KTA 3211_1_2000

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

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

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.

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.

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.

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.

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

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.

KTA 3211.1

Page 10

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.

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.

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

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.


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:

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


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

KTA 3211.1

Page 15

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



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.

KTA 3211.1

Page 16


(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


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.

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

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

KTA 3211.1

Page 19

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



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.


(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

KTA 3211_1_2000

Documents

Transcript of KTA 3211_1_2000