KTA 3905 (2012-11) Load Attaching Points on Loads in ... · Safety Standards of the Nuclear Safety...

Safety Standards of the Nuclear Safety Standards Commission (KTA)

KTA 3905 (2012-11)

Load Attaching Points on Loads in Nuclear Power Plants

(Lastanschlagpunkte an Lasten in Kernkraftwerken)

Previous versions of this Safety Standard were issued 1994-06 and 1999-06

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

Editor:

KTA-Geschaeftsstelle c/o Bundesamt fuer Strahlenschutz (BfS) Willy-Brandt-Strasse 5 • 38226 Salzgitter • Germany Telephone +49 (0) 30 18333-1621 • Telefax +49 (0) 30 18333-1625

KTA SAFETY STANDARD

2012-11

Load Attaching Points on Loads in Nuclear Power Plants KTA 3905

CONTENTS

Fundamentals .............................................................. 6

1 Scope .................................................................. 6

2 Definitions ........................................................... 6

3 General provisions .............................................. 6

4 Special provisions ............................................... 6

4.1 Classification ....................................................... 6

4.2 Load attaching points with additional requirements ....................................................... 6

4.3 Load attaching points with increased requirements ....................................................... 6

4.4 Load attaching points on core components ........ 7

5 Analytical and structural design .......................... 7

5.1 General ............................................................... 7

5.2 Structural steel components ............................... 8

5.3 Lifting lugs, bolts, tie rods and similar components ........................................................ 9

5.4 Bolted connections ........................................... 10

5.5 Application of loads into structural concrete components ....................................................... 11

5.6 Ropes and chains ............................................. 12

5.7 Core components ............................................. 12

5.8 Analytical proof using the finite element method .............................................................. 13

6 Materials ........................................................... 14

6.1 Manufacture ...................................................... 14

6.2 Selection of Materials ....................................... 14

6.3 Testing of materials .......................................... 14

6.4 Materials identification marking ........................ 14

7 Design approval ................................................ 15

7.1 Required documents ......................................... 15

7.2 Procedure ......................................................... 16

7.3 Certification of design approval ........................ 16

8 Final inspection ................................................. 16

8.1 General ............................................................. 16

8.2 Load attaching points in acc. with Sec-tion 4.2 or 4.3 .................................................... 17

8.3 Load attaching points in acc. with Sec-tion 4.4 .............................................................. 17

9 Acceptance test ................................................ 17

9.1 Load attaching points in acc. with Sec-tion 4.2 or 4.3 .................................................... 17

9.2 Load attaching points in acc. with Sec-tion 4.4 .............................................................. 17

10 In-service inspections ......................................... 6

10.1 Load attaching points in acc. with Sec-tion 4.2 or 4.3 ...................................................... 6

10.2 Load attaching points in acc. with Sec-tion 4.4 ................................................................ 6

11 Operation and maintenance ................................ 6

11.1 Load attaching points in acc. with Sec-tion 4.2 or 4.3 ...................................................... 6

11.2 Load attaching points in acc. with Sec-tion 4.4 ................................................................ 7

12 Documentation .................................................... 7

12.1 General ............................................................... 7

12.2 Compilation of documents .................................. 7

12.3 Procedure of documentation ............................... 7

Annex A: Materials test sheets (WPB)...................... 11

Annex B: Non-destructive testing (NDT) ................... 28

Annex C: Graphical representation of the delimitation between load attaching point and load for several examples ......... 38

Annex D: Examples for the classification of load attaching points ......................................... 41

Annex E: Regulations and literature referred to in this Safety Standard .................................. 43

Annex F: Changes with respect to the edition 1999-06 and explanations (informative) .... 47

PLEASE NOTE: Only the original German version of this safety standard represents the joint resolution of the 50-member Nuclear Safety Standards Commission (Kerntechnischer Ausschuss, KTA). The German version was made public in the Bundesanzeiger (BAnz) of January, 23th, 2013. Copies may be ordered through the Wolters Kluwer Deutschland GmbH, Postfach 2352, 56513 Neuwied, Germany (Telefax +49 (0) 2631 801-2223, E-Mail: [email protected]).

All questions regarding this English translation should please be directed to:

KTA-Geschaeftsstelle c/o BfS, Willy-Brandt-Str. 5, 38226 Salzgitter, Germany

Comments by the editor:

Taking into account the meaning and usage of auxiliary verbs in the German language, in this translation the follow-ing 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 than those 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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Fundamentals

(1) The Safety Standards of the Nuclear Safety Standards Commission (KTA) have the task of specifying those safety related requirements which shall be met with regard to pre-cautions to be taken in accordance with the state of science and technology against damage arising from the construction and operation of the facility (Sec. 7 para 2 subpara 3 Atomic Energy Act -AtG -) in order to attain the protection goals spec-ified in the Atomic Energy Act and the Radiological Protection Ordinance (StrlSchV) and which are further detailed in the ”Safety Criteria for Nuclear Power Plants” and in the ”Incident Guidelines”.

(2) The requirements to be derived from the above are specified in this Safety Standard for load attaching points. Regarding the danger potential the general provisions and

a) additional requirements or

b) increased requirements

for load attaching points as well as

c) special requirements for load attaching points on core components

shall be taken into account.

(3) This Safety Standard deals with the design and analysis, materials, tests and inspections, operation and maintenance including documentation of load attaching points functioning as connecting element between load suspending device and load.

(4) Special requirements specific to a component are not dealt with here, but shall be taken into account where re-quired.

(5) General requirements regarding quality assurance are specified in Safety Standard KTA 1401. Quality assurance requirements exceeding those of KTA 1401 are laid down in this Safety Standard for each individual case.

1 Scope

(1) This Safety Standard shall apply to load attaching points on loads which are handled in nuclear power plants during specified normal operation and must comply with the special provisions of Section 4.

(2) This Safety Standard shall furthermore apply to load attaching points of the following core components:

a) fuel elements, control elements and in-core instrumenta-tion lances for pressurized water reactors,

b) fuel elements, control rods and fuel assembly channels for boiling water reactors

(3) Load attaching points on core component encapsula-tions are to be considered load attaching points on core com-ponents.

(4) This Safety Standard does not apply to:

a) load attaching points on reactor pressure vessel internals Note: Load attaching points on reactor pressure vessel internals are covered by KTA 3204.

b) load attaching points on containers for the storage, han-dling and internal transport of radioactive substances, which meet the requirements of KTA 3604.

2 Definitions

(1) Load attaching point (LAP)

The load attaching point is the connecting element between load suspending device and load and is either

a) an integral part of the load or

b) bolted on or

c) welded on or

d) anchored in the concrete in the case of structural concrete components

Note: The delimitation between load attaching point and load is de-scribed in Annex C with reference to examples.

(2) Authorized inspectors

Authorized inspectors for the tests and inspections for the purpose of this Safety Standard are the following on the basis of nuclear, building or traffic legislation:

a) authorized inspectors consulted by the licensing or super-visory authority in accordance with Sec. 20 of the Atomic Energy Act,

b) authorized inspectors from the institution competent under the building code of the respective State or the inspecting engineers put in charge by this institution,

c) authorized inspectors from the institution competent under the traffic legislation or the authorized inspector consulted by this agency.

3 General provisions

Load attaching points shall at least comply with the generally accepted engineering standards.

4 Special provisions

4.1 Classification

The classification of the load attaching points with respect to the additional or increased requirements shall be specified within the framework of the nuclear licensing and supervisory procedure. Examples for the classification and for the proce-dural steps of classification are given in Annex D.

4.2 Load attaching points with additional requirements

If, in the course of transportation of nuclear fuel, other radio-active substances, radioactive plant components or other loads, a failure of the load attaching point is expected to lead

a) to the immediate danger of a release of radioactivity with a subsequent radioactive exposure of persons in the plant subjected to an effective dose by inner exposure exceed-ing 1 mSv or to an external exposure exceeding 5 mSv

or

b) to a loss of reactor coolant which cannot be isolated, or to a detrimental effect on, and going beyond the redundancy of, the safety equipment which is necessary to shut down the reactor at any time, to maintain the reactor in the shut-down condition or to remove residual heat, and no dan-gers as per Section 4.3 need be expected,

then the additional requirements specified in this Safety Standard that exceed the requirements under Section 3 shall apply to these load attaching points.

4.3 Load attaching points with increased requirements

If, in the course of transportation of nuclear fuel, other radio-active substances, radioactive components or other loads, a failure of the lifting equipment is expected to lead

a) to a criticality accident

or

b) to the danger of a release of radioactivity where the maxi-mum allowable discharge into the atmosphere may be ex-ceeded as laid down in the license or the radioactive ex-posure of individual persons of the population in the nu-clear power plant environment may exceed the limit values of the Radiological Protection Ordinance (StrlSchV)

KTA 3905

then more stringent requirements specified in this Safety Standard that exceed the requirements under Section 3 shall apply to these load attaching points.

4.4 Load attaching points on core components

Load attaching points on core components according to clause 1 (2) shall, in addition to the general provisions of Sec-tion 3, meet the requirements of the pertinent Sections of this Safety Standard.

5 Analytical and structural design

5.1 General

5.1.1 Load assumptions

(1) In the case of statically indeterminate systems where the calculated load distribution over all load attaching points is not ensured by the load suspending device, the maximum possi-ble load, however, at least one half of the total load, shall be proved for each load attaching point.

(2) Where additional forces, e.g. as a result of breaking loose, static friction or tilting, cannot be precluded by design measures, these forces shall be taken into account.

(3) Ambient conditions such as pressure, temperature, fluid and radiation exposure shall be considered in the design.

(4) Component-specific requirements for the analytical and structural design, calculation, materials, tests and inspections, operation and maintenance shall be considered.

(5) For load attaching points used as support and attach-ment on the transportation means during transportation out-side the nuclear power plant, the loadings resulting from transports inside and outside the nuclear power plant shall be considered in the analysis for cyclic operation.

(6) For load attaching points no verification of adequate protection against external impacts is required.

5.1.2 Stress analysis

(1) The following analytical proofs shall be performed:

a) a general stress analysis,

b) additionally, an analysis for cyclic operation

ba) for structural steel components to DIN 15018-1 as of a number of stress cycles Nσ exceeding 2 ⋅ 104

bb) for other components of load attaching points at more than 6,000 stress cycles.

Note: Other components of load attaching points refer, inter alia, to components where a stress evaluation on the basis of nominal stresses is not purposeful.

The number of stress cycles shall be determined in accord-ance with clause 5.1.3.

(2) Analytical proofs may be performed by calculation or experimentally or as a combination of calculation and experi-ments. To this end, the calculation methods described in Annex B of KTA 3201.2 may be applied (e.g. Finite Element Method) or other methods to be specified. When applying the Finite Element Method the requirements of Section 5.8 shall be met.

(3) The stress evaluation shall principally be based on nomi-nal stresses. Where a stress evaluation on the basis of nominal stresses is not purposeful (e.g. in the case of volume-type com-ponents with complex cross-sections and notches), the stress evaluation shall be made to specific requirements for each indi-vidual case.

Note: For bolted load attachment points of transport vessels for radioac-tive substances to be used within and outside nuclear power

plants the requirements for the analytical proofs as well as the evaluation criteria for the general stress analysis are defined e.g. in the Guideline BAM-GGR 012.

(4) In the case of connections made with bolts to be re-assembled upon disassembly, the following applies in addi-tion to (1):

a) Where an analysis for cyclic operation is to be carried out as per (1), the stress cycles resulting from disassembly and re-assembly operations shall be taken into account in the analysis.

b) Where no analysis for cyclic operation is required as per subcl. (1) and a maximum of 10 disassembly and re-assembly operations is carried out, an analysis for cyclic operation may be waived.

c) Where more than 10 disassembly and re-assembly opera-tions are carried out, an analysis for cyclic operation shall be carried out independently of the requirements of subcl. (1). In this case, both the stress cycles from operational loadings and from disassembly and re-assembly opera-tions shall be taken into account.

5.1.3 Determination of the load collective

(1) As regards the analysis for cyclic operation, the compo-nent stresses shall be calculated in due consideration of the load assumptions to cl. 5.1.1 and be classified as to their magnitudes. With the related number of stress cycles the load collective shall be determined.

(2) In doing so, the number of stress cycles shall be calcu-lated in accordance with the following equation

Nσ = U ⋅ ZSch ⋅ ka (5.1-1)

using ka = 3

ZSch = 10 for converter drives and cable drives with creep speed

ZSch = 20 for other drives

Where

ka number of stress cycles as a result of a switching operation

Nσ number of (dynamic) stress cycles

U number of operational load cycles; an operational load cycle is the process between taking up and setting down of the load

Zsch number of switching operations per operational load cycle (switching on to accelerate corresponds to one switching operation; switching over to brak-ing, likewise).

(3) The cyclic history for the strength analysis shall be con-verted by the elementary Miner’s Rule (linear damage accu-mulation at continuous stress number diagram in a double logarithmic representation in accordance with Sections B 1.2.1.3 and B 1.2.2.1 of KTA 3902) to a damage-equivalent single-step load collective. The stress amplitude belonging to Nσ shall be determined under consideration of the load coeffi-cient (live load factor) specified in the following Sections for the individual components. Where the stresses within an op-erational load cycle are unknown, the maximum stress ampli-tude after connection of the load shall be assumed as remain-ing constant over the entire operational load cycle.

(4) If the actual stresses within a load cycle are known from experimental investigations or from appropriate estimation of the cyclic stressing history with suitable analytical models (e.g. taking account of the vibration energy consumed by the work loss being impressed on the system by the coupling impact), the analysis for cyclic operation may be performed on this basis.

KTA 3905

5.1.4 Structural design

5.1.4.1 Load attaching points in acc. with Section 4.2 or 4.3

(1) DIN 15018-1 and DIN 15018-2 shall apply to structural steel components and weld seams.

(2) The requirements in accordance with VDI 2230 Sheet 1 apply to the construction of bolted connections.

(3) Only those load attaching points are permissible which are either an integral part of the load, are bolted on or welded on and, in the case of concrete parts, are anchored in the concrete.

(4) The load attaching point shall be designed such that it can only be positively attached to the lifting equipment. Safe-guards shall be provided to prevent any inadvertent release of the load suspending device from the load attaching point.

(5) Load attaching points shall be constructed or marked such that they cannot be used in an inadmissible manner and the ergonomic requirements of KTA 3902, Section 4.7, as to the connection to the load suspending device are satisfied.

(6) In the case of welded-on load attaching points the de-sign shall ensure that either

a) the stress level in the weld does not exceed 80 % of the allowable stress (weld quality not to be proved)

or

b) the non-destructive examination of the full volume of the attachment weld is possible.

(7) Load-carrying welds shell satisfy level B of DIN EN ISO 5817.

(8) When employing rope slings in accordance with DIN EN 13414-1 and DIN EN 13414-2 and chain slings in accordance with DIN EN 818-4 with load carrying attachments and load attachment rigging, only 50 % of the load capacity specified in these standards shall be used. This shall be taken into ac-count in the structural design of load attaching points.

(9) The surfaces of load attaching points shall be such that they can be easily decontaminated.

5.1.4.2 Load attaching points in acc. with Section 4.4

(1) The load attaching point shall be designed such that it can only be positively attached to the lifting equipment. Safe-guards shall be provided to prevent any inadvertent release of the load suspending device from the load attaching point.

(2) For welded joints the provisions of the drawings and related specifications apply.

(3) The requirements in accordance with VDI 2230 Sheet 1 apply to the construction of bolted connections.

5.2 Structural steel components

5.2.1 Additional requirements

5.2.1.1 Live load factor

(1) The dead weight of the load shall be multiplied by a live load factor of ψ = 1.35 for determination of the load assump-tions.

(2) Where the maximum hoist speed is known, the live load factor resulting from lifting class H3 to DIN 15018-1 may be used instead of the live load factor as per sub-clause (1) above.

(3) Where a live load factor less than that of sub-clauses (1) or (2) is to be used, the maximum dynamic load factor occur-ring at the load attaching point during one operational load cycle shall be determined by means of calculation or experi-mentally in each individual case. As regards the determination

of the live load factor this dynamic load factor shall be multi-plied by a safety factor of 1.12.

5.2.1.2 General stress analysis

The general stress analysis shall be carried out in accordance with DIN 15018-1 for the “main forces” load case, H. For structural steel components made of the austenitic steels 1.4541, 1.4306 and 1.4571 to DIN EN 10088-2 or DIN EN 10088-3 the allowable stresses shall be taken from KTA 3902, Annex D.

5.2.1.3 Analysis for cyclic operation

(1) In accordance with DIN 15018-1, the loading level group B 3 shall be used in the analysis of the cyclic operation of structural steel components.

(2) The allowable stresses for the analysis of cyclic ope-ration shall be in accordance with KTA 3902 Annex D, Section D1, when using austenitic steels 1.4541, 1.4306 and 1.4571 to DIN EN 10088-2 or DIN EN 10088-3.

(3) Where the operating conditions are exactly known, e.g. the actually occurring loadings and stress cycles, the analysis for cyclic loading for a single-step or multi-step load collective on the basis of a stress-number diagram may be performed to KTA 3902 Annex C for the steels S235 and S355, or on the basis of a stress-number diagram be performed to KTA 3902 Section D 2 for the austenitic steels 1.4541, 1.4306 and 1.4571.

The following safety factor as regards maximum stress shall be observed:

σσ=ν /D ≥ 1.12.

5.2.2 Increased requirements


(1) The dead weight of the load shall be multiplied by

a) a live load factor of ψ = 1.45 in case of redundant load attaching points

b) an increased live load factor of ψ = 1.8 in case of non-redundant load attaching points

for determination of the load assumptions. Note: The value ψ = 1.8 is obtained from the live load factor ψ = 1.45 multiplied with a safety factor 1.25 in the case of non-redundant load attaching points (ψ = 1.45 ⋅ 1.25 ≈ 1.80).

(2) Where the maximum hoist speed is known, the live load factor resulting from lifting class H4 to DIN 15018-1 may be used instead of the live load factor as per sub-clause (1) above. In the case of non-redundant load attaching points 1.25 times the live load factor shall be used in the calculation.

(3) Where a live load factor less than that of sub-clauses (1) or (2) is to be used, the maximum dynamic load factor occur-ring at the load attaching point during one operational load cycle shall be determined by means of calculation or experi-mentally in each individual case. As regards the determination of the live load factor this dynamic load factor shall be multi-plied

a) in case of redundant load attaching points by a safety fac-tor of 1.25

and

b) in case of non-redundant load attaching points by a safety factor of 1.25 and an additional safety factor of 1.25.

(4) The loads resulting from shifting of the load due to a failure of a component of the lifting equipment in accordance with Sec. B 2.1.2 KTA 3902 shall be taken into account if more unfavourable stresses result than those determined with the live load factors specified above. It is permissible to use

KTA 3905

τKt

1.1 times the stresses of the “main and additional forces” load case, HZ, in accordance with DIN 15018-1 for this load case.


The general stress analysis shall be carried out in accordance with DIN 15018-1 for the “main forces” load case, H. For structural steel components made of the austenitic steels 1.4541, 1.4306 and 1.4571 to DIN EN 10088-2 or DIN EN 10088-3 the allowable stresses shall be taken from KTA 3902 Annex D, Section D1.


(1) The loading level group B 4 to DIN 15018-1 shall be used in the analysis for cyclic operation of structural steel components.

(2) The allowable stresses for the analysis of cyclic ope-ration shall be in accordance with KTA 3902 Annex D Section D2 when using austenitic steels 1.4541, 1.4306 and 1.4571 to DIN EN 10088-2 or DIN EN 10088-3.

(3) The requirements of sub-clause 5.2.1.3 (3) shall be met in which case the following safety factor against the maximum stress shall be obtained:

σσ=ν /D ≥ 1.25.

5.3 Lifting lugs, bolts, tie rods and similar components





(3) Where a live load factor less than that of sub-clauses (1) or (2) is to be used, the maximum dynamic load factor occur-ring at the load attaching point during one operational load cycle shall be determined by way of calculation or experimen-tally in each individual case. As regards the determination of the live load factor this dynamic load factor shall be multiplied by a safety factor of 1.12.


(1) The following safety factors shall be proved for the com-ponents

νσ = 5.1RorR 2.0peH ≥

σ (5.3-1)

ντ = τ

τst ≥ 1.5 (5.3-2)

5.1RorR

v

2.0peHv

≥σ

=νσ (5.3-3)

σv = σ τ2 23+ ⋅ (5.3-4)

where

σ normal stress from the maximum load occurring

σV stress intensity

ReH or Rp0.2 yield point or proof stress

τ shear stress

τst yield point for torsional stress

< 3/R or 3/R p0.2eH

(2) The weld seams shall be dimensioned in accordance with DIN 15018-1 for the “main forces” load case, H.


(1) In the case of Nσ < ND the safety for the creep rupture shall be proved as follows:

νσ = σ

σD ≥ 2.0 (5.3-5)

ντ = ττD ≥ 2.0 (5.3-6)

and 22

D

2

D 0.2

0.1

≤

τ

τ+

σ

σ (5.3-7)

(2) The safety for the endurance strength range Nσ ≥ ND shall be proved as follows:

νσ = σ

σD ≥ 2.0 (5.3-8)

ντ = τ

τD ≥ 2.0 (5.3-9)

and 22

D

2

D 0.2

0.1

≤

τ

τ+

σ

σ (5.3-10)

where

σD = f (σn, Kn) endurance strength for normal stresses

σn endurance strength of the material test specimen for normal stresses at a 50 % survival probability

Kn product of endurance strength reduction factor, roughness factor and shape factor for normal stresses

ND 5 ⋅ 106 stress cycles

Nσ number of actual stress cycles

Rm tensile strength

σD creep rupture stress for normal stresses

τD = ( )f t K tτ τ, endurance strength for torsional stresses

τt endurance strength of the material test specimen for torsional stresses at a 50 % survival probability

τD creep rupture stress for shear stresses

product of endurance strength reduction factor, roughness factor and shape factor for torsional stresses

(3) The stress-number diagrams shall be determined using the requirements for shafts, axles and similar component parts laid down in clause B 1.2.2.1 of KTA 3902.

(4) Material characteristics, endurance strength reduction factor, roughness factor, stress concentration factor and shape factor shall be taken from the relevant literature, e.g. [1] to [7] (see Annex E).

(5) If materials not dealt with in the literature in Annex E are used, the above-mentioned characteristic values shall be veri-fied and guaranteed in each individual case.

(6) The requirements of DIN 15018-1 loading level group B 6 shall apply for dimensioning the weld seams.

KTA 3905





b) an increased live load factor of ψ = 1.8 in case of non-redundant load attaching points.

for determination of the load assumptions.

Note: The value ψ = 1.8 is obtained from the live load factor ψ = 1.45 multiplied with a safety factor 1.25 in the case of non-redundant load attaching points (ψ = 1.45 ⋅ 1.25 ≈ 1.80).


(3) Where a live load factor less than that of sub-clauses (1) or (2) is to be used, the maximum dynamic load factor occur-ring at the load attaching point during one operational load cycle shall be determined by way of calculation or experimen-tally in each individual case. As regards the determination of the live load factor this dynamic load factor shall be multiplied


and


(4) The loads resulting from shifting of the load due to a failure of a component of the lifting equipment in accordance with Sec. B 2.1.2 KTA 3902 shall be taken into account if more unfavourable stresses result than those determined with live load factors specified above. A general stress analysis shall be performed for this load case, where a safety factor equal to or greater than 1.25 against the yield point shall be taken into account. In the case of weld seams it is permissible to use 1.1 times the stresses of the “main and additional forc-es” load case, HZ, in accordance with DIN 15018-1.


(1) The safety factors in accordance with Section 5.3.1.2 shall be proved for the components.

(2) Weld seams shall be dimensioned in accordance with DIN 15018-1 for the “main forces” load case, H.


(1) In the case of Nσ < ND the safety for the creep rupture shall be proved as follows:

νσ = σ

σD ≥ 2.5 (5.3-11)

ντ = ττD ≥ 2.5 (5.3-12)

and 22

D

2

D 5.2

0.1

≤

τ

τ+

σ

σ (5.3-13)

(2) The safety for the endurance strength range Nσ ≥ ND shall be proved as follows:

νσ = σ

σD ≥ 2.5 (5.3-14)

ντ = τ

τD ≥ 2.5 (5.3-15)

and

22

D

2

D 5.2

0.1

≤

τ

τ+

σ

σ (5.3-16)

(3) The stress-number diagrams shall be determined using the requirements for shafts, axles and similar component parts laid down in clause B 1.2.2.1 of KTA 3902.

(4) Material characteristics, endurance strength reduction factor, roughness factor, stress concentration factor and shape factor shall be taken from relevant literature, e.g. [1] to [7] (see Annex E).

(5) If materials not dealt with in the literature in Annex E are used, the above-mentioned characteristic values shall be veri-fied and guaranteed in each individual case.

(6) The requirements of DIN 15018-1 loading level group B 6 shall apply for dimensioning the weld seams.

5.4 Bolted connections







(1) VDI 2230 Sheet 1 shall be used for dimensioning bolted connections. The following requirements shall be met:

a) the degree of utilization of the yield stress limit when tight-ening shall be limited to 0.7,

b) the degree of utilization of the yield stress limit as a result of operational additional bolt forces shall be limited to 0.1.

(2) If bolted connections to DIN EN ISO 898-1 and DIN EN ISO 898-2 or DIN EN ISO 3506-1 and DIN EN ISO 3506-2 subject to additional tensional loading are used, then the de-termined bolt load shall be increased by a factor of 1.12.


(1) The analysis for cyclic operation shall be performed in accordance with VDI 2230 Sheet 1. A safety factor of at least 2.0 shall be observed with regard to the endurance strength of the thread.

(2) In case of a multi-step load collective (e.g. due to as-sembly and disassembly activities), the loading history cov-ered by the stress analysis to (1) shall be modelled as dam-age-equivalent single-step stress collective. The damage-equivalent stress pertinent to the number of stress cycles ND shall be determined as follows in the analysis of finally quenched and tempered bolts:

c

1

D

c

1

i

ii

1 N

N

σ

σ⋅

⋅σ=σ∑

(5.4-1)

KTA 3905

where the following is to be used:

ND = 2 ⋅ 106

c = 3

with:

σ1 actual stress amplitude of 1st step of load collective step (maximum stress)

σi actual stress amplitude of the respective step of load collective

Ni actual number of stress cycles of the respective step of load collective

The following shall be verified:

ASVσσ

≤ 2.0 (5.4-2)

with:

σASV stress amplitude of endurance limit of finally quenched and tempered bolts to VDI 2230 Sheet 1

Note: Where in the analysis of final-rolled bolts, the stress amplitude of the endurance limit is determined in a suitable manner in due consideration of its dependence on the mean stress, the damag-ing-equivalent stress may be determined analogously by using σASG (stress amplitude of endurance limit of final-rolled bolts in ac-

cordance with VDI 2230 Sheet 1) in lieu of σASV and c=6.





b) an increased live load factor of ψ = 1.8 in case of non-redundant load attaching points

for determination of the load assumptions.





and


(4) The loads resulting from shifting of the load due to a failure of a component of the lifting equipment in accordance with Sec. B 2.1.2 KTA 3902 shall be taken into account if more unfavourable stresses result than those determined with live load factors specified above. The degree of utilization of the yield stress limit due to additional bolt loads shall be lim-ited to 0.3 for this load case.


(1) VDI 2230 Sheet 1 together with the conditions specified in 5.4.1.2 shall apply to the dimensioning of bolted connec-tions.

(2) If bolted connections in accordance with DIN EN ISO 898-1 and DIN EN ISO 898-2 or DIN EN ISO 3506-1 and DIN EN ISO 3506-2 subject to additional tensional loading are used, then the required number of bolts shall be doubled or the determined bolt load shall be increased by a factor of 1.5. These requirements are not imposed, if bolts in accordance with Materials Test Sheet WPB 14 to Annex A are used.


(1) The analysis for cyclic operation shall be performed in accordance with VDI 2230 Sheet 1. A safety factor of at least 2.5 shall be verified with regard to failure due to fatigue of the thread.

(2) In the case of a multi-step load collective the analysis to (1) shall be performed in accordance with clause 5.4.1.3. The following shall be verified:

ASVσσ

≤ 2.5 (5.4-3)

5.5 Application of loads into structural concrete components



(1) The dead weight of the load shall be multiplied by a live load factor of ψ = 1.35.



5.5.1.2 Application of load

(1) The proof of load application into a structural concrete component shall be performed in accordance with the re-quirements specified in DIN EN 1992-1-1 in connection with DIN EN 1992-1-1/NA. The loads shall be assumed to be characteristic impacts and shall be proved by permanent and temporary evaluation of loadings.

(2) DIN EN 1991-1-1 in connection with DIN EN 1991-1-1/NA and DIN EN 1990 in connection with DIN EN 1990/NA shall apply to the determination of load assumptions. In addition to the requirements of these standards, the live load factor as per clause 5.5.1.1 shall be considered.

(3) Construction products or types of construction for which proof of load application is not rendered on the basis of tech-nical building regulations, may be used upon approval by the authorizes inspector to § 20 Atomic Energy Act if their suitabil-ity has been proved as follows:

a) by means of an approval under building regulation or

b) by means of a European technical approval or

c) by other suitable proofs (approval on a case-by-case-basis).

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(4) The additional load on the structural concrete compo-nent resulting from the load test specified in no. 3 d) of Ta-

ble 9-1 shall individually be taken into account corresponding to the application of the load. In this case, the combination of loads applied shall be assigned to load category A2 to DIN 25449.





or

b) an increased live load factor of ψ = 1.8 in case of non-redundant load attaching points.





and


(4) The loads resulting from shifting of the load due to a failure of a component of the lifting equipment in accordance with Sec. B 2.1.2 KTA 3902 shall be taken into account if more unfavourable stresses result than those determined with the live load factors specified above.

5.5.2.2 Application of load

The requirements of clause 5.5.1.2 shall be met in which case the live load factor as per clause 5.5.2.1 shall be considered.

5.6 Ropes and chains

Ropes and chains are not permitted as load attaching points.

5.7 Core components

5.7.1 General

For the determination of the load assumptions the dead weight of the load shall be multiplied by a load intensification factor fÜ = 2.0. The load intensification factor comprises the live load factor and additional forces from frictional contacts.

Note: As regards the proof for the specific load case “load shifting” see clause 5.7.5.

5.7.2 General stress analysis

(1) For the load attaching points of core components only primary stresses are considered. The following stress intensi-ties shall be complied with:

a) allowable primary membrane stress intensity

Pm,zul = 0.66 ⋅ Rp0.2T (5.7-1)

b) allowable primary membrane plus bending stress intensity

Pm+b,zul = 1.0 ⋅ Rp0.2T (5.7-2)

with

Rp0.2T elevated temperature proof stress

Note: Primary stresses are stresses necessary to satisfy the laws of equalibrium of external forces and moments.

Membrane stresses are defined as the average stress value of the individual stress component over the cross-section under consideration.

Bending stresses are defined as variable linear stresses propor-tional to their distance from the neutral axis.

(2) The stress intensities shall be derived from the individual stress components in accordance with the theory of von-Mises.

(3) The allowable primary stress intensities for welds are derived from the allowable primary stress intensity of the base material multiplied by the weld factors v and v2 for the type of loading and weld quality. The weld factors v shall be taken from Table 5-1.

For the weld factors v2 to consider the weld quality the follow-ing values shall be used:

v2 = 1.0 for proved weld quality (5.7-3)

v2 = 0.5 without proof of weld quality (5.7-4)

Type of weld Type of loading Weld factor v

Butt weld

Tension 1.0

Compression 1.0

Bending 1.0

Shear 0.8

Fillet weld Any loading 0.8

Table 5-1: Weld factors v to consider the respective type of loading

(4) VDI 2230 Sheet 1 shall be used for dimensioning bolted connections. The following requirements shall be met:

a) the degree of utilization of the yield stress limit when tight-ening shall be limited to 0.7,

b) the degree of utilization of the yield stress limit as a result of operational additional bolt forces shall be limited to 0.1.

5.7.3 Experimental analysis

(1) For load attaching points of core components the limits of primary membrane plus bending stress intensity need not be complied with if, by testing on a series-produced compo-nent or prototype component, it can be proved that

a) Lmax ≤ LG (5.7-5)

and

b) Lmax ≤ 0.44 ⋅⋅⋅⋅ LU (5.7-6)

where

Lmax = fÜ ⋅⋅⋅⋅ dead weight (design load)

fÜ = 2.0 (load intensification factor)

LG service load (deformations are limited such that de-taching or attaching of the load suspending device is still possible)

LU rupture load or maximum test load

(2) For all experimental analyses the differences between the conditions on the test component and the most unfavour-able combination of the components used (e.g. dimensional

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tolerances, specified minimum design strength values) shall be taken into account. The load applied during the test shall reflect the true conditions on the component. The considera-tion of these requirements shall ensure that the loads deter-mined during the test reflect the conservative load carrying capacity of the true structure at specified loads.

5.7.4 Analysis for cyclic operation

For load attaching points on core components the number of stress cycles Nσ is less than 2 ⋅ 104. Therefore, no analysis for cyclic operation need be made.

5.7.5 Analytical proof for the special load case “load shifting”

(1) The loadings arising from shifting of load due to failure of an equipment lifting component as per KTA 3902, clause B 2.1.2, shall be considered if they lead to more unfavourable loadings than those determined with the load intensification factor to clause 5.7.1.

(2) For this load case it shall be proved that the hold func-tion of the load attaching point is maintained.

Where the dead weight of the load is multiplied with a load intensification factor fÜ = 4.0 for use in this analytical proof, this will be considered a load assumption to cover this special load case. Alternatively, the proof may be based on a smaller load intensification factor as far as this factor has been proved for the lifting equipment to be operated.

(3) The proof as per (2) is considered to have been ren-dered if the criteria to a) or b) have been satisfied and the deformations are limited in accordance with the requirement under c).

a) A general stress analysis as per 5.7.2 shall be performed in which case the following allowable stress intensities shall be adhered to:

aa) allowable primary membrane stress intensity

Pm,zul = 0.7 ⋅ RmT (5.7-7)

ab) allowable primary membrane plus primary bending stress intensity

Pm+b,zul = 1.0 ⋅ RmT (5.7-8)

with RmT : Tensile stress at handling temperature

b) An experimental analysis to clause 5.7.3 shall be per-formed to prove that

Lmax ≤ 0.8 ⋅⋅⋅⋅ LU (5.7-9)

where

Lmax : fÜ ⋅⋅⋅⋅ dead weight (design load)

fÜ : load intensification factor due to load shifting

LU : rupture load or maximum load applied in the test

c) the deformations shall be limited such that the hold func-tion of the load attaching point is maintained.

5.8 Analytical proof using the finite element method

5.8.1 General

(1) Besides the analytical proofs described in Sections 5.2 to 5.4 and 5.7 it is also permitted to perform strength analyses on the basis of the finite element method (FEM).

(2) When using the finite element method, the requirements of KTA 3201.2, Annex B3 shall be met.

(3) The requirements of Section 5.8.2 apply to the stress analysis using the finite element method in connection with the evaluation based on nominal stresses.

Note: As regards the procedure to be followed for components where a stress evaluation based on nominal stresses is not purposeful, re-fer to sub-clause 5.1.2 (3).

(4) Deviating from the stipulations in clause 5.8.2 a suitable stress limitation procedure shall be fixed, e.g. in accordance with VDI 2230, Sheet 1, Guideline BAM-GGR 012.

(5) The requirements of Section 5.7 apply to the stress limi-tation for load attaching points on core components.

5.8.2 Stress analysis


(1) Stresses shall be classified in dependence of the cause of stress and its effect on the mechanical behaviour of the structure as per KTA 3201.2, Sec. 7.7.2 into stress catego-ries, i.e. primary stresses, secondary stresses and peak stresses and be limited in different ways with regard to their classification.

(2) Remote from discontinuities only primary stresses shall be considered.

(3) Primary stresses (P) are stresses which satisfy the laws of equilibrium of external forces and moments (loads). Here, membrane stresses (Pm) are defined as the average value of the respective stress component over the section governing the load-bearing behaviour, in the case of plane load-bearing structures the average value of the respective stress compo-nent distributed across the thickness. Primary bending stresses (Pb) are defined as stresses that can be altered line-arly across the considered section and proportionally to the distance from the neutral axis, in the case of plane load bear-ing structures as the portion of the stresses distributed across the thickness that can be altered linearly.

(4) The stress intensity shall be derived from the linearized individual stress.

(5) The location of linearization outside the area of influence of geometric discontinuities shall be selected such that

a) only primary stress portions are covered,

b) the maximum sum of primary stress portions is covered.

(6) The requirements of (5) a) und (5) b) are deemed to have generally been met if linearization is effected at a dis-tance sR ⋅ to the geometric discontinuity in which case R

and s are defined as follows:

a) shells (e.g. skirts, pipes) R : mean smallest radius of shell s : smallest wall thickness

b) bars and sections R, s : radius of bar or half the smallest dimension of

cross-section

c) other shapes

R : half the smallest dimension of flange, T-section, plate or round section, half the smallest leg width of angle section, radius of bore.

s : smallest wall thickness

Linearisation may also be effected at other distances, but a suitable analytical proof as regards compliance with the re-quirements of (5) a) and (5) b) shall be performed.

(7) The stress intensity derived from the linearized stress portions shall not exceed the following values for the load cases H, HZ and HS:

a) remote from discontinuity: as per DIN 15018-1

b) at the discontinuity:

ba) for load case H σv ≤ 0.8 · Rp0.2

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bb) for load case HZ σv ≤ 0.9 · Rp0.2

bc) for load case HS σv ≤ Rp0.2

with Rp0.2 : yield strength

(8) The stress limitation for σv at the discontinuity need not be satisfied if it can be proved by means of a limit analysis that the allowable lower limit loads as per KTA 3201.2, Sec-tion 7.7.4 are not exceeded in which case, for the purpose of calculating the lower bound collapse load, the following yield stress values shall be taken

a) in load case H: σF = 1.2 ⋅ Rp0.2

b) in load case HZ: σF = 1.32 ⋅ Rp0.2

c) in load case HS: σF = 1.44 ⋅ Rp0.2

and the specified load shall not exceed 67 % of the lower bound collapse load in accordance with KTA 3201.2, Section 7.7.4.1.

(9) For the evaluation as per (7) the stress intensity to be taken shall be the maximum of

a) the stress intensity to the von Mises theory and

b) the largest principal stress.

(10) For the allowable stresses of welds DIN 15018-1 shall apply.


(1) The analysis for cyclic operation when using specific strength analyses differs from the procedures under Sections 5.1 to 5.3 only with respect to the determination of the nomi-nal stress. Here, the stress intensity determined by means of a general stress analysis shall be evaluated on the basis of the linearized individual stress components.

(3) The analysis for cyclic operation shall be performed in accordance with Sections 5.1 to 5.3 using the safety factors specified there.

(4) The fatigue strength reduction factor may also be deter-mined on the basis of a FEM analysis alternatively to the re-quirements of Section 5.3. In this case, the fatigue strength reduction factor is calculated to be conservative and is formed by the quotient of maximum stress intensity (non-linerarized) and the stress intensity derived from primary membrane and bending stresses as per subclause (1).

6 Materials

6.1 Manufacture

The materials used for load attaching points to Sections 4.2 to 4.4 shall be manufactured to meet the basic requirements specified in Section 3 of KTA 1401.

Note: The qualification of the materials manufacturer is deemed to have been proved e.g. if

a) the manufacturer is accepted to VdTÜV instruction sheet 1253/1,

b) the product is a regulated construction product or a non-regulated construction product which bears the specimen mark of conformity (Ü mark of conformity).

6.2 Selection of Materials

6.2.1 General

(1) The selection of materials shall be based, in addition to the strength characteristics (yield point, tensile strength) gov-erning the dimensioning, also on the toughness characteris-tics (resistance to brittle fracture) and, if necessary, on the suitability for welding, the loading capacity in thickness direc-tion and where required the corrosion resistance.

(2) In the case of bolted connections a suitable combination of materials shall be used. For the coating of ferritic bolts and nuts the following applies:

a) The requirements of DIN 18800-7 (items 518 and 519) shall be met.

b) Besides hot dip galvanized coatings other metallic corro-sion-protection coatings may be used if

ba) the compatibility with the steel is ensured and

bb) hydrogen-induced embrittlement is precluded and

bc) proof of adequate tightening characteristics is provided.

c) Electrogalvanized bolts of property classes 8.8 and 10.9 shall not be used.

(3) The filler metals and consumables shall have been ap-proved to VdTÜV instruction sheet 1153.

6.2.2 Materials in accordance with Annex A

(1) Materials tests are represented in the form of materials test sheets in Annex A for the usually employed materials; the materials shall be within the dimensional range as speci-fied in the quality standards.

(2) The requirements of sub-clause 6.2.1 (2) shall also apply to bolts listed under material test sheet WPB 14.

(3) Acceptance inspection certificates 3.2 shall be confirmed or be established by the respective authorized inspector as per clause 2 (2) or by the technical inspecting agency tasked by him.

(4) Instead of acceptance inspection certificate 3.1 to DIN EN 10204 (2005-01) acceptance inspection certificate 3.1.B to DIN EN 10204 (1995-08) will be recognized.

(5) Instead of acceptance inspection certificate 3.2 to DIN EN 10204 (2005-01) acceptance inspection certificate 3.1.C to DIN EN 10204 (1995-08) will be recognized.

6.2.3 Other materials

(1) Other materials and dimensional limits than those speci-fied in the materials test sheets under Annex A are only per-mitted if corresponding materials test sheets have been com-piled and have been subjected to design approval.

(2) Where materials are used for which no allowable stress-es are specified in the generally valid engineering standards, the allowable stresses for the general stress analysis and analysis for cyclic operation shall be derived by theoretical analysis or from realistic experiments.

6.3 Testing of materials

(1) The tests specified in the materials test sheets under Annex A shall be conducted and certified in accordance with their classification.

(2) The test results shall meet the specified requirements.

6.4 Materials identification marking

(1) The materials identification marking of the product forms shall be maintained during processing.

(2) The transfer of markings on product forms for further processing shall, in the case of a classification in accordance with Section 4.2, be checked by the manufacturer’s employee authorized to transfer identification marks and, in the case of a classification in accordance with Section 4.3, by the author-ized inspector.

(3) Where during further processing of product forms no material identification mark can be applied for operational or fabrication-dependent reasons, production-accompanying measures shall be taken to ensure that unambiguous identifi-cation and traceability is possible.

KTA 3905

7 Design approval

7.1 Required documents

(1) The documents specified below shall be submitted in clear and checkable form for design approval by the author-ized inspector.

Note: In the case of components to be tested under building legislation, the design approval in accordance with this Safety Standard is conducted as a static test.

In the case of components subject to approval under traffic legis-lation, the design approval in accordance with this Safety Stand-ard is carried out within the framework of type testing under traffic legislation.

(2) A cover sheet shall list the individual design approval documents in addition to the exact designations of the parts, sub-units or components to be subjected to design approval. It shall also contain a table on the state of the latest revisions and a list of all KTA Safety Standards and specifications ap-plicable to design, manufacture and testing as well as any testing, inspection and work instructions.

7.1.1 Load attaching points in acc. with Section 4.2 or 4.3

7.1.1.1 Design data sheet

The design data sheet shall contain the following data:

a) classification of the load attaching point,

b) dead weight of the load and specifications regarding the centre of gravity, point of load application and direction of forces as well as temperatures, fluids and radiological ex-posure which may impair the material characteristics,

c) loads resulting from shifting of the load due to a failure of a component of the lifting equipment in accordance with Sec. B 2.1.2 KTA 3902 in the case of increased require-ments.

d) in case of joints with pre-tensioned bolts which, after dis-assembly, have to be re-assembled again:

Indication of the number of disassembly and re-assembly operations and on intended tests and examinations prior to re-using them (e.g. visual examination, check of load-bearing bolts and related nut threads by ring and plug gauges).

7.1.1.2 General arrangement drawings, detailed drawings and parts lists with material data

The general arrangement drawings, detailed drawings and parts lists with material data shall contain the following data:

a) location and arrangement of the load attaching points,

b) description of the delimitation between load attaching point and load,

c) dimensions for strength calculation,

d) correlation of the individual parts to the materials test sheets,

e) type of fasteners, specifications in the case of bolted joints pre-tensioned as specified.

7.1.1.3 Strength calculations

The strength calculations shall contain the following data:

a) stress, strength and safety analyses for all components in the lines of force up to and including the connection of the load attaching point to the load,

b) Indication of model structure and quotation of program description, insofar as the calculations are made using da-ta processing systems,

c) stress-strain measurement program if this is planned to supplement the calculations.

7.1.1.4 Materials test sheets

For materials not listed in Annex A materials test sheets with the following data shall be established:

a) identification number of the materials test sheet,

b) product form,

c) material designation,

d) test requirements for the material with indication of the extent of testing and the certification in accordance with DIN EN 10 204,

e) identification marking of the material.

7.1.1.5 Welding procedure sheet

The welding procedure sheet shall contain the following data:

a) type of weld seams and their assignment,

b) base metals, weld filler metals and consumables,

c) welding procedure and welder’s certification,

d) heat treatment,

e) welder’s qualification,

f) evaluation group,

g) welding data.

Note: As regards design approval documents required for production tests see Section 8.1.

7.1.1.6 Test instructions for non-destructive examinations

(1) Test instructions shall be established for non-destructive examinations, where required in Section 8 or Annex B.

(2) These instructions may be established for identical test objects in standardized form.

(3) The test instructions shall contain detailed information on:

a) assignment to the individual test objects,

b) time of testing as far as it influences the extent and per-formance of the test in accordance with the test and in-spection sequence plan,

c) test requirements, test methods and test facilities/equip-ment to be used, type of sensitivity adjustment for ultra-sonic testing,

d) if required, additional explanations regarding the perfor-mance of the test (e.g. drawing to scale),

e) reference system and counting direction for a description of indications assigned to a test object,

f) information for recording and evaluating of indications,

g) intended substitute measures to be taken if the applicabil-ity of the requirements of Annex B is restricted.

7.1.1.7 Test and inspection sequence plan for final inspec-tion

(1) The test and inspection sequence plan shall contain the following data:

a) requirements and extent of the tests and inspections in accordance with Section 8,

b) test and inspection sequence as well as type of tests and inspections and certificates,

c) person performing the test or inspection (manufacturer, authorized inspector).

(2) As regards the sequence of performance of tests and inspections, the test and inspection sequence plan shall be subdivided into test and inspections to be performed prior to, during and upon finalization of production.

(3) Where required due to the complexity of tests and in-spections, the test and inspections listed under Table 8-1

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shall be subdivided into individual test and inspection steps in the test and inspection sequence plan.

7.1.1.8 Test and inspection sequence plan for the ac-ceptance test

The test and inspection sequence plan shall contain the fol-lowing data:


b) test and inspection sequence.

7.1.1.9 Test and inspection sequence plan for in-service inspections

The test and inspection sequence plan shall contain the fol-lowing data:


b) intervals between tests and inspections.

7.1.2 Load attaching points in acc. with Section 4.4

7.1.2.1 Drawings, parts lists and specifications

The general arrangement drawings, detailed drawings, parts lists and specifications shall contain the following data:

a) dimensions for strength calculation of load attaching points,

b) material data to make assignment of individual parts to the materials test sheets possible,

c) type of fasteners, specifications in the case of bolted joints pre-tensioned as specified.

7.1.2.2 Strength calculations

The strength calculations shall contain the following data:

a) location and arrangement of the load attaching points,

b) description of the delimitation between load attaching point and load,

c) dead weight of the load and indication of the point of load application and direction of forces as well as tempera-tures, fluids and radiological exposure which may impair the material characteristics,

d) stress, strength and safety analyses for the load attaching point,

e) Indication of model structure and quotation of program description, insofar as the calculations are made using da-ta processing systems,

f) description of the test program and test results in the case of experimental analysis.

7.1.2.3 Materials test sheets

For materials not listed in Annex A materials test sheets with the following data shall be established:

a) identification number of the materials test sheet,

b) product form,

c) material designation,

d) test requirements for the material with indication of the extent of testing and the certification in accordance with DIN EN 10204,

e) identification marking of the material.

7.1.2.4 Welding procedure documentation

Where a welding procedure is applied during fabrication of the load attaching point, a document shall be established to spec-

ify the applied welding procedure qualification requirements. These requirements comprise the establishment of welding procedure sheets, the performance of welding procedure qualification and, where required, the welder’s qualification in the case of manual welding.

Note: As regards design approval documents required for production tests see Section 8.1.

7.1.2.5 Test and inspection documents

The tests and inspections to be performed by the manufactur-er shall be fixed.

7.2 Procedure

(1) The documents submitted in accordance with Sec-tion 7.1.1 or 7.1.2 shall be checked for:

a) completeness,

b) correspondence of the data with the specified values and requirements,

c) compliance with the licensing provisions and requests of the supervisory authority.

(2) The documents submitted in accordance with Sec-tions 7.1.1.1 and 7.1.1.2 shall, additionally, be checked for:

a) accessibility of the load attaching points for maintenance and repair work and for in-service inspections,

b) correspondence of the data regarding materials in the parts lists and in the associated materials test sheets.

(3) The documents submitted in accordance with Sec-tions 7.1.1.3 and 7.1.2.2 shall, additionally, be checked for:

a) correctness and completeness of the load assumptions,

b) correctness and completeness of the calculations,

c) observance of the allowable stresses and safety factors.

(4) The materials test sheets compiled in accordance with Sections 7.1.1.4 and 7.1.2.3 shall be checked for correctness with regard to the extent of testing and type of certification.

(5) The welding procedure sheet submitted in accordance with Sections 7.1.1.5 and 7.1.2.4 shall be checked with regard to the suitability of the intended welding procedure as well as to the correctness and completeness of the data.

7.3 Certification of design approval

(1) The authorized inspector shall establish a certificate on the performance of the design approval and the results ob-tained.

(2) In the event of a positive result, the design approval is regarded as concluded upon submission of this certificate.

8 Final inspection

8.1 General

(1) Prior to the beginning of production, the observance of the following requirements regarding manufacture shall be proved:

a) confirmation of the manufacturer’s ability to meet the quality assurance requirements to KTA 1401,

b) attestation of qualification to DIN 18800-7, Class E, with extension to the requirements of DIN 15018-2 (the attesta-tion of qualification shall be provided on the basis of weld-ing procedure qualifications to DIN EN ISO 15614-1),

c) welders’ approval test certificates,

d) certification of supervisory personnel and NDT personnel,

e) suitability of production, measuring and test facilities,

f) validity of marking-transfer certificate,

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g) calibration of welding equipment and heat treatment facili-ties,

h) suitability of the devices for measuring the tightening pa-rameters of bolted joints.

(2) Where materials and welding procedures are used which are not part of the welder's qualification in accordance with clause (1) b), welding procedure qualifications to DIN EN ISO 15614-1 shall be submitted. If no principal rules for the performance of welding procedure qualifications are available for welded joints between certain materials, production tests shall be performed to design-approved documents within the scope of final inspection.

(3) Deviations from the design-approved documents are only permitted by agreement with the authorized inspector.

8.2 Load attaching points in acc. with Section 4.2 or 4.3

8.2.1 General

Within the final inspection the correspondence of the design approval documents with the construction of the load attach-ing point shall be checked.

8.2.2 Documents

The following documents shall be available:

a) test and inspection sequence plan for the final inspection in accordance with 7.1.1.7,

b) detailed drawings and parts lists with data on materials,

c) materials documentation,

d) certificate concerning the transfer of markings on product forms in accordance with Section 6.4,

e) welding procedure sheets in accordance with 7.1.1.5,

f) certificates on the suitability for welding in accordance with 8.1,

g) test instructions.

8.2.3 Extent of tests and inspections

The extent of the tests prior to the beginning of production is specified in Section 8.1, the extent of final inspection on the components shall be taken from Table 8-1. The non-destructive tests shall be conducted in accordance with An-

nex B. The manufacturer shall perform 100 % of the tests. The tests and inspections to be performed by the authorized inspector are specified for the individual test and inspection steps in Table 8-1.

8.2.4 Certification of final inspection

(1) The authorized inspector shall establish a certificate on the performance of the final inspection and the results ob-tained.

(2) In the event of a positive result, the final inspection is regarded as concluded upon submission of this certificate.

8.3 Load attaching points in acc. with Section 4.4

8.3.1 General

Within the final inspection the correspondence of the design approval documents with the construction of the load attach-ing point shall be checked.

8.3.2 Documents

The following documents shall be available:

a) drawings, parts lists and specifications,

b) test and inspection documents in accordance with 7.1.2.5,

c) materials documentation in accordance with materials test sheets,

d) welding procedure qualifications to 7.1.2.4,


The type and extent of the tests and inspections to be per-formed by the manufacturer shall be taken from the related specification. The extent of tests and inspections by the au-thorized inspector are specified in Table 8-1.

8.3.4 Certification of final inspection

(1) The type of certificate of the tests and inspections to be performed by the manufacturer shall be laid down in the spec-ification.

(2) The authorized inspector shall establish a certificate on the performance of the final inspection and the results ob-tained.

(3) In the event of a positive result, the final inspection is regarded as concluded upon submission of this certificate.

9 Acceptance test


9.1.1 General

Before the load attaching point is put into service an ac-ceptance test shall be conducted by the authorized inspector to prove that the load attaching point in its ready-for-operation condition meets the requirements with regard to load-carrying capacity and functional capability.

9.1.2 Documents

The following documents shall be available for the acceptance test:

a) test and inspection sequence plan for the acceptance test in accordance with 7.1.1.8,

b) documentation of the tests and inspections in accordance with Sections 7 and 8 with the associated test certificates.


(1) The extent of the tests and inspections is shown in Ta-

ble 9-1.

(2) Tests already conducted and documented within the framework of the final inspection may be dispensed with in the acceptance test.

9.1.4 Certification of acceptance test

(1) The authorized inspector shall establish a certificate on the performance of the acceptance test and the results ob-tained.

(2) In the event of a positive result, the acceptance test is regarded as concluded upon submission of this certificate.


For load attaching points on core components an acceptance test is not required.

KTA 3905 Page 6

10 In-service inspections


10.1.1 General

(1) Unless otherwise specified, the in-service inspections shall be conducted by the licensee in test intervals as speci-fied in 10.1.3. The inspection dates shall be agreed upon in good time between the licensee and the authorized inspector.

(2) If the in-service inspections lead to the detection of de-fects on load attaching points, a new inspection to an extent related to the size of the repaired defects is required after repair. The period for repair of the defects shall be agreed upon with the authorized inspector.

10.1.2 Documents

In addition to the test and inspection sequence plan for in-service inspections the following documents shall be availa-ble:

a) test instructions to KTA 1202,

b) certificate of the last in-service inspection; the acceptance test certificate shall be submitted for the first in-service in-spection,

c) records on all maintenance and repair work carried out,

d) records on the number of transports carried out since the last in-service inspection in the case of load attaching points on loads transported inside and outside the nuclear power plant.

Note: A transport means the entire cycle consisting of to-and-fro con-veyance to or from the site of the nuclear power plant.

e) in case of joints with pre-tensioned bolts:

records on disassembly and re-assembly and on the in-spections performed prior to re-using such bolts.

10.1.3 Inspection intervals

(1) The inspection intervals are specified under Table 10-1. If other inspection intervals are specified for the component assigned to the load attaching point in KTA Safety Standards (e.g. KTA 3201.4), intervals deviating from Table 10-1 may be specified in the test and inspection sequence plan.

Note: The necessity of co-ordinating the inspection intervals laid down for the components is derived from operational boundary conditions, e.g. accessibility, radiation protection.

As the test and inspection plan is subject to design approval, the presence of the authorized inspector in the tests and in-spections is ensured.

(2) If load attaching points on loads are not used for an in-terval longer than that between two in-service inspections specified in Table 10-1, it is permitted to conduct the next in-service inspection, at the latest, prior to the next use of these load attaching points.

10.1.4 Performance of tests and inspections

(1) The extent of the tests and inspections is specified under Table 10-1.

(2) The following requirements apply to visual examinations for condition monitoring:

a) Visual examinations shall preferably be performed as di-rect examinations to DIN EN 13018.

b) The examinations shall be performed as local visual ex-aminations.

c) The test personnel shall meet the requirements of DIN EN 13018 and shall have been qualified and certified to DIN EN 473.

d) Deviations from the specified conditions shall be docu-mented as noticeable condition and be evaluated.

e) Crack-like discontinuities are not permitted. Where discon-tinuities cannot be clearly identified they shall be subject-ed to a surface examination to Annex B.

(3) Non-destructive tests shall be conducted in accordance with Annex B.

(4) If non-destructive tests are not possible because of local conditions (accessibility), regulations shall be specified by agreement with the authorized inspector in each individual case.

(5) The in-service inspections shall be performed in the presence of the authorized inspector.

10.1.5 Certification of in-service inspections

(1) The authorized inspector shall establish a certificate on the in-service inspections carried out.

(2) In the event of a positive result, the in-service inspection is regarded as concluded upon submission of this certificate.


For load attaching points on core components no in-service inspections are required.

11 Operation and maintenance


(1) The operating instructions shall be observed when using the load attaching points.

(2) The licensee shall take care to ensure that the tests specified in the test manual (in accordance with KTA 1202) are conducted properly and in time.

(3) The load attaching points shall be checked for obvious defects before each use. If defects impairing safety are de-tected, the load attaching points shall not be used before the defect has been repaired.

(4) Maintenance work shall be carried out such that safety is not impaired. Load attaching points not properly repaired shall not be used.

(5) Records containing at least the following data shall be kept on all maintenance work carried out:

a) unambiguous designation of the load attaching point,

b) type of maintenance work,

c) designation of the associated documents.

(6) The records of maintenance work shall be included in the documentation and submitted to the authorized inspector during the in-service inspections in accordance with Sec-tion 10.

(7) The records on disassembly and re-assembly work done on joints with pre-tensioned bolts and on the tests and inspec-tions performed prior to re-using such bolts, shall be added to the documentation and be submitted to the authorized inspec-tor during the in-service inspections to Section 10.

(8) The design approval in accordance with Section 7 may be omitted for those parts to be newly installed which are manufactured exclusively in accordance with the design ap-proval documents of the initial construction. The materials test shall be conducted in accordance with Section 6, the final inspection in accordance with Section 8 and the acceptance test in accordance with Section 9.

In the case of replacement of bolts in the lines of force of the load attaching point (LAP) by new ones, a new load test in

KTA 3905 Page 7

accordance with Table 9-1 may be omitted, provided, less than 50 % of the bolts at the LAP are replaced.


(1) The operating instructions shall be observed when using the load attaching points.

(2) Repair shall be carried out in accordance with a qualified procedure and be documented accordingly.

12 Documentation

12.1 General

The documentation shall ensure that all monitored manufac-turing processes and tests, in-service inspections and maintenance tasks in accordance with Sections 6 to 11 can be traced back.

12.2 Compilation of documents

(1) The documents shall be compiled in accordance with the requirements of KTA 1404.

(2) The compiled documents shall include the design ap-proval documents as well as all proofs, records and certifica-tions which confirm the actual condition and the tests and inspections carried out.

12.3 Procedure of documentation

(1) Documentation of manufacturing documents shall ac-company the manufacturing process. The manufacturer shall ensure that the documentation, including that of sub-contractors, is complete.

(2) The licensee is responsible for the continued documen-tation of maintenance and in-service inspections, unless pro-vided otherwise in individual cases.

KTA 3905 Page 8

Inspection by authorized inspector

Test / Inspection Additional requirements to Section 4.2

Increased requirements to Section 4.3

Core components to Section 4.4

a) Receiving inspection of identification marks and stampings, if any, on the product forms

b) Material identification marks of components for compliance with parts list to Section 6.4 X X X

c) For tensile-loaded components (in thickness direction) an ul-trasonic test for detecting laminations in weld-junction areas 25 % 25 %

d) Check for compliance of the location, arrangement, dimen-sions and assembly with design approval documents X X X

e) Check of threads on load-bearing bolts and nuts with addi-tional tensile load using thread ring gauge and thread plug gauge to DIN ISO 965-2

X

f) Observation of welding data 25 % 25 % X

g) Visual examination of welds 25 % 25 % X

h) Non-destructive testing of load-bearing welds 1):

- Examination of surfaces

25 %

25 %

X

- Ultrasonic test or radiography:

For butt welds between ferritic steels with wall thicknesses equal to or smaller than 15 mm radiography shall prefera-bly be used, if the wall thickness is equal to or greater than 8 mm alternatively ultrasonic testing; for wall thicknesses greater than 15 mm and equal to or smaller than 40 mm ultrasonic testing shall preferably be used, alternatively ra-diography. For wall thicknesses exceeding 40 mm ultra-sonic testing shall be used.

For all wall thicknesses of austenitic butt welds radiography shall be used.

For attachment welds the test procedure shall be laid down in a test instruction. In the case of austenitic attachment welds radiographic examinations shall be preferred.

25 % 2) 100 % 2)

i) Examination of repair welds in acc. with a design-approved repair welding procedure specification or a qualified welding procedure

X

X

X

j) Examination of surfaces within the area of machined surfac-es in finished condition 25 % 100 %

k) Examination of the bolting torque of pre-tensioned bolted joints in accordance with DIN 18800-7 unless specified otherwise in the design approval documents

10 %

10 %

X

l) Where ultrasonic testing is to be carried out as in-service inspection in lieu of an examination of surfaces, an ultrason-ic test as basic inspection shall additionally be carried out on lifting lugs, bolts, tie-rods and similar components in their finished condition. The type and extent of this basic inspec-tion shall be fixed in an inspection instruction.

X

X Inspection by authorized inspector, i.e. partial inspection to enable the inspector to confirm that the objectives of the respective inspec-tion stage have been attained.

No inspection by the inspector.

% Percentage share of inspection by the authorized inspector. 1) Where the stress level in the weld does not exceed 30 % of the allowable stress, no examination is required. 2) Where the weld quality has to be verified.

Table 8-1: Extent of final inspection

KTA 3905 Page 9

No. Test object Tests and inspections Performance

1 Bolted-on LAP a) Identification marking

b) Visual inspections

c) Correct assembly

d) Loading test 1.25 times the load to be absorbed by the LAP. If the load is applied statically, a 1.5 times high-er test load shall be applied

e) Functional test with the load carrying at-tachment or load attachment rigging

f) Examination of bolting torque after the load test

DIN 18800-7 unless specified otherwise in the design approval documents

g) In the case of load attaching points in ac-cordance with Section 4.3:

examination of surfaces (alternatively ultra-sonic examination 1) on all surfaces in the lines of force (e.g. weld seams, lifting lugs, bolts, tie-rods and similar components) after the load test

in accordance with Annex B

2 Welded-on LAP and LAP as integral part of the load

a) Identification marking

b) Visual inspection

c) Correct location and arrangement

d) Loading test 1.25 times the load to be absorbed by the LAP. If the load is applied statically, a 1.5 times high-er test load shall be applied


f) In the case of load attaching points in ac-cordance with Section 4.3:

examination of surfaces (alternatively ultra-sonic examination 1) on all surfaces in the lines of force (e.g. weld seams, lifting lugs, bolts, tie-rods and similar components) after the load test


3 LAP anchored in the concrete struc-tural part

a) Identification marking

b) Visual inspection

c) Correct location and arrangement

d) Loading test 2) 1.25 times the load to be absorbed by the LAP. If the load is applied statically, a 1.5 times high-er test load shall be applied


f) Check on the concrete surface in the load application areas for inadmissible crack formation

g) In the case of load attaching points in ac-cordance with Section 4.3:

examination of surfaces (alternatively ultra-sonic examination 1) on all surfaces in the lines of force which remain accessible after concreting (e.g. weld seams, lifting lugs, bolts, tie-rods and similar components) after the load test


1) See Table 8-1 l) 2) Taking clause 5.5.1.2 (4) into account

Table 9-1: Extent of acceptance testing

KTA 3905 Page 10

No. Test object Tests and inspections

Intervals between inspections

LAP of loads used only inside the nuclear power

plant

LAP of loads used inside and outside the nuclear power plant and also subject to

traffic legislation

Section 4.2 Section 4.3 Section 4.2 Section 4.3

1 Bolted-on LAP

a) Condition, deformations, wear, corrosion

1 year 1 year 15 transports, at the latest after 3 years

15 transports, at the latest after 3 years

b) Smooth engagement of movable parts

c) Bolting torque of bolted joints in accordance with DIN 18800-7 unless specified otherwise in the design approval documents

d) Check for adherence to the allowable num-ber of disassembly and re-assembly opera-tions on pre-tensioned bolts as laid down in the design approval documents

e) Check of threads on load-bearing bolts and nuts with additional tensile load using thread ring gauge and thread plug gauge to DIN ISO 965-2 (random)


f) Examination of surfaces (alternatively ultra-sonic examination 1)) on all surfaces in the lines of force (e.g. weld seams, lifting lugs, bolts, tie-rods and similar components)

3 years 2)


g) Condition, deformations (e.g. by means of check as per serial no. 1 e), wear, corrosion after dismantling the LAP

3 years 3)


h) Load test in the assembled condition (see Table 9-1 No. 1d)


i) Examination of surfaces (alternatively ultra-sonic examination 1)) on all surfaces in the lines of force (e.g. weld seams, lifting lugs, bolts, tie-rods and similar components) after the load test

2 Welded-on LAP and LAP as integral part of the load



15 transports, at the latest after 3 years b) Smooth engagement of movable parts

c) Examination of surfaces (alternatively ultra-sonic examination 1)) on all surfaces in the lines of force (e.g. weld seams, lifting lugs, bolts, tie-rods and similar components)

3 years 2)


3 LAP an-chored in the concrete structural part




b) Inadmissible crack formation on the concrete surface in the load application area

c) Smooth engagement of movable parts

d) Examination of surfaces (alternatively ultra-sonic examination 1)) on all surfaces in the lines of force which remain accessible after concreting (e.g. weld seams, lifting lugs, bolts, tie-rods and similar components)

3 years 2)


1) See Table 8-1 l) 2) 6 years where it is proved in each individual case that for these components utilization reserves

5.1nutilizatioofperiodltheoreticaofportionconsumed

nutilizatioofperiodltheoretica

S

D>=

are available for the intended service life. See BGV D8 – Accident Prevention Regulations - Performance instruction Annex A for the de-termination of D and S. When determining D and S the same load shall always be used as reference load.

This does not apply to components made of austenitic materials where the risk of stress corrosion cracking may occur. 3) 6 years for bolted joints that will not be disassembled for operational reasons.

Table 10-1: Extent and test intervals of in-service inspections

KTA 3905 Page 11

Annex A

Materials test sheets (WPB)

WPB Load attaching points

1 Hot rolled plates and sheets, strips, wide flats and steel sections of structural carbon steel to DIN EN 10025-2

2 Hot rolled bars made of structural carbon steels to DIN EN 10025-2

3 Forged bars and open-die forgings made of general structural steels to DIN EN 10250-2

4 Welded tubes made of carbon steels to DIN EN 10217-1

5 Seamless tubes made of carbon steels to DIN EN 10216-1

6 Seamless or welded hot finished hollow sections of structural carbon steels to DIN EN 10210-1

7 Bars and forgings made of quenched and tempered steels to DIN EN 10083-2, DIN EN 10083-3 or SEW 550

8 Plates, sheets and strips made of austenitic steels to DIN EN 10088-2 and of ferritic-austenitic steels to DIN EN 10028-7

9 Bars and forgings made of austenitic steels to DIN EN 10088-3 or DIN EN 10250-4 and of ferritic-austenitic steels to DIN EN 10222-5 or DIN EN 10272

10 Seamless tubes made of austenitic steels to DIN EN 10216-5

Note: Material instruction sheet WPB 11 was deleted.

12 Bolts and nuts ≤ M 39 to DIN EN ISO 898-1, DIN EN ISO 898-2 and DIN EN ISO 3269

13 Bolts and nuts made of austenitic steels to DIN EN ISO 3506-1, DIN EN ISO 3506-2 and DIN EN ISO 3269

14 Bolts and studs, thread rolled, head bolts with forged-on head, and subsequently heat-treated

15 Welded tubes made of austenitic steels to DIN EN 10217-7

16 Bars and forgings made of stainless martensitic steels to DIN EN 10088-3 or DIN EN 10250-4

17 Plates, sheets and strips made of zirconium alloys

18 Forged bars and open-die forgings made of weldable fine grain structural steel to DIN EN 10222-4

KTA 3905 Page 12

Materials test sheet 1: Hot rolled plates and sheets, strips, wide flats and steel sections of structural carbon steel to DIN EN 10025-2

MATERIALS TEST SHEET WPB 1

Load attaching points

Product form: Hot rolled plates and sheets, strips, wide flats and steel sections

Materials: S235J0 (1.0114), S235J2 (1.0117), S235JR (1.0038), S355J2 (1.0577), S355K2 (1.0596)

Requirements: DIN EN 10025-1, DIN EN 10025-2 1), DIN EN 10164

Tests and inspections

Certificate to DIN EN 10204 (2005-01) 2) for

additional requirements to Section 4.2

increased requirements to Section 4.3

1. Chemical composition:

Ladle analysis

3.1

3.1

2. Attestation of heat treatment condition or of as-delivered condition

3.1

3.1

3. Tensile test at room temperature:

3.1 One specimen per melt and test unit

3.1

3.2

3.2 Three tensile specimens in thickness direction for product thicknesses > 20 mm and tensile loading in thickness direction:

Test unit to DIN EN 10164 3) Quality grade Z 25 to DIN EN 10164

3.1

3.2

4. Notched bar impact test at test temperature to DIN EN 10025-2:

One set of impact test specimen per tensile test spec-imen as per no. 3.1 as far as the nominal dimension is ≥ 6 mm

3.1

3.2

5. Visual inspection and dimensional check:

Each component

3.1

3.2

See Table 8-1 c) regarding ultrasonic testing of components under tensile loading in thickness direction.

Products with thicknesses ≥ 6 mm shall at least meet the requirements of quality class S1 to DIN EN 10160 for the plane surface and E1 for the edge zone.

Material identification:

Manufacturer's mark, steel grade, melt number, specimen number or identification number (the plate, sheet or strip number may also be used as specimen number), inspector's mark, Z 25 (if demonstrated)

1) Repair welding is not permitted. 2) See clause 6.2.2 as to the use of acceptance inspection certificates to DIN EN 10204 (1995-08). 3) Where the materials S235J0 and S235JR are loaded in thickness direction, the test shall be performed on each rolled panel in acc.

with test no. 3.2.

KTA 3905 Page 13

Materials test sheet 2: Hot rolled bars made of structural carbon steels to DIN EN 10025-2



Product form: Hot-rolled bars

Materials: S235J0 (1.0114), S235J2 (1.0117), S235JR (1.0038), S355J2 (1.0577), S355K2 (1.0596)

Requirements: DIN EN 10025-1, DIN EN 10025-2 1)






Ladle analysis

3.1

3.1


3.1

3.1


One specimen per melt and test unit

3.1

3.2

4. Notched bar impact test at test temperature to DIN EN 10025-2 and nominal dimensions to DIN EN 10025-1:

One set of impact test specimens per tensile test specimen

3.1

3.2


Each component

3.1

3.2

6. Ultrasonic testing:

For bar steel with product thicknesses ≥ 30 mm each component subject to 100 % in acc. with Annex B

3.1

3.2


Manufacturer's mark, steel grade, melt number, specimen number or identification number, inspector's mark

1) Repair welding is not permitted. 2) See clause 6.2.2 as to the use of acceptance inspection certificates to DIN EN 10204 (1995-08).

KTA 3905 Page 14

Materials test sheet 3: Forged bars and open-die forgings made of general structural steels to DIN EN 10250-2



Product form: Forged bars and open-die forgings

Materials: S235JRG2 (1.0038), S235J2G3 (1.00116), S355J2G3 (1.0570)

Requirements: DIN EN 10250-1, DIN EN 10250-2 1)






Ladle analysis

3.1

3.1

2. Attestation of heat treatment condition 3.1 3.1


One specimen per melt and test unit

3.1

3.2


One set of impact test specimens per tensile test specimen, as far as the nominal dimension is ≥ 15 mm

3.1

3.2


Each component

3.1

3.2


For bar steel with product thicknesses ≥ 30 mm and forgings with a weight in final heat treatment condition ≥ 300 kg, each component subject to 100 % in acc. with Annex B

3.1

3.2




KTA 3905 Page 15

Materials test sheet 4: Welded tubes made of carbon steels to DIN EN 10217-1



Product form: Welded tubes

Materials: P235TR1 (1.0254), P235TR2 (1.0255), P265TR1 (1.0258), P265TR2 (1.0259)

Requirements: DIN EN 10217-1 1)

Tests and inspections Certificate to DIN EN10204 (2005-01) 2)

for additional requirements to Section 4.2


Ladle analysis

3.1


3.1

3. Tensile test at room temperature (base material):

Lot size and extent of testing in acc. with DIN EN 10217-1 no. 10.1, Table 12 and Table 13

3.1

4. Tensile test at room temperature transverse to the weld (at an outside diameter DA > 508 mm):

Lot size and extent of testing in acc. with DIN EN 10217-1 no 10.1, Table 12 and Table 13

3.1

5. Notched bar impact test at test temperature of 0 °C (base material) in the case of materials no. 1.0255 and 1.0259:

One set of impact test specimen per tensile test spec-imen

3.1

6. Flattening test or drift-expanding test:


3.1

7. Weld bend test on submerged-arc welded tubes:


3.1

8. Non-destructive testing of welds:

In acc. with DIN EN 10217-1 Section 11.11

3.1

9. Tightness test:

Each tube in acc. with DIN EN 10217-1 Sec. 11.8

3.1


Each tube

3.1


Manufacturer's mark, steel grade, melt number, specimen number or identification number, inspector's mark, type of tube in acc. with DIN EN 10217-1 Table 1

1) Repair welding in the base material is not permitted. 2) See clause 6.2.2 as to the use of acceptance inspection certificates to DIN EN 10204 (1995-08).

KTA 3905 Page 16

Materials test sheet 5: Seamless tubes made of carbon steels to DIN EN 10216-1



Product form: Seamless tubes

Materials: P235TR1 (1.0254), P235TR2 (1.0255), P265TR1 (1.0258), P265TR2 (1.0259)


Tests and inspections Certificate to DIN EN (2005-01) 2)

for additional requirements to Section 4.2


Ladle analysis

3.1


3.1



3.1

4. Notched bar impact test at test temperature of 0 °C in the case of materials no. 1.0255 and 1.0259:

One set of impact test specimen per tensile test spec-imen

3.1

5. Tightness test:


3.1


Each tube

3.1




KTA 3905 Page 17

Materials test sheet 6: Seamless or welded hot finished hollow sections of structural carbon steels to DIN EN 10210-1



Product form: Hot formed hollow sections (seamless or welded)

Materials: S275J0H (1.0149), S275J2H (1.0138), S355J0H (1.0547), S355J2H (1.0576)







Ladle analysis

3.1

3.1


3.1

3.1


One specimen per melt, test unit and nominal dimen-sion each

3.1

3.2



3.1

3.2


Each component

3.1

3.2

6. Non-destructive testing of weld:

Each component over its full length in acc. with DIN EN 10210-1 Section 9.4

3.1

3.2



1) Repair welding in the base material is not permitted. 2) See clause 6.2.2 as to the use of acceptance inspection certificates to DIN EN 10204 (1995-08).

KTA 3905 Page 18

Materials test sheet 7: Bars and forgings made of quenched and tempered steels to DIN EN 10083-2, DIN EN 10083-3 or SEW 550



Product form: Bars and forgings

Materials: Quenched and tempered steels to DIN EN 10083-2, DIN EN 10083-3 or SEW 550

Requirements: DIN EN 10083-1, DIN EN 10083-2 1), DIN EN 10083-3 1) or SEW 550


The performance of the following tests and inspections shall be verified for the quenched and tempered condition





Ladle analysis

3.1

3.1


3. Hardness test for verification of uniform heat treat-ment:

On one end of each component three measuring points each

3.1

3.1


One specimen per melt, dimensional range and heat treatment batch each

3.1

3.2

5. Notched bar impact test at room temperature:


3.1

3.2


Each component

3.1

3.2

7. Materials identification check for alloyed steels:

Each component, e.g. by spectroscopy

3.1

3.1


For bar steel with product thicknesses ≥ 30 mm and forgings with a weight in final heat treatment condition ≥ 300 kg each component subject to 100 % in acc. with Annex B

3.1

3.2




KTA 3905 Page 19

Materials test sheet 8: Plates, sheets and strips made of austenitic steels to DIN EN 10088-2 and of ferritic-austenitic steels to DIN EN 10028-7



Product form: Plates, sheets and strips

Materials: Austenitic steels to DIN EN 10088-2, X2CrNiMoN22-5-3 (1.4462) to DIN EN 10028-7

Requirements: DIN EN 10088-2 1), DIN EN 10028-7 1)



additional requirements to

Section 4.2

increased requirements to

Section 4.3

core components to Section 4.4


Ladle analysis

3.1

3.1

3.1

2. Attestation of heat treatment condition 3.1 3.1 3.1

3. Check for intergranular corrosion resistance 3):

One specimen per melt and heat treatment batch each

3.1

3.1

3.1


One specimen to DIN EN 10088-2 Table 21, in the case of X2CrNiMoN22-5-3 (1.4462) lot size and ex-tent of testing on acc. with DIN EN 10028-7 Table 16

3.1

3.2

3.1


One set of impact test specimen per tensile test spec-imen 4)

3.1

3.2

3.1


Each component; surface condition in acc. with man-ufacturer's specification

3.1

3.2

3.1

7. Material identification check:


3.1

3.1

3.1

See Table 8-1 ser. no. c) regarding ultrasonic testing of components under tensile loading in thickness direction.

Products with thicknesses ≥ 6 mm shall at least meet the requirements of quality class S1 to DIN EN 10160 for the plane surface and E1 for the edge zone.


Manufacturer's mark, steel grade, melt number, specimen number or identification number (the plate, sheet or strip number may also be used as specimen number), inspector's mark

1) Repair welding is not permitted. 2) See clause 5.1.5 as to the use of acceptance inspection certificates to DIN EN 10204 (1995-08). 3) According to DIN EN ISO 3651-2 procedure A sensitisation T1 or T2 (in the case of material 1.4462 only sensitisation T2) and only if

components are welded and are in contact with water. 4) Only for steel X2CrNiMoN22-5-3 (1.4462) as far as thickness of plate/sheet s ≥ 10 mm.

KTA 3905 Page 20

Materials test sheet 9: Bars and forgings made of austenitic steels to DIN EN 10088-3 or DIN EN 10250-4 and of ferritic-austenitic steels to DIN EN 10222-5 or DIN EN 10272




Materials: Austenitic steels to DIN EN 10088-3 or DIN EN 10250-4 as well as X2CrNiMoN22-5-3 (1.4462) to DIN EN 10222-5 or DIN EN 10272

Requirements: DIN EN 10088-3 1), DIN EN 10250-4 1), DIN EN 10222-5 1) or DIN EN 10272 1)




Section 4.2


Section 4.3



Ladle analysis

3.1

3.1

3.1

2. Attestation of heat treatment condition 3.1 3.1 3.1



3.1

3.1

3.1


One specimen to DIN EN 10088-3 Table 26 or DIN EN 10250-1 Section 11 or DIN EN 10222-1 Section 12 or DIN EN 10272 Table 13

3.1

3.2

3.1


Each component; surface condition in acc. with man-ufacturer's specification

3.1

3.2

3.1



3.1

3.1

3.1



3.1

3.2



1) Repair welding is not permitted. 2) See clause 6.2.2 as to the use of acceptance inspection certificates to DIN EN 10204 (1995-08). 3) According to DIN EN ISO 3651-2 procedure A sensitisation T1 or T2 (in the case of material 1.4462 only sensitisation T2) and only if

components are welded and are in contact with water.

KTA 3905 Page 21

Materials test sheet 10: Seamless tubes made of austenitic steels to DIN EN 10216-5



Product form: Seamless tubes

Materials: Austenitic stainless steels to DIN EN 10216-5

Requirements: DIN EN 10216-5 (test category 2) 1)






Ladle analysis

3.1

3.1




3.1

3.1


Lot size and extent of testing in acc. with DIN EN 10216-5 Table 15

3.1

3.2

5. Technological test procedures:

Type and extent of testing in acc. with DIN EN 10216-5 Table 15 and Table 16

3.1

3.2


Each tube, surface condition in acc. with manufactur-er's specification

3.1

3.2


Each tube, e.g. by spectroscopy

3.1

3.1

8. Non-destructive testing:

Type and extent of testing in acc. with DIN EN 10216-5 Table 15

3.1

3.2

9. Tightness test:

Each tube in acc. with DIN EN 10216-5 Table 15

3.1

3.1



1) Repair welding is not permitted. 2) See clause 6.2.2 as to the use of acceptance inspection certificates to DIN EN 10204 (1995-08). 3) According to DIN EN ISO 3651-2 procedure A sensitisation T1 or T2 and only if components are welded and are in contact with water.

Note: Material instruction sheet WPB 11 was deleted.

KTA 3905 Page 22

Materials test sheet 12: Bolts and nuts ≤≤≤≤ M 39 to DIN EN ISO 898-1, DIN EN ISO 898-2 and DIN EN ISO 3269



Product form: Bolts and nuts ≤ M 39

Materials: Property classes

Bolts 4.6, 5.6, 6.8, 8.8 and 10.9

Nuts 5, 8 and 10

Requirements: Bolts: DIN EN ISO 898-1, DIN EN ISO 3269, DIN EN 26157-3 (Testing of mechanical properties in accordance with DIN EN ISO 898-1, test series MP1 plus

additional re-tempering test in connection with DIN EN 26157-3. Where test series MP1 is not practicable, test series MP2 plus re-tempering test may be performed.)

Nuts: DIN EN ISO 898-2, DIN EN ISO 3269, DIN EN ISO 6157-2





Proof (by continuous recording in the manufacturer's works) that the requirements regarding mechanical proper-ties, surface condition and dimensional accuracy have been met

2.2 2) or 3.1 3)

2.2 2) or 3.1 3)


Bolts in acc. with DIN EN ISO 898-1

Nuts in acc. with DIN EN ISO 898-2

1) See clause 6.2.2 as to the use of acceptance inspection certificates to DIN EN 10204 (1995-08). 2) In lieu of the certificate 2.2 stamping will suffice if the manufacturer is recognized in acc. with VdTÜV instruction sheet 1253/4.

3) For bolts of property classes 8.8 and 10.9 as well as for nuts of property classes 8 and 10 a certificate 3.1 is required.

Materials test sheet 13: Bolts and nuts made of austenitic steels to DIN EN ISO 3506-1, DIN EN ISO 3506-2 and

DIN EN ISO 3269



Product form: Bolts and nuts ≥ M 10 and ≤ M 39

Materials: Property classes 50, 70 and 80

Steel group: A2, A3, A4 and A5

Requirements: DIN EN ISO 3506-1, DIN EN ISO 3506-2, DIN EN ISO 3269, DIN EN 26157-3, DIN EN ISO 6157-2




Section 4.2


Section 4.3


Proof (by continuous recording in the manufacturer's works) that the requirements regarding mechanical proper-ties, surface condition and dimensional accuracy have been met

2.2 2)

2.2 2)

2.2 2)


In acc. with DIN EN ISO 3506-1, DIN EN ISO 3506-2

1) See clause 6.2.2 as to the use of acceptance inspection certificates to DIN EN 10204 (1995-08). 2) In lieu of the certificate 2.2 stamping will suffice if the manufacturer is recognized in acc. with VdTÜV instruction sheet 1253/4.

KTA 3905 Page 23

Materials test sheet 14: Bolts and studs, thread rolled, head bolts with forged-on head, and subsequently heat-treated



Product form: Bolts and studs, thread rolled, head bolts with forged-on head, heat-treated

Materials: DIN EN 10083-2 and DIN EN 10083-3, DIN EN 10269, 1.4313 +QT780 to DIN EN 10088-3, SEW 400

Requirements: DIN EN 10083-1, DIN EN 10083-2, DIN EN 10083-3, DIN EN 10269, DIN EN ISO 3269, DIN EN 26157-1, DIN EN ISO 898-1, DIN EN 10088-3, SEW 400 and supplementary sheet to this materials test sheet





1. Tests on basic material (bar)

1.1 Chemical composition:

Ladle analysis

2.2

3.1

1.2 Materials identification check for alloyed steels:

Each bar

2.2

3.1

1.3 Ultrasonic testing:

For bars with thicknesses ≥ 30 mm each component in acc. with Annex B

3.1

3.2

2. Tests on finished parts based on DIN EN ISO 898-1:

2.1 Heat treatment condition including confirmation of dephosphorization

3.1

3.1

2.2 Hardness test for verification of uniform heat treat-ment on 10 % of all bolts and studs

3.1

3.1

2.3 Tensile test at room temperature:

Number of test specimen sets to DIN EN ISO 3269 and supplementary sheet to this materials test sheet 2)

3.1

3.2

2.4 Notched bar impact test at room temperature:

In the case of bolts and studs ≥ M16 one set of impact test specimen per tensile test specimen

3.1

3.2

2.5 Examination of surfaces:

Procedure and evaluation based on DIN EN 26157-1

3.1

3.2

2.6 Visual inspection and dimensional check:

In acc. with DIN EN ISO 3269 (number of random samples: 20) 2)

3.1

3.2

2.7 Test of edge decarburization and carburization 3):

Based on DIN EN ISO 898-1

Number of specimens to DIN EN ISO 3269 and sup-plementary sheet to this materials test sheet 2)

3.1

3.1


Manufacturer's mark, steel grade, melt number, inspector's mark

1) See clause 6.2.2 as to the use of acceptance inspection certificates to DIN EN 10204 (1995-08). 2) All specimens shall meet the requirements (acceptance number Ac = 0). 3) Not required for material 1.4313 +QT780.

Supplementary sheet to materials test sheet WPB 14: Sampling plan for destructive testing of mechanical properties

Number of pieces Number of specimen sets for mechanical testing

≤ 200 1

> 200 up to ≤ 400 2

> 400 up to ≤ 800 3

> 800 up to ≤ 1200 4

> 1200 up to ≤ 1600 5

> 1600 up to ≤ 3000 6

> 3000 up to ≤ 3500 7

> 3500 DIN EN ISO 3269

If it is proved that the bolts and studs delivered are of the same melt and heat treatment testing of 4 specimen sets irrespective of the number of pieces will suffice.

KTA 3905 Page 24

Materials test sheet 15: Welded tubes made of austenitic steels to DIN EN 10217-7



Product form: Welded tubes

Materials: Austenitic stainless steels to DIN EN 10217-7

Requirements: DIN EN 10217-7 (test category 2) 1)






Ladle analysis

3.1

3.1




3.1

3.1


Lot size and extent of testing in acc. with DIN EN 10217-7 Section 10.1 and Table 13

3.1

3.2

5. Technological tests:

Type and extent of testing acc. to DIN EN 10217-7 Tables 13 and 14

3.1

3.2


Each tube; surface condition in acc. with manufactur-er's specification

3.1

3.2


Each tube, e.g. by spectroscopy

3.1

3.1

8. Non-destructive testing:

Type and extent of testing acc. to DIN EN 10217-7 Section 11.11 and Table 13

3.1

3.2

9. Tightness test:


3.1

3.1



1) Repair welding in the base material is not permitted. 2) See clause 6.2.2 as to the use of acceptance inspection certificates to DIN EN 10204 (1995-08). 3) According to DIN EN ISO 3651-2 procedure A sensitisation T1 or T2 and only if components are welded and are in contact with water.

KTA 3905 Page 25

Materials test sheet 16: Bars and forgings made of stainless martensitic steels to DIN EN 10088-3 or DIN EN 10250-4




Materials: X17CrNi16-2 - QT800 (1.4057), X39CrMo17-1 - QT750 (1.4122), X3CrNiMo13-4 - QT780 (1.4313), X5CrNiCuNb16-4 - P800 (1.4542), X5CrNiCuNb16-4 - P930 (1.4542)

Requirements: DIN EN 10088-3 1) or DIN EN 10250-4 1)






Ladle analysis

3.1

3.1

2. Attestation of heat treatment condition (for 1.4313 indication of strength grade)

3.1

3.1


Test lot and extent of testing to DIN EN 10088-3 Table 26 or DIN EN 10250-1 Section 11

3.1

3.2


Test lot and extent of testing as for tensile test (only for nominal dimension ≥ 15 mm)

3.1

3.2

5. Hardness test for verification of uniform heat treat-ment:

On one end of each component three measuring points each

3.1

3.2


Each component, surface quality and dimensions in acc. with manufacturer's specification

3.1

3.2



3.1

3.1



3.1

3.2




KTA 3905 Page 26

Materials test sheet 17: Plates, sheets and strips made of zirconium alloys



Product form: Plates, sheets and strips with thicknesses s ≤ 4.7 mm

Materials: Zirconium alloys Grade R60802 or Grade R60804

Requirements: ASTM B352 / B352M-11




1. Chemical composition 2):

1.1 On the ingot (ladle analysis)

One specimen of head, middle and tail of each ingot

3.1

1.2 On the plate, sheet or strip (product analysis)

One specimen per lot (considered to be a material identification check)

3.1


One specimen in longitudinal and transverse direction each per lot in acc. with DIN EN ISO 6892-1 or ASTM 8 / E8M-11

3.1

3. Corrosion resistance

Two specimens per lot to ASTM G2 / G2M-11

3.1



3.1


Identification marking, melt number or ingot number or lot number, specimen number or plate, sheet, strip number respec-tively

1) See clause 6.2.2 as to the use of acceptance inspection certificates to DIN EN 10204 (1995-08).

2) The oxygen content is limited to 0.09 % up to 0.16 %.

KTA 3905 Page 27

Materials test sheet 18: Forged bars and open-die forgings made of weldable fine grain structural steel to DIN EN 10222-4



Product form: Forged bars and open-die forgings

Materials: P355QH1 (1.0571), P420QH (1.8936)

Requirements: DIN EN 10222-1 1) und DIN EN 10222-4 1)






Ladle analysis

3.1

3.1

2. Heat treatment condition 3.1 3.1


Test lot and extent of testing to DIN EN 10222-1 Sec-tion 12

3.1

3.2

4. Notched bar impact test at test temperature to DIN EN 10222-4 Table 3:

Test lot and extent of testing as for tensile test (only for nominal dimension ≥ 15 mm)

3.1

3.2



3.1

3.2



3.1

3.1



3.1

3.2


Manufacturer's mark, steel grade, melt number, specimen number, inspector's mark


KTA 3905 Page 28

Annex B

Non-destructive testing (NDT)

Contents

B 1 Scope .................................................................................................................................................... 29

B 2 General specifications .......................................................................................................................... 29

B 2.1 Personnel .............................................................................................................................................. 29

B 2.2 Equipment and test fluids ..................................................................................................................... 29

B 2.3 Requirements for surfaces .................................................................................................................... 29

B 2.4 Point in time of NDT during production test .......................................................................................... 29

B 3 NDT procedural requirements .............................................................................................................. 29

B 3.1 Visual examination ................................................................................................................................ 29

B 3.2 Examination of surfaces by magnetic particle and liquid penetrant methods ....................................... 29

B 3.3 Radiography ......................................................................................................................................... 30

B 3.4 Ultrasonic testing .................................................................................................................................. 30

B 4 Performance and evaluation of tests on ferritic product forms ............................................................ 31

B 4.1 Bars ...................................................................................................................................................... 31

B 4.2 Bolts and trunnions ............................................................................................................................... 32

B 5 Performance and evaluation of tests on product forms made of austenitic steels (rolled or forged components) ............................................................................................................... 32

B 5.1 Examination of surfaces ....................................................................................................................... 32

B 5.2 Ultrasonic testing .................................................................................................................................. 32

B 6 Performance and evaluation of tests on ferritic welds .......................................................................... 33

B 6.1 General ................................................................................................................................................. 33

B 6.2 Ultrasonic testing of weld junction areas for plates under tensile loading in thickness direction ................................................................................................................................................ 33

B 6.3 Visual examination of welds ................................................................................................................. 33

B 6.4 Examination of weld surfaces ............................................................................................................... 33

B 6.5 Radiography of welds ........................................................................................................................... 33

B 6.6 Ultrasonic testing of welds .................................................................................................................... 33

B 7 Performance and evaluation of tests on welds between austenitic steels ............................................ 33

B 7.1 General ................................................................................................................................................. 34

B 7.2 Ultrasonic testing of weld junction areas for plates under tensile loading in thickness direction ................................................................................................................................................ 34

B 7.3 Visual examination of welds ................................................................................................................. 34

B 7.4 Examination of weld surfaces ............................................................................................................... 34

B 7.5 Radiography on welds .......................................................................................................................... 34

KTA 3905 Page 29

B 1 Scope

(1) This Annex applies to the performance of non-destructive tests and contains procedural requirements and evaluation criteria for non-destructive testing.

(2) Deviations from this Annex may be possible in justified individual cases.

Note: The procedure, extent and point in time of NDT are laid down in material test sheets as well as in in-process test and inspection sequence plans.

B 2 General specifications

B 2.1 Personnel

(1) Test supervisors shall have the technical knowledge required to perform their tasks and know the possibilities of application as well as limits of test procedures. The test su-pervisory personnel

a) in case of production tests, shall have basic knowledge of the fabrication processes used and of the characteristic appearance of fabrication imperfections; they shall nor-mally be independent from the fabrication department and the authorized inspector shall be notified of their names;

b) in case of in-service inspections, shall be familiar with the characteristic features of operationally caused defects.

The test supervisory personnel is responsible for the applica-tion of the test procedure and for the details of the implemen-tation of the test in accordance with the relevant specifica-tions. They are responsible for the employment of qualified and certified NDT operators. This applies also to the employ-ment of personnel not belonging to the works. The test super-visory personnel shall sign the test report.

(2) The test supervisory personnel shall have been qualified and certified for the examination procedures in the relevant product or industrial sectors at least with level 2 to DIN EN 473. For radiographic and ultrasonic testing level 3 qualification and certification is required.

(3) The NDT operators shall have been qualified and certi-fied to DIN EN 473 for the applicable examination procedure in the relevant product or industrial sectors. For radiographic and ultrasonic testing at least level 2 qualification and certifi-cation is required.

B 2.2 Equipment and test fluids

The measuring and testing equipment to be used shall be monitored. The type and intervals of monitoring shall be fixed by the equipment manufacturer with a view to the accuracy of the equipment. The testing of such measuring and testing equipment shall be certified.

B 2.3 Requirements for surfaces

(1) The surfaces shall be free from scale, weld spatters or any other contaminants. Any grooves or notches affecting the test result shall be eliminated.

(2) The arithmetical mean deviation of the assessed profile (average roughness) Ra to DIN EN ISO 4287 shall not exceed

a) 10 µm for examination of surfaces by magnetic particle and liquid penetrant methods,

b) 20 µm for ultrasonic testing on the scanning and opposite surface if it is used as reflection surface.

(3) In the case of waviness of the scanning surfaces for ultrasonic testing the waviness shall be so little as to provide sufficient probe shoe contact. This is generally the case if the distance between probe shoe surface and scanning surface does not exceed 0.5 mm at any point.

(4) Coatings with a thickness up to and including 50 µm are permitted when performing non-destructive examinations, except for the liquid penetrant surface examination method.

(5) Upon completion of the examination the components shall be properly cleaned to remove test liquid residuals.

B 2.4 Point in time of NDT during production test

The product forms shall be tested in the as-delivered condi-tion and welds in the final-heat treatment condition, where possible, and prior to any coating.

B 3 NDT procedural requirements

B 3.1 Visual examination

Visual examinations shall be performed to DIN EN ISO 17637.

B 3.2 Examination of surfaces by magnetic particle and liquid penetrant methods

B 3.2.1 Viewing conditions

(1) The viewing conditions of DIN EN ISO 3059 shall be observed. In addition, the requirements of para. (2) to (6) shall be met:

(2) Where fluorescent detection media are used, the intensi-ty of irradiation of the ultraviolet light on the examination sur-face shall not be less than 10 W/m2. In the case of higher intensity of irradiation a proportionally higher illuminance is admitted on the examination surface in which case the inten-sity of irradiation shall not exceed 50 W/m2.

(3) The eyes of the operator shall have at least 5 minutes to adapt to the light conditions. Photo-chromatic spectacles shall not be used during the examination with ultraviolet radiation.

(4) For the purpose of better detectability of defects suffi-cient contrast shall be provided in magnetic particle examina-tion by the use of suitable media (e.g. fluorescent detection media or application of a thin colour coat only slightly covering the underground). Ultraviolet radiation may additionally be used to improve the contrast in liquid penetrant examination using fluorescent penetrants.

(5) During the examination the angle of viewing shall not deviate by more than 30 degrees from the surface normal. During viewing the distance to the examination surface shall normally be approximately 300 mm.

(6) For the inspection auxiliary means (e.g. magnifying glasses, contrast-improving spectacles, mirrors) are permitted.

B 3.2.2 Magnetic particle testing

B 3.2.2.1 Methods and performance of examination

Magnetic particle examinations shall be performed to DIN EN ISO 9934-1 to meet the following requirements.

B 3.2.2.1.1 Methods

(1) Where magnetisation is achieved in partial areas by the current flow technique or yoke magnetisation, AC magnetisa-tion shall normally be used.

(2) The DC magnetisation method shall only be used upon agreement by the authorized inspector.

(3) The residual magnetic field strength shall not exceed 800 A/m unless a lower value is required. Where the specified value is exceeded, the part shall be demagnetised and the value of the residual magnetic field strength be recorded.

KTA 3905 Page 30

B 3.2.2.1.2 Contact areas in case of current flow technique

(1) Where the examination is performed by current flow technique, consumable electrodes (e.g. lead fin alloys) shall be used, if possible. It shall be ensured that in the contact areas overheating of the material to be examined is avoided.

(2) Where overheating has occurred the overheated areas shall be marked, ground over after the examination and be examined for surface cracks, preferably by a magnetic particle method using yoke magnetisation.

B 3.2.2.1.3 Direction of magnetisation

Each location on the surface shall be examined from two di-rections of magnetisation offset by approximately 90 degrees.

B 3.2.2.1.4 Magnetic field strength Note: a) The magnetic flux in the component surface is decisive for

quality of examination. The required minimum flux density is 1 T. b) Due to technical measuring difficulties to determine the mag-

netic flux in the component, the tangential field strength is usually used as auxiliary variable.

c) The tangential field strength is the tangential component of the magnetic field strength at the test object surface. In low-carbon steels the require flux density of 1T is obtained with a field strength of 2 kA/m

(1) In the case of AC magnetisation the tangential field strength on the surface shall be at least 2 ⋅ 103 A/m and shall not exceed 6.5 ⋅ 103 A/m.

(2) It shall be checked by measurements that these values are adhered to or test conditions shall be determined under which these values may be obtained.

B 3.2.2.1.5 Magnetisation times

The following guide values apply with respect to the applica-tion of the magnetic particles and magnetisation:

a) Magnetisation and application: at least 3 seconds

b) Subsequent magnetisation: at least 5 seconds.

B 3.2.2.2 Inspection medium

(1) According to DIN EN ISO 9943-2 sample-examined me-dia shall be used. Verification of such sample examination shall be submitted to the authorized inspector.

(2) Magnetic particles with a grain size in the range di ex-ceeding 1.5 µm and du less than 30 µm shall be used. De-pending on application, black, fluorescent or coloured pow-ders may be used.

(3) Prior to bathing the surface care shall be taken to ensure that the magnetic powder is distributed uniformly in the vehi-cle fluid and is kept in suspension. Prior to and during the examination the powder suspension shall be spot-checked by suitable pre-magnetised test units (e. g. by reference block 1 to DIN EN ISO 9934-2).

B 3.2.2.3 Test instruments

The test instruments shall meet the requirements of DIN EN ISO 9934-3.

B 3.2.3 Liquid penetrant testing

B 3.2.3.1 Test system

(1) Liquid penetrants shall preferably be used. Fluorescent penetrants or fluorescent dye penetrants may be used.

(2) Solvents or water or both in combination may be used as penetrant remover.

(3) Only wet developers suspended in an aqueous solvent shall be used. Dry developers may only be applied on the scanning surface by electrostatic charging.

(4) For the test system at least the following sensitivity class to DIN EN ISO 3452-2 shall be adhered to:

a) sensitivity class 3 for fluorescent penetrants,

b) sensitivity class 3 for liquid penetrants.

(5) The suitability of the test system (penetrant, solvent re-mover and developer) shall be demonstrated by means of a sample examination as to DIN EN ISO 3452-2. Verification shall be submitted to the authorized inspector.

(6) Liquid penetrants in test equipment and partly used open tanks (except for aerosol cans) shall be monitored by the user with flux indicator 2 to DIN EN ISO 3452-3. In this test the penetration and development times shall not exceed the times specified for the evaluation. The examination sensi-tivity obtained shall be recorded.

B 3.2.3.2 Performance

(1) Liquid penetrant testing shall be performed in accord-ance with DIN EN 571-1 and the following requirements.

(2) The penetration time shall be at least half an hour.

(3) As soon as possible after drying of the developer, the first inspection should take place. A further inspection shall be performed at the earliest half an hour after the first inspection.

(4) Further points in time of inspection are required if crack-like indications are detected by the second inspection which were not discernible after the first inspection.

Note: Further points in time of inspection may be necessary if during the second inspection essential changes or additional indications are detected.

(5) The evaluation shall be made in due consideration of all inspection results.

B 3.3 Radiography

(1) The radiography of welds shall be performed to DIN EN 1435 class B.

(2) The image quality indicators to DIN EN 462-1 shall be used.

B 3.4 Ultrasonic testing

B 3.4.1 Requirements for test frequencies, transducer (crys-tal) dimension and sound entry positions

The test frequency, transducer dimension and scanning posi-tions are laid down in Sections B 4 to B 6. These specifica-tions are considered guide values from which deviations are possible in justified cases.

B 3.4.2 Performance

B 3.4.2.1 Test instructions

For the ultrasonic testing of

a) parts for which test instructions are required in Section B4, and

b) parts with geometries the examination of which is not cov-ered by Sections B 4 and B 5,

c) attachment welds

the details shall be laid down in test instructions.

KTA 3905 Page 31

B 3.4.2.2 Setting of sensitivity (examination levels)

The sensitivity shall be set on the test object, on calibration block no. 1 to DIN EN 12223 or on calibration block No. 2 to DIN EN ISO 7963 or on equivalent reference blocks of the same geometry by using suitable reference reflectors. Refer-ence reflectors may be back walls, grooves and boreholes. The reference block dimensions should not differ by more than 10 % from the test piece dimensions.

B 3.4.2.3 Adaptation of the probe to curved surfaces

The probe shall be centred in the probe index area. The dis-tance between the probe base and the test surface should not exceed 0.5 mm at any point. If required, the probe base of angle probes shall be adapted accordingly (see Figure B-1).

≤0.

5m

m

adapted convexlyProbe base must be

R

R

Concave couplingsurface

or adapted concavely

surfaceConvex coupling

Probe base not adapted

≤0.

5m

m

≤0.

5m

m

≤0.

5m

m

Figure B-1: Adaptation of probe base to curved surfaces

B 4 Performance and evaluation of tests on ferritic

product forms

B 4.1 Bars

B 4.1.1 Examination of surfaces


(1) The entire surface shall be tested in its finished condi-tion. Magnetic particle testing shall preferably be used.

(2) Magnetic particle testing shall be performed in accord-ance with B 3.2.2. The evaluation shall be made during re-magnetization.

(3) Liquid penetrant testing shall be performed in accord-ance with B 3.2.3.

B 4.1.1.2 Evaluation of magnetic particle test and liquid pen-etrant test

(1) Indications which suggest the presence of crack-like de-fects are not permitted. Indications with a maximum extension equal to or smaller than 1.5 mm detected by magnetic particle testing and indications equal to or smaller than 3 mm detect-ed by liquid penetrant testing shall not be included in the evaluation. Indications proved to be non-metallic inclusions as well as rounded indications up to an extension of 6 mm are permitted.

(2) The frequency of permissible indications shall be locally limited to a number of 5 per square decimetre referred to the entire surface area, but not exceeding 10 per square metre.

(3) In case of greater extension or frequency or in case of systematically occurring discontinuities these locations shall

be repaired or the product’s further usability shall be deter-mined by agreement with the authorized inspector.

B 4.1.2 Ultrasonic testing


Section B 3.4 applies to the performance of ultrasonic testing.

B 4.1.2.2 Scanning positions and conditions and evaluation for round bars

(1) The scanning positions for round bars are shown in Fig-

ure B-2.

(2) Straight beam scanning shall be effected in positions 1, 2 and 3. For round bars with a diameter d equal to or smaller than 60 mm position 3 will suffice.

(3) The scanning conditions shall be taken from Table B-1.

(4) Where, during straight beam or angle-bream scanning recordable indications of reflectors are detected in the area of lateral wall influence, they shall be verified by means of straight-beam scanning with calibration on a flat bottom hole (diameter 4 mm) with comparable sound path as the indica-tion or by means of purposive angle-beam scanning. The per-formance of angle-beam scanning shall be laid down in a test instruction.

Where the area of lateral wall influence is omitted due to the cutting into sections of the test object, this condition shall be given priority and be examined anew by straight-beam scan-ning without lateral wall influence.

The results of all examinations shall be covered by the evalu-ation.

(5) The evaluation shall be made in accordance with Table B-2.

Figure B-2: Scanning positions for round bars

B 4.1.2.3 Scanning positions and conditions, evaluation for rectangular or polygonal bars

(1) The scanning positions are shown in Figure B-3.

(2) Straight beam scanning shall be effected in positions 1, 2 and 3, in the latter case, on three paths offset by 120 de-grees (hexagonal bar) or on two paths offset by 90 degrees (rectangular bar). For rectangular or polygonal bars with d equal to or smaller than 60 mm position 3 will suffice.

(3) The scanning conditions shall be taken from Table B-3.

(4) Where, during straight beam or angle-bream scanning recordable indications of reflectors are detected in the area of lateral wall influence, they shall be verified by means of straight-beam scanning with calibration on a flat bottom hole (diameter 4 mm) with comparable sound path as the indica-

KTA 3905 Page 32

tion or by means of purposive angle-beam scanning, the latter being subject to agreement by the authorized inspector.

Where the area of lateral wall influence is omitted due to the cutting into sections of the test object, this condition shall be given priority and be examined anew by straight-beam scan-ning without lateral wall influence.

The results of all examinations shall be covered by the evalu-ation.

(5) The evaluation shall be made in accordance with Table B-4.

Figure B-3: Scanning positions for rectangular or polygonal bars

B 4.2 Bolts and trunnions

B 4.2.1 Examination of surfaces

Examination of surfaces shall be performed and evaluated in accordance with B 4.1.1.

B 4.2.2 Ultrasonic testing

B 4.2.2.1 Extent and point in time of testing

The test shall be performed in a state of simple geometry (with plane-parallel or cylindrical surfaces, pre-machined where required) in which case the full volume shall be tested. Edges with weld preparation, if any, shall be indicated for test-ing. When examining the weld edge areas the conditions of testing prior to welding shall be considered.

B 4.2.2.2 Scanning conditions

(1) The parts shall be tested such that each volumetric area is tested from at least two scanning positions offset by ap-proximately 90 degrees. If this cannot be done by straight beam scanning, angle-beam scanning from two opposite di-rections shall be performed for each straight-beam scanning omitted.

(2) For rough-turned cylindrical non-stepped shafts and ax-les the scanning positions of B 4.1.2.2 shall apply.

(3) Figure B-4 shows examples of rough-turned stepped axles and shafts.

(4) Where the scanning conditions of subparas 2 and 3 cannot be applied (e.g. due to specific geometric conditions), test instructions shall be established.

B 4.2.2.3 Evaluation

The evaluation shall be made in accordance with Table B-2.

3

31

2¢

Figure B-4: Scanning positions for rough-turned stepped bolts and trunnions (examples)

B 5 Performance and evaluation of tests on product

forms made of austenitic steels (rolled or forged

components)

B 5.1 Examination of surfaces

(1) The entire surface shall be tested in its finished condi-tion.

(2) The tests shall be performed in accordance with B 3.2.1 and B 3.2.3.

(3) The evaluation shall be made in accordance with B 4.1.1.2.

B 5.2 Ultrasonic testing

B 5.2.1 Extent and point in time of testing

The test shall be performed in a state of simple geometry (with plane-parallel or cylindrical surfaces, pre-machined where required) in which case the full volume shall be tested.

B 5.2.2 Determination of testability

(1) For the purpose of determining the test object testability the back wall echoes shall be determined in a grid by straight-beam scanning in wall thickness direction. In areas of non-parallel or non-concentric walls reference echoes shall be used for this test (e.g. bores available, edges or through transmission).

(2) For the area with the largest determinable sound attenu-ation it shall be proved that the required recording levels can be observed.

B 5.2.3 Scanning conditions

The specifications of Section B 4 shall apply to the scanning conditions. The test frequencies shall normally range from 2 MHz to 4 MHz.

B 5.2.4 Performance and Evaluation

The performance and evaluation shall be made in accordance with the specifications of Section B 4. If these criteria cannot be complied with, separate specifications shall be laid down with the authorized inspector.

KTA 3905 Page 33

B 6 Performance and evaluation of tests on ferritic welds

B 6.1 General

The examination area shall include the weld metal and the adjacent base metal on both sides over a width of

a) 10 mm on each side for wall thicknesses equal to or smaller than 30 mm,

c) 20 mm on each side for wall thicknesses exceeding 30 mm.

B 6.2 Ultrasonic testing of weld junction areas for plates un-der tensile loading in thickness direction

Ultrasonic testing of the weld junction areas shall be effected in accordance with DIN EN 10160. The examined weld junc-tion areas shall meet the requirements of quality class E4 of DIN EN 10160, Table 5. The test shall be performed with the recording level of circular disk reflector 3.

B 6.3 Visual examination of welds

B 6.3.1 Performance

The visual examination shall be performed to DIN EN ISO 17637.

B 6.3.2 Evaluation

Welds subject to dynamic loadings shall satisfy the require-ments of quality level B and welds primarily subject to static loadings shall satisfy the requirements of quality level C of DIN EN ISO 5817.

B 6.4 Examination of weld surfaces

B 6.4.1 Performance

(1) Surface crack detection shall be performed in accord-ance with B 3.2.2 or B 3.2.3.

(2) As far as practicable, magnetic particle testing shall be performed. The evaluation shall be made during re-magne-tization.

B 6.4.2 Evaluation

(1) Indications which suggest the presence of crack-like de-fects are not permitted. Indications with a maximum extension equal to or smaller than 1.5 mm detected by magnetic particle testing and indications equal to or smaller than 3 mm detect-ed by liquid penetrant testing shall not be included in the evaluation. Indications proved to be non-metallic inclusions as well as rounded indications up to an extension of 6 mm are permitted.

(2) The frequency of permissible indications may locally be up to 3 per 100 mm weld length.

(3) In the case of larger dimensions or frequency or system-atically occurring discontinuities these locations shall be re-paired or decision shall be made by agreement with the au-thorized inspector on the acceptability of the component.

B 6.5 Radiography of welds

(1) Radiography shall be performed and evaluated in ac-cordance with B 3.3.

(2) For the evaluation acceptance level 1 to DIN EN 12517-1 applies.

B 6.6 Ultrasonic testing of welds

B 6.6.1 Butt welds

(1) All butt welds shall be scanned from both sides for pres-ence of longitudinal and of transverse defects. The scanning positions are shown in Table B-5. The sensitivity adjustment shall preferably be performed in accordance with the DGS method. When the reference block method or the DAC meth-od is used, the reference reflectors to Figure B-5 shall be used for sensitivity adjustment.

Wall thickness or nominal wall thickness of the test object, mm

Side view of the reference block

s ≤ 10

£

j

1

1

s

10 < s ≤ 15

£ j

j

1 s

2b =

s

b

1

15 < s ≤ 20

j

j

5

bb = s 10

s

5b

20 < s ≤ 40

j

js

b10sb =

bb

b

55

2

40 < s ≤ 80

j

j

10

3

55

b

bb

b

b =s b b

s

s > 80

j

j

sb =

4

10

5b

b s

5b

b

The length of the reference reflectors shall be at least the beam width referred to a 20 dB echo amplitude decrease regarding the maximum sound path to the reference reflector.

Figure B-5: Reference blocks for sensitivity level adjust-ment when using the DAC method- or the refer-ence block method

KTA 3905 Page 34

(2) The scanning conditions shall be taken from Table B-6. For the examination of transverse defects, the beam angle shall normally be selected such that the incident angle on defects which are perpendicular to the surface is as small as possible.

(3) In the case of differing nominal wall thicknesses the grea-ter nominal wall thickness shall govern the determination of the number of beam angles and the smaller nominal wall thick-ness shall govern the determination of the recording level.

(4) The evaluation of longitudinal defects shall be made in accordance with Tables B-7 and B-8.

(5) The recording level for the examination for transverse defects shall be taken from Table B-7. Indications reaching or exceeding the recording level are permitted only if they occur individually or as spots and if they are not accompanied by frequent indications up to 12 dB below the recording level.

(6) In the case of unacceptable indications it may be demon-strated by further examinations (e.g. by radiography, by tell-tale holes) that the use of the part or component is permitted.

(7) Where recordable echoes are classified as geometry-related indications, control measurements to detect the cause of indication shall be performed.

(8) Where, by measurement of the projection distances on the test piece, it shall be proved that the echoes recorded on both sides of the weld are caused by the two faces of an un-machined weld root and not by weld defects, the exact projec-tion distance shall be determined on reference reflectors. If the locations of the reflections are found to be distinctly sepa-rate from each other, the indications are considered to be ge-ometry-related. Where a distance of less than 3 mm is found, the reflections shall not be treated as separate reflections.

(9) Indications due to geometric discontinuities shall be en-tered in the test reports with indication of location, position and size.

B 6.6.2 Attachment welds

(1) The ultrasonic testing of attachment welds shall be per-formed to DIN EN ISO 17640 test class B.

(2) For the evaluation acceptance level 2 to DIN EN ISO 11666 applies.

B 7 Performance and evaluation of tests on welds be-

tween austenitic steels

B 7.1 General

The examination area shall include the weld metal and the adjacent base metal on both sides over a width of

a) 10 mm on each side for wall thicknesses equal to or smaller than 30 mm,

c) 20 mm on each side for wall thicknesses exceeding 30 mm.

B 7.2 Ultrasonic testing of weld junction areas for plates un-der tensile loading in thickness direction

Ultrasonic testing of the weld junction areas shall be effected in accordance with DIN EN 10307. The examined weld junc-tion areas shall meet the requirements of quality class E4 of DIN EN 10307, Table 5. The test shall be performed with the recording level of circular disk reflector 3.

B 7.3 Visual examination of welds

B 7.3.1 Performance

The visual examination shall be performed to DIN EN ISO 17637.

B 7.3.2 Evaluation

Welds subject to dynamic loadings shall satisfy the require-ments of quality level B and welds primarily subject to static loadings shall satisfy the requirements of quality level C of DIN EN ISO 5817.

B 7.4 Examination of weld surfaces

The examination of surfaces shall be performed and evaluat-ed in accordance with Section B 6.2 using liquid penetrant testing to Section B 3.2.3.

B 7.5 Radiography on welds

(1) Radiography shall be performed and evaluated in ac-cordance with B 3.3.

(2) For the evaluation the requirements of acceptance level 1 to DIN EN 12517-1 apply.

Diameter d, in mm Scanning positions Nominal angle of refraction, degrees

Frequency, MHz

30 < d ≤ 60 3 0 4

60 < d ≤ 120 1 to 3 0 4

4 and 5 70 4

d > 120

1 and 2 0 4

3 0 2 to 4

4 and 5 70 2 to 4

Table B-1: Scanning conditions for round bars

KTA 3905 Page 35

Scanning positions 1 and 2 3 4 and 5

Recording level (diameter of equivalent flat bottom hole deq in mm)

60 < d ≤ 120 : 4 d > 120 : 6

d ≤ 60 : 3 60 < d ≤ 120 : 4

d > 120 : 6

3 2)

Permissible excess of the echo amplitude over the recording level, dB

< 6 < 6 < 6

Permissible half-amplitude length 1), mm ≤ 10 ≤ d, maximum 50 ≤ 10

Allowable frequency of indication per metre

5 d ≤ 60 : 3 d > 60 : 5

5

1) When evaluating the half-amplitude length of reflectors, the probe displacement at a signal amplitude drop of 6 dB to the maximum echo height shall be determined.

2) In the case of contoured probes the distance amplitude correction method (DAC) shall apply; the recording level then is: the echo height of the transverse bore with 3 mm diameter plus a sensitivity allowance of 6 dB.

Table B-2: Evaluation of ultrasonic test on round bars

Lateral dimension d in mm

Scanning positions Nominal angle of refraction, degrees

Frequency, MHz

30 < d ≤ 60 3 0 4

d > 60

1 and 2 0 4

3 0 2 to 4

4 and 5 70 2 to 4

Table B-3: Scanning conditions for rectangular or polygonal bars

Scanning positions 1 and 2 3 4 and 5

Recording level (diameter of equivalent flat bottom hole deq in mm)

60 < d ≤ 120: 4 d > 120: 6

d ≤ 60: 3 60 < d ≤ 120: 4

d > 120: 6

3

Permissible excess of echo amplitude over the recording level, dB

< 6 < 6 < 6

Permissible half-amplitude length 1), mm ≤ 10 ≤ d, maximal 50 ≤ 10

Allowable frequency of indication per metre

5 d ≤ 60 : 3 d > 60 : 5

5

1) When evaluating the half-amplitude length of reflectors, the probe displacement at a signal amplitude drop of 6 dB to the maximum echo height shall be determined.

Table B-4: Evaluation of ultrasonic test on rectangular or polygonal bars

KTA 3905 Page 36

Ser. No.

Accessibility for scanning

Required surface condi-tion of the weld

Scanning positions

1 From both sides of the weld and from one surface at one skip distance

Pos. 2Pos. 1

s

Pos. QF

Test for longitudinal

discontinuities:

Positions 1 and 2 at p 1)

Test for transverse

discontinuities: Position QF at p in the two opposite directions on the weld 2).

2 From both sides of the weld and from both surfaces at ½ skip distance


discontinuities: Positions 1 up to 4 at p/2

Test for transverse

discontinuities: Position QF at p or QF and QF′ at p/2, each in the two opposite direc-tions on the weld 2)

3 From one side of the weld and from both surfaces at one skip distance

Outside and inside machined flat


discontinuities: Positions 1 and 2 at p

Test for transverse

discontinuities: Position QF at p or QF and QF′ at p/2, each in the two opposite direc-tions on the weld

4

From one side of the weld and from one surface at 1 ½ skip distances. If s > 40 mm, second beam angle at one skip distance.

Outside and inside machined flat


discontinuities: Position 1 at 3/2 p

If s ≤ 20 mm position 1 us-ing 60 degrees permitted.

If s > 40 mm position 1 with second angle at p

Test for transverse

discontinuities: Position QF at p in the two opposite directions on the weld

p : skip distance

1) In the case of wall thicknesses > 40 mm, this shall only apply to the smaller beam angle, the evaluation up to P/2 shall be sufficient for the large beam angle.

2) Where the examination for transverse defects is not possible on the weld, the examination may be performed at the base material sur-face adjacent to the weld (in an acute angle as possible to the weld).

Table B-5: Scanning positions for butt welds

Nominal wall thickness s in mm

s ≤ 20 20 < s ≤ 40 s > 40

Beam angle, general 70 degrees 60 degrees 45 degrees and 60 degrees

Beam angle in direction of curvature or in the case of wall thickness transitions

45 degrees up to 60 degrees


35 degrees up to 45 degrees and


Frequency, MHz 4 2 to 4 2 to 4

Table B-6: Scanning conditions for butt welds

KTA 3905 Page 37

Reference reflector Arc of calibration block no. 1 or no. 2 or cylindrical bore with a diameter of 3 mm or groove with a depth of 1 mm

Evaluation method DGS or reference block or DAC method

Recording level 8 ≤ s ≤ 15: 50 % echo amplitude of cylindrical bore or groove or circular disk reflector CDR 1.5

15 ≤ s ≤ 40: 50 % echo amplitude of cylindrical bore or circular disk reflector CDR 2 s > 40: 50 % echo amplitude of cylindrical bore or circular disk reflector CDR 3

Permissible excess over the recording level < 6 dB 1)

Permissible length of record-able indications

in accordance with Table B-8

Permissible distances be-tween recordable indications

For every two indications the distance of which is smaller than twice the length of the larger indication, the indication distance shall be covered by the evaluation. In this connection, par-ticularly the orientation of the indications in relation to each other and in the weld, their reflec-tion behaviour from different scanning directions and the wall thickness shall be taken into consideration. The following generally applies:

a) Indications of the same depth (dz < 2.5 mm) and the same width (dy < 5 mm) located in the direction of welding shall have a distance from each other of at least the length of the longer indication (dx ≥ L2). Otherwise, the indications are considered to be continuous. Where more than two indications follow each other closely, they shall be compared to each other in pairs and shall fulfil the above criteria.

b) Indications of the same width (dy < 5 mm) located in thickness direction shall have a dis-tance dz at least exceeding half the length of the longer indication, but not less than 10 mm.

c) Indication of the same depth (dz < 2.5 mm) located side by side shall have a distance dy of at least 10 mm in the direction of width.

y

1

3

x

2

z

z

xy

d

l

l

dl

d

1) Per metre of weld an indication with a length ≤ 10 mm may exceed the recording level by up to 12 dB. When calculating the cumulative length this indication shall be considered with 10 mm.

Table B-7: Evaluation of ultrasonic tests on butt welds

Nominal wall thick-ness s 1) in mm

Maximum allowable length 1) of individual reflectors Allowable cumulated length (sum of individual re-

flector’s lengths) per reference length 2)

15 < s ≤ 40 ≤ 25 mm, but ≤ s ≤ 1.5 ⋅ s

40 < s ≤ 60 ≤ 30 mm ≤ 1.5 ⋅ s

60 < s ≤ 120 ≤ 40 mm ≤ 2 ⋅ s

s >120 ≤ 50 mm ≤ 2 ⋅ s

1) When evaluating the length of reflectors, the probe displacement at a signal amplitude drop of 6 dB to the maximum echo height shall be determined (half-amplitude length).

2) The reference length is 6 x s.

Table B-8: Acceptance levels for the length of recordable indications detected by ultrasonic testing for longitudinal defects

KTA 3905 Seite 38

Annex C

Design of load attaching points and representation of the delimitation between load attaching point and

load for several examples

Load

Load attaching point

Note:

Trunnion (welded on)

Trunnion (as integral part of load)

Lifting lug (bolted on)

Trunnion (bolted on)Fig. C-1:

Fig. C-3:

Fig. C-2:

Fig. C-4:

KTA 3905 Page 39

Note:

Load


Eyelet (welded on)

Lifting lug ( runder building egulation approved,

welded-on an anchor plate anchored in concrete)

Reinforcement bolt bushing anchored in concrete

Tie bar anchored in concrete

Fig. C-7:

Fig. C-6:

Fig. C-8:

Fig. C-5:

KTA 3905 Page 40

Load

Note:


Fuel assembly head for BWR

Fuel assembly head for PWR

Control rod head for BWR

Control rod spider for PWRFig. C-9:

Fig. C-11:

Fig. C-10:

Fig. C-12:

KTA 3905 Page 41

Annex D

Examples for the classification of load attaching points

No.

Component

Additional requirements in accordance with

Section 4.2

Increased requirements in accordance with

Section 4.3

1 Reactor pressure vessel cover X

2 Stud tensioner for reactor pressure vessel cover bolts X

3

Sluice gate for separate cask pool, sluice gate be-tween reactor well and set-down area as well as sluice gate between fuel element storage pool and set-down area

X

4 Horizontal slab over reactor well and set-down area X

5 Spent fuel shipping cask X

Table D-1: Examples for a PWR plant

No.

Component

Additional requirements in accordance with

Section 4.2

Increased requirements in accordance with

Section 4.3

1 Reactor pressure vessel cover X

2 Stud tensioner for reactor pressure vessel cover bolts X

3 Shielding slab in reactor well X

4 Sluice gate between fuel element storage pool and set-down pool

X

5 Shipping cask for irradiated fuel elements X

6

Container for radioactive waste, provided, it is han-dled in the storage pool area (e.g. mosaic and SAB-container)

X

Table D-2: Examples for a BWR plant

K

yes

no

yes

no

no

Have additional measures been taken by which, in case of load attaching point failure,

damage to fuel assembly or other damage that may lead to a criticality accident, can be safely

excluded?

no

Restricted lifting equipment travel

way or lifting height

(< 1,2 m) 1)

Component mass

> 200 kg 1)

Component mass

> 80 kg 1)

Classification

no

Can impairment of safety-relevant components and a non-

isolatable LOCA leak be excluded ?

yes no

yesHa

nd

lin

g w

ith

in t

he

pla

nt

bu

ild

ing

no

In case of load attaching point failure, max. allowable release to atmosphere less than permitted by nuclear licence

and radiation exposure to individual persons below limit values of Radiation

Protection Ordinance

Is release of radioactive substances to be assumed due to

failure of load attaching point?

Section 4.3

"Increased requirements"

Section 4.2

"Additional requirements"

Section 3

"General provisions"

Handling in/over

open RPV (RPV fuel assembly-

loaded)

Handling in/over

fuel pool

Handling in vicinity

of fuel assembly

storage pool

Handling in other

areas within plant

buildings

Handling on plant area

(outside plant buildings,

but within NPP

boundary fence)

yes

ye

s

yes

yes

no

Radiological exposure per person due to load attaching point failure

- external < 5 mSv 2)

- internal < 1 mSv 2)

1) The numerical values are based on experience and are guide values only. Attaching points shall be classified in due consideration of the actual conditions (inter alia location of use, component geometry) with-in the nuclear licensing and supervisory procedure.

2) Attaching points shall be classified in due consideration of the actual conditions (inter alia location of use, frequency and duration of transport operations) within the nuclear licensing and supervisory proce-dure.

Figure D-1: Examples for procedural steps of classifying load attaching points

KTA 3905 Page 43

Annex E

Regulations and literature referred to in this Safety Standard

(The references exclusively refer to the version given in this annex. Quotations of regulations referred to therein refer to the version available when the individual reference below was established or issued.)

Atomic Energy Act (AtG) Act on the Peaceful Utilization of Atomic Energy and the Protection against its Hazards (Atomic Energy Act) of December 23, 1959 (BGbl. I, p. 814) as Amended and Promulgated on July 15, 1985 (BGBl. I, p. 1565), last Amendment by article 5 para. 1 of the Law dated 24th February 2012 (BGbl. I, p. 212)

StrlSchV Ordinance on the Protection against Damage and Injuries Caused by Ionizing Radiation (Ra-diation Protection Ordinance) dated 20th July 2001 (BGBl. I 2001, No. 38, p. 1714), last Amendment by article 5 para. 7 of the Law dated 24th February 2012 (BGbl. I, p. 212)

Safety Criteria (1977-10) Safety criteria for nuclear power plants of 21 October 1977 (BAnz. No. 206 of November 3, 1977)

Design Basis (1983-10) Guidelines for the assessment of the design of nuclear power plants with pressurized water Accident Guidelines reactors against design basis accidents as defined in Sec. 28, para. 3 StrlSchV (Design Basis

Accident Guidelines) of October 18, 1983 (Addendum to BAnz. No. 245 of December 31, 1983)

KTA 1202 (2009-11) Requirements for the testing manual

KTA 1401 (1996-06) General Requirements Regarding Quality Assurance

KTA 1404 (2001-06) Documentation during the Construction and Operation of Nuclear Power Plants

KTA 3201.2 (1996-06) Components of the Reactor Coolant Pressure Boundary of Light Water Reactors; Part 2: Design and analysis

KTA 3201.4 (2010-11) Components of the reactor coolant pressure boundary of light water reactors; Part 4: In-service inspections and operational monitoring

KTA 3204 (2008-11) Reactor Pressure Vessel Internals

KTA 3604 (2005-11) Storaging, handling and on-site transportation of radioactive substances (other than fuel ele-ments) in nuclear power plants

KTA 3902 (2012-11) Design of lifting equipment in nuclear power plants

DIN EN 462-1 (1994-03) Non-destructive testing; image quality of radiographs; Part 1: image quality indicators (wire type); determination of image quality values; German version EN 462-1:1994

DIN EN 473 (2008-09) General principles for qualification and certification of NDT personnel; German version of EN 473:1992

DIN EN 571-1 (1997-03) Non-destructive testing - Penetrant testing - Part 1: General principles; German version EN 571-1:1997

DIN EN 818-4 (2008-12) Short link chain for lifting purposes – Safety - Part 4: Chain slings - Grade 8; German ver-sion EN 818-4:1996+A1:2008

DIN EN ISO 898-1 (2009-08) Mechanical properties of fasteners made of carbon steel and alloy steel - Part 1: Bolts, screws and studs with specified property classes - Coarse thread and fine pitch thread (ISO 898-1:2009); German version EN ISO 898-1:2009

DIN EN ISO 898-2 (2012-08) Mechanical properties of fasteners made of carbon steel and alloy steel - Part 2: Nuts with specified property classes - Coarse thread and fine pitch thread (ISO 898-2:2012); German version EN ISO 898-2:2012

DIN ISO 965-2 (1999-11) ISO general purpose metric screw threads - Tolerances - Part 2: Limits of sizes for general purpose external and internal screw threads; medium quality (ISO 965-2:1998)

DIN EN 1435 (2002-09) Non-destructive examination of welds. Radiographic examination of welded joints; German version of EN 1435:1997

DIN EN 1559-2 (2000-04) Founding - Technical conditions of delivery - Part 2: Additional requirements for steel cast-ings; German version EN 1559-2:2000

DIN EN 1990 (2010-12) Eurocode: Basis of structural design; German version EN 1990:2002 + A1:2005 + A1:2005/AC:2010

DIN EN 1990/NA (2010-12) National Annex - Nationally determined parameters - Eurocode: Basis of structural design

DIN EN 1991-1-1 (2010-12) Eurocode 1: Actions on structures - Part 1-1: General actions - Densities, self-weight, imposed loads for buildings; German version EN 1991-1-1:2002 + AC:2009

DIN EN 1991-1-1/NA (2010-12) National Annex - Nationally determined parameters - Eurocode 1: Actions on structures - Part 1-1: General actions - Densities, self-weight, imposed loads for buildings

KTA 3905 Page 44

DIN EN 1992-1-1 (2011-01) Eurocode 2: Design of concrete structures - Part 1-1: General rules and rules for buildings; German version EN 1992-1-1:2004 + AC:2010

DIN EN 1992-1-1/NA (2011-01) National Annex - Nationally determined parameters - Eurocode 2: Design of concrete struc-tures - Part 1-1: General rules and rules for buildings

DIN EN ISO 3059 (2002-01) Non-destructive testing - Penetrant testing and magnetic particle testing - Viewing conditions (ISO 3059:2001); German version EN ISO 3059:2001

DIN EN ISO 3269 (2000-11) Fasteners - Acceptance inspection (ISO 3269:2000); German version EN ISO 3269:2000

DIN EN ISO 3452-2 (2006-11) Non-destructive testing - Penetrant testing - Part 2: Testing of penetrant materials (ISO 3452-2:2006); German version EN ISO 3452-2:2006

DIN EN ISO 3452-3 (1999-02) Non-destructive testing - Penetrant testing - Part 3: Reference test blocks (ISO 3452-3:1998); German version EN ISO 3452-3:1998

DIN EN ISO 3506-1 (2010-04) Mechanical properties of corrosion-resistant stainless steel fasteners - Part 1: Bolts, screws and studs (ISO 3506-1:2009); German version EN ISO 3506-1:2009

DIN EN ISO 3506-2 (2010-04) Mechanical properties of corrosion-resistant stainless steel fasteners - Part 2: Nuts (ISO 3506-2:2009); German version EN ISO 3506-2:2009

DIN EN ISO 3651-2 (1998-08) Determination of resistance to intergranular corrosion of stainless steels - Part 2: Ferritic, aus-tenitic and ferritic-austenitic (duplex) stainless steels - Corrosion test in media contain-ing sul-phuric acid (ISO 3651-2:1998); German version EN ISO 3651-2:1998

DIN EN ISO 4287 (2010-07) Geometrical product specification (GPS). Surface texture: Profile method. Terms, definitions and surface texture parameters. (ISO 4287:1997); German version of EN ISO 4287:1998

DIN EN ISO 5817 (2006-10) Welding - Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding exclud-ed) - Quality levels for imperfections (ISO 5817:2003 + Cor. 1:2006); German version EN ISO 5817:2007 (Corrigendum 2007-10)

DIN EN ISO 6157-2 (2004-10) Fasteners - Surface discontinuities - Part 2: Nuts (ISO 6157-2:1995); German version EN ISO 6157-2:2004

DIN EN ISO 6892-1 (2009-12) Metallic materials - Tensile testing - Part 1: Method of test at room temperature (ISO 6892-1:2009); German version EN ISO 6892-1:2009

DIN EN ISO 7963 (2010-12) Non-destructive testing - Ultrasonic testing - Specification for calibration block No. 2 (ISO 7963:2006); German version EN ISO 7963:2010

DIN EN ISO 9934-1 (2002-03) Non-destructive testing - Magnetic particle testing - Part 1: General principles (ISO 9934-1:2001); German version EN ISO 9934-1:2001

DIN EN ISO 9934-2 (2003-03) Non-destructive testing - Magnetic particle testing - Part 2: Detection media (ISO 9934-2:2002); German version EN ISO 9934-2:2002

DIN EN ISO 9934-3 (2002-10) Non-destructive testing - Magnetic particle testing - Part 3: Equipment (ISO 9934-3:2002); German version EN ISO 9934-3:2002

DIN EN 10025-1 (2005-02) Hot rolled products of structural steels - Part 1: General technical delivery conditions; Ger-man version EN 10025-1:2004

DIN EN 10025-2 (2005-04) Hot rolled products of structural steels - Part 2: Technical delivery conditions for non-alloy struc-tural steels; German version EN 10025-2:2004

DIN EN 10028-7 (2008-02) Flat products made of steels for pressure purposes - Part 7: Stainless steels; German version EN 10028-7:2007

DIN EN 10083-1 (2006-10) Steels for quenching and tempering - Part 1: General technical delivery conditions; German version EN 10083-1:2006

DIN EN 10083-2 (2006-10) Steels for quenching and tempering - Part 2: Technical delivery conditions for non alloy steels; German version EN 10083-2:2006

DIN EN 10083-3 (2007-01) Steels for quenching and tempering - Part 3: Technical delivery conditions for alloy steels; German version EN 10083-3:2006 (Corrigendum 2009-01)

DIN EN 10088-2 (2005-09) Stainless steels - Part 2: Technical delivery conditions for sheet/plate and strip of corrosion resisting steels for general purposes; German version EN 10088-2:2005

DIN EN 10088-3 (2005-09) Stainless steels - Part 3: Technical delivery conditions for semi-finished products, bars, rods, wire, sections and bright products of corrosion resisting steels for general purposes; German version EN 10088-3:2005

DIN EN 10160 (1999-09) Ultrasonic testing of steel flat product of thickness equal to or greater than 6 mm (reflection method); German version EN 10160:1999

DIN EN 10164 (2005-03) Steel products with improved deformation properties perpendicular to the surface of the product - Technical delivery conditions; German version EN 10164:2004

KTA 3905 Page 45

DIN EN 10204 (1995-08) Metallic products - Types of inspection documents (includes Amendment A1:1995); German version EN 10204:1991 + A1:1995

DIN EN 10204 (2005-01) Metallic products - Types of inspection documents; German version EN 10204:2004

DIN EN 10210-1 (2006-07) Hot finished structural hollow sections of non-alloy and fine grain steels - Part 1: Technical de-livery conditions; German version EN 10210-1:2006

DIN EN 10213 (2008-01) Steel castings for pressure purposes; German version EN 10213:2007 (Corrigendum 2008-11)

DIN EN 10216-1 (2004-07) Seamless steel tubes for pressure purposes - Technical delivery conditions - Part 1: Non-alloy steel tubes with specified room temperature properties; German version EN 10216-1:2002 + A1:2004

DIN EN 10216-5 (2004-11) Seamless steel tubes for pressure purposes - Technical delivery conditions - Part 5: Stainless steel tubes; German version EN 10216-5:2004

DIN EN 10217-1 (2005-04) Welded steel tubes for pressure purposes - Technical delivery conditions - Part 1: Non-alloy steel tubes with specified room temperature properties; German version EN 10217-1:2002 + A1:2005

DIN EN 10217-7 (2005-05) Welded steel tubes for pressure purposes - Technical delivery conditions - Part 7: Stainless steel tubes; German version EN 10217-7:2005

DIN EN 10222-1 (2002-07) Steel forgings for pressure purposes - Part 1: General requirements for open die forgings (in-cludes Amendment A1:2002); German version EN 10222-1:1998 + A1:2002

DIN EN 10222-4 (2001-12) Steel forgings for pressure purposes - Part 4: Weldable fine grain steels with high proof strength (includes Amendment A1:2001); German version EN 10222-4:1998 + A1:2001

DIN EN 10222-5 (2000-02) Steel forgings for pressure purposes - Part 5: Martensitic, austenitic and austenitic-ferritic stain-less steels; German version EN 10222-5:1999

DIN EN 10250-1 (1999-12) Open die steel forgings for general engineering purposes - Part 1: General requirements; Ger-man version EN 10250-1:1999

DIN EN 10250-2 (1999-12) Open die steel forgings for general engineering purposes - Part 2: Non-alloy quality and special steels; German version EN 10250-2:1999

DIN EN 10250-4 (2000-02) Open die steel forgings for general engineering purposes - Part 4: Stainless steels; German version EN 10250-4:1999 / Correction 2008-12

DIN EN 10269 (2006-07) Steels and nickel alloys for fasteners with specified elevated and/or low temperature properties; German version EN 10269:1999 + A1:2006 (Corrections 2006-10, 2007-02 and 2009-05)

DIN EN 10272 (2008-01) Stainless steel bars for pressure purposes; German version EN 10272:2007

DIN EN 10307 (2002-03) Non-destructive testing - Ultrasonic testing of austenitic and austenitic-ferritic stainless steels flat products of thickness equal to or greater than 6 mm (reflection method); German version EN 10307:2001

DIN EN ISO 11666 (2011-04) Non-destructive testing of welds - Ultrasonic testing - Acceptance levels (ISO 11666:2010); German version EN ISO 11666:2010

DIN EN 12223 (2000-01) Non-destructive testing - Ultrasonic examination - Specification for calibration block No. 1; German version EN 12223:1999

DIN EN 12517-1 (2006-06) Non-destructive testing of welds - Part 1: Evaluation of welded joints in steel, nickel, titanium and their alloys by radiography - Acceptance levels; German version EN 12517-1:2006

DIN EN 13018 (2001-07) Non-destructive testing - Visual testing - General principles; German version EN 13018:2001

DIN EN 13414-2 (2009-02) Steel wire rope slings - Safety - Part 2: Specification for information for use and maintenance to be provided by the manufacturer; German version EN 13414-2:2003+A2:2008

DIN EN 13414-3 (2009-02) Steel wire rope slings - Safety - Part 3: Grommets and cable-laid slings; German version EN 13414-3:2003+A1:2008

DIN 15018-1 (1984-11) Cranes; Steel structures; Verification and analyses

DIN 15018-2 (1984-11) Cranes; Steel structures; Principles of design and construction

DIN EN ISO 15614-1 (2012-06) Specification and qualification of welding procedures for metallic materials - Welding procedure test - Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys (ISO 15614-1:2004 + Amd. 1:2008 + Amd. 2:2012); German version EN ISO 15614-1:2004 + A1:2008 + A2:2012

DIN EN ISO 17640 (2011-04) Non-destructive testing of welds - Ultrasonic testing - Techniques, testing levels, and assess-ment (ISO 17640:2010); German version EN ISO 17640:2010

DIN 18800-7 (2008-11) Steel structures - Part 7: Execution and constructor's qualification

DIN 25449 (2008-02) Reinforced and pre-stressed concrete components in nuclear facilities - Safety concept, ac-tions, design and construction

KTA 3905 Page 46

DIN EN 26157-1 (1991-12) Fasteners; surface discontinuities; bolts, screws and studs subject to general requirements (ISO 6157-1:1988); German version EN 26157-1:1991

DIN EN 26157-3 (1991-12) Fasteners; surface discontinuities; bolts, screws and studs subject to special requirements (ISO 6157-3:1988); German version EN 26157-3:1991

SEW 400 (1997-02) Stainless rolling and forging steels

SEW 550 (1976-08) Steels for larger forgings, quality regulations

VDI 2230 Blatt 1 (2003-02) Systematic calculation of high duty bolted joints - Joints with one cylindrical bolt

VdTÜV MB 1153 (2009-01) Guidelines for the testing, monitoring and certification of welding filler materials

VdTÜV MB 1253/1 Materials; List of material manufacturers recognized by the German technical inspection agen-cy (TÜV)

(the latest edition of this VdTÜV instruction sheet shall be used)

VdTÜV MB 1253/4 List of bolts, screws, studs, and nuts manufacturers (or processing firms) recognized by the German technical inspection agency (TÜV) (the latest edition of this VdTÜV instruction sheet shall be used)

ASTM B352 (2011) Standard Specification for Zirconium and Zirconium Alloy Sheet, Strip, and Plate for Nuclear /B352M-11 Application

ASTM E8/E8M-11 (2011) Standard Test Methods for Tension Testing of Metallic Materials

ASTM G2/G2M-06 (2011) Standard Test Method for Corrosion Testing of Products of Zirconium, Hafnium, and Their Al-loys in Water at 680 °F [360 °C] or in Steam at 750 °F [400 °C]

BAM-GGR 012 (2012-11) Guidelines for the design of cover systems and load attaching systems of transport containers for radioactive substances

Literature

[1] Niemann, G. et al. Maschinenelemente Band 1: Konstruktion und Berechnung von Verbindungen, Lagern, Wellen; Springer Verlag Berlin/Göttingen/Heidelberg 2005, 4. Auflage (Machine Elements. Vol. 1: Design and analysis of connections, bearings, shafts; Springer Verlag, Ber-lin/Göttingen/Heidelberg 2005, 4th edition)

[2] Hähnchen, R. Dauerfestigkeit für Stahl- und Gußeisen, Carl Hanser Verlag, München 1963 (Endurance Strength for Steel and Cast Iron, Carl Hanser Verlag, Munich 1963)

[3] Decker, K.-H. Maschinenelemente, Carl Hanser Verlag, München 1982 (Machine Elements, Carl Hanser Verlag, Munich 1982)

[4] Leitfaden für eine Betriebsfestigkeitsberechnung; Empfehlung zur Lebensdauerabschätzung von Maschinenbau-teilen, 4. Auflage, 1999, Herausgegeben vom Verein zur Förderung der Forschung und und der Anwendung von Betriebsfestigkeitskenntnissen in der Eisenhüttenindustrie (VBFEh) im Stahlinstitut VDEh

(Guidelines for service life strength calculation; recommendations for service life evaluation of machine parts. 4th edition 1999; published by the Association for promoting research and for the application of knowledge of service life strength in the iron and steel industry

[5] DIN-Fachbericht „Berechnungsgrundsätze für Hebezeuge“, 1. Auflage 1982, DIN-Fachbericht 1982, Herausge-geben vom Normenausschuss Maschinenbau, Fachbereich Fördertechnik im DIN (DIN technical report „Calculation Principles for Lifting Equipment“, 1st edition 1982, published by the DIN stan-dardisation committee engineering, technical section conveyor technology)

[6] Bork, C.-P., Hackbarth, A., Wohler, H. Schwingfestigkeitsuntersuchungen an geschweißten Proben aus austenitischen Stählen im Hinblick auf Lastanschlagpunkte in Kernkraftwerken, Bundesanstalt für Materialforschung und -prüfung, Berlin, Januar 1993 (auch veröffentlicht als Bandnummer BMU-1993-385 in der Schriftenreihe „Reaktorsicherheit und Strahlen-schutz“ des Bundesministeriums für Umwelt, Naturschutz und Reaktorsicherheit) (Endurance Strength Tests on Welded Test Specimens made of Austenitic Steels with Regard to Load Attaching Points in Nuclear Power Plants, Federal Institute for Material Research and Testing, Berlin, January 1993) (also published as Vol. BMU-1993-385 of the series : Reactor safety and Radiation Protection” by the Federal Ministry for the Environment, Nature Conservation and Nuclear Safety)

[7] Bork, C.-P., Ernsberger M. Schwingfestigkeitsuntersuchungen an geschweißten Proben aus austenitischen Stählen in Kernkraftwerken zur Festlegung von Kennwerten im Regelwerk“, Bundesanstalt für Materialforschung und -prüfung, Berlin, März 2003 (Endurance strength tests an welded specimens from austenitic steels in nuclear power plants for the purpose of determining strength values in technical rules and standards, Federal Institute for Materials Research and Tes-ting (BAM), Berlin, March 2003)

KTA 3905 Page 47

Annex F (informative)

Changes with respect to the edition 1999-06 and explanations

(1) The requirements of KTA 3905 are still based on the standard series DIN 15018, as the European standards in-tended to form the design basis will have to be established and introduced as an integral standard series with the status of harmonized standards.

(2) Sub-section 1 of the Section “Fundamentals“ was adapted to the formulation uniformly used in all KTA Safety Standards, sub-section 2 was revised editorially and sub-section 5 was put more precisely with respect to the require-ments for quality assurance.

(3) The criteria of Sections 4.2 and 4.3 regarding the neces-sity of additional and increased requirements were put more precisely in the text of this standard and by inclusion of a classification system in Annex D.

(4) The requirements for analytical and structural design (Section 5) were changed as follows:

a) In clause 5.1.2, and in connection with the changes in clause 5.1.3, a differentiation as to the number of stress cycles was made at which an analysis for cyclic operation is to be performed. For “other components of load attach-ing points” the values available for steel components to DIN 15018-1 on which experience made with the stress evaluation based on nominal stresses and with the mate-rials to Table 8 and section 6.4 of DIN 15018-1 is based, cannot be used to form the basis of analysis. Therefore, the number of operational load cycles which require analysis for cyclic operation, were left unchanged in due consideration of the new value of ka determined in clause 5.1.3. In this connection it was made clear that the number of stress cycles has to be determined in ac-cordance with clause 5.1.3. It was additionally pointed out that the stresses are to be evaluated to meet specific re-quirements if a stress evaluation on the basis of nominal stresses is not purposeful, and the requirements for bolted joints were added which after disassembly have to be re-assembled.

b) The value Ka = 3 to be used as per 5.1.3 was determined on the basis of available operating experience made and values measured with a view to the analysis based on a single-step damage-equivalent stress collective. Here it was taken into account that due to comparative calcula-tions and measured values lower dynamic loadings occur per load cycle than assumed up to now with Ka = 10 .

c) It was pointed out that, when the maximum hoist speed is known, the live load factor resulting from the respective lifting class to DIN 15018-1 may be used instead of the live load factor as per clause 5.1.3.

d) For structural steel components made of the austenitic steels 1.4541, 1.4306 and 1.4571 to DIN EN 10088-2 or DIN EN 10088-3 requirements for the general stress anal-ysis and analysis for cyclic operation were included. The allowable stresses prescribed here were derived from ex-perimental analyses performed by the Federal Institute for Materials Research and Testing (BAM) on behalf of the Federal Ministry for the Environment, Nature Conservation and Nuclear Safety.

e) A new requirement was included to permit that the analyti-cal proof of cyclic operation and endurance limit may be performed basing on Annex C of KTA 3902 (derived from DIN 15018-1, Tables 14 and 17) and on Annex D of KTA 3902 (based on experiments performed by Bundesanstalt für Materialforschung und -prüfung/BAM) if the operating conditions are exactly known.

f) New text was included to require that the ergonomic re-quirements of KTA 3902, Section 4.7, are to be met in conjunction with the load suspending device.

g) The requirements as to the design of welded-on load at-taching points were put more precisely.

h) The requirements regarding load application into structural concrete components in Section 5.5 were updated in due consideration of the valid standards.

i) Section 5.7 was supplemented to cover requirements re-garding the proof of the specific load case “load shifting”. These requirements meet the specified allowable stresses laid down by KTA 3204 for loading level D and ensure the hold function of the load attaching point by limiting plastic deformations.

j) In the new Section 5.8 rules for analytical proofs using the finite element method (FEM) were taken over.

(5) Section 6 “Materials“ was

a) supplemented to include requirements for the manufacture of materials and for welding consumables,

b) adapted to the current state of standards,

c) supplemented to include rules for the application of DIN EN 10204, edition 2005-01, which make the use of test certificates possible to both the new edition, (2005-01 - 3.2/3.1) and the former edition (1995-08 - 3.1.C/3.1.B),

d) supplemented to cover requirements for the use of bolted joints and metallic corrosion-protection coatings which cor-respond to the specifications of DIN 18800-1 (2008-11) and DIN 18800-7 (2008-11).

Clause 6.2.1, Section 8.1, Table 8-1, item k), Table 9-1, item 1), Table 10-1, item 1c) further refer to the standard DIN 18800-7 withdrawn in 2012-02, since the new European standards introduced under the building regulations have not yet been transposed by the manufacturers and a period of co-existence will prevail by 1st July 2014 as regards the national standards (among others DIN 18800-7) and the standard series EN 1090.

(6) In Section 7 “Design approval“ the following changes were made:

a) Requirements regarding the cover sheet were included.

b) Requirements for joints with pre-tensioned bolts were in-cluded which have to be re-assembled upon disassembly to meet design requirements.

c) Requirements for test instructions were included which are required for final, acceptance and periodic inspections.

(7) In Section 8 “Final inspection“ the following changes were made:

a) Analogous to the stipulations in other KTA Safety Standards requirements regarding manufacture were taken over.

b) The welder’s and welding procedure qualifications laid down in Section 7.1.1.6 were taken over in Section 8.1 and revise to meet current requirements.

c) The stipulations in Table 8-1 for ultrasonic and radiographic testing of butt welds were adapted to the requirements of Tables B-5 and B-6 with respect to wall thickness limitations. In addition, the formulation found at several locations “For all wall thicknesses of austenitic butt welds radiography shall be used unless a clear test result can be obtained by ultrasonic testing“ was replaced by the formulation “For all wall thicknesses of austenitic butt welds radiography shall be used“, since volumetric ultrasonic examinations of aus-tenitic welds do not represent the state-of-the-art.

KTA 3905 Page 48

(8) Section 10 “Periodic inspections“ was changed as fol-lows:

a) The specification of test intervals for load attaching points not used for a long period of time was transferred from clause 10.1.1 to clause 10.1.3.

b) The first two sub-clauses of clause 10.1.3 were deleted since all requirements are laid down in Table 10-1 and reference to this table will suffice. In addition, the text was put more precisely.

c) Clause 10.1.4 was renamed to “Performance of tests and inspections” and supplemented to include visual examina-tions for condition monitoring.

d) The requirements in Table 10-1 were changed as follows:

da) The column headlines were put more precisely. As a consequence, footnote 1 could be deleted.

db) As regards the requirements in ser. no. 1a), 1g), 2a) and 3a) the term “cracks” was deleted since here no selected visual examination to Annex B is meant. In connection with the supplements made in Section 10.1.4 it is considered sufficient to mention condition monitoring in this table.

dc) Under item 1d) requirements for bolted joints were added which upon disassembly have to be re-assembled.

dd) The examination as per item 1e) was limited to load attaching points (LAP) used within nuclear power plants, which are also subject to traffic regulations. For these load attaching points the examination is fur-ther considered necessary due to the specific load-ings. In the case of load attaching points on loads only used within nuclear power plants this examination was replaced by a more informative examination of condi-tion upon dismantling of the LAP as per item 1g) which was supplemented to read that the examination for deformations is to be performed e.g. by means of a check as per item 1e).

de) In connection with the new footnote 2 the inspection intervals for items 1f), 2c) and 3d) may be extended from 3 to 6 years under certain circumstances. Exten-sion of the inspection interval is only possible if it is proved by calculation that for the respective compo-nents utilization reserves of more than 50 % are avail-able for the intended service life. With this require-ment the test and inspection requirements for load at-taching points are brought into correspondence with the in-service inspections for load suspending devices.

(9) The material test sheets in Annex A were completely revised to adapt to the current state of standards. In many material test sheets the requirements for non-destructive test-ing were put more precisely. In addition, the material test sheets (WPB) were extended to cover several materials not contained up to now, but frequently used. WPB 11 for austen-itic cast steel was deleted as no applications are known. The numbering of the subsequent WPBs was maintained for rea-sons of traceability. In WPB 12 the bolts of property class 6.8 and nuts of property class 6 were deleted since their use in structural steel construction is no more permitted by DIN EN 1991-1-8/NA.

(10) Annex B „Non-destructive testing“ was completely re-vised in due consideration of the current state of standards to ensure uniform rules for the performance and evaluation of the tests and inspections. Here care was taken to ensure that uniform terms are used. In its essentials, the following chang-es were made:

a) In Sections B 2, B 3.1 and B 3.2 the requirements were adapted by uniform formulations as regards other KTA Safety Standards (e.g. KTA 3211.1, KTA 3211.3) to the current state of nuclear rules.

b) In Sections B 3.1, B 6.3 and B 7.3 new requirements for visual examinations were added.

c) In Section B 3.4.2.1 the formulation as regards the neces-sity of test instructions was revised due to changes made in other Sections of Annex B.

d) Up to now no stipulations regarding the occurrence of sys-tematic defects had been laid down. In Section B 4.1.1.2, sub-clause 3 a respective requirement was included.

e) The requirements in Sections B 5.2.2 (new), B 5.2.3 and B 5.2.4 as well as in the related Tables were changed and supplemented such that ultrasonic testing on austenitic product forms is also covered. For austenitic product forms not only straight-beam scanning, but also angle-beam scanning is required to correspond to the state-of-the-art.

f) The ultrasonic testing of butt welds within manufacturing was supplemented to cover an examination for transverse defects (Section B 6.6.1) thus improving the reliability of the test results. In sub-clauses 6 and 9 of Section B 6.6.1 the requirements were put more precisely on the basis of the stipulations laid down in KTA 3201.3 (2007-11). In sub-clause 8 it was laid down that during ultrasonic testing two adjacent indications are to be considered one indica-tion if their distance is less than 3 mm (formerly: less than 2 mm). This regulation corresponds to the state-of-the-art. The former sub-clause 10 of this Section (in the wording of 1999-06) was deleted since this requirement is no more necessary due to the changes made in sub-clause 6.

g) At several locations in Annex B the figures were put more precisely and supplemented and the test conditions put more precisely in due consideration of the current stand-ards and quality levels.

(11) In Annex C its was pointed out that not only the delimita-tion between load attaching point and load, but also examples for the design of load attaching points are concerned. The representation in Figures C-4 to C-8 was put more precisely.

(12) Annex D was supplemented to include a classification scheme representing classification principles that have proved to be effective in practice when applying KTA 3905. The criteria for this classification scheme are justified as fol-lows:

a) The evaluation of radiological exposure is based on the limit values as per §§ 46 and 47 of the Radiation Protec-tion Ordinance (StrlSchV). Limit values of the Radiation Protection Ordinance may also be exceeded without or in case of slight release of activity (e.g. if a shielding is dam-aged and therefore direct radiation is increased). Whether the activity release is sufficiently less than the limit values can only be determined in each individual case for the re-spective number of occurrences of activity release. Where activity is released on prescribed paths (release paths) it can be assumed that the activity release values are suffi-ciently less than the limit values if the permitted limit val-ues are observed.

The classification criteria contained in the classification scheme were determined on the basis of the danger po-tential arising from failure of a load attaching point used in nuclear power plants. In this respect, the limit values for admissible radiation exposure in case of load attaching point failure laid down in this standard more precisely than those in the edition 1999-06 and the examples included in Annex D for classifying load attaching points were formu-lated on the basis of experience with licencing and super-vising procedures in nuclear power plants. Within the pro-cedure of revising KTA 3905 it was not discussed whether and under which conditions the criteria laid down in KTA 3905 regarding the design as per Section 4.2 or per Sec-tion 4.3 can be transferred to nuclear facilities outside the scope of KTA 3905, e.g. to fuel element intermediate stor-

KTA 3905 Page 49

age plants and to the respective danger potential in these facilities in case of load attaching point failure.

Note: The requirements for the design of lifting equipment in fuel ele-ment intermediate storage plants are laid down in the “Guide-lines for dry intermediate storage of radiated fuel elements and heat-generating radioactive waste in casks”. These guidelines prescribe, inter alia, that design to increased requirements can be waived if it is proved that in the case of fuel handling acci-dents, e.g. upon fall of a cask, the accident planning reference levels of §§ 49 or 50 in conjunction with § 117, section 16 of the Radiation Protection Ordinance are adhered to and the struc-ture is designed to withstand consequential damage.

b) When classification is made with respect to the maximum allowable activity releases to the environment, it shall be based on both the permitted short-term values (releases per day) and the long-term values (per year, during 180 successive days, etc.) laid down in the license by the li-censing and supervising authorities.

c) The value shown for the radiological exposure of person-nel was laid down in conformance with the yearly limit val-

ue of category B laid down in the Radiation Protection Or-dinance for radiation-exposed persons as it cannot be ex-cluded that radiation-exposed persons of category B are present in the vicinity of lifting equipment.

d) The value of 200 kg for component masses was chosen in conformance with criteria E 2.4.1 of the “Ordinance on the Nuclear Safety Officer and the Reporting of Incidents and other Events” (ATSMV) and in Annex 1 (edition 2004-12) to the notification of the Federal Ministry for the Environment (BMU) dated 13th May 1993 (RS I 5-14009) “Reporting of events liable to report in plants used for the fission of nu-clear materials” which contains explanations to the term “heavy load” used under criteria E 2.4.1.

In Table D-2 the example “mobile auxiliary platform” was de-leted as these load attaching points cannot be uniformly clas-sified due to varying boundary conditions.

(13) The former Annexes E and F were replaced by references to the respective stipulations in KTA 3902 thus ensuring that the same procedure is applied over the total load path.

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