QO AD 2000-Merkblatt ICS 23.020.30 July 2012 edition Manufacture and Procedure testing for joining processes ‘AD 2000-Merkblatt testing of 1 ot tissu veseoll Procedure testing for welded joints HP 2/1 The AD 2000-Merkblater are prepared by the seven associations sted below who together form the “Arbeitsgemeinschalt Druck- bahaltar (AD). The sirscture and the application of the AD 2000 Code and the procedural guidelines are covered by AD 2000-Merk- late G1. The AD 2000-Merkbistter contain safety requiromants fo be met under normal opersting conditions. f above-normal loadings are fo be expected during the operation ofthe pressure vessel, this shall be taken into account by meeting special requirements. If there are any divergences from the requirements ofthis AD 2000-Merkbist, it shat bo possible to prove thatthe standard of safety of this Code has bean maintained by other moans, e.g. by materials tasting, tess, stress analysis, operating expertence. Fechverband Dampkessot, Behaitr- und Rotreitungsbau e.V. (FDBR), Dosseldort Deutsche Gesetzlche Untalversicherung (OGUV), Bern Verband der Chomischen Industrie o.V. (VC), Frankfurtdsin Verband Deutscher Maschinen- und Arlagenbau eV. (VDMA), Fachgemeinschat Verfahrenstechrische Maschinen Lund Apparat, Frenkfury@4ain ‘Stahlinsttut VOER, Dasseldod VGB PowerTech eV, Essen Verband der TOV eV. (VATOV), Bertin ‘The above associations continuously update the AD 2000-Merkblater in line with technical progress. Please address any proposels for {his o the pubisher: Verband der TOV e.V., FriedrichstraBe 136, 10117 Berlin. Contents Page Foreword. ‘Scope. Procedure qualiteation Principles of testing oon Working temperatures. Aggravating conditions..r.ne Proved tests for special applications. ‘Special cases.. : Supplementary testing and repetition of procedure test. ‘Supersedes May 2011 edition; | = amendments to previous edition [ab 2000 Meritt ae protected by copyright The Aghia of usa, pareulany of any wanelaon, reproduction, exact of figures, ansmision by ‘Polomacharical means and storage fn data felieval systems, even of exvace, ave feseved to he auor. Beuh Verlag has taken al reasonable ‘oases fe ensue the accuracy of tus tancltion but regres tht no responsiblity con be secepte fr any error, emission or naeewrory n eases of ‘oF cope, the latest edion of tho German txt ely vaiAD 2000-Merkblatt Page 2 AD2000-Mekbiat HP 2/, 072012 edion 0 Foreword The AD 2000 Gode can be applied to satisfy the basic safety requirements of the Pressure Equipment Directive, principally forthe conformity assessment in accordance with modules “G" and"B + F. ‘The AD 2000 Code is structured along the fines of a self-contained concept. If other technical rules are used in accordance with the state of the art to solve related probiems, itis assumed that the overall concept has been taken into account The AD 2000 Code can be used as appropriate for other modules of the Pressure Equipment Directive or for different sectors of the law. Responsibility for testing s as specified in the provisions of the relevant sector of the law. 1 Scope “This AD 2000-Merkblatt regulates the procedure test for welded joints and surfacing as a condition for the manufacture of welded pressure vessels or welded pressure vessel components. 2 Procedure qualification 24 Manufacturers of welded pressure vessels or pressure vessel components shall prove to the relevant thitd party Using a procedure test suited to the manufacturing process that they have mastered the welding procedure in use. ‘Supplementary testing is necessary if materials, dimensions or welding procedures have changed beyond the scope of the procedure test. 2.2 The testing shall be performed under the supervision of the relevant third perty. The relevant third party shall satisfy himself that the procedure test has been properly performed and shall state its expert opinion on the results of the tests. ‘The resuits of the procedure test shall be available prior to the commencement of manufacture. 3. Principles of testing 3.1 General specifications ‘The suitabilly of the welding procedure shall be established according to 6.2 of DIN EN ISO 15607 by means of procedure testing, For procedure testing, the following apply DIN EN ISO 1561441 ‘Arc and gas welding of steels and are welding of nickel and nickel alloys DIN EN ISO 15614-2: ‘Are welding of aluminium and its alloys DIN EN ISO 156145: ‘Arc welding of titanium, zirconium and their alloys DINEN ISO 156146: ‘Arc and gas welding of copper and its alloys DINEN ISO 156147: Overlay welding DINEN ISO 156148: ‘Welding of tubes to tube-plate joints DIN ENISO 15614-11: Electron and laser beam welding DIN EN ISO 15614-12: Spot, seam and projection welding ‘The material sub-groups are classified according to DIN V 1738:2000-07 (CR ISO 15608:2000). ‘The procedure tests shall be adapted to sult materials which have to meet particular requirements regarding corrosion (e.g. tisk of stress corrosion cracking). If the filet weld calculation provides for minimum penetration, this shall be proven in @ procedure test. This test covers all welds with @ required smaller penetration. 344 Filler metals Filer metals include other filer metals with comparable mechanical characteristics and the same nominal composition if the suitablity of the same type of filer metal has been established according to 4.3 of AD 2000-Merkolatt W 0 and this covers the scope of the procedure test. 3.4.2 Heat treatment “The procedure testis valid for the heat treatment condition prevailing at the time of the test. By way of deviation from the DIN EN ISO 15614 series of standards, the heat treatment of the test piece shall be performed in such a way that the heat treatment condition achieved is comparable to that achieved for the component itself. 3.4.3 Test requirements for non-destructive testing Non-destructive testing is performed and evaluated according to AD 2000-Merkbiatt HP 5/3.AD 2000-Merkblatt AD 2000-Mavatiet HP 21, 072012 eston Pago 3 3.2. Supplementary provisions 3.24 Supplementary procedure testing on steel, nickel and nickel alloys 3.244 Scope of test ‘As a deviation from 7.4 end Table 1 of DIN EN iSO 155141, the following test specimens are algo to be taken from the test pieces: 41) Longitudinal tensile test specimen according fo DIN EN ISO 5178 with a minimum diameter of 6 mm from test plates 20 mm thick for but welds. The test specimen shall meet the minimum requements for the parent metal”) 2) impact test specimens according to DIN EN ISO 148-1 can be taken for wal thicknesses over 5 mm up to 12 rm, these shall always be taken from the middle of the weld metal for each welding positon in accordance with DIN EN 180 6847 for all the material groups and, for material groups 2, 3, 4, 5, 6, 7, 9, 10 ftom the weld-to-parent metal interface (HAZ) also. 3) Microsection from materials of material (sub)groups 8.1 (if welded with filer metas with <3 % delta fete inthe weld metal), 82, 10, 41 to 48. The structural constitution shall be described andilustrated. 3.2.4.2 Test requirements for non-destructive testing For non-destructive testing, DIN EN ISO 18614-1 applies in conjunction with Table 1. 324.3 Deviating scope 3.24.31 Relative to the material thickness ‘As a deviation from Table § of DIN EN ISO 16614-1, for single-run welding, two-run welding and for procedures without filer metals, the upper limit is 1,1 times the material limit used for the procedure test 32.4.3.2 Relative to the welding position In the procedure test, proof shall be provided of the welding positions occurring in the menufacture. 32.2 Supplementary procedure testing on aluminium and aluminium alloys. 32.24 Scope of test ‘As a deviation from 7.1 and Table 1 and 7.2 and Figures § and 6 of DIN EN ISO 15614. shall also be taken from the test pieces: 1) Impact test specimens according to DIN EN ISO 148-1 from the middle of the weld metal for wall thicknesses over 5 mm for material sub-groups 22.3 and 22.4. If a procedure test is carried out on a specific object for pressure vessels not subjected to sudden stresses, the impact test can be dispensed with 2) Microsection for materials groups 22 to 26. The structural constitution shall be described and illustrated. 3) Weld metal analysis for all material groups. it may be dispensed with ifthe analysis of the filer metal is availabe. , the following test specimens 3.2.22 Test requirements for destructive testing DIN EN ISO 15614-2 and also Table 2 apply for destructive testing. If, in the case of aluminium alloys of material eub- groups 22.2, 22.3 and 22.4 of thicknesses greater than 20mm, the minimum tensile strength of the parent metal is not attained in the tensile test transverse to the weld, an additional tensile test shall be carried out on a weld metal specimen 40 mm in diameter and Lp = 5 d in which the 0,2 % proof stress, the tensile strength and elongation at fallure shall be determined. 3223 De 1g scope 3.2.2.3. Relative to the material groups (1) As a deviation from Table 4 of DIN EN ISO 15614-2, a procedure test on material subgroups of material group 22 includes only the low alloy material subgroups in each case. (2) Procedure tests on materials of material group 23 apply only to the welded material 3.2.2.3.2 Relative to the material thickness ‘As a deviation from 8.3.2 of DIN EN ISO 18614-2, for single-run welding, two-run welding and for procedures without filer metals, the upper limits 1,1 times the material limit used for the procedure test. 1) The longitudinal tensile test specimen can be clspensed with if suitability forte filer metal has been established in accordance to 4.3 of AD 2000-Merkbatt W 0.AD 2000-Merkblatt Page AD 2000-Matiot MP2, 072012 ction 3.2.2.3.3 Relative to the welding positions In the procedure test, proof shall be provided of the welding positions occurring in the manufacture. 3.2.3 Supplementary procedure testing on titanium, zirconium and their alloys 3.234 Scope of test ‘As a deviation rom 7.1 and Table 1 of DIN EN ISO 186145, the folowing test specimens are also tobe faken from the test pieces: 4) Longitudinal tensile test specimen according to DIN EN ISO 5178 with a minimum diameter of 6 mm from test plates 220 mm thick for butt welds. The test specimen shall meet the minimum requirements for the parent metal."? 2) For materials of material groups 51 to 4 and 61 and 62, with wall thicknesses greater than § mm, impact test specimens; notch shape according to the specification for the parent metal, test specimen location and notch ofientation WT according to DIN EN ISO 9016. 3) Hardness test HV 5 on the macrosection. 4) Microsection transverse to the weld. The structural constitution shall be described and illustrated, 32.32. Test requirements for destructive testing DIN EN ISO 15614-5 applies for destructive testing. The following also apes: 41) The impact energy shall correspond to the minimum requirement for the parent metal. 2) The hardening determined in the welded joint in the hardiness test shall not be more than $0 hardness units greater than that of the unaffected parent metal 3.2.3.3 Deviating scope 3.2.3.3.1 Relative to the material thickness, ‘As a deviation from the requirements in 8.3.2 of DIN EN ISO 19614-5, for single-run welding, two-run welding and for procedures without filer metals, the upper limit is 1,1 times the material limit used for the procedure test. 32.3.3.2 Relative to the welding positions In the procedure test, proof shall be provided of the welding positions occurring in the manufacture. 3.2.4 Supplementary procedure testing for copper and copp loys 3.2.4.1 Deviating scope 3.2.41 Scope for plates and pipes. ‘As a deviation from 9.3.2.4 of DIN EN ISO 19614-6, the qualification for plates does not include qualification for pipes. 3.2.4.4.2 Rolative to the material thickness ‘As a deviation from 9.3.2 of DIN EN ISO 15614-6, for single-run welding, two-run welding and for procedures without filer ‘metals, the upper limitis 1,1 times the material mit used for the procedure test. 3.2.4.1.3 Relative to the welding positions In the procedure test, proof shall be provided of the welding positions oceurring in the manufacture. 3.2.8 Supplementary procedure testing for overlay welding When hardfacing, as @ supplement fo the requirements of 7.1 of DIN EN ISO 156147, the heataffected zone of the substrate material shall be examined for any embritlement. For this, 2 face bend test specimens FBC as specified in clause 4 of DIN EN ISO 5173 shall be taken transversely to the direction of welding progression, Test specimen thickness ‘approx. 10 mm; with a thicker substrate material, remove down to 10 mm. The hardfacing shall be removed to a height of 0,5 mm above the substrate material. Test the bend test specimens with a mandrel diameter 6 x a. ‘Supplementary recommendation for test specimen preparation: transverse grooves (approx. 2mm to 3mm wider 0,3 mm deep) shall be made in the hardfacing approx. 10 mm apart. The test specimens shail be bent beforehand to produce cracks in the cladding. The cracks in the cladding shall not continue into the heat-aftected zone or the parent metal 1) See pagesAD 2000-Merkblatt ‘AD 2000-Mertat HP, 072012 eden PogoS 3.2.6 Welding of tubes to tube-plate joints, 32.6.1 Scope of test and test requirements For strength welds of tube to tube-plate joints, a tube push-out or tube pull-out test shall be carried out on two pipe welds. The minimum strength of the tube material shall be attained. ‘The section assessment and evaluation of the hardness tests shall be according to Table 1 and the requirements of 3.2.3 ‘of this AD 2000-Merkblat for materials of material groups 61 to 54, 61 and 62 3.2.7 Electron and laser beam welding 3.2.74 Scope of test and requirements The basis for procedure tests with electron and laser beam welding shal be quality level B according to DIN EN ISO 13919 Parts 1 and 2. Hardness tests are requited for materials of material groups 4 to 7, 9 to 11, 51 to 54, 61 and 62, Hardness HV1 shall be determined preferably. The hardness testis assessed according to Table 1 or the requirements of 3.2.3 for materials of material groups 1 to 54, 61 and 62. ‘The section assessment for materials of material groups 8 and 41 to 48 is according to Table 1. For materials of material (sub)groups 1 to 7, 9 to 11, 22.1, 22.2, 41 to 48, 51 to $4 and 61 and 62 with wall thicknesses greater than 5 mm, an impact testis required. The notch shape corresponds to the requirements for the parent metal, test ‘specimen location and notch orientation WT according to DIN EN [SO 9016. Requirements according to Table 1 or 2 and 3.2.8.2 of his AD 2000-Merkblatt shall be met ‘Transverse bend tests according to DIN EN ISO 6173 shall be carried out. The requirements and assessment shall be as Indicated in Tables 1 and 2, 3.2.7.2 Deviating scope 1) relative to the joint geometry: The maximum gap width of the welding groove proven in the procedure test applies, according to the tolerances of the pWPS. 2) relative to the parent metal: ‘The requirements of Parts 1, 2 and 5 of DIN EN ISO 15614 apply 3) relative to the filer metal Welding with and without filer metal shall be proven separately. 3.2.8 Spot, seam and projection welding The following welding procedures may be used: 211 One-sided resistance spot welding 212 Two-sided resistance spot welding 221 Lap seam welding 281 One-sided projection welding 232 Two-sided projection welding ‘The test conditions for other welding procedures shall be agreed with the relevant third party. 3.2.8.1 Scope of test and requirements ‘The scope of testis specified in Table 3. In addition to the requirements of 8.3 of DIN EN ISO 15614-12, testing a material for the particular material group according to OR ISO 15608 appies. Where there are different wall thicknesses, the combinations of the thinnest and thickest materials shall be tested. The intermediate thicknesses are considered as qualified within the context ofthis standard. 4 Working temperatures 41 Procedure tests ate valid from ~10 °C up to the applicable upper operating temperature for the parent metal or the filler metal. 4.2 Where the working temperatures are less than ~10 °C, procedure testing in stress category | is valid down to the lowest test temperature at which the requirements regarding impact strength have been met, but not lower than theAD 2000-Merkblatt Page 6 AD 2000-Makiat HP 2, 072012 ection lowest permissible operating temperature for the parent metal or filler metal. f procedure testing has been performed at the lowest operating temperature as specified in column 4 of Table 1 in AD 2000-Merkblatt W 10, itis also valid for the lowest temperatures in stress categories II and Il. 43 If testing is performed at a temperature higher than thet specified in column 4 of Table 1 in AD 2000-Merkbiatt W 10, the same temperature differences 2s for the parent metals apply i the procedure testis used for stress categories Il and Ii. 5 Aggravating conditions If aggravating conditions are present during manufacture or assembly, they shall be taken into account in the procedure tests. 6 Procedure tests for special applications Procedure tests for special applications shall be carried out wth the agreement ofthe relevant third party. 7 Special cases If there is a need for procedure tests which are designed fo cater for special cases, @.g. projection welds, welding of clad steals, studding and diffcit weld repairs during production involving steels sensitive to welding, then their scope shall be ‘agreed withthe relevant third party. 8 Supplementary testing and repetition of procedure test 8.1 If the specified conditions are altered to any appreciable extent, a supplementary test is required. The supplementary test can be performed as a production test. 8.2 _ Inthe event of the production of pressure vessels or pressure vessel components being completely discontinued for a period in excess of one year, procedure testing shal be repeatedAD 2000-Merkblatt ‘AD 2000-Meriat HP.2, 072012 etton Page ‘Table 1 — Test requirements for welded joints in steels, nickel and nickel alloys, “Type of test Requirements, Transverse tensile test to ‘Tensile strength as specified for the parent metal or established in the suitability test DIN EN ISO 4136 for the filer metal Congitudinal tensile test to ‘Yield point of 0,2 % proof stress, tensile strength and elongation at failure as DINEN ISO 5178 0naweld | specified for the parent metal or established in the suitabilty test forthe filler metal metal test specimen’? Impact test to For working temperatures | As specified forthe parent metal in the transverse DIN EN ISO 148-1 (radtus of | trom —10 °C and higher direction, but at least 27 J If ferrite-2ustenitic, the 2mm stiker, KV) from the austenitic and nickel base-alloy filer metals are middle ofthe weld used: 2 40 J. The testis carried out atthe lowest (est specimen location and working ferperature, but not lower than the test notch orientation VWT to temperature in the parent metal test and not higher DIN EN ISO 9016) than 20°, For working temperatures | As specified forthe parent metal in the transverse lower than ~10 °C citection ifferitc filer metals are used = 27 Jif {ortitic-austenitic, austenitic and nickel base-aloy filler metals are used: > 32 J®). The test is carried out at the lowest working temperature. The specifica- tions in 4.2 and 4.3 shall be noted Impact testo Forworking temperatures | » 27 49) at the lowest working temperature, but not DINEN ISO 1484 (actus of | from=10°C and higher | lower than the test temperature in the parent metal the 2 mm sire, KV) from the test and not higher than 29 °C. 1d interface area eat ee i eaion and | Forworking emperatures | 227 JP at the lowest working temperature. The Cech orcinen vine lower than ~10°C Specificaions in 4.2 and 4.3 shal be noted DINEN ISO 9016) Bend testo DINENISO6173 | Bend angle | Material Bending mandrel : diameter) 730) Material groups") 1107, 8, 1 with a minimum tensile strength < 430 MPa 2a minimum tensile strength 2 430 to < 460 MPa | 2.5: @ tminimum tensile strength = 460 MPa 3a 180° Material groups 8, 41 to 48. 2-a Material group 10 and high-temperature steel of material group 8 ee if 180" bend angles are net attained, the folowing eppies 290 Elongation (Lg = width of weld + wal thickness, symmetrical relative te weld) > minimam elongation at failure A ofthe parent metal <90 Elongation over width of weld > 30 %7) and fracture free from any evidence of detects Section assessment Microsections shall be examined for cracks, Only hot cracks are permissible tothe ‘extent that they are cated as isolated hot cracks in terms of numbers and location ‘and the relevant third party agrees that they are permissible given the material and application area. Hardness testo “The limit values in Table 2 of DIN EN ISO 156414- apply in principle. However, DINEN ISO 9015-1 values greater than 350 HV 10 in narrow transition zones shall only be accepted if they are limited locally. For materials of material group 3.2 the mit values shall be agreed with the relevant third partyAD 2000-Merkblatt Page ® AD2000-Merkiait HP 2, 07.2012 editon “The longitudinal tensile lest specimen can be dlepensed wih f eutabilly has boon established in aocordance with 4:3 of AD 2000- Merkbiatt W 0. 2) For test specimens that do not correspond to the standarcized 10 mm width, the impact energy requirements are reduced in Proportion to the specimen cross-section. 3) Only one individual valuo may fll below the minimum mean value, but by no more than 20 %. 44) Inthe case of welding joints on X20CrMeV11-1, a value of up to 10 % less Is permited 5) The relevant thickness with regard to tenite stenath isthe smallest hickness range. 8) A bend angle of 180° shal be deemed to have bean attained If the bend test me the requirements in DIN EN ISO 5173 and the specimen was ferced thraugh the suppers without the appearance of any surface cracks, 7) In the case of staels not welded in the eame way (e.g. XBNI), ethor values may be agraad in consultation withthe relevant thin party. 8) Procedure tests performed with smaller bending mance! dlamaters meet the requirements as welAD 2000-Merkblatt ‘AD 2000-Mertlat HP 21, 07:20"2 clon Page S c~ _ Table 2 — Test requirements for welded joints in alumi Type of est Requirements Fonsverse tensile testo | Tenale svengih as speci fore parent metal or established nthe sutabliy test DIVEN 180 4136, forthotilr metal Frensie test to 102% prot stress, teal svenalh and elongation al falar os spedted forthe DINEN ISO 8178 on parent metal or esabtshed inte slab test othe ier etal a weld meal fat specinen Impact test! to At room temperature +2 16 J, no individual value less than 12 J. DINEN 180 148-1 (aus of eae BMENISO te Cerusot Tacworting tamara |'4. onal ae lesan 12 J mde ofthe weld [fos specimen focation and neh orentation VW to DIN EN ISO 9016; mean value from 3 test specimens) Bend ist to DINENISO S173 | Bend-anglo [Material Bending rendrel a diameter?) 78 ENAW.AB.98 2a CO |ierest5 mm ; renoverse bed test specimens ENAW a9 3 Seo -A09 onthe top selon tho rot ENAW.A007 EN AWAIT foc 15mm ; 7G side bend test specimens ua EN AM AIMASEEE ° EN AW.AMG2Mo0 8 EN AW AIG 6n0,7 If 180° bend angles are not attained, the following applies: 290 Elongation (lg = width of weld + wal thickness, symmetica lative fo wold)» mifimum elongation a fafure A of the parent meta So Elongation over with of weld> 20% and facture free from any tendonce of detects Secon sssecemont "The macroselion of he welding joint shall provide evidence of atsfactony bule-up and il ponevation welding. Mtosectons sha be examined for presence of imurooracks,Grack are nt permissible, “7 Only for aluminium alloys in material group Al 2 as specified in Table 2a of AD 2000-Merkblatt HP 0. If a procedure test is rN performed on spectfic objects for pressure vessels not subjected fo shock stresses, the impact test may be dispensed with. 2) Procedure tests performed with smaller bending mandrel diameters mest the requirements as wellAD 2000-Merkblatt age 10 AD 2000-Menbat HP 21, 07.2012 ediéon ‘Table 3 — Scope of test and requirements for spot, seam and projection welding Test piecolspecimen Type of test Number of test specimens | ___Requirements Single-spot, Visual examination al dupiex-spot, ‘uiiple-spot or Surface crack test 100% Pec As cectedos projection welding test permitted a ‘Tensile shear test or 7 Urensie test? Macrosection® 2 Hardness test 2 Table t Lop, Visual examination al seam welding test specimen fae Peliest___ 1 Length, min, 350 mm toate shettiest 4 Bureting pressuretest?” (3 Macrosection® 3 Harcness test 2 Tabet ‘Substitute fst for the tense shear test when there is mainly crs tension involved. “The two sections are offset 90° and perpendicular tothe sheet plane in the case of longtusinal projections in the two main axes. ‘Substitute tas! forthe peel tes there is mainly tensile shear stress involve. (Only ttightness is required (cushion test specimen), 1 trangverse section and 1 longitudinal secon.AD 2000-Merkblatt AD 2000-Meskat HP 2/1, 07.2012 eon Page ttAD 2000-Merkblatt Page 12 AD 2000Merkbiat HP2/, 072012 elton Publisher: Vetere cer TOVev. E-Mail: beriin@vatuev.de btipyeww.vdtuev.de Source of supply: Beuth Beuth Verlag GmbH 10772 Berlin Tel. 030/26 01-22 60 Fax 030 /26 01-12 60 info@beuth.« www. beuth.de