIN EN 10 002-1 and DIN EN 10 002-5 and for notched-bar impact bend tests, the test coupons shall be taken such that the specimen axis is located at one quarter of the wall thickness under the outside surface and at one half of the wall thickness under the end face or as close as possible to that location. (7) Specimens for determination of reduction of area at fracture on perpendicular specimens shall be taken at the same location as for the room-temperature tensile-test specimens. 5.4.4.2 Extent of tests and examinations

(1) The following procedures shall be performed for the chemical analysis: a) One ladle analysis per heat. b) One product analysis on each of two manufacturing lengths per heat.

(2) The mechanical and technological characteristics shall be determined by performing: a) Room-temperature tensile tests for every 20 manufacturing lengths of the same heat, dimension and heat treatment aa) at one end of one manufacturing length for pipes of normalized or air quenched and tempered steels ab) at both ends of one manufacturing length for pipes of liquid quenched and tempered steels. b) One elevated-temperature tensile test per heat, dimension and heat treatment if the design temperature is higher than 100 C. The test temperature is defined in Section A 3 or in the authorized inspector's appraisal. c) Tensile tests on three perpendicular specimens, taken from one sampling location every 20 manufacturing lengths of the same heat, dimension and heat treatment, to determine the reduction of area at fracture for pipes with nominal wall thicknesses equal to or larger than 10 mm and subjected to loading perpendicular to the surface. This test may be waived for steel grades for which it was demonstrated in the material appraisal that the mean value of reduction of area afire fracture of three perpendicular specimens is at least 45 % and that none of the individual values is smaller than 35 %. d) One notched-bar impact bend test to clause 4.4.6.5 at 33 C or at the lowest operating temperature, whichever is lower, at one end of one manufacturing length per 20 manufacturing lengths of the same heat, dimension and heat treatment for pipes of normalized or air quenched and tempered steels with nominal thicknesses equal to or smaller than 38 mm, and at one end of each manufacturing length for pipes with nominal thicknesses larger than 38 mm. For pipes of steel grade 15 MnNi 6 3, the test temperature shall be 0 C. e) One notched-bar impact bend test to clause 4.4.6.5 at 33 C or at the lowest operating temperature, whichever is lower, at both ends of one manufacturing length per 20 manufacturing lengths of the same heat, dimension and heat treatment for pipes of liquid quenched and tempered steels with nominal wall thicknesses equal to or smaller than 16 mm, and at both ends of each manufacturing length for pipes with nominal wall thicknesses larger than 16 mm. f) Notched-bar impact bend tests for determination of an energy absorbed vs. temperature curve to clause 4.4.6.6 at one end of one manufacturing length per heat, dimension and heat treatment for pipes with nominal wall thicknesses equal to or larger than 10 mm. At least four test temperatures shall be used, of which two shall be 0 C and the lowest loading temperature. This test may be waived for pipes of steel grade 15 MnNi 6 3. g) One notched-bar impact bend test to clause 4.4.6.5 at one end of each manufacturing length to determine the upper shelf energy for pipes of normalized or air quenched and tempered steels with nominal wall thicknesses larger than 38 mm as well as for pipes of liquid quenched and tempered steels with nominal wall thicknesses larger than 16 mm. This test may be performed during determination of the energy absorbed vs. temperature curves. In general, 80 C shall be selected as the test temperature. This test shall be performed only in test group A 1, and may be waived if the value of energy absorbed determined per d) or e) is equal to or greater than 100 J. h) Technological tests per Table 5.4-1 at both ends of each manufacturing length for pipes with nominal wall thicknesses equal to or smaller than 40 mm.

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KTA 3211.1

Nominal wall thickness s of the pipes in mm s< 2 2 s 16 16 < s 40

Nominal outside diameter of the pipes in mm 146 Flattening test Ring expanding test Flattening test
1)

5.4.6

Verification of quality characteristics

> 146 Ring tensile test Ring tensile test

(1) The results of the ladle analysis, product analysis, materials identification check, tightness test and non-destructive examinations performed by the manufacturer shall be documented with acceptance test certificates 3.1.B to DIN EN 10 204, which shall include an indication of the delivery condition. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. 5.5 5.5.1 Seamless pipe elbows larger than DN 50 Scope

1) The drift test also may be performed.

Table 5.4-1: Dimensional ranges for application of the technological tests to pipes (3) Non-destructive examinations shall be subject to the following requirements: a) All pipes shall be examined ultrasonically for longitudinal defects to SEP 1915. Pipes of test group A 1 equal to or larger than DN 100 shall additionally be subjected to an ultrasonic transverse-defect examination to SEP 1918 as well as to an examination for laps to SEP 1919. Pipes of test group A 2 equal to or larger than DN 100 shall be examined for transverse defects to SEP 1918 if they were hot-pilger-rolled or subjected to hot pilger rolling during the manufacturing process. b) One surface-crack detection shall be performed on every fourth pipe of test group A 1. The outside surface shall be examined completely and the inside surface shall be examined over a length of 1 times the outside diameter from each end of the pipe. The acceptance criteria are defined in Table 5.2-1. c) Pipes with nominal wall thicknesses larger than 30 mm and diameters larger than DN 600 shall be examined to Annex H as hollow forged or hollow rolled parts. (4) Each pipe shall be subjected to a materials identification check. (5) The inside and outside surfaces of each pipe shall be subjected to a visual inspection. (6) The diameter and wall thickness shall be checked for dimensional accuracy at both ends of each pipe. (7) Each pipe shall be examined for leak tightness either by an internal hydrostatic pressure test or, at the manufacturers discretion, by an appropriate non-destructive examination to SEP 1925. For the internal hydrostatic pressure test, the test pressure shall generally be 8 MPa. The test pressure shall be limited such that the factor of safety relative to the yield point at room temperature is never less than 1.1. 5.4.5 Marking

(1) This Section shall apply to seamless pipe elbows (weldin elbows) made from seamless rolled, extruded or forged pipes by cold or hot forming followed by heat treatment (normalization; quenching and tempering). (2) This Section shall not apply to pipe bends made with inductive bending machines or by cold forming with or without subsequent heat treatment. These pipe bends are subject to the requirements of KTA 3211.3 Section 6. 5.5.2 Materials

(1) The following steel grades may be used: a) steel grades to Section A 3 and b) other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspectors appraisal. (2) The toughness requirements of clause 4.3.1 a) for the lowest operating temperature shall be considered in selecting materials. (3) For finished pipe elbows, the values of the mechanical and technological characteristics to Section A 3 shall apply even if forged hollow parts are used as starting products. 5.5.3 Starting products

(1) Forged hollow parts to Section 5.3 and seamless pipes to Section 5.4 may be used as starting products. (2) Starting products that have not been completely examined and heat-treated to the stipulations in Sections 5.3 or 5.4 may also be used, provided the finished pipe elbows are examined individually to clause 5.5.4.2. In this case the determination of mechanical and technological characteristics and the corresponding verification may be waived for the starting products. An acceptance test certificate 3.1.B to DIN EN 10 204 shall then be adequate for visual inspection and dimensional check of the starting products. 5.5.4 5.5.4.1 Tests and examinations of pipe elbows Sampling and specimen preparation

(1) Each pipe shall be marked at both ends, 300 mm from the ends, with the following information: a) manufacturers symbol, b) steel grade (for carbon steels additionally quality level, for steels with guaranteed reduction of area at fracture perpendicular to the product surface additionally quality class to DIN EN 10 164) and c) authorized inspectors mark. (2) Each pipe shall additionally be marked at one end with the following information: a) heat number, b) pipe number and c) mark of the non-destructive examinations performed.

(1) Specimens shall be taken from the ends of the pipe elbows in conformity with the authorized inspectors appraisal. (2) The specimen axes shall be located at one quarter of the wall thickness under the outside surface and at one half of the wall thickness under the end face or as close as possible to that location. (3) Transverse specimens shall be taken for tensile tests and notched-bar impact bend tests. If this is not possible, longitudinal specimens shall be selected.

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KTA 3211.1

(4) Notched-bar impact bend tests shall be performed only for pipe elbows with nominal wall thicknesses equal to or larger than 10 mm. (5) If starting products that have not been completely examined and heat-treated to the stipulations in Sections 5.3 or 5.4 are used, test coupons shall be taken from both ends of pipe elbows with an arc length greater than 3000 mm, measured along the outside of the bend. (6) In all other cases, test coupons shall be taken from only one end of the pipe elbow. (7) If the pipe elbows are not tested individually, test units consisting of pipe elbows of the same heat, dimension and heat treatment shall be formed for determination of mechanical and technological characteristics. (8) For the room-temperature tensile tests and for the notched-bar impact bend tests, the number of pipe elbows per test unit shall not exceed: a) 30 pieces for pipe elbows smaller than DN 200 b) 20 pieces for pipe elbows equal to or larger than DN 200 and smaller than DN 350 c) 10 pieces for pipe elbows equal to or larger than DN 350. 5.5.4.2 Extent of tests and examinations

as the test temperature. This test shall be performed only in test group A 1, and may be waived if the value of energy absorbed determined per d) or e) is equal to or greater than 100 J. f) For pipe elbows grouped together as test units, one hardness test per pipe elbow to verify uniformity.
Note: Verification of uniformity shall be acknowledged if the difference between the highest and lowest hardness values in a test unit does not exceed 30 HB units.

(3) Non-destructive examinations shall be subject to the following requirements: a) For pipe elbows equal to or larger than DN 100, the outside and inside surfaces shall be subjected to a surfacecrack detection. For pipe elbows smaller than DN 100, the outside surface shall be subjected to a complete surfacecrack detection and the inside surface shall be subjected to a surface-crack detection wherever it is accessible. The acceptance criteria are defined in Table 5.2-1. b) All pipe elbows smaller than DN 100 shall be ultrasonically examined to SEP 1915 and SEP 1918 for longitudinal and transverse defects in the surface zones that are not accessible to surface-crack detection. c) Pipe elbows with nominal wall thicknesses larger than 30 mm and diameters larger than DN 600 shall be examined to Annex H as hollow forged or hollow rolled parts. d) If an ultrasonic examination is performed on the pipe elbow, the corresponding examination on the starting product may be waived. (4) Each pipe elbow shall be subjected to a materials identification check. (5) The inside and outside surfaces of each pipe elbow shall be subjected to a visual inspection. (6) For each pipe elbow, the wall thickness and, depending on the purchase order, either the outside or inside diameter shall be measured over the arc length, including the ends, and to a sufficient extent over the circumference. The smallest wall thickness as well as the ovality shall be determined. 5.5.5 Marking

(1) The chemical composition shall be verified on the basis of the starting product. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test for each sampling location of one pipe elbow per test unit, and for each sampling location of each pipe elbow in the case of individual testing. b) One elevated-temperature tensile test for one sampling location of one pipe elbow per heat, dimension and heat treatment, and for one sampling location of each pipe elbow in the case of individual testing. The test temperature is defined in Section A 3 or in the authorized inspectors appraisal. c) One notched-bar impact bend test to clause 4.4.6.5 at 33 C or at the lowest operating temperature, whichever is lower, for each sampling location of one pipe elbow per test unit for pipe elbows of normalized or air quenched and tempered steels with nominal wall thicknesses equal to or smaller than 38 mm, as well as for pipe elbows of liquid quenched and tempered steels with nominal wall thicknesses equal to or smaller than 16 mm. For greater wall thicknesses as well as in the case of individual testing, this test shall be performed at each sampling location of each pipe elbow. For pipe elbows of steel grade 15 MnNi 6 3, the test temperature shall be 0 C. d) Notched-bar impact bend tests for determination of an energy absorbed vs. temperature curve to clause 4.4.6.6 for one sampling location of one pipe elbow per heat, dimension and heat treatment for pipe elbows with nominal wall thicknesses equal to or larger than 10 mm. At least four test temperatures shall be used, of which two shall be 0 C and the lowest loading temperature. This test may be waived for pipe elbows of steel grade 15 MnNi 6 3. e) One notched-bar impact bend test to clause 4.4.6.5 to determine the upper shelf energy at one sampling location of each elbow for pipe elbows of normalized or air quenched and tempered steels with nominal wall thicknesses equal to or larger than 38 mm as well as for pipe elbows of liquid quenched and tempered steels with nominal wall thicknesses larger than 16 mm. This test may be performed during determination of the energy absorbed vs. temperature curves. In general, 80 C shall be selected

(1) Each pipe elbow shall be marked with the following information: a) manufacturer's symbol, b) steel grade (for steels with guaranteed reduction of area at fracture perpendicular to the product surface additionally quality class to DIN EN 10 164), c) heat number, d) pipe-elbow number e) authorized inspector's mark and f) mark of the non-destructive examinations performed. 5.5.6 Verification of quality characteristics

(1) The results of the ladle analysis, product analysis, materials identification check, hardness test and non-destructive examinations performed by the manufacturer shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204, which shall include an indication of the delivery condition. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204.

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KTA 3211.1

5.6 5.6.1

Seamless fittings larger than DN 50 Scope

b) 10 pieces for fittings equal to or larger than DN 100. 5.6.4.2 Extent of tests and examinations

(1) This Section shall apply to the following seamless fittings: a) reducers made from seamless rolled, extruded or forged pipes by cold or hot forming followed by heat treatment (normalization; quenching and tempering), b) tees fabricated to the liqued bulge method.
Note: The nominal diameter of a reducer or of a tee shall refer to the end with the larger diameter.

(1) The chemical composition shall be verified on the basis of the starting product. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per test unit. b) One elevated-temperature tensile test per heat, dimension and heat treatment, if the design temperature is higher than 100 C. The test temperature is defined in Section A 3 or in the authorized inspector's appraisal. c) One notched-bar impact bend test to clause 4.4.6.5 at 33 C or at the lowest operating temperature, whichever is lower, on one piece per test unit for fittings of normalized or air quenched and tempered steels with nominal wall thicknesses equal to or larger than 38 mm, as well as for fittings of liquid quenched and tempered steels with nominal wall thicknesses equal to or larger than 16 mm. For fittings of steel grade 15 MnNi 6 3, the test temperature shall be 0 C. d) Notched-bar impact bend tests for determination of an energy absorbed vs. temperature curve to clause 4.4.6.6 on one piece per heat, dimension and heat-treatment lot for fittings with nominal wall thicknesses equal to or larger than 10 mm. At least four test temperatures shall be used, of which two shall be 0 C and the lowest loading temperature. This test may be waived for fittings of steel 15 MnNi 6 3. e) One notched-bar impact bend test to clause 4.4.6.5 on each piece to determine the upper shelf energy for fittings of normalized or air quenched and tempered steels with nominal wall thicknesses larger than 38 mm as well as for fittings of liquid quenched and tempered steels with nominal wall thicknesses larger than 16 mm. In general, 80 C shall be selected as the test temperature. This test may be performed during determination of the energy absorbed vs. temperature curves. This test shall be performed only in test group A 1, and may be waived if the value of energy absorbed determined per d) or e) is equal to or greater than 100 J. f) For fittings grouped together as test units, one hardness test per fitting to verify uniformity.
Note: Verification of uniformity shall be acknowledged if the difference between the highest and lowest hardness values in a test unit does not exceed 30 HB units.

5.6.2

Materials

(1) The following steel grades may be used: a) steel grades to Section A 3 and b) other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspectors appraisal. (2) The toughness requirements of clause 4.3.1 a) for the lowest operating temperature shall be considered in selecting materials. (3) For fabricated fittings, the values of the mechanical and technological characteristics to Section A 3 shall apply even if forged hollow parts are used as starting products. 5.6.3 Starting products

(1) Forged hollow parts to Section 5.3 and seamless pipes to Section 5.4 may be used as the starting product. (2) Starting products that have not been completely examined and heat-treated to the stipulations in Sections 5.3 or 5.4 may also be used, provided the fabricated fittings are examined individually per clause 5.6.4.2. In this case the determination of mechanical and technological characteristics and the corresponding verification may be waived for the starting products. An acceptance test certificate 3.1.B to DIN EN 10 204 shall then be adequate for visual inspection and dimensional check of the starting products. 5.6.4 5.6.4.1 Tests and examinations of fittings Sampling and specimen preparation

(1) Specimens shall be taken from one end of the fittings in conformity with the authorized inspectors appraisal. (2) The specimen axes shall be located at one quarter of the wall thickness under the outside surface and at one half of the wall thickness under the end face or as close as possible to that location. (3) Where transverse specimens can be taken from nondirectional test coupons they shall be taken for tensile tests and notched-bar impact bend tests. If this is not possible, longitudinal specimens shall be selected. (4) Notched-bar impact bend tests shall be performed only for fittings with nominal wall thicknesses equal to or larger than 10 mm. (5) If the fittings are not tested individually, test units consisting of fittings of the same heat, dimension and heat treatment shall be formed for determination of mechanical and technological characteristics. (6) For the room-temperature tensile tests and for the notched-bar impact bend tests, the number of fittings per test unit shall not exceed: a) 30 pieces for fittings smaller than DN 100

(3) Non-destructive examinations shall be subject to the following requirements: a) For fittings larger than or equal to DN 100, the outside and inside surfaces shall be subjected to a surface-crack detection. For fittings smaller than DN 100, the outside surface shall be examined completely and the inside surface shall be examined wherever it is accessible. The acceptance criteria are defined in Table 5.2-1. b) All fittings smaller than DN 100 shall be ultrasonically examined to SEP 1915 and SEP 1918 for longitudinal and transverse defects in the surface zones that are not accessible to surface-crack detection. c) Fittings with nominal wall thicknesses larger than 30 mm shall be examined to Annex H as hollow forged parts. d) If an ultrasonic examination is performed on the fitting, the corresponding examination on the starting product may be waived. (4) Each fitting shall be subjected to a materials identification check.

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KTA 3211.1

(5) The inside and outside surfaces of each fitting shall be subjected to a visual inspection. (6) For each fitting, the ovality, diameter and thickness shall be measured at the ends. 5.6.5 Marking

(4) For each casting model, the description of the casting technique shall be attached to the interim file (internal manufacturer documentation) for retention by the manufacturer. (5) Together with the drawing of the casting in the asdelivered condition, the following documents shall generally be submitted as standard plans for the design approval: a) test and inspection sequence plan and heat-treatment plan, in case of differences from the standard production scheme to Figure B-12, b) for forgings of test group A 1 with nominal widths equal to or larger than 200 mm, instructions for the non-destructive examinations as well as a coordinate reference system (reference-point grid), c) for prototypes of test groups A 2 and A 3 with nominal widths equal to or greater than 200 mm a film location plan and a radiation source plan, d) welding procedure qualification and welding procedure sheet for production welds and if applicable construction welds (see Annex C), e) test and inspection sequence plan for construction welds, if necessary. f) list of planned production control tests. (6) If changes are made compared with the conditions stipulated in the welding procedure sheet, or if a different welding method is chosen, the welding procedure sheet shall be amended accordingly and resubmitted for design approval. 5.7.3 5.7.3.1 Tests and examinations Sampling and specimen preparation

(1) Each fitting shall be marked with the following information: a) manufacturers symbol, b) steel grade (for carbon steels additionally quality level, for steels with guaranteed reduction of area at fracture perpendicular to the product surface additionally quality class to DIN EN 10 164), c) heat number, d) fitting number or test lot number, e) authorized inspectors mark and f) mark of the non-destructive examinations performed. 5.6.6 Verification of quality characteristics

(1) The results of the ladle analysis, product analysis, materials identification check, hardness test and non-destructive examinations performed by the manufacturer shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204, which shall include an indication of the delivery condition. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. 5.7 5.7.1 Castings Materials

(1) Castings with a delivery weight equal to or lighter than 500 kg shall be tested in lots, and castings with a delivery weight heavier than 500 kg shall be tested individually. (2) The number of sampling locations shall be as indicated in Table 5.7-1. Product weight (delivery weight) in kg 100 Number of sampling locations 1

(1) The following cast-steel grades may be used: a) cast-steel grades to Section A 4 and b) other cast-steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspectors appraisal. (2) The toughness requirements of clause 4.3.1 a) for the lowest operating temperature shall be considered in selecting materials. 5.7.2 Requirements for casting condition

Test unit At most 2500 kg per heat, dimension and heat-treatment lot At most 10 pieces, but not more than 2500 kg per heat, dimension and heattreatment lot Individual piece Individual piece

> 100 up to 500

(1) As regards their general internal and external finish, the castings shall meet the conditions of Table B-3 applicable to their test group. (2) Feeder heads and large casting-related thickenings that impair amenability of castings to heat treatment shall be eliminated before normalization or quenching and tempering. (3) The casting technique shall be designed according to the principles of controlled solidification. For castings with nominal widths equal to or larger than 200 mm, the gate and feeder technique shall be explained on the basis of the saturation calculation as well as drawings illustrating the position of the feeders, feed zones and specimen location.
Note: The feature characterizing the dimensions of the body or case shall be the nominal width, as follows: a) for pumps, the nominal width of the pressure nozzle, b) for valves, the largest nominal width involved, c) for safety valves, the nominal width of the inlet nozzle.

> 500 up to 1000 > 1000

1 2

Table 5.7-1: Number of sampling locations on castings made of ferritic steels of material group W I (3) The specimens shall be taken from cast-on test coupons or from overlengths. Separately cast test coupons are permitted only for castings with piece weights equal to or lighter than 150 kg. (4) The test coupons shall be provided in sufficient number and size that the prescribed specimens can be taken. (5) The thickness of the cast-on test coupons shall be calculated by comparison of volume/surface ratios at the governing wall thickness. However, it shall be at most 150 mm.
Note: In this connection, the governing wall thickness shall be the thickness of the wall subjected to pressure loading, and not the thickness of cast-on flanges or local thickenings.

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KTA 3211.1

(6) Cast-on test coupons at the gate system are not permitted. (7) The specimens shall be taken at a distance of half the thickness of the cast-on test coupons from the end and side faces as well as at one quarter from one of the other faces. (8) For castings with piece weights heavier than 1000 kg, the position of the cast-on test coupons on the casting shall be documented by a photograph or in a sketch. 5.7.3.2 Extent of tests and examinations

b) c) d) e)

steel grade, heat number, specimen number and authorized inspector's mark. Verification of quality characteristics

5.7.5

(1) The following procedures shall be performed for the chemical analysis: a) One ladle analysis per heat. b) One product analysis for one sampling location per test unit. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per sampling location. The value of reduction of area at fracture shall also be determined for information. b) One elevated-temperature tensile test per heat, dimension and heat-treatment lot. The test temperature is defined in Section A 4 or in the authorized inspectors appraisal. The value of reduction of area at fracture shall also be determined for information. c) One notched-bar impact bend test to clause 4.4.6.5 per sampling location at 33 C or at the lowest operating temperature, whichever is lower. d) Notched-bar impact bend tests for determination of an energy absorbed vs. temperature curve to clause 4.4.6.6 at one sampling location per test unit. At least four test temperatures shall be used, of which two shall be 33 C or the lowest loading temperature and 0 C. e) One notched-bar impact bend test to clause 4.4.6.5 to verify the upper shelf energy at one sampling location per test unit. In general, this test shall be performed at 80 C. The test shall be performed only in test group A 1, and may be waived if the notched-bar impact bend test at the lower of 33 C or the lowest loading temperature has already verified that the requirements are met. f) One hardness test on each piece to verify uniformity of the quenching and tempering treatment in the case of lotwise examination of castings of quenched and tempered steel. (3) The non-destructive examinations of the castings shall be subject to the requirements of Annex B. (4) Each casting shall be subjected to a materials identification check. (5) Each casting shall be subjected in the as-delivered condition to a visual inspection of its external finish. (6) Each casting shall be subjected in the as-delivered condition to a dimensional check. (7) Each casting shall be subjected in a condition suitable for the purpose, generally by the further processor, to a tightness test in the form of an internal pressure test, which shall be performed to DIN 50 104. Pressurizing fluid, test pressure and withstand time shall be indicated in the purchase order. The test pressure shall never lead to a load higher than 90 % of the 0.2 % proof stress of the cast-steel grade. 5.7.4 Marking

(1) The results of the ladle analysis, product analysis, materials identification check and non-destructive examinations performed by the manufacturer as well as of the hardness test shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204. A certificate documenting the heat-treatment condition shall be attached to the acceptance test certificate. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. (3) For castings with piece weights heavier than 1000 kg, a photograph or a sketch of the location of the cast-on test coupons on the casting shall be attached to the acceptance test certificate.

6 6.1 6.1.1 (1) a) b) c) d) e) f) g) h) i) j) k) l)

Product forms of ferritic steels of material group W II Sheets and plates Materials

The following steel grades may be used: 15 MnNi 63 to Section A 1 WStB 255 to DIN 17 102 P275NH to DIN EN 10 028-3 WStE 285 to DIN 17 102 WStE 315 to DIN 17 102 P355NH to DIN EN 10 028-3 WStE 355 to DIN 17 102 16Mo3 to DIN EN 10 028-2 15 Mo 3 to DIN 17 155 S235J2G3 to DIN EN 10 025 St 37-3 to DIN 17 100 other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspector's appraisal.

(2) The selection of materials shall be based on the requirements of clause 4.3.2 and the lowest operating temperature. 6.1.2 Additional requirements for the materials

(1) Plates with nominal thicknesses equal to or larger than 10 mm which are subjected to loading perpendicular to the rolled surface shall at least meet the requirements of quality class Z 25 to DIN EN 10 164. This shall be specified in the purchase order. (2) For steel grades b), d) and e) to clause 6.1.1 (1), the stipulations in the authorized inspector's appraisal for conventional pressure vessels subject to supervision shall be taken into consideration. (3) The surface finish shall satisfy the stipulations of DIN EN 10 163-2 Class B Subgroup 3. Elimination of surface defects by welding is not permitted.

(1) Each casting shall be marked with the following information: a) manufacturer's symbol, Page 24

KTA 3211.1

6.1.3 6.1.3.1

Tests and examinations Sampling and specimen preparation

(2) The marking shall be applied such that it appears upright when viewed in the main rolling direction. 6.1.5 Verification of quality characteristics

(1) Specimens shall be taken to the applicable DIN standards and, for steel grade 15 MnNi 6 3, to clause 5.1.3. (2) Specimens for determination of the reduction of area at fracture on perpendicular specimens shall be taken to the stipulations of DIN EN 10 164. 6.1.3.2 Extent of tests and examinations

(1) The following procedures shall be performed for the chemical analysis: a) One ladle analysis per heat. b) One product analysis on one sampling location of one rolled plate per heat. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per sampling location. b) One tensile test at a temperature of 300 C per heat, dimensional range and at most 30 metric tons. c) Three room-temperature tensile tests to DIN EN 10 164 at one sampling location per rolled plate for plates with nominal thicknesses equal to or larger than 10 mm and subject to loading perpendicular to the rolled surface, in order to determine the reduction of area at fracture. d) One notched-bar impact bend test to clause 4.4.6.5 per sampling location at 0 C or at 20 C for nominal thicknesses equal to or larger than 5 mm. e) Notched-bar impact bend tests for determination of an energy absorbed vs. temperature curve to clause 4.4.6.6 at one sampling location per heat, dimensional range and identical heat treatment for plates with nominal thicknesses equal to or larger than 10 mm. At least four test temperatures shall be used, of which one shall be 0 C or 20 C. This test may be waived for plates of steel grade 15 MnNi 6 3. (3) The non-destructive examinations shall be subject to the following requirements: a) Each plate with a nominal thickness equal to or larger than 10 mm shall be subjected to an ultrasonic surface examination to SEL 072 by the manufacturer. If the examination is not performed with automated examination systems, 10 % of the delivery shall additionally be examined by the authorized inspector. b) The stipulations of Class 3 to SEL 072 shall apply to the surface examination. (4) Each rolled plate shall be subjected to a materials identification check. (5) Each plate shall be subjected to a visual inspection of its external finish. (6) 6.1.4 The thickness of each rolled plate shall be measured. Marking

(1) The results of the ladle analysis, product analysis, materials identification check and ultrasonic examination performed by the manufacturer shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204, which shall also indicate the delivery condition, and the results of the visual inspection and dimensional check shall be documented with an acceptance test report 3.1.C to DIN EN 10 204. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificate as an acceptance test certificate 3.1.C to DIN EN 10 204. 6.2 6.2.1 (1) a) b) c) d) e) f) g) h) i) j) k) l) Dished or pressed product forms made from plate Materials

The following steel grades may be used: 15 MnNi 6 3 to Section A 1 WStE 255 to DIN 17102 P275NH to DIN EN 10 028-3 WStE 285 to DIN 17 102 WStE 315 to DIN 17 102 P355NH to DIN EN 10 028-3 WStE 355 to DIN 17 102 16Mo3 to DIN EN 10 028-2 15 Mo 3 to DIN 17 155 S235J2G3 to DIN EN 10 025 St 37-3 to DIN 17 100 other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspector's appraisal.

(2) The selection of materials shall be based on the requirements of clause 4.3.2 and the lowest operating temperature. 6.2.2 Additional requirements for the materials

(1) Product forms with nominal wall thicknesses equal to or larger than 10 mm and subjected to loading perpendicular to the rolled surface shall at least meet the requirements of quality class Z 25 to DIN EN 10 164. This shall be specified in the purchase order. (2) For steel grades b), d) and f) per clause 6.2.1 (1), the stipulations in the authorized inspector's appraisal for conventional pressure vessels subject to supervision shall be taken into consideration. 6.2.3 Starting plates

(1) Starting plates shall be subject to the stipulations in Section 6.1. (2) If the finished parts are tested individually to clause 6.2.4.2, the tests to clause 6.1.3.2 as well as the corresponding verifications can be omitted.
Note: The stipulations of KTA 3211.3 shall apply to welded joints made with the starting plates and remaining in the finished parts.

(1) Each plate shall be marked with the following information: a) manufacturer's symbol, b) steel grade (for steels with guaranteed reduction of area at fracture perpendicular to the product surface additionally quality class to DIN EN 10 164), c) heat number, d) specimen number and e) authorized inspector's mark.

(3) If it is agreed in the purchase order that the ultrasonic examination will be performed on the starting plates, this examination shall be performed to clause 6.1.3.2 (3) in the agreed delivery condition.

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6.2.4

Testing and examination of dished or pressed product forms made from plates

or 20 C. This test may be waived for product forms of steel grade 15 MnNi 6 3. (2) The non-destructive examinations shall be subject to the following requirements: a) If agreed in the purchase order, the starting plates or the finished parts with nominal wall thicknesses equal to or larger than 10 mm shall be subjected to an ultrasonic surface examination to clause 6.1.3.2 (3). b) The flange and knuckle of each head (end) shall be subjected to a surface-crack detection in the finishmachined condition after the last heat treatment. The acceptance criteria are defined in Table 5.2-1. (3) Each product form shall be subjected to a materials identification check. (4) Each product form shall be subjected to a visual inspection of its external finish. (5) Each product form shall be checked for accuracy regarding dimensions and form. 6.2.5 Marking

6.2.4.1 Sampling and specimen preparation (1) For product forms with a diameter or length equal to or smaller than 3000 mm, the tests or examinations shall be performed on one part per rolled plate and heat-treatment lot. The maximum permissible lot size shall be 10 parts.
Note: Correlation of parts with the rolled plate can be achieved, for example, through the specimen number of the starting plates.

(2) For product forms with a diameter or length greater than 3000 mm, each part shall be tested. For lengths or diameters exceeding 6 m one test coupon each shall be taken at two opposite sides. (3) One test coupon shall be taken from each part to be examined regardless of its diameter or length. (4) The test coupons shall be taken such that transverse specimens can be machined. Deviations up to 20 degrees from the theoretical transverse direction are permitted for heads (ends) and similar parts. If this is not possible, a different type of sampling shall be agreed with the authorized inspector. (5) Round tensile-test specimens with a test diameter equal to or larger than 10 mm shall be made for both the roomtemperature and elevated-temperature tensile tests. For nominal wall thicknesses larger than 40 mm, the specimen axis shall be located at a distance of one quarter of the product-form thickness under the rolled surface. For product-form thicknesses that do not permit a test diameter of 10 mm, the largest possible diameter shall be chosen. (6) For nominal wall thicknesses equal to or smaller than 40 mm, one side of the specimens for the notched-bar impact bend test shall be as close as possible to the rolled surface. For nominal wall thicknesses larger than 40 mm, the specimen axis shall be located at a distance of one quarter of the product-form thickness under the rolled surface. 6.2.4.2 Extent of tests and examinations

(1) Each finished part shall be marked with the following information: a) symbol of the manufacturer of the product form, b) steel grade (for steels with guaranteed reduction of area at fracture perpendicular to the product surface additionally quality class to DIN EN 10 164), c) heat number, d) specimen number and e) authorized inspector's mark. (2) In the case of lotwise examination, the product form from which the specimens were taken shall also be marked. (3) The marking shall be applied such that it appears upright when viewed in the main rolling direction of the rolled plate. 6.2.6 Verification of quality characteristics

(1) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per sampling location. b) One tensile test at a temperature of 300 C per heat, dimensional range and at most 30 metric tons. c) Three room-temperature tensile tests to DIN EN 10 164 at one sampling location per rolled plate for product forms with nominal wall thicknesses equal to or larger than 10 mm and subject to loading perpendicular to the rolled surface, in order to determine the reduction of area at fracture. This test may be waived if it has already been performed on the rolled plate and documented with an acceptance test certificate 3.1.C to DIN EN 10 204.
Note: Correlation of parts with the rolled plate can be achieved, for example, through the specimen number.

(1) The results of the ladle analysis, product analysis, materials identification check and non-destructive examinations performed by the manufacturer shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204, which shall also indicate the heat-treatment condition. The results of the visual inspection and dimensional check shall be documented with an acceptance test certificate 3.1.C to DIN EN 10 204. The forming method shall be indicated in the acceptance test certificate 3.1.B to DIN EN 10 204. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. 6.3 6.3.1 (1) a) b) c) d) e) f) Forgings, bar steel and rolled rings Materials

d) One notched-bar impact bend test to clause 4.4.6.5 per sampling location at 0 C or at 20 C for nominal wall thicknesses equal to or larger than 5 mm. e) Notched-bar impact bend tests for determination of an energy absorbed vs. temperature curve to clause 4.4.6.6 at one sampling location per heat, dimensional range and heat-treatment lot for product forms with nominal wall thicknesses equal to or larger than 10 mm. At least four test temperatures shall be used, of which one shall be 0 C

The following steel grades may be used: 15 MnNi 6 3 to Section A 2 C22.8 to DIN 17 243 15Mo3 to DIN 17 243 WStE 355 to DIN 17 103 St 37-3 to DIN 17 100 other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspector's appraisal.

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(2) The selection of materials shall be based on the requirements of clause 4.3.2 and the lowest operating temperature. 6.3.2 Additional requirements for the materials

location for D smaller than or equal to 500 mm; and from two sampling locations separated by 180 degrees for D larger than 500 mm. (7) At the opposite end, specimens shall be taken from one sampling location for normalized or air quenched and tempered bars having a finished length longer than 5000 mm and for liquid quenched and tempered bars having a finished length longer than 2000 mm. For bars diameters smaller than or equal to 500 mm, this sampling location shall be offset by 180 degrees relative to that at the other end. 6.3.3.1.3 Sampling depth

For steel grade WStE 355, the stipulations in the authorized inspectors appraisal for conventional pressure vessels subject to supervision shall be taken into consideration. 6.3.3 6.3.3.1 6.3.3.1.1 Tests and examinations Sampling and specimen preparation Test units

(1) Unless otherwise stipulated in clause 6.3.3.2, pieces with heat-treatment weights between 100 kg and equal to or lighter than 500 kg from the same heat, with similar dimensions and from the same heat-treatment lot shall be grouped as test units containing at most 10 parts, while pieces with heattreatment weights lighter than or equal to 100 kg may be grouped as test units of 1000 kg each. (2) Pieces with heat-treatment weights heavier than 500 kg shall be tested individually. 6.3.3.1.2 Sampling locations

The specimens shall be taken from at least one quarter of the governing heat-treatment thickness but at most 80 mm under the heat-treatment surfaces. 6.3.3.1.4 Specimen direction

(1) Transverse specimens shall be taken for tensile tests and notched-bar impact bend tests if geometrically possible and nothing to the contrary is stipulated in the authorized inspectors appraisal. (2) Notwithstanding the foregoing, longitudinal specimens or axial specimens taken from bars are permitted, specifically for tensile tests if the diameter or greatest length of a crosssectional edge is smaller than 160 mm, or for notched-bar impact bend tests if the diameter or the greatest length of a cross-sectional edge is smaller than 68 mm. 6.3.3.2 Extent of tests and examinations

(1) For forged hollow parts, e.g., for shell courses, nozzles or valve bodies, specimens shall be taken from one end as a function of inside diameter Di as follows: from one sampling location for Di equal to or smaller than 500 mm; from two sampling locations separated by 180 degrees for Di between 500 mm and 2000 mm; and from three sampling locations separated by 120 degrees for Di larger than 2000 mm. (2) At the opposite end, specimens shall be taken from one sampling location for normalized or air quenched and tempered forgings having a finished length longer than 5000 mm and for liquid quenched and tempered forgings having a finished length longer than 2000 mm. For pieces with inside diameters smaller than or equal to 500 mm, this sampling location shall be offset by 180 degrees relative to that at the other end (according to Figures 5.3-1 and 5.3-2).
Note: Finished length designates the length of the product form during the governing heat treatment, less the length of the test coupons.

(1) The following procedures shall be performed for the chemical analysis: a) One ladle analysis per heat. b) One product analysis on in each of two separately manufactured products per heat. If possible, the top zone of one piece and the bottom zone of the other shall be tested. For piece weights equal to or heavier than 5000 kg, one product analysis shall be performed on one sampling location of each piece. It possible, the top or bottom of the starting ingot shall be tested. (2) The mechanical and technological characteristics shall be determined by performing: a) One hardness test per piece to verify uniformity for pieces grouped together in test units.
Note: Verification of uniformity shall be acknowledged if the difference between the highest and lowest hardness values in a test unit does not exceed 30 HB units.

(3) For seamless rolled or forged rings or flanges, specimens shall be taken from the circumference or end of the flange. They may also be taken from the end of the welding end, if the heat-treatment thickness of the welding end is equal to that of the flange. Specimens shall be taken as follows: from one sampling location for inside diameters Di smaller than or equal to 1000 mm; from two sampling locations separated by 180 degrees for Di between 1000 mm and 2000 mm; and from three sampling locations separated by 120 degrees for Di larger than 2000 mm (according to Figure 5.3-3). (4) For plates such as tubesheets, tube plates or blankingoff covers with heat-treatment weights lighter than 1000 kg, specimens shall be taken from one sampling location. If permitted by the forging method employed, this location shall be in the top or bottom zone (according to Figure 5.3-4). (5) For plates with heat-treatment weights equal to or heavier than 1000 kg, specimens shall be taken from two sampling locations. If permitted by the forging method employed, these locations shall be in the top and bottom zones (according to Figure 5.3-4). (6) For forged bars, specimens shall be taken at one end as a function of the diameter D of the bars: from one sampling

b) One room-temperature tensile test per sampling location. c) For pieces of similar dimension, one elevated-temperature tensile test per heat and heat-treatment lot. d) One notched-bar impact bend test to clause 4.4.6.5 per sampling location at 0 C or at 20 C. e) Notched-bar impact bend tests for determination of an energy absorbed vs. temperature curve to clause 4.4.6.6 at one sampling location per heat and heat-treatment lot for pieces with heat-treatment weights greater than 150 kg. At least four test temperatures shall be used, of which one shall be 0 C or 20 C. (3) Each piece shall be subjected to a non-destructive examination to Annex H. (4) Each piece shall be subjected to a materials identification check.

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(5) Each piece shall be subjected in the as-delivered condition to a visual inspection of its external finish. (6) 6.3.4 A dimensional check of each piece shall be performed. Marking

6.4.3

Additional requirements for the materials

Pipes with nominal wall thicknesses equal to or larger than 10 mm and subjected to loading perpendicular to the rolled surface shall at least meet the requirements of quality class Z 25 to DIN EN 10 164. This shall be specified in the purchase order. 6.4.4 6.4.4.1 (1) Tests and examinations Sampling and specimen preparation

(1) Each piece shall be marked with the following information: a) manufacturers symbol, b) steel grade (for steels with guaranteed reduction of area at fracture perpendicular to the product surface additionally quality class to DIN EN 10 164), c) heat number, d) specimen number or test lot number, e) authorized inspectors mark and f) mark of the non-destructive examinations performed. (2) In the case of lotwise examination, the piece from which the specimens were taken shall additionally be marked. 6.3.5 Verification of quality characteristics

The pipes shall be tested in manufacturing lengths.

(2) Specimens shall be taken from the ends of manufacturing lengths. (3) The specimens for tensile tests and notched-bar impact bend tests shall be taken to the applicable DIN standards and, for steel 15 MnNi 6 3, to clause 5.4.4. 6.4.4.2 Extent of tests and examinations

(1) The results of the ladle analysis, product analysis, materials identification check and non-destructive examinations performed by the manufacturer, and if necessary of the hardness test shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204, which shall include an indication of the delivery condition. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. 6.4 6.4.1 Seamless pipes larger than DN 50 Scope

(1) The following procedures shall be performed for the chemical analysis: a) One ladle analysis per heat. b) One product analysis on each of two manufacturing lengths per heat. (2) Where round or square bar steel blooms are used as starting product for the fabrication of pipes of steel grade St 35.8 III, one disc of each round or square bar cut from the top end, shall be subjected to a pickling test to ascertain whether the head end was cut off far enough from the ingot. At the discretion of the manufacturer, an ultrasonic examination for detecting shrinkage cavities may substitute this pickling disc test. (3) The mechanical and technological characteristics shall be determined by performing: a) Room-temperature tensile tests for every 50 manufacturing lengths of the same heat, dimension and heat treatment, at one end of one manufacturing length for pipes of normalized or air quenched and tempered steels. b) One tensile test at 300 C per heat, dimension and heat treatment, if the design temperature is higher than 100 C. c) Tensile tests on perpendicular specimens per 50 manufacturing lengths of the same heat, dimension and heat treatment, to determine the reduction of area at fracture for pipes with nominal wall thicknesses equal to or larger than 10 mm and subjected to loading perpendicular to the surface. This test may be waived for steel grades for which it was demonstrated in the material appraisal that the mean value of reduction of area at fracture of three perpendicular specimens per test set is at least 35 % and that none of the individual values is smaller than 25 %. d) One notched-bar impact bend test to clause 4.4.6.5 at 0 C or 20 C at one end of one manufacturing length per 50 manufacturing lengths of the same heat, dimension and heat treatment for pipes of normalized or air quenched and tempered steels with nominal wall thicknesses equal to or larger than 10 mm up to and including 38 mm, and at one end of each manufacturing length for nominal wall thicknesses larger than 38 mm. For pipes of steel grade 15 MnNi 6 3, the test temperature shall be 0 C. e) Notched-bar impact bend tests for determination of the energy absorbed vs. temperature curve to clause 4.4.6.6 at one end of one manufacturing length per heat, dimension and heat treatment for pipes with nominal wall thicknesses equal to or larger than 16 mm for pipes of normalized or air quenched and tempered steels. At least four test temperatures shall be used, of which one shall be

(1) The stipulations of this Section shall apply to seamless, rolled or pressed pipes larger than DN 50.
Note: For forged pipes Section 6.3 shall apply.

(2) The stipulations of this Section shall also apply to pipes equal to or smaller than DN 50 if pipe elbows larger than DN 50 are made from such pipes. (3) The stipulations of this Section shall not apply to pipes for vessel shells. 6.4.2 (1) a) b) c) d) e) f) g) Materials

The following steel grades may be used: 15 MnNi 6 3 to Section A 3 St 35.8 III to DIN 17 175 WStE 255 to DIN 17 179 WStE 285 to DIN 17 179 WStE 355 to DIN 17 179 15 Mo 3 to DIN 17 175 other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspectors appraisal.

(2) The selection of materials shall be based on the requirements of clause 4.3.2 and the lowest operating temperature.

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0 C or 20 C. This test may be waived for pipes of steel grade 15 MnNi 6 3. f) Technological tests to Table 5.4-1 at both ends of each manufacturing length for pipes with nominal wall thicknesses equal to or smaller than 40 mm. (4) Non-destructive examinations shall be subject to the following requirements: a) All pipes shall be examined ultrasonically for longitudinal defects to SEP 1915. b) Pipes of test group A 2 equal to or larger than DN 100 shall additionally be subjected to an ultrasonic transversedefect examination to SEP 1918 as well as to an examination for laminations to SEP 1919, if they were hotpilger-rolled or subjected to hot pilger rolling during the manufacturing process. c) Pipes with nominal thicknesses larger than 30 mm and diameters larger than DN 600 shall be examined as hollow forged or hollow rolled parts. (5) Each pipe shall be subjected to a materials identification check. (6) The inside and outside surfaces of each pipe shall be subjected to a visual inspection. (7) The diameter and wall thickness shall be checked for dimensional accuracy at both ends of each pipe. (8) Each pipe shall be examined for leak tightness either by an internal hydrostatic pressure test or, at the manufacturer's discretion, by an appropriate non-destructive examination to SEP 1925. For the internal hydrostatic pressure test, the test pressure shall generally be 8 MPa. The test pressure shall be limited such that the factor of safety relative to the yield point at room temperature is never less than 1.1. 6.4.5 Marking

6.5 6.5.1

Seamless pipe elbows larger than DN 50 Scope

(1) This Section shall apply to seamless pipe elbows (weldin elbows) made from seamless rolled, extruded or forged pipes by cold or hot forming followed by heat treatment (normalization; quenching and tempering). (2) This Section shall not apply to pipe bends made with inductive bending machines or by cold forming with or without subsequent heat treatment. These pipe bends shall be subject to the requirements of KTA 3211.3 Section 6. 6.5.2 (1) a) b) c) d) e) f) g) Materials

The following steel grades may be used: 15 MnNi 6 3 to Section A 3 St 35.8 III to DIN 17 175 WStE 255 to DIN 17 179 WStE 285 to DIN 17 179 WStE 355 to DIN 17 179 15 Mo 3 to DIN 17 175 other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspector's appraisal.

(2) The selection of materials shall be based on the requirements of clause 4.3.2 and the lowest operating temperature. (3) For finished pipe elbows, the values of the mechanical and technological characteristics for pipes shall apply even if forged hollow parts are used as starting products. 6.5.3 Starting products

(1) Forged hollow parts to Section 6.3 and seamless pipes to Section 6.4 may be used as starting products. (2) Starting products that have not been completely examined and heat-treated per the stipulations in Sections 6.3 or 6.4 may also be used, provided the finished pipe elbows are examined individually per clause 6.5.4.2. In this case, the determination of mechanical and technological characteristics and the corresponding verification may be waived for the starting products. An acceptance test certificate 3.1.B to DIN EN 10 204 shall then be adequate for visual inspection and dimensional check of the starting products. 6.5.4 6.5.4.1 Tests and examinations of pipe elbows Sampling and specimen preparation

(1) Each pipe shall be marked at both ends, 300 mm from the ends, with the following information: a) manufacturer's symbol, b) steel grade (for carbon steels additionally quality level, for steels with guaranteed reduction of area at fracture perpendicular to the product surface additionally quality class to DIN EN 10 164) and c) authorized inspector's mark. (2) Each pipe shall additionally be marked at one end with the following information: a) heat number, b) pipe number and c) mark of the non-destructive examinations performed. 6.4.6 Verification of quality characteristics

(1) Specimens shall be taken from the ends of the pipe elbows in conformity with the authorized inspector's appraisal. (2) The specimens for tensile tests and notched-bar impact bend tests shall be taken to the applicable DIN standards and, for steel 15 MnNi 6 3, to clause 5.4.4. (3) Transverse specimens shall be taken for tensile tests and notched-bar impact bend tests. If this is not possible, longitudinal specimens shall be used. (4) If starting products that have not been completely examined and heat-treated to the stipulations in Sections 6.3 or 6.4 are used, test coupons shall be taken from both ends of pipe elbows with a chord length greater than 3000 mm, measured along the outside of the bend. (5) In all other cases, test coupons shall be taken from only one end of the pipe elbow. (6) If the pipe elbows are not tested individually, test units consisting of pipe elbows of the same heat, dimension and

(1) The results of the ladle analysis, product analysis, pickling disc test, if any, materials identification check, tightness test and non-destructive examinations performed by the manufacturer shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204, which shall include an indication of the delivery condition. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204.

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heat treatment shall be formed for determination mechanical and technological characteristics.

of

(7) For the room-temperature tensile tests and for the notched-bar impact bend tests, the number of pipe elbows per test unit shall not exceed: a) 50 pieces for pipe elbows smaller than DN 200 b) 25 pieces for pipe elbows equal to or larger than DN 200 and smaller than DN 350 c) 10 pieces for pipe elbows equal to or larger than DN 350. 6.5.4.2 Extent of tests and examinations

(6) For each pipe elbow, the wall thickness and, depending on the purchase order, either the outside or inside diameter shall be measured over the arc length, including the ends, and to a sufficient extent over the circumference. The smallest wall thickness as well as the ovality shall be determined. 6.5.5 Marking

(1) The chemical composition shall be verified on the basis of the starting product. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test on one pipe elbow per test unit. b) One tensile test at 300 C on one pipe elbow per heat, dimension and heat treatment, if the design temperature is higher than 100 C. c) One notched-bar impact bend test to clause 4.4.6.5 at 0 C or at 20 C on one pipe elbow per test unit for pipe elbows with nominal wall thicknesses equal to or larger than 10 mm. For pipe elbows of steel grade 15 MnNi 6 3, the test temperature shall be 0 C. d) Notched-bar impact bend tests for determination of the energy absorbed vs. temperature curve to clause 4.4.6.6 on one pipe elbow per heat, dimension and heat treatment for pipe elbows of test group A 2 with nominal wall thicknesses equal to or larger than 16 mm. At least four test temperatures shall be used, of which one shall be 0 C or 20 C. This test may be waived for pipe elbows of steel grade 15 MnNi 6 3. e) For pieces grouped together as test units, one hardness test per piece to verify uniformity.
Note: Verification of uniformity shall be acknowledged if the difference between the highest and lowest hardness values in a test unit does not exceed 30 HB units.

(1) Each pipe elbow shall be marked with the following information: a) manufacturer's symbol, b) steel grade (for carbon steels additionally quality level, for steels with guaranteed reduction of area at fracture perpendicular to the product surface additionally quality class to DIN EN 10 164), c) heat number, d) elbow number, e) authorized inspector's mark and f) mark of the non-destructive examinations performed. 6.5.6 Verification of quality characteristics

(1) The results of the ladle analysis, product analysis, materials identification check, hardness test and nondestructive examinations performed by the manufacturer shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204, which shall include an indication of the delivery condition. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. 6.6 6.6.1 Seamless fittings larger than DN 50 Scope

(3) Non-destructive examinations shall be subject to the following requirements: a) For pipe elbows of test group A 2 equal to or larger than DN 100, the outside and inside surfaces shall be subjected to a surface-crack detection. For pipe elbows smaller than DN 100, the outside surface shall be examined completely and the inside surface shall be examined only where it is accessible. The acceptance criteria are defined in Table 5.2-1. b) All pipe elbows of test group A 2 smaller than DN 100 shall be ultrasonically examined for longitudinal defects to SEP 1915 and for transverse defects to SEP 1918 in the surface zones that are not accessible to surface-crack detection. c) Pipe elbows with nominal wall thicknesses larger than 30 mm shall be examined to Annex H as hollow forged parts. d) If an ultrasonic examination is performed on the pipe elbow, the corresponding examination on the starting pipe may be waived. (4) Each pipe elbow shall be subjected to a materials identification check. (5) The inside and outside surfaces of each pipe elbow shall be subjected to a visual inspection.

(1) This Section shall apply to the following seamless fittings: a) reducers made from seamless rolled, extruded or forged pipes by cold or hot forming followed by heat treatment (normalization; quenching and tempering), b) tees fabricated to the liqued bulge method.
Note: The nominal diameter of a reducer or of a tee shall refer to the end with the larger diameter.

6.6.2 (1) a) b) c) d) e) f) g)

Materials

The following steel grades may be used: 15 MnNi 6 3 to Section A 3 St 35.8 III to DIN 17 175 WStE 255 to DIN 17 179 WStE 285 to DIN 17 179 WStE 355 to DIN 17 179 15 Mo 3 to DIN 17 175 other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspector's appraisal.

(2) The selection of materials shall be based on the requirements of clause 4.3.2 and the lowest operating temperature. (3) For fabricated fittings, the values of the mechanical and technological characteristics for pipes shall apply even if forged hollow parts are used as starting products.

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6.6.3

Starting products

(1) Forged hollow parts to Section 6.3 and seamless pipes to Section 6.4 may be used as starting products. (2) Starting products that have not been completely examined or heat-treated to the stipulations in Sections 6.3 or 6.4 may also be used, provided the fabricated fittings are examined individually to clause 6.6.4.2. In this case the determination of mechanical and technological characteristics and the corresponding verification may be waived for the starting products. An acceptance test certificate 3.1.B to DIN EN 10 204 shall then be adequate for visual inspection and dimensional check of the starting products. 6.6.4 6.6.4.1 Tests and examinations of fittings Sampling and specimen preparation

(3) Non-destructive examinations shall be subject to the following requirements: a) For fittings of test group A 2 equal to or larger than DN 100, the outside and inside surfaces shall be subjected to a surface-crack detection. For fittings smaller than DN 100, the outside surface shall be examined completely and the inside surface shall be examined only where it is accessible. The acceptance criteria are defined in Table 5.2-1. b) All fittings of test group A 2 smaller than DN 100 shall be ultrasonically examined for longitudinal defects to SEP 1915 and for transverse defects to SEP 1918 in the surface zones that are not accessible to surface-crack detection. c) Fittings with nominal wall thicknesses larger than 30 mm shall be examined to Annex H as hollow forged parts. d) If an ultrasonic examination is performed on the fitting, the corresponding examination on the starting product may be waived. (4) Each fitting shall be subjected to a materials identification check. (5) The inside and outside surfaces of each fitting shall be subjected to a visual inspection. (6) For each fitting, the ovality, diameter and thickness shall be measured at the ends. 6.6.5 Marking

(1) Specimens shall be taken from the ends of the fittings in conformity with the authorized inspectors appraisal. (2) The specimens for tensile tests and notched-bar impact bend tests shall be taken to the applicable DIN standards and, for steel 15 MnNi 6 3, to clause 5.4.4. (3) Where transverse specimens can be taken from nondirectional test coupons they shall be taken for tensile tests and notched-bar impact bend tests. If this is not possible, longitudinal specimens shall be selected. (4) If the fittings are not tested individually, test units consisting of fittings of the same heat, dimension and heat treatment shall be formed for determination of mechanical and technological characteristics. (5) For the room-temperature tensile tests and for the notched-bar impact bend tests, the number of fittings per test unit shall not exceed: a) at most 50 pieces for fittings with nominal diameters smaller than 100, b) at most 25 pieces for fittings of unalloyed steels with nominal diameters equal to or larger than 100, or at most 10 pieces for such fittings of alloyed steels. 6.6.4.2 Extent of tests and examinations

(1) Each fitting shall be marked with the following information: a) manufacturer's symbol, b) steel grade (for carbon steels additionally quality level, for steels with guaranteed reduction of area at fracture perpendicular to the product surface additionally quality class to DIN EN 10 164), c) heat number, d) authorized inspector's mark. e) fitting number or test lot number, f) mark of the non-destructive examinations performed. 6.6.6 Verification of quality characteristics

(1) The chemical composition shall be verified on the basis of the starting product. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per test unit. b) One tensile test at 300 C per heat, dimension and heat treatment, if the design temperature is higher than 100 C. c) One notched-bar impact bend test to clause 4.4.6.5 at 0 C or at 20 C on one piece per test unit for fittings with nominal wall thicknesses equal to or larger than 10 mm. For fittings of steel grade 15 MnNi 6 3 the test temperature shall be 0 C. d) Notched-bar impact bend tests for determination of the energy absorbed vs. temperature curve to clause 4.4.6.6 on one piece per heat, dimension and heat treatment for fittings with nominal wall thicknesses equal to or larger than 16 mm. At least four test temperatures shall be used, of which one shall be 0 C or 20 C. This test may be waived for pipe elbows of steel grade 15 MnNi 6 3. e) One hardness test on each fitting to verify uniformity.
Note: Verification of uniformity shall be acknowledged if the difference between the highest and lowest hardness values in a test unit does not exceed 30 HB units.

(1) The results of the ladle analysis, product analysis, materials identification check, hardness test and nondestructive examination performed by the manufacturer shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204, which shall include an indication of the delivery condition. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificate as an acceptance test certificate 3.1.C to DIN EN 10 204. 6.7 6.7.1 Castings Materials

(1) The following cast-steel grades may be used: a) GS-C25 to DIN 17 245, b) other cast-steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspector's appraisal. (2) The selection of materials shall be based on the requirements of clause 4.3.2 and the lowest operating temperature.

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6.7.2

General requirements for casting finish

(1) As regards their general internal and external finish, the castings shall satisfy the stipulations of Table B-2 applicable to their test group. (2) Feeder heads and large casting-related thickenings that impair amenability of castings to heat treatment shall be eliminated before the heat treatment for establishment of the mechanical and technological characteristics. (3) The casting technique shall be designed according to the principles of controlled solidification. For castings with nominal widths equal to or larger than 200 mm, the gate and feeder technique shall be explained on the basis of the saturation calculation as well as drawings illustrating the position of the feeders, feed zones and specimen location. (4) For each casting model, the description of the casting technique shall be attached to the interim file (internal manufacturer documentation) for retention by the manufacturer.
Note: The feature characterizing the dimensions of the body or case shall be the nominal width, as follows: a) for pumps, the nominal width of the pressure nozzle, b) for valves, the largest nominal width involved, c) for safety valves, the nominal width of the inlet nozzle.

(2) The specimens shall be taken from cast-on test coupons or from overlengths. Separately cast test coupons are permitted only for castings with piece weights equal to or lighter than 50 kg. The test coupons shall be provided in sufficient number and size that the prescribed specimens can be taken. (3) The thickness of the cast-on test coupons shall be calculated by comparison of volume/surface ratios at the governing wall thickness. However, it shall be at most 150 mm. In this connection, the governing wall thickness shall be the thickness of the wall subjected to pressure loading, and not the thickness of cast-on flanges or local thickenings. Cast-on test coupons at the gate system are not permitted. The specimens shall be taken at a distance of half the thickness of the cast-on test coupons from the end and side faces as well as at one quarter from one of the other faces. (4) For castings with piece weights heavier than 1000 kg, the position of the cast-on test coupons on the casting shall be documented by a photograph or in a sketch. 6.7.3.2 Extent of tests and examinations

(5) Together with the drawing of the casting in the asdelivered condition, the following documents shall generally be submitted as standard plans for the design approval: a) test and inspection sequence plan and heat-treatment plan, in case of differences from the standard production scheme to Figure B-12, b) for prototypes of test groups A 2 and A 3 with nominal widths equal to or greater than 200 mm a film location plan and a radiation source plan, c) welding procedure qualification and welding procedure sheet for production welds and if applicable construction welds (see Annex C) c) test and inspection sequence plan for construction welds, if necessary. d) list of planned production control tests. (6) If changes are made compared with the conditions stipulated in the welding procedure sheet, or if a different welding method is chosen, the welding procedure sheet shall be amended accordingly and resubmitted for design approval. 6.7.3 6.7.3.1 Tests and examinations Sampling and specimen preparation

(1) The following procedures shall be performed for the chemical analysis: a) One ladle analysis per heat. b) One product analysis for one sampling location per test unit. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per sampling location. The value of reduction of area at fracture shall also be determined for information. b) One tensile test at 350 C per heat, dimension and heattreatment lot, if the design temperature is higher than 100 C. c) One notched-bar impact bend test to clause 4.4.6.5 per sampling location at 0 C or at 20 C. d) One hardness test on each piece to verify uniformity of the quenching and tempering treatment in the case of lotwise examination of castings of quenched and tempered steel. (3) The non-destructive examinations of the castings shall be subject to the requirements of Annex B. (4) Each casting shall be subjected to a materials identification check. (5) Each casting shall be subjected in the as-delivered condition to a visual inspection of its surface finish. (6) Each casting shall be subjected in the as-delivered condition to a dimensional check. (7) Each casting shall be subjected in a condition suitable for the purpose, generally by the further processor, to a tightness test in the form of an internal pressure test, which shall be performed to DIN 50 104. Pressurizing fluid, test pressure and pressure-loading duration shall be indicated in the purchase order. However, the nominal pressure shall never lead to a load higher than 90 % of the 0.2 % proof stress of the caststeel grade. 6.7.4 Marking

(1) Castings with a delivery weight equal to or lighter than 500 kg shall be tested in lots, and castings with a delivery weight heavier than 500 kg shall be tested individually. The number of sampling locations shall be as indicated in Table 6.7-1. Product weight (delivery weight) in kg 100 > 100 up to 500 Test unit At most 2500 kg per heat, dimension and heat-treatment lot At most 10 pieces, but not more than 2500 kg per heat, dimension and heattreatment lot Individual piece Individual piece Number of sampling locations 1

> 500 up to 1000 > 1000

1 2

Table 6.7-1: Number of sampling locations on castings made of ferritic steels of material group W II

(1) Each casting shall be marked with the following information: a) manufacturer's symbol, b) cast-steel grade, c) heat number, d) specimen number and e) authorized inspector's mark.

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6.7.5

Verification of quality characteristics

(1) The results of the ladle analysis, product analysis, materials identification check and non-destructive examinations performed by the manufacturer as well as of the hardness test shall be certified with an acceptance test certificate 3.1.B to DIN EN 10 204. A certificate documenting the heat-treatment condition shall be attached to the acceptance test certificate. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. For castings with piece weights heavier than 1000 kg, a photograph or a sketch of the location of the cast-on test coupons on the casting shall be attached to the acceptance test certificate.

(2) Elevated-temperature tensile tests shall be performed using, a) for plates with nominal thicknesses equal to or smaller than 12 mm, flat tensile-test or round tensile-test specimens, b) for plates with nominal thicknesses larger than 12 mm, round tensile-test specimens. (3) The notched-bar impact bend test shall be subject to the following requirements: a) For plates with nominal thicknesses smaller than or equal to 16 mm, a notched-bar impact bend test is not required. b) For plates with nominal thicknesses larger than 16 mm and equal to or smaller than 30 mm, specimens shall be taken from 2 mm under the rolled surface. c) For plates with nominal thicknesses larger than 30 mm and equal to or smaller than 75 mm, specimens shall be taken from 1/4 of the plate thickness under the rolled surface. (4) The sampling depth for plates with nominal thicknesses greater than 75 mm shall be subject to the stipulations in the authorized inspector's appraisal. (5) The specimens shall be taken as transverse specimens such that the specimens are located halfway between long edges and centerline of the plates. (6) The number of sampling locations shall be as required in DIN 17 440. 7.1.3.2 Extent of tests and examinations

7 7.1 7.1.1 (1) a) b) c) d) e)

Product forms of austenitic steels Sheets and plates Materials

The following steel grades may be used: X6CrNiNb18-10 to DIN 17 440 X6CrNiTi18-10 to DIN 17 440 X6CrNiMoTi17-12-2 to DIN 17 440 X6CrNiMoNb17-12-2 to DIN 17 440 other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspectors appraisal. The stipulations of clause 4.3.3 shall be met.

(2)

(3) For hot (operating temperature T 200 C) reactor water containing product form and components in BWR plants only the steel grade to clause (1) a), and only with the following additional requirements for the chemical composition shall be used: C 0.03 % Si 0.5 % P 0.025 % S 0.010 % 18.0 (% Cr) 19.0 13 x (% C) (% Nb) 0.65 The test certificate shall show the boron and nitrogen content. 7.1.2 Additional requirements for the materials

(1) The following procedures shall be performed for the chemical analysis: a) One ladle analysis per heat. b) One product analysis on one sampling location of one plate per heat. The nitrogen content shall be shown if the delta ferrite content is determined theoretically. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per sampling location. b) One tensile test at 350 C per heat, dimensional range and heat-treatment lot, if the design temperature in test group A 1 is higher than 200 C and in test groups A 2 and A 3 is higher than 300 C. c) One notched-bar impact bend test to clause 4.4.6.5 per sampling location for plates with nominal thicknesses equal to or larger than 16 mm. (3) One test for resistance to intergranular corrosion to DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 C) shall be performed per heat, dimensional range and heat-treatment lot. (4) One bead-on-plate test to determine the delta ferrite content to Annex D shall be performed per heat, if values smaller than 3 are found in calculation of the ferrite number from the chemical composition in the ladle analysis. (5) The non-destructive examinations shall be subject to the following requirements: a) Each plate with nominal thickness equal to or larger than 10 mm shall be subjected to an ultrasonic surface examination to SEL 072 by the manufacturer. If the examination is not performed with automated examination systems, 10 % of the delivery shall additionally be examined by the authorized inspector. b) The stipulations of Class 3 to SEL 072 shall apply to the surface examination.

(1) The surfaces shall be free of ferritic impurities. Scale layers and tempering colours developed during hot forming or heat treatment shall be removed. (2) The surface condition to DIN 17 740 shall be indicated in the purchase order. The requirements of non-destructive examination shall be considered in this respect. 7.1.3 7.1.3.1 Tests and examinations Sampling and specimen preparation

(1) Room-temperature tensile tests shall be performed using a) for plates with nominal thicknesses equal to or smaller than 30 mm, flat tensile-test specimens containing both rolled surfaces, b) for plates with nominal thicknesses larger than 30 mm and equal to or smaller than 75 mm, flat tensile-test specimens at least 30 mm thick, containing at least one intact rolled surface.

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c) Where ultrasonic examination of the root area of welds to KTA 3211.3 Section 11 is required, the weld edges shall be subject to an ultrasonic examination to Annex H. (6) Each plate shall be subjected to a materials identification check. (7) Each plate shall be subjected to a visual inspection of its external finish. (8) 7.1.4 (1) a) b) c) d) e) f) The thickness of each plate shall be measured.

7.2.2

Additional requirements for the materials

(1) The surfaces shall be free of ferritic impurities. Scale layers and tempering colours developed during hot forming or heat treatment shall be removed. (2) The surface condition to DIN 17 740 shall be indicated in the purchase order. The requirements of non-destructive examination shall be considered in this respect. 7.2.3 Tests and examinations of the starting plates

Marking

Each plate shall be marked with the following information: manufacturers symbol, steel grade, heat number, specimen number, authorized inspectors mark and mark of the non-destructive examinations performed.

(1) Starting plates shall be subject to the stipulations in Section 7.1. (2) If the finished parts are tested individually to clause 7.2.4.2, the tests to clause 7.1.3.2 (2) as well as the corresponding verifications shall not be required.
Note: The stipulations of KTA 321 1.3 shall apply to welded joints made with the starting plates and remaining in the finished parts.

(2) The marking shall be applied transverse to the rolling direction. For plates cut from strip, roller stamping in the longitudinal direction is also permitted. 7.1.5 Verification of quality characteristics

(3) If it is agreed in the purchase order that the ultrasonic examination will be performed on the starting plates, this examination shall be performed in the agreed delivery condition. 7.2.4 7.2.4.1 Tests and examinations of dished or pressed product forms made from plates Sampling and specimen preparation

(1) The heat-treatment condition as well as the results of the ladle analysis, product analysis, test for intergranular corrosion resistance, determination of the delta ferrite content, materials identification check and non-destructive examinations performed by the manufacturer shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204. (2) For plates of test groups A 1 and A 2, the results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. For plates of test group A 3, the stipulations shall be the same as for steels for conventional pressure vessels subject to supervision to AD-Merkblatt W 2. 7.2 7.2.1 (1) a) b) c) d) Dished or pressed product forms made from plates Materials

(1) For product forms with a diameter or length smaller than or equal to 500 mm and a wall thickness smaller than or equal to 16 mm, the mechanical tests shall be performed on one part per heat, thickness range and heat-treatment lot. The maximum permissible lot size shall be 20 parts, but the lot weight shall not exceed 500 kg. (2) For product forms with a diameter or length greater than 500 mm or wall thickness greater than 16 mm, each part shall be tested individually, in which case a) for product forms with a diameter or length greater than 500 mm and equal to or smaller than 6000 mm or a wall thickness greater than 16 mm one test coupon shall be taken, b) for product forms with a diameter or length greater than 6000 mm one test coupon each from two opposite sides shall be taken. (3) The test coupons shall be taken such that transverse specimens can be machined. Deviations up to 20 degrees from the theoretical transverse direction are permitted for heads (ends) and similar parts. In making the specimens, plastic deformation of the specimen in the zone of the gauge length shall be avoided. If applicable, a different type of sampling or procedure for making specimens shall be agreed with the authorized inspector. (4) The stipulations of clause 7.1.3.1 and of DIN 17 440 shall apply as relevant to sampling. 7.2.4.2 Extent of tests and examination

The following steel grades may be used: X 6 CrNiNb 18 10 to DIN 17 440 X 6 CrNiTi 18 10 to DIN 17 440 X 6 CrNiMoTi 17 12 2 to DIN 17 440 X 6 CrNiMoNb 17 12 2 to DIN 17 440

e) other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspectors appraisal. (2) The stipulations of clause 4.3.3 shall be met. (3) For hot (operating temperature T 200 C) reactor water containing product form and components in BWR plants only the steel grade to clause (1) a), and only with the following additional requirements for the chemical composition shall be used: C 0.03 % Si 0.5 % P 0.025 % S 0.010 % 18.0 (% Cr) 19.0 13 x (% C) (% Nb) 0.65 The test certificate shall show the boron and nitrogen content.

(1) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per sampling location. b) One tensile test at 350 C per heat, thickness range and heat-treatment lot, if the design temperature in test group A 1 is higher than 200 C and in test groups A 2 and A 3 is higher than 300 C. c) One notched-bar impact bend test to clause 4.4.6.5 at room temperature per sampling location for product forms with nominal wall thicknesses larger than 16 mm.

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(2) One test for resistance to intergranular corrosion to DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 C) shall be performed per heat, dimensional range and heat-treatment lot. (3) One bead-on-plate test to determine the delta ferrite content to Annex D shall be performed per heat, if values smaller than 3 are found in calculation of the ferrite number from the chemical composition in the ladle analysis. This test may be replaced by a corresponding test of the starting plates. (4) The non-destructive examinations shall be subject to the following requirements: a) If agreed in the purchase order, the starting plates or the product forms with a nominal wall thickness equal to or larger than 10 mm shall be subjected by the manufacturer to an ultrasonic surface examination to clause 7.1.3.2 (5). b) The flange and knuckle of each head (end) shall be subjected to a surface-crack detection in the finishmachined condition after the last heat treatment. The acceptance criteria are defined in Table 5.2-1. (5) Each product form shall be subjected to a materials identification check. (6) Each product form shall be subjected to a visual inspection of its external finish. (7) Each product form shall be checked for accuracy regarding dimensions and form. 7.2.5 Marking

7.3 7.3.1 (1) a) b) c) d) e)

Forgings, bar steel, rings and extrusions Materials

The following steel grades may be used: X 6 CrNiNb 18 10 to DIN 17 440 X 6 CrNiTi 18 10 to DIN 17 440 X 6 CrNiMoTi 17 12 2 to DIN 17 440 X 6 CrNiMoNb 17 12 2 to DIN 17 440 other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspector's appraisal. The stipulations of clause 4.3.3 shall be met.

(2)

(3) For hot (operating temperature T 200 C) reactor water containing product form and components in BWR plants only the steel grade to clause (1) a), and only with the following additional requirements for the chemical composition shall be used: C 0.03 % Si 0.5 % P 0.025 % S 0.010 % 18.0 (% Cr) 19.0 13 x (% C) (% Nb) 0.65 The test certificate shall show the boron and nitrogen content. 7.3.2 Additional requirements for the materials

(1) Each product form shall be marked with the following information: a) manufacturer's symbol, b) steel grade, c) heat number, d) specimen number e) authorized inspector's mark and f) mark of the non-destructive examinations performed. (2) In the case of lotwise examination, the product form from which the specimens were taken shall additionally be marked. (3) The marking shall be applied such that it appears upright when viewed in the main rolling direction of the rolled plate. 7.2.6 Verification of quality characteristics

(1) The surfaces shall be free of ferritic impurities. Scale layers and tempering colours developed during hot forming or heat treatment shall be removed. (2) The surface condition shall meet the requirements of non-destructive examination and be indicated in the purchase order. 7.3.3 7.3.3.1 Tests and examinations Test units

(1) Pieces from the same heat, with similar dimensions and from the same heat-treatment lot shall be grouped as test units weighing at most 500 kg. (2) Pieces with heat-treatment weights heavier than 500 kg or governing dimensions exceeding 250 mm shall be tested individually. 7.3.3.2 7.3.3.2.1 Sampling for forgings, rings and extrusions Sampling location

(1) The heat-treatment condition as well as the results of the ladle analysis, product analysis, test for intergranular corrosion resistance, determination of the delta ferrite content, materials identification check and non-destructive examinations performed by the manufacturer shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204. The forming method shall be indicated in the acceptance test certificate 3.1.B. (2) For product forms of test groups A 1 and A 2, the results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. For product forms of test group A 3, the stipulations shall be the same as for steels for conventional pressure vessels subject to supervision to AD-Merkblatt W 2. Certification of the forming method shall be attached to the quality verification.

Specimens shall be taken from one end face of the prices. For heat treatment weights exceeding 2500 kg specimens shall be taken from both ends of the forging. At diameters exceeding 1000 mm the specimens shall be taken offset by 180 degrees. Unless otherwise stipulated, specimens shall be taken from one piece per test unit. 7.3.3.2.2 Sampling depth

(1) The sampling location for longitudinal and transverse specimens shall be at least 25 mm from the end face. (2) The sampling location shall also be at least one sixth of the heat-treatment thickness but not farther than 50 mm from the second surface, perpendicular to the end face. The heattreatment thickness shall be defined as the nominal wall

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thickness for hollow parts and as the outside diameter during heat treatment for solid parts. (3) If the exact sampling location cannot be given in advance for any pieces, it shall be agreed with the authorized inspector. 7.3.3.2.3 Specimen direction

(4) One bead-on-plate test to determine the delta ferrite content shall be performed per heat, if values of ferrite number smaller than 3 are calculated by the procedure of Annex D from the chemical composition in the ladle analysis. (5) The non-destructive examinations shall be subject to the stipulations in Annex H. (6) Each piece shall be subjected to a materials identification check. (7) Each piece shall be subjected to a visual inspection of its external finish. (8) 7.3.4 A dimensional check shall be performed for each piece. Marking

(1) Specimens shall be taken transverse to the main forming direction. (2) Longitudinal specimens are permitted in the following cases: tensile-test specimens for pieces with a cross-sectional area corresponding to solid parts with a diameter smaller than 160 mm; and notched-bar impact-test specimens for pieces with a cross-sectional area corresponding to solid parts with a diameter smaller than 100 mm. 7.3.3.3 7.3.3.3.1 (1) Sampling for bars Sampling location

Specimens shall be taken from one end of the bars.

(2) Unless otherwise stipulated, specimens shall be taken from one piece per test unit. 7.3.3.3.2 Sampling depth

(1) Each piece shall be marked durably with the following information: a) manufacturer's symbol, b) steel grade, c) heat number, d) specimen number, e) authorized inspector's mark and f) mark of the non-destructive examinations performed. (2) In the case of lotwise examination, the piece from which the specimens were taken shall additionally be marked. 7.3.5 Verification of quality characteristics

(1) For bars with a diameter or heat-treatment thickness smaller than or equal to 25 mm, specimens shall be taken from the core of the bars. (2) For bars with a diameter or heat-treatment thickness larger than 25 mm and smaller than or equal to 160 mm, specimens shall be taken at least 12.5 mm under the surface. (3) The sampling depths for bars with larger diameter or larger heat-treatment thickness shall be determined by the stipulations in the authorized inspectors appraisal. (4) The distance of the sampling location from the end faces shall be at least 25 mm. 7.3.3.3.3 Specimen direction

(1) The heat-treatment condition, results of the ladle analysis, product analysis, test for intergranular corrosion resistance, determination of the delta ferrite content, materials identification check and non-destructive examinations performed by the manufacturer shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204. (2) For pieces of test groups A 1 and A 2, the results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. For pieces of test group A 3, the stipulations shall be the same as for steels for conventional pressure vessels subject to supervision to AD-Merkblatt W 2. 7.4 7.4.1 Seamless pipes larger than DN 50 Scope

Longitudinal specimens shall be taken for bars with a diameter or heat-treatment thickness smaller than or equal to 100 mm, and transverse specimens shall be taken for bars with a diameter or heat-treatment thickness larger than 100 mm. 7.3.3.4 Extent of tests and examinations

(1) The following procedures shall be performed for the chemical analysis: a) One ladle analysis per heat. b) One product analysis per heat. The nitrogen content shall be shown if the delta ferrite content is determined to Annex D. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per sampling location. b) One tensile test at 350 C per heat, similar dimension and heat-treatment lot, if the design temperature in test group A 1 is higher than 200 C and in test groups A 2 and A 3 is higher than 300 C. c) One notched-bar impact bend test to clause 4.4.6.5 at room temperature per sampling location. (3) One test for resistance to intergranular corrosion to DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 C) shall be performed per heat, similar dimension and heat-treatment lot.

(1) The stipulations of this Section shall apply to seamless, rolled or pressed pipes larger than DN 50.
Note: For forged pipes Section 7.3 shall apply.

(2) The stipulations of this Section shall also apply to pipes equal to or smaller than DN 50 if pipe elbows larger than DN 50 are made from such pipes. 7.4.2 (1) Materials The following steel grades may be used: to DIN 17 458 to DIN 17 458 to DIN 17 458

a) X 6 CrNiNb 18 10 b) X 6 CrNiTi 18 10 c) X 6 CrNiMoTi 17 12 2

d) X 6 CrNiMoNb 17 12 2 to DIN 17 458 e) other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspector's appraisal. (2) The stipulations of clause 4.3.3 shall be met.

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(3) For hot (operating temperature T 200 C) reactor water containing product form and components in BWR plants only the steel grade to clause (1) a), and only with the following additional requirements for the chemical composition shall be used: C 0.03 % Si 0.5 % P 0.025 % S 0.010 % 18.0 (% Cr) 19.0 13 x (% C) (% Nb) 0.65 The test certificate shall show the boron and nitrogen content. 7.4.3 Additional requirements for the materials

groups A 2 and A 3 is higher than 300 C. The test shall be performed at 350 C. e) One notched-bar impact bend test to clause 4.4.6.5 at room temperature at the end of one pipe per manufacturing length for pipes with nominal wall thicknesses larger than 16 mm. f) For pipes for shells of pressure vessels with nominal wall thicknesses greater than 10 mm or diameters larger than 200 mm and smaller than or equal to 600 mm, one notched-bar impact bend test to clause 4.4.6.5 at room temperature at the end of one pipe per manufacturing length. g) For pipes with wall thicknesses smaller than or equal to 40 mm, technological tests per Table 7.4-1 at both ends of each manufacturing length. (3) One test for resistance to intergranular corrosion to DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 C) shall be performed per heat, dimension and heat-treatment lot. Nominal wall thickness s of the pipes in mm s< 2 2 s 16 16 < s 40 Nominal outside diameter of the pipes in mm > 146 146 Flattening test Ring expanding test Flattening test
1)

(1) The surfaces shall be free of ferritic impurities. Scale layers and tempering colours developed during hot forming or heat treatment shall be removed. (2) The surface condition shall meet the requirements of the non-destructive examination and be indicated in the purchase order. 7.4.4 7.4.4.1 (1) Testing and examinations Sampling and specimen preparation

Ring tensile test Ring tensile test

The pipes shall be tested in manufacturing lengths.

1) The drift test also may be performed.

(2) Specimens shall be taken from the ends of manufacturing lengths. (3) The distance between pipe end and sampling location shall be at least equal to the nominal wall thickness but shall not exceed 25 mm. (4) Transverse specimens shall be taken, if possible. In the case of outside diameters Da smaller than or equal to 200 mm, longitudinal specimens shall be taken for tensile tests. (5) For pipes with wall thicknesses larger than or equal to 20 mm, specimens shall be taken from the middle of the pipe wall if at all possible. Specimen forms to DIN EN 10 002-1 may also be used for tensile tests. 7.4.4.2 Extent of tests and examinations

Table 7.4-1: Technological tests to be employed as a function of pipe dimensions (4) One bead-on-plate test to determine the delta ferrite content shall be performed per heat, if the calculation to Annex D yields values of ferrite number smaller than 3 from the chemical composition in the ladle analysis. (5) The non-destructive examinations shall be subject to the following requirements: a) All pipes shall be examined ultrasonically for longitudinal defects to SEP 1915. b) Pipes of test group A 1 larger than or equal to DN 100 and pipes for shells of pressure vessels with design pressures higher than 8 MPa shall be subjected to an ultrasonic transverse-defect examination to SEP 1918. Pipes of test group A 2 larger than or equal to DN 100 shall be examined for transverse defects if they were hot-pilgerrolled or subjected to hot pilger rolling during the manufacturing process. c) For hot-finished pipes of test group A 1 with outside diameters larger than 100 mm and nominal wall thicknesses larger than 16 mm, comparative sound attenuation measurements by means of angle-beam scanning shall be made at both pipe ends and at the pipe center. The measurements shall be made at four places staggered by 90 degrees, alternating between the circumferential direction and axial direction. They shall be performed with the same nominal frequency as in the examination for longitudinal and transverse defects. If the values determined close to the test defects in the test pipe are exceeded by more than 6 dB, the maximum amounts in excess of 6 dB shall be added on for sensitivity adjustment for the examination of longitudinal and transverse defects. If it is found in the course of the examinations that adequate uniformity of sound attenuation exists for the manufacturing method, material and dimension, the extent of sound attenuation measurements may be reduced, subject to approval of the authorized inspector.

(1) The following procedures shall be performed for the chemical analysis: a) One ladle analysis per heat. b) One product analysis per heat. The nitrogen content shall be shown if the delta ferrite content is determined to Annex D. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test for every 50 manufacturing lengths of the same heat, dimension and heat-treatment lot. b) For pipes with nominal wall thicknesses greater than 16 mm, one room-temperature tensile test at the end of one pipe per manufacturing length. c) For pipes for shells of pressure vessels with wall thicknesses greater than 10 mm or diameters larger than 200 mm and smaller than or equal to 600 mm, one roomtemperature tensile test at the end of one pipe per manufacturing length. d) One tensile test at 350 C per heat, dimensional range and heat-treatment lot, if the design temperature for pipes of test group A 1 is higher than 200 C and for pipes of test

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d) One surface-crack detection shall be performed on every fourth pipe of test group A 1. The outside surface shall be examined completely and the inside surface shall be examined over a length of one times the outside diameter from each end of the pipe. The acceptance criteria are defined in Table 5.2-1. (6) Each pipe shall be subjected to a materials identification check. (7) The inside and outside surfaces of each pipe shall be subjected to a visual inspection. (8) The diameter and wall thickness shall be checked for dimensional accuracy at both ends of each pipe. (9) Each pipe shall be examined for leak tightness either by an internal hydrostatic pressure test or by a non-destructive examination to SEP 1925. For the internal hydrostatic pressure test, the test pressure shall generally be 8 MPa. In each case the test pressure shall be limited such that the factor of safety relative to the yield point at room temperature is not less than 1.1. 7.4.5 Marking

b) c) d) e)

X6CrNiTi18-10 to DIN 17 440 or DIN 17 458 X6CrNiMoTi17-12-2 to DIN 17 440 or DIN 17 458 X6CrNiMoNb17-12-2 to DIN 17 440 or DIN 17 458 other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspector's appraisal. The stipulations of clause 4.3.3 shall be met.

(2)

(3) For hot (operating temperature T 200 C) reactor water containing product form and components in BWR plants only the steel grade to clause (1) a), and only with the following additional requirements for the chemical composition shall be used: C 0.03 % Si 0.5 % P 0.025 % S 0.010 % 18.0 (% Cr) 19.0 13 x (% C) (% Nb) 0.65 The test certificate shall show the boron and nitrogen content. (4) For finished pipe elbows, the values of the mechanical and technological characteristics for pipes shall apply even if forged hollow parts are used as starting product. 7.5.3 Additional requirements for the materials

(1) Each pipe shall be marked durably with the following information at one end: a) manufacturers symbol, b) steel grade with abbreviation for the type of construction and the designation S for seamless products to DIN 17 458, c) heat number, d) pipe number, e) authorized inspector's mark and f) mark of the non-destructive examinations performed. 7.4.6 Verification of quality characteristics

(1) The surfaces shall be free of ferritic impurities. Scale layers and tempering colours developed during hot forming or heat treatment shall be removed. (2) The surface condition shall meet the requirements of the non-destructive examination and be indicated in the purchase order. 7.5.4 Starting products

(1) The results of the ladle analysis, product analysis, test for intergranular corrosion resistance, determination of the delta ferrite content, materials identification check, tightness test and non-destructive examinations performed by the manufacturer shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. (3) For pipes of test group A 3 and wall thicknesses smaller than or equal to 5.6 mm, an acceptance test certificate 3.1.B to DIN EN 10 204 will suffice. 7.5 7.5.1 Seamless pipe elbows larger than DN 50 Scope

(1) Forged hollow parts to Section 7.3 or seamless pipes to Section 7.4 may be used as starting products. (2) If the starting products used are not in the solutionannealed and quenched condition or have not been completely examined to the stipulations in Sections 7.3 or 7.4, the finished pipe elbows shall be examined individually to clause 7.5.5.2. (3) If the finished pipe elbows are examined individually to clause 7.5.5.2, the determination of mechanical and technological characteristics and the corresponding verification may be waived for the starting products. An acceptance test certificate 3.1.B to DIN EN 10 204 shall then be adequate for visual inspection and dimensional check of the starting products. 7.5.5 7.5.5.1 Tests and examinations of pipe elbows Sampling and specimen preparation

(1) This Section shall apply to seamless pipe elbows (weldin elbows) made from seamless rolled, extruded or forged pipes by cold or hot forming followed by heat treatment (solution annealing and quenching). (2) This Section shall not apply to pipe bends made with inductive bending machines or by cold forming with or without subsequent heat treatment. These pipe bends shall be subject to the requirements of KTA 3211.3 Section 6. 7.5.2 Materials

(1) Specimens shall be taken from the ends of the pipe elbows in conformity with the authorized inspector's appraisal. (2) The distance between pipe-elbow end and sampling location shall be at least equal to the nominal wall thickness but shall not exceed 25 mm. Deviations from the foregoing are permitted, subject to the authorized inspector's approval. (3) Where transverse specimens can be taken from nondirectional test coupons they shall be tested. In the case of outside diameters Da smaller than or equal to 200 mm, longitudinal specimens shall be taken for tensile tests.

(1) The following steel grades may be used: a) X6CrNiNb18-10 to DIN 17 440 or DIN 17 458 Page 38

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(4) For pipe elbows with nominal wall thicknesses larger than or equal to 20 mm, specimens shall be taken from the middle of the pipe wall if at all possible. (5) If the pipe elbows are not tested individually, test units consisting of pipe elbows of the same heat, dimension and heat treatment shall be formed for determination of mechanical and technological characteristics. (6) For the room-temperature tensile tests and for the notched-bar impact bend tests, the number of pipe elbows per test unit shall not exceed: a) 50 pieces for pipe elbows smaller than DN 200 b) 25 pieces for pipe elbows larger than or equal to DN 200 to smaller than DN 350 c) 10 pieces for pipe elbows larger than or equal to DN 350. 7.5.5.2 Extent of tests and examinations

and transverse defects. If it is found in the course of the examinations that adequate uniformity of sound attenuation exists for the manufacturing method, material and dimension, the extent of sound attenuation measurements may be reduced, subject to approval of the authorized inspector. d) If an ultrasonic examination is performed on the pipe elbow, the corresponding examination on the starting product may be waived. (6) Each pipe elbow shall be subjected to a materials identification check. (7) The inside and outside surfaces of each pipe elbow shall be subjected to a visual inspection. (8) For each pipe elbow, the wall thickness and, depending on the purchase order, either the outside or inside diameter shall be measured over the arc length, including the ends, and to a sufficient extent over the circumference. The smallest wall thickness as well as the ovality shall be determined. 7.5.6 Marking

(1) The chemical composition shall be verified on the basis of the starting product. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test on one pipe elbow per test unit or, in the case of individual testing, on each pipe elbow. b) One tensile test at 350 C on one pipe elbow per heat, dimension and heat-treatment lot, if the design temperature for pipe elbows of test group A 1 is higher than 200 C and for pipe elbows of test groups A 2 and A 3 is higher than 300 C. c) One notched-bar impact bend test to clause 4.4.6.5 at room-temperature per test unit for wall thicknesses larger than 16 mm. (3) One test for resistance to intergranular corrosion to DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 C) shall be performed per heat, dimension and heat-treatment lot. (4) One bead-on-plate test to determine the delta ferrite content to Annex D shall be performed per heat, if values smaller than 3 are found in calculation of the ferrite number from the chemical composition in the ladle analysis. This test may be replaced by a corresponding test on the starting product. (5) Non-destructive examinations shall be subject to the following requirements: a) For pipe elbows larger than or equal to DN 100, the outside and inside surfaces shall be subjected to a surfacecrack detection. For pipe elbows smaller than DN 100, the outside surface shall be examined completely and the inside surface shall be examined wherever it is accessible. The acceptance criteria are defined in Table 5.2-1. b) All pipe elbows smaller than DN 100 shall be ultrasonically examined for longitudinal and transverse defects to SEP 1915 and SEP 1918 in the surface zones that are not accessible to surface-crack detection. c) For hot-finished pipe elbows of test group A 1 with outside diameters larger than 100 mm and nominal wall thicknesses larger than 16 mm, comparative sound attenuation measurements by means of angle-beam scanning shall be made at both elbow ends. The measurements shall be made at four places staggered by 90 degrees, alternating between the circumferential direction and axial direction. They shall be performed with the same nominal frequency as in the examination for longitudinal and transverse defects. If the values determined close to the test defects in the test elbow are exceeded by more than 6 dB, the maximum amounts in excess of 6 dB shall be added on for sensitivity adjustment for the examination of longitudinal

(1) Each pipe elbow shall be marked with the following information: ) manufacturer's symbol, b) steel grade with abbreviation for the type of construction and the designation S for seamless products to DIN 17 458 for the starting pipes, c) heat number, d) elbow number or test lot number and e) authorized inspector's mark, f) mark of the non-destructive examinations performed, g) designation X in the case of hot-finished elbows (of the Hamburg type) from the steel grades X 6 CrNiTi 18 10 and X 6 CrNiMoTi 18 10 in accordance with the stipulations for hot-finished pipes to DIN 17 458. 7.5.7 Verification of quality characteristics

(1) The results of the ladle analysis, test for intergranular corrosion resistance, materials identification check and nondestructive examinations performed by the manufacturer shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. (3) For pipe elbows of test group A 3 with wall thicknesses smaller than or equal to 5.6 mm, an acceptance test certificate 3.1.B to DIN EN 10 204 will suffice. 7.6 7.6.1 Seamless fittings larger than DN 50 Scope

(1) This Section shall apply to the following seamless fittings: a) reducers made from seamless rolled, extruded or forged pipes by cold or hot forming followed by heat treatment (solution annealing and quenching), b) tees fabricated to the liqued bulge method.
Note: The nominal diameter of a reducer or of a tee shall refer to the end with the larger diameter.

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7.6.2 (1) a) b) c) d) e)

Materials

The following steel grades may be used: X6CrNiNb18-10 to DIN 17 440 or DIN 17 458 X6CrNiTi18-10 to DIN 17 440 or DIN 17 458 X6CrNiMoTi17-12-2 to DIN 17 440 or DIN 17 458 X6CrNiMoNb17-12-2 to DIN 17 440 or DIN 17 458 other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspectors appraisal. The stipulations of clause 4.3.3 shall be met.

(6) For the room-temperature tensile tests and for the notched-bar impact bend tests, the number of fittings per test unit shall not exceed: a) 50 pieces for fittings smaller than DN 100 b) 10 pieces for fittings larger than or equal to DN 100 7.6.5.2 Extent of tests and examinations

(1) The chemical composition shall be verified on the basis of the starting product. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per test unit. b) One tensile test at 350 C per heat, dimension and heattreatment lot, if the design temperature for fittings of test group A 1 is higher than 200 C and for fittings of test groups A 2 and A 3 is higher than 300 C. c) One notched-bar impact bend test to clause 4.4.6.5 at room-temperature per test unit for wall thicknesses larger than 16 mm. (3) One test for resistance to intergranular corrosion to DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 C) shall be performed per heat, dimension and heat-treatment lot. (4) One bead-on-plate test to determine the delta ferrite content to Annex D shall be performed per heat, if values smaller than 3 are found in calculation of the ferrite number from the chemical composition in the ladle analysis. This test may be replaced by a corresponding test on the starting product. (5) Non-destructive examinations shall be subject to the following requirements: a) For fittings larger than or equal to DN 100, the outside and inside surfaces shall be subjected to a surface-crack detection. For fittings smaller than DN 100, the outside surface shall be examined completely and the inside surface shall be examined wherever it is accessible. The acceptance criteria are defined in Table 5.2-1. b) All fittings smaller than DN 100 shall be ultrasonically examined for longitudinal and transverse defects to SEP 1915 and SEP 1918 in the surface zones that are not accessible to surface-crack detection. c) For hot-finished fittings of test group A 1 with outside diameters larger than 100 mm and nominal wall thicknesses larger than 16 mm, comparative sound attenuation measurements by means of angle-beam scanning shall be made at both ends. The measurements shall be made at four places staggered by 90 degrees, alternating between the circumferential direction and axial direction. They shall be performed with the same nominal frequency as in the examination for longitudinal and transverse defects. If the values determined close to the test defects in the test elbow are exceeded by more than 6 dB, the maximum amounts in excess of 6 dB shall be added on for sensitivity adjustment for the examination of longitudinal and transverse defects. If it is found in the course of the examinations that adequate uniformity of sound attenuation exists for the manufacturing method, material and dimension, the extent of sound attenuation measurements may be reduced, subject to approval of the authorized inspector. d) If an ultrasonic examination is performed on the fitting, the examination on the starting pipe may be waived. (6) Each fitting shall be subjected to a materials identification check. (7) The inside and outside surfaces of each fitting shall be subjected to a visual inspection.

(2)

(3) For hot (operating temperature T 200 C) reactor water containing product form and components in BWR plants only the steel grade to clause (1) a), and only with the following additional requirements for the chemical composition shall be used: C 0.03 % Si 0.5 % P 0.025 % S 0.010 % 18.0 (% Cr) 19.0 13 x (% C) (% Nb) 0.65 The test certificate shall show the boron and nitrogen content. (4) For the mechanical and technological characteristics of fabricated fittings, the values of the mechanical and technological characteristics for pipes shall apply even if forged hollow parts are used as starting products. 7.6.3 Additional requirements for the materials

(1) The surfaces shall be free of ferritic impurities. Scale layers and tempering colours developed during hot forming or heat treatment shall be removed. (2) The surface condition shall meet the requirements of the non-destructive examination and be indicated in the purchase order. 7.6.4 Starting products

The stipulations in Section 7.3 or 7.4 shall apply to the starting products. 7.6.5 7.6.5.1 Tests and examinations of fittings Sampling and specimen preparation

(1) Specimens shall be taken from the ends of the fittings in conformity with the authorized inspector's appraisal. (2) The specimen axes shall be located at one half of the wall thickness under the end face or as close as possible to that location. (3) Where transverse specimens can be taken from nondirectional test coupons they shall be tested. In the case of outside diameters Da smaller than or equal to 200 mm, longitudinal specimens shall be taken for tensile tests. (4) For fittings with nominal thicknesses larger than or equal to 20 mm, specimens shall be taken from the middle of the pipe wall if at all possible. (5) If the fittings are not tested individually, test units consisting of fittings of the same heat, dimension and heattreatment lot shall be formed for determination of characteristics.

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(8) For each fitting the ovality, diameter and wall thickness shall be measured at the ends. 7.6.6 Marking

(5) For each casting model, the description of the casting technique shall be attached to the interim file (internal manufacturer documentation) for retention by the manufacturer.
Note: The feature characterizing the dimensions of the body or case shall be the nominal width, as follows: a) for pumps, the nominal width of the pressure nozzle, b) for valves, the largest nominal width involved, c) for safety valves, the nominal width of the inlet nozzle.

(1) Each fitting shall be marked with the following information: a) manufacturers symbol, b) steel grade with abbreviation for the type of construction and the designation S for seamless products to DIN 17 458 for the starting pipes, c) heat number, d) number of the fitting or test lot number, e) authorized inspector's mark, f) mark of the non-destructive examinations performed, g) designation X in the case of hot-finished fittings from the steel grades X 6 CrNiTi 18 10 and X 6 CrNiMoTi 18 10 in accordance with the stipulations for hot-finished pipes to DIN 17 458. 7.6.7 Verification of quality characteristics

(6) Together with the drawing of the casting in the asdelivered condition, the following documents shall generally be submitted as standard plans for the design approval: a) test and inspection sequence plan and heat-treatment plan, in case of differences from the standard production scheme to Figure B-12. b) for castings of test group A 1 with nominal widths equal to or larger than 200 mm, instructions for the non-destructive examinations as well as a coordinate reference system (reference-point grid). c) for prototypes of test groups A 2 and A 3 with nominal widths greater than 200 mm a film location plan and a radiation source plan, d) welding procedure qualification and welding procedure sheet for production welds and if applicable construction welds (see Annex C) e) test and inspection sequence plan for construction welds, if necessary. f) list of planned production control tests. (7) If changes are made compared with the conditions stipulated in the welding procedure sheet, or if a different welding method is chosen, the welding procedure sheet shall be resubmitted for design approval in this respect. 7.7.3 Tests and examinations Sampling and specimen preparation

(1) The results of the ladle analysis, test for intergranular corrosion resistance, materials identification check and nondestructive examinations performed by the manufacturer shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. (3) For fittings of test group A 3 with wall thicknesses smaller than or equal to 5.6 mm, an acceptance test certificate 3.1.B to DIN EN 10 204 will suffice. 7.7 7.7.1 (1) a) b) c) d) e) Castings Materials The following cast-steel grades may be used: G-X 5 CrNiNb 18 9 to DIN 17 445 GX5CrNiNb19-11 to DIN EN 10 213-4 G-X 5 CrNiMoNb 18 10 to DIN 17 445 GX5CrNiMoNb19-12 to DIN EN 10 213-4 other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspector's appraisal. The stipulations of clause 4.3.3 shall be met. General requirements for casting condition

7.7.3.1

(1) Castings with a delivery weight lighter than or equal to 500 kg shall be tested in lots, and castings with a delivery weight heavier than 500 kg shall be tested individually. (2) The number of sampling locations shall be as indicated in Table 7.7-1. Product weight (delivery weight) in kg 100 > 100 up to 500 Number of sampling locations 1

Test unit At most 2500 kg per heat, dimension and heat-treatment lot At most 10 pieces, but not more than 2500 kg per heat, dimension and heattreatment lot Individual piece Individual piece

(2) 7.7.2

(1) The base metal shall have a delta ferrite content corresponding to ferrite numbers of 2 to 12 to Annex D. (2) As regards their general internal and external finish, the castings shall satisfy the stipulations of Table B-2 applicable to their test group. (3) Feeder heads and large casting-related thickenings that impair the heat treatment of the casting shall be eliminated before the heat treatment for establishment of the mechanical and technological characteristics. (4) The casting technique shall be designed according to the principles of controlled solidification. For castings with nominal widths larger than or equal to 200 mm, the gate and feeder technique shall be explained on the basis of the saturation calculation as well as drawings illustrating the position of the feeders, feed zones and specimen location. > 500 up to 1000 > 1000

1 2

Table 7.7-1: Number of sampling locations on castings made of austenitic steels (3) The specimens shall be taken from cast-on test coupons or from overlengths. Separately cast test coupons are permitted only for castings with piece weights equal to or lighter than 50 kg. The test coupons shall be provided in sufficient number and size that the prescribed specimens can be taken.

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(4) The thickness of the cast-on test coupons shall be calculated by comparison of volume/surface ratios at the governing nominal wall thickness. However, it shall be at most 150 mm. In this connection, the governing nominal wall thickness shall be the thickness of the wall subjected to pressure loading, and not the thickness of cast-on flanges or local thickenings. Caston test coupons at the gate system are not permitted. The specimens shall be taken at a distance of half the thickness of the cast-on test coupons from the end and side faces as well as at one quarter from one of the other faces. (5) For castings with piece weights heavier than 1000 kg, the position of the cast-on test coupons on the casting shall be documented by a photograph or in a sketch. 7.7.3.2 Extent of tests and examinations

7.7.5

Verification of quality characteristics

(1) The results of the ladle analysis, product analysis, test for resistance to intergranular corrosion, determination of the delta ferrite content, materials identification check and nondestructive examinations performed by the manufacturer shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificate as an acceptance test certificate 3.1.C to DIN EN 10 204. For castings with piece weights heavier than 1000 kg, a photograph or a sketch of the location of the cast-on test coupons on the casting shall be attached to the acceptance test certificate.

(1) The following procedures shall be performed for the chemical analysis: a) One ladle analysis per heat. b) One product analysis for one sampling location per test unit. The nitrogen content shall be shown if the delta ferrite content is determined to Annex D. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per sampling location. b) One tensile test at 350 C per heat, dimension and heattreatment lot, if the design temperature for castings of test group A 1 is higher than 200 C and for castings of test groups A 2 and A 3 is higher than 300 C. c) One notched-bar impact bend test to clause 4.4.6.5 at room-temperature per sampling location. (3) One test for resistance to intergranular corrosion to DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 C) shall be performed per heat, dimension and heat-treatment lot. (4) The delta ferrite content shall be determined from the nitrogen content by the method of Annex D. If the value of the ferrite number calculated from the chemical composition per the ladle analysis is smaller than 3, the delta ferrite content shall be determined metallographically per heat. (5) The non-destructive examinations of the castings shall be subject to the requirements of Annex B. (6) Each casting shall be subjected to a materials identification check. (7) Each casting shall be subjected in the as-delivered condition to a visual inspection of its external finish. (8) Each casting shall be subjected in the as-delivered condition to a dimensional check. (9) Each casting shall be subjected in a condition suitable for the purpose, generally by the further processor, to a tightness test in the form of an internal pressure test, which shall be performed to DIN 50 104. Pressurizing fluid, pressure level and pressure-loading duration shall be indicated in the purchase order. However, the nominal pressure shall never lead to a load higher than 90 % of the 0.2 % proof stress of the cast-steel grade. 7.7.4 Marking

8 8.1

Bolts and nuts Scope

This Section shall apply to: a) bolts and nuts made by machining from quenched and tempered ferritic bars, b) bolts and nuts made by machining from solution-annealed and quenched austenitic bars, c) bolts and nuts made by hot or cold forming from ferritic bars and then quenched and tempered, d) bolts and nuts of unalloyed and alloyed ferritic steels of the strength classes to DIN EN ISO 898-1, DIN EN 20 898-2 and DIN EN ISO 898-6 as well as of austenitic steels of steel groups A 2, A 3, A 4 and A 5 to DIN EN ISO 3506-1 and DIN EN ISO 3506-2 within the limits of Table 8-1.
Note: Thread rolling shall not be considered as cold forming that requires renewed heat treatment.

8.2

Materials

(1) The following steel grades may be used: a) steel grades to Section A 5, b) steel grades Ck 35, 24 CrMo 5 and 21 CrMoV 5 7 to DIN 17 240 as well as C35E and 21CrMoV5-7 to DIN EN 10 269 in combination with the additional requirements of Section 8.3 as well as the dimensional limits and other stipulations in Section A 6, c) steel grades X 22 CrMoV 12 1 and X 8 CrNiMoBNb 16 16 to DIN 17 240 as well as X22CrMoV12-1 and X7CrNiMoBNb16-16 to DIN EN 10 269 in combination with the dimensional limits and other stipulations in Section A 6, d) ferritic and austenitic steel grades for bolts and nuts to Table 8-1, within the strength classes and limits of application indicated therein, e) other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspector's appraisal. (2) 8.3 Locking by welding is not permitted. Additional requirements for the materials

(1) Each casting shall be marked with the following information: a) manufacturer's symbol, b) cast-steel grade, c) heat number, d) specimen number and e) authorized inspector's mark.

(1) For ferritic steels for bolts, except martensitic steels containing 12 % chromium and steel grades to clause 8.1 d), the following additional stipulations shall apply in the notchedbar impact bend test on Charpy V-notch longitudinal specimens at room temperature: a) for dimensions larger than M 24 and smaller than or equal to M 100, the smallest individual value of lateral expansion shall not be less than 0.6 mm and

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b) for dimensions larger than M 100 the smallest individual value of energy absorbed shall not be less than 61 J and the smallest individual value of lateral expansion shall not be less than 0.6 mm. 8.4 8.4.1 8.4.1.1 (1) Bolts and nuts made by machining from ferritic bars Tests and examinations on the bars Sampling and specimen preparation

equal to the bar diameter of the bars for bolts and equal to half the bar diameter of the bars for nuts are permitted. The indication length shall be determined by the halfamplitude technique. (4) Each bar shall be subjected to visual inspection of its external finish. (5) (6) The marking on each bar shall be inspected. Each bar shall be inspected for dimensional accuracy.

Longitudinal specimens shall be taken.

(2) The test cross section of the tensile-test and notched-bar impact-test specimens shall be located at least one half of the bar diameter from the end face, and the specimen axis shall be located at the bar center for diameters equal to or smaller than 40 mm and at a depth of one sixth of the diameter under the surface for diameters larger than 40 mm. 8.4.1.2 Test units

(7) Each bar shall be subjected to a materials identification check. 8.4.2 Tests and examinations on finished parts

(1) A surface-crack detection shall be performed randomly on bolts and nuts. The extent of random examination and the acceptance levels shall be subject to the stipulations in Table 8-3. Indications that prove the presence of cracks are not permitted. Further findings shall be assessed to Table 8-10. (2) The main and secondary features of randomly checked bolts and nuts shall be examined to Table 8-2. The extent of random examination and the acceptance levels shall be subject to the stipulations in Table 8-3. Subject to agreement of the authorized inspector, it is permitted to supplement or replace the secondary features cited in Table 8-2 by application-specific requirements. (3) The marking shall be checked at random. The extent of random checking shall be subject to the stipulations in Table 8-3. (4) Bolts and nuts of alloyed steels shall randomly subjected to a materials identification check. The extent of random checking shall be subject to the stipulations in Table 8-4. The acceptance level shall be zero, regardless of the extent of random checking. 8.5 8.5.1 8.5.1.1 (1) Bolts and nuts made by machining from solutionannealed and quenched austenitic bars Tests and examinations on the bars Sampling and specimen preparation

The bars shall be tested in test units of at most 5000 kg, consisting of bars of the same dimension, same heat and same heat-treatment lot. 8.4.1.3 (1) Extent of tests and examinations

One ladle analysis shall be performed per heat.

(2) The mechanical and technological characteristics shall be determined by performing: a) Hardness test to DIN EN ISO 6506-1 as follows: with one indentation at one end of each bar of the test unit for bars with diameter larger than 120 mm; and with one indentation at one end of 10 % of the bars of the test unit for bars with diameter equal to or smaller than 120 mm, except that at least 10 bars or, if the test unit consists of fewer than 10 bars, every bar shall be tested. b) One room-temperature tensile test on the bars exhibiting the lowest and highest hardness values. c) One additional tensile test at 350 C on bars for fabrication of bolts of test group A 1, if the design temperature is higher than 100 C. d) One notched-bar impact bend test to clause 4.4.6.5 at room-temperature to determine the energy absorbed and lateral expansion for bars with diameters equal to or larger than 14 mm on both bars that were subjected to the tensile test. (3) The ultrasonic examination of the bars shall be subject to the following requirements: a) All bars with diameters equal to or larger than 30 mm for bolts and nuts shall be examined in quenched and tempered condition by the manufacturer for internal defects. During the acceptance procedure, 10 % of the bars for bolts or at least 10 of those bars per delivery and 5 % of the bars for nuts or at least 2 of those bars per delivery shall be examined by the authorized inspector. b) The ultrasonic examination shall be performed as follows: along two scan paths separated by 90 degrees for round bars; and along three scan paths separated by 60 degrees for hexagonal bars. All echo amplitudes corresponding to a circular-disk reflector diameter of 1.5 mm and larger shall be registered. To define the recording limit, a reference reflector in the form of a radial flat-bottomed hole with its bottom located at the center of the bar shall be made. The diameter of this hole shall be 4 to 6 mm. The cited sensitivity shall be adjusted by means of an appropriate gain increase. c) In the case of radial beam entry, indications up to 12 dB above the recording limit and up to a maximum length

Longitudinal specimens shall be taken.

(2) The axis of the tensile-test and notched-bar impact-test specimens shall be located at the center for sizes with diameters smaller than or equal to 25 mm and at least 12.5 mm under the surface for sizes with diameters larger than 25 mm. 8.5.1.2 Test units

The bars shall be tested in test units of at most 500 kg, consisting of bars of the same dimension, same heat and same heat-treatment lot. 8.5.1.3 (1) Extent of tests and examinations

One ladle analysis shall be performed per heat.

(2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test on one bar per test unit. b) One tensile test at 350 C on bars for fabrication of bolts of test group A 1, if the design temperature for test group A 1 is higher than 200 C. c) One notched-bar impact bend test to clause 4.4.6.5 at room-temperature for bars with diameters equal to or larger than 14 mm on the same bar that was subjected to the tensile test.

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(3) One test for resistance to intergranular corrosion to DIN EN ISO 3651-2 shall be performed per heat and heattreatment lot. (4) The ultrasonic examination of the bars shall be subject to the following requirements: a) All bars with diameters equal to or larger than 30 mm for bolts and nuts shall be examined in solution-annealed and quenched condition by the manufacturer for internal defects. During the acceptance procedure, 10 % of the bars for bolts or at least 10 of those bars per delivery and 5 % of the bars for nuts or at least 2 of those bars per delivery shall be examined by the authorized inspector. b) The ultrasonic examination shall be performed as follows: along two scan paths separated by 90 degrees for round bars; and along three scan paths separated by 60 degrees for hexagonal bars. All echo amplitudes corresponding to a circular-disk reflector diameter of 2 mm and larger shall be registered. To set the recording limit, a reference reflector in the form of a radial flat-bottomed hole with its bottom located at the center of the bar shall be made. The diameter of this hole shall be 4 to 6 mm. The cited examination sensitivity shall be adjusted by means of an appropriate gain increase. c) In the case of radial beam entry, indications up to 12 dB above the recording limit and up to a maximum length equal to the bar diameter of the bars for bolts and equal to half the bar diameter of the bars for nuts are permitted. The indication length shall be determined by the halfamplitude technique. (5) Each bar shall be subjected to visual inspection of its external finish. (6) (7) The marking on each bar shall be inspected. Each bar shall be inspected for dimensional accuracy.

(3) Each bar shall be subjected to a materials identification check. (4) The marking on each bar shall be inspected. Tests and examinations on finished parts

8.6.1.2

The tests and examinations shall be performed on the bolts and nuts themselves. If this is not possible because of the dimensions of the bolts and nuts, specimens for tensile and notched-bar impact bend tests shall be taken from bar segments that have been turned down to the heat-treatment diameter governing the heat treatment of the formed bolts and nuts and that have been heat-treated together with these bolts and nuts. In this case the stipulations of clause 8.4.1.1 shall apply to the sampling location. 8.6.1.3 Test units

(1) The test shall be performed after the final heat treatment on test units consisting of parts of similar dimension and originating from the same heat and same heat-treatment lot. (2) The number of pieces to be tested shall depend on the number of pieces in the test unit and on the test method. The stipulations in Table 8-5 shall apply. 8.6.1.4 Extent of tests and examinations

(8) Each bar shall be subjected to a materials identification check. 8.5.2 Tests and examinations on finished parts

(1) A surface-crack detection shall be performed randomly on the bolts and nuts. The extent of random examination and the acceptance levels shall be subject to the stipulations in Table 8-3. Indications that prove the presence of cracks are not permitted. Further findings shall be assessed per Table 8-10. (2) The main and secondary features of randomly checked bolts and nuts shall be examined per Table 8-2. The extent of random examination and the acceptance levels shall be subject to the stipulations in Table 8-3. Subject to agreement of the authorized inspector, it is permitted to supplement or replace the secondary features cited in Table 8-2 by application-specific requirements. (3) The marking shall be checked at random. The extent of random checking shall be subject to the stipulations in Table 8-3. (4) Bolts and nuts shall be randomly subjected to a materials identification check. The extent of random checking shall be subject to the stipulations in Table 8-4. The acceptance level shall be zero, regardless of the extent of random checking. 8.6 8.6.1 8.6.1.1 (1) Bolts and nuts made from ferritic bars by hot or cold forming and subsequently heat-treated Tests and examinations Tests and examinations on the bars

(1) The mechanical and technological characteristics shall be determined by performing: a) Hardness testing of the bolts and nuts of a test unit per Table 8-5 (DIN EN ISO 6506-1). If traveller bar segments were quenched and tempered for the tests to Sections 3 and 4, the hardness shall also be determined on these bar segments. b) One room-temperature tensile test on turned-down specimens to DIN EN ISO 898-1 or, in the case of testing of quenched and tempered traveller bar segments, on specimens to DIN 50 125. The piece for which the smallest value of hardness was determined in the hardness test shall also be subjected to this tensile test. c) One notched-bar impact bend test to clause 4.4.6.5 at room-temperature to determine the energy absorbed, for bolts larger than M 19 per Table 8-5; for bolts larger than M 24, the lateral expansion shall additionally be determined. The piece for which the largest value of hardness was determined in the hardness test shall also be subjected to this notched-bar impact bend test. (2) A drift test to DIN EN 493 shall be performed on nuts per Table 8-5. The piece for which the largest value of hardness was determined shall also be subjected to this drift test. (3) The non-destructive examinations shall be subject to the following requirements: A surface-crack detection shall be performed randomly on bolts and nuts. The extent of random examination and the acceptance levels shall be subject to the stipulations in Table 8-3. Indications that prove the presence of cracks are not permitted. Further findings shall be evaluated to Table 8-10. (4) In the dimensional check, the main and secondary features shall be randomly examined to Table 8-2. The extent of random checking and the acceptance levels shall be subject to the stipulation in Table 8-3. Subject to agreement of the authorized inspector, it is permitted to supplement or replace the secondary features cited in Table 8-2 by application-specific requirements. (5) The marking shall be checked at random. The extent of random checking shall be subject to the stipulations in Table 8-3.

One ladle analysis shall be performed per heat.

(2) Each bar shall be subjected to visual inspection of its external finish.

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(6) Bolts and nuts of alloyed steels shall be randomly subjected to a materials identification check. The extent of random checking shall be subject to the stipulations in Table 8-4. The acceptance level shall be zero, regardless of the extent of random checking. 8.7 8.7.1 8.7.1.1 Bolts and nuts of strength classes Tests and examinations Sampling and specimen preparation

(4) Bolts and nuts of austenitic steels shall be tested to DIN EN ISO 3506-1 and DIN EN ISO 3506-2. (5) Examinations and assessments for defect types per Table 8-7 shall be performed as follows: to DIN EN 26 157-3 for bolts, and to DIN EN 493 for nuts. (6) Bolts and nuts shall be subjected randomly to a dimensional check. The main and secondary features of Table 8-2 shall be examined. Subject to agreement of the authorized inspector, it is permitted to supplement or replace the secondary features cited in Table 8-2 by application-specific requirements. The number of pieces to be inspected and the acceptance levels shall be subject to the stipulations in Table 8-3. 8.8 8.8.1 Marking Marking of the bars

(1) The tests and examinations shall normally be performed on the bolts themselves. (2) If this is not possible because of the dimensions of the bolts: a) specimens for tensile and notched-bar impact bend tests in the case of ferritic steels shall be taken from bar segments that have been turned down to the heat-treatment diameter governing the quenching and tempering of the formed bolts and that have been heat-treated together with these bolts. In this case the stipulations of clause 8.4.1.1 shall apply for the sampling location, and b) bolts of correspondingly greater length shall be made for the tensile tests of each test unit in the case of austenitic steels. 8.7.1.2 Test units

(1) The marking shall be applied on labels for bars with diameters equal to or smaller than 25 mm and on the bars themselves for bars with diameters larger than 25 mm. (2) a) b) c) d) The marking shall contain the following information: manufacturer's symbol, steel grade, heat number, if necessary abbreviation and authorized inspector's mark. Marking of the bolts and nuts

The test shall be performed after the final heat treatment on test units consisting of parts of similar dimension and the same heat, originating from the same heat-treatment lot. The number of pieces to be tested shall depend on the number of pieces in the test unit. The stipulations in Table 8-6 shall apply. 8.7.1.3 Extent of tests and examinations

8.8.2

(1) Bolts of ferritic steels shall be tested to DIN EN ISO 898-1, test program A. If test program A is not feasible, the tests shall be performed per test program B. For dimensions larger than M 19, verification of energy absorbed shall be required. (2) For bolts of ferritic steels of strength class 8.8 for allowable operating temperatures higher than 50 C, the elevated-temperature yield point shall be verified at design temperature on specimens to DIN 50 125. (3) Nuts of ferritic steels shall be tested to DIN EN 20 898-2 or DIN EN ISO 898-6 in combination with DIN EN 493. Steel grades Unalloyed and alloyed ferritic steels Product form Bolts

The marking shall contain the following information: a) manufacturer's symbol, b) steel grade or strength class, c) the heat number for dimensions larger than M 52, if necessary an abbreviation for nuts, d) the authorized inspector's mark for bolts larger than M 52, e) a mark of correlation to the certificate for bolts larger than M 24, except for bolts of steels to Section 8.7. 8.9 Verification of quality characteristics

(1) The stipulations in Table 8-8 shall govern verification of the quality characteristics of parts as per Sections 8.4, 8.5 and 8.6. (2) The stipulations in Table 8-9 shall govern verification of the quality characteristics of bolts and nuts as per Section 8.7.

Strength class 5.6 and 8.8 per DIN EN ISO 898-1

Limits of application M 30 for the scope of application: 2.5 MPa and 100 C 1); strength class 8.8 only in combination with flanges DN 500 M 30 for the scope of application: < 4 MPa and 300 C; strength class 8 only in combination with flanges DN 500

Nuts

5-2 and 8 per DIN EN 20 898-2 or DIN EN ISO 898-6

Austenitic steels of steel groups A 2 2), Bolts and nuts A 3, A 4 2) and A 5 to DIN EN ISO 3506-1 and DIN EN ISO 3506-2

50 and 70 M 39, to DIN EN ISO 3506-1 to strength class 70 only for M 30 DIN EN ISO 3506-2

1) Without verification of the elevated temperature proof stress, bolts made of the steels for strength class 8.8 shall only be used up to 50 C. 2) Bolts and nuts from non-stabilized austenitic steel grades of groups A 2 and A 4 shall not be used if in permanent contact with the fluid.

Exceptions shall be agreed between purchaser and authorized inspector.

Table 8-1:

Limits of application of bolts and nuts to DIN EN ISO 898-1, DIN EN 20 898-2 and DIN EN ISO 898-6 as well as DIN EN ISO 3506-1 and DIN EN ISO 3506-2 Page 45

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Main features Thread limit dimensions (trueness to gauge size) Force-application areas for assembly Transition under the bolt head Thread root radius at the thread-to-shank transition Secondary features Lengths (bolt length, thread length) Deviations from shape and location Bearing surfaces Heights (head heights, nut heights) Diameters
Note: Further features as well as their classification can be defined in the purchase order.

Table 8-2:

Features to be inspected during the dimensional check as well as their classification as main or secondary features

Extent of random checking Number of pieces in the test unit Dimensional check for main features and check of identification marking Bolts up to 151 up to 281 up to 150 280 500 32 32 125 125 200 315 Nuts 20 20 80 80 125 200 Dimensional check for secondary features and surface crack detection Bolts 20 80 80 125 200 315 Nuts 13 50 50 80 125 200 0 0 1 1 2 3 Dimensional check for main features

Acceptance levels Dimensional check for secondary features and surface crack detection 0 1 1 2 3 5 Check of identification marking

0 0 0 0 0 0

501 up to 1200 1201 up to 3200 3201 up to 10000 Table 8-3:

Extent of random checking and acceptance levels for the dimensional check, surface-crack detection and check of identification marking

Number of pieces in the test unit 151 281 501 1201 3201 up to 150 up to 280 up to 500 up to 1200 up to 3200 up to 10000

Extent of random checking 1) 20 32 50 80 125 200

1) The acceptance level is always zero, regardless of the extent of random checking.

Table 8-4:

Extent of random materials identification checking on bolts and nuts

Hardness test

Tensile test Notched-bar impact bend test Drift test 8 13 20 32 50 80

Number of pieces per test unit Number of pieces to be tested Number of pieces per test unit Number of pieces to be tested 151 281 501 1201 3201 Table 8-5: up to 150 up to 280 up to 500 up to 1200 up to 3200 up to 10000 up to 300 301 up to 800 more than 800 1 2 4

Number of pieces to be subjected to the mechanical and technological tests of bolts and nuts to Section 8.6 Page 46

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Number of pieces per test unit (test lot) up to 201 up to 401 up to 801 up to 1201 up to 1601 up to 3001 up to 200 400 800 1200 1600 3000 3500

Number of pieces to be tested (extent of random checking) 1 2 3 4 5 6 7

If the bolts of one delivery verifiably originate from one heat with the same heat treatment, it will suffice to test 4 specimen sets regardless of the number of pieces.

Table 8-6:

Number of pieces to be subjected to the mechanical and technological tests of bolts and nuts to Section 8.7

Examination of Type of defect ferritic Hardening cracks Crop cracking Head cracks Shear cracks Score marks Pits Cracks in the thread Damage (e.g., tool marks) Bursting Wrinkling Table 8-7: X X X X X X X X X bolts austenitic X X X X X X X X ferritic X X X X X X X X X nuts austenitic X X X X X X X X

Defects of bolts and nuts of ferritic and austenitic steels per clause 8.7.1.3 (5) and testing for such defects (see Figure 8-1 for visible manifestations and Table 8-10 for assessment)

Type of required certificate to DIN EN 10 204 Test Bars to Section 8.4 and 8.5 for Bolts Nuts 2.2 2) 3.1.B 3.1.C 3.1.C 3.1.C 3.1.B 3.1.C 3.1.B 3.1.C 3.1.B 2.2 2) 3.1.B 3.1.B 3.1.B 3.1.C 3.1.B 3.1.B 3.1.B 3.1.B 3.1.B Finished parts to Section 8.4 and 8.5 Bolts 1) Nuts 1) 3.1.C 3.1.C 3.1.C 3.1.B 3.1.B 3.1.B 3.1.B 3.1.B Bars for parts to Section 8.6 2.2 3.1.B 3.1.B 3.1.B Finished parts to Section 8.6 Bolts 1) Nuts 1) 2.2 2) 3.1.B 3.1.C 3.1.C 3.1.C 3.1.C 3.1.C 3.1.B 2.2 2) 3.1.B 3.1.B 3.1.B 3.1.B 3.1.B 3.1.B 3.1.B

Ladle analysis Hardness test Strength test Notched-bar impact toughness test Drift test Non-destructive examination Resistance to intergranular corrosion 3) Visual inspection Dimensional check Inspection of the marking Materials identification check

1) Certificates for the tests on the bars are additionally necessary. 2) This verification may also be included in the acceptance test certificate. 3) For products to Section 8.5.

Table 8-8:

Review of required tests and test certificates for products to Sections 8.4, 8.5 and 8.6 Page 47

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Steel grades Unalloyed and alloyed ferritic steels Bolts Nuts Austenitic steel grades of steel groups A 2, A 3, A 4 and A 5

Product

Strength class 4.6 and 5.6 8.8 5 and 8 50 and 70

Certificate to DIN EN 10 204 3.1.B 1) 3.1.C 2) 3.1.B 1) 3.1.B

Bolts and nuts

1) The requirement of filling out an acceptance test certificate 3.1.B to DIN EN 10 204 may be waived if the manufacturer has constantly

carried out the tests necessary as basis for filling out an acceptance test certificate 3.1.B and has kept the results ready for review by the authorized inspector at all times. In this case the marking to Section 8.8 will suffice as the quality verification.
2) For pressure vessels for which the product of capacity [I] in liters and pressure [p] in MPa is less than or equal to 500 (l x p 500) an

acceptance test certificate 3.1.B to DIN EN 10 204 will suffice.

Table 8-9:

Review of required test certificates for bolts and nuts to Section 8.7

Defect type Pits (shallow depressions on the surface) Validity Full diameter bolts Nuts

Scoremarks Tool marks (narrow, straight or slightly curved depressions) Full diameter bolts Full diameter Nuts bolts Reducedshank bolts Nuts Figure 8-1 (Sketch 3)

Surface defects on the thread

Wrinkles

Damage

Full diameter bolts Reduced-shank bolts

Nuts

Full diameter bolts

Visible a) Bolt shank, manifestabearing surfaces tions, of the bolts and location nuts b) Other surfaces of the bolt head, of the nut Figure 8-1 (Sketch 1) Assessment criteria a) Bolts Permissible depth: 0.02 d, max. 0.25 mm Percentage of pit area 5% Bolts Permissible depth: 0.015 d + 0.1 mm max. 0.4 mm Permissible width: max. 0.13 mm

Figure 8-1 (Sketch 4)

Figure 8-1 (Sketch 5)

No definite geometric form, location or direction as external effect

Bolts Peak-to-valley height (RZ) 16 m

Tool marks on the transition between head Nuts Nuts Permissible depth: Permissible depth: and shank as well as on the 0.25 mm max. 0.3 mm Percentage of pit Permissible score shank are not permitted. area 5 % of depth: bearing surfaces 0.02 D Nuts Peak-to-valley b) Bolts height Permissible depth: (RZ) 16 m 0.03 d, on the bearing max. 0.4 mm surface Nuts Permissible depth: 0.02 D, max. 0.6 mm
D : thread end diameter (nuts) d : thread end diameter (bolts)

Shuts and laps are not permissible at the following places: - thread root - loaded thread flanks The following defects are permitted: - wrinkles with a depth of max. 0.25 H1 at the thread crests - thread crests not completely rolled out - shuts and laps, as long as they run toward the outside diameter on the unloaded flank and are not deeper than 0.25 H1 and at most are 1/2 turn on one thread

Wrinkles in the bearing surfaces and wrinkles penetrating into the bearing surfaces are not permitted.

If damage is present, the usability of the parts shall be decided on a case-by-case basis. Damage due to external effects shall not impair the function and usability of the parts.

RZ : averaged peak-to-valley height H1 : to DIN 13-19

Table 8-10:

Assessment criteria for surface irregularities of bolts and nuts

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Pits
Pits

Pits

Sketch 1

Score marks

Excessive rolling or score mark, normally straight or slightly bent path in longitudinal direction

Sketch 2

Score marks

Tool mark
Tool marks

Tool mark due to deburring

Sketch 3

Figure 8-1:

Visible manifestations and location of defects on bolts and nuts (Part 1)

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Loading direction Impermissible excessive rolling

0.25 H1

Outside diameter
H1

Pitch diameter Root diameter

Permissible excessive rolling

0.25 H1

Surface defects on the thread

Outside diameter
H1

Pitch diameter Root diameter

Permissible deviation from profile Outside diameter Pitch diameter

Sketch 4

Root diameter
Compression wrinkle on the end or bearing surface

Wrinkles

Compression wrinkle of the side

Compression wrinkle of the perimeter of the bearing surface of flange nuts

Sketch 5

Compression wrinkles

Figure 8-1:

Visible manifestations and location of defects on bolts and nuts (Part 2)

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9 9.1 9.1.1 (1)

Product forms of steels for special loads Forgings, bar steel and rolled rings Materials The following steel grades may be used:

a) X 4 CrNi 13 4 per SEW 400, b) other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspectors appraisal. (2) 9.1.2 The stipulations of clause 4.3.4 shall be met. Additional requirements for the materials

b) One tensile test at 350 C per heat, similar dimension and heat-treatment lot, if the design temperature is higher than 100 C. For piece weights heavier than 3000 kg in test group A 1, each piece shall be tested. c) One notched-bar impact bend test to clause 4.4.6.5 at room temperature per sampling location. d) One hardness test (at least 3 hardness indentations) to DIN EN ISO 6506-1 on each piece. (3) The non-destructive examinations shall be subject to the stipulations in Annex H. (4) Each piece shall be subjected to a materials identification check. (5) Each piece shall be subjected to a visual inspection of its external finish. (6) 9.1.4 A dimensional check shall be performed for each piece. Marking

(1) The surfaces shall be free of impurities. Scale layers and tempering colours developed during hot forming or heat treatment shall be removed. (2) The surface condition shall meet the requirements of non-destructive examination and be indicated in the purchase order. 9.1.3 9.1.3.1 Tests and examinations Sampling location and specimen preparation

(1) Specimens from the same heat, with similar dimensions and from the same heat-treatment lot shall be grouped into test units. One test unit shall contain at most 25 pieces but shall not weigh more than 500 kg. (2) Pieces with heat-treatment weights heavier than 500 kg, open-die forged flanges with a piece weigth havier than 300 g and hollow parts with a diameter exceeding 600 mm shall be tested individually. (3) The specimens shall be taken at one end of the pieces.

(1) Each piece shall be marked durably with the following information: a) manufacturer's symbol, b) steel grade, c) heat number, d) specimen number and e) authorized inspector's mark. (2) In the case of lotwise examination, the piece from which the specimens were taken shall additionally be marked. 9.1.5 Verification of quality characteristics

(4) The specimens of each test unit shall be taken from one piece. For bars or similar pieces that are longer than 3 m but are not heat-treated in the continuous furnace, specimens shall be taken from both ends of the piece selected for testing. (5) The sampling locations shall be at least one sixth of the diameter or one sixth of the heat-treatment thickness but not more than 30 mm under the heat-treatment surface. The tests shall be performed on transverse specimens. Longitudinal specimens are permitted in the following cases: tensile-test specimens for pieces with a cross-sectional area corresponing to solid parts with a diameter smaller than 160 mm; and notched-bar impact-test specimens for pieces with a crosssectional area corresponding to solid parts with a diameter smaller than 100 mm. (6) If welding followed by heat treatment will be performed during further processing, one test coupon shall be provided for traveller specimens. 9.1.3.2 Extent of tests and examinations

(1) The heat-treatment condition, results of the ladle analysis, product analysis, materials identification check and non-destructive examinations performed by the manufacturer shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. 9.2 9.2.1 Castings Materials

(1) The following cast-steel grades may be used: a) G-X 5 CrNi 13 4 to DIN 17 445 b) GX4CrNi13-4 to DIN EN 10 213-2 b) other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspector's appraisal. (2) 9.2.2 The stipulations of clause 4.3.4 shall be met. General casting finish

(1) The following procedures shall be performed for the chemical analysis: a) One ladle analysis per heat. b) One product analysis at one sampling location on each of two separately manufactured pieces per heat. If possible, the top or bottom of the starting ingot shall be tested. For pieces heavier than 5000 kg, the analysis shall be perormed on one sampling location of each piece. If possible, the top or bottom of the starting ingot shall be tested. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per sampling location.

(1) As regards their general internal and external finish, the castings shall satisfy the stipulations of Table B-2 applicable to their test group. (2) Feeder heads and large casting-related thickenings that impair amenability of the casting to the heat treatment shall be eliminated before the heat treatment for establishment of the mechanical and technological characteristics. (3) The casting technique shall be designed according to the principles of controlled solidification. For castings with nominal widths equal to or larger than 200 mm, the gate and feeder

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technique shall be explained on the basis of the saturation calculation as well as drawings illustrating the position of the feeders, feed zones and specimen location. For each casting model, the description of the casting technique shall be attached to the interim file (internal manufacturer documenation) for retention by the manufacturer.
Note: The feature characterizing the dimensions of the body or case shall be the nominal width, as follows: a) for pumps, the nominal width of the pressure nozzle, b) for valves, the largest nominal width involved, c) for safety valves, the nominal width of the inlet nozzle.

(3) The specimens shall be taken from cast-on test coupons or from overlengths. Separately cast test coupons are permitted only for castings with piece weights equal to or lighter than 150 kg. The test coupons shall be provided in sufficient number and size that the prescribed specimens can be taken. (4) The thickness of the cast-on test coupons shall be calculated by comparison of volume/surface ratios at the governing nominal wall thickness. However, it shall be at most 150 m. In this connection, the governing nominal wall thickness shall be the thickness of the wall subjected to pressure loading, and not the thickness of cast-on flanges or local thickenings. Cast-on test coupons at the gate system are not permitted. The specimens shall be taken at a distance of half the thickness of the cast-on test coupons from the end and side faces as well as at one quarter from one of the other faces. (5) For castings with piece weights heavier than 1000 kg, the position of the cast-on test coupons on the casting shall be documented by a photograph or in a sketch. 9.2.3.2 Extent of tests and examinations

(4) Together with the drawing of the casting in the asdelivered condition, the following documents shall generally be submitted as standard plans for the design approval: a) test and inspection sequence plan and heat-treatment plan, in case of differences from the standard production scheme to Figure B-12. b) for castings of test group A 1 with nominal widths larger than 200 mm, instructions for the non-destructive examinations as well as a coordinate reference system (reference-point grid). c) for prototypes of test groups A 2 and A 3 with nominal widths greater than 200 mm a film location plan and a radiation source plan, d) welding procedure qualification and welding procedure sheet for production welds and if applicable construction welds (see Annex C). e) test and inspection sequence plan for construction welds, if necessary. f) list of planned production control tests. (5) Stipulations for production welds including procedure inspection and production control test are listed in Annex C. (6) If changes are made compared with the conditions stipulated in the welding procedure sheet, or if a different welding method is chosen, the welding procedure sheet shall be resubmitted for design approval in this respect. 9.2.3 9.2.3.1 Tests and examinations Sampling and specimen preparation

(1) The following procedures shall be performed for the chemical analysis: a) One ladle analysis per heat. b) One product analysis for one sampling location per test unit. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per sampling location. The value of reduction of area at fracture shall also be determined for information. b) One tensile test at 350 C per heat, dimension and heattreatment lot, if the design temperature is higher than 100 C. The elevated-temperature tensile test is not required if the value of yield point determined in the roomtemperature tensile test is 30 N/mm2 or more above the required minimum value. c) One notched-bar impact bend test to clause 4.4.6.5 at room-temperature per sampling location. d) One hardness test on each piece to verify uniformity of the quenching and tempering treatment in the case of lotwise examination of castings of quenched and tempered steel. (3) The non-destructive examinations of the castings shall be subject to the stipulations in Annex B. (4) Each casting shall be subjected to a materials identification check. (5) Each casting shall be subjected in the as-delivered condition to a visual inspection of its surface finish. (6) Each casting shall be subjected in the as-delivered condition to a dimensional check. (7) Each casting shall be subjected in a condition suitable for the purpose, generally by the further processor, to a tightness test in the form of an internal pressure test, which shall be performed to DIN 50 104. Pressurizing fluid, pressure level and pressure-loading duration shall be indicated in the purchase order. However, the nominal pressure shall never lead to a load higher than 90 % of the 0.2 % proof stress of the cast-steel grade. 9.2.4 Marking

(1) Castings with a delivery weight equal to or lighter than 500 kg shall be tested in lots, and castings with a delivery weight heavier than 500 kg shall be tested individually. (2) The number of sampling locations shall be as indicated in the following table: The number of sampling locations shall be as indicated in Table 9-1. Product weight (delivery weight) in kg 100 Number of sampling locations 1

Test unit At most 2500 kg per heat, dimension and heat-treatment lot At most 10 pieces, but not more than 2500 kg per heat, dimension and heattreatment lot Individual piece Individual piece

> 100 up to 500

> 500 up to 1000 > 1000 Table 9-1:

1 2

Number of sampling locations on castings made of steels for special loads

(1) Each casting shall be marked with the following information: a) manufacturer's symbol,

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b) c) d) e)

cast-steel grade, heat number, specimen number and authorized inspectors mark. Verification of quality characteristics

c) One technological test to Table 10-1 at one end of each manufacturing length for tubes of test group A 1. For tubes of test groups A 2 and A 3, 20 % of every 100 manufacturing lengths of the same heat, dimension and heat treatment shall be subjected to a technological test to Table 10-1 at one end.

9.2.5

(1) The results of the ladle analysis, product analysis, materials identification check, non-destructive examinations performed by the manufacturer and hardness test shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204. A certificate documenting the heat-treatment condition shall be attached to the acceptance test certificate. (2) The results of all other tests and examinations shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. For castings with piece weights heavier than 1000 kg, a photograph or a sketch of the location of the cast-on test coupons on the casting shall be attached to the acceptance test certificate.

Nominal outside diameter Da in mm Da 21.3 21.3 < Da 38 Table 10-1:

Nominal wall thickness s of the tubes in mm s2 2<s4 Flattening test Flattening test Flattening test Ring expanding test

Dimensional ranges for application of the technological tests

10 10.1

Heat-exchanger tubes Seamless straight heat-exchanger tubes of ferritic steels with wall thicknesses smaller than or equal to 4 mm and with outside diameters smaller than or equal to 38 mm Materials

(3) Each tube shall be subjected examination to Annex E.

to

non-destructive

(4) Each tube shall be subjected to a materials identification check. (5) The inside and outside surfaces of each tube shall be subjected to a visual inspection. (6) The diameter and wall thickness shall be checked for dimensional accuracy at both ends of each tube. (7) Each tube shall be examined for leak tightness by an internal hydrostatic pressure test. The test pressure shall chosen such that the factor of safety relative to the yield point at room temperature is never less than 1.1; in general it shall be 8 MPa. If the tube is bent, the tightness test shall be performed on the bent tube. In this case the tightness test on the straight tube is not required. 10.1.3 Marking

10.1.1 (1) a) b) c) d) e)

The following steel grades may be used: St 35.8 III to DIN 17 175 15 Mo 3 to DIN 17 175 13 CrMo 4 4 to DIN 17 175 10 CrMo 9 10 to DIN 17 175 other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspectors appraisal. Tests and examinations Sampling and specimen preparation

10.1.2 10.1.2.1

(1) The tubes shall be tested in manufacturing lengths. Every hundred manufacturing lengths of the same production run, heat, dimension and heat treatment shall be grouped together as one test unit. (2) Specimens shall manufacturing lengths. be taken from the ends of

(1) Lists of tubes shall be maintained for tubes scheduled for bending. In this case the tubes shall be marked with heat number and tube number at one end. Other tubes may be marked in the same way if lists of tubes are maintained. The authorized inspectors mark shall be entered in the list of tubes. (2) If lists of tubes are not maintained, the tubes shall be marked at one end with the following information: a) manufacturers symbol, b) steel grade, c) heat number, d) tube number, e) authorized inspectors mark and f) mark of the non-destructive examinations performed if applicable. 10.1.4 Verification of quality characteristics (1) The results of the ladle analysis and examination of the starting material shall be documented with a manufacturers test certificate or with an acceptance test certificate 3.1.B to DIN EN 10 204. (2) The results of the materials identification check, tightness test and non-destructive examinations shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204.

(3) Specimen forms to DIN EN 10 002-1 may also be used for tensile tests. 10.1.2.2 Extent of tests and examinations

Note: The extent of tests and examinations shall apply both to tubes used as straight tubes and to tubes that will subsequently be bent.

(1)

One ladle analysis shall be performed per heat.

(2) The mechanical and technological characteristics shall be determined by performing: a) One pickling test on one disc of each round or square bar originating from the top end of an ingot, for tubes manufactured from rough-rolled round or square steel. Alternatively, an ultrasonic examination for shrinkage cavities may be performed at the manufacturers discretion. b) For each production run, two tensile tests for each of the first two test units and one tensile test for the further test units at one end of one manufacturing length.

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(3) The results of all other tests and examinations shall be documented for tubes of test group A 3 made of unalloyed steels with an acceptance test certificate 3.1.B to DIN EN 10 204, and for tubes of test groups A 1 and A 2 made of unalloyed steels as well as for all tubes made of alloyed steels shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. 10.2 Seamless bent heat-exchanger tubes of ferritic steels with wall thicknesses smaller than or equal to 4 mm and with outside diameters smaller than or equal to 38 mm Materials

10.2.3.2 (1)

Sampling and specimen preparation

Test coupons shall be taken from the ends of tube legs.

(2) Specimen forms to DIN EN 10 002-1 may also be used for tensile tests. 10.2.3.3 Extent of tests and examinations

10.2.1 (1) a) b) c) d) e)

The following steel grades may be used: St 35.8 III to DIN 17 175 15 Mo 3 to DIN 17 175 13 CrMo 4 4 to DIN 17 175 10 CrMo 9 10 to DIN 17 175 other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspectors appraisal. Starting tubes

(1) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test at one end of one tube per 100 bent tubes of the same heat, dimension and heat treatment for heat-treated tubes. b) One technological test to Table 10-1 at both ends of one tube per 100 bent tubes of the same heat, dimension and heat treatment for heat-treated tubes. (2) Each bent tube shall be subjected to a materials identification check. (3) The outside surface and, wherever it is accessible, the inside surface of each bent tube shall be subjected to a visual inspection. (4) A visual inspection and a magnetic-particle examination of the inside surface shall be performed on two cut-open elbows from the series of tubes with the smallest bend radius. (5) The diameter and wall thickness shall be checked for dimensional accuracy at both ends of each bent tube. In addition, the ovality, arc shape and leg length as well as the wall thickness shall be checked for dimensional accuracy on two cut-open elbows from the series of tubes with the smallest bend radius. (6) Each bent tube shall be examined for leak tightness by an internal hydrostatic pressure test. The test pressure shall chosen such that the factor of safety relative to the yield point at room temperature is never less than 1.1; in general it shall be 8 MPa. (7) The ball-pass test shall be performed on each bent tube. Marking

10.2.2

Only tubes per Section 10.1 may be used. Lists of tubes per clause 10.1.3 (1) shall be maintained for the tubes. 10.2.2.1 (1) Production methods

The bends shall be made by cold bending.

(2) Smooth transition from the tube leg to the tube elbow shall be demonstrated to the authorized inspector on a specimen bent prior to beginning bending work. (3) For the case of partial heat treatment of the bent zone, the quality of the transition zone shall be verified by a one-time appraisal of the authorized inspector. 10.2.2.2 Requirements for the geometric form of bent tubes

10.2.4 (1) Bulge-like transitions as well as any kind of wrinkles are not permitted. (2) The maximum allowable ovality shall be 0.10 x Di, where Di is the tube inside diameter (nominal diameter). (3) A ball of diameter DK = Di (largest permissible negative tolerance on size + 0.1 Di + 2 mm) shall pass through freely. 10.2.2.3 Heat treatment

(1) Lists of tubes shall be maintained for bent tubes. Each bent tube shall be marked with heat number and tube number at one end. The authorized inspectors mark shall be entered in the list of tubes. 10.2.5 Verification of quality characteristics

(1) Certificates per clause 10.1.4 shall be provided for the starting tubes. (2) The results of the materials identification check, tightness test and ball-pass test shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204, which shall also indicate the heat-treatment condition of the bent tubes. (3) The results of all other tests and examinations shall be documented for bent tubes of test group A 3 made of unalloyed steels with an acceptance test certificate 3.1.B to DIN EN 10 204, and for bent tubes of test groups A 1 and A 2 made of unalloyed steels as well as for all tubes made of alloyed steels shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204.

(1) Heat treatment is not required after cold bending of tubes with bend radius rm equal to or larger than 1.3 x Da. (2) Heat treatment of the bent zone or of the entire tube to the instructions of DIN 17 175 for annealing after cold processing shall be performed after cold bending of tubes with a bend radius rm smaller than 1.3 x Da. 10.2.3 10.2.3.1 Tests and examinations Heat-treatment condition of specimens

Verification of the mechanical and technological characteristics shall be required only if the entire tube was heat-treated after bending. In this case the test coupons shall be taken from the product after the last heat treatment.

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10.3

Seamless straight heat-exchanger tubes of austenitic steels with wall thicknesses smaller than or equal to 3.6 mm and with diameters smaller than or equal to 42.4 mm Materials

(5) Each tube shall be subjected to a materials identification check. (6) The inside and outside surfaces of each tube shall be subjected to a visual inspection. (7) The diameter and wall thickness shall be checked for dimensional accuracy at both ends of each tube. (8) Each tube shall be examined for leak tightness by an internal hydrostatic pressure test. The test pressure shall chosen such that the factor of safety relative to the yield point at room temperature is never less than 1.1; in general it shall be 8 MPa. If the tube is bent, the tightness test shall be performed on the bent tube. In this case the tightness test on the straight tube is not required. 10.3.3 Marking

10.3.1 (1) a) b) c) d) e)

The following steel grades may be used: X 6 CrNiTi 18 10 to DIN 17 458 X 6 CrNiNb 18 10 to DIN 17 458 X 6 CrNiMoTi 17 12 2 to DIN 17 458 X 6 CrNiMoNb 17 12 2 to DIN 17 458 other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspectors appraisal. Tests and examinations Sampling and specimen preparation

10.3.2 10.3.2.1 (1)

The tubes shall be tested in manufacturing lengths.

(2) Specimens shall be taken from the ends of manufacturing lengths. (3) Specimen forms to DIN EN 10 002-1 may also be used for tensile tests. 10.3.2.2 Extent of tests and examinations

(1) Lists of tubes shall be maintained for tubes scheduled for bending. In this case the tubes shall be marked with heat number and tube number at one end. Other tubes may be marked in the same way if lists of tubes are maintained. The authorized inspector's mark shall be entered in the list of tubes. (2) If lists of tubes are not maintained, the tubes shall be marked with the following information: a) manufacturer's symbol, b) steel grade with abbreviation for the type of construction and the designation S for seamless products to DIN 17 458, c) heat number, d) tube number, e) authorized inspector's mark and f) mark of the non-destructive examinations performed if applicable.

Note: The extent of tests and examinations shall apply both to tubes used as straight tubes and to tubes that will subsequently be bent.

(1)

One ladle analysis shall be performed per heat.

(2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per 100 manufacturing lengths of the same heat, dimension and heat treatment. b) One technological test to Table 10-2 at one end of each manufacturing length for tubes of test group A 1. The extent of testing shall be reduced to 25 % of the tubes for test group A 2 and to 2 % of the tubes for test group A 3. Diameter of the tubes in mm outside (Da) Da 21.3 inside (Di) Di > 15 Di 15 Di > 15 Di 15 Nominal wall thickness s of the tubes in mm s2 Flattening test Flattening test Flattening test 2<s4 Ring expanding test 1) Flattening test Ring expanding test 1) Ring expanding test 1)

10.3.4

Verification of quality characteristics

(1) The results of the ladle analysis shall be documented with a manufacturer's test certificate or with an acceptance test certificate 3.1.B to DIN EN 10 204. (2) The results of the materials identification check, tightness test, test for resistance to intergranular corrosion and nondestructive examinations shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204. (3) The results of all other tests and examinations shall be documented for tubes of test group A 3 with an acceptance test certificate 3.1.B to DIN EN 10 204, and for tubes of test groups A 1 and A 2 shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. 10.4 Seamless bent heat-exchanger tubes of austenitic steels with wall thicknesses smaller than or equal to 3.6 mm and with diameters smaller than or equal to 42.4 mm Materials

21.3 < Da 42.4

1) At the manufacturers discretion, the ring expanding test may

be replaced by the drift test.

10.4.1 Table 10-2: Dimensional ranges for application of technological tests to tubes (1) a) b) c) d) e)

(3) One test for resistance to intergranular corrosion to DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 C) shall be performed per heat and heat treatment. (4) Each tube shall be subjected to non-destructive examination to Annex E.

The following steel grades may be used: X 6 CrNiTi 18 10 to DIN 17 458 X 6 CrNiNb 18 10 to DIN 17 458 X 6 CrNiMoTi 17 12 2 to DIN 17 458 X 6 CrNiMoNb 17 12 2 to DIN 17 458 other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspector's appraisal.

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10.4.2

Starting tubes

Only tubes to Section 10.3 may be used. Lists of tubes shall be maintained for the tubes. 10.4.2.1 (1) Production methods

inspection. A visual inspection and a liquid-penetrant examination shall be performed on two cut-open elbows from the series of tubes with the smallest bend radius. (5) The diameter and wall thickness shall be checked for dimensional accuracy at both ends of each bent tube. In addition, the ovality, bend shape and leg length shall be checked for dimensional accuracy and the wall thickness shall be measured on two cut-open elbows from the series of tubes with the smallest bend radius. (6) Each bent tube shall be examined for leak tightness by an internal hydrostatic pressure test. The test pressure shall chosen such that the factor of safety relative to the yield point at room temperature is never less than 1.1; in general it shall be 8 MPa. (7) One ball-pass test shall be performed on each bent tube. Marking

The bends shall be made by cold bending.

(2) Smooth transition from the tube leg to the tube elbow shall be demonstrated to the authorized inspector on a specimen bend prior to beginning bending work. (3) For the case of partial heat treatment of the bent zone, the quality of the transition zone shall be verified by a one-time appraisal of the authorized inspector. 10.4.2.2 Requirements for the geometric form of bent tubes

(1) Bulge-like transitions as well as any kind of wrinkles are not permitted. (2) The maximum permissible ovality shall be 0.10 x Di, where Di is the tube inside diameter (nominal diameter). (3) A ball of diameter DK = Di (largest permissible negative tolerance on size + 0.1 Di + 2 mm) shall pass through freely. 10.4.2.3 Heat treatment

10.4.4

The bent tubes shall be marked with heat number and tube number at one end. The authorized inspector's mark shall be entered in the list of tubes. 10.4.5 Verification of quality characteristics

(1) Certificates per clause 10.3.4 shall be provided for the starting tubes. (2) The results of the materials identification check, tightness test, ball-pass test and test for resistance to intergranular corrosion shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204, which shall also indicate the heat-treatment condition of the bent tubes. (3) The results of all other tests and examinations shall be documented for bent tubes of test group A 3 with an acceptance test certificate 3.1.B to DIN EN 10 204, and for bent tubes of test groups A 1 and A 2 shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204. 10.5 Longitudinally welded straight heat-exchanger tubes of austenitic steels with wall thicknesses smaller than 2 mm and with diameters Da smaller than or equal to 38 mm Materials

(1) Heat treatment is not required after cold bending of tubes with bend radius rm larger than or equal to 1.3 x Da. (2) The bent zone or the entire tube shall be subjected to solution annealing or to annealing in the temperature range of stabilization annealing after cold bending of tubes with a bend radius rm smaller than 1.3 x Da. 10.4.3 10.4.3.1 Tests and examinations Heat-treatment condition of specimens

Verification of the mechanical and technological characteristics shall be required only if the entire tube was heat-treated after bending. In this case the test coupons shall be taken from the product form after the heat treatment (solution annealing and quenching). 10.4.3.2 (1) Sampling and specimen preparation

10.5.1

Test coupons shall be taken from the ends of tube legs.

(2) Specimen forms to DIN EN 10 002-1 may also be used for tensile tests. 10.4.3.3 Extent of tests and examinations

(1) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per 100 bent tubes of the same heat, dimension and heat treatment for heattreated tubes. b) One technological test to Table 10-2 at the end of both legs of one tube per 100 tubes of the same heat, dimension and heat treatment for heat-treated tubes. (2) One test for resistance to intergranular corrosion to DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 C) shall be performed per heat and heat treatment. (3) Each bent tube shall be subjected to a materials identification check. (4) The outside surface and, wherever it is accessible, the inside surface of each bent tube shall be subjected to a visual

(1) The following steel grades may be used: a) X 6 CrNiTi 18 10 to DIN 17 457 b) X 6 CrNiMoTi 17 12 2 to DIN 17 457 c) other steel grades meeting the prerequisites of Section 3 in combination with the stipulations in the authorized inspector's appraisal. 10.5.2 Additional requirements

(1) Only tubes drawn and sunsequently heat-treated after welding are permitted. (2) The requirements of surface finish and dimensional tolerances shall be determined per purchaser's specifications, but shall be at least as follows: a) surface finish d2 to DIN 17 457, b) thickness tolerances: ISO tolerance, class T3 to DIN EN ISO 1127 and c) the allowable deviation of outside diameter and ovality as per ISO tolerance, class D2.

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10.5.3 10.5.3.1 (1)

Tests and examinations Sampling and specimen preparation

The tubes shall be tested in manufacturing lengths.

(2) Specimens shall be taken from the ends of manufacturing lengths. (3) Specimen forms to DIN EN 10 002-1 may also be used for tensile tests. 10.5.3.2 Extent of tests and examinations

(8) Each tube shall be examined for leak tightness by an internal hydrostatic pressure test. The test pressure shall chosen such that the factor of safety relative to the yield point at room temperature is never less than 1.1; in general it shall be 8 MPa. 10.5.4 Marking

(1) The chemical composition shall be determined by performing one ladle analysis of the starting material per heat. (2) The mechanical and technological characteristics shall be determined by performing: a) One room-temperature tensile test per 100 manufacturing lengths of the same heat, dimension and heat treatment. b) One flattening test at both ends of each manufacturing length. (3) One test for resistance to intergranular corrosion to DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 C) shall be performed per heat and heat treatment. (4) Each tube shall be subjected examination to Annex E. to non-destructive

(1) If lists of tubes are not maintained, the tubes shall be marked at one end with the following information: a) manufacturer's symbol, b) steel grade with abbreviation for the type of construction and the gesignation W for welded construction, c) heat number, d) tube number, e) authorized inspector's mark and f) mark of the non-destructive examinations performed. 10.5.5 Verification of quality characteristics

(1) The results of the ladle analysis, materials identification check, tightness test, test for resistance to intergranular corrosion and non-destructive examinations shall be documented with an acceptance test certificate 3.1.B to DIN EN 10 204. (2) The results of all other tests and examinations shall be documented for tubes of test group A 3 with an acceptance test certificate 3.1.B to DIN EN 10 204, and for tubes of test groups A 1 and A 2 shall be certified by the authorized inspector and combined with the above-mentioned certificates as an acceptance test certificate 3.1.C to DIN EN 10 204.

(5) Each tube shall be subjected to a materials identification check. (6) The outside and inside surfaces of each tube shall be subjected to a visual inspection. (7) The diameter and wall thickness shall be checked for dimensional accuracy at both ends of each tube.

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Annex A Material characteristic data

A 1 Ferritic steels of material group W I for sheets and plates as well as parts made from sheets and plates A 1.1 General Section A 1 defines the details for manufacture, chemical composition, characterizing mechanical and technological characteristics and heat treatment as well as for further processing of the following steel grades a) 15 MnNi 6 3 b) 20 MnMoNi 5 5 c) 15 NiCuMoNb 5 S d) WStE 255 S e) WStE 285 S f) WStE 315 S g) WStE 355 S for plates and parts made from plates. A 1.2 Manufacture of the materials and delivery condition A 1.2.1 Manufacture (1) The steels shall be smelted by the basic oxygen process or in the electric furnace. If other processes are used, proof of equivalence shall be furnished. (2) The steels shall be made in particularly killed condition.

(2) The characteristic values of the mechanical and technological characteristics in the elevated-temperature tensile test are stipulated in Table A 1-3. The test temperatures for carrying out the elevated-temperature tensile test shall be as follows: a) 15 MnNi 6 3 300 C b) 20 MnMoNi 5 5 350 C c) 15 NiCuMoNb 5 S 350 C d) WStE 255 S 300 C e) WStE 285 S 300 C f) WStE 315 S 300 C g) WStE 355 S 300 C (3) The characteristic values of energy absorbed and lateral expansion of Charpy V-notch specimens are stipulated in Table A 1-4. (4) The data for energy absorbed and lateral expansion shall apply to standard specimens with a specimen width of 10 mm. (5) For nominal thicknesses smaller than 10 mm, the characteristic values of energy absorbed shall be reduced as a function of specimen width, moreover, the stipulations for lateral expansion shall be waived. (6) The mechanical and technological characteristics shall be verified on specimens subjected to simulated stress-relief annealing. Unless otherwise agreed in the purchase order, the conditions for simulated stress-relief annealing shall be as follows: a) holding time: 900 minutes, b) annealing temperature: 560 C to 580 C, 600 C to 620 C for steel grades 20 MnMoNi 5 5 and 15 NiCuMoNb 5 S. (7) The characteristic values shall apply to specimens taken and tested as per the stipulations in the Sections relating to product forms. The stipulations of Table A 1-5 shall be taken into consideration for plates. A 1.3.3 Grain size (1) The steels listed below shall have ferrite grain sizes as shown by EURONORM 103-71: a) 15 MnNi 6 3 at least grain size classification number 6, b) 20 MnMoNi 5 5 at least grain size classification number 5, c) 15 NiCuMoNb 5 S at least grain size classification number 6, d) WStE 255 S at least grain size classification number 6, e) WStE 285 S at least grain size classification number 6, f) WStE 315 S at least grain size classification number 6, g) WStE 355 S at least grain size classification number 6. (2) For steels with contents of bainitic structure, the requirements shall apply only to the microstructural proportions of polygonal ferrite. A 1.3.4 Physical characteristics

A 1.2.2 Delivery condition (1) The usual delivery condition for the steel grades is as follows: a) 15 MnNi 6 3 normalized b) 20 MnMoNi 5 5 quenched and tempered in liquid c) 15 NiCuMoNb 5 S normalized and tempered d) WStE 255 S normalized e) WStE 285 S normalized f) WStE 315 S normalized g) WStE 355 S normalized (2) If the governing heat treatment is performed during further processing, the plates to be supplied in normalized condition may also be delivered in rolled condition, and the plates to be supplied in quenched and tempered condition may also be delivered in normalized or tempered condition or, in special cases, even in rolled condition. (3) In special cases, a tempering treatment may be necessary for steel grades 15 MnNi 6 3 and WStB 355 S. This tempering treatment shall be indicated in the certificate. A 1.3 Material characteristic values A 1.3.1 Chemical composition The values stipulated in Table A 1-1 shall apply to the chemical composition per the ladle and product analyses. A 1.3.2 Mechanical and technological characteristics (1) The characteristic values of the mechanical and technological characteristics in the room-temperature tensile test are stipulated in Table A 1-2.

Reference values for the physical characteristics can be found in Annex AP.

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A 1.4 Data on heat treatment Reference values for heat treatment are presented in Table A 1-6. A 1.5 Forming A 1.5.1 Hot forming
Note: Hot forming shall designate forming at temperatures above the highest temperature permissible for stress-relief annealing, even if the product forms are heated to the corresponding temperature only locally, in the forming zone. The term hot forming shall also include adaptation and straightening work at the corresponding temperatures.

(2) Stress-relief annealing shall be required after forming with degrees of cold forming between 2 % and smaller than or equal to 5 %, (3) The governing heat treatment shall be performed after cold forming with degrees of forming larger than 5 %. (4) For plates with a degree of cold forming not exceeding 10 %, stress-relief annealing may be performed instead of the governing heat treatment if it is proved on a case-by-case basis that the stipulations for mechanical and technological characteristics are met. (5) If different procedures equivalence shall be furnished. are employed, proof of

(1) For hot forming, the plates shall be heated above the lower limit temperature for normalization but not above 1050 C. Grain coarsening due to excessively long times or to overheating shall be avoided. (2) After hot forming, the complete product forms shall be subjected to renewed heat treatment as per the data in Table A 1-6. (3) If the complete product form was heated above the lower limit temperature for normalization but not above 1000 C in the case of one-time hot forming or before the last step of hot forming in the case of hot forming in several steps, and if the forming process was completed above 750 C, or above 700 C in the case that the degree of forming in the last step did not exceed 5 %, subsequent normalization is not required for steel grades 15 MnNi 6 3, WStE 255 S, WStE 285 S, WStE 315 S and WStE 355 S; steel grade 15 NiCuMoNb 5 S shall merely require to be tempered. However, hot forming in several steps is subject to the condition that, before being heated for the last step, the product form in the case of steel grades 15 MnNi 6 3, WStE 255 S, WStE 285 S, WStE 315 S und WStE 355 S be cooled to a temperature below 550 C and in the case of steel grade 15 NiCuMoNb 5 S be cooled to a temperature below 350 C. (4) The temperature control program shall be monitored.

A 1.6 Thermal cutting and welding A 1.6.1 Thermal cutting SEW 088 shall be taken into consideration for thermal cutting. Recommended preheating temperatures are presented in Table A 1-7. A 1.6.2 Welding (1) Use of the following welding methods has been appraised as suitable for the steel grades to this Annex: a) manual arc welding with basic-flux-coated rod electrodes, b) submerged-are welding with basic fluxes, c) inert-gas-shielded welding with wire electrodes or with basic-flux-cored wire electrodes. (2) The examined work areas for welding are listed in Table A 1-7. Other work areas for welding are permitted, provided procedure qualification tests per KTA 3211.3 have been performed. (3) The stipulations for welding per SEW 088 shall be observed. The content of diffissible hydrogen, determined to DIN 8572-1 and DIN 8572-2, shall not exceed HD5 to DIN 8572-E in manual arc welding or HD7 to DIN 8572-UP in submerged-arc welding. (4) Post-weld stress-relief annealing may be required, depending on wall thickness and geometry of the parts. The nominal thicknesses at which stress-relief annealing may be waived are listed in Table A 1-7. (5) Post-weld non-destructive examinations shall be performed after a waiting time of at least 48 hours after completion of the welding work. The waiting time may be waived for welds that are subjected to stress-relief annealing, hydrogen degassing or delayed cooling, or that were welded under shield gas.

(5) If the procedures employed differ from stipulations (1) to (3), e.g., in the case of forming with local heating without subsequent heat treatment of the complete product form, proof of equivalence shall be furnished. A 1.5.2 Cold forming
Note: Cold forming shall designate forming at room temperature or with heating up to the highest temperature permissible for stress-relief annealing.

(1) Heat treatment is not required after cold forming with degrees of forming smaller than or equal to 2 %.

Page 59

Steel grade C Ti V 0.020 0.020 0.020 0.020 0.020 0.020 0.30 0.005 0.084) 0.114) 0.304) 0.254) 0.184) 0.254) 0.022 0.344) 0.304) 0.344) 0.084) 0.114) 0.084) 0.114) 0.005 0.005 0.005 0.005 0.005 0.005 0.35 0.30 0.35 0.30 0.35 0.305) 0.355) 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.015 0.005 0.015 0.015 0.06 0.15 0.05 0.004 0.010 0.013 0.011 0.0113) 0.004 0.20 0.20 0.20 0.30 0.35 0.304) 0.344) 0.304) 0.344) 0.114) 0.084) 0.07 0.12 0.016 0.025 0.016 0.013 0.0133) 0.025 0.020 0.010 0.020 0.006 0.020 0.020 0.015 0.015 0.025 0.020 0.020 0.020 0.015 0.015 0.025 0.020 0.020 0.020 0.015 0.015 0.025 0.020 0.020 0.020 0.015 0.015 0.025 0.020 0.020 0.022 0.020 0.184) 0.022 0.254) 0.020 0.184) 0.022 0.254) 0.020 0.184) 0.005 0.022 0.007 0.008 0.017 0.012 0.0123) 0.0123) 0.016 0.005 Si P Mo Nb Ni Sn Mn S Altotal

KTA 3211.1

Verification by

Limit value

Content by mass, % 1) 2) Cr Cu N As

15 MnNi 6 3

Ladle analysis

Product analysis

20 MnMoNi 5 5

Ladle analysis

Product analysis 0.17 0.19 0.18 0.40 0.45 0.40 0.45 0.45 0.20 0.18 0.20 0.18 0.20 0.20 0.22

0.12 0.18 0.10 0.20 0.17 0.23 0.15 0.25 0.020 0.055 0.015 0.065 0.010 0.040 0.010 0.050 0.015 0.123) 0.50 0.80 0.45 0.85 0.015 0.025 0.010 0.030 0.05 0.40 0.55 0.403) 0.55 0.25 0.40 0.20 0.45

15 NiCuMoNb 5 S

Ladle analysis

Product analysis

0.15 0.35 0.15 0.37 0.15 0.30 0.10 0.35 0.25 0.50 0.21 0.54

0.50 0.85 0.50 0.90 0.50 0.80 0.45 0.85 1.00 1.30 0.95 1.35

WStE 255 S

Ladle analysis

Product analysis

WStE 285 S

Ladle analysis

Page 60

Product analysis

WStE 315 S

Ladle analysis

Product analysis

WStE 355 S

Ladle analysis

Product analysis

min. max. min. max. min. max. min. max. min. max. min. max. min. max. min. max. min. max. min. max. min. max. min. max. min. max. min. max. 0.50 0.10 0.50 0.05 0.55 1.20 1.65 1.15 1.70 1.20 1.50 1.15 1.55 0.80 1.20 0.75 1.25 0.40 1.30 0.30 1.40 0.50 1.40 0.40 1.50 0.60 1.50 0.50 1.60 0.90 1.65 0.80 1.75

1) The differences that the tabulated values indicate between chemical compositions per the ladle and product analyses are sometimes smaller than would be expected from the metallurgical relationship.

The reason is that the limit values for chemical composition per the product analysis are in this case based only on the heats covered by the appraisal. Thus the values will be reviewed once additional documents become available. 2) If the indicated limit contents per the ladle analysis are exceeded, the limit contents per the product analysis shall govern. 3) If these values are exceeded and allowance must be made in the product analysis for contents up to P 0.015 %, S 0.015 %, Mo 0.63 %, Cu 0.18 %, Sn 0.016 % and N total 0.015 %, the authorized inspector shall check, until further information becomes available, as to whether welding simulation tests and if necessary tangential microsection examinations are necessary. If intermediate annealing at 550 C is planned during further processing, the permissibility of this annealing temperature shall be verified during the said tests or examinations. The scope and conduct of these tests shall be agreed with the authorized inspector. The tests may be waived if so stipulated in the material appraisal. 4) The sum of the contents of chromium, copper and molybdenum shall not exceed 0.45 % in the ladle analysis or 0.50 % in the product analysis. 5) Depending on the authorized inspector's appraisal relative to the individual manufacturer, the maximum permissible nickel content shall be 0.85 % in the ladle analysis and 0.90 % in the product analysis.

Table A 1-1: Chemical composition of steel grades per the ladle and product analyses

KTA 3211.1

Steel grade

Nominal thickness s in mm

Tensile strength Rm in N/mm2

Yield point 1) ReH in N/mm2 at least

Elongation at fracture A in % at least

Specimen direction

Reduction of area at fracture Z in % (individual value) at least

15 MnNi 6 3

15 MnNi 6 3 normalized and stress-reliefannealed 20 MnMoNi 5 5

15 NiCuMoNb 5 S

WStE 255 S

WStE 285 S

WStE 315 S

WStE 355 S

5 < s 38 38 < s 50 50 < s 80 80 < s 100 100 < s 150 5 < s 38 38 < s 50 50 < s 80 80 < s 100 100 < s 150 30 < s 70 70 < s 150 150 < s 600 s 35 35 < s 50 50 < s 70 70 < s 85 85 < s 100 100 < s 125 125 < s 150 s 35 35 < s 50 50 < s 70 70 < s 85 85 < s 100 100 < s 125 125 < s 150 150 < s 250 s 35 35 < s 50 50 < s 70 70 < s 85 85 < s 100 100 < s 125 125 < s 150 150 < s 250 s 35 35 < s 50 50 < s 70 70 < s 85 85 < s 100 100 < s 125 125 < s 150 150 < s 250 s 35 35 < s 50 50 < s 70 70 < s 85 85 < s 100 100 < s 125 125 < s 150 150 < s 250

510 to 630 510 to 630 490 to 610 470 to 600 470 to 650 490 to 610 490 to 610 490 to 610 470 to 600 470 to 600 590 to 730 570 to 710 560 to 700 610 to 780 610 to 780 600 to 760 600 to 760 600 to 760 600 to 750 590 to 740 360 to 480 360 to 480 360 to 480 350 to 470 340 to 460 330 to 450 320 to 440 310 to 430 390 to 510 390 to 510 390 to 510 380 to 500 370 to 490 360 to 480 350 to 470 340 to 470 440 to 560 440 to 560 440 to 560 430 to 550 420 to 540 410 to 530 400 to 520 390 to 520 490 to 630 490 to 630 490 to 630 480 to 620 470 to 610 460 to 600 450 to 590 440 to 590

370 350 330 320 310 330 330 330 320 310 450 430 390 440 440 430 430 430 420 410 255 245 235 225 215 205 195 185 285 275 265 255 245 235 225 215 315 305 295 285 275 265 255 245 355 345 335 325 315 305 295 285

22

longitudinal or transverse

45

22

longitudinal or transverse longitudinal or transverse

45

18

45 2) 45 45

16

25

23

24

22

23

21

22

20

1) If the yield point is not emphasized, the values shall be applicable for the 0.2 % proof stress. 2) For the steel grade 20 MnMoNi 5 5, the reduction of area at fracture shall additionally be subject to a smallest individual value of 35 % and a mean

value of 45 % on perpendicular specimens.

Table A 1-2: Characteristic values of the mechanical and technological characteristics in the room-temperature tensile test on longitudinal and transverse specimens Page 61

KTA 3211.1

Steel grade for nominal thicknesses in mm > 50 80 > 50 80 > 80 100 > 80 150 5 50 > 100 150 at least for nominal thicknesses in mm

Test temperature

Tensile strength Rm in N/mm2 at least Elongation at fracture A in %

0.2 % proof stress Rp0.2 in N/mm2 at least

in C

5 50

15 MnNi 6 3 normalized

15 MnNi 6 3 normalized and stress-reliefannealed

100 145 200 250 300 350 100 145 200 250 300 350 440 420 410 410 410 410 420 410 410 400 400 400 for nominal thicknesses in mm > 30 70 > 70 150 412 392 371 363 358 353 382 371 353 343 338 333 431 412 392 382 377 371 > 150 200 > 200 320 370 360 350 343 330 320 > 320 600 370 350 330 315 300 290 > 150 600 520 505 505 505 505 490 340 320 290 270 250 230 300 290 260 250 230 210 for nominal thicknesses in mm > 70 150 530 510 510 510 505 500

470 450 440 440 440 440 420 410 410 400 400 400 460 440 430 430 430 430 420 410 410 400 400 400 315 290 260 250 230 210 300 290 260 250 230 210 295 270 240 230 210 190 280 270 240 230 210 190 305 280 250 240 220 200 290 280 250 240 220 200

Page 62

30 70

20 MnMoNi 5 5

100 200 300 350 375 400

550 530 530 530 530 530

17 16 16 16 16 16

Table A 1-3: Characteristic values of the mechanical and technological characteristics in the elevated-temperature tensile test on longitudinal and transverse specimens (Part 1)

Steel grade > 150 250

Test temperature

in C

Elongation at fracture A in % at least

15 NiCuMoNb 5 S

WStE 255 S

WStE 285 S

Page 63

WStE 315 S

WStE 355 S

100 150 200 250 300 350 400 100 150 200 250 300 350 400 100 150 200 250 300 350 400 100 150 200 250 300 350 400 100 150 200 250 300 350 400 167 147 137 117 88 68 59 196 176 157 137 108 88 68 216 196 176 157 127 108 88 245 225 206 186 167 147 117

70 540 530 520 520 520 510 500 335 315 300 290 290 280 270 360 345 330 320 320 305 295 400 385 370 360 360 350 340 430 420 410 400 400 390 380 35 402 392 383 373 363 353 333 226 206 186 167 137 118 108 255 235 206 186 157 137 118 275 255 226 206 177 157 137 304 284 255 235 216 196 167

Tensile strength Rm in N/mm2 at least for nominal thicknesses in mm > 70 > 85 > 100 > 125 > 150 85 100 125 150 250 540 540 530 520 530 530 520 510 520 520 510 500 520 520 510 500 520 520 510 500 510 510 500 490 500 500 490 480 325 315 305 300 290 305 295 285 280 270 290 280 270 265 255 280 270 260 255 245 280 270 260 255 245 270 260 250 245 235 260 250 240 235 225 350 340 330 320 310 335 325 315 305 295 320 310 300 290 280 310 300 290 280 270 310 300 290 280 270 295 285 275 270 265 285 275 265 260 255 390 380 370 360 350 375 365 355 345 335 360 350 340 330 320 350 340 330 320 310 350 340 330 320 310 340 330 320 310 300 330 320 310 300 290 420 410 400 390 380 410 400 390 380 370 400 390 380 370 360 390 380 370 360 350 390 380 370 360 350 380 370 360 350 340 370 360 350 340 330 > 35 70 402 392 383 373 363 353 333 216 196 186 167 137 118 108 245 226 206 186 157 137 118 265 245 226 206 177 157 127 294 275 255 235 216 196 167 > 125 150 382 373 363 353 343 333 313 177 157 147 127 98 78 69 206 186 167 147 118 98 78 226 206 186 167 137 118 98 255 235 216 196 177 157 127

0.2 % proof stress Rp0.2 in N/mm2 at least for nominal thicknesses in mm > 85 > 70 > 100 85 100 125 402 402 392 392 392 382 383 383 373 373 373 363 363 363 353 353 353 343 333 333 323 206 196 186 186 177 167 177 167 157 157 147 137 127 118 108 108 98 88 98 88 78 235 226 216 216 206 196 196 186 177 177 167 157 147 137 127 127 118 108 108 98 88 255 245 235 235 226 216 216 206 196 196 186 177 167 157 147 147 137 127 118 118 108 284 275 265 265 255 245 245 235 226 226 216 206 206 196 186 186 177 167 157 147 137

KTA 3211.1

Table A 1-3: Characteristic values of the mechanical and technological characteristics in the elevated-temperature tensile test on longitudinal and transverse specimens (Part 2)

KTA 3211.1

Steel grade

Nominal thickness s in mm

Nature of value 1) -20

Energy absorbed (Charpy-V) in J at the temperature in C at least 0 110 90 41 34 41 34 21 15 16 11 41 34 41 34 68 3) 100 68 3) 100 68 3) 100 68 3) 100 5 130 100 20 130 100 33 130 100 Upper shelf 2) 130 100

Lateral expansion in mm at the temperature in C at least -20 5 33 Upper shelf 2)

15 MnNi 6 3

5 s 0 150 30 s 600
4)

MW EW

80 68

0.9

1.3

1.3

1.3

20 MnMoNi 5 5

MW EW

0.9 3) 0.9 3) 0.9 3)

1.3

15 NiCuMoNb 5 S

10 s 150 10 s 150 150 s 250 4)

MW EW

1.3

WStE 255 S WStE 285 S WStE 315 S WStE 355 S

MW EW MW EW

1.3

0.9 3)

1.3

1) MW : mean value of 3 specimens, EW : individual value. 2) The test is generally performed at 80 C. The test may be waived if the requirements were already verified to be met at a lower

temperature.
3) If agreed in the purchase order, this requirement shall also apply at lower temperature, but not below 0 C. 4) For nominal thicknesses exceeding 150 mm, the smallest individual value of energy absorbed (Charpy-V transverse specimens) at the

middle of the wall thickness at 80 C shall not be less than 68 J.

Table A 1-4: Characteristic values of energy absorbed and lateral expansion in the notched-bar impact bend test on Charpy-Vnotch specimens (transverse specimens)

Steel grade 15 MnNi 6 3

Nominal thickness in mm all nominal thicknesses 30 to 600 all nominal thicknesses

Delivered product length l in m per rolled plate l<7 l>7 all lengths l<7

Sampling and location of the test coupons relative to the product width b at one end at b/4 at both ends at b/4 at both ends at b/2 1) at one end at b/4

20 MnMoNi 5 5 WStE 255 S WStE 285 S WStE 315 S WStE 355 S 15 NiCuMoNb 5 S

l>7

at both ends at b/4

1) The test cross sections shall be located by at least half the product thickness under the end and side surfaces from the edges

straightened for the heat treatment. Notwithstanding the foregoing, the test sections from plates with nominal thicknesses > 320 mm for pipe elbows shall be located at least 80 mm under the end and side surfaces from the edges straightened for the heat treatment.

Table A 1-5: Sampling and location of the test coupons (sampling locations)

Page 64

KTA 3211.1

Steel grade

Normalization C

Temperature range in C for Quenching and tempering Austenitization Tempering 870 to 930 2) 3) 900 to 980 1) 630 to 690 2) 640 to 680 2) Stress-relief annealing 530 to 580 2) 580 to 620 2) 4) 580 to 620 2) 530 to 580 2) 530 to 580 2) 530 to 580 2) 530 to 580 2)

15 MnNi 6 3 20 MnMoNi 5 5 15 NiCuMoNb 5 S WStE 255 S WStE 285 S WStE 315 S WStE 355 S

880 to 960 1)

900 to 950 1) 900 to 950 1) 890 to 940

1)

880 to 940 1)

1) Cooling in stationary air after the temperature has been reached over the entire cross section. 2) The heating and cooling rate, the temperature and the holding time shall be defined by the manufacturer and processor as a function of

dimensions of the part, chemical composition and preceding heat treatments such that the requirements for mechanical and technological characteristics are met even allowing for subsequent heat treatments for the final condition of the complete part. Claddings shall also be taken into consideration (corrosion resistance, ductility).
3) Water cooling. 4) For multiple stress-relief annealing steps, the indicated temperature range shall be applicable for the last stress-relief annealing step.

Preceding stress-relief annealing steps can be performed at 530 C to 570 C.

Table A 1-6: Data for heat treatment

Steel grade

Nominal Thermal cutting Welding 2) thickness s Preheating Holding Preheating temperature TV and temperature 1) TH in mm temperature TV interpass in C temperature TZ in C in C s 15 RT TV RT TV 100 TV 120 TV 150 TV 250 RT TV RT TV 70 TV 120 TV RT TV RT TV RT TV 120 TV RT TV RT TV 100 TV 120 TV RT T 150 80 T 180 100 T 220 120 T 220 150 T 250 120 T 180 4) RT T 150 80 T 180 100 T 220 120 T 220 RT T 150 RT T 180 80 T 200 120 T 220 RT T 150 80 T 180 100 T 220 120 T 220 RT TH RT TH RT TH RT TH 150 TH 250 5) 120 TH 180 4) 5) RT TH RT TH 200 TH 120 TH RT TH RT TH 80 TH 120 TH RT TH RT TH 200 TH 120 TH 15 < s 30 30 < s 50 50 < s 150

Cooling time t8/5 in seconds

Limit wall thickness for waiving stress-relief annealing after welding in mm

15 MnNi 6 3

8 to 25

38 3)

20 MnMoNi 5 5

s > 15 s 15

7 to 25 Stress-relief annealing shall always be required

15 NiCuMoNb 5 S

15 < s 30 30 < s 50 s > 50 s 15 15 < s 50 30 < s 50 s > 50 s 15 15 < s 30 30 < s 50 s > 50

8 to 35

WStE 255 S WStE 285 S WStE 315 S

8 to 28

38 3)

WStE 355 S

8 to 25

38 3)

1) See DIN EN ISO 13 916 for definition. 2) If welding tests per KTA 3211.3 prove that the characteristics required for the application are also achieved with adequate safety under

conditions other than those listed here, those conditions may be employed.
3) In the case of simple geometric form and 100 % non-destructive examination of the welds, it is permitted to increase to 50 mm the limit

wall thickness up to which post-welded stress-relief annealing may be waived.

4) For weld cladding. 5) The part shall be subjected to post-weld heating at about 280 C from the heat of welding for more than 2 hours or to delayed cooling,

unless stress-relief annealing is performed directly from the heat of welding or inert-gas-shielded welding is employed.

Table A 1-7: Particulars of thermal cutting and welding, together with limit wall thicknesses for stress-relief annealing Page 65

KTA 3211.1

A 2 Ferritic steels of material group W I for forgings, bar steel and rolled rings A 2.1 General Section A 2 defines the details for manufacture, chemical composition, characterizing mechanical and technological characteristics and heat treatment as well as for further processing of the following steel grades a) 15 MnNi 6 3 b) 20 MnMoNi 5 5 c) 15 NiCuMoNb 5 S d) C 22.8 S e) WStE 355 S for forgings, bar steel and rolled rings.

(4) The data for energy absorbed and lateral expansion shall apply to standard specimens with a specimen width of 10 mm. (5) The mechanical and technological characteristics shall be verified on specimens subjected to simulated stress-relief annealing. For product forms of steel 20 MnMoNi 5 5 with nominal thicknesses up to and including 50 mm that are to be welded, the mechanical and technological characteristics shall be verified in the delivery condition. (6) For simulated stress-relief annealing the requirements of Table A 2-7 shall apply. (7) The characteristics shall apply to specimens taken and tested as per the stipulations in the Sections relating to product forms. A 2.3.3 Grain size

A 2.2 Manufacture of the materials and delivery condition A 2.2.1 Manufacture (1) The steels shall be smelted by the basic oxygen process or in the electric furnace. If other processes are used, proof of equivalence shall be furnished. (2) The steels shall be made in particularly killed condition.

(1) (1) The steels listed below shall have ferrite grain sizes as shown by EURONORM 103-71: a) 15 MnNi 6 3 at least grain size classification number 6, b) 20 MnMoNi 5 5 at least grain size classification number 5, c) 15 NiCuMoNb 5 S at least grain size classification number 6, d) C 22.8 S at least grain size classification number 4, e) WStE 355 S at least grain size classification number 6. (2) For steels with contents of bainitic structure, the requirements shall apply only to the microstructural proportions of polygonal ferrite. A 2.3.4 Physical characteristics Reference values for the physical characteristics can be found in Annex AP. A 2.4 Data on heat treatment Reference values for heat treatment are presented in Table A 2-5. A 2.5 Forming A 2.5.1 Hot forming
Note: Hot forming shall designate forming at temperatures above the highest temperature permissible for stress-relief annealing, even if the product forms are heated to the corresponding temperature only locally, in the forming zone. The term hot forming shall also include adaptation and straightening work at the corresponding temperatures.

A 2.2.2 Delivery condition (1) The usual delivery condition for the steel grades is as follows: a) 15 MnNi 6 3 normalized b) 20 MnMoNi 5 5 quenched and tempered in liquid c) 15 NiCuMoNb 5 S normalized and tempered (quenched and tempered in air) or quenched and tempered in liquid d) C 22.8 S normalized, or also quenched and tempered in liquid for nominal thicknesses 150 mm e) WStE 355 S normalized or quenched and tempered A 2.3 Material characteristic values A 2.3.1 Chemical composition The values stipulated in Table A 2-1 shall apply to the chemical composition per the ladle and product analyses. A 2.3.2 Mechanical and technological characteristics (1) The characteristic values of the mechanical and technological characteristics in the room-temperature tensile test are stipulated in Table A 2-2. (2) The characteristic values of the mechanical and technological characteristics in the elevated-temperature tensile test are stipulated in Table A 2-3. The test temperatures for carrying out the elevated-temperature tensile test for the various steel grades shall be as follows: 15 MnNi 6 3 300 C 20 MnMoNi 5 5 15 NiCuMoNb 5 S C 22.8 S WStE 355 S 350 C 350 C 300 C 300 C

(1) For hot forming, the forgings shall be heated to at least 750 C but not above 1050 C. For hot forming, the forgings of 15 MnNi 6 3 shall be heated to at least 750 C but not above 1100 C. Grain coarsening due to excessively long times or to overheating shall be avoided. Hot forming of tubular forgings, e.g., for the manufacture of pipe elbows, shall be subject to the stipulations in Section A 3. (2) After hot forming, the complete product forms shall be subjected to renewed heat treatment per the data in Table A 2-5. (3) If the procedures employed differ from stipulations (1) and (2), e.g., in the case of forming with local heating without subsequent heat treatment of the complete product form, proof of equivalence shall be furnished. (4) The temperature control program shall be monitored.

(3) The characteristic values of energy absorbed and lateral expansion of Charpy V-notch specimens are stipulated in Table A 2-4. Page 66

KTA 3211.1

A 2.6 Thermal cutting and welding A 2.6.1 Thermal cutting SEW 088 shall be taken into consideration for thermal cutting. Recommended preheating temperatures are presented in Table A 2-6. A 2.6.2 Welding (1) Use of the following welding methods has been appraised as suitable for the steels per this Annex: a) manual arc welding with basic-flux-coated rod electrodes, b) submerged-arc welding with basic fluxes, c) inert-gas-shielded welding with wire electrodes or with basic-flux-cored wire electrodes. (2) The examined work areas for welding are listed in Table A 2-6. Other work areas for welding are permitted, provided

procedure qualification tests per KTA 3211.3 have been performed. (3) The stipulations for welding per SEW 088 shall be observed. The content of difflisible hydrogen, determined to DIN 8572-1 and DIN 8572-2, shall not exceed HD5 to DIN 8572-E in manual arc welding or HD7 to DIN 8572-UP in submerged-arc welding. (4) Post-weld stress-relief annealing may be required, depending on wall thickness and geometry of the parts. The nominal thicknesses at which stress-relief annealing may be waived are listed in Table A 2-6. (5) Post-weld non-destructive examinations shall be performed after a waiting time of at least 48 hours after completion of the welding work. The waiting time may be waived for welds that are subjected to stress-relief annealing, hydrogen degassing or delayed cooling, or that were welded under shield gas.

Page 67

Steel grade C Si Mn P S 0.005 0.015 0.015 0.06 0.15 0.05 0.004 0.010 0.020 0.020 0.013 0.011 0.0113) 0.004 0.20 0.20 0.05 0.40 0.55 0.40 0.07 0.12 0.016 0.025 0.016 0.013 0.0133) 0.025 0.020 0.022 0.15 0.30 0.35 0.005 0.006 0.30 5) 0.35 5) 0.020 0.020 0.18 0.020 0.022 0.007 0.008 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.015 0.017 0.012 0.0123) 0.0123) 0.016 0.005 0.006 0.010 0.015 0.015 0.020 0.015 0.075 0.020 0.016 0.020 0.020 0.025 Cu Altotal N Cr As Ti Mo Ni Nb Sn V

KTA 3211.1

Verification by

Limit value

Content by mass, % 1) 2)

15 MnNi 6 3

Ladle analysis

Product analysis

20 MnMoNi 5 5

Ladle analysis

Product analysis

min. max. min. max. min. max. min. max. 0.12 0.18 0.10 0.20 0.17 0.23 0.15 0.25 0.15 0.35 0.15 0.37 0.15 0.30 0.10 0.35 1.20 1.65 1.15 1.70 1.20 1.50 1.15 1.55 0.50 0.85 0.50 0.90 0.50 0.80 0.45 0.85 0.020 0.055 0.015 0.065 0.010 0.040 0.010 0.050

15 NiCuMoNb 5 S 0.015 0.025 0.010 0.030

Ladle analysis

Product analysis

0.12 3) 0.20 0.50 0.80 0.30 0.45 0.85 0.35 1.00 1.30 0.95 1.35

0.55 3) 0.25 0.40 0.20 0.45

C 22.8 S

Ladle analysis

Product analysis 0.20 0.22 0.05 0.55 0.84 1.75

0.10 0.17 0.08 0.19 0.18 0.23 0.16 0.25 0.25 0.50 0.21 0.54 0.15 0.35 0.10 0.40 0.10 0.50 0.80 1.20 0.75 1.25 0.40 0.90 0.36 0.95 0.90 1.65 0.18 4) 0.30 4) 0.084) 0.25 4) 0.34 4) 0.114) 0.015 0.035 0.010 0.040 0.015 0.050 0.010 0.055 0.020 0.070

Page 68

WStE 355 S

Ladle analysis

min. max. min. max. min. max. min. max. min. max.

Product analysis

min. max.

1) The differences that the tabulated values indicate between chemical compositions per the ladle and product analyses are sometimes smaller than would be expected from the metallurgical relationship.

The reason is that the limit values for chemical composition per the product analysis are in this case based only on the heats covered by the appraisal. Thus the values will be reviewed once additional documents become available. 2) If the indicated limit contents per the ladle analysis are exceeded, the limit contents per the product analysis shall govern. 3) If these values are exceeded and allowance must be made in the product analysis for contents up to P 0.015 %, S 0.015 %, Mo 0.63 %, Cu 0.18 %, Sn 0.016 % and N total 0.015 %, the authorized inspector shall check, until further information becomes available, as to whether welding simulation tests and if necessary tangential microsection examinations are necessary. If intermediate annealing at 550 C is planned during further processing, the permissibility of this annealing temperature shall be verified during the said tests or examinations. The scope and conduct of these tests shall be agreed with the authorized inspector. The tests may be waived if so stipulated in the material appraisal. 4) The sum of the contents of chromium, copper and molybdenum shall not exceed 0.45 % in the ladle analysis or 0.50 % in the product analysis. 5) Depending on the authorized inspector's appraisal relative to the individual manufacturer, the maximum permissible nickel content shall be 0.85 % in the ladle analysis and 0.90 % in the product analysis.

Table A 2-1: Chemical composition of steel grades per the ladle and product analyses

KTA 3211.1

Steel grade

Heat-treatment wall thickness s in mm

Tensile strength Rm in N/mm2

Yield point 1) ReH in N/mm2 at least

Specimen direction

Elongation at fracture A in % at least

Reduction of area at fracture Z in % Individual value 45 45 45 45 45 35 45 35 45 45 45 45 45 45 Mean value 45 45

15 MnNi 6 3

s 70 70 < s 100 100 < s 150 150 < s 250 250 < s 350

470 to 590 470 to 590 470 to 590 440 to 580 440 to 580

320 310 300 285 275

longitudinal / transverse longitudinal / transverse longitudinal / transverse longitudinal / transverse longitudinal / transverse perpendicular longitudinal / transverse perpendicular longitudinal transverse longitudinal transverse longitudinal transverse longitudinal transverse longitudinal transverse longitudinal transverse longitudinal transverse

22 22 22 22 22 19 20 18 25 20 25 19 25 19 23 21 21 19 21 19

20 MnMoNi 5 5 s 1000 15 NiCuMoNb 5 S C 22.8 S 560 to 700 390

s 400 s 150 150 < s 320 320 < s 500

580 to 740 410 to 540 400 to 520 400 to 520 490 to 630 470 to 630 470 to 630

430 230 210 200 335 295 275

WStE 355 S

s 100 100 < s 250 250 < s 400

1) If the yield point is not emphasized, the values shall be applicable for the 0.2 % proof stress.

Table A 2-2: Characteristic values of the mechanical and technological characteristics in the room-temperature tensile test

Page 69

KTA 3211.1

Steel grade

Test temperature in C

Tensile strength Rm in N/mm2 at least

350 15 MnNi 6 3 100 145 200 250 300 350 420 410 400 400 400 400

Elongation at fracture A in % at least (longitudinal or transverse) for heat-treatment wall thicknesses in mm > 70 > 100 > 150 > 250 70 100 150 250 350 0.2 % proof stress Rp0.2 in N/mm2 at least 290 280 270 245 235 280 270 260 225 215 250 240 230 205 195 240 230 220 185 175 220 210 200 165 155 200 190 180 145 135 for heat-treatment wall thicknesses in mm > 320 320 1000 320 370 370 360 350 350 330 343 315 330 300 320 290 for heat-treatment wall thicknesses in mm 400 402 389 376 363 350 337 324 for heat-treatment wall thicknesses in mm > 150 > 320 150 320 500 220 200 190 200 180 170 175 160 155 155 140 135 135 125 115 115 105 100 90 85 80 for heat-treatment wall thicknesses in mm > 100 > 250 100 250 400 294 275 255 235 216 196 167 255 235 216 196 177 157 127 235 215 197 179 160 142 117 17 16 16 16 16 16

1000 20 MnMoNi 5 5 100 200 300 350 375 400 520 505 505 505 505 490 400 15 NiCuMoNb 5 S 100 150 200 250 300 350 400 540 530 520 510 500 490 480

> 320 1000 16 16 15 14 14 14

500 C 22.8 S 100 150 200 250 300 350 400 360 350 340 335 335 335 300

400 WStE 355 S 100 150 200 250 300 350 400 410 400 390 380 380 370 360

Table A 2-3: Characteristic values of the mechanical and technological characteristics in the elevated-temperature tensile test

Page 70

KTA 3211.1

Steel grade

Nominal thickness s in mm

Nature of value 1)

Energy absorbed (Charpy-V) in J at the temperature in C at least - 20 0 +5 +20 +33 Upper shelf
2)

Lateral expansion in mm at the temperature in C at least - 20 +5 + 33 Upper shelf

2)

15 MnNi 6 3

s 150 150 < s 350

MW EW MW EW MW EW MW EW MW EW MW EW

80 68 70 56

110 90 90 72 41 34 80 56 41 34 41 34

130 100 110 88

130 100 130 100

130 100 130 100 68 3)

130 100 130 100 100 100 100 100 0,9 0,9 1,3 1,3 1,3 1,3 0,9 3) 0,9 3) 0,9 3) 0,9 3) 1,3 1,3 1,3 1,3 1,3 1,3

20 MnMoNi 5 5 15 NiCuMoNb 5 S C 22.8 S WStE 355 S

s 1000 s 400 s 500 s 400

60 42

95 66 49 42 68 3) 68 3) 68 3)

1) MW : mean value of 3 specimens, EW : individual value. 2) The test is generally performed at 80 C. The test may be waived if the requirements were already verified to be met at a lower

temperature.
3) If agreed in the purchase order, this requirement shall also apply at lower temperature, but not below 0 C.

Table A 2-4: Characteristic values of energy absorbed and lateral expansion in the notched-bar impact bend test on Charpy-Vnotch specimens (transverse specimens)

Steel grade

Normalization C

Temperature range for Quenching and tempering Austenitization C Tempering C

Stress-relief annealing 3) C 530 to 580

15 MnNi 6 3 20 MnMoNi 5 5 5) 15 NiCuMoNb 5 S

880 to 960 1) 870 to 940 2) 900 to 980 1) 880 to 930 4) 630 to 680 640 to 670 640 to 690 4) 640 to 660 610 to 680

580 to 620 580 to 620 580 to 620 530 to 600 530 to 580

C 22.8 S WStE 355 S

880 to 920 880 to 920

1) 1)

870 to 910 880 to 940

2) 4)

1) Cooling in stationary air after the temperature has been reached over the entire cross section. 2) Cooling in water. 3) For multiple stress-relief annealing steps, the indicated temperature range shall be applicable for the last stress-relief annealing step.

Preceding stress-relief annealing steps can be performed at 530 C to 570 C.

4) Cooling in oil or water. This treatment shall be employed for relatively large heat-treatment wall thicknesses, in order to be able to

maintain the minimum temperature of 640 C for tempering.

5) Two-stage quenching and tempering are permitted, depending on the authorized inspector's appraisal.

Table A 2-5: Data for heat treatment

Page 71

KTA 3211.1

Steel grade

Nominal thickness s in mm

Thermal cutting Preheating temperature TV in C RT TV RT TV 100 TV 120 TV 150 TV 250 RT TV RT TV 100 TV 120 TV RT TV RT TV 120 TV RT TV RT TV 100 TV 120 TV

Welding 2) Preheating Holding temperature TV and temperature interpass temperature TH 1) TZ in C in C RT T 150 80 T 180 100 T 220
3)

Cooling time t8/5 in seconds 8 to 25

Limit wall thickness for waiving stressrelief annealing after welding in mm

15 MnNi 6 3

s 15 15 < s 30 30 < s 50 50 < s 150

RT TH RT TH 100 TH 120 TH 150 TH 250 120 TH 180 4) RT TH 100 TH 120 TH RT TH RT TH 120 TH RT TH RT TH 100 TH 120 TH

38 5)

120 T 220 3) 150 T 250 3) 80 T 180 100 T 180 120 T 220 120 T 220 80 T 150 80 T 200 120 T 220
3) 3)

20 MnMoNi 5 5

s > 15

7 to 25

Stress-relief annealing shall always be required Stress-relief annealing shall always be required

15 NiCuMoNb 5 S

s 15 15 < s 30 30 < s 50 s > 50 s 30 30 < s 50 s > 50 s 15 15 < s 30 30 < s 50 s > 50

10 to 25

C 22.8 S

8 to 25

30

WStE 355 S

RT T 150 80 T 180 100 T 220 3) 120 T 220 3)

8 to 25

38 5)

1) See DIN EN ISO 13 916 for definition. 2) If welding tests per KTA 3211.3 prove that the characteristics required for the application are also achieved with adequate safety under

conditions other than those listed here, those conditions may be employed.
3) At most 180 C for weld cladding. 4) The part shall be subjected to post-weld heating at about 280 C from the heat of welding for more than 2 hours or to delayed cooling,

unless stress-relief annealing is performed directly from the heat of welding or inert-gas-shielded welding is employed.
5) In the case of simple geometric form and 100 % non-destructive examination of the welds, it is permitted to increase the limit wall

thickness to 50 mm, unless special requirements of heat-treatment condition are imposed.

Table A 2-6: Particulars of thermal cutting and welding, together with limit wall thicknesses for stress-relief annealing

Simulated stress-relief annealing Steel grade 15 MnNi 6 3 20 MnMoNi 5 5 15 NiCuMoNb 5 S C 22.8 S WStE 355 S yes
2)

Verification necessary

Temperature in C 560 to 580 600 to 620 600 to 620 580 to 600 560 to 580

Holding time 1) in minutes

900

1) These data shall apply only if no other particulars were required in the purchase order. 2) See clause A 2.3.2 (5) for verification of product forms of the steel 20 MnMoNi 5 5.

Table A 2-7: Necessity for verification of mechanical characteristics in the simulated stress-relief-annealed condition, and performance of the simulated stress-relief annealing process Page 72

KTA 3211.1

A 3 Ferritic steels of material group W I for seamless pipes, seamless pipe elbows and seamless reducers A 3.1 General Section A 3 defines the details for manufacture, chemical composition, characterizing mechanical and technological characteristics and heat treatment as well as for further processing of the following steel grades a) 15 MnNi 6 3 b) 20 MnMoNi 5 5 c) 15 NiCuMoNb 5 S for seamless pipes, seamless pipe elbows and seamless reducers. A 3.2 Manufacture of the materials and delivery condition A 3.2.1 Manufacture (1) The steels shall be smelted by the basic oxygen process or in the electric furnace. If other processes are used, proof of equivalence shall be furnished. (2) The steels shall be made in particularly killed condition.

(4) The data for energy absorbed and lateral expansion shall apply to standard specimens with a specimen width of 10 mm. (5) For wall thicknesses between 5 and 10 mm, the requirements for energy absorbed shall be reduced as a function of specimen width. For product-form thicknesses smaller than 10 mm, the stipulations on lateral expansion shall be waived. (6) The mechanical and technological characteristics shall be verified on specimens subjected to simulated stress-relief annealing (see Table A 3-5). For product forms of steel 20 MnMoNi 5 5 with nominal thicknesses up to and including 50 mm that are to be welded, the mechanical and technological characteristics shall be verified in the delivery condition. A 3.3.3 Grain size (1) The steel grades listed below shall have ferrite grain sizes as shown by Euronorm 103: a) 15 MnNi 6 3 at least grain size classification number 6, b) 20 MnMoNi 5 5 at least grain size classification number 5, c) 15 NiCuMoNb 5 S at least grain size classification number 6. (2) For steels with contents of bainitic structure, the requirements shall apply only to the microstructural proportions of polygonal ferrite. A 3.3.4 Physical characteristics Reference values for the physical characteristics can be found in Annex AP. A 3.4 Data on heat treatment Reference values for heat treatment are presented in Table A 3-6. A 3.5 Forming A 3.5.1 Hot forming
Note: Hot forming shall designate forming at temperatures above the highest temperature permissible for stress-relief annealing, even if the product forms are heated to the corresponding temperature only locally, in the forming zone. The term hot forming shall also include adaptation and straightening work at the corresponding temperatures.

A 3.2.2 Delivery condition (1) The usual delivery condition for the steel grades is as follows: a) 15 MnNi 6 3 normalized b) 20 MnMoNi 5 5 quenched and tempered in liquid c) 15 NiCuMoNb 5 S normalized and tempered (quenched and tempered in air) or quenched and tempered in liquid (2) If the governing heat treatment is performed during further processing, the pipes to be supplied in normalized condition may also be delivered in rolled condition, and the pipes to be supplied in quenched and tempered condition may also be delivered in normalized or tempered condition or, in special cases, even in rolled condition. A 3.3 Material characteristic values A 3.3.1 Chemical composition The values stipulated in Table A 3-1 shall apply to the chemical composition per the ladle and product analyses. A 3.3.2 Mechanical and technological characteristics (1) The characteristic values of the mechanical and technological characteristics in the room-temperature tensile test are stipulated in Table A 3-2. (2) The characteristic values of the mechanical and technological characteristics in the elevated-temperature tensile test are stipulated in Table A 3-3. The test temperature for carrying out the elevated-temperature tensile test for the various steel grades shall be as follows: 15 MnNi 6 3 300 C 20 MnMoNi 5 5 15 NiCuMoNb 5 S 350 C 350 C

(1) For hot forming, the pipes shall be heated to at least 750 C but not above 1050 C. For hot forming, the pipes of steel 15 MnNi 6 3 shall be heated to at least 750 C but not above 1100 C. Forging and upsetting shall be performed in the upper portion of the temperature range at 1100 C to 900 C. Hot bending of pipes and similar forming work shall be performed in the lower portion of the temperature range. Grain coarsening due to excessively long times or to overheating shall be avoided. (2) After hot forming, the complete product forms shall be subjected to renewed heat treatment as per the data in Table A 3-5. (3) If the procedures employed differ from stipulations (1) to (2), e.g., in the case of forming with local heating without subsequent heat treatment of the complete product form, proof of equivalence shall be furnished. (4) The temperature control program shall be monitored.

(3) The characteristic values of energy absorbed and lateral expansion of Charpy V-notch specimens are stipulated in Table A 3-4.

Page 73

KTA 3211.1

A 3.5.2 Cold forming and cold bending

Note: Cold forming and cold bending shall designate forming at room temperature or with heating up to the highest temperature permissible for stress-relief annealing.

A 3.6.2 Welding (1) Use of the following welding methods has been appraised as suitable: a) manual arc welding with basic-flux-coated rod electrodes, b) submerged-arc welding with basic fluxes, c) inert-gas-shielded welding with wire electrodes or with basic-flux-cored wire electrodes (2) The examined work areas for welding are listed in Table A 3-7. Other work areas for welding are permitted, provided procedure qualification tests per KTA 3211.3 have been performed. (3) The stipulations for welding per SEW 088 shall be observed. The content of diffusible hydrogen, determined to DIN 8572-1 and DIN 8572-2, shall not exceed HD5 to DIN 8572-E in manual arc welding or HD7 to DIN 8572-UP in submerged-arc welding (4) Post-weld stress-relief annealing may be required, depending on nominal thickness and geometry of the parts. The nominal thicknesses at which stress-relief annealing may be waived are listed in Table A 3-7. (5) Post-weld non-destructive examinations shall be performed after a waiting time of at least 48 hours after completion of the welding work, The waiting time may be waived for welds that are subjected to stress-relief annealing, hydrogen degassing or delayed cooling, or that were welded under shield gas.

(1) Heat treatment is not required after cold forming with degrees of forming smaller than or equal to 2 %. (2) Stress-relief annealing shall be required after forming with degrees of cold forming between 2 % and smaller than or equal to 5 %. (3) The governing heat treatment shall be performed after cold forming with degrees of forming larger than 5 %. (4) If different procedures equivalence shall be furnished. are employed, proof of

(5) For cold-bending processes, heat treatment after cold bending may be waived if appropriate proof is furnished. Weld-on work and straightening work shall not be permitted in the zone of cold bends.
Note: Cold bends shall be defined as machine-made cold bends of pipes with DN 150 and with bend radii Rm > 2.5 Da.

A 3.6 Thermal cutting and welding A 3.6.1 Thermal cutting SEW 088 shall be taken into consideration for thermal cutting. Recommended preheating temperatures are presented in Table A 3-7.

Page 74

Steel grade C Si Mn P S Altotal 0.015 0.015 0.06 0.15 0.05 0.004 0.010 0.013 0.011 0.0113) 0.85 0.004 0.80 0.45 0.20 0.05 0.40 0.55 0.40 0.20 0.07 0.12 0.016 0.025 0.016 0.013 0.0133) 0.025 0.020 0.022 0.020 0.020 0.005 0.007 0.008 0.040 0.010 0.015 0.017 0.012 Ti Ni Sn Mo Nb V

Verification by

Limit value

Content by mass, % 1) 2) As N Cr Cu

15 MnNi 6 3 0.12 0.18 0.10 0.20 0.17 0.23 1.50 1.15 1.55 0.30 0.15 4) 0.10 0.25 0.35
4)

Ladle analysis 0.15 0.35 0.15 0.37 0.15 1.20 1.65 1.15 1.70 1.20 0.020 0.055 0.015 0.065 0.010 0.50 0.85 0.50 0.90 0.50

0.020 0.020 0.020 0.020 0.020 0.020

Product analysis

20 MnMoNi 5 5

Ladle analysis

min. max. min. max. min.

Product analysis

max. min.

max.

15 NiCuMoNb 5 S 0.10 0.17 0.08 0.19 0.25 0.50 0.21 0.54 0.80 1.20 0.75 1.25

Ladle analysis

Product analysis

min. max. min. max.

0.0123) 0.0123) 0.050 0.015 0.016 0.005 0.035 0.010 0.020 0.006 0.040 0.15 0.025 0.010 0.030

0.12 3) 0.20 0.50 0.80 0.30 0.45 0.85 0.35

0.55 3) 0.25 0.40 0.20 0.45

1.00 1.30 0.95 1.35

1) The differences that the tabulated values indicate between chemical compositions per the ladle and product analyses are sometimes smaller than would be expected from the metallurgical relationship.

The reason is that the limit values for chemical composition per the product analysis are in this case based only on the heats covered by the appraisal. Thus the values will be reviewed once additional documents become available.

2) If the indicated limit contents per the ladle analysis are exceeded, the limit contents per the product analysis shall govern.

Page 75

3) If these values are exceeded and allowance must be made in the product analysis for contents up to P 0.015 %, S 0.015 %, Mo 0.63 %, Cu 0.18 %, Sn 0.016 % and N total 0.015 %, the authorized inspector shall check, until further information becomes available, as to whether welding simulation tests and if necessary tangential microsection examinations are necessary. If intermediate annealing at 550 C is planned during further processing, the permissibility of this annealing temperature shall be verified during the said tests or examinations. The scope and conduct of these tests shall be agreed with the authorized inspector. The tests may be waived if so stipulated in the material appraisal.

4) For quenched and tempered wall thicknesses smaller than or equal to 30 mm, the following C contents shall be permissble: larger than or equal to 0.14 % and smaller than or equal to 0.18 % for the ladle

analysis; and larger than or equal to 0.12 % and smaller than or equal to 0.20 % for the product analysis.

Table A 3-1: Chemical composition of steel grades per the ladle and product analyses

KTA 3211.1

KTA 3211.1

Steel grade

Heat-treatment wall thickness in mm

Tensile strength Rm in N/mm2

Yield point 1) ReH in N/mm2 at least

Specimen direction

Elongation at fracture A in % at least 24 22 22 24 19 19 19 17

Reduction of area at fracture Z in % at least Individual Mean value value 45 45 45 45 35 45 45 35 25 45 45 35

70 15 MnNi 6 3 > 70 130 15 100 20 MnMoNi 5 5 < 100 200

490 to 610

330

longitudinal transverse transverse longitudinal perpendicular longitudinal / transverse longitudinal / transverse perpendicular longitudinal transverse perpendicular

470 to 590

310

570 to 710

430

560 to 700

390

15 NiCuMoNb 5 S

60

610 to 760

440

1) If the yield point is not emphasized, the values shall be applicable for the 0.2 % proof stress.

Table A 3-2: Characteristic values of the mechanical and technological characteristics in the room-temperature tensile test

Steel grade

Test temperature in C

Tensile strength Rm in N/mm2 at least 70 > 70 130 400 375 375 375 375 375 > 100 200 530 510 510 510 505 500 60

0.2 % proof stress Rp0.2 in N/mm2 at least 70 285 275 245 220 210 190 15 100 412 392 371 363 358 353 60 422 412 402 392 382 373 343 > 70 130 260 240 220 200 190 170 > 100 200 370 360 350 343 330 320

for heat-treatment wall thicknesses in mm

Elongation at fracture A in % at least (longitudinal or transverse)

15 MnNi 6 3

100 145 200 250 300 350

420 415 400 400 400 390 15 100

for heat-treatment wall thicknesses in mm

20 MnMoNi 5 5

100 200 300 350 375 400

530 513 513 513 505 500

16

for heat-treatment wall thicknesses in mm 100 150 200 250 300 350 400 540 530 520 520 520 510 500

15 NiCuMoNb 5 S

Table A 3-3: Characteristic values of the mechanical and technological characteristics in the elevated-temperature tensile test Page 76

KTA 3211.1

Steel grade

Nominal thickness s in mm

Nature of value 1)
-20

Energy absorbed (Charpy-V) in J at the temperature in C at least

0 +5 +20 +33 Upper shelf
2)

Lateral expansion in mm at the temperature in C at least

-20 +5 +33 Upper shelf
2)

15 MnNi 6 3 20 MnMoNi 5 5 15 NiCuMoNb 5 S

130 200 60

MW EW MW EW MW EW

80 68

110 90 41 4) 34 4) 80 56

130 100

130 100

130 100 68 3)

130 100 100 100 0,9 1,3 1,3 0,9 0,9 1,3 1,3 1,3

60 42

95 66 68 3)

1) MW : mean value of 3 specimens, EW : individual value. 2) The test is generally performed at 80 C. The test may be waived if the requirements were already verified to be met at a lower

temperature.
3) If agreed in the purchase order, this requirement shall also apply at lower temperature, but not below 0 C. 4) For longitudinal specimens the minimum mean value shall be 60 J and the minimum individual value shall be 51 J.

Table A 3-4: Characteristic values of energy absorbed and lateral expansion in the notched-bar impact bend test on Charpy-Vnotch specimens (transverse specimens)

Steel grade 15 MnNi 6 3 20 MnMoNi 5 5 15 NiCuMoNb 5 S

Verification necessary yes yes yes

Simulated stress-relief annealing Temperature in C Holding time 1) in minutes 560 to 580 600 to 620 600 to 620 900 900 900

1) These data shall apply only if no other particulars were required in the purchase order.

Table A 3-5: Necessity for verification of mechanical characteristics in the simulated stress-relief-annealed condition, and performance of the simulated stress-relief annealing process

Steel grade

Normalization

Temperature range for quenching and tempering Austenitization C 870 to 930 2) 900 to 980 1) 880 to 930
4)

Stress-relief annealing 3) C 530 to 580 580 to 620 580 to 620

C 15 MnNi 6 3 20 MnMoNi 5 5 15 NiCuMoNb 5 S 880 to 960 1)

Tempering C 630 to 690 640 to 680 640 to 690

4)

580 to 620

1) Cooling in stationary air after the temperature has been reached over the entire cross section. 3) Cooling in water. 3) For multiple stress-relief annealing steps, the indicated temperature range shall be applicable for the last stress-relief annealing step.

Preceding stress-relief annealing steps can be performed at 530 C to 570 C.

4) Cooling in oil or water. This treatment shall be employed for relatively large heat-treatment wall thicknesses, in order to be able to

maintain the minimum temperature of 640 C for tempering.

Table A 3-6: Data for heat treatment

Page 77

KTA 3211.1

Steel grade

Nominal thickness s in mm

Thermal cutting Preheating temperature TV in C RT TV RT TV 100 TV 120 TV 150 TV 250 RT TV RT TV 100 TV 120 TV

Welding 2) Holding Preheating temperature TV and interpass temperature TZ temperature 1) in C TH in C RT T 150 80 T 180 100 T 220 150 T 250 80 T 150 100 T 180 120 T 220 3) 120 T 220 3)
3)

Limit wall thickness for waiving stressrelief annealing after welding in seconds in mm Cooling time t8/5 8 to 25 38 5)

15 MnNi 6 3

s 15 15 < s 30 30 < s 50 s > 50

RT TH RT TH 100 TH 120 TH 150 TH 250 4) 120 TH 180 6) RT TH 100 TH 120 TH

120 T 220 3)
3)

20 MnMoNi 5 5 15 NiCuMoNb 5 S

s 15 s 15 15 < s 30 30 < s 50 s > 50

7 to 25 10 to 30 Stress-relief annealing shall always be required

1) See DIN EN ISO 13 916 for definition. 2) If welding tests per KTA 3211.3 prove that the characteristics required for the application are also achieved with adequate safety under

conditions other than those listed here, those conditions may be employed.
3) At most 180 C for weld cladding. 4) The part shall be subjected to post-weld heating at about 280 C from the heat of welding for more than 2 hours or to delayed cooling,

unless stress-relief annealing is performed directly from the heat of welding or inert-gas-shielded welding is employed.
5) In the case of simple geometric form and 100 % non-destructive examination of the welds, it is permitted to increase the limit wall

thickness to 50 mm, unless special requirements of heat-treatment condition are imposed.

6) For weld cladding.

Table A 3-7: Particulars of thermal cutting and welding, together with limit wall thicknesses for stress-relief annealing

Page 78

KTA 3211.1

A 4 Castings for cases and bodies of ferritic cast steel of material group W I A 4.1 General Section A 4 defines the details for manufacture, chemical composition, characterizing mechanical and technological characteristics and heat treatment as well as for further processing of the following steel grades a) GS-18 NiMoCr 3 7 b) GS-C 25 S for cases and bodies.
Note: The following stipulations are provisional, since the appraisal of cast-steel grade GS-18 NiMoCr 3 7 and the supplementary appraisal of cast-steel grade GS-C 25 S with regard to meeting the requirements beyond those for cast-steel grade GS-C 25 (material number 1.0619) to DIN 17 245 have not yet been completed.

A 4.3.2 Mechanical and technological characteristics (1) The characteristic values of the mechanical and technological characteristics in the room-temperature tensile test, including the minimum values of elongation at fracture, are stipulated in Table A 4-2. (2) The characteristic values of the mechanical and technological characteristics at elevated temperatures are stipulated in Table A 4-3. Verification shall be required only if the design temperature is higher than 100 C for cast-steel grade GS-C 25 S and higher than 200 C for cast-steel grade GS-18 NiMoCr 3 7, unless otherwise stipulated in the authorized inspector's appraisal. (3) The characteristic values of energy absorbed are stipulated in Table A 4-4. (4) The data for energy absorbed shall apply to standard specimens with a specimen width of 10 mm. (5) The mechanical and technological characteristics shall be verified as per Table A 4-6. A 4.3.3 Physical characteristics Reference values for the physical characteristics can be found in Annex AP. A 4.4 Data on heat treatment Reference values for heat treatment are presented in Table A 4-5.

A 4.2 Manufacture of the steels The steels shall be smelted by the basic oxygen process or in the electric furnace. If other processes are used, proof of equivalence shall be furnished. A 4.3 Material characteristic values A 4.3.1 Chemical composition The values stipulated in Table A 4-1 shall apply to the chemical composition per the ladle and product analysis.

Page 79

Steel grade C Si Mn P 0.015 0.010 0.015 0.30 0.18 0.18 0.12 0.12 1) 0.60 1) 0.40 0.60 0.40 0.60 1.10 0.60 1.10 0.011 0.011 1) 0.015 0.015 0.025 0.025 0.015 1) 0.012 0.010 0.015 0.012 0.012 1) 0.012 1) 0.02 0.02 0.02 0.02 S Altotal Cr Cu Mo Ni Sn V

KTA 3211.1

Verification by

Limit value

Content by mass, % As N

GS-C 25 S

Ladle analysis

Product analysis

GS-18 NiMoCr 3 7 Ladle analysis

Product analysis

min. max. min. max. min. max. min. max. 0.18 0.22 0.18 0.22 0.17 0.23 0.16 0.23 0.30 0.60 0.30 0.60 0.30 0.50 0.25 0.50 0.50 1.10 0.50 1.10 0.70 1.10 0.70 1.20 0.020 0.070 0.020 0.070 0.020 0.050 0.020 0.050 0.30 0.30 0.50 0.30 0.50

1) If these values are exceeded and allowance must be made in the product analysis for contents up to P 0.015 %, S 0.015 %, Mo 0.63 %, Cu 0.18 %, Sn 0.016 % and N total 0.015 %, the

authorized inspector shall check, until further information becomes available, as to whether welding simulation tests and if necessary tangential microsection examinations are necessary. If intermediate annealing at 550 C is planned during further processing, the permissibility of this annealing temperature shall be verified during the said tests or examinations. The scope and conduct of these tests shall be agreed with the authorized inspector. The tests may be waived if so stipulated in the material appraisal.

Table A 4-1: Chemical composition of steel grades per the ladle and product analyses

Page 80

Steel grade 0.2 %-proof stress Rp0.2 in N/mm2 at least 245 390 maximum 100 300

Nominal thickness in mm

Tensile strength Rm in N/mm2 440 to 590 570 to 735

Elongation at fracture A in % at least 22 16

GS-C 25 S GS-18 NiMoCr 3 7

Table A 4-2: Characteristic values of the mechanical and technological characteristics in the room-temperature tensile test

Steel grade

0.2 %-proof stress 1) Rp0.2 in N/mm2

Tensile strength 1) Rm in N/mm2

Elongation at fracture 1) A in %

100 130 (338) (410) (570) 135 343

200

at least at temperature in C 350 300 250 375 400 100 200 (400) (550)

at least at temperature in C 350 300 250 (400) (535) (390) (520) (375) 490

375 (475)

400 (355)

100 (21) (16)

200 (20) (15)

at least at temperature in C 350 300 250 (19) (14) (18) (13) (20) 12

375 (11)

400 (25)

GS-C 25 GS-18 NiMoCr 3 7

(205) (370)

175 (360)

(160) (350)

145 (345)

1)

The values in parentheses must still be substantiated by statistics.

Table A 4-3: Characteristic values of the mechanical and technological characteristics in the elevated-temperature tensile test

KTA 3211.1

Steel grade

Energy absorbed (Charpy-V) in J at least at 0 C Mean value of 3 specimens Individual value 34

at 33 C 1) Individual value 68

Upper shelf 2) of the energy absorbed (Charpy-V) in J at least Individual value 100

GS-C 25 S GS-18 NiMoCr 3 7

+ 10 C for GS-18 NiMoCr 3 7.

41

1) If agreed in the purchase order, this requirement shall also apply at lower temperature, but not below + 5 C for GS-C 25 S and not below 2) The test is generally performed at 80 C.

Table A 4-4: Characteristic values of energy absorbed in the notched-bar impact bend test on Charpy-V-notch specimens

Quenching and tempering Steel grade Hardening C GS-C 25 S GS-18 NiMoCr 3 7 900 to 940 1) 880 to 950 2) Tempering C 650 to 700 650 to 700

Preheating C 100 to 250 3) 150 to 250

Stress-relief annealing 4) C 580 to 620 580 to 620

1) Quenching in oil or water. 2) Hardening two times in water. 3) Preheating may be waived if adequate experience is available. 4) If applicable, higher temperatures up to 30 K below the actually employed tempering temperatures may be permissible for stress-relief

annealing.

Table A 4-5: Particulars of preweld heat treatment and preheating, of thermal cutting and of stress-relief annealing

Simulated stress-relief annealing Steel grade GS-C 25 S GS-18 NiMoCr 3 7 Verification necessary Temperature in C 600 to 620 Holding time in minutes 900

yes

Table A 4-6: Necessity for verification of mechanical and technological characteristics in the simulated stress-relief-annealed condition, and performance of the simulated stress-relief annealing process

Page 81

KTA 3211.1

A 5 High-tensile steels for quenching and tempering for bolts and nuts A 5.1 General Section A 5 defines the details for manufacture, chemical composition, characterizing mechanical and technological characteristics and heat treatment as well as for further processing of high-tensile steels for quenching and tempering for bolts and nuts. These stipulations shall apply not only to rolled or forged bars but also to the bolts and nuts made from the bars. A 5.2 Manufacture of the steels and delivery condition A 5.2.1 Manufacture
Note: The steels shall be high-tensile steels for quenching and tempering with stipulated minimum values of elevatedtemperature strength characteristics.

presents the allowable deviations of chemical composition per the product analysis from the limit values of chemical composition per the ladle analysis. A 5.3.2 Mechanical and technological characteristics (1) The mechanical and technological characteristics shall apply to the delivery condition. The values shall be verified on longitudinal specimens from the sampling locations as per Section 8. (2) The characteristic values of the mechanical and technological characteristics in the room-temperature tensile test, including the minimum values of reduction of area at fracture, are stipulated in Table A 5-3. (3) The characteristic values of the mechanical and technological characteristics in the elevated-temperature tensile test are stipulated in Table A 5-4. (4) The characteristic values of energy absorbed and lateral expansion of Charpy V-notch specimens are stipulated in Table A 5-5. A 5.3.3 Physical characteristics Reference values for the physical characteristics can be found in Annex AP. A 5.4 Data on heat treatment Data for heat treatment are presented in Table A 5-6. A 5.5 Further processing Only machining is permitted.
Note: No provisions shall be made for hot or cold forming (thread rolling shall not qualify as cold forming).

(1) The steels shall be smelted by the basic oxygen process or in the electric furnace. If other processes are used, proof of equivalence shall be furnished. Steel grades 26 NiCrMo 14 6 and 34 CrNiMo 6 S shall be subjected to metallurgical ladle post-treatment or remelted in vacuum or by the electroslag refining process. (2) The steels shall be made in particularly killed condition.

A 5.2.2 Delivery condition The steels shall be delivered in the quenched and tempered condition or in the quenched and tempered plus stress-reliefannealed condition. A 5.3 Material characteristic values A 5.3.1 Chemical composition The values stipulated in Table A 5-1 shall apply to the chemical composition per the ladle analysis. Table A 5-2

Steel grade

Limit value C min. 0.18 0.25 0.25 0.30 0.30 0.38 Si 0.15 0.40 0.30 0.15 0.40 Mn 0.30 0.50 0.20 0.50 0.40 0.70 P

Content by mass in % S 0.010 0.010 0.010 Cr 1.20 1.50 1.20 1.70 1.40 1.70 Mo 0.25 0.50 0.35 0.55 0.15 0.35 Ni 3.40 4.00 3.30 3.80 1.40 1.70 V 0.08 1) Altotal 0.020 0.050 0.020 0.050

20 NiCrMo 14 5

max. min.

0.020 0.020 0.020

26 NiCrMo 14 6

max. min.

34 CrNiMo 6 S

max.

1) Values larger than 0.08 and smaller than or equal to 0.12 % may be approved by appraisals on a case-by-case basis.

Table A 5-1: Chemical composition per the ladle analysis of high-tensile steels for quenching and tempering for bolts and nuts

Page 82

KTA 3211.1

Element C Si Mn P S Al Cr Mo Ni V

Allowable limit deviation 1) of values per the product analysis Content by mass in % 0.02 0.03 0.04 + 0.005 + 0.005 0.005 0.05 0.04 0.05 2) + 0.02

1) If several product analysis are performed for one heat and deviations of chemical composition per the product analysis are found from the

permissible values of chemical composition per the ladle analysis, these deviations for a given element shall be allowable only if they are either all above or all below the limit values as per Table A 5-1. 2) For permissible nickel contents of 2.00 to 4.00 % per the ladle analysis, deviations of 0.07% Ni in the values per the product analysis shall be allowable.

Table A 5-2: Allowable deviations of chemical composition per the product analysis from the limit values of chemical composition per the ladle analysis Diameter (bar steel), in mm 0.2% proof stress Rp0.2 in N/mm2 at least 940 130 980 940 830 Tensile strength Rm in N/mm2 1040 to 1240 1080 to 1280 1040 to 1240 930 to 1130 Elongation at fracture A in % at least 14 14 14 16 Reduction of area at fracture Z in % at least 55 55 50 45

Steel grade 20 NiCrMo 14 5 (I) 20 NiCrMo 14 5 (II) 26 NiCrMo 14 6 34 CrNiMo 6 S

Table A 5-3: Characteristic values of the mechanical and technological characteristics in the room-temperature tensile test Diameter (bar steel), in mm in mm 20 NiCrMo 14 5 (I) 20 NiCrMo 14 5 (II) 26 NiCrMo 14 6 34 CrNiMo 6 S 0.2% proof stress Rp0.2 in N/mm2 at 300 C 785 830 790 630 350 C 735 785 785 560 Tensile strength Rm in N/mm2 at 300 C 860 900 860 760 350 C 840 880 820 735 Elongation at fracture A in % at 300 C 350 C 14 14 14 16 14 14 14 16 Reduction of area at fracture Z in % at 300 C 350 C 55 55 45 45 55 55 45 45

Steel grade

130

Table A 5-4: Minimum values of the mechanical and technological characteristics in the elevated-temperature tensile test Diameter (bar steel) in mm 130 Energy absorbed in J Mean value Individual value 76 76 61 72 76 Lateral expansion in mm Individual value

Steel grade 20 NiCrMo 14 5 (I) 20 NiCrMo 14 5 (II) 26 NiCrMo 14 6 34 CrNiMo 6 S

0.65

Table A 5-5: Characteristic values of energy absorbed and lateral expansion on Charpy V-notch longitudinal specimens at 20 C Temperature range in C for austenitization 840 to 900 800 to 900 840 to 870 820 to 870 Temperature range in C for Tempering Stress-relief annealing 520 to 600 500 to 580 530 to 580 550 to 640 430 to 470 430 to 470 450 to 500 450 to 500

Steel grade 20 NiCrMo 14 5 (I) 20 NiCrMo 14 5 (II) 26 NiCrMo 14 6 34 CrNiMo 6 S

Cooling fluid

Water or oil

Table A 5-6: Data for heat treatment of high-tensile steels for quenching and tempering for bolts and nuts Page 83

KTA 3211.1

A 6 Bar steel for bolts and nuts; additional stipulations to DIN 17 240 and DIN EN 10 269 A 6.1 General Section A 6 shall apply in addition to the stipulations of DIN 17 240 (7/76) and DIN EN 10 269 (11/99) for the steel grades listed in Table A 6-1 when used for bolts and nuts within the scope of validity of this safety standard. (2) The stipulations shall apply to rolled or forged bar steel and to the bolts and nuts made from it. A 6.2 Dimensional limits The steel grades listed in Table A 6-1 may be used up to the dimensional limits indicated therein.

A 6.3 Notched-bar impact bend test Table A 6-1 presents the values of energy absorbed and lateral expansion to be verified in the notched-bar impact bend test at 20 C with Charpy V-notch specimens (longitudinal), taking the stipulations of clause 8.2.2 into consideration. A 6.4 Elevated-temperature tensile test Table A 6-1 also presents the values of tensile strength at elevated temperatures.

Steel grade Abbreviated name Heattreatment condition Standard

Diameter in mm

Energy absorbed in J (Charpy-V specimens, longitudinal)

Lateral Tensile strength expansion Rm in N/mm2 in mm at least at the temperature of 300 C 350 C

at room temperature Mean value, at least Individual value, at least 39 39 82 70 52 52 37 19 37 19 33 35 Individual value, at least 0,60 0,60 0,95 0,85 0,60 0,60

Ck 35 C35E 24 CrMo 5 21 CrMoV 5 7 21CrMoV5-7 X 22 CrMoV 12 1 1)

V +QT V V +QT V

DIN 17 240 DIN EN 10 269 DIN 17 240 DIN 17 240 DIN EN 10 269 DIN 17 240

60 60 100 > 100 to 130 100 100 60 > 60 to 100 2) 60 > 60 to 100 2) 80 80

55 55 118 102 63 63 52 27 52 27 47 50

400 400 460 460 590 590 620 620 620 620 510 530

390 390 440 440 560 560 600 600 600 600 500 505

X22CrMoV12-1 X 8 CrNiMoBNb 16 16 X7CrNiMoBNb16-16

+QT1 WK+AL

DIN EN 10 269 DIN 17 240

+WW+P DIN EN 10 269

1) Tensile strength at room temperature 800 N/mm2 to 950 N/mm2. 2) Only for nuts.

Table A 6-1: Limits of permissible dimensions and additional stipulations for steels to DIN 17 240 and DIN EN 10 269 for bolts and nuts Page 84

KTA 3211.1

Annex AP Reference data on physical characteristics

AP 1 Scope of application This Annex contains reference data on a) specific density, b) dynamic modulus of elasticity, c) mean coefficient of linear thermal expansion, d) mean specific heat capacity and e) thermal conductivity for the steel grades cited in Sections A 1 through A 5. AP 2 Characteristic values AP 2.1 General The characteristic values listed in Table AP-1 for physical characteristicfs are reference data compiled on the basis of measurements on individual heats and of literature data [3].

AP 2.2 Determination of characteristic values At present a standardized method has not been defined for determination of the characteristic values presented here for physical characteristics. AP 2.3 Scatter band of characteristic values (1) Changes in chemical composition and heat treatment lead to a certain scatter band of physical characteristics. Any grain orientation has a particularly strong influence on the values of modulus of elasticity. (2) Differences between the measurement employed may lead to additional scattering. methods

(3) The documents available at present are not adequate for statistical evaluation of reliability. (4) The statements on the scatter band of characteristic values in footnotes 1 to 5 of Table AP-1 were taken from the literature. They relate to the average scatter band of the measured values acquired there.

Page 85

Steel grade
3)

KTA 3211.1

Specific density 1) in 106 g/m3 Mean coefficient of linear thermal expansion in 10-6 K-1 between 20 C and the temperature in C at the temperature in C 400 20 100 200 300 41 42 41 31 31 36 43 38 43 42 42 42 42 43 37 43 43 43 43 43 37 42 34 42 43 43 43 43 31 31 37 41 32 41 42 42 42 42 39 40 40 40 40 42 43 43 43 44 44 30 30 42 14.1 44 44 29 29 14.2 0.46 0.49 0.51 0.52 0.53 14.0 14.9 13.9 13.8 13.8 13.8 13.8 34 14.0 12.2 12.2 350 40 40 39 31 31 36 39 400 100 200 300 350 400 100 200 300 350 13.6 13.3 13.6 13.6 12.1 12.1 13.7 13.6 14.8 13.4 13.3 13.3 13.3 13.3 12.9 13.0 13.2 11.6 11.6 13.2 13.1 13.9 12.9 12.8 12.8 12.8 12.8 12.4 183 12.4 12.7 11.2 11.2 12.5 183 12.5 12.6 12.2 12.3 12.3 12.3 12.3 175 177 184 184 184 184 184 Mean specific heat capacity 4) in J g-1 K-1 between 20 C and the temperature in C

Dynamic modulus of elasticity in 103 N/mm2 Thermal conductivity in W m-1 K-1

2)

5)

at the temperature in C 200 300 350 400 187 191 191 192 182 182 182 192 185 186 192 192 192 192 198 199 199 191 191 191 200 194 196 200 200 200 200

at 20 C

20

100

15 MnNi 6 3

7.85

211

206

15 NiCuMoNb 5 S

7.84

210

206

20 MnMoNi 5 5

7.86

211

206

20 NiMoCr 14 5

7.84

205

200

26 NiMoCr 14 6

7.84

205

200

34 CrNiMo 6 S

7.80

205

200

C 22.8 S

7.80

212

205

GS-18 NiMoCr 3 7

7.86

210

203

GS-C 25 S

7.83

211

204

WStE 255 S

7.85

212

207

Page 86

WStE 285 S

7.85

212

207

WStE 315 S

7.84

212

207

WStE 355 S

7.83

212

207

1) Average bandwidth of measured values 0.05 106 g/m3. 2) Average bandwidth of measured values 5 103 N/mm2. 3) Average bandwidth of measured values 0.8 10-6 K-1. 4) Average bandwidth of measured values 0.01 J g-1 K-1.

5) Average bandwidth of measured values 3.5 W m-1 K-1 for ferritic steels; 1.5 W m-1 K-1 for austenitic steels.

Table AP-1: Reference data on specific density, dynamic modulus of elasticity and mean coefficient of linear thermal expansion of the steel grades as per Sections A 1 through A 5

KTA 3211.1

Annex B Non-destructive examinations of steel castings

B 1 General This Annex shall apply to the non-destructive examinations of castings for cases and bodies to Sections 5.7, 6.7, 7.7 and 9.2. B 4.2 Test groups A 2 and A 3 (1) The first three castings of a production lot (prototypes) shall be subjected completely to a volumetric examination. (2) All further castings of the same production lot with the same melting and casting technique shall be examined in the following zones: a) zones that are complex from the viewpoint of casting and stress, b) welding ends, c) relatively large production welds, d) places at which defects with acceptable limit sizes were observed in the examination of the prototypes. (3) The zones that are complex from the viewpoint of casting and stress shall be determined by decision among the participants, who shall also decide upon the consolidation of production lots. (4) For small production welds, it is also permitted, starting with the fourth casting, to perform an ultrasonic examination instead of the radiographic examination. (5) All internal and external surfaces, including those of production welds as well as the excavations for production welds, shall be subjected to a surface-crack detection.

B 2 Type of examinations B 2.1 Examination methods for cast steel The examination methods for the different cast-steel grades and part zones can be found in Table B-1. B 2.2 Type and extent of ultrasonic examination (1) In the zones listed below (see Figures B-1 through B-11), the ultrasonic examination shall be employed as a volumetric examination: a) on rough-turned flanges with nominal thickness equal to or larger than 20 mm, b) on machined seat portions with nominal thickness equal to or larger than 40 mm, c) on ribs and cast-on parts with nominal thickness equal to or larger than 40 mm. (2) These zones shall be examinable in at least two mutually perpendicular scanning directions. (3) In addition, it is permitted to perform an ultrasonic examination instead of the radiographic examination on the small production welds of test group A 2, provided the requirements of Section B 4.2 are met. (4) If the ultrasonic examination is employed as a volumetric examination in zones other than those illustrated in Figures B-1 through B-11, the procedure shall be subject to the authorized inspectors approval on a part-by-part basis.

B 5 Method-related requirements B 5.1 Surface finish The surface prepared for the non-destructive examination shall be evaluated to DIN EN 1370. The castings shall have a surface quality equal to or better than that of reference samples BNIF 3S1 or 4S2. Castings to be examined by the liquid-penetrant method shall have a surface quality equal to or better than that of reference sample BNIF 3S2. B 5.2 Radiographic examination B 5.2.1 Procedure (1) Radiographic examination shall be performed per test class A of DIN 54 111-2 and DIN EN 462-3 image quality class A under consideration of DIN EN 444, in which case the image quality indicator to DIN EN 462-1 shall be used, unless otherwise stipulated in the following. (2) The film processing shall be made to DIN EN 584-2.

B 3 Point of time of examinations and participation in examinations (1) The point of time of non-destructive examinations in the production sequence as well as the participation in examinations is defined for cast-steel cases and bodies in Figure B-12. (2) If further machining is performed by the component manufacturer, a surface-crack detection shall additionally be made of the surfaces produced by such machining.

(3) Welding ends and zones intended for construction welds shall be radiographed in test class B of DIN 54 111-2. B 4 Extent of examinations B 4.1 Test group A 1 (1) All cast products including production welds shall be completely radiographed. For ferritic and martensitic cast-steel grades, it is permitted as an alternative to perform an ultrasonic examination of the casting zones identified in Figures B-1 through B-11. (2) All internal and external surfaces, including those of production welds as well as the excavations for production welds, shall be subjected to a surface-crack detection. B 5.2.2 Film locations (1) Steel castings with an outside diameter equal to or smaller than 200 mm shall be radiographed as per film arrangement 7 of Table 1 to DIN 54 111-2. (2) For steel castings with an outside diameter larger than 200, film arrangement 7 of Table 1 to DIN 54 111-2 shall be selected only if film arrangements 3 or 4 are not feasible or if the assessment capabilities shall be improved.

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KTA 3211.1

B 5.2.3 Special conditions for overall filming (1) Overall films shall be prepared preferably by using linear accelerators. Notwithstanding the standard, total wall thicknesses of 2 x s equal to or larger than 40 mm may be radiographed under these conditions. (2) The radiographic density shall be greater than 2.0.

B 6 Acceptance limits B 6.1 Cast products including production welds and welding ends (1) The quality levels allocated to the test groups are presented in Table B-2. (2) The acceptance limits for the findings of the radiographic, ultrasonic, magnetic-particle and liquid-penetrant examinations shall be those to DIN 1690-2. (3) If impermissible findings are observed in overall films, they shall be checked by additional selective films. B 6.2 Excavations for production welds (1) The only permissible indications shall be those that do not impair weldability and are not associated with impermissible surface and volumetric defects that shall be eliminated. (2) The welding supervisory agency and inspection supervisory agency of the manufacturer shall be required to decide jointly on potential impairment of weldability by findings that are left in place.

(3) When the overall filming technique is employed, a reference-point grid shall be required only if partial zones are radiographed and continuity with the adjoining zones radiographed with internally disposed radiation sources shall be demonstrated. B 5.3 Ultrasonic examination of ferritic steel castings (1) The ultrasonic examination shall be performed to SEP 1922, test class I. (2) If production welds with a depth of equal to or smaller than 15 mm are examined from their own surface, examination with a normal probe (transmitter-receiver) will suffice. In all other cases, production welds shall be examined whenever feasible by means of angle-beam scanning with an angle probe in four mutually perpendicular beam-entry positions. In all cases the adjoining base-metal zones shall be included in the examination. B 5.4 Magnetic-particle examination B 5.4.1 Procedure Magnetic-particle examination shall be performed to SEP 1935 and Annex G. B 5.5 Liquid-penetrant examination B 5.5.1 Procedure Liquid-penetrant examination shall be performed to SEP 1936 and Annex G.

B 7 Documentation The inspection reports shall contain all particulars and data (including radiation source plan and film location plan) that permit reproducible conduct of the examination. The presentation of findings of the volumetric examination shall be clear and unambiguous and shall permit correlation with the part at every place.

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KTA 3211.1

Figure B-1: Valve body

Figure B-2: Angle-valve body

Figure B-3: Wedge-type gate-valve body

Figure B-4: Swing-check-valve body

Figure B-5: Multi-way-valve body

Figure B-6: Discharge casing

Figure B-7: Suction casing

Figure B-8: Scroll casing

Figure B-9: Double scroll casing

Figures B-1 through B-11: Examples of valve-body or pumpcasing zones for which ultrasonic examination is permissible

Figure B-10: Annular casing

Figure B-11: Barrel-type-pump casing Page 89

KTA 3211.1

Cast-steel group Ferritic cast-steel grades Martensitic cast-steel grades Austenitic cast-steel grades

Casting zones Cast product Magnetic particle examination 4) Radiographic examination 3) Magnetic particle examination 4) Radiographic examination 3) Liquid-penetrant examination Radiographic examination Adjoining zones 1) Magnetic particle examination 4) Welding ends 6) Magnetic particle examination 4) Radiographic examination 3) Magnetic particle examination 4) Radiographic examination 3) Liquid-penetrant examination Radiographic examination Excavations Liquid-penetrant examination Radiographic examination Liquid-penetrant examination Radiographic examination Liquid-penetrant examination Radiographic examination Production weld 2) Magnetic particle examination 4) Radiographic examination 5) Magnetic particle examination 4) Radiographic examination 5) Liquid-penetrant examination Radiographic examination

Magnetic particle examination 4)

Liquid-penetrant examination

1) Adjoining zones are zones located outside the pressure-retaining wall, such as

feet, brackets, lugs, external fins, cams.

2) See DIN 17 245 for definition of relatively large production weld. 3) Alternatively, it is permitted to perform an ultrasonic examination as per Section B 2.2. 4) Magnetic-particle examination shall be preferred for magnetizable materials. However, liquid-penetrant examination may be employed:

a) in zones that are difficult to magnetize because of geometry or accessibility considerations b) for cast-steel grade G-X 5 CrNi 13 4, material No.1.4313.
5) In test group A 2, it is permitted to replace the radiographic examination of small production welds by an ultrasonic examination, starting

with the 4th casting of a production lot.

6) Also applicable for zones of construction welds.

Table B-1: Examination methods for cast-steel grades and their casting zones

Quality levels to DIN 1690-2 Test group A1 A2 A3 Case or body including production welds S1-V2 S2-V3 S2-V3 S1-V1 S3-V3 Welding ends Adjoining zones 1) 2)

1) Adjoining zones are zones located outside the pressure-retaining wall, such as

- feet, - brackets, - lugs.

2) For test groups A 1 through A 3 of materials to Sections 7.7 and 9.2, the quality level for the adjoining zones shall be S3-V4.

Table B-2: Quality levels as a function of test group and casting zones

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KTA 3211.1

Casting Quenching and tempering or solution annealing Setting of the surface quality per Section B 5.1 Complete surface-crack detection by manufacturer (H)

Procedure 1 Production welds with complete heat treatment Grooving out and liquid-penetrant examination of the places prepared for welding by H Documentation of the larger production welds 4) for the interim file and informing of the authorized inspector (S) Welding per Annex C Soaking, if required in Material Annex Grinding the welds smooth Surface-crack detection of the production welds by H

Procedure 2 Production welds without subsequent heat treatment for establishing the mechanical and technological characteristics Grooving out and liquid-penetrant examination of the places prepared for welding by H Documentation, for the final file, of all production welds in material group W 1, larger production welds 4) in W 2 and austenite Permission1) for welding in W 1 by authorized inspector Welding per Annex C Grinding the welds smooth Ferrite: stress-relief annealing Martensite: tempering Austenite: none no Surface-crack detection of the production welds by H

yes

Impermissible indications

Volumetric examination 2) by H Evaluation of the films by H and S Ultrasonic re-examination by S if there is ferrite

yes

Impermissible indications

no

Volumetric examination 2) by H yes Impermissible indications and findings no Evaluation of the films by H and S

yes Heat treatment to establish the mechanical and technological characteristics Quenching and tempering or solution annealing Setting of the surface quality per Section B 5.1 Complete surface-crack detection

Impermissible indications and findings

no

Grooving out and liquid-penetrant examination of the places prepared for welding by H Documentation, for the final file, of all production welds in material group W 1, larger production welds 4) in W 2 and austenite Permission for welding by authorized inspector in A 1 yes Welding per Annex C Grinding the welds smooth Ferrite: stress relief annealing Martensite: tempering

Impermissible indications

no Surface-crack detection and radiography of the production weld by H Evaluation of the films by H and S 1) Applies only to material group W I, test group A 1. 2) Note when there are additional volumetric examinations: Radiographed welds and casting zones with permissible findings need not be re-examined. 3) If, in exceptional cases in the course of further processing, it becomes necessary for the component manufacturer to perform production welds in order to eliminate casting defects in an advanced state of processing, then deviations relative to the standard production scheme shall be permissible by agreement with the authorized inspector. DIN 17 245 Annex B shall apply to cast-steel grade GS-C25. 4) See DIN 17 245 for definition of larger production weld. Ultrasonic re-examination by S if there is ferrite

yes

Impermissible indications and findings

no

Acceptance Complete surface-crack detection 3) by H and S Mechanical and technological tests Compilation of the documentation

Figure B-12:

Production scheme for cast steel cases and bodies made of ferritic, austenitic or martensitic cast-steel grades

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KTA 3211.1

Annex C Production welds of steel castings

C 1 General This Annex shall apply in addition to the stipulations of DIN 1690-2 and SEW 110 for production welds on steel castings.
Note: Production welds shall be employed only if the defect cannot be repaired in another way without reducing the thickness below the nominal value.

C 5 Welding procedure qualifications (1) For all materials to be welded and for all welding methods, a welding procedure qualification as per SEW 110 and per the following stipulations shall be performed before the start of production welding for each planned heat treatment, welding position and wall thickness. (2) The welding procedure qualification for a particular steel shall also be applicable for other steels within the limits set in KTA 3211.3. (3) The duration of validity of a welding procedure qualification shall be 24 months after successful completion of the welding procedure qualification. This period shall begin with the date of the written opinion of the authorized inspector. If production is started within these 24 months and production control tests to Section C 6 have been performed, the initial period shall be extended by a further 24 months, counting from the start of validity of the production control test. (4) If production is not started within 24 months after successful completion of the welding procedure qualification or is interrupted for longer than 24 months, the first production control test prior to starting or resuming production shall be treated as a repeat of the welding procedure qualification. The stipulations of the original welding procedure qualification shall govern the scope of this production control test, with regard to both the start of validity and the duration of validity. (5) Before the welding procedure qualification is performed, a welding procedure sheet and, if necessary, a heat-treatment plan shall be submitted to the authorized inspector. (6) It shall not be necessary to use for the welding procedure qualification the same heats of base metal or the same batches of weld filler metals and welding consumables as are used for welding of parts. (7) The welding shall be performed under constraint conditions. (8) Welding records of welding procedure qualifications shall be kept. Blank forms per KTA 3211.3 or sheets with identical information content shall be used for this purpose. (9) The scope of the welding procedure qualification as per SEW 110 is stipulated in Table C-1. Table C-2 additionally contains stipulations on the technological bend test. (10) Welding procedure qualifications that are still valid but are not fully in conformity with the stipulations of Table C-1 regarding the scope of testing may be added to by supplementary tests in a preliminary production control test.

C 2 Prerequisites (1) The general requirements per Section 3 shall be met.

(2) Production welds as well as their examination and documentation shall be classified as per the production scheme of Figure B-12 in the process of casting manufacture. The individual production steps shall be completed in the described sequence. In the event of deviations from the standard production sequence, a design approval of the sequence of production steps shall be required. A distinction shall be made between Procedure 1 (production welding with subsequent quenching and tempering or solution annealing and quenching) on the one hand, and Procedure 2 (production welding without subsequent quenching and tempering or solution annealing and quenching) on the other hand. (3) If the castings are not quenched and tempered or solution-annealed and quenched after production welding, for example, because of the machining condition, the authorized inspectors consent regarding production welding shall be obtained if required in Annex B. In this case the production welds shall be documented as per Figure B-12. (4) For relatively large production welds that will subsequently be quenched and tempered or solutionannealed and quenched, the authorized inspector shall be given adequate advance notification of the welding work. Suspension of the production sequence is not required.
Note: See DIN 17 245 for definition of relatively large production weld.

(5) For small production welds that will subsequently be quenched and tempered or solution-annealed and quenched, it is not required to notify the authorized inspector.

C 3 Weld filler metals and welding consumables The weld filler metals and welding consumables shall meet the requirements of KTA 1408.1, KTA 1408.2 and KTA 1408.3 Section 3.

C 4 Heat supply during welding and post-weld heat treatment (1) The appropriately defined preheating temperature shall be met for welding as well as for all cutting and joining work. (2) The welding conditions and welding parameters for ferritic and martensitic cast-steel grades shall be selected such that the lowest possible hardness values are achieved for the particular material. Work specimens shall be taken to verify that hardness values of 350 HV 10 are not exceeded. (3) Production welds on castings of ferritic or martensitic steels shall be heat-treated as per Figure B-12. (4) Correlation of the castings with the heat-treatment lot shall be ensured.

C 6 Production control tests (1) Depending on scope of validity of the welding procedure qualification, the manufacturer shall be required to perform one production control test per year during production in the presence of the authorized inspector. KTA 3211.3 Section 5 shall apply in addition to the stipulations of this section. (2) Production control tests on a steel of material group W I shall also cover production control tests on the same steel for use in material group W II. (3) The test coupons for production control tests shall be taken from one of the heats involved. (4) The weld filler metals and welding consumables shall be taken from one of the manufacturing lots involved.

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KTA 3211.1

(5) The test coupons shall be welded by welders who participate in production. (6) Production control tests shall be performed as fullpenetration welds. They shall cover all partial penetration weldings. (7) The test pieces shall be subjected to simulated heat treatment approved by the authorized inspector or shall be traveller pieces subjected to the same heat treatment as the casting.

(8) The extent of examination and requirements are stipulated in Table C-3. C 7 Documentation The documentation of welding procedure qualification and production control tests, including the associated design approval documents, shall be organized per the stipulations set forth for welding procedure qualification in SEW 110, and shall be attached to the acceptance test certificate.

Type of examination Non-destructive examinations

Number of specimens, specimen location, requirements 100 % surface-crack detection 100 % volumetric examination, examination procedure and requirements as per the stipulations of SEW 110. a) Base metal (DIN EN 10 002-1) 1 specimen (DIN 50 125) at room temperature Requirements to Sections 5.7, 6.7, 7.7 or 9.2 b) Welded joint (DIN EN 895) 2 specimens (DIN EN 895, Figure 2a or 2b, parallel length Lc = weld width + at least 60 mm) at room temperature. Rm and fracture location shall be tested (tensile-strength requirement as for the base metal). c) All-weld metal (DIN EN 10 002-1) 1 specimen (DIN 50 125, L0 = 5 d0) at room temperature. Requirements for Rp0.2, Rm, A, Z, as well as Rp1.0 for austenite, stipulated as for the weldability test. Ferritic steels of material group W I One specimen set of base metal at 0 C. One specimen set each of weld metal and heat-affected zone at 0 C, 33 C and 80 C. Specimen location as per Figure C-1. See clause 4.3.1 for requirements. If the temperature at which 68 J (smallest individual value) and 0.9 mm lateral expansion (smallest individual value) is reached lies between 0 C and 33 C, the exact value of this temperature may be determined by interpolation and used as the lowest permissible loading temperature. The ductile fracture percentage of the fractured area shall be determined. Ferritic steels of material group W II One specimen set of base metal at 0 C (20 C permissible if the lowest loading temperature exceeds 20 C and the weld metal as well as the heat affected zone are tested at 20 C). One specimen set each of weld metal and heat-affected zone at 0 C (20 C permissible if the lowest loading temperature exceeds 20 C). Specimen location as per Figure C-1. See clause 4.3.2 for requirements. The ductile fracture percentage of the fractured area shall be determined. Austenitic steels One specimen set each of weld metal at room temperature. Specimen location as per Figure C-1. See clause 4.3.3 for requirements. Martensitic steels One specimen set of base metal at room temperature. Requirements as per Sections 5.7 or 9.2. One specimen set each of weld metal and heat-affected zone at room temperature. Specimen location as per Figure C-1. Requirements as for the base metal. One specimen each with root and cover pass on the tension side; see Table C-2 for bending-mandrel diameter and requirements. Weld metal Not required for unalloyed steels. Elements to be verified per weldability test of the weld filler metals.

Tensile test (DIN EN 895 and DIN EN 10 002-1)

Notched-bar impact bend test (DIN EN 10 045-1) on Charpy-V specimens

Technological bend test (DIN EN 910) Chemical composition

Table C-1: Extent of examination and stipulations for procedure qualification for production welds on steel castings (Part 1) Page 93

KTA 3211.1

Type of examination Metallographic examinations with photographic documentation

Number of specimens, specimen location, requirements a) Macrograph To be evaluated: Weld buildup, penetration, slag, pores. Requirements: Satisfactory weld buildup, satisfactory penetration; isolated slag inclusions and pores are permitted. b) Micrograph, magnification at least 100 : 1 (not required for unalloyed steels). To be evaluated: Microstructure. For austenite, delta ferrite content in the weld metal shall additionally be determined. Requirement: A ferrite content of 4 to 10 % should be targeted; a closed lattice structure is not permitted. as per SEW 110 Austenitic steels Specimen location: root side without additional sensitization. Requirement: freedom from cracks.

HV 10 hardness test (DIN EN ISO 6507-1) Verification of intergranular corrosion resistance (DIN EN ISO 3651-2)

Table C-1: Extent of examination and stipulations for welding procedure qualification for production welds on steel castings (Part 2)

Steel group Ferritic and martensitic steels

Tensile strength Rm in N/mm2 Rm < 430 430 Rm < 460 Rm 460

Bending mandrel diameter 2a 2.5 a 3a 3a

Bend angle in degrees 180 180 180 180

Allowable deviation Cracks shall not be longer than 1.6 mm. Bursting open due to pores or lack of fusion are permitted. As for ferritic and martensitic steels with Rm < 460 N/mm2, but in addition: - If the specimen breaks at a bend angle 90, the elongation of the gauge length (L0 = weld width + wall thickness) shall reach the minimum value of elongation at fracture A of the base metal. - If the specimen breaks at a bend angle < 90, the elongation over the weld width shall reach at least 30 %. The fracture surface appearance shall be free of defects.

Austenitic steels

Table C-2: Bending-mandrel diameter for the technological bend test to DIN EN 910 in connection with welding procedure qualification for production welds on cast steel

a) Specimen location in the weld metal

0.5 0.3

c) Specimen location in the HAZ or transition 0.5 0.3

b) Specimen location in the HAZ or transition

d) only if b) is not feasible

Figure C-1: Location of the notch in notched-bar impact bend-test specimens Page 94

KTA 3211.1

Type of examination Non-destructive examinations Tensile test (DIN EN 895, DIN EN 10 002-1 and DIN EN 10 002-5)

Number of specimens, specimen location, requirements 100 % surface-crack detection 100% volumetric examination, examination procedure and requirements as per the stipulations for the base metal. a) Welded joint (DIN EN 895) 2 specimens (DIN EN 895, Figure 2a or 2b, parallel length Lc = weld width + at least 60 mm) at room temperature. Rm and fracture location shall be tested (tensile-strength requirement as for the base metal). b) All-weld metal (DIN EN 10 002-1 and DIN EN 10 002-5) 1 specimen (DIN 50 125, L0 = 5 d0) at room temperature and design temperature 1). Requirements for Rp0.2, Rm, A, Z, as well as Rp1.0 for austenite, stipulated as for the weldability test.

Notched-bar impact bend test (DIN EN 10 045-1) on Charpy-V specimens

Ferritic steels of material group W I One specimen set each of weld metal and heat-affected zone at 0 C and at the lowest loading temperature or at 33 C, if correlation with a particular component is not possible. Specimen location per Figure C-1. See clause 4.3.1 for requirements. If the temperature at which 68 J (smallest individual value) and 0.9 mm lateral expansion (smallest individual value) is reached lies between 0 C and 33 C, the exact value of this temperature may be determined by interpolation and used as the lowest permissible loading temperature. If the requirement for minimum values of energy absorbed and lateral expansion at the lowest operating temperature is already met at 0 C, the test at higher temperature is not required. The ductile fracture percentage of the fractured area shall be determined. Ferritic steels of material group W II One specimen set each of weld metal and heat-affected zone at 0 C or at 20 C, if the lowest loading temperature exceeds 20 C. Specimen location as per Figure C-1. See clause 4.3.2 for requirements. The ductile fracture percentage of the fractured area shall be determined. Austenitic steels One specimen set each of weld metal and heat-affected zone at room temperature. Specimen location as per Figure C-1. See clause 4.3.3 for requirements. Martensitic steels One specimen set each of weld metal and heat-affected zone at room temperature. Specimen location as per Figure C-1. Requirements as for the base metal.

Metallographic examinations with photographic documentation

a) Macrograph To be evaluated: Weld buildup, penetration, slag, pores. Requirements: Satisfactory weld buildup, satisfactory penetration; isolated slag inclusions and pores are permitted. b) Micrograph, magnification at least 100 : 1 (not required for unalloyed steels). To be evaluated: Microstructure. For austenite, delta ferrite content in the weld metal shall additionally be determined. Requirement: A ferrite content of 4 to 10 % should be targeted; a closed lattice structure is not permitted. Ferritic steels One hardness profile through base metal, heat-affected zone and weld metal, as close as possible under the surface. Requirement: 350 HV 10 shall not be exceeded. Austenitic steels Specimen location: root side without additional sensitization. Requirement: freedom from cracks.

HV 10 hardness test (DIN EN ISO 6507-1)

Verification of intergranular corrosion resistance (DIN EN ISO 3651-2)

1) The elevated-temperature tensile test shall be required if the operating temperature is higher than 200 C (test groups A 1 and A 2) or

higher than 300 C (test group A 3). In these cases, the elevated-temperature tensile test shall be performed at 350 C for ferritic steels, at 400 C for austenitic steels and at 320 C for martensitic steels.

Table C-3:

Extent of examination and stipulations for production control tests for production welds on steel castings

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Annex D Procedure for determining the delta ferrite content

D 1 General This annex specifies details for the procedures required for the determination of the products delta ferrite content under Sec. 4.4.6.8 (1). D 2 Metallographic determination on castings in the as-delivered condition (1) A test specimen shall be taken from the product at the specified sampling location, be ground and polished in the usual way and etched in accordance with Murakami [4]. The etched surface shall have an area of at least 10 mm by 10 mm. (2) The evaluation shall be performed at a magnification of 100:1. (3) A representative location of the etched surface shall be documented as photograph at a magnification of 100:1. (4) With regard to the quantitative evaluation it is recommended to compare the micrograph with a corresponding delta ferrite reference sheet and classify it accordingly. Alternatively, the procedure of a quantitative microstructure analysis may be employed. (5) The test report shall state: a) the shape, size and direction of the test specimen as well as the sampling location, b) the heat treatment condition, c) the delta ferrite content in %. A micrograph shall be contained in the test report. D 3 Metallographic analysis of the bead-on-plate test specimen (1) A test specimen of the following size shall be taken from the product form at the specified sampling location: length 200 mm, thickness 25 mm, width 40 mm. (2) A melt run with a length of at least 180 mm shall be deposited on the test specimen with a TIG burner without weld filler metals, using the following weld parameters (guidance values): voltage about 20 V, current about 160 A, feed rate about 20 cm/min. (3) In the case of product forms that do not allow taking of test specimens with a size as specified under (1) and where the weld parameters as specified under (2) cannot be applied, the specimen shape and heat input shall be adjusted as closely as possible to the welding to be performed later on the product. (4) A disc shall be taken from the middle of the melt run perpendicular to the surface of the test specimen and to the weld run axis; one side of this cross-section shall be ground and polished in the usual way and etched in accordance with Murakami [4]. (5) The evaluation shall be performed at a magnification of 1000:1. (6) A representative location of the surface-deposited weld zone on the etched surface shall be documented as photograph at a magnification of 1000:1. (7) With regard to the quantitative evaluation it is recommended to compare the micrograph with a corresponding delta ferrite reference sheet [5] and classify it accordingly. Alternatively, the procedure of a quantitative microstructure analysis may be employed. (8) The test report shall state: a) the shape, size and direction of the test specimen as well as the sampling location, b) the actual values of the welding parameters, c) the delta ferrite content in %. A micrograph with a specification of its location shall be added to the test report. D 4 Metallographic determination for weld material (during the procedure qualification and production weld test for weldings on castings) production (1) A slice through the entire cross-section shall be taken from the weld. For the metallographic examination, the slice shall be ground and polished for on one side in the usual way, as well as etched in accordance with Murakami [4]. (2) An overall photograph shall be taken of the entire weld cross section. (3) The evaluation shall be performed at a magnification of 1000:1. (4) With regard to the quantitative evaluation it is recommended to compare the micrograph with a corresponding delta ferrite reference sheet [5] and classify it accordingly. Alternatively, the procedure of a quantitative microstructure analysis may be employed. (5) Micrographs at a magnification of 1000:1 shall be made of at least three zones representative of the delta ferrite content. (6) The test report shall state: a) the sampling location, b) the heat treatment condition, c) the delta ferrite content in %. (7) The overall photograph as per (2) and the micrographs as per (5) shall be attached to the test report. The location of the zones as per (5) shall be marked in the overall photograph. D 5 Mathematical estimation according to De Long
Note: Figure D-1 in accordance with De Long [4] is used for the mathematical estimation of the delta ferrite content of the base metal molten during welding as well as of the weld material. In this graph the delta ferrite content is shown in relation to the chemical composition, however, not in terms of its volumetric ratio but rather on the basis of a special calibration (cf. DIN 32 514-1), in terms of the characteristic "ferrite number (FN)". In the range of small ferrite numbers up to FN 7, the ferrite number is identical to the delta ferrite content in %.

(1) The nickel equivalent NiE shall be calculated from the chemical composition of the base metal according to the equation NiE = % Ni + 30 (% C + % N) + 0.5 % Mn CrE = % Cr + % Mo + 1.5 % Si + 0.5 % Nb (D 5-1) (D 5-2) and the chrome equivalent CrE according to the equation

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(2) The calculated values of the nickel equivalent and chrome equivalent are the coordinates of a point in Figure D-1. The corresponding ferrite number is read from the graph. Where required, the values can be interpolated between the straight lines of constant ferrite numbers.

20 Austenite 18

Fe rri te no .
0 2 4

Nickel equivalent NiE

(3) The documentation of the mathematical estimation shall contain the following:: a) the chemical composition of the base metal, b) the value of the nickel equivalent, c) the value of the chrome equivalent, d) the delta ferrite content in terms of the ferrite number.

16 14 12 10 16 17 18 19 20 21 22
Aus hffl e t Ma enite r rten and site

Sc

8 0 1 2 1 4 1 6 1 8 1

Austenite and Ferrite 23 24 25 26 27

Chrome equivalent CrE

Figure D-1: Relationship between chemical composition and ferrite numbers of molten base metal or weld material (according to W.T. De Long [4])

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Annex E Non-destructive examinations of heat-exchanger tubes

E 1 Scope of application This Annex shall apply to non-destructive examinations of heat-exchanger tubes. E 2 Type, extent and point of time of non-destructive examinations Each tube shall be examined over its entire length and full cross section. The type, extent and point of time of nondestructive examinations can be found in Table E-1. E 3 Eddy-current examination E 3.1 Method-related prerequisites E 3.1.1 General The eddy-current examination shall be performed to DIN 54 141-3 in combination with the particulars of the following Sections. E 3.1.2 Examination system Encircling pass-through coils operating by the differential method shall be employed for the examination. The tubes shall pass concentrically through the examination coils. The coils shall be constructed such that optimum resolution is achieved at the chosen examination frequency. The value of the amplitude of the signals caused by indications shall be evaluated. E 3.1.3 Examination frequency (1) To define appropriate examination frequencies as a function of material, tube size and fabrication condition, sharpedged notches with a length of 20 mm, a width of smaller than or equal to 0.5 mm and a depth of less than or equal to 20 % of the nominal thickness but at least 0.15 mm shall be made on the outside and inside in the longitudinal axis of the tube. (2) For tubes of austenitic steels, the examination frequencies shall range from 10 to 50 kHz for wall thicknesses equal to or smaller than 1 mm and from 7 to 20 kHz for wall thicknesses larger than 1 mm and up to and including 2 mm. (3) The notches shall be made such that they do not cause perceptible changes of the microstructural characteristics of the material. (4) The geometry, shape and dimension of the notches shall be verified. (5) The examination frequency shall be selected such that the internal notch is verified with optimum signal-to-noise ratio. (6) The examination parameters employed shall be logged. examined shall be used to set the examination sensitivity. Three holes separated by 120 degrees and having 0.8 mm diameter shall be drilled in these tubes. The spacing of holes in the longitudinal direction of the tube should be sufficiently large that the holes yield separate and distinguishable signals. The smallest signal shall reach the response threshold of the indicating and recording instruments. The basic sensitivity setting shall be made at the examination speed planned for the examination, using the hole of 0.8 mm diameter. This basic sensitivity setting shall be corrected by a tube-diameterdependent dB value per Figure E-1.

0 +1 +2 +3 +4 +5

dB

+6 +7 +8 +9 +10 +11 +12 +13 0 10 20 30 40

Sensitivity II

Sensitivity I

Tube outside diameter [ mm ]

Figure E-1: Sensitivity of the eddy-current examination relative to a hole diameter of 0.8 mm

E 3.2 Examination procedure and assessment of the results E 3.2.1 Check of examination sensitivity (1) Before the examination is started, the examinationsensitivity setting and the stability of the instrument settings shall be verified by at least three passes of the test tube. (2) After every 100 tubes examined, the examination sensitivity shall be checked by another pass of the test tube. If a loss of more than 2 dB in examination sensitivity is noted, the examination shall be repeated on all tubes that were examined between the sensitivity setting to be corrected and the preceding sensitivity setting. E 3.2.2 Recording limits All indications shall be recorded that reach or exceed the signal amplitude of 0.8 mm diameter hole in accordance with clause E 3.1.4 (3), corrected by the diameter dependent dB value to Figure E-1.

E 3.1.4 Examination sensitivity (1) If the theoretical load factor of the tube wall is equal to or smaller than 30 %, examination sensitivity II to Figure E-1 shall be employed. Otherwise examination sensitivity I shall be required. (2) The required examination sensitivity shall be specified in the purchase order. (3) Test tubes with identical examination-related characteristics and the same dimensions as the tubes to be

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KTA 3211.1

E 3.2.3 Marking of indication sites All sites on tubes with indications having amplitudes that reach or exceed the recording limit shall be marked with a coloured marker. E 3.2.4 Assessment of indications (1) All tubes or tube sections with indications that reach or exceed the recording limit shall be sorted out. (2) These tubes shall be repaired within the permissible nominal thickness, after which they shall be subjected to another examination. Indication sites on tubes that have been sorted out may be re-examined with a different nondestructive examination method (e.g., visual inspection, radiographic examination) for observation of defect type and size. Verification that the indications are not objectionable shall be required.

examination. The geometry, shape and size of the reference reflector shall be verified. E 4.2 Examination procedure and assessment of the results E 4.2.1 Check of examination sensitivity (1) Before the examination is started, the examination sensitivity and instrument stability shall be verified by several passes of the test tube. (2) After every 2 hours, the examination sensitivity shall be checked by another pass of the test tube. If a loss of more than 2 dB in examination sensitivity is noted, the examination shall be repeated on all tubes that were examined between the sensitivity setting to be corrected and the preceding sensitivity setting. E 4.2.2 Recording limits (1) All indications shall be recorded that reach or exceed the reference echo amplitude. (2) The reference echo amplitude is the echo amplitude of the reference reflectors to clause E 4.1.2. E 4.2.3 Marking of indication sites All sites on tubes with indications having amplitudes that reach or exceed the recording limit shall be marked with a coloured marker. E 4.2.4 Assessment of indications (1) All tubes or tube sections with indications that reach or exceed the recording limit shall be sorted out. (2) These tubes shall be repaired within the allowable nominal thickness, after which they shall be subjected to another examination. Indication sites on tubes that have been sorted out may be re-examined with a different nondestructive examination method (e.g., visual inspection, radiographic examination) for observation of defect type and size. Verification that the indications are not objectionable shall be required. Diameter in mm 38 Extent of examination Examination method in % H S US WS X X 4) alternatively 100 St. 3) X X X

E 4 Ultrasonic examination E 4.2 Method-related prerequisites E 4.1.1 General An examination for longitudinal and transverse defects shall be performed to SEP 1915 and SEP 1918. The stipulations in the following sections shall apply in addition. E 4.1.2 Reference reflectors (1) Sharp-edged 60-degree V-notches or rectangular notches made on the outside and inside surfaces shall be used as reference reflectors. The notch depth shall be at least 10 % of the nominal thickness or at least 0.1 mm, with an allowable deviation of 20 m. (2) The length of the reference reflectors shall be matched to the transducer size, but shall not exceed 10 mm. The reference reflector for the transverse-defect examination may be of circumferential nature if the effective transducer width does not exceed 10 mm. Circular-segment notches with a depth of 20 % of nominal thickness but at least 0.2 mm may also be used on the tube outside for the transverse-defect Type of tubes Manufacture/material Longitudinally welded austenitic tubes, stretch-reduced by roll drawing 1) Longitudinally welded austenitic tubes, sized Seamless tubes of austenitic or ferritic steels Seamless tubes of austenitic or ferritic steels
1) Total deformation > 20 % 2) Straight tube in final condition

Examination point of time As-delivered condition 2) As-delivered condition As-delivered condition As-delivered condition

Nominal thickness in mm 2

2 2 >2 3.6

38 42.4 42.4

3) St. : spot check of examination system 4) As an alternative, eddy-current examination with examination sensitivity II instead of US transverse-defect examination.

H: S: US WS

Manufacturer Authorized inspector : Ultrasonic examination : Eddy current examination

Table E-1:

Extent of examination and examination methods Page 99

KTA 3211.1

Annex F Performance of manual ultrasonic examinations

(The wording of this Annex is identical in safety standards KTA 3201.1, KTA 3201.3, KTA 3211.1 and KTA 3211.3.) F 1 General requirements (1) This Annex covers the performance of manual nondestructive examinations. (2) In this Annex, stipulations have been laid down for the calibration of ultrasonic equipment for the pulse-echo method with reflectors or through-transmission and for the description of indications. F 2 Definitions, symbols, formulae F 2.1 Definitions The definitions of DIN 54 119 apply. F 2.2 Symbols In this Annex the following symbols are used: Symbol A a, a AVG C D0 Deff Dk DKSR Dz DS d dref f Variable or designation Scan path related to near field length in the general DGS diagram Projected surface distance Distance / gain / size Sound beam width, referred to dB echo amplitude decrease Transducer dimension Effective transducer dimension Diameter of round bottom hole Diameter of circular disk reflector Diameter of cylindrical bore Beam diameter, referred to db echo amplitude decrease Curvature diameter of test object Curvature diameter of opposite face Band width (difference between upper and lower base frequency) referred to 3 dB amplitude decrease Nominal frequency Reflector diameter referred to effective transducer diameter Instrument gain when setting the reference reflector for screen height level Instrument gain when setting the transmission indication for screen height level Arithmetical average of GT values Instrument gain setting for recording limit Beam spread angle for 6 dB limit Echo amplitude referred to screen height Main echo Unit mm mm mm mm mm mm mm mm mm mm MHz S1 S2 SE SEL s sj V V V Vkoppl VS

Symbol No. 1 No. 2 KSR

Variable or designation Calibration block to DIN EN 12 223 Calibration block to DIN EN 27 963 Dimension of circular disk reflector

Unit mm

L N

Sound attenuation coefficient (deviating dB/mm from DIN 54 119; sound attenuation referred to sound path) Search unit dimension in direction of mm curvature Ultrasonic wave length Near field length mm mm m mm mm mm mm mm mm mm dB dB dB dB dB dB dB

NE1; NE2 Spurious echoes from wave mode conversion n p Ra RL RLK S Number of individually measured values Projected surface distance for double traverse Average roughness to DIN EN ISO 4287 Recording length Corrected recording length Sound path (distance between transducer and reflector) Sound path in reference block Sound path in component Transmitter - receiver Transmitter-receiver longitudinal waves Wall thickness Thickness of calibration block Gain in the general DGS diagram Sensitivity correction Sound attenuation correction referred to a certain sound path Coupling correction Beam spread correction of back reflection curve Corrected gain for considering transfer variations Transfer correction

fN G GK GT

MHz dB dB

V~
VT

GT

dB dB degree

F 2.3 Formulae The variables to be calculated shall be determined by means of the following formulae: a) The beam width C referred to a 20 dB echo amplitude decrease: S C = 2 (F-1) D0

GR 6 H HE

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KTA 3211.1

b) Conversion of side-drilled hole echo amplitudes to circular disk reflector echo amplitudes:
DKSR = 2 DZ S ,

(F-2)

where S > 0.7 N and DZ > 1.5 . c) Conversion of round bottom hole echo amplitudes to circular disk reflector echo amplitude:

transducer dimensions to be used in the examination shall be based both on the required sensitivity level (recording limit) for the volume areas to be examined and the geometry of the part (sound path). In general, a frequency of 4 MHz shall be used for wall thicknesses 40 mm, and a frequency of 2 MHz for wall thicknesses > 40 mm. (6) In the case of curved examination surfaces the search unit probe shall be located with the probe index on the centre of the surface. At no point shall the probe shoes have a distance greater than 0.5 to the examination surface. Where the distance is greater, the probe shall be ground. This is the case if L2 exceeds 2 x d. (7) The use of auxiliary means for determining the echo amplitude (e.g. scales) is permitted if it is ensured that an evaluation as per F 4 is performed. F 3.2 Test equipment

DKSR =

Dk ,

(F-3)

where S > 0.7 N and Dk > 1.5 . d) The beam diameter DS referred to a 6 dB echo amplitude decrease: DS = 2 S tan 6, (F-4) e) Average value of instrument gain setting GT : GT =

GT =
n

sum of individual values , number of individual values

(F-5)

(1) The test equipment and accessories used including the required auxiliary means shall show sufficient accuracy and stability for the intended use. (2) The combination of equipment, cables and search units of various manufacturers is permitted if it is ensured (e.g. by measurements on reference reflectors) that the exactness of results is not affected. F 3.3 Test object (1) The test surfaces shall be free from discontinuities and impurities (e.g. notches, scale, weld spatter, tool marks).

f) Corrected recording length RLK: RLK D = RL D S 1 S RL (F-6)

g) Sound path without lateral wall influence s Deff S = 2 h) Corrected gain V : V ~ = 1.7 or

T ( GT ) G2 n

(F-7)

n 1

(F-8)

(2) Where an opposite face is used as reflecting surface it shall meet the same requirements as the test surface. (3) The test surfaces waviness shall be so little that the probe shoe surface has sufficient contact. This is generally the case if the distance between probe shoe surface and test surface does not exceed 0.5 mm at any point. F 3.4 Reference blocks and reference reflectors

V ~ = 1.7
i)

(GT GT )
n 1

(F-9)

Sensitivity correction V: S V =30 lg 2 S1

(F-10)

F 3 General requirements F 3.1 Performance of examination (1) For the calibration and examination the same couplant shall be used. Only such couplants shall be used which do not damage the object (e.g. corrosion). Upon examination, all couplant residues shall be removed from the test object. (2) Test object, reference block and search units shall approximately have the same temperature. (3) When setting the sensitivity level and during the examination only the gain control, but no other control element (e.g. for frequency range, pulse energy, resolution, threshold value) shall be adjusted. A threshold value may only be used in exceptional justified cases. (4) Prior to the examination, the sensitivity level and range adjustments shall be made after the warm-up periods given by the instrument manufacturer. Both adjustments shall be checked at suitable intervals. Where in this check clear deviations from the check made before are found, all examinations performed after that check shall be repeated with a corrected adjustment. (5) The nominal frequency shall be within a range of 1 to 6 MHz. The selection of the nominal frequencies and

(1) When using differing materials for search units and test object the difference in sound velocity shall be into account for range adjustment and for the angular deviation in case of angle beam scanning. (2) When calibration blocks No. 1 or No. 2 are not used for calibration the following applies: a) to the calibration block used: aa) The sound beam shall not be impaired in its development, i.e. all dimensions vertical to the main beam path for sound paths up to 2 x N shall be greater than the transducer dimension and for greater sound paths exceed the beam width C. ab) The dimensions of the coupling surface shall exceed 1.5 times the effective probe shoe dimension. ac) The location of the reference reflectors in the reference block shall be selected such that the reference echoes do no interfere with each other and cannot be confused with corner echoes. ad) Claddings on the reference block shall be provided if their acoustic properties on the test object need not be taken into account. b) to the calibration reflector used: ba) the back walls shall be plane and vertical to the main beam as well as have dimensions exceeding the beam width C, but not less than the transducer dimension.

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KTA 3211.1

bb) Side-drilled holes shall be vertical to the main beam and parallel to the coupling surface. The lengths of the side-drilled holes shall be greater than the sound beam width C, but not less than the transducer dimension. The diameter shall generally be 3 mm. bc) The bottom of flat bottom holes shall be vertical to the main beam when applying the single-probe technique. bd) Round bottom holes shall be oriented such that the directions of hole axis and main beam deviate from each other as little as possible. be) Rectangular notches shall be vertical (transverse) to the main beam and the notch edges be vertical to the surface. The notches shall have a rectangular crosssection, a width 10 mm and, if not specified for the respective product form, have a depth of 1.0 mm. The length of rectangular notches shall exceed the beam width C, but not be less than the transducer dimension. bf) Where the echo amplitudes of side-drilled and round bottom holes are to be converted to echo amplitudes of circular disk reflectors, the formulas (F-2) and (F-3) shall be considered additionally. F 4 Calibration of test systems F 4.1 Range adjustment (1) The range shall be calibrated on the test object, the calibration block No. 1, the calibration block No. 2 or on similar calibration blocks. (2) For longitudinal wave search units a calibration block (e.g. to Figure F-1) shall be used.

1
1

sj

s 10

b 1

1 Bore hole diameter = 3mm b= sj 2

5

sj

c 10 < s 15

b sj

b Bore hole diameter = 3mm b = sj 10

c 15 < s 20

5 b b 5 sj

b b
Two methods may be used a) range calibration using a straight beam search unit on the test object or on the calibration block and subsequent pulse zero-point correction with an angle beam search unit (delay path), b) calibration on two far-distant holes. In each case an advance calibration should be made on calibration block No. 1 or No. 2 with a straight beam search unit.
Note: This procedure is required due to the transverse wave portion occurring under another beam angle.

Bore hole diameter = 3mm

b=

sj 10 2
5bbb5 sj

c 20 < s 40

bbb Bore hole diameter = 3mm b= sj 10 3

5bbbb5 sj

c 40 < s 80

F 4.2 Application of the DGS method F 4.2.1 Criteria for the application of the DGS method The following criteria apply: a) Echoes shall not be influenced by the original pulse. b) The sound path to be evaluated begins, for transceiver probes, at S = 0.7 x N and for dual crystal search units at the beginning of the focal area. c) In the case of a lateral wall effect the DGS method may only be used up to the beam path given in Section F 2.3, formula (F-7). d) In the case of angle-beam scanning the DGS method can only be applied for wall thicknesses exceeding 5 x e) Where probe-specific DGS diagrams are not available, a specific diagram for the respective probe may be derived from the general diagram (Figure F-2) where data on the near field length are available. f) In the case of highly attenuated search units the DGS method may only be used if the ratio of the band width (f) to the nominal frequency is less than 0.75.

Bore hole diameter = 3mm

Figure F-1:

b=

sj 10 4

c s > 80

Calibration blocks for sensitivity level calibration for angle beam scanning

g) For longitudinal wave dual angle beam search units and focussing search units the DGS method shall not be used. h) In the case of curved examination surfaces the conditions of Table F-1 shall be satisfied for transceiver probes when applying the DGS method. Where the search units (probes) have to be adapted in accordance with clause F 3.1 (7), the DGS method is applicable only if, in addition to the requirements of Table F-1, side-drilled, flat bottom

Page 102

KTA 3211.1

or round bottom holes in the test object or in a reference block (deviations from diameter a thickness 10 % at maximum) are used as reference reflectors. F 4.2.2 Reference reflectors to be used (1) To generate a reference echo the following reflectors shall be used unless back wall echoes can be generated from the test object: a) calibration block No. 1 with a thickness of 25 mm and calibration block No. 2 with a thickness of 12.5 mm, b) calibration block No. 1 with a 100 mm arc of circle or calibration block No. 2 with a 25 mm arc of circle if the probe-specific correction factors (difference between the echo indications of the arc of a circle and plane back wall) are known or have been determined, c) Side-drilled, flat bottom or round bottom holes. (2) For the conversion of the echo amplitude of a side-drilled or round bottom bore into the echo amplitude of a circular disk reflector formulas (F-2) and (F-3) shall be used. F 4.3 Adjustment of the sensitivity level by the reference echo or DAC method (1) In the reference echo method the indication from the test object is directly compared to the reference reflector having nearly the same sound path. This may be done with reference reflectors in the part or reference block. (2) For comparison the reference reflector with the same or next-longer sound path shall be used. In exceptional cases (e.g. for reflectors close to the opposite face) the reference reflector may be distanced from the opposite at a maximum of 20 % of the wall thickness, but not to exceed 20 mm. (3) For simplifying the echo amplitude description it is recommended to generate a DAC curve by means of one or several equal reflectors located at different depths in reference blocks (e.g. step wedge or to Figure F-1) or by means of reference reflectors in the test object located at different distances. Clause F 3.4.3 applies with regard to the requirements for reference reflectors.

Pos.1 Pos.2 Pos.3

or

Pos.1 Pos.2 Pos.3

Bore hole diameter

3mm

Pos.1 Pos.2 Pos.3

Figure F-3:

Generation of indications from side-drilled holes located at different positions

Increased DAC curve ( e.g. by 12 dB )

GR
Figure F-4:

GR + 12 dB
Staged DAC curve

0 10 20 30
1.0 G= =0.8 .6 G =0 G 0.4 G= =0.3 G 0.2 5 G= =0.1 0 G 0.1 8 G= =0.0 5 G 0.0 G=

(4) The DAC curve shall be generated upon range calibration by at least three responses from the reference reflectors (e.g. side-drilled holes) in various positions (see Figure F-3). The echo with the highest amplitude shall be adjusted for approximately 80 % of the screen height. The curve obtained may be extrapolated by a maximum of 20 % beyond the range limited by the reflector indications. The gain setting of the equipment shall be selected such that the DAC curve is within the calibration range between 20 % and 100 % of the screen height. If this is not possible for the entire calibration range, the gain shall be set as per Figure F-4. F 4.4 Corrections of sensitivity level adjustment

V [ dB ]

G=

F 4.4.1 Transfer correction

40 50 60

(1) The transfer correction shall be determined on at least 4 points of the test object in the intended direction of examination. (2) The transfer correction shall be determined in accordance with Figure F-5 by means of scanning on the calibration beam and on the test object. (3) To consider the general transfer correction in anglebeam scanning VT with Vee or W path shall be used.
80 100

0.5

0.8 1

3 4 5 6 8 10

20 30 40 50

A S A= N
Figure F-2:

F 4.4.2 Sound attenuation correction

D G = KSR Deff

(1) The sound attenuation for straight-beam scanning shall be determined as per Figure F-6 and for angle-beam scanning as per Figure F-7 in consideration of VS. (2) The determination of the sound attenuation may be omitted if it is considered by an allowance independent from the sound path (e.g. by a general transfer correction). Page 103

Standard DGS Diagram

KTA 3211.1

S1

2S1

S2

2S2

2S1

2S2

Calibration block ( 1 ) 2S1

Test object ( 2 ) 2S2

V-path

W-path

40%

40%

40%

40%

S1
GT1 = . . . dB

S2
G T2 = . . . dB

S1
GT1 = . . . dB

S2
G T2 = . . . dB

G T 2 G T1 VS 2 ( S 2 S1 )

( dB / mm)

Figure F-7:

Determination of sound attenuation for anglebeam scanning

VT = GT 2 GT1 VS = Vkoppl + V
V = 2 ( 2 S2 1 S1)

V [ dB ]

VS = VS2 VS1

sjust

Test object ( 2 ) Calibration block ( 1 )

Figure F-5:

Determination of transfer correction for straightbeam scanning or for angle-beam scanning with Vee or W path

0 10

Reference echo

V [ dB ]

30 40 50 60

1.0 0.8

H1

0.6 Circular disk

H2

0.4 consideration 0.2 2000

reflector with of sound attanuation

Test object
= G T 2 G T1 VS 2 (S 2 S1 )

S1

S2
G T1 = . . . dB G T 2 = . . . dB

( dB / mm)

50

100

200 300

500

1000

s [ mm ]
V = 2 S 2 S just 1

Figure F-6:

Determination of sound attenuation for straightbeam scanning

[ dB]

Figure F-8:

Consideration of sound attenuation in the DGS diagram for 2 > 1

F 4.4.3 Coupling and sound attenuation variations (1) For the transfer correction the average value of the scanning values obtained from the test object shall be used if the range of variation does not exceed 6 dB. Where the range exceeds 6 dB, the average value from 20 scanning values plus an allowance V~ = 1.7 x standard deviations to be calculated in accordance with clause F 2.3 (h) shall be used. (2) Where the V~ value thus determined is greater than 6 dB, the test object shall be subdivided into sections where the transfer correction of each section shall be considered separately. This subdivision shall be such that in each section V~ is equal to or smaller than 6 dB. F 4.4.4 Consideration of corrections (1) Taking the aforementioned sensitivity level correction into account, the following recording limit is obtained for the equipment sensitivity GR = GK + VT + V, where VT = Vkoppl + V (F-12) (F-11)

(2) Where sound attenuation in dependence of the sound path is taken into account this shall be made with the attenuation portion V contained in VT as per Figure F-8

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20

Vkorr.

KTA 3211.1

when using the DGS method or as per Figure F-9 when using the DAC method. (3) If it is not necessary to consider the sound attenuation in dependence of the sound path, VT shall contain a constant sound attenuation portion V independent of the sound path. (4) Where an additional correction for considering greater variations as per clause F 4.4.3 is required, this shall be done by means of V~ . Otherwise, the correction value in the above equation shall be omitted.

Reflector

Search unit

Transferred or set-up DAC curve DAC curve upon sound attenuation correction
V = 2 S ( 2 1 )

Echo amplitude

Recording limit

Recording length

Search unit displacement

6 dB

Figure F-9:

Consideration of sound attenuation for the DAC method for the case 2 > 1

Echo amplitude

[ dB]

Recording limit

F 4.5 Setting of instrument gain Taking the coupling and attenuation losses into account the instrument gain shall be adjusted such that the recording limit for the respective calibration range attains at least 20 % of the screen height. F 5 Description of indications F 5.1 Echo amplitude The maximum echo amplitude of a reflector referred to the respective valid recording limit is to be indicated in dB.
Note: The reproduceability of the echo amplitude determination is generally 3 dB.

Recording length

Search unit displacement

Echo amplitude

Recording limit

12 dB

Recording length

Search unit displacement

Figure F-10: Determination of recording length

F 5.2 Extension of reflectors F 5.2.1 General requirements Recording lengths equal to or greater than 10 mm shall be measured. The measured lengths shall be given as integral multiple rounded up or down to 5 mm (e.g. 10, 15, 20 etc.). Shorter recording lengths shall be recorded as < 10. F 5.2.2 Determination of the recording length The extension of reflector (see Figure F-10) shall be given by the search unit displacement range. This range is determined as the distance between locations where the echo amplitude is lower by either 0 dB, 6 dB or 12 dB. Where the noise level limit is reached, the recording length shall be documented as the distance between the points where the signal disappears in the noise level. F 5.2.3 Determination of half-amplitude and quarteramplitude length When measuring the half-amplitude or quarter-amplitude length of reflectors, the search unit displacements at echo amplitude decreases of 6 dB or 12 dB compared to the maximum echo amplitude shall be determined. Here, for dual search units the acoustic separating line and for line focussing search units the line focus shall be vertical to the reflector direction of extension.

F 5.2.4 Methods for the exact determination of reflector extension (1) The determination of the reflector extension may be optimized by one of the following additional corrections or examinations if this measurement alone is decisive for the assessment of the acceptability of an indication. (2) The reflector shall be measured from the scan position or angle of incidence at which the scan path shows the slightest deviation from 1.0 x near field length however is greater than 0.7 x near field length. In such a case, another frequency than that for generating the maximum echo amplitude may be used. (3) The beam diameter shall be determined at the reflector location. If the measured length exceeds this measured beam diameter the recording length shall be the corrected recording length calculated as per formula (F-6). (4) The beam diameter shall be determined by calculation or experimental analysis. It may be calculated according to formula (F-4) if non-adapted search units are used. (5) In the case of angle beam scanning the horizontal included angle shall be inserted for 6. The included angle shall be taken from the data sheets on the search units used. (6) Where the included angle has to be determined by experimental analysis, measurements shall be made on a reference block to correspond to the test object.

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KTA 3211.1

(7) To this end, reference reflectors shall be bored into this reference block at the same depth location like for the indication to be corrected. As reference reflector a cylindrical hole or flat bottom hole of 3 mm diameter or a round bottom hole with a diameter exceeding 1.5 x may be suited. (8) The half-amplitude length shall be determined on the reference reflector on the same sound path as for the reflector to be corrected. The value determined such shall correspond to the beam diameter at the respective depth of indication. (9) By means of suitable dual search units or focused beam search units the reflector shall be measured in the focal area and be evaluated as follows: a) Where the difference between the quarter-amplitude and half-amplitude length is 1.5 times the beam diameter, the half-amplitude length shall be the recording length. b) Where the difference between the quarter-amplitude and half-amplitude length exceeds 1.5 times the beam

diameter, the quarter-amplitude length minus the beam diameter shall be the recording length. c) Where the half-amplitude length is smaller than the beam diameter, the beam diameter or the focal width at the depth location shall be the recording length. (10) In a measurement of lengths with focused beam search units several echo volumes shall be recorded to increase the measuring accuracy and to improve the reproduceability on a grid pattern. The grid-line distances should be smaller than the diameter of the focusing beam. A typical set-up of measuring equipment to record echo volumes is shown in Figure F-11. F 5.2.5 Determination of depth extension
Note: Stipulations in course of preparation.

Search unit guiding mechanism ( schematic )

Rotary potentiometer with friction-wheel drive Search unit

Ultrasonic instrument

Distance of adjacent grid lines of grid pattern

Monitor ( Puls amplitude )

Reflector
Echo amplitude

Signal

Signal Noise

Displacement

Figure F-11: Set-up of measuring equipment when using focused-beam search units for measuring reflector extensions

Classification as to geometry Curved-surface full material (e.g. bars)

Type of scanning Straight-beam, radial angle-beam, axial and in circumferential direction Straight-beam, radial Straight-beam, axial and in curcumferential direction Straight-beam, in thickness direction angle-beam, tangentially d>5N

Range of application d > 2.5 N Evaluation up to p/2 d>5N d > 2.5 N dref > 10 N d > 10 N d>5N dref > 20 N for evaluation up to p/2; for evaluation beyond p/2 for evaluation up to p/2; for evaluation beyond p/2

Concentric, uniaxial curved surface (e.g. pipes)

Concentric, biaxial curved surface (e.g. dished heads, tube-sheets)

Table F-1:

Range of application of DGS method for transceiver probe techniques Page 106

KTA 3211.1

F 5.3 Structural discontinuities (1) Where indications from the root area of a weld are to be classified as geometric discontinuities, control measurements shall be made to determine the cause of indication.
>10

Section A-A
70

45

(2) If it is to be proved that the echos reflected from the two weld sides arise on the two flanks of the excess penetration and are not caused by weld defects, the control measurement shall be made by measuring the projected-surface distance on the test piece. The exact projected-surface distances shall be determined on rectangular notches with a depth and width of 1 mm each on a reference block (see Figure F-12). Where it is found out that the projected-surface distances of the respective indications clearly overlaps [(2a - a) equal to or greater than 2 mm], the echo amplitudes are considered to be caused by geometric discontinuities. Where a smaller distance than 2 mm is found, the reflectors shall no more be treated separately.

150

45

F 6 Creeping wave method F 6.1 Description of method (1) Longitudinal wave probes with usual angles of incidence of 75 to 80 degrees generate additionally to the longitudinal main wave a longitudinal wave propagating in parallel to the examination surface (primary creeping waves). (2) By the propagation of the creeping wave along the examination face transverse waves are permanently radiated so that the intensity of the creeping wave rapidly decreases with the sound path. In the case of creeping wave twin probes with transducer dimensions of e.g. D0 6 x 13 mm2 the focal distance will be approximately 10 mm. (3) Where, for geometric reasons, the creeping wave will dip into the volume, e.g. in the case of attachment welds, it will propagate as normal longitudinal wave without radiation. This leads to greater usable sound paths of 30 mm to approximately 50 mm. F 6.2 Reference blocks (1) For the calibration of creeping wave probes the reference blocks as shown in Figure F-13 shall be taken. (2) When examining with adapted probes, the curvatures of the examination faces of the reference block and the test object shall match, if possible.

35 25 15 5
50 100

1.5

A
25

75

125

Flat bottom holes 3 mm The recording limit corresponds to the echo height of the flat bottom hole indications
Figure F-13: Reference block and recording limit for the calibration of creeping wave probes

F 6.3 Adjustment of sensitivity For the examination area a DAC curve shall be generated to meet the requirements of Section F 4.3 by means of scanning the respective reference reflectors in the reference blocks in accordance with Section F 6.2. F 6.4 Adaptation of probes

a a a 2a - a 3 mm

(1) When examining on convex curved examination faces with d equal to or greater than L2/2 , the adaption of the probes may be waived. (2) In the case of examination faces with L2/3 d < L2/2 an adaptation by shaped refracting prisms (wedges) or by shaping of the probe shoe is permitted. (3) In the case of examination faces with d < L2/3 specially designed probes shall be used.

1
s 1

F 7 Wave mode conversion method F 7.1 Description of method (1) When transverse waves hit an opposite face at an angle of approximately 31 degrees, a longitudinal wave (secondary creeping wave) is generated which is nearly parallel to the surface (Figure F-14). The angle of incidence of 31 degrees is obtained, in the case of plane-parallel test objects, by the

Figure F-12: Proof of indications cause by structural discontinuities from the root area of single-side welds

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KTA 3211.1

accompanying transverse wave of a 70-degree longitudinal probe. (2) Due to its scattered propagation the secondary creeping wave is e.g. used to examine the root area of a welded joint without being influenced by the excess penetration (Figure F-15). In this case it shall be taken into account that the intensity of the secondary creeping wave will rapidly decrease with the sound path subject to the permanent radiation of transverse waves. (3) During scanning with the longitudinal wave probe on plane-parallel test objects a sequence of echoes is generated the individual echoes of which are called NE 1 and NE 2 (Figure F-16). For the detection of reflectors the echo NE 2 is used. The echo NE 1 may be used for reflector depth estimation. (4) When scanning thin test objects (8 mm < s 20 mm) with the longitudinal wave probe (Type 70 degree SEL) an echo amplitude is generated which contains both the longitudinal wave portion (main echo-HE) and the converted transverse wave portion (sequence of secondary echoes-NE) (Figure F-17).
Note: Spurious echoes may be generated due to the transverse wave generated simultaneously with the beam entry into the test object, since the transverse wave entering at a very steep angle is highly sensitive to irregularities of the probe-remote surface, such as gauge marks, identification markings, etc. and reacts to deviations from shape. Therefore, it is especially important to - consider the probe position in relation to the centre of the welded joint, - know the sound velocities and the related angle of incidence of the transverse wave, - know the various echo dynamics. When exactly allocating the indication to the welded joint and considering the fact that a reflector has a great dynamic effect when being scanned with longitudinal waves - contrary to the accompanying transverse wave of approx. 31 degrees- a distinction between such spurious echoes and real defects is possible. Scanning with secondary creeping waves in accordance with subpara (2) and (3) is purposeful beginning with a wall thickness > 15 mm. In the case of wall thicknesses 8 mm < s 20 mm the examination shall be performed with longitudinal wave probes (Type 70 degree SEL). The presence of the main echo HE and the secondary echo NE shows that the sound waves are reflected at deep material discontinuities. Indications of root notches of little depth are distinguished from deep defects due to the fact that secondary echoes are not obtained (Figure F-17).

(3) A correction of the precalibration (zero point displacement) by taking the transverse wave portions in the sound path into account shall be made on the test object or reference block by the scanning of a rectangular groove according to the wave conversion method. Here, the secondary echo NE 2 is optimized. a is determined on the coupling surface. With a and in consideration of the above formula the zero point displacement can be made (SEL probe). A marking on the screen is purposeful. At one edge the calibration can be checked by means of secondary echoes NE 1 and NE 2 (Figure F-16). S = 1.5 s + a F 7.4 Adjustment of sensitivity levels (1) The sensitivity shall be adjusted on a similar reference block with regard to material and geometry. (2) To generate a reference echo rectangular grooves as per clause F 3.4 (2) be) shall be used. (3) When examining with the secondary creeping wave the secondary echo NE 2 reflected from the groove is optimized and thus the sensitivity level is obtained. (4) In the case of examination as per clause F 7.1 (4) the sensitivity shall be adjusted on corresponding rectangular grooves with longitudinal waves. The recording limit is the reference echo amplitude of the direct longitudinal wave minus 6 dB. The indication of the edge on the reference block shall exceed the recording limit by at least 10 dB. Otherwise, the recording limit shall be reduced accordingly. F 7.5 Corrections during sensitivity level adjustment F 7.5.1 Transfer correction The transfer correction shall be made with two transverse wave angle probes of the same kind (angle of incidence greater than 35 degrees) with V-transmission through the base metal of the component and the reference block. In this case, the frequency of the longitudinal wave probe shall be used. F 7.5.2 Correction of sound attenuation caused by the welded joint Different sensitivity levels caused by the filler metal shall be determined by suitable means and be taken into account. F 7.6 Performance of examination The examination is usually performed by displacing the probe on a small area parallel to the welded joint. Here, the probe position is optimized by moving the probe vertically to the welded joint. This has to be done on several tracks so that the total area to be examined is completely covered. (F-13)

F 7.2 Probe In the case of plane-parallel surfaces 70 degree longitudinal wave probes are used as single transducer or transceiver design which besides the longitudinal wave below 70 degrees transmit an accompanying transverse wave of approx. 31 degrees to generate a secondary creeping wave on the internal surface.
Note: For the selection of the probe its dependency on the echo amplitude from the groove depth related to the echo NE 2 and to the wall thickness to be examined shall be known.

F 7.3 Range calibration (1) The range shall be calibrated for longitudinal waves. Figure F-14: Reflexion with wave mode conversion for longitudinal wave angle probe

(2) A precalibration for sound velocity adjustment (velocity range) shall be made by means of straight beam scanning on the test object or on a similar reference block.

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70

70 31
31

Beaming characteristics
Figure F-15: Examination of internal near-surface area of welded joints by means of secondary creeping waves

NE1

NE2 NE1 a
Figure F-16: Sound field geometry during transverse wave conversion

NE2 4 6 8 10

HE

HE 0 2 4 6 8 10

HE NE

HE

NE 0 2 4 6 8 10

HE: Main echo, NE: Secondary echo Figure F-17: Examination of components with wall thicknesses 8 mm < s 20 mm by means of longitudinal waves (70 degree SEL probe) Page 109

KTA 3211.1

Annex G Performance of surface crack detection by magnetic particle and liquid penetrant methods
(The wording of this Annex is identical in safety standards KTA 3201.1, KTA 3201.3, KTA 3211.1 and KTA 3211.3.)

G 1 General requirements G 1.1 Surface condition (1) The surfaces to be examined shall show a condition suitable for the examination. (2) They shall be free from scale, weld spatter or other disturbing impurities. (3) Grooves and notches affecting the test result shall be removed. G 1.2 Visibility conditions G 1.2.1 Fluorescent tests fluids (1) When using fluorescent test fluids the inspection shall be made under ultraviolet light with a wave length maximum of 365 nm 10 nm. (2) The ultraviolet light incident on the examination surface shall have an intensity of at least 10 W/m2. (3) The ultraviolet lamps shall have attained their full luminous intensity prior to using it. (4) The eyes of the operator shall have at least 5 minutes to adapt to the light conditions. (5) The examination shall be performed in a darkened room without disturbing incidence of light, in which case the illuminance shall be limited to 20 lx. G 1.2.2 Non-fluorescent agents (1) For the evaluation, the examination surfaces shall be illuminated by daylight or artificial light with an illuminance of at least 500 lux. (2) During examination, disturbing reflections and incident light shall be avoided. G 1.2.3 Auxiliary means for evaluation For the inspection auxiliary means (e.g. magnifying glasses, contrast-improving spectacles, mirrors) are permitted. G 1.3 Post-cleaning Upon completion of examination, the parts shall be properly cleaned to remove residues from the test fluid. G 2 Magnetic particle examination G 2.1 Magnetisation G 2.1.1 Methods (1) The possibilities of magnetisation are given in DIN 54 130.

(4) The residual magnetic field strength shall principally not exceed 103 A/m (12.5 Oe) unless a lower value is required for the fabrication. Where the specified value is exceeded, the part shall be demagnetised and the value of the residual magnetic field strength be recorded. G 2.1.2 Contact areas in case of direct magnetisation (1) Where the examination is performed by inherent magnetic flux, consumable electrodes (e.g. lead fin alloys) shall be used, if possible. It shall be ensured that in the contact areas overheating of the material to be examined is avoided. (2) Where overheating has occurred the overheated areas shall be marked, ground over after the examination and be examined for surface cracks, preferably by a magnetic particle method using yoke magnetisation. G 2.1.3 Direction of magnetisation Each location on the surface shall be examined from two directions of magnetisation offset by approximately 90 degrees. G 2.1.4 Magnetic field strength
Note: a) The magnetic flux in the test object surface governs the quality of the examination. The required minimum flux density is 1 T. b) Due to the difficulties in measuring the magnetic field strength in the part, the tangential field strength is used as auxiliary variable. c) Tangential field strength is the tangential component of the magnetic field strength on the test object surface. In lowcarbon steels the required flux density is obtained at a field strength of 2 k/A. d) Possibilities of checking whether the magnetisation of the test object suffices are given in the guideline of the Deutsche Gesellschaft fr Zerstrungsfreie Prfverfahren e.V. (DGZfP), Berlin, DGZfP-EM-3, Instruction sheet for the checking of examination parameters during magnetic particle examination.

(1) In the case of AC magnetisation the tangential field strength on the surface shall be at least 2 x 103 A/m (approx. 25 Oe) and shall not exceed 6.5 x 103 A/m (approx. 80 Oe). (2) It shall be checked by measurements that these values are adhered to or test conditions shall be determined under which these values may be obtained. G 2.1.5 Magnetisation times (1) The following guide values apply with respect to the application of the magnetic particles and magnetisation: a) Magnetisation and application: at least 3 seconds b) Subsequent magnetisation: at least 5 seconds (2) The evaluation shall be made during subsequent magnetisation.

(2) Where magnetisation is achieved in partial areas by inherent direct magnetisation or yoke magnetisation, AC magnetisation shall normally be used. (3) The DC magnetisation method shall only be used upon agreement by the authorized inspector.

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KTA 3211.1

G 2.2 Inspection medium G 2.2.1 Wet particle inspection method (1) Only such particles shall be used as vehicle which do not cause corrosive damage on the test object even after prolonged application. The examination surface shall be wettable by the vehicle fluid. For example, water is permitted with respective anti-corrosion and low-surface tension additives. (2) Only fine-grained iron oxide shall be used as magnetic particles. Depending on application, black, fluorescent or coloured powders may be used. (3) Prior to bathing the surface care shall be taken to ensure that the magnetic powder is distributed uniformly in the vehicle fluid and is kept in suspension. Prior to and during the examination the powder suspension shall be spot-checked by suitable test units. When using the Berthold test unit the crossrecessions shall be oriented at an angle of approximately 45 to the direction of magnetisation and be wetted during the check. The concentration of the magnetic powder will suffice if the cross-recession can be clearly and completely identified. G 2.2.2 Dry particle method (1) The dry particle method is subject to agreement by the authorized inspector except for the intermediate check in warm condition. Care shall be exercised to ensure that the power used is sufficiently dry. (2) The device for applying the powder shall make possible such a fine spraying that no accumulations of powder occurs. It shall be ensured that the powders used do not agglomerate under the influence of the workpiece temperature. G 2.2.3 Contrast Sufficient contrast shall be provided to improve the detectability of defects by using suitable means (e.g. fluorescent inspection medium or application of a thin colour coating just covering the surface).
Note: Sufficient contrast is obtained if black magnetic powder is used on metallic bright surfaces.

G 3 Liquid penetrant examination G 3.1 Examination system (1) Liquid penetrants shall preferably be used. Fluorescent penetrants or fluorescent dye penetrants may be used. (2) Solvents or water or both in combination may be used as penetrant remover. (3) Only wet developers suspended in an aqueous solvent shall be used. Dry developers may only be applied on the examination surface by electrostatic charging. (4) For the examination system at least sensitivity class 3 to DIN 54 152-3 shall be adhered to. (5) The suitability of the examination system (penetrant, solvent remover and developer) shall be demonstrated to the authorized inspector by means of a sample examination as to DIN 54 152-2. (6) In the case of multiple use or storage of the penetrants in open containers, the effectiveness of the examination system shall be verified on reference block B to DIN 54 152-3 prior to beginning the examination. In this test the maximum penetration and development times shall not exceed the minimum times specified for the evaluation. The examination sensitivity obtained shall be recorded. G 3.2 Performance (1) Liquid penetrant examinations shall be performed to DIN 54 152-1 to meet the following requirements. (2) The penetration time shall be at least half an hour.

(3) As soon as possible after drying of the developer a first evaluation shall be made. A further evaluation shall not be made before half an hour after the first evaluation has passed. (4) Further evaluation times are required if during the second evaluation crack-like indications are detected which were not visible during the first evaluation.
Note: Further evaluation times are required if during the second evaluation crack-like indications are detected which were not visible during the first evaluation.

(5) The evaluation shall be made in consideration of the results of all evaluations.

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Annex H Additional stipulations for non-destructive examination of forgings, bar steel, rings and extrusions

H1

Forgings, bar steel and rolled rings of ferritic steels

H 1.1 Scope This Annex shall apply in addition to the stipulations of clause 4.4.7 and to Annexes F and G to the performance and evaluation of non-destructive examinations for forgings, bar steel and rolled rings of ferritic steels. H 1.2 General (1) The ultrasonic examination shall be performed after the governing heat treatment for establishment of the mechanical and technological characteristics, while the materials have the minimum possible of contours. (2) If, during the ultrasonic examination, indications that shall be registered are found in zones that will be removed during further processing of the piece being examined, they need not be considered in the evaluation. All indications due to structural condition of the piece shall not be covered by the evaluation, but be indicated in the test report. (3) If, for material-related reasons (e.g., reduction of the heat-treatment cross section), the geometry after heat treatment does not allow the entire volume to be examined with the required ultrasonic scanning directions, the zones that will subsequently have restricted examinability shall be additionally examined prior to the heat treatment, while the geometric condition is appropriately favorable, subject to approval of the authorized inspector. (4) The entire surface shall be subjected to a surface-crack detection while it is in the finish-machined, unbored condition. The parts made from bars shall be subjected to a surfacecrack detection when they are in the finish-machined condition. When the magnetic particle method is used, minor redressing without further examination is allowable if the results of the original examination are not impaired.
Note: Surfaces that have been prepared for final assembly or pressure testing and that will not be subjected to further machining are considered to be finish-machined.

(3) For product forms with nominal thicknesses equal to or larger than 100 mm, all sites shall be registered at which the expected back-wall echo decreases in the region of the recording limit as per (1). (4) All sites shall be registered with clusters of echo indications that are 6 dB below the recording limit and cannot be resolved into individual echo indications in one probe position or during probe travel or that cannot be clearly classified or correlated with the scanning directions to be employed. (5) All sites shall be registered where the signal-to-noise ratio to the recording limit is less than 6 dB. Nominal thickness s in final condition in mm Diameter in mm of the corresponding circular-disk reflector Straight-beam Angle-beam scanning scanning 2 3 4 6
1) 1)

s 40 40 < s 120 120 < s 250 s > 250

2 3 3 3

1) These values shall be applicable only if the back-wall echo is

observable, otherwise the same values as for angle-beam scanning shall apply.

Table H-1:

Recording limits

H 1.3.3 Evaluation of the examination results (1) If the back-wall echo vanishes or becomes very weak, or if the signal-to-noise ratio to the recording limit is less than 6 dB, the manufacturer shall perform investigations such as sound attenuation measurements, by agreement with the authorized inspector, aimed at permitting a decision on usability. (2) If the acceptance limits are exceeded or if clusters of reflection sites are found with echo amplitudes that are as much as 6 dB below the recording limit and cannot be separated into individual echo indications in one probe position or resolved during probe travel or that cannot be clearly classified or correlated, additional investigations such as through-transmission in several directions shall be performed. If these investigations reveal signs of areal separations, e.g., loss of intensity of a sound-transmission signal by comparison with indication-free zones of the product form, these sites are not permitted. (3) Local indications with echo amplitudes up to 18 dB above the recording limit are permitted. Indications with length extent under curve 1 presented in Figure H-1 are also permitted. (4) Zonal indications observed in nominal thicknesses larger than 250 mm are permitted if the back-wall echo is not attenuated by more than 6 dB relative to indication-free zones. Sporadic local indications up to 12 dB above the recording limits are permitted in such zones. Zonal indications shall be

H 1.3 Ultrasonic examination of forged flat plates H 1.3.1 General Ultrasonic examination shall be performed by straight-beam scanning in thickness direction, with complete scanning of one end face. If necessary, examination shall be performed from the opposite end face in order to maintain the required examination sensitivity. H 1.3.2 Recording limits (1) All echo amplitudes reaching or exceeding the values presented in Table H-1 shall be registered. (2) If the nominal thickness in the finished condition is not known during the examination, the following recording limits shall be selected regardless of scanning direction; that of circular-disk reflector 2 for nominal thicknesses equal to or smaller than 60 mm in the examination condition, and that of circular-disk reflector 3 for nominal thicknesses larger than 60 mm.

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defined as a cluster of reflection sites appearing on the screen as a large number of amplitudes that are no longer resolvable. (5) The frequency of individual indications that shall be registered, when projected on one end face, shall not exceed 10 per square meter locally and 5 per square meter relative to the total area of the end face.
+24

Indications 1.5 mm individual

Indications Indications > 1.5 mm up > 6 mm to 6 mm, caused by non-metallic inclusions Acceptable to be included in the frequency

Linear Indications > 1.5 mm

Acceptable not to be included in the evaluation

Unacceptable Unacceptable

+18

Maximum echo amplitude above registration limit

[dB]

Table H-3:

Acceptance standards for magnetic-particle examination

+12

Curve 2

Curve 1

H 1.5 Ultrasonic examination of hollow parts H 1.5.1 Scanning directions

+6

Permissible region

(1) Products with a length-to-diameter ratio equal to or larger than 3 shall be examined by straight-beam scanning from the cylindrical surface. Products of material group W I shall additionally be examined by angle-beam scanning in both circumferential directions from the cylindrical surface. (2) Products with a length-to-diameter ratio smaller than 3 shall be examined by straight-beam scanning in radial and axial direction. (3) In straight-beam scanning, examination shall be performed from both cylindrical surfaces and end faces if necessary, in order to maintain the required examination sensitivity. H 1.5.2 Recording limits

0.5

1.0

Indication length relative to nominal wall thickness in finished condition

Figure H-1: Allowable indication lengths and echo amplitudes in the ultrasonic examination

H 1.4 Surface-crack detection of forged flat plates The following shall apply to the evaluation of the examination results: The frequency of allowable indications shall not exceed 10 per square decimeter locally or 5 per square decimeter relative to the total area. The stipulations of Tables H-2 and H-3 shall also apply.
Note: A liquid-penetrant indication shall be considered to have a longitudinal extension (linear indication) if its dimension in the direction of maximum extension is at least three times as large as its smallest dimension transverse to that direction.

(1) All echo amplitudes reaching or exceeding the values presented in Table H-1 shall be registered. (2) If the nominal thickness in the finished condition is not known during the examination, the following recording limits shall be selected regardless of scanning direction: that of circular-disk reflector 2 for wall thicknesses equal to or smaller than 60 mm in the examination condition, and that of circulardisk reflector 3 for wall thicknesses larger than 60 mm. (3) For product forms with nominal thicknesses equal to or larger than 100 mm, all sites shall be registered at which the expected back-wall echo decreases in the region of the recording limit as per (1). (4) All sites shall be registered with clusters of echo indications that are 6 dB below the recording limit and cannot be resolved into individual echo indications in one probe position or during probe travel or that cannot be clearly classified or correlated with the scanning directions to be employed. (5) All sites shall be registered where the signal-to-noise ratio to the recording limit is less than 6 dB. H 1.5.3 Evaluation of the examination results (1) If echo indications that shall be registered are observed from reflection sites in the zone with lateral wall influence during straight-beam scanning, they shall be evaluated by means of angle-beam scanning. (2) If the back-wall echo vanishes or becomes very weak, or if the signal-to-noise ratio to the recording limit is less than 6 dB, the manufacturer shall perform investigations such as sound-attenuation measurements, by agreement with the

Indications 3 mm individual Acceptable not to be included in the evaluation

Round indications > 3 mm up to 6 mm Acceptable to be included in frequency

Round indications > 6 mm

Linear indications > 3 mm

Unacceptable Unacceptable Where it is shown that the indications are caused by nonmetallic inclusions, indications 6 mm are acceptable and shall be included in the frequency.

Table H-2:

Acceptance standards for liquid-penetrant examination

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authorized inspector, aimed at permitting a decision on usability. (3) If the acceptance limits are exceeded or if clusters of reflection sites are found with echo amplitudes that are as much as 6 dB below the recording limit and cannot be separated into individual echo indications in one probe position or resolved during probe travel or that cannot be dearly classified or correlated, additional investigations such as through-transmissions in several directions shall be performed. If these investigations reveal signs of areal separations, e.g., loss of intensity of a sound-transmission signal by comparison with indication-free zones of the product form, these sites are not permitted. (4) For hollow parts with length-to-diameter ratio larger than 3, indications below curve 2 of Figure H-1 are permitted both in straight-beam and angle-beam scanning. In straight-beam scanning, indications below curve 1 in Figure H-1 are also permitte echo amplitudes reaching 6 dB or more above the recording limit are not observed at these sites during anglebeam scanning. However, the largest allowable reflector length shall be limited to 120 mm. (5) For rings with length-to-diameter ratio smaller than or equal to 3, indications below curve 2 in Figure H-1 are permitted. However, the largest allowable reflector length shall be limited to 60 mm. (6) Reflection sites with extensions in the thickness direction are not permitted. The frequency of reflection sites relative to the external surface shall not exceed 10 per square meter locally and 5 per square meter overall. H 1.6 Surface-crack detection of hollow parts

scanning from both ends. Furthermore, cylindrical zones shall be examined by angle-beam scanning in both circumferential directions. H 1.7.2.2 Forgings containing bored holes (1) The entire volume shall be examined by straight-beam scanning from all external surfaces running parallel to the hole. (2) For parts of material group W I, the ultrasonic examination shall additionally be performed axially by straightbeam scanning from the ends. Furthermore, cylindrical zones shall be examined by angle-beam scanning in both circumferential directions. H 1.7.2.3 Scanning directions for restricted examination after the heat treatment (1) Straight-beam scanning shall be performed from all external surfaces with radii of curvature larger than 30 mm. (2) For parts of material group W I, angle-beam scanning in both circumferential directions in the cylindrical zones of opendie forgings may be performed as an alternative to straightbeam scanning. H 1.7.2.4 Recording limits (1) All echo amplitudes reaching or exceeding the values presented in Table H-1 shall be registered. (2) If the nominal thickness in the finished condition is not known during the examination, the following recording limits shall be selected regardless of scanning direction: that of circular-disk reflector 2 for wall thicknesses equal to or smaller than 60 mm in the examination condition, and that of circulardisk reflector 3 for wall thicknesses larger than 60 mm. H 1.7.2.5 Evaluation of the examination results (1) The stipulations of clauses H 1.5.3 (1) to (3) shall apply, together with the stipulations of the following paragraphs. (2) Local indications that shall be registered but that have echo amplitudes less than or equal to 12 dB above the recording limit are permitted in all volume zones and for all scanning directions. Indications with longitudinal extension but with values below curve 2 in Figure H-1 are permitted, provided the direction of extent of the indication does not coincide with the thickness direction of the part to be made from the object of examination. (3) The frequency of indications relative to the external surface of the piece being examined shall not exceed 10 per square meter locally and 5 per square meter overall. (4) For smaller forgings with an external surface area of less than one square meter, 3 indications per forging are permitted. H 1.8 Surface-crack detection of open-die forgings for cases and bodies The stipulations of Section H 1.4 shall apply to the evaluation of the examination results. H 1.9 Ultrasonic examination of bar steel H 1.9.1 Scanning directions (1) For diameters or widths across flats larger than 30 mm, straight-beam scanning in radial direction shall be performed. For parts of material group W I, the examination shall be performed by angle-beam scanning in both circumferential

For the evaluation of the examination results the stipulations of Section H 1.4 shall apply. H 1.7 Ultrasonic examination of open-die forgings for cases and bodies H 1.7.1 General The ultrasonic examination shall be performed after the governing heat treatment for establishment of the mechanical and technological characteristics, while the materials have the minimum possible of contours. If the contour after the heat treatment permits only restricted examination, an examination as per clause H 1.7.2.1 shall be performed before the heat treatment and an examination per clause H 1.7.2.3 shall be performed after the heat treatment. H 1.7.2 Scanning directions H 1.7.2.1 Forgings not containing bored holes (1) The forgings shall be examined by straight-beam scanning as follows: a) cylindrical forgings from the external cylindrical surface, b) square forgings from two faces oriented at 90 degrees to each other and running parallel to the longitudinal axis, and c) hexagonal forgings from 3 faces adjoining each other and running parallel to the longitudinal axis. (2) If indications under the respective evaluation criterion with echo amplitudes larger than 50 % of the maximum allowable echo amplitude are observed during examination of square and hexagonal forgings, these zones shall be reexamined from the respective opposite faces. (3) For parts of material group W I, the ultrasonic examination shall additionally be performed by straight-beam

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directions for round bars with diameters larger than 120 mm. The scanning angle for angle-beam scanning shall be 35 degrees. (2) Straight-beam scanning from the lateral surface shall be performed over the entire circumference of round bars and over half the periphery for square or hexagonal bars. (3) If indications under the respective evaluation criteria with echo amplitudes larger than 50 % of the maximum allowable echo amplitude are observed during examination of square or hexagonal forgings, these zones shall be re-examined from the respective opposite faces. H 1.9.2 Evaluation of the examination results For diameters or widths across flats smaller than or equal to 60 mm, indications with echo amplitudes not exceeding circular-disk reflector 2 are permitted. For diameters or widths across flats larger than 60 mm, indications with echo amplitudes not exceeding circular-disk reflector 3 are permitted. For diameters or widths across flats larger than 120 mm, indications up to circular-disk reflector 4 are permitted. H 1.10 Surface-crack detection of bar steel The stipulations of Section H 1.4 shall apply to the evaluation of the examination results. H 1.11 Ultrasonic examination of drop-forged parts and hot-formed extrusions H 1.11.1 General (1) For drop-forged parts and hot-formed extrusions, the ultrasonic examination on stock material with diameters or widths across flats larger than 50 mm shall be performed to SEP 1920 test group 4. The stock material shall meet the requirements of size class C. (2) For drop-forged parts and hot-formed extrusions with nominal values larger than 150 mm, an ultrasonic examination shall additionally be performed, if permitted by the geometry, after the governing heat treatment for establishment of the mechanical and technological material characteristics, while the materials have the minimum possible of contours. H 1.11.2 Scanning directions (1) The examination of drop-forged parts and hot-formed extrusions shall be performed with straight-beam scanning from the external surface. Ultrasonic examination is not required in zones with radii of curvature smaller than 30 mm. H 1.11.3 Recording limits (1) For drop-forged parts and hot-formed extrusions, all indications with echo amplitudes reaching or exceeding the values presented in Table H-1 shall be registered. (2) If the nominal thickness in the finished condition is not known during the examination, the following recording limits shall be selected regardless of scanning direction: that of circular-disk reflector 2 for nominal thicknesses equal to or smaller than 60 mm in the examination condition, and that of circular-disk reflector 3 for nominal thicknesses larger than 60 mm. H 1.11.4 Evaluation of the examination results For drop-forged parts and hot-formed extrusions examined with straight-beam scanning, indications without length extent

and with echo amplitudes smaller than or equal to 12 dB above the recording limit are permitted in all volume zones. H 1.12 Surface-crack detection of drop-forged parts and hot-formed extrusions H 1.12.1 Extent and point of time Prior to delivery, the entire surface of drop-forged parts and hot-formed extrusions shall be subjected to surface-crack detection in the forging shop. All mechanically machined and accessible surfaces of the finish-machined part shall also be subjected to surface-crack detection. Examination of surfaces of blind holes and through holes equal to or smaller than 50 mm and of threaded holes is not required. H 1.12.2 Evaluation of the examination results The stipulations of Section H 1.4 shall apply.

H 2 Forgings, bar steel, rings and extrusions of austenitic steels H 2.1 Scope of application This Annex shall apply in addition to the stipulations of clause 4.4.7 the performance and evaluation of non-destructive examinations for forgings, bar steel, rings and extrusions of austenitic steels H 2.2 Ultrasonic examination H 2.2.1 Scanning directions (1) For bars with diameters or widths across flats larger than 30 mm, straight-beam scanning in radial direction shall be performed. For parts with diameters or widths across flats larger than 120 mm, an examination shall be additionally performed by angle-beam scanning in both circumferential directions, in which case the scanning angle for angle-beam scanning in the circumferential direction shall be 35 degrees. (2) The stock material for drop-forged parts with diameters or widths across flats larger than 50 mm shall be examined by straight-beam scanning from the lateral surface. Examination in the condition that has not been solution-annealed is also permitted. (3) For drop-forged parts larger than DN 150, straight-beam scanning shall be performed from the external surface, provided the radius of curvature is larger than 30 mm. (4) The entire volume of free-forged valve bodies shall be examined by straight-beam scanning from all external surfaces. In addition, angle-beam scanning in both circumferential directions shall be performed in the cylindrical zones in the rough-turned or finish-machined condition. In this case the recording limit shall be related to the wall thickness in the examination condition. (5) Hollow parts with a length-to-outside-diameter ratio equal to or larger than 3 shall be examined by straight-beam scanning from the cylindrical surface and by angle-beam scanning in both circumferential directions. Hollow parts with a length-to-outside-diameter ratio smaller than 3 shall be examined by straight-beam scanning in radial and axial direction. In straight-beam scanning, examination shall be performed from both cylindrical surfaces and from both end faces if necessary, in order to maintain the required examination sensitivity.

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H 2.2.2 Examination prerequisites and procedure H 2.2.2.1 Examination technique and examinability H 2.2.2.1.1 Examination technique (1) For the straight-beam method frequencies between 2 and 5 MHz and for the angle-beam method a frequency of 2 MHz shall be selected where during the examination of weld edges and nozzle areas miniature transverse wave probes shall basically be used. The examination shall be performed to detect longitudinal defects (defect orientation parallel to the direction of welding progress). Here, the incidence angle shall be selected such that the angle at the inner surface lies within the usable range of the corner effect (impinging angle possibly 35 degrees to 55 degrees). (2) The examination technique for examining the weld edge and nozzle areas shall be determined on a similar reference reflector or if practicable (e.g. where excess lengths are available) on the test object. When using a reference reflector it shall be representative for the test object with respect to geometry, acoustic properties and surface condition. (3) To obtain a sufficient signal-to-noise ratio of at least 6 dB or to be within the recording limits the examination technique may be optimised upon agreement with the authorized inspector, e.g. by the following measures: a) probes with a low nominal frequency, b) use of frequency selective equipments, c) use of twin probes, d) use of highly attenuated probes, e) use of longitudinal waves also for the angle beam method. H 2.2.2.1.2 Determination of examinability (1) The examinabilty shall be determined for each test object. (2) The examinabilty shall be determined jointly by the parties involved in the examination. (3) The wave lengths used for determining the examinability shall not be greater than those used for the straight and angle beam examinations that follow. (4) For plates the back wall echo shall be determined in all centre ranges of a grid of 200 mm and at the border line by means of straight-beam scanning and at intended frequency. (5) For all other product forms a grid of 200 mm shall be provided on each test object in the area of parallel or concentric walls to determine the examinability. In all centre ranges of this grid and additionally on all border lines of forgings the back wall echoes shall be determined by straightbeam scanning in wall thickness direction. In areas of non parallel or non-concentric walls reference reflectors shall be used (e.g. boreholes, edges or through-transmission) for this examination. (6) The number and density of examination points required to determine the examinability shall be in a reasonable relationship to the size and geometry of the test object. Here, the absolute number of measuring points may be limited to 50. (7) Where the examination has to be performed by straightbeam scanning, the sound wave attenuation in areas with a back wall echo attenuation greater than 6 dB shall also be determined by means of angle-beam scanning, e.g. by V-scanning. (8) Areas with a high sound wave attenuation (back wall echo variation greater than 12 dB) shall be identified and be enveloped by a narrow measuring point grid in which case the absolute number of measuring points shall be increased

accordingly. The maximum sound attenuation shall be recorded for each required scanning direction. (9) For the weld edges and nozzle areas the examinability shall be determined for the conditions of weld examination. This shall be done, like for the examination to follow, by means of angle-beam scanning. A circumferential groove as reference reflector shall be provided on the test object in the area where the weld will be laid, however, at a sufficient distance to the edge. The grooves shall not exceed a width of 1.5 mm, the reflection area shall be perpendicular to the surface. The depth of the reference reflector shall be determined in dependence of the wall thickness of the finished part in accordance with Table H-4. Where the reflector cannot be provided on the test object, a reference reflector in accordance with clause H 2.2.2.1.1 (2) with a circumferential groove (if practicable over the full circumference, but at least with a length of 50 mm) shall be provided. On the test object with circumferential groove the groove shall be scanned over the full circumference. By observation of the groove echo the area with the greatest sound attenuation will be determined. Where using a reference reflector, the test object areas with the greatest sound attenuation shall be determined by observing the edge reflection. By comparison of the edge reflexion at the test object and the reference reflector the differences in amplification referred to the reference echo amplitude shall be determined in accordance with clause H 2.2.2.5 (4) and be taken into account. Wall thickness s, mm 8 < s 20 Groove depth, mm Table H-4: 1.5 20 < s 40 2 40 < s 3

Depth of reference reflector for the examination of weld edges end nozzle areas

H 2.2.2.1.3 Unrestricted examinability If it can be proved for the area under examination with the greatest sound attenuation that a) for plates the required recording limits to 7.1.3.2 (5) c) b) for all the other product forms with respect to the straight and each angle beam scanning method the recording limits to clause H 2.2.2.5 can be satisfied, the test object has unrestricted examinability. H 2.2.2.1.4 Restricted examinability (1) Where for one or more sound beam entry directions in a sound attenuation region the recording limit according to clause H 2.2.2.5 or the required signal-to-noise ratio of 6 dB cannot be maintained even with an optimised examination technique (see clause H 2.2.2.1.1 (2)), these volumetric regions with restricted examinability and the corresponding degree of restriction shall be determined. (2) If, in the course of subsequent mechanical processing, more favourable conditions with regard to ultrasonic examinations are created for these regions (e.g. reduction of the wall thickness, shorter sound paths, removal of the regions of restricted examinability), then the ultrasonic examination of the regions in question may be carried out for the missing beaming directions in this subsequent fabrication condition. This examination may also be carried out by the subsequent manufacturer, provided the producer of the forging and the subsequent manufacturer agree. If the required testing sensitivity is achieved in the subsequent fabrication condition, these regions shall also be considered to be unrestrictedly examinable.

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H 2.2.2.2 Sensitivity adjustment (1) During the sensitivity adjustment the largest sound wave attenuation values shall be considered for all probes and beaming directions. (2) The evaluation of the echo indications shall be carried out with respect to the sound wave attenuation determined in the immediate vicinity of the echo indications. (3) When examining the weld edge and nozzle areas the sensitivity shall be adjusted to the reference echo method. In addition to the requirements of Annex F the following applies. The sensitivity shall be adjusted on a rectangular groove with a width not to exceed 1.5 mm and the reflection area of which is perpendicular to the surface. The groove depth shall be fixed in dependence of the wall thickness of the finished part in accordance with Table H-4. Where an equivalent reference reflector is used, the groove length shall be 50 mm with the groove run-out not being taken into account. The run-out radius shall not exceed 50 mm. Where the sensitivity is adjusted on the test object, the groove shall be provided on the circumference with sufficient distance to the edge. H 2.2.2.3 Size of reflectors Deviating from clause 4.4.7.2.1 (8) the reflector size is given by the probe movement at which the echo amplitude has dropped by 6 dB under the maximum echo amplitude (halfamplitude technique according to clause F 5.2.3). H 2.2.2.4 Types of examination (1) The test objects shall be subjected either to an overall ultrasonic examination or to a selective ultrasonic examination. Whether an overall or selective ultrasonic examination is to be performed shall be agreed between the forging manufacturer and the manufacturer and be recorded in the design review documents. The type of examination shall be indicated in the test record as overall US or selective US. (2) In the overall ultrasonic examination a detailed knowledge of the components to be fabricated from the test object is not required. In this examination the acceptance limit is equal to the recording limit. (3) In the selective ultrasonic examination it is required to know the shape and final dimensions of the components to be fabricated from the test object. To be able to correctly apply the recording limits and evaluation criteria on the nominal wall thickness, shape and location of the walls of the finished component it is required that at the point of time of examination drawings of the components to be fabricated from the test object are available. These drawings shall be submitted by the purchaser of the test object.
Note: The nominal wall thickness is the wall thickness indicated in the drawing of the finished component (used in the power plant).

of stock material for drop forgings the recording limit of Table H-5 shall be used. (3) In the selective ultrasonic examination in accordance with clause H 2.2.2.4 (3) the recording limits of Table H-6 apply. To obtain a sufficient signal-to-noise ratio (6 dB from the recording limit) the recording limit may partially be raised by 6 dB for the respective sound beam entry positions and volumetric regions. These regions as well as the recording limits obtained for the different beam entry directions shall be recorded. However, the evaluation criteria according to clause H 2.2.3.2 refer to the originally prescribed recording limit to Table H-6. Where the raised recording limit cannot be obtained in consideration of the extent of restrictions (number and type of beam entry directions, number and size of volumetric regions), substitute measures shall be agreed with the authorized inspector. (4) When examining the weld edge and nozzle areas all indications shall be recorded which are equal to or greater than the reference echo amplitude. The reference echo amplitude is the echo amplitude of the reference reflector to Table H-4 reduced by 12 dB. In addition, regions shall be recorded where the signal-to-noise ratio is less than 6 dB. H 2.2.3 Evaluation of the examination results H 2.2.3.1 General requirements All indications liable to record during angle-beam scanning which are not liable to record during straight-beam scanning shall be thoroughly examined with respect to their orientation. Indications with a size in thickness direction are not permitted. H 2.2.3.2 Bars and stock material for drop-forged parts Echo amplitudes up to the recording limits cited in Table H-5 are permitted. H 2.2.3.3 Forgings and extrusions (1) When referring the echo amplitude to the dimension in the test condition, echo indications up to the recording limits specified in Table H-5 are permitted. (2) When referring the echo amplitude to the nominal wall thickness of the finished product, the following requirements apply: a) In the case of straight and angle-beam scanning echo indications exceeding the recording limits specified in Table H-6 by up to 12 dB are permitted. b) The allowable frequency of recorded reflections shall be, in the case of nominal wall thicknesses or diameters of: ba) s or d 60 mm 3 per m2 locally and 2 per m2 overall, bb) s or d > 60 mm 5 per m2 locally and 3 per m2 overall. In the case of an examination with raised recording limit in accordance with clause H 2.2.2.5 (3) only half the number of recorded reflexions is permitted. c) In the case of straight-beam scanning in wall thickness direction reflexions with a length smaller or equal to the nominal wall thickness are permitted. d) For the other scanning direction reflexions with a length smaller than or equal to the nominal wall thickness, but at maximum 50 mm, are permitted.

H 2.2.2.5 Recording limits (1) For all forgings the following shall be recorded: a) all echo indications the amplitude of which is equal to or greater than the values indicated in Tables H-5 or H-6, b) locations on forgings with wall thicknesess, diameters or side lengths equal to or exceeding 100 mm where the back wall echo to be expected drops to a value near the recording limit. (2) In an overall ultrasonic examination in accordance with clause H 2.2.2.4 (2) and in the examination of bars as well as

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Scanning directions

Wall Reference Echo Method DGS thickness Recordable echo Method in test amplitudes referenced to Circular condition a 4 mm cylindrical bore disk s (mm) hole reflector 60 > 60 50 % (-6 dB) 100 % 3 4

H 2.2.3.4 Regions of weld edges and nozzles (1) Indications exceeding the recording limit by up to 6 dB are permitted if their number per meter of weld edge length at a minimum recording length of 10 mm is limited to 3 indications, and at a maximum recording length of 20 mm to one indication. (2) Where these limits are exceeded or areas are present where the groove or weld edge signal-to-noise ratio is less than 6 dB, further steps shall be agreed with the authorized inspector. H 2.3 Surface crack detection H 2.3.1 Extent and point of time

all

Table H-5: Recording limits and acceptance standards for ultrasonic examination on forgings with reference to the dimensions in the test condition and stock material for drop-forged parts a) Recording limits for DGS method. Recordable echo amplitudes referred to circular disk reflector (mm) Scanning direction Straight beam scanning Angle-beam scanning Nominal wall thickness of finished product (mm) s 15 2
1)

All accessible surfaces on the finished product shall be subjected to a liquid penetrant examination. H 2.3.2 Evaluation of the examination results (1) The requirements specified in Table H-7 apply.

15 < s 30 30 < s 60 3 2 3 3

s > 60 4 4

(2) The frequency of acceptable indications shall, locally, not exceed 10 per square decimetre and, relative to the entire surface, 5 per square decimetre.

b) Recording limits for distance gain size or reference echo method. Recordable echo amplitudes referred to the echo amplitudes of cylindrical bore holes 4 mm Scanning direction all Nominal wall thickness of finished product (mm) s 30 50 % = (- 6 dB) s > 30 100 % Circular Circular Indications indications indications 3 mm > 3 mm to > 6 mm individual 6 mm allowable, shall not be included in the evaluation allowable, not shall be allowable included in the frequency Linear indications 1) > 3 mm not allowable. If it is shown that the indications are due to carbon nitride inclusions, indications up to 6 mm are allowed and shall be included in the frequency.

1) Where scanning is performed on the nominal wall thickness,

the recording limit is the echo amplitude of a rectangular groove at the end of the second path to be evaluated with the following dimensions: Depth 1.0 mm Width 1.5 mm Length > Sound beam width When scanning with full skip distance reference echo amplitudes from the inner and outer groove can be used for the respective sound path regions. Regions scanned in the pre-fabricated condition which have a wall thickness s > 15 mm at the point of time of test, may be examined with a recording limit: circular disk reflector 2 mm.

1) A liquid penetrant indication is considered to be linear (linear

indication) if the length of its longest dimension is at least three times larger than the length in transverse direction.

Table H-6: Recording limits for ultrasonic examination on forgings with reference to the nominal wall thickness of the finished product

Table H-7: Acceptance standards for liquid penetrant examination

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Annex I Regulations and literature referred to in this Safety Standard

(The references exclusively refer to the version given in this annex. Quotations of regulations referred to therein refer to the version available when the individual reference below was established or issued.)

AtG

Act on the Peaceful Utilization of Atomic Energy and the Protection against its Hazards (Atomic Energy Act) of December 23, 1959 (BGbl. I, p. 814) as Amended and Promulgated on July 15, 1985 (BGBl. I, p. 1565), last Amendment by the Act of April 6, 1998 (BGbl. I, p. 694) Ordinance on the Protection against Damage and Injuries Caused by Ionizing Radiation (Radiological Protection Ordinance) as promulgated on June 30, 1989 and corrected on Oct. 16, 1989, at last amended by the Act of August 18, 1997 (BGBl. I, Page 2113) (6/96) (6/85) General Requirements Regarding Quality Assurance Quality Assurance for Weld Filler Materials and Weld Additives for Pressure and Activity Retaining System in Nuclear Power Plants; Part 1: Suitability Testing Quality Assurance for Weld Filler Materials and Weld Additives for Pressure and Activity Retaining System in Nuclear Power Plants; Part 2: Manufacturing Quality Assurance for Weld Filler Materials and Weld Additives for Pressure and Activity Retaining System in Nuclear Power Plants; Part 3: Processing Pressure and Activity Retaining Components of Systems outside the Primary Circuit; Part 2: Design and Analysis Pressure and Activity Retaining Components of Systems outside the Primary Circuit; Part 3: Manufacture ISO general purpose metric screw threads - Part 19: Nominal profiles Approval testing of welders - Fusion welding - Part 1: Steels (includes Amendment A1:1997); German version EN 287-1:1992 + A1:1997 Non-destructive testing; general principles for the radiographic examination of metallic materials using X-rays and gamma-rays; German version EN 444:1994 Non-destructive testing; image quality of radiographs; Part 1: Image quality indicators (wire type); determination of image quality values; German version EN 462-1:1994 Non-destructive testing - Image quality of radiogrammes - Part 3: Image quality classes for ferrous metals; German version EN 462-3:1996 Qualification and certification of NDT personnel; general principles; German version EN 473:1992 Fasteners; surface discontinuities; nuts; German version EN 493:1992 Non-destructive testing - Industrial radiographic film - Part 2: Control of film processing by means of reference values; German version EN 584-2:1996 Destructive tests on welds in metallic materials - Transverse tensile test; German version EN 895:1995 Mechanical properties of fasteners made of carbon steel and alloy steel - Part 1: Bolts, screws and studs (ISO 898-1:1999); German version EN ISO 898-1:1999 Mechanical properties of fasteners - Part 6: Nuts with specified proof load values; fine pitch thread (ISO 898-6:1994); German version EN ISO 898-6:1995

StrlSchV

KTA 1401 KTA 1408.1

KTA 1408.2

(6/85)

KTA 1408.3

(6/85)

KTA 3211.2 KTA 3211.3 DIN 13-19 DIN EN 287-1 DIN EN 444

(6/92) (6/90) (11/99) (8/97) (4/94)

DIN EN 462-1

(3/94)

DIN EN 462-3 DIN EN 473 DIN EN 493 DIN EN 584-2

(11/96) (7/93) (7/92) (1/97)

DIN EN 895 DIN EN ISO 898-1

(5/99) (11/99)

DIN EN ISO 898-6

(2/96)

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DIN EN 910 DIN EN ISO 1127

(5/96) (3/97)

Destructive test on welds in metallic materials - Bend tests; German version EN 910:1996 Stainless steel tubes - Dimensions, tolerances and conventional masses per unit length (ISO 1127:1992); German version EN ISO 1127:1996 Founding - Surface roughness inspection by visual tactile comparators; German version EN 1370:1996 Technical delivery conditions for castings made from metallic materials; steel castings; classification into severity levels on the basis of nondestructive testing Mechanical properties of corrosion-resistant stainless steel fasteners Part 1: Bolts, screws and studs (ISO 3506-1:1997); German version EN ISO 3506-1:1997 Mechanical properties of corrosion-resistant stainless steel fasteners Part 2: Nuts (ISO 3506-2:1997); German version EN ISO 3506-2:1997 Determination of resistance to intergranular corrosion of stainless steels - Part 2: Ferritic, austenitic and ferritic-austenitic (duplex) stainless steels - Corrosion test in media containing sulfuric acid (ISO 3651-2:1998); German version EN ISO 3651-2:1998 Geometrical Product Specifications (GPS) - Surface texture: Profile method - Terms, definitions and surface texture parameters (ISO 4287:1997); German version EN ISO 4287:1998 Metallic materials - Brinell hardness test - Part 1: Test method (ISO 6506-1:1999); German version EN ISO 6506-1:1999 Metallic materials - Vickers hardness test - Part 1: Test method (ISO 6507-1:1997); German version EN ISO 6507-1:1997 Determination of diffusible hydrogen in weld metal; manual arc welding Determination of diffusible hydrogen in weld metal; submerged arc welding Tensile testing of metallic materials; method of test at ambient temperature (including Corrigendum AC1:1990); German version EN 10002-1:1990 and AC 1:1990 Tensile testing of metallic materials; method of testing at elevated temperature; German version EN 10002-5:1991 Hot rolled products of non-alloy structural steels; technical delivery conditions (includes amendment A1:1993); German Version EN 10025:1990 Flat products made from steel for pressure purposes; Part 2: Non-alloy and alloy steels with specified elevated temperature properties; German version EN 10028-2:1992 Flat products made from steel for pressure purposes; Part 3: Weldable fine grain steels, normalized; German version EN 10028-3:1992 Charpy impact test on metallic materials; Part 1: Test method; German version EN 10045-1:1990 Technical delivery conditions for the surface condition of hot rolled steel plate, wide flats and sections; Part 2: Plate and wide flats; German version EN 10163-2:1991 Steel products with improved deformation properties perpendicular to the surface of the product; technical delivery conditions; German version of EN 10164:1993 Metallic products - Types of inspection documents (includes Amendment A1:1995); German version EN 10204:1991 + A1:1995 Technical delivery conditions for steel castings for pressure purposes Part 2: Steel grades for use at room temperature and elevated temperatures; German version EN 10213-2:1995 Technical delivery conditions for steel castings for pressure purposes Part 4: Austenitic and austenitic-ferritic steel grades; German version EN 10213-4:1995 Page 120

DIN EN 1370 DIN 1690-2

(2/97) (6/85)

DIN EN ISO 3506-1

(3/98)

DIN EN ISO 3506-2 DIN EN ISO 3651-2

(3/98) (8/98)

DIN EN ISO 4287

(10/98)

DIN EN ISO 6506-1 DIN EN ISO 6507-1 DIN 8572-1 DIN 8572-2 DIN EN 10 002-1

(10/99) (1/98) (3/81) (3/81) (4/91)

DIN EN 10 002-5 DIN EN 10 025

(2/92) (3/94)

DIN EN 10 028-2

(4/93)

DIN EN 10 028-3 DIN EN 10 045-1 DIN EN 10 163-2

(4/93) (4/91) (10/91)

DIN EN 10 164

(8/93)

DIN EN 10 204 DIN EN 10 213-2

(8/95) (1/96)

DIN EN 10 213-4

(1/96)

KTA 3211.1

DIN EN 10 233 DIN EN 10 234 DIN EN 10 236 DIN EN 10 237 DIN EN 10 269 DIN EN 12 223 DIN EN ISO 13 916

(1/94) (1/94) (1/94) (1/94) (11/99) (1/00) (11/96)

Metallic materials; tube; flattening test; German version EN 10233:1993 Metallic materials; tube; drift expanding test; German version EN 10234:1993 Metallic materials; tube; ring expanding test; German version EN 10236:1993 Metallic materials; tube; ring tensile test; German version EN 10237:1993 Steels and nickel alloys for fasteners with specified elevated and/or low temperature properties; German version EN 10269:1999 Non-destructive testing - Ultrasonic examination - Specification for calibration block No. 1; German version EN 12223:1999 Welding - Guidance on the measurement of preheating temperature, interpass temperature and preheat maintenance temperature (ISO 13916:1996); German version EN ISO 13916:1996 Steels for general structural purposes; quality standard Weldable normalized fine grain structural steels; technical delivery conditions for plate, strip, wide flats, sections and bars Weldable fine grain structural steel forgings; technical delivery conditions Creep resistant steel plate and strip; technical delivery conditions Seamless tubes of heat-resistant steels; technical conditions of delivery Seamless circular fine grain steel tubes subject to special requirements; technical delivery conditions Heat resisting and highly heat resisting materials for bolts and nuts; quality specifications Weldable heat resisting steel forgings and rolled or forged steel bars; technical delivery conditions Ferritic steel castings with elevated temperature properties; technical delivery conditions Stainless steels - Technical delivery conditions for plates, hot rolled strip and bars for pressure purposes, drawn wire and forgings Stainless steel castings; technical delivery conditions Welded circular austenitic stainless steel tubes subject to special requirements; technical delivery conditions Seamless circular austenitic stainless steel tubes subject to special requirements; technical delivery conditions Mechanical properties of fasteners; Part 2: Nuts with specified proof load values; coarse thread (ISO 898-2:1992); German version EN 20898-2:1993 Fasteners; surface discontinuities; bolts, screws and studs subject to special requirements (ISO 6157-3:1988); German version EN 261573:1991 Welds in steel; calibration block No. 2 for ultrasonic examination of welds (ISO 7963:1985); German version EN 27963:1992 Determination of ferrite number in austenitic weld metal; measurement method Testing of hollow bodies by internal pressure; leak detection up to a certain pressure value; general specifications Notched bar impact testing of metallic materials using test pieces other than ISO test pieces Test pieces for the tensile testing of metallic materials Materials testing machines - Generals for requirements and for verification and calibration of materials testing machines Non-destructive testing; testing of metallic materials by X-rays or gamma rays; radiographic techniques for castings of ferrous materials Page 121

DIN 17 100 DIN 17 102 DIN 17 103 DIN 17 155 DIN 17 175 DIN 17 179 DIN 17 240 DIN 17 243 DIN 17 245 DIN 17 440 DIN 17 445 DIN 17 457 DIN 17 458 DIN EN 20 898-2

(1/80) (10/83) (10/89) (10/83) (5/79) (5/86) (7/76) (1/87) (12/87) (9/96) (11/84) (7/85) (7/85) (2/94)

DIN EN 26 157-3

(12/91)

DIN EN 27 963 DIN 32 514-1 DIN 50 104 DIN 50 115 DIN 50 125 DIN 51 220 DIN 54 111-2

(6/92) (6/90) (11/83) (4/91) (4/91) (1/96) (6/82)

KTA 3211.1

DIN 54 119 DIN 54 130 DIN 54 141-3 DIN 54 152-1 DIN 54 152-2 DIN 54 152-3 DIN 58 220-3 DIN 58 220-5 EURONORM 103-71 SEL 072 SEP 1805 SEP 1915 SEP 1918 SEP 1919 SEP 1920 SEP 1922 SEP 1925 SEP 1935 SEP 1936 SEW 088 SEW 110 SEW 400 AD HP 3 AD W 2

(8/81) (4/74) (2/87) (7/89) (7/89) (7/89) (1/97) (1/97) (11/71) (12/77) (3/76) (9/94) (1/92) (6/77) (12/84) (7/85) (1/80) (6/82) (6/82) (10/93) (7/86) (2/97) (4/96) (1/00)

Non-destructive testing; ultrasonic inspection; terms Non-destructive testing; magnetic leakage flux testing, general Non-destructive testing; eddy current testing of pipes and tubes; procedure Non-destructive testing; penetrant inspection; procedure Non-destructive testing; penetrant inspection; verification of penetrant inspection materials Non-destructive testing; penetrant inspection; reference blocks for determination of the sensitivity of penetrant systems Visual acuity testing - Part 3: Test for use in expertise Visual acuity testing - Part 5: Vision screening test for general use Microscopic determination of the ferritic or austenitic grain size of steels Ultrasonically tested heavy plate; technical delivery specifications Sampling and sample preparation for the product analysis in the case of steel Ultrasonic testing of pipes for longitudinal defects Ultrasonic testing of pipes for transverse defects Ultrasonic testing for laminations of pipes of creep-resistant steels Ultrasonic testing of rolled semi-finished products on internal material discontinuities Ultrasonic testing of forgings of ferritic steel Electromagnetic testing of pipes for the proof of impermeability Seam testing of castings of steel; magnetic powder test Seam testing of castings of steel; penetration testing Weldable fine-grained structural steels; guidelines for processing, in particular for fusion welding (incl. supplementary sheets 1 and 2) Procedure test for production welding at cast steel Stainless rolled and forged steels Welding systems - Welders Austenitic steels

Literature
[1] [2] [3] Handbuch fr das Eisenhttenlaboratorium De Long, W. T. Richter, F. Loseblattsammlung (Loose-leaf edition); Verlag Stahleisen, Dsseldorf Welding Research Supplement 53 (1974), S. 273/286 Physikalische Eigenschaften von Sthlen und ihre Temperaturabhngigkeit, Stahleisen-Sonderberichte Heft 10, 1983, Verlag Stahleisen, Dsseldorf. Metallkundliche technische Reihe; Metallographisches 6. Auflage; Berlin, Stuttgart, Borntraeger, 1994 tzen,

[4] [5]

Petzow, G.

Reference-Atlas for a comparative evaluation of ferrite percentage in the fused zone of austenitic stainless steel welded joints; Internationales Institut fr Schweitechnik: Istituto Italiano della Saldatura, Genova, 1972

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Annex K (informative) Changes with respect to the edition 6/91

(1) The wording of the requirements regarding the accuracy of the test and inspection facilities and their testing to clause 3.4 (2) was adapted to DIN 51 220, edition 1/96 without change in contents. (2) The procedural requirements for ultrasonic examination in clause 4.4.7, in correspondence with clause 3.3.8 of KTA 3201.1 (6/98), as well as the requirements for the ultrasonic examination of product forms made of austenitic steels were adapted to the actual state of knowledge. (3) In Section 4.3 it was pointed out that for steel castings no sampling direction for notched-bar impact test specimens is specified due to the directional independence of mechanical characteristics. (4) For hot (T 200 C) reactor water containing piping and components to be fabricated anew for boiling-water reactors only the steel grade X 6 CrNiNb 18 10 with a restricted chemical composition compared to that of the standard composition shall be used. Corresponding stipulations have been included in clauses 4.3.3, 7.1.1, 7.2.1, 7.3.1, 7.4.1, 7.5.1 and 7.6.1. (5) Sections 5, 6, 8 and 9 were adapted to the actual state of standardisation. (6) The scope of Sections 5.6, 6.6 and 7.6 was extended to cover tees fabricated to the liquid-bulge method. (7) The test certificates required by Sections 6 and 7 for test group A 3 were adapted to the requirement of PmB 50 N/mm2 defined for test group A 2. (8) The requirements of Table 8-1 were adapted to Annex 1 of AD Merkblatt W 7 (2/98). (9) In Annexes B and C it was pointed out that for the term "large production weld" the definition of DIN 17 245 will govern. According to the actual standard DIN EN 10 213-1 a large production weld is meant if its depth exceeds 40 % of the effective wall thickness. DIN 17 245 additionally specifies that for grades 1 and 2 (e.g. welding ends) the depth shall not exceed 25 mm. For wall thickneses over 60 mm the definition to DIN 17 245 therefore is more stringent. The more stringent

requirements of DIN 17 245 shall be adhered to for the scope of KTA 3211.1. (10) Annex D "Procedure for determining the delta ferrite content" was changed in correpondence with KTA 3201.1 (6/98). (11) In Annex E the term "recording limit" not defined up to now was clarified by inclusion of supplementary stipulations. (12) Annex F "Performance of manual ultrasonic examinations" and Annex G "Performance of surface crack detection by magnetic particle and liquid penetrant methods" were replaced by the respective Annexes of KTA 3201.1 (6/98). (13) In Annex G requirements regarding the sensitivity of the examination system as per DIN 54 152-3 wer taken over. (14) In Section H 1.2 it was pointed out that when using the magnetic particle method minor redressing without further examination is allowable if the test result of the original examination is not impaired. (15) Annex I was adapted to the actual state of standardisation. The references to the material standards DIN 17 100 (1/80), DIN 17 102 (10/83), DIN 17 103 (10/89), DIN 17 155 (10/83), DIN 17 240 (7/76), DIN 17 243 (1/87), DIN 17 245 (12/87) and DIN 17 445 (11/84) as well as to DIN 54 152-1 (7/89) and DIN 54 152-3 (7/89) for the performance of penetrant examination were maintained for the following reasons, although they have been withdrawn in the meantime: - the withdrawn standards are further needed as specification for some allowable materials. For these materials no other standards covering the actual range of application exist. - the application of DIN EN 571-1 (3/97) (document substituting DIN 54 152-1) and DIN ISO 3452-3 (document subsituting DIN 54 152-3) is at present not practically feasible, as long as the stipulations contained in the other parts of DIN 54 152 regarding the calibration blocks to be used, the checking of penetrant fluids etc. will not be replaced by DIN EN Standards in a manner compatible with DIN EN 571-1.

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