-
Safety Standardsof theNuclear Safety Standards Commission
(KTA)
KTA 3211.1 (6/00) (incl. rectification from BAnz 132,
19.07.01)
Pressure- and activity-retaining components of systemsoutside
the primary circuitPart 1: Materials
(Druck- und aktivittsfhrende Komponenten von Systemenauerhalb
des Primrkreises; Teil 1: Werkstoffe)
A previous version of this Safety Standardwas 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 GermanyTelephone
+49-5341/885-(0) 901 Telefax +49-5341/885-905
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KTA SAFETY STANDARDJune 2000 Pressure- and activity-retaining
components of systems outsidethe primary circuit; Part 1: Materials
KTA 3211.1
CONTENTS
Fundamentals..............................................................................................................................................................
5
1 Scope
..............................................................................................................................................................
52
Definitions........................................................................................................................................................
5
3 General
principles............................................................................................................................................
63.1 Selection of materials
......................................................................................................................................
63.2 Appraisal of the materials
................................................................................................................................
63.3 General quality-assurance requirements
.........................................................................................................
63.4 Requirements to be met by the manufacturer
..................................................................................................
63.5 Design
approval...............................................................................................................................................
73.6 In-process inspection by the authorized inspector to 20 of the
Atomic Energy Act ....................................... 73.7
Verification of quality characteristics
................................................................................................................
73.8
Marking............................................................................................................................................................
73.9 Repairs
............................................................................................................................................................
73.10 Material characteristic data for design
analysis................................................................................................
74 Generally applicable stipulations for materials and material
tests
....................................................................
74.1
General............................................................................................................................................................
74.2 Allowable
materials..........................................................................................................................................
74.3 Requirements for the materials and their product forms
..................................................................................
74.4 Testing and examination of materials and product
forms.................................................................................
84.5
Re-examinations............................................................................................................................................
11
5 Product forms of ferritic steels of material group W
I......................................................................................
125.1 Sheets and plates
..........................................................................................................................................
125.2 Dished or pressed product forms made from plate
........................................................................................
135.3 Forgings, bar steel and rolled
rings................................................................................................................
155.4 Seamless pipes larger than DN 50
................................................................................................................
195.5 Seamless pipe elbows larger than DN 50
......................................................................................................
205.6 Seamless fittings larger than DN
50...............................................................................................................
225.7 Castings
........................................................................................................................................................
236 Product forms of ferritic steels of material group W
II.....................................................................................
246.1 Sheets and plates
..........................................................................................................................................
246.2 Dished or pressed product forms made from plate
........................................................................................
256.3 Forgings, bar steel and rolled
rings................................................................................................................
266.4 Seamless pipes larger than DN 50
................................................................................................................
286.5 Seamless pipe elbows larger than DN 50
......................................................................................................
296.6 Seamless fittings larger than DN
50...............................................................................................................
306.7 Castings
........................................................................................................................................................
317 Product forms of austenitic steels
..................................................................................................................
337.1 Sheets and plates
..........................................................................................................................................
337.2 Dished or pressed product forms made from
plates.......................................................................................
347.3 Forgings, bar steel, rings and extrusions
.......................................................................................................
357.4 Seamless pipes larger than DN 50
................................................................................................................
367.5 Seamless pipe elbows larger than DN 50
......................................................................................................
387.6 Seamless fittings larger than DN
50...............................................................................................................
397.7 Castings
........................................................................................................................................................
41
(Continued next page)PLEASE NOTE: Only the original German
version of this safety standard represents the joint resolution of
the50-member Nuclear Safety Standards Commission (Kerntechnischer
Ausschuss, KTA). The German version wasmade public in
Bundesanzeiger No. 194a on October 14, 2000. Copies may be ordered
through the Carl HeymannsVerlag 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
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CONTENTS(Continued)
8 Bolts and
nuts................................................................................................................................................
428.1 Scope
............................................................................................................................................................
428.2
Materials........................................................................................................................................................
428.3 Additional requirements for the materials
......................................................................................................
428.4 Bolts and nuts made by machining from ferritic bars
.....................................................................................
438.5 Bolts and nuts made by machining from solution-annealed and
quenched austenitic bars............................ 438.6 Bolts
and nuts made from ferritic bars by hot or cold forming and
subsequently heat-treated ....................... 448.7 Bolts and
nuts of strength classes
.................................................................................................................
458.8 Marking
.........................................................................................................................................................
458.9 Verification of quality
characteristics..............................................................................................................
459 Product forms of steels for special loads
.......................................................................................................
519.1 Forgings, bar steel and rolled
rings................................................................................................................
519.2 Castings
........................................................................................................................................................
51
10 Heat-exchanger tubes
...................................................................................................................................
5310.1 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
................................................................
5310.2 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
................................................................
5410.3 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...................................................................
5510.4 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.......................................................................
5510.5 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
...............................................................
56
Annex A: Material characteristic
data.....................................................................................................................
58
Annex AP: Reference data on physical characteristics
............................................................................................
85Annex B: Non-destructive examinations of steel
castings......................................................................................
87Annex C: Production welds of steel
castings..........................................................................................................
92Annex D: Procedure for determining the delta ferrite
content.................................................................................
96Annex E: Non-destructive examinations of heat-exchanger tubes
.........................................................................
98Annex F: Performance of manual ultrasonic examinations
..................................................................................
100
Annex G: Performance of surface crack detection by magnetic
particle and liquid penetrant methods ................ 110Annex H:
Additional stipulations for non-destructive examination of
forgings, bar steel, rings and extrusions..... 112Annex I:
Regulations and literature referred to in this Safety
Standard...............................................................
119Annex K: Changes with respect to the edition 6/91 (informative)
.........................................................................
123
Comments by the editor:
Taking into account the meaning and usage of auxiliary verbs in
the German language, in this translation thefollowing agreements
are effective:
shall indicates a mandatory requirement,shall basically 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 thanthose in the case of shall normally - are
specified in the text of the safety standard,
shall normally indicates a requirement to which exceptions are
allowed. However, the exceptions used,shall be substantiated during
the licensing procedure,
should indicates a recommendation or an example of good
practice,may indicates an acceptable or permissible method within
the scope of this safety standard.
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KTA 3211.1
Page 5
Fundamentals
(1) The safety standards of the Nuclear Safety
StandardsCommission (KTA) have the task of specifying those
safetyrelated requirements which shall be met with regard
toprecautions to be taken in accordance with the state ofscience
and technology against the damage arising from theconstruction and
operation of the facility (Sec. 7 para 2subpara 3 Atomic Energy
Act) in order to attain the protectiongoals specified in the Atomic
Energy Act and the RadiologicalProtection Ordinance (StrlSchV) and
which are further detailedin the Safety Criteria for Nuclear Power
Plants and in theGuidelines for the Assessment of the Design of PWR
NuclearPower Plants against Incidents pursuant to Sec. 28 para 3
ofthe Radiological Protection Ordinance (StrlSchV) -
IncidentGuidelines.(2) In the Safety Criteria, Criterion 1.1
("Principles of safetyprecautions") requires, among other things,
extensive qualityassurance in manufacturing, erection and
operation, whileCriterion 2.1 ("Quality guarantee") requires, among
othermatters, the application, establishment and observance
ofdesign, material, construction, inspection and
operatingspecifications as well as documentation of quality
monitoring.Criteria 4.2 ("Residual heat removal in
as-specifiedoperation"), 4.3 ("Residual heat removal after
loss-of-coolantaccidents"), 5.3 ("Equipment for nuclear-reactor
control andshutdown") and 8.5 ("Heat removal from the
containmentsystem") set forth further design and fabrication
requirementsfor safety systems. KTA safety standards series 3211
defineprovisions to be made to meet these requirements within
theirscope of application. For this purpose it also draws
uponnumerous individually cited rules from conventionalengineering,
especially DIN Standards.(3) The scope of application defined here
covers thepressure- and activity-containing systems and
componentslocated outside the pressure boundary (KTA safety
standardsseries 3201) but having relevance specifically to
reactorengineered safety per the Reactor Safety Commission
(RSK)Guideline (Section 4.2).(4) KTA 3211.1 specifically defines
the requirements to beimposed on:a) organizations involved in
manufacturing,b) manufacture of materials and product forms as well
as
their chemical composition, mechanical and
technologicalcharacteristics, physical characteristics, heat
treatmentand further processing,
c) verification and inspection methods for achieving
andmaintaining the required quality of materials and productforms,
such as destructive and non-destructive exami-nations,
d) provision of documents for documentation of the test
andinspection results.
1 Scope(1) This safety standard shall apply to the materials
andproduct forms of the pressure-retaining walls of pressure-
andactivity-containing light-water-reactor systems and compo-nents
that do not belong to the reactor-coolant pressureboundary but have
relevance specifically to reactorengineered safety. This definition
shall include systems andcomponents meeting one of the following
criteria:a) The plant section is necessary for accident control
by
means of shutdown, maintenance of long-term subcriti-cality and
direct residual heat removal. Requirements forcomponents in systems
involved only indirectly in residualheat removal - in other words
the closed cooling-watersystems and secondary cooling-water systems
which donot carry activity - shall be established on a
plant-specific
basis with consideration of the multiple design
(e.g.,redundancy-type, diversity-type).
b) Considerable energy is released in the event of failure ofthe
plant section, and the consequences of failure are notlimited by
structural provisions, spatial separation or othersafety provisions
to an extent that is acceptable for nuclearsafety.
c) Failure of the plant section can lead directly or via a
chainof conceivable subsequent events to an accident asdefined by
28 Par. 3 of the Radiation ProtectionRegulation.
(2) The following components fall within the scope ofapplication
of this safety standard:a) pressure vessels,b) piping systems and
piping-system parts,c) pumps andd) valves and fittingsincluding the
integral zones of the component supportstructures.
(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
pressure-
containing 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
suctionzone,
e) parts for force and power transmission to pumps and tovalves
and fittings as well as inspections for verification offunctional
capability,
f) weld filler metals and welding consumables,g) small
parts.
Note:Small parts are subject to the stipulations of Section 10
and ofTable 2-3 of KTA 3211.3.
2 Definitions
(1) Loading temperature, lowestThe lower of the pressure-test
temperature or lowest operatingtemperature is designated the lowest
loading temperature.(2) Test groups A1, A2 and A3The components in
the scope of application of this safetystandard shall be classified
in test groups A1, A2 or A3depending on design data and dimensions,
with considerationof the planned materials and stresses. KTA 3211.2
defines thecriteria for classification of a component. The plant
suppliershall decide upon the classification by consultation with
theauthorized inspector.(3) RepairsRepairs are deviations from the
planned production flowduring manufacture of product forms.
Production welds tocastings shall not be considered as repairs in
the context ofthis safety standard.(4) Authorized inspectorAn
authorized inspector for the tests and examinations for thepurpose
of this safety standard is a cognizant person ororganization who or
which shall be consulted on the basis oflegal requirements,
guidelines, directives or orders or who orwhich has been called in
on behalf of licensing or supervisoryauthorities.
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KTA 3211.1
Page 6
(5) Material groups W I and W IIThe ferritic materials for
manufacturing components within thescope of application of this
safety standard shall be classifiedin material groups W I or W II
according to their qualityfeatures, especially chemical composition
and toughnesscharacteristics. The allocation of materials to test
groups isdefined in KTA 3211.2.
3 General principles3.1 Selection of materials(1) Materials
appropriate for the intended use shall beselected, with
consideration of the mechanical, thermal andchemical loadings as
well as the design conditions to KTA3211.2.
(2) The materials shall safely withstand the loadings duringthe
pressure test, during operation and all specified plantconditions.
Any materials on which welding is to be performedshall be suitable
for welding.
Note:The selection of material shall be made by the purchaser,
ifnecessary after consultation with the material manufacturer.
3.2 Appraisal of the materials(1) The materials shall be
appraised to determine whetherthey are suitable for the intended
use and the plannedprocessing conditions.(2) Ferritic steels for
service in material group W I shall beappraised in consultation
with the authorized inspector.(3) As regards nature and scope of
appraisal tests, all othersteels shall be treated as steels for
conventional pressurevessels subject to supervision. If these
steels for use inconventional pressure vessels subject to
supervision havealready been approved, they shall qualify as
appraised.(4) If in individual cases a material is used outside the
scopeof validity of its approval, or if a different material is
used, aspecial appraisal shall be required. The special appraisal
shallbe mentioned in the acceptance test certificate.
3.3 General quality-assurance requirementsThe stipulations in
KTA 1401 shall apply to the general quality-assurance
requirements.
3.4 Requirements to be met by the manufacturer(1) The
manufacturer shall possess facilities that permitproper and
state-of-the-art production of materials and productforms.
(2) The manufacturer shall possess test and inspectionfacilities
that permit testing and inspection of the materials andproduct
forms in accordance with the applicable DINstandards or other rules
pertinent to the conduct of materialstesting and inspection. The
test equipment shall correspond toDIN 51 220 and be inspected in
accordance with DIN 51 220.Within the measuring range of the test
equipment, thepermitted measuring inaccuracy of the forces
measuringequipment shall not exceed 1 %. Upon request, the
testreports to DIN 51 220 shall be submitted to the
authorizedinspector. If test facilities of other agencies are
employed, theyshall be subject to the same stipulations.(3) The
manufacturer shall have access in its own works orat other agencies
to facilities with which the non-destructiveexaminations required
by this safety standard can beperformed.
(4) Mechanized or automated facilities to be employed forthe
non-destructive examinations required by this safety stan-dard
shall undergo an appraisal by the authorized inspector.(5) Lists of
necessary procedure instructions for the produc-tion and testing
facilities shall be compiled.(6) Through quality monitoring with
corresponding recor-dings, the manufacturer shall ensure proper
manufacture andprocessing of the materials and product forms as
well asadherence to the governing technical rules.(7) The
manufacturer shall employ skilled personnel capableof performing
the tests and examinations properly.(8) The test supervisory
personnel for the non-destructiveexaminations shall be part of the
staff of the manufacturersworks. It shall be organisationally
independent from thefabrication department and shall be named to
the authorizedinspector.(9) The test supervisory personnel shall be
responsible thatthe test procedures are applied in accordance with
therequirements under the product-form related Sections and thatthe
individual steps of performing the tests are applied inaccordance
with the corresponding regulations. The operatorsshall be employed
by the test supervisory personnel. This alsoapplies to the
employment of works-external personnel. Thetest supervisory
personnel shall analyse the test results andsign the test
report.(10) The NDT operators carrying out the
non-destructiveexaminations shall be part of the staff of the
manufacurer'sworks. They shall have sufficient basic technical
knowledgeand shall be capable of performing the examinations
inaccordance with the requirements. These abilities shall
bedemonstrated to the test supervisory personnel. The NDToperators
shall have sufficient visual capacity which is to bechecked by an
ophtalmologist, optician or another medicalperson in conjunction
with DIN EN 473. A capacity of 1.0 (toDIN 58 220-3 and DIN 58
220-5) is required for the evaluationof radiographs and the
evaluation of tests by means ofmagnetic particle and liquid
penetrant methods at a distanceof 0.33 m with or without visual
aids. The operators visualcapacity shall be checked yearly. NDT
operators from outsidethe manufacturer's works may perform
examination tasks onlywhen the radiographic method is being
employed, but whenthe ultrasonic examination method is being
employed theymay perform such tasks only in addition to inspectors
of themanufacturer's works.
(11) The manufacturer shall be entitled to issue acceptancetest
certificates only if he employs a works' inspector qualifiedin
accordance with the conditions of DIN EN 10 204. Thename and stamp
of the works' inspector shall be announced tothe authorized
inspector.(12) If welding work is performed on the product forms in
thecourse of manufacture, the manufacturer shall employ his
ownsupervisory staff and welders qualified to DIN EN 287-1
inconjunction with AD Merkblatt HP 3. Only qualified weldersshall
be used for the welding jobs. The welding supervisorshall be a
member of the staff of the manufacturer's works andbe named to the
authorized inspector.(13) A procedure by which all deviations from
the qualityrequirements observed during production are reported to
theresponsible agency shall be set forth in writing.(14) The
manufacturer shall have a quality department that isindependent of
the production department.(15) The organizational classification
and assignment ofduties of the works' inspector, test supervisory
personnel, NDToperators and quality department and, if applicable,
thewelding supervisory personnel, shall be set forth in
writing.
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KTA 3211.1
Page 7
(16) The authorized inspector shall review whether
therequirements have been met before production can be started.The
review shall be repeated at intervals of about one to twoyears,
unless the authorized inspector can be convinced byother means that
the conditions are still being met.
3.5 Design approvalUnless otherwise stipulated in the following
sections, materialtesting and sampling plans shall be required only
for productforms for production of components from ferritic steels
ofmaterial group WI. In fact, such plans shall be required only
ifsampling is not clearly defined in the Sections relating
toproduct forms. They shall be submitted to the authorizedinspector
for design approval.
3.6 In-process inspection by the authorized inspector to 20 of
the Atomic Energy Act
The authorized inspector shall have the right to be
presentduring the manufacturing processes. However, he shall
notimpair the manufacturing operations.
3.7 Verification of quality characteristics(1) The quality
characteristics of the materials and productforms shall be
determined by tests and examinations, whichshall be performed in
the manufacturer's works.(2) The quality characteristics of the
materials and productforms shall be verified by material test
certificates to DIN EN10 204. The governing stipulations for the
required type ofquality verification shall be those in the
following Sectionsrelating to product forms. Confirmation that the
requirementsof this safety standard have been met shall be required
in thecertificates.
3.8 MarkingThe product forms shall be clearly and durably
marked, if at allpossible without notching, in accordance with the
stipulationsin the following Sections relating to product forms.
The use ofcode characters is permitted. The complete text of the
markingshall be indicated in the test certificates. A clear
correlationbetween the test certificates and product forms shall
bepossible at all times.
3.9 Repairs(1) Any necessary repairs shall be reported to the
authorizedinspector. Further action shall be determined in
consultationwith the authorized inspector.(2) Repairs by welding
shall be subject to the stipulations ofKTA 3211.3.
3.10 Material characteristic data for design analysisThe
characteristic data critical to strength design analysis shallbe
taken from Annex A, from the appropriate DIN standardsor, in the
case of special steels, from the authorizedinspector's
appraisal.
4 Generally applicable stipulations for materials andmaterial
tests
4.1 General(1) The requirements for material characteristics
shall applyto the final condition of the components after the
in-processinspection and pressure test. On the basis of the tests
andexaminations to be performed on materials and product forms,
the material characteristics shall be verified on
sufficientlylarge test coupons in the heat-treatment conditions
requiredfor the particular purpose.(2) The products shall have
smooth surfaces consistent withthe forming method employed.
Impermissible surface defectsshall be eliminated. The resulting
depressions shall be groundflush. The wall thickness shall not be
less than the allowableminimum nominal wall thickness.
4.2 Allowable materials
Materials shall be allowable if they fulfill the prerequisites
ofSection 3.1 and their suitability has been established
inaccordance with Section 3.2 of this safety standard.
4.3 Requirements for the materials and their product forms4.3.1
Ferritic steels of material group W IFerritic steels of material
group W I shall meet the followingconditions: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
theprimary membrane stress is higher than 50 N/mm2, thesmallest
individual value of energy absorbed of the basemetal, weld metal
and heat-affected zone shall not be lessthan 68 J, and the smallest
individual value of lateralexpansion shall not be less than 0.9
mm.
b) The smallest individual value of upper shelf
energy,determined on Charpy V-notch transverse specimens, shallnot
be less than 100 J. This only applies to the base metal.
c) The energy absorbed, determined on Charpy V-notchtransverse
specimens, shall not be less than 41 J at thetest temperature of 0
C. Only one individual value belowthe required mean value shall be
permitted, and it shall notbe smaller than 29 J. This requirement
applies to the basemetal, 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 IIFerritic steels of
material group W II shall meet the followingconditions: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 whendefining the
chemical composition, especially thepermissible contents of
microalloying elements.
b) In the notched-bar impact bend test on Charpy
V-notchtransverse specimens, the mean value shall not be lessthan
41 Jba) at the test temperature of 0 C if the lowest loading
temperature is lower than 20 C, orbb) 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 valueshall be permitted,
and it shall not be smaller than 29 J.The requirement applies for
the base metal, the weld metaland the heat-affected zone.For cast
steel the specimen direction is not specified.
4.3.3 Austenitic steels
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
Page 8
b) Steels for hot (operating temperature 200 C) reactorwater
containing product forms and components in boilingwater reactor
plants shall be resistant to IGSCC. Detailsare specified in the
product-form related Sections.
c) The chemical composition shall be defined such that hotcracks
do not develop during welding.
d) In the case of steels for product forms with a wall
thicknessgreater than 16 mm or DN greater than 150 mm,
theenergy-absorbed value of the base metal, weld metal
andheat-affected zone, determined on Charpy V-notchtransverse
specimens at the test temperature of 20 C,shall not be less than 70
J (mean value of threespecimens, smallest individual value not less
than 60 J) inthe solution-annealed and quenched condition, or 55
J(mean value of three specimens, smallest individual valuenot less
than 40 J) in the annealed condition.
e) For parts on which welding work without weld filler metalwill
be performed during further processing, the depositedbase metal
shall have a delta ferrite content of 2 % to 10 %(ferrite number 2
to 11) to Annex D. For sheets on whichwelding work with weld filler
metal will be performed duringfurther processing, the deposited
base metal shall have adelta ferrite content of 1 % to 10 %
(ferrite number 1 to 11)to Annex D. A close ferrite lattice
structure is not permittedin either case. Deviations are permitted
if the characte-ristics of the welded joint satisfy the
stipulations of KTA3211.3.
f) For rolled and forged product forms made of austeniticsteels
as well as parts made from such forms, the requiredultrasonic
examinability, the further processability and thespecified
mechanical and technological characteristicsshall not be impaired
by coarse-grained microstructuralzones.
Note:Based on available experience, every effort should be made
toachieve a grain size corresponding to a characterizing
numberlarger than or equal to 4 to Euronorm 103-71.
4.3.4 Steels for special loadsIf special loads such as erosion,
corrosion and wear arepresent, materials matched to the
requirements of theparticular application shall be employed. The
conditions forsuch materials shall be defined on a case-by-case
basis inconsultation with the authorized inspector.
4.4 Testing and examination of materials and productforms
4.4.1 Designation of specimen direction in product formsThe
following designations shall be used to describe thedirection of
specimens in product forms (see Figures 4-1and 4-2):a) Designation
based on direction relative to fibre:
Longitudinal specimens (L):Longitudinal axis of specimen in the
main formingdirection; for notched-bar impact specimens, the notch
axisshall be perpendicular to the plane of the transverse
andlongitudinal directions.Transverse specimens (Q):Longitudinal
axis of specimen transverse to the mainforming direction; for
notched-bar impact specimens, thenotch axis shall be perpendicular
to the plane of thetransverse and longitudinal
directions.Perpendicular specimens (S):Longitudinal axis of
specimen perpendicular to the plane ofthe transverse and
longitudinal directions; for notched-bar
impact specimens, the notch axis shall be in the mainforming
direction.
b) Designation based on direction relative to
productgeometry:Axial specimens (A):Longitudinal axis of specimen
parallel to the axis ofrotational symmetry; for notched-bar impact
specimens,the notch axis shall be perpendicular to the
cylindricalsurface.Tangential specimens (T):Longitudinal axis of
specimen in the circumferentialdirection; for notched-bar impact
specimens, the notch axisshall be perpendicular to the cylindrical
surface.Radial specimens (R):Longitudinal axis of specimen
perpendicular to thecylindrical surface; for notched-bar impact
specimens, thenotch axis shall be in the main forming
direction.
4.4.2 Location of specimens in product formsThe specimen
location shall be identified as follows: asregards depth below the
surface, by the location of thespecimen axis; as regards distance
from the edge, by thelocation of the cross section to be inspected.
Furtherparticulars are defined in the following Sections relating
toproduct forms.
4.4.3 Size of test coupons(1) The quantity of material to be
taken shall be largeenough to provide an adequate quantity of
material forsubstitute specimens in addition to the material for
verificationof mechanical and technological characteristics.(2) If
further specimen quantities are needed for additionaltests, the
number and dimensions of the additional testcoupons shall be
specified in the purchase order. In the caseof castings, additional
test plates from the heats used forthese coupons shall be kept
available if required.
HUR
1 1
2
23
3
Perpendicular specimen
Main forming direction
Longitudinal specimen2: 3:
1:
Transverse specimenHUR:
Figure 4-1: Designation of specimen directions for
flatproducts
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KTA 3211.1
Page 9
HUR a
xial
HUR tangential
1
22
3
31
Specimen direction relative toMain forming direction
(HUR)SpecimenNo. Productgeometry tangential axial
1 radial perpendicular perpendicular2 axial transverse
longitudinal3 tangential longitudinal transverse
Figure 4-2: Designation of specimen directions forrotationally
symmetric parts
4.4.4 Marking of test coupons and specimensFor the acceptance
tests, the test coupons shall be markedlegibly and clearly before
removal from the product form, andthe specimens shall be marked
likewise before specimenremoval from the test coupon. The specimen
marking shallpermit exact correlation with its location in the
product form.
4.4.5 Heat-treatment conditions of specimens(1) All test coupons
shall be heat-treated on and togetherwith the product form
(normalizing, quenching and tempering,solution annealing and
quenching).(2) If the product forms are not delivered in the
heat-treatment condition governing establishment of
thecharacteristics, but receive this heat treatment only in
thecourse of further processing, the material manufacturer
shallperform tests on specimens from test coupons subjected
tocorresponding heat treatment.
Note:Unless otherwise stipulated in the appraisal,
stress-reliefannealing shall not constitute the heat treatment
governingestablishment of the mechanical and technological
characteristics.
(3) Should simulated stress-relief annealing be required inAnnex
A or in the authorized inspectors appraisal, it shall beperformed
in accordance with the conditions stipulatedtherein.
4.4.6 Tests and test methods to be employed4.4.6.1 General(1)
The stipulations of clause 4.4.6 shall apply if perfor-mance of the
tests cited in the following is required in theSections relating to
product forms and if nothing to thecontrary is expressly stipulated
there.(2) The particulars needed for materials testing and
takenfrom the classification into test and material groups per
KTA3211.2 shall be announced to the material or
product-formmanufacturer in the purchase order.
4.4.6.2 Chemical analysis(1) The elements indicated for the
corresponding material inAnnex A shall be determined during ladle
and productanalyses.(2) Specimen taking and preparation for product
analysisshall be governed by SEP 1805 [Steel and Iron Test
andExamination Data Sheet 1805].(3) In case of doubt the chemical
composition shall bedetermined by the test method developed by the
ChemistsCommittee of the Association of German Ferrous
Metallurgists(VDEh) (see Manual for the Ferrous Metallurgy
Laboratory[1]).
4.4.6.3 Hardness test
(1) Hardness tests shall be performed to DIN EN ISO 6506-1or DIN
EN ISO 6507-1.(2) Other hardness test methods may also be used,
subjectto approval of the authorized inspector.
4.4.6.4 Tensile test
Tensile tests shall be performed to DIN EN 10 002-1 andDIN EN 10
002-5, using specimens to DIN 50125.
4.4.6.5 Notched-bar impact bend testNotched-bar impact bend
tests shall be performed to DIN EN10 045-1 on Charpy V-notch
specimens. One set consisting ofthree specimens shall be
tested.
4.4.6.6 Energy absorbed vs. temperature curves(1) Notched-bar
impact bend tests to clause 4.4.6.5 shall betested at a minimum of
four temperatures to plot energyabsorbed vs. temperature curves.(2)
The temperatures shall be chosen such that theyencompass the upper
shelf energy, characterized by a dullfracture surface representing
a proportion of about 100 % ofthe total fracture surface, as well
as the transition to brittlefracture behaviour, characterized by a
dull fracture surfacerepresenting a proportion of about 50% of the
total fracturesurface.(3) A set of three specimens shall be tested
at each testtemperature. For all notched-bar specimens of ferritic
steelsused to plot energy absorbed vs. temperature curves,
thelateral expansion to DIN 50 115 and the proportion of
dullfracture surface as a percentage of total fracture surface
shallbe determined.
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KTA 3211.1
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4.4.6.7 Technological tests on pipesThe technological tests on
pipes shall be performed to:DIN EN 10 233 - Flattening testDIN EN
10 234 - Drift testDIN EN 10 236 - Ring expanding testDIN EN 10 237
- Ring tensile test
4.4.6.8 Metallographic examinations(1) The microstructural
condition shall be determined bypreparing micrographs at a
magnification that permits anunequivocal evaluation.(2) The
grain-size characterizing number shall be deter-mined to Euronorm
103-71.
4.4.6.9 Determination of delta ferrite content
(1) If required in the Sections relating to product forms,
thedelta ferrite content of products of austenitic steels
oraustenitic cast steel as well as of composite pipes pressure-clad
with austenitic cladding layers shall be determined by oneof 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 ofthe methods indicated under (1) a) to c) is
to be employed.Other methods are also permitted, subject to
agreement bythe authorized inspector. One such example is the
physicalmeasurement method to DIN 32 514-1.(3) If the theoretical
estimate yields ferrite numbers lowerthan 3, the delta ferrite
content shall also be determinedmetallographically 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 indicatedin the quality
certificate.
4.4.6.10 Corrosion-resistance testingThe resistance to
intergranular corrosion shall be verified toDIN EN ISO 3651-2.
4.4.6.11 Materials identification check
(1) Materials identification checks shall be performed by
asuitable method. Comparison of stamp markings shall not
beadequate.(2) For pieces that have undergone a product analysis,
it ispermitted to acknowledge that analysis as the
materialsidentification check.
4.4.6.12 Dimensional check
Before shipment of the products, the dimensions andtolerances
specified in the purchase order shall be checked.
4.4.6.13 Visual inspectionDuring the acceptance procedure, the
products shall besubjected to a visual inspection of their external
finish.
4.4.7 Non-destructive examinations4.4.7.1 General(1) The
stipulations of clause 4.4.7 shall apply unless otherstipulations
are made in the Sections relating to product forms.
Note:Deviations from the requirements of clause 4.4.7 are
permitted byagreement with the authorized inspector.
(2) The nature, extent and date of the examinations
arestipulated in the Sections relating to product forms.(3)
Depending on machining location, the non-destructiveexaminations
shall be performed by the product-form manu-facturer or component
manufacturer. The ultrasonic exami-nation shall take place after
the last forming step and heattreatment and in general shall be
performed by the product-form manufacturer. If non-destructive
examinations are notperformed completely by the product-form
manufacture, acorresponding note shall be made in the acceptance
testcertificate.(4) Stipulations for automated or mechanized
examinationmethods can be found in the respective Sections relating
toproduct forms.(5) Where automated or mechanized non-destructive
testmethods are used, test instructions shall be prepared on
thebasis of an evaluation of the test systems which demonstratethe
equivalency of the test results with those obtained with
thedescribed manual methods. The test instructions shall
besubmitted to the authorized inspector within the course of
thedesign approval procedure.(6) Where weld edges and nozzles are
dressed, thesedressed areas shall be subjected to an ultrasonic
examinationprior to dressing the fusion faces. In this case, the
conditionsof testing prior to welding shall be considered. In the
case ofwall thicknesses or sections at the point of connection
equal toor greater than 30 mm a section width equal to the
wallthickness plus 10 mm is considered the weld edge or nozzlearea,
in the case of greater wall thicknesses or sections at thepoint of
connection, a section width equal to the wall thicknessplus 20 mm
adjacent to the fusion face or nozzle hole.
4.4.7.2 Method-related stipulations4.4.7.2.1 Manual ultrasonic
examinations
(1) The general stipulations of Annex F as well as
therequirements of the Sections relating to products shall
apply.(2) The root mean square roughness index Ra to DIN ENISO 4287
shall not exceed 20 m on the examination surface.(3) Should it be
impossible to maintain the boundaryconditions for examination by
the distance-gain-size method(DGS method) to Section F 4.2 or the
DGS method cannot beapplied due to the sound attenuation of the
material, thereference-echo method to Section F 4.3 shall be
employed.(4) When the DGS method is employed, the recording
limitsgiven as a function of nominal wall thickness or of bar or
roddiameter in the Sections relating to product forms shall
apply.(5) When the reference-echo method is employed,
allindications with echo amplitudes equal to or greater than 50 %of
the echo amplitude of the reference reflector shall
beregistered.(6) If in manual examination the coupling cannot be
checkedby other means (e.g., by observing a back-wall echo), the
gainshall be increased until the noise background becomes
visible.(7) The echo amplitudes to be registered and theacceptance
limits are defined as a function of product formand dimensions in
the Sections relating to product forms.
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KTA 3211.1
Page 11
Should the permissible findings be exceeded, the furtheractions
shall be determined by agreement between product-form manufacturer
and authorized inspector.(8) If indications can exhibit a
longitudinal or areal extension,the reflector extension shall be
given, unless otherwisestipulated, by that probe displacement for
which, dependingon wall thickness:a) the echo amplitudes correspond
to the recording limit for
wall thicknesses equal to or smaller than 10 mm, orb) the echo
amplitudes have dropped 6 dB below the
recording limit for wall thicknesses greater than 10 mm andequal
to or smaller than 40 mm, or
c) the echo amplitudes have dropped 12 dB below therecording
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
inthe background. The accuracy in measurement of reflectorextension
shall then be improved by additional investigations ifthese
dimensions alone are critical for evaluation of accep-tability.
Reflectors with extensions smaller than 10 mm shallqualify as local
indications.
4.4.7.2.2 Surface-crack detection(1) The general stipulations of
Annex G as well as therequirements of the Sections relating to
products shall apply.(2) The root mean square roughness index Ra
determined inaccordance with DIN EN ISO 4287 shall not exceed
thefollowing values depending on the process of surfacetreatment:a)
unmachined surfaces Ra 20 mb) machined surfaces Ra 10 m(3)
Examination for surface crack detection shall basically beperformed
by the magnetic particle method unless specifiedotherwise by the
product form-related sections.(4) When subjecting large areas to a
magnetic particleexamination, the yoke magnetization method shall
preferablybe used. Small parts shall be examined, if practicable
bymeans of the auxiliary or coil technique.(5) Methods other than
magnetic-particle or liquid-penetrantexamination are permitted,
subject to approval by theauthorized inspector. They shall
preferably be mechanizedmethods such as eddy-current examination or
magnafluxmethod with probes for detection of surface defects.
4.4.7.2.3 Radiographic examinationThe general stipulations of
Annex B as well as therequirements 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 non-destructive
examinations to the extent specified by this safetystandard.(2) The
authorized inspector shall perform or participate inthe
non-destructive examinations to the extent specified bythis safety
standard. The scope of random non-destructiveexaminations by the
authorized inspector shall be 25 % in testgroup A 1 and 10 % in
test group A 2. Examination by theauthorized inspector is not
required in test group A 3.(3) When equipment for mechanized or
partly automatedexamination is used, the authorized inspector shall
participateat random in the examinations and in the process and
shall
check the sensitivity adjustments and whether the procedureis
performed as stipulated in the initial appraisal(4) The authorized
inspector shall participate at random tothe extent stipulated in
(2), in the surface-crack detections tobe performed in general by
the manufacturer.(5) When the ultrasonic-examination method is
employed,the authorized inspector shall check the test reports.
Theresults of the ultrasonic examinations performed by
themanufacturer shall be randomly checked by the
authorizedinspector to the extent stipulated in (2).(6) When the
radiographic-examination method is employed,the authorized
inspector shall check the performance of theexaminations at random
and shall evaluate the results on thebasis of the test report and
the radiographs.(7) If the authorized inspector has participated in
the non-destructive examinations performed by the manufacturer,
heshall include confirmation to this effect in the
manufacturerscertificates.(8) If the authorized inspector has
performed his ownexaminations, he shall check the manufacturers
examinationresults for agreement within the error inherent to
theexamination technique. Should agreement exist, he shallconfirm
this in the manufacturers certificates.(9) If substantial
differences from the results of the manufac-turers examinations are
found, the authorized inspector andmanufacturer together shall
perform and document additionalchecks.
4.5 Re-examinations
(1) Test results that are based on incorrect taking
orpreparation of the test specimens (test specimen sets),
onincorrect performance of the test or on a random narrow
flawlocation in one test specimen are invalid. The examinationshall
be repeated.(2) Should the results of a properly performed
examinationfail to meet the above requirements, the following
actions shallbe taken:a) Lotwise examination
aa) The test coupon from which the unsatisfactoryspecimen (or
specimen set) was taken shall beexcluded from the lot. It shall be
replaced by twofurther test coupons from the lot, and the
requiredexaminations shall be repeated on those coupons.
ab) The examination shall qualify as passed if the resultsof the
re-examination meet the requirements.
ac) The lot shall be rejected if any result of the two
re-examinations fails to meet the requirements. However,a check
examination of the characteristic found to beout of specification
is permitted on each individualpiece of the lot.
b) Individual examinationba) For each unsatisfactory specimen
(or specimen set),
two further specimens (or specimen sets) from thesame sampling
location shall be examined.
bb) The results of both examinations shall meet
therequirements.
(3) Should it be impossible by appropriate heat treatment
toeliminate the reason for the unsatisfactory result of
anexamination, a new heat treatment shall be required, afterwhich
the test unit shall be submitted again for examination.(4) The
cause of the unsatisfactory result of the firstexamination shall be
investigated.
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KTA 3211.1
Page 12
5 Product forms of ferritic steels of material group W I5.1
Sheets and plates5.1.1 Materials
(1) The following steel grades may be used:a) steel grades to
Section A 1b) other steel grades meeting the prerequisites of
Section 3 in
combination with the stipulations in the authorizedinspectors
appraisal.
(2) The toughness requirements of clause 4.3.1 a) for thelowest
operating temperature shall be considered in
selectingmaterials.
5.1.2 Additional requirements for the materials(1) Plates with
nominal thicknesses equal to or larger than10 mm subjected to
loading perpendicular to the rolled surfaceshall at least meet the
requirements of quality class Z 35 toDIN EN 10 164. This shall be
specified in the purchase order.(2) For plates with nominal
thicknesses equal to or greaterthan 150 mm, the smallest individual
value of energy ab-sorbed (Charpy V-notch transverse specimens) at
the middleof the plate thickness at 80 C shall not be less than 68
J.(3) The requirements of (1) shall apply when plates are usedfor
tubesheets. In addition, the same requirements as forspecimens
longitudinal to or transverse to the main rollingdirection shall
apply for the room-temperature yield point or0.2 % proof stress and
tensile strength of standard specimensperpendicular to the plate
surface. This shall be specified inthe purchase order.(4) The
surface finish shall satisfy the stipulations of DIN EN10 163-2
Class B Subgroup 3. Elimination of surface defectsby welding is not
permitted.
5.1.3 Tests and examinations5.1.3.1 Sampling and specimen
preparation(1) The sampling locations are stipulated in Section A
1.(2) The following specimens shall be taken for the tensiletest at
room temperature:a) For plates with nominal thicknesses equal to or
larger than
40 mm, flat tensile-test specimens containing both
rolledsurfaces. Round tensile-test specimens may also be used.
b) For plates with nominal thicknesses larger than 40 mm,
flattensile-test specimens at least 40 mm thick containing atleast
one intact rolled surface. Round tensile-test speci-mens with the
specimen axis at one quarter of nominalthickness under the rolled
surface (test diameter equal toor larger than 10 mm) may also be
used.
(3) The following specimens shall be taken for the tensiletest
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-testspecimens.
c) For plates with nominal thicknesses larger than 40 mm,round
tensile-test specimens with the specimen axis at onequarter of
nominal thickness under the rolled surface (testdiameter equal to
or larger than 10 mm).
(4) The notched-bar impact bend test shall be subject to
thefollowing requirements:a) For plates with nominal thicknesses
smaller than 5 mm, a
notched-bar impact bend test is not required.
b) For plates with nominal thicknesses between 5 mm andsmaller
than 10 mm, specimens with a width equal to theplate thickness
shall be taken. The rolled surfaces shall beground. Dressing of the
specimens is permitted, in whichcase specimens 5 or 7.5 mm wide are
preferable.
c) For plates with nominal thicknesses equal to or larger than10
mm up to and including 40 mm, specimens shall betaken at the rolled
surface.
d) For plates with nominal thicknesses larger than 40
mm,specimens with their axis at one quarter of the platethickness
under the rolled surface shall be taken.
(5) Transverse specimens shall be used for the tensile
andnotched-bar impact bend tests.(6) Specimens for determination of
the reduction of area atfracture on perpendicular specimens shall
be taken and be pre-pared in accordance with the stipulations in
DIN EN 10 164.(7) Standard specimens shall be used for
determination of theroom-temperature yield point or 0.2 % proof
stress and tensilestrength on specimens perpendicular to the plate
surface.
5.1.3.2 Extent of tests and examinations(1) The chemical
composition shall be determined by per-forming: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 shallbe determined by performing:a) One
room-temperature tensile test per sampling location.b) One
elevated-temperature tensile test per heat, dimensio-
nal range and at most 30 metric tons. The test temperatureis
defined in Section A 1 or in the authorized
inspector'sappraisal.
c) Three room-temperature tensile tests to DIN EN 10 164 atone
sampling location per rolled plate for plates withnominal
thicknesses equal to or larger than 10 mm, inorder 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
persampling location at 33 C or at the lowest operatingtemperature,
whichever is lower, for plates with nominalthicknesses equal to or
larger than 5 mm. Notwithstandingthe foregoing, the energy absorbed
for steel grade15 MnNi 6 3 shall be determined at 0 C.
e) Notched-bar impact bend tests at one sampling location
fordetermination of the energy absorbed vs. temperaturecurve to
clause 4.4.6.6 per heat, dimensional range andidentical heat
treatment for plates with nominal thicknessesequal to or larger
than 10 mm and equal to or smaller than38 mm, and per rolled plate
for plates with nominalthicknesses larger than 38 mm. At least four
testtemperatures shall be used, of which two shall be 0 C andthe
lowest loading temperature. This test may be waivedfor plates of
steel grade 15 MnNi 6 3.
f) One notched-bar impact bend test to clause 4.4.6.5 at
onesampling location per rolled plate, to determine the uppershelf
energy for plates with nominal thicknesses largerthan 16 mm. This
test may be performed during determina-tion of the energy absorbed
vs. temperature curves. Ingeneral, 80 C shall be selected as the
test temperature.The test shall be performed only in test group A
1, andmay be waived if the value of energy absorbed determinedper
d) is equal to or greater than 100 J.
g) One notched-bar impact bend test to clause 4.4.6.5 at80 C at
one sampling location in the middle of the platethickness of each
rolled plate for plates with nominal
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KTA 3211.1
Page 13
thicknesses equal to or greater than 150 mm, unlessotherwise
stipulated in the appraisal.
(3) The non-destructive examinations shall be subject to
thefollowing requirements:a) Each plate with nominal thickness
equal to or larger than
10 mm shall be subjected to an ultrasonic surface exami-nation
to SEL 072 by the manufacturer. If the examinationis not performed
with automated examination systems,10 % of the delivery shall
additionally be examined by theauthorized inspector.
b) The requirements of Class 3 to SEL 072 shall apply to
thesurface examination.
(4) Each rolled plate shall be subjected to a
materialsidentification check.(5) Each plate shall be subjected to
a visual inspection of itsexternal finish.(6) The thickness of each
rolled plate shall be measured.
5.1.4 Marking(1) Each plate shall be marked with the
followinginformation:a) manufacturers symbol,b) steel grade (for
steels with guaranteed reduction of area at
fracture perpendicular to the product surface
additionallyquality 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
uprightwhen viewed in the main rolling direction of the rolled
plate.
5.1.5 Verification of quality characteristics(1) The results of
the ladle analysis, product analysis,materials identification check
and ultrasonic examination per-formed by the manufacturer shall be
documented with anacceptance test certificate 3.1.B to DIN EN 10
204, and theresults of the visual inspection and dimensional check
with anacceptance test certificate 3.1.C to DIN EN 10 204. The
deli-very condition shall be indicated in the acceptance
testcertificate 3.1.B.
(2) The results of all other tests and examinations shall
becertified by the authorized inspector and combined with
theabove-mentioned certificate as an acceptance test
certificate3.1.C to DIN EN 10 204.
5.2 Dished or pressed product forms made from plate5.2.1
Materials
(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 theauthorized
inspectors appraisal.
(2) The toughness requirements of clause 4.3.1 a) for thelowest
operating temperature shall be considered in
selectingmaterials.
5.2.2 Additional requirements for the materials(1) Product forms
with nominal thicknesses equal to orlarger than 10 mm subjected to
loading perpendicular to therolled surface shall at least meet the
requirements of quality
class Z 35 to DIN EN 10 164. This shall be specified in
thepurchase order.(2) For product forms with nominal thicknesses
greater than150 mm, the smallest individual value of energy
absorbed(Charpy V-notch transverse specimens) at the middle of
theproduct-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 inSection 5.1.(2) If the finished parts are tested
individually in accordancewith clause 5.2.4.2, the tests to clause
5.1.3.2 (2) as well asthe corresponding verifications can be
omitted.(3) For the tests to clauses 5.1.3.2 (4) to (6), an
acceptancetest certificate 3.1.B to DIN EN 10 204 will suffice.
Note:The stipulations of KTA 3211.3 shall apply to welded joints
madewith the starting plates and remaining in the finished
parts.
(4) If it is agreed in the purchase order that an
ultrasonicexamination will be performed on the starting plates,
thisexamination shall be performed to clause 5.1.3.2 (3) in
theagreed delivery condition.
5.2.4 Tests and examinations of dished or pressed productforms
made from plates
5.2.4.1 Sampling and specimen preparation(1) For product forms
with a diameter or length equal to orsmaller than 3000 mm, the
tests or examinations shall beperformed 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,
forexample, through the specimen number of the starting plates.
(2) For product forms with a diameter or length greater than3000
mm, each part shall be tested. For lengths or diametersexceeding 6
m one test coupon each shall be taken at twoopposite sides.(3) One
test coupon shall be taken from each part to beexamined regardless
of its diameter or length.(4) The test coupons shall be taken such
that transversespecimens can be machined. Deviations up to 20
degreesfrom the theoretical transverse direction are permitted for
heads(ends) and similar parts. If this is not possible, a different
wayof sampling shall be agreed with the authorized inspector.(5)
Round tensile-test specimens with a test diameter equalto or larger
than 10 mm shall be made for both the room-temperature and
elevated-temperature tensile tests. Fornominal thicknesses larger
than 40 mm, the specimen axisshall 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 diame-ter of 10
mm, the largest possible diameter shall be chosen.(6) For nominal
wall thicknesses equal to or smaller than40 mm, one side of the
specimens for the notched-bar impactbend test shall be as close as
possible to the rolled surface.For nominal wall thicknesses larger
than 40 mm, the specimenaxis shall be located at a distance of one
quarter of theproduct-form thickness under the rolled surface.
5.2.4.2 Extent of tests and examinations
(1) The mechanical and technological characteristics shallbe
determined by performing:
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KTA 3211.1
Page 14
a) One room-temperature tensile test per sampling location.b)
One elevated-temperature tensile test per heat, dimensio-
nal range and at most 30 metric tons. The test temperatureis
defined in Section A 1 or in the authorized
inspectorsappraisal.
c) Three tensile tests (three perpendicular specimens toDIN EN
10 164) at one sampling location per rolled platefor product forms
with nominal wall thicknesses equal to orlarger than 10 mm subject
to loading perpendicular to therolled surface, in order to
determine the reduction of areaat fracture. This test may be waived
if it has already beenperformed on the rolled plate and documented
with anacceptance test certificate 3.1.C to DIN EN 10 204.
Note:Correlation of parts with the rolled plate can be achieved,
forexample, through the specimen number of the starting plates.
d) One notched-bar impact bend test to clause 4.4.6.5
persampling location at 33 C or at the lowest operating
tem-perature, whichever is lower, for nominal wall thicknessesequal
to or larger than 5 mm. Notwithstanding the fore-going, the energy
absorbed for steel grade 15 MnNi 6 3shall be determined at 0 C.
e) Notched-bar impact bend tests at one sampling location
fordetermination of the energy absorbed vs. temperaturecurve to
clause 4.4.6.6 per heat, dimensional range andheat-treatment lot
for product forms with nominal wallthicknesses equal to or larger
than 10 mm and equal to orsmaller than 38 mm, and per rolled plate
for product formswith nominal wall thicknesses larger than 38 mm.
At leastfour test temperatures shall be used, of which two shall
be0 C and the lowest loading temperature. This test may bewaived
for product forms of steel grade 15 MnNi 6 3.
f) One notched-bar impact bend test to clause 4.4.6.5 at
onesampling location of each part to be tested to determinethe
upper shelf energy for product forms with nominal wallthicknesses
larger than 16 mm. This test may be per-formed during determination
of the energy absorbed vs.temperature curve. In general, 80 C shall
be selected asthe test temperature. The test shall be performed
only intest group A 1, and may be waived if the value of
energyabsorbed determined per d) is equal to or greater than100
J.
g) One notched-bar impact bend test to clause 4.4.6.5
persampling location at 80 C in the middle of the product-form
thickness for product forms with nominal wallthicknesses equal to
or greater than 150 mm, unlessotherwise stipulated in the
appraisal.
(2) The non-destructive examinations shall be subject to
thefollowing requirements:
a) If agreed in the purchase order, the starting plates or
thefinished parts with nominal wall thicknesses equal to orlarger
than 10 mm shall be subjected to an ultrasonicsurface examination
per clause 5.1.3.2 (3).
b) The flange and knuckle of each head (end) shall besubjected
to a surface-crack detection in the finish-machined condition after
the last heat treatment. Theacceptance criteria are defined in
Table 5.2-1.
(3) Each product form shall be subjected to a
materialsidentification check.(4) Each product form shall be
subjected to a visualinspection of its external finish.(5) Each
product form shall be checked for accuracyregarding dimensions and
form.
5.2.5 Marking(1) Each product form shall be marked with the
followinginformation: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
additionallyquality class to DIN EN 10 164),
c) heat number,d) specimen number ande) authorized inspector's
mark.(2) In the case of lotwise examination, the product form
fromwhich the specimens were taken shall additionally be marked.(3)
The marking shall be applied such that it appears uprightwhen
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 examina-tions performed by the manufacturer,
and of the heat-treatment condition shall be documented with an
acceptancetest certificate 3.1.B and the results of the visual
inspectionand dimensional check with an acceptance test
certificate3.1.C to DIN EN 10 204. The delivery condition shall
beindicated in the acceptance test certificate 3.1.B.(2) The
forming method shall be indicated in acceptance testcertificate
3.1.B to DIN EN 10 204.
(3) The results of all other tests and examinations shall
becertified by the authorized inspector and combined with
theabove-mentioned certificate as an acceptance test
certificate3.1.C to DIN EN 10 204.
Material groupAllowable actual extension of defect
in main forming direction, in mmInspectionon for wall
thicknesses 10 mm
for wallthicknesses
> 10 mm
Allowable length ofnonmetallic
inclusions 1) in themain forming direction
in mm
Maximumallowable
frequency per10 x 10 cm2
StartingproductSteels with specified
yield point > 370 N/mm2 Formedproduct
1,5 1,5 6 10
Startingproduct 1,5 3 6 10Steels with specified
yield point 370 N/mm2 Formedproduct 1,5 3 10 10
1) For several similar indications, verification by a specimen
randomly taken from the test coupon is permitted.
Table 5.2-1: Acceptance criteria for findings of the
liquid-penetrant and magnetic-particle examinations
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KTA 3211.1
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5.3 Forgings, bar steel and rolled rings5.3.1 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 authorizedinspectors
appraisal.
(2) The toughness requirements of clause 4.3.1 a) for thelowest
operating temperature shall be considered in
selectingmaterials.
5.3.2 Additional requirements for the materialsFor products with
heat-treatment thicknesses greater than150 mm and heat-treatment
weights heavier than 500 kg, thesmallest individual value of energy
absorbed (Charpy V-notchtransverse specimens) at the middle of the
wall thickness at80 C shall not be less than 68 J.
Note:Heat-treatment thickness and heat-treatment weight
designate thewall thickness and piece weight of the product forms
in thecondition in which the heat treatment governing establishment
ofthe mechanical and technological characteristics is
performed.
5.3.3 Tests and examinations5.3.3.1 Sampling and specimen
preparation5.3.3.1.1 Test units
(1) Unless otherwise required in clause 5.3.3.2, the followingis
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-treatmentlot shall be
grouped as test units containing at most 10parts.
c) Pieces with heat-treatment weights heavier than 500 kgshall
be tested individually.
5.3.3.1.2 Sampling locations(1) For forged hollow parts, e.g.,
for shell courses, nozzlesor valve bodies, specimens shall be taken
from one end as afunction of inside diameter Di as follows: from
one samplinglocation for Di equal to or smaller than 500 mm; from
twosampling locations separated by 180 degrees for Di between500 mm
and 2000 mm; and from three sampling locationsseparated by 120
degrees for Di larger than 2000 mm.(2) At the opposite end,
specimens shall be taken from onesampling location for normalized
or air quenched andtempered forgings having a finished length
longer than5000 mm and for liquid quenched and tempered
forgingshaving a finished length longer than 2000 mm. For pieces
withinside diameters smaller than or equal to 500 mm, thissampling
location shall be offset by 180 degrees relative tothat at the
other end (see Figures 5.3-1 and 5.3-2).
Note:Finished length designates the length of the product form
duringthe governing heat treatment, less the length of the test
coupons.
(3) For seamless rolled or forged rings or flanges,specimens
shall be taken from the circumference or end of theflange. They may
also be taken from the end of the weldingend, if the heat-treatment
wall thickness of the welding end isequal to that of the flange.
Specimens shall be taken asfollows: from one sampling location for
inside diameters Di
smaller than or equal to 1000 mm; from two samplinglocations
separated by 180 degrees for Di between 1000 mmand 2000 mm; and
from three locations separated by 120degrees for Di larger than
2000 mm (see Figure 5.3-3).(4) For plates such as tubesheets, tube
plates or blanking-off covers with heat-treatment weights lighter
than 1000 kg,specimens shall be taken from one sampling location.
Ifpermitted by the forging method employed, this location shallbe
in the top or bottom zone (see Figure 5.3-4).(5) For plates with
heat-treatment weights equal to orheavier than 1000 kg, specimens
shall be taken from twosampling locations. If permitted by the
forging methodemployed, these locations shall be in the top and
bottomzones (see Figure 5.3-4).(6) For forged bars, specimens shall
be taken at one end asa function of the diameter D of the bars:
from one samplinglocation for D smaller than or equal to 500 mm;
and from twosampling locations separated by 180 degrees for D
larger than500 mm.
(7) At the opposite end, specimens shall be taken from
onesampling location for normalized or air quenched andtempered
bars having a finished length longer than 5000 mmand for liquid
quenched and tempered bars having a finishedlength longer than 2000
mm. For bars having diameterssmaller than or equal to 500 mm, this
location shall be offsetby 180 degrees relative to that at the
other end.
5.3.3.1.3 Sampling depth(1) For normalized and air quenched and
tempered parts,the specimens shall be taken from at least one
quarter of thegoverning heat-treatment thickness but at most 80 mm
underthe heat-treatment surfaces.(2) For liquid quenched and
tempered parts, except forplates with heat-treatment thicknesses
larger than 320 mm,the specimens shall be taken from at least one
quarter of thegoverning heat-treatment thickness but at most 80 mm
underthe governing heat-treatment surface and at least from
themiddle of the governing heat-treatment thickness (s/2) and
atmost 160 mm under the other surfaces.(3) For liquid quenched and
tempered plates with heat-treatment thicknesses larger than 320 mm,
the specimensshall be taken from at least 80 mm under the
heat-treatmentsurfaces.(4) For parts with a governing
heat-treatment thickness lar-ger than 150 mm and a heat-treatment
weight heavier than500 kg, samples shall be taken additionally at
one locationfrom the middle of the governing heat-treatment
thickness(s/2).
Note:In the case of plates for tubesheets, the question of
whether thisrequirement is met shall be verified in the appraisal
by the energyabsorbed at the middle of the wall thickness.
5.3.3.1.4 Specimen direction(1) Transverse specimens shall be
taken for tensile testsand notched-bar impact bend tests if
geometrically possibleand nothing to the contrary is stipulated in
Section A 2 or inthe authorized inspector's appraisal.(2)
Notwithstanding the foregoing, longitudinal specimens oraxial
specimens may be taken from bars, specifically fortensile tests if
the diameter or greatest length of a cross-sectional edge is
smaller than 160 mm, or for notched-barimpact bend tests if the
diameter or the greatest length of across-sectional edge is smaller
than 68 mm.
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KTA 3211.1
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5.3.3.2 Extent of tests and examinations
(1) The following procedures shall be performed for thechemical
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 shallbe 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 differencebetween the highest and
lowest hardness values in a test unitdoes not exceed 30 HB
units.
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
testtemperature is defined in Section A 2 or in the
authorizedinspectors appraisal.
d) One notched-bar impact bend test to clause 4.4.6.5
persampling location at 33 C or at the lowest operatingtemperature,
whichever is lower. Notwithstanding the fore-going, the energy
absorbed for steel grade 15 MnNi 6 3shall be determined at 0 C.
e) Notched-bar impact bend tests for determination of theenergy
absorbed vs. temperature curve to clause 4.4.6.6.ea) per heat and
heat-treatment lot for pieces with heat-
treatment weights equal to or lighter than 500 kgeb) per piece,
at one sampling location, for pieces with
heat-treatment weights equal to or heavier than500 kg.
At least four test temperatures shall be used, of which twoshall
be 0 C and the lowest loading temperature. This testmay be waived
for pieces of steel grade 15 MnNi 6 3 withwall thicknesses smaller
than or equal to 150 mm.
f) One notched-bar impact bend test to clause 4.4.6.5 at
onesampling location per test unit to verify the upper shelfenergy
for pieces with heat-treatment weights equal to orheavier than 150
kg in the normalized or air quenched andtempered condition and
equal to or heavier than 50 kg inthe liquid quenched and tempered
condition. It shall bedemonstrated that the smallest individual
value of uppershelf energy is equal to or larger than 100 J. This
test maybe performed during determination of the energy absorbedvs.
temperature curves. In general, 80 C shall be selected
as the test temperature. The test shall be performed onlyin test
group A 1, and may be waived if the value of energyabsorbed
determined per d) is equal to or greater than100 J. This test may
be waived for pieces of steel grade15 MnNi 6 3 with wall
thicknesses smaller than or equal to150 mm.
g) One notched-bar impact bend test to clause 4.4.6.5 at80 C at
one sampling location in the middle of thethickness for products
with heat-treatment weights heavierthan 500 kg and heat-treatment
thicknesses larger than150 mm, unless otherwise stipulated in the
appraisal.
(3) Each piece shall be subjected to a
non-destructiveexamination to Annex H.
(4) Each piece shall be subjected to a materials
identificationcheck.
(5) Each piece shall be subjected in the as-deliveredcondition
to a visual inspection of its external finish.(6) A dimensional
check of each piece shall be performed.
5.3.4 Marking(1) Each piece shall be marked with the
followinginformation:a) manufacturer's symbol,b) steel grade (for
steels with guaranteed reduction of area at
fracture perpendicular to the product surface
additionallyquality class to DIN EN 10 164),
c) heat number,d) specimen number,e) authorized inspector's mark
andf) mark of the non-destructive examinations performed.(2) In the
case of lotwise examination, the piece from whichthe 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 examina-tions performed by the manufacturer,
and if necessary of thehardness test shall be documented with an
acceptance testcertificate 3.1.B to DIN EN 10 204, which shall
include anindication of the delivery condition.(2) The results of
all other tests and examinations shall becertified by the
authorized inspector and combined with theabove-mentioned
certificate as an acceptance test certificate3.1.C to DIN EN 10
204.
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KTA 3211.1
Page 17
No. Finished length Inside diameter Di Examples for sampling
1 500 mm
2
Normalized and air quenchedand tempered pieces:L 5000 mmPieces
quenched andtempered in liquid:L 2000 mm
> 500 mm up to 2000 mm
3 > 2000 mm
4 500 mm
5
Normalized and air quenchedand tempered pieces:L > 5000
mmPieces quenched andtempered in liquid:L > 2000 mm
> 500 mm up to 2000 mm
6 > 2000 mm
Figure 5.3-1: Examples for sampling from forged hollow parts
x
Example 3
s
x
s/4
x
s
x
s/4
ss/
4
L
Example 2
HUR
HU
R
HUR
Example 1
L
HUR: Main forming direction
ss/4
Example 4
L
HUR
L
for pieces quenched and tempered in liquid: x = s/2for
normalized and air quenched and tempered pieces: x = s/4
Figure 5.3-2: Examples for sampling from forged valve bodies
i
x
s
D
Di
L
Di
x
s
Di
xs/
4s/
4s/
4s/
4s/
4s
s/4
L
Di
L
L
L
L
s
for normalized and airquenched and temperedpieces: x = s/4
x
iD
tempered in liquid: x = s/2
s
x
s
x
for pieces quenched and
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KTA 3211.1
Page 18
i
1
2
1
1
1
1
i
1
iD D
s
s
x
/4
x
ii
s
i
/4
/4
x
s
s
1
s
D
1
s
D
s
2000 mm2000 mmD
/4s/2
b) Distribution of sampling locations on the circumference or at
the end as a function of inside diameter
D
For normalized or air quenched and tempered parts: x =For parts
quenched and tempered in liquid: x =
1000 mm
Example 3
a) Examples for sampling
Example 1 Example 2
1000 mm
Figure 5.3-3: Examples for sampling from seamless rolled or
forged rings or flanges
>
>
s/2
80ss/2 s
80
x 80
80
s/2
x
x
80
s/4
80
s
80
80
s/4
plates with s 320 mm
Sampling from top andSampling from top andbottom zones not
possiblefor s 150 mm
b) Sampling for
Contour for quenchingand tempering
Test couponDelivery contour
bottom zones possible
plates with s 320 mmc) Sampling for
Sampling at s/2 only
For normalized or air quenched andin liquid: x = s/2 (max. 160
mm)For plates quenched and tempered
plates with s 320 mma) Sampling for
tempered plates: x = s/4 (max. 80 mm)
Figure 5.3-4: Examples for sampling from forged plates
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5.4 Seamless pipes larger than DN 505.4.1 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
pipesequal to or smaller than DN 50 if pipe elbows larger thanDN 50
are made from such pipes.(3) The stipulations of this Section shall
not apply to pipesfor 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 authorizedinspectors
appraisal.
(2) The toughness requirements of clause 4.3.1 a) for thelowest
operating temperature shall be considered in
selectingmaterials.
5.4.3 Additional requirements for the materialsPipes with
nominal wall thicknesses equal to or larger than10 mm and subject
to loading perpendicular to the surfaceshall at least meet the
requirements of quality class Z 35 toDIN EN 10 164. This shall be
specified in the purchase order.
5.4.4 Tests and examinations5.4.4.1 Sampling and specimen
preparation(1) The pipes shall be tested in manufacturing
lengths.(2) Specimens shall be taken from the ends of
manufac-turing lengths.(3) Transverse specimens shall be taken for
tensile testsand notched-bar impact bend tests. If this is not
possible, it ispermitted to take longitudinal specimens.(4)
Notched-bar impact bend tests shall be performed onlyfor pipes with
nominal wall thicknesses equal to or larger than10 mm.
(5) Specimen forms to DIN EN 10 002-1 and DIN EN 10 002-5may
also be used for tensile tests.(6) For tensile tests other than
those to DIN EN 10 002-1and DIN EN 10 002-5 and for notched-bar
impact bend tests,the test coupons shall be taken such that the
specimen axis islocated at one quarter of the wall thickness under
the outsidesurface and at one half of the wall thickness under the
endface or as close as possible to that location.(7) Specimens for
determination of reduction of area atfracture on perpendicular
specimens shall be taken at thesame location as for the
room-temperature tensile-testspecimens.
5.4.4.2 Extent of tests and examinations
(1) The following procedures shall be performed for thechemical
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 shallbe
determined by performing:a) Room-temperature tensile tests for
every 20 manufacturing
lengths of the same heat, dimension and heat treatmentaa) at one
end of one manufacturing length for pipes of
normalized or air quenched and tempered steelsab) 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 than100
C. The test temperature is defined in Section A 3 or inthe
authorized inspector's appraisal.
c) Tensile tests on three perpendicular specimens, takenfrom one
sampling location every 20 manufacturinglengths of the same heat,
dimension and heat treatment, todetermine the reduction of area at
fracture for pipes withnominal wall thicknesses equal to or larger
than 10 mmand subjected to loading perpendicular to the surface.
Thistest may be waived for steel grades for which it
wasdemonstrated in the material appraisal that the mean valueof
reduction of area afire fracture of three perpendicularspecimens is
at least 45 % and that none of the individualvalues is smaller than
35 %.
d) One notched-bar impact bend test to clause 4.4.6.5 at33 C or
at the lowest operating temperature, whichever islower, at one end
of one manufacturing length per 20manufacturing lengths of the same
heat, dimension andheat treatment for pipes of normalized or air
quenched andtempered steels with nominal thicknesses equal to
orsmaller than 38 mm, and at one end of each manufac-turing length
for pipes with nominal thicknesses larger than38 mm. For pipes of
steel grade 15 MnNi 6 3, the testtemperature shall be 0 C.
e) One notched-bar impact bend test to clause 4.4.6.5 at33 C or
at the lowest operating temperature, whichever islower, at both
ends of one manufacturing length per 20manufacturing lengths of the
same heat, dimension andheat treatment for pipes of liquid quenched
and temperedsteels with nominal wall thicknesses equal to or
smallerthan 16 mm, and at both ends of each manufacturinglength for
pipes with nominal wall thicknesses larger than16 mm.
f) Notched-bar impact bend tests for determination of anenergy
absorbed vs. temperature curve to clause 4.4.6.6at one end of one
manufacturing length per heat,dim