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TVIS-Prfgrundlagen

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AD 2000-Merkblatt A 4
Version
11.2015
Publisher: Verband der TV e.V. (VdTV)
For technical experts of TV only Reprint not permitted

TVIS

AD 2000-Merkblatt

Accessory housings

A4
edition 11.2015 *)

These TVIS-Prfgrundlagen provide a tool for experts. The documents contain the relevant regulations.
Interpretations and explanations developed by technical committees are included. Please consider that the
individual documents differ with regard to their mandatory application. VdTV has taken all reasonable measures to
ensure the accuracy of this translation but regrets that no responsibility can be accepted for any error, omission or
inaccuracy. In cases of doubt or dispute, the latest edition of the German text only is valid.
The AD 2000-Merkbltter are prepared by the seven associations listed below who together form the Arbeitsgemeinschaft Druckbehlter (AD). The structure and the application of the AD 2000 Code and the procedural guidelines are covered by AD 2000-Merkblatt G 1.
The AD 2000-Merkbltter contain safety requirements to be met under normal operating conditions. If above-normal loadings are to be
expected during the operation of the pressure vessel, this shall be taken into account by meeting special requirements.
If there are any divergences from the requirements of this AD 2000-Merkblatt, it shall be possible to prove that the standard of safety of
this Code has been maintained by other means, e.g. by materials testing, tests, stress analysis, operating experience.
FDBR e. V. Fachverband Anlagenbau, Dsseldorf
Deutsche Gesetzliche Unfallversicherung (DGUV), Berlin
Verband der Chemischen Industrie e. V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main

AD 2000-Merkblatt

Stahlinstitut VDEh, Dsseldorf


VGB PowerTech e. V., Essen
Verband der TV e. V. (VdTV), Berlin
The above associations continuously update the AD 2000-Merkbltter in line with technical progress. Please address any proposals for
this to the publisher:

Verband der TV e. V., Friedrichstrae 136, 10117 Berlin.

Contents
Page

0
Foreword.................................................................................................... 2
1
Scope......................................................................................................... 2
2
Definitions .................................................................................................. 2
3
Classification .............................................................................................. 2
4
Materials and design .................................................................................. 2
5
General principles for design, manufacture and associated tests .............. 3
6
Testing of housings .................................................................................... 3
7
Marking ...................................................................................................... 6
8
Certificates for the finished accessories..................................................... 7
Annex 1 to AD 2000-Merkblatt A 4 .................................................................... 8

*) supersedes August 2013 edition; | amendments to previous edition


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Foreword

The AD 2000 Code can be applied to satisfy the basic safety requirements of the Pressure Equipment Directive,
principally for the conformity assessment in accordance with modules G and B F.
The AD 2000 Code is structured along the lines of a self-contained concept. If other technical rules are used in accordance with the state of the art to solve related problems, it is assumed that the overall concept has been taken into account.
The AD 2000 Code can be used as appropriate for other modules of the Pressure Equipment Directive or for different
sectors of the law. Responsibility for testing is as specified in the provisions of the relevant sector of the law.

Scope

This AD 2000-Merkblatt applies to pressure-bearing accessory housings and safety accessory housings for pressure
vessels and piping with a maximum allowable pressure (PS) exceeding 0,5 bar.
Clauses 4 to 8 of this AD 2000-Merkblatt, excluding 6.4.1, do not apply to accessory housings in refrigeration and heatpumping plant, see AD 2000-Merkblatt HP 801 No. 14 Druckbehlter in Klteanlagen und Wrmepumpenanlagen
(Pressure equipment in refrigerating and heat-pumping plant).

Definitions

2.1
Accessory housings are pressure-bearing housings and have independent chambers. Pressure-bearing housings
include the load-absorbing connecting elements that hold the pressure-bearing parts of the housing together.
Valves include slide gate valves, cocks, gate valves, etc.

2.3
The nominal size (DN) of an accessory housing is a numerical size designation. It is a round number used as the
nominal size and approximately relates to the manufactured dimensions.
2.4
The volume V of a valve is the geometrical size of the chamber with an open flow diameter starting at the nearest
detachable connection, or at connections used instead of detachable connections less the volume of the permanent
internal parts.
2.5
Fluids are gases, liquids or vapours as a pure phase and their mixtures. Fluids may contain a suspension of solid
materials.
2.6
Permanent internal parts are all the parts including pipe assemblies and other hollow bodies installed inside the
chamber for the specified mode of operation by means of a friction or interference fit or which cannot be detached.
2.7
A quality system is the structural and procedural organization introduced mandatorily and documented by the
manufacturer for providing quality assurance and the means necessary for this in accordance with the requirements of the
Pressure Equipment Directive (quality assurance system modules).

Classification

Accessory housings are classified into the conformity assessment tables on the basis of their maximum allowable
pressure (PS ), their nominal size (DN) or volume (V ) as appropriate and the group of fluids for which they are intended. In
some cases, both the volume (V ) and the nominal size (DN) are regarded as suitable. In these cases, the accessory shall
be classified into a higher category. For valves, the nominal size (DN) is normally better suited.
The tables in the Pressure Equipment Directive are applicable. Safety accessories are classified into category IV. Safety
accessories that are manufactured for specific pressure equipment may be classified in the same category as the
pressure equipment to be protected.

Materials and design

The materials and design shall be selected in accordance with the intended application, taking into account factors such
as pressure and temperature stressing and charging material (fluids); dynamic stresses, e.g. pressure surges or pulsating
loads shall be noted in particular.

4.1

General principles for manufacturers and materials

The material manufacturer and the materials for pressure-bearing accessory housings shall meet the requirements of the
W series of the AD 2000-Merkbltter. For accessory housings of category I the requirements may be applied as
appropriate.

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2.2

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4.2

Suitable materials

The following materials may be used for accessory housings within the specified application limits given for each:
(1)

non-alloy and alloy steel grades as specified in AD 2000-Merkbltter W 1, W 4, W 7, W 8, W 9, W 12 and W 13,

(2)

austenitic and austenitic-ferritic steel grades as specified in AD 2000-Merkblatt W 2,

(3)

cast steel as specified in AD 2000-Merkblatt W 5,

(4)

spheroidal-graphite cast iron as specified in AD 2000-Merkblatt W 3/2,

(5)

aluminium and aluminium alloys, wrought materials as specified in AD 2000-Merkblatt W 6/1,

(6)

copper and copper alloys, wrought materials as specified in AD 2000-Merkblatt W 6/2, and

(7)

non-metallic materials as specified in the N series of the AD 2000-Merkbltter.

AD 2000-Merkblatt W 10 shall also be observed for working temperatures below 10 C.


Other materials may be used as long as it has been established that they are suitable for the intended purpose. This can
be established on the basis of appraisals, if appropriate taking into account operating proofs; for accessory housings of
categories I II:
by the manufacturer,
categories III IV: by the relevant third party.

4.3

Material testing and proof

AD 2000-Merkblatt

4.3.1
The scope of the tests for materials for accessory housings of categories II to IV are specified in the requirements
of the W series of the AD 2000-Merkbltter.
Proof of the testing is carried out for materials for accessory housings:
of categories III and IV in accordance with the requirements of the W series of the AD 2000-Merkbltter,
of category II by means of an inspection certificate 3.1 according to DIN EN 10204,
of category I with a test report 2.2 as specified in DIN EN 10204.
4.3.2
As a deviation from Clause 6 of AD 2000-Merkblatt W 3/2, spheroidal-graphite cast iron with a nominal tensile
strength 400 N/mm2 for accessory housings of categories III and IV with DN 150 may be supplied with an inspection
certificate 3.1 if the manufacturers works has provided the relevant third party with proof of equivalent and fault-free
production.

General principles for design, manufacture and associated tests

The manufacturer and manufacture of accessory housings shall meet the requirements of the HP series of the AD 2000Merkbltter. The requirements may be applied as appropriate for category I.
5.1
The design information in AD 2000-Merkblatt HP 1 is used as appropriate for accessory housings. Accessory
housings are designed in accordance with DIN EN 12516-2 retaining the safety factors according to AD 2000-Merkblatt B 0.
5.2
Where the mechanical production of accessory housings remains uniform through circumferential welds, testing of
welded coupon plates as specified in AD 2000-Merkblatt HP 5/2 may be dispensed with under the following conditions:
(1)

The accessory housing is made of a material from test group 1 or 6 as described in AD 2000-Merkblatt HP 0 and

(2)

the welding processes


tungsten inert-gas welding,
manual metal arc welding,
submerged arc welding,
gas shielded metal arc welding with tubular cored electrodes
are applied individually or in combination.
The relevant third party shall carry out random tests to convince itself that the conditions are adhered to and of the results
of the non-destructive test.

6
6.1

Testing of housings
The following tests are required for accessory housings:

(1)

stress evaluation and structural safety test;

(2)

visual examination of the completed housing for flaws;

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(3)

checking of the completed housing for dimensional accuracy in accordance with the documents in (1);

(4)

strength test P 10 as described in DIN EN 12266-11). The test pressure for valve bodies with pressure/temperature
correlation is 1,5 times the maximum permissible pressure at 20 C. For valve bodies exclusively designed for PS and
TS the test pressure is to be determined according to AD 2000-Merkblatt HP 30. If accessory housings consist of
different materials and/or if the components of the housing are assigned different design temperatures, the procedure
detailed in AD 2000-Merkblatt HP 30, 4.17 can be adopted for determining the yield strength conditions. When testing
housings with liners, AD 2000-Merkblatt HP 30, 4.18 shall also be observed. When testing gaseous media, AD 2000Merkblatt HP 30, 4.19 shall be observed.

(5)

non-destructive tests of the product types for accessory housings and of the welds in pressure-bearing walls and

(6)

check to ensure correct materials have been used in the case of all housing parts made of alloy materials.
In the stress evaluation and the structural safety test as specified in 6.1 (1), the following aspects are verified:

(1)

adequate dimensioning in accordance with 5.1 taking note of the characteristic strength values as specified in the
W series of the AD 2000-Merkbltter or the proof of suitability of the materials used;

(2)

perfect design from a safety viewpoint;

(3)

use of suitable materials and

(4)

correct processing of the materials.

If it is not possible to determine the stress as specified in 6.1 (1) by calculation particularly if other materials are used
the deformation shall be measured or a burst test shall be carried out as a random test. In this test, proof shall be provided
that the safety factor to be used in the calculation in accordance with AD 2000-Merkblatt B 0 has been adhered to
specifically against deformation when calculating using the yield strength or proof stress (Rp0,2, Rp1,0) and against rupture
when calculating using the tensile strength. The experimental design 2 ) without calculation is to be carried out in
accordance with AD 2000-Merkblatt S 5 or equivalent Code in agreement with the relevant third party.
6.3
The following requirements shall be noted when carrying out the non-destructive tests on the product types for
accessory housings and on the welds of pressure-bearing walls as specified in 6.1 (5).
6.3.1
(1)

Product types
Steel grades as specified in 4.2 (1) and (2).
The product types shall be tested as follows:
Ultrasonic test:
a) plates as specified in AD 2000-Merkblatt W 1, ultrasonically tested,
b) pipes as specified in AD 2000-Merkblatt W 2 or W 4,
c) flanges as specified in AD 2000-Merkblatt W 9,
d) seamless hollow bodies as specified in AD 2000-Merkblatt W 12,
e) forgings as specified in AD 2000-Merkblatt W 13,
f)
rolled bars and sections with diameter or edge length s 30 mm,
grid scanning coverage according to DIN EN 10308:
Dimension
Ferritic, martensitic steel
Austenitic, austenitic-ferritic steel
s 50 mm
s 50 mm to 100 mm
s 100 mm

Quality class 4
Quality class 3
Quality class 2

Quality class 3
Quality class 2
Quality class 1

Where sizing of discontinuities is required it is performed applying the 6 dB drop technique.

1)

The tightness of the accessory parts with regard to functioning is not the subject of this AD 2000-Merkblatt. The requirements shall
be agreed at the time of ordering, see e.g. DIN EN 12266-1, Test P 11, P 12, or DIN EN 12266-2, P 20.

2)

See 2.2.2 and 2.2.4 of Annex I of the Pressure Equipment Directive.

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6.2

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Surface testing:
a) hot-formed small areas,
b) drop forgings, except those with a gross weight 30 kg, made of non-alloy steels, 16Mo3, 13CrMo4-5,
X6CrNiTi18-10, X6CrNiMoTi17-12-2 and X6CrNiNb18-10. The surface test can also be dispensed with for
material 10CrMo9-10 if agreed with the relevant third party. This subclause is not applicable to drop-forged
flanges as specified in AD 2000-Merkblatt W 9.
Permissible flaws: linear indications 3 mm.
(2)

Cast steel grades as specified in 4.2 (3).


Accessory housings are tested as described in Table 1, quality level 2. For accessory housings with
DN 150 and
DN 150, if the product of the nominal size DN and the maximum allowable pressure in bar does not exceed
20000
quality level 4 of Table 1 is adequate.
Weld ends for accessory housings of categories I to IV are tested in accordance with Table 1, quality level 1. A zone
of 40 mm is considered to be the weld end of housings without shoed butt weld end.

AD 2000-Merkblatt

Table 1 Assignment of quality levels and scope of the test


Quality levels assigned to the test methods

Quality
level

Scope of the test

11)

PT2)

MT3)

RT4)

UT5)

100 %

SP1, CP1

SM1

100 %

SP2, CP2, LP2, AP2

SM2, LM2, AM2

1. Prototype:
100 %
2. Series: random testing of the critical
zones or generally difficult points
regarding the casting process recognised
on the prototype. Surface testing is
carried out on all parts.

SP4, CP4, LP4, AP4

SM3, LM3, AM3

1)

Linear indications or indications in series are not permissible for surface testing.

2)

Liquid penetrant testing PT as specified in DIN EN 1371-1 or DIN EN 1371-2.

3)

Magnetic particle testing MT as specified in DIN EN 1369.

4)

Radiographic examination RT as specified in DIN EN 12681/acceptance criteria as specified in Annex 1 to AD 2000-Merkblatt A 4.

5)

Ultrasonic examination UT as specified in DIN EN 12680-2.

(3)

Spheroidal-graphite cast iron as specified in 4.2 (4).


The test is carried out following agreement with the customer.

(4)

Materials as specified in 4.2 (5) to (7) shall be tested in accordance with the relevant AD 2000-Merkbltter.

(5)

Other materials as specified in 4.2.


For accessory housings of
categories I II: test/type of test in accordance with establishment of suitability by the manufacturer,
categories III IV: test in accordance with establishment of suitability by the relevant third party.

6.3.2

Welds of the pressure-bearing walls

(1)

The welds of category I to III accessory housings shall be tested as described in AD 2000-Merkblatt HP 5/3. With
regard to the scope of the test, the requirements of AD 2000-Merkblatt HP 5/3 are applicable, but it shall be at least
10 %. This minimum 10 % scope of testing does not apply, however, if it is dealing with non-alloy materials, or
test group 6 materials in accordance with AD 2000-Merkblatt HP 0 and the nominal size of the accessory housing
does not exceed DN 100.

(2)

All the welds of category IV accessory housings shall be subjected to 100 % non-destructive testing over their whole
length. If these are nozzle welds as shown in Figure 1, a volume test is required. As a deviation from this, a surface
d
test is adequate for nozzles with dAi 50 mm and Ai 0,1.
di
The test procedure, test class and assessment are specified in AD 2000-Merkblatt HP 5/3.

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Figure 1 Nozzle welds, example


6.4

Carrying out the tests

6.4.1

The tests shall be carried out on accessory housings:

(1)

of categories I to III: in accordance with the requirements of the conformity assessment procedures in Annex III of the
Pressure Equipment Directive. The unit verification (module G) may also be carried out by the relevant third party,

(2)

of category IV: by the relevant third party.

Proof shall be provided by an inspection certificate 3.1 as specified in DIN EN 10204. For product types for category IV
accessory housings, the test results are assessed finally by the relevant third party.
6.4.3
Verification that the correct materials have been used, as specified in 6.1 (6), is carried out by the accessory
housing manufacturer.
6.5

Validation of the tests

6.5.1
The tests on categories I to III accessory housings shall be validated by an inspection certificate 3.1 as specified
in DIN EN 10204.
It is adequate for a list of the relevant material validations to be attached to the inspection certificate 3.1.
6.5.2
As a deviation from 6.5.1, it is adequate for the manufacturer of category I accessory housings of nominal sizes
50 to add the mark of the manufacturing works.
6.5.3
For category IV accessory housings, the tests shall be validated by an inspection certificate 3.2 as specified in
DIN EN 10204. The inspection certificate 3.2 shall contain the material validations of the basic materials in accordance
with the W series of the AD 2000-Merkbltter (see 4.3). For safety valves with type test as specified in AD 2000-Merkblatt A 2, the tests are validated by an inspection certificate 3.1 unless otherwise specified in the type test.
6.5.4
See 6.4.2 for the non-destructive testing of product types for accessory housings and of the welds of pressurebearing walls and their validation.

7
7.1

Marking
Accessory housings shall be permanently marked with:

(1)

the mark of the casting manufacturer and of the manufacturer (company processing, assembling and testing the
accessories),

(2)

the material designation,

(3)

(4)

the nominal size (DN),

(5)

the type number of the EC type-examination,

(6)

the year of manufacture.

the rated pressure (PN) or


the maximum allowable pressure (PS) and the maximum/minimum allowable temperature (TS),

7.2
The completed accessory shall also be marked with the CE marking and the identification number of the relevant
third party if specified in the Pressure Equipment Directive.

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6.4.2
The non-destructive tests specified in 6.1 (5) are generally carried out and assessed by the
manufacturer of the product type on the product types and/or
manufacturer of the housing on welds of pressure-bearing walls.

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Certificates for the finished accessories

8.1
The required conformity certificates and declarations of conformity are issued in accordance with the provisions of
the selected modules.
(1)

The certificate of conformity of the relevant third party represents the result of the tests carried out on the item of
pressure equipment and its compliance with the relevant requirements of the Pressure Equipment Directive.

(2)

The declaration of conformity of the manufacturer shall be in accordance with the Pressure Equipment Directive.

AD 2000-Merkblatt

8.2
The operating instructions shall be prepared in accordance with Annex I of the Pressure Equipment Directive, if
required.

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Annex 1 to AD 2000-Merkblatt A 4
Table A.1 Maximum permissible errors of indication for the radiographic examination RT
Maximum permissible errors for quality
levels

Code letter
according to
ASTM1)

for
wall thicknesses in
mm

Assessment
according to
ASTM1)

22)

42)

Gas bubbles

up to 51
over 51 up to 114
over 114 up to 305

E446
E186
E280

A1
A1
A1

A3
A3
A3

A4
A4
A4

Non-metallic
inclusions

up to 51
over 51 up to 114
over 114 up to 305

E446
E186
E280

B1
B1
B1

B3
B3
B3

B4
B4
B4

Blowholes

Type

up to 51

Cracks
Core supports
and chill castings

over 51 up to 114
over 114 up to 305

E446
E186
E280

D+E

Ca1, Cb1,
Ca2, Cb2,
Ca4, Cb4,
Cc1, Cd1,
Cc2, Cd2,
Cc4, Cd4,
Ca1, Cb1, Cc1 Ca3, Cb2, Cc2 Ca4, Cb4, Cc4
Ca1, Cb1, Cc1 Ca2, Cb2, Cc2 Ca4, Cb4, Cc4
not permitted

up to 51
over 51 up to 114
over 114 up to 305

E446
E186
E280

not permitted3) not permitted3)

not permitted
not permitted
not permitted

not permitted
not permitted
not permitted

F14)
F14)
F14)

1)

Title: ASTM-E446 Reference radiographs for steel castings up to 2 in. (51 mm) in thickness,
ASTM-E186 Reference radiographs for heavy walled (2 to 4 1/2 in. (51 to 114 mm)) steel castings and
ASTM-E280 Reference radiographs for heavy walled (4 1/2 to 12 in. (114 to 305 mm)) steel castings.

2)

If it is demonstrated, e.g. by ultrasonic examination, that errors are present in the core zone (see Figure A.1), the specifications of the numerically
higher quality class apply (e.g. 3 instead of 2), unless otherwise specified in the order.

3)

As long as it is not demonstrated by fracture mechanical test that cracks are uncritical.

4)

Core supports may be present but have to be welded flawless to the surface.

Figure A.1 Division of wall into zones


(The division refers to the thickness d of the finished casting.)

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