3211_1e

Safety Standardsof theNuclear Safety Standards Commission (KTA)

KTA 3211.1 (6/00) (incl. rectification from BAnz 132, 19.07.01)

Pressure- and activity-retaining components of systemsoutside the primary circuitPart 1: Materials

(Druck- und aktivitätsführende Komponenten von Systemenaußerhalb des Primärkreises; Teil 1: Werkstoffe)

A previous version of this Safety Standardwas issued 6/91

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

Editor:

KTA-Geschaeftsstelle c/o Bundesamt fuer Strahlenschutz (BfS)Willy-Brandt-Strasse 5 • 38226 Salzgitter • GermanyTelephone +49-5341/885-(0) 901 • Telefax +49-5341/885-905

Page 2

Page 3

KTA SAFETY STANDARD

June 2000Pressure- and activity-retaining components of systems outside

the primary circuit; Part 1: Materials KTA 3211.1

CONTENTS

Fundamentals.............................................................................................................................................................. 5

1 Scope .............................................................................................................................................................. 5

2 Definitions........................................................................................................................................................ 5

3 General principles............................................................................................................................................ 63.1 Selection of materials ...................................................................................................................................... 63.2 Appraisal of the materials ................................................................................................................................ 63.3 General quality-assurance requirements ......................................................................................................... 63.4 Requirements to be met by the manufacturer .................................................................................................. 63.5 Design approval............................................................................................................................................... 73.6 In-process inspection by the authorized inspector to § 20 of the Atomic Energy Act ....................................... 73.7 Verification of quality characteristics ................................................................................................................ 73.8 Marking............................................................................................................................................................ 73.9 Repairs ............................................................................................................................................................ 73.10 Material characteristic data for design analysis................................................................................................ 7

4 Generally applicable stipulations for materials and material tests .................................................................... 74.1 General............................................................................................................................................................ 74.2 Allowable materials.......................................................................................................................................... 74.3 Requirements for the materials and their product forms .................................................................................. 74.4 Testing and examination of materials and product forms................................................................................. 84.5 Re-examinations............................................................................................................................................ 11

5 Product forms of ferritic steels of material group W I...................................................................................... 125.1 Sheets and plates .......................................................................................................................................... 125.2 Dished or pressed product forms made from plate ........................................................................................ 135.3 Forgings, bar steel and rolled rings................................................................................................................ 155.4 Seamless pipes larger than DN 50 ................................................................................................................ 195.5 Seamless pipe elbows larger than DN 50 ...................................................................................................... 205.6 Seamless fittings larger than DN 50............................................................................................................... 225.7 Castings ........................................................................................................................................................ 23

6 Product forms of ferritic steels of material group W II..................................................................................... 246.1 Sheets and plates .......................................................................................................................................... 246.2 Dished or pressed product forms made from plate ........................................................................................ 256.3 Forgings, bar steel and rolled rings................................................................................................................ 266.4 Seamless pipes larger than DN 50 ................................................................................................................ 286.5 Seamless pipe elbows larger than DN 50 ...................................................................................................... 296.6 Seamless fittings larger than DN 50............................................................................................................... 306.7 Castings ........................................................................................................................................................ 31

7 Product forms of austenitic steels .................................................................................................................. 337.1 Sheets and plates .......................................................................................................................................... 337.2 Dished or pressed product forms made from plates....................................................................................... 347.3 Forgings, bar steel, rings and extrusions ....................................................................................................... 357.4 Seamless pipes larger than DN 50 ................................................................................................................ 367.5 Seamless pipe elbows larger than DN 50 ...................................................................................................... 387.6 Seamless fittings larger than DN 50............................................................................................................... 397.7 Castings ........................................................................................................................................................ 41

(Continued next page)

PLEASE NOTE: Only the original German version of this safety standard represents the joint resolution of the50-member Nuclear Safety Standards Commission (Kerntechnischer Ausschuss, KTA). The German version wasmade public in Bundesanzeiger No. 194a on October 14, 2000. Copies may be ordered through the Carl HeymannsVerlag KG, Luxemburger Str. 449, 50939 Koeln (Telefax +49-221-94373-603).

All questions regarding this English translation should please be directed to:KTA-Geschaeftsstelle c/o BfS, Willy-Brandt-Strasse 5, 38226 Salzgitter, Germany

Page 4

CONTENTS(Continued)

8 Bolts and nuts................................................................................................................................................ 428.1 Scope ............................................................................................................................................................ 428.2 Materials........................................................................................................................................................ 428.3 Additional requirements for the materials ...................................................................................................... 428.4 Bolts and nuts made by machining from ferritic bars ..................................................................................... 438.5 Bolts and nuts made by machining from solution-annealed and quenched austenitic bars............................ 438.6 Bolts and nuts made from ferritic bars by hot or cold forming and subsequently heat-treated ....................... 448.7 Bolts and nuts of strength classes ................................................................................................................. 458.8 Marking ......................................................................................................................................................... 458.9 Verification of quality characteristics.............................................................................................................. 45

9 Product forms of steels for special loads ....................................................................................................... 519.1 Forgings, bar steel and rolled rings................................................................................................................ 519.2 Castings ........................................................................................................................................................ 51

10 Heat-exchanger tubes ................................................................................................................................... 5310.1 Seamless straight heat-exchanger tubes of ferritic steels with wall thicknesses smaller than or equal to

4 mm and with outside diameters smaller than or equal to 38 mm ................................................................ 5310.2 Seamless bent heat-exchanger tubes of ferritic steels with wall thicknesses smaller than or equal to

4 mm and with outside diameters smaller than or equal to 38 mm ................................................................ 5410.3 Seamless straight heat-exchanger tubes of austenitic steels with wall thicknesses smaller than or equal

to 3.6 mm and with diameters smaller than or equal to 42.4 mm................................................................... 5510.4 Seamless bent heat-exchanger tubes of austenitic steels with wall thicknesses smaller than or equal to

3.6 mm and with diameters smaller than or equal to 42.4 mm....................................................................... 5510.5 Longitudinally welded straight heat-exchanger tubes of austenitic steels with wall thicknesses smaller

than 2 mm and with diameters Da smaller than or equal to 38 mm ............................................................... 56

Annex A: Material characteristic data..................................................................................................................... 58

Annex AP: Reference data on physical characteristics ............................................................................................ 85

Annex B: Non-destructive examinations of steel castings...................................................................................... 87

Annex C: Production welds of steel castings.......................................................................................................... 92

Annex D: Procedure for determining the delta ferrite content................................................................................. 96

Annex E: Non-destructive examinations of heat-exchanger tubes ......................................................................... 98

Annex F: Performance of manual ultrasonic examinations .................................................................................. 100

Annex G: Performance of surface crack detection by magnetic particle and liquid penetrant methods ................ 110

Annex H: Additional stipulations for non-destructive examination of forgings, bar steel, rings and extrusions..... 112

Annex I: Regulations and literature referred to in this Safety Standard............................................................... 119

Annex K: Changes with respect to the edition 6/91 (informative) ......................................................................... 123

Comments by the editor:

Taking into account the meaning and usage of auxiliary verbs in the German language, in this translation thefollowing agreements are effective:

shall indicates a mandatory requirement,

shall basically is used in the case of mandatory requirements to which specific exceptions (and onlythose!) are permitted. It is a requirement of the KTA that these exceptions - other thanthose in the case of shall normally - are specified in the text of the safety standard,

shall normally indicates a requirement to which exceptions are allowed. However, the exceptions used,shall be substantiated during the licensing procedure,

should indicates a recommendation or an example of good practice,

may indicates an acceptable or permissible method within the scope of this safety standard.

KTA 3211.1

Page 5

Fundamentals

(1) The safety standards of the Nuclear Safety StandardsCommission (KTA) have the task of specifying those safetyrelated requirements which shall be met with regard toprecautions to be taken in accordance with the state ofscience and technology against the damage arising from theconstruction and operation of the facility (Sec. 7 para 2subpara 3 Atomic Energy Act) in order to attain the protectiongoals specified in the Atomic Energy Act and the RadiologicalProtection Ordinance (StrlSchV) and which are further detailedin the “Safety Criteria for Nuclear Power Plants” and in the“Guidelines for the Assessment of the Design of PWR NuclearPower Plants against Incidents pursuant to Sec. 28 para 3 ofthe Radiological Protection Ordinance (StrlSchV) - IncidentGuidelines”.

(2) In the Safety Criteria, Criterion 1.1 ("Principles of safetyprecautions") requires, among other things, extensive qualityassurance in manufacturing, erection and operation, whileCriterion 2.1 ("Quality guarantee") requires, among othermatters, the application, establishment and observance ofdesign, material, construction, inspection and operatingspecifications as well as documentation of quality monitoring.Criteria 4.2 ("Residual heat removal in as-specifiedoperation"), 4.3 ("Residual heat removal after loss-of-coolantaccidents"), 5.3 ("Equipment for nuclear-reactor control andshutdown") and 8.5 ("Heat removal from the containmentsystem") set forth further design and fabrication requirementsfor safety systems. KTA safety standards series 3211 defineprovisions to be made to meet these requirements within theirscope of application. For this purpose it also draws uponnumerous individually cited rules from conventionalengineering, especially DIN Standards.

(3) The scope of application defined here covers thepressure- and activity-containing systems and componentslocated outside the pressure boundary (KTA safety standardsseries 3201) but having relevance specifically to reactorengineered safety per the Reactor Safety Commission (RSK)Guideline (Section 4.2).

(4) KTA 3211.1 specifically defines the requirements to beimposed on:

a) organizations involved in manufacturing,

b) manufacture of materials and product forms as well astheir chemical composition, mechanical and technologicalcharacteristics, physical characteristics, heat treatmentand further processing,

c) verification and inspection methods for achieving andmaintaining the required quality of materials and productforms, such as destructive and non-destructive exami-nations,

d) provision of documents for documentation of the test andinspection results.

1 Scope

(1) This safety standard shall apply to the materials andproduct forms of the pressure-retaining walls of pressure- andactivity-containing light-water-reactor systems and compo-nents that do not belong to the reactor-coolant pressureboundary but have relevance specifically to reactorengineered safety. This definition shall include systems andcomponents meeting one of the following criteria:

a) The plant section is necessary for accident control bymeans of shutdown, maintenance of long-term subcriti-cality and direct residual heat removal. Requirements forcomponents in systems involved only indirectly in residualheat removal - in other words the closed cooling-watersystems and secondary cooling-water systems which donot carry activity - shall be established on a plant-specific

basis with consideration of the multiple design (e.g.,redundancy-type, diversity-type).

b) Considerable energy is released in the event of failure ofthe plant section, and the consequences of failure are notlimited by structural provisions, spatial separation or othersafety provisions to an extent that is acceptable for nuclearsafety.

c) Failure of the plant section can lead directly or via a chainof conceivable subsequent events to an accident asdefined by § 28 Par. 3 of the Radiation ProtectionRegulation.

(2) The following components fall within the scope ofapplication of this safety standard:

a) pressure vessels,

b) piping systems and piping-system parts,

c) pumps and

d) valves and fittings

including the integral zones of the component supportstructures.

(3) This safety standard shall not apply to:

a) piping systems and to valves and fittings of DN 50 size orsmaller,

b) internals of components (that are not part of the pressure-containing wall) and accessories,

c) systems and plant sections that perform auxiliary functionsfor the systems in question here,

d) system parts in which the system pressure is determinedexclusively by the geodetic pressure head in the suctionzone,

e) parts for force and power transmission to pumps and tovalves and fittings as well as inspections for verification offunctional capability,

f) weld filler metals and welding consumables,

g) small parts.

Note:Small parts are subject to the stipulations of Section 10 and ofTable 2-3 of KTA 3211.3.

2 Definitions

(1) Loading temperature, lowest

The lower of the pressure-test temperature or lowest operatingtemperature is designated the lowest loading temperature.

(2) Test groups A1, A2 and A3

The components in the scope of application of this safetystandard shall be classified in test groups A1, A2 or A3depending on design data and dimensions, with considerationof the planned materials and stresses. KTA 3211.2 defines thecriteria for classification of a component. The plant suppliershall decide upon the classification by consultation with theauthorized inspector.

(3) Repairs

Repairs are deviations from the planned production flowduring manufacture of product forms. Production welds tocastings shall not be considered as repairs in the context ofthis safety standard.

(4) Authorized inspector

An authorized inspector for the tests and examinations for thepurpose of this safety standard is a cognizant person ororganization who or which shall be consulted on the basis oflegal requirements, guidelines, directives or orders or who orwhich has been called in on behalf of licensing or supervisoryauthorities.

KTA 3211.1

Page 6

(5) Material groups W I and W II

The ferritic materials for manufacturing components within thescope of application of this safety standard shall be classifiedin material groups W I or W II according to their qualityfeatures, especially chemical composition and toughnesscharacteristics. The allocation of materials to test groups isdefined in KTA 3211.2.

3 General principles

3.1 Selection of materials

(1) Materials appropriate for the intended use shall beselected, with consideration of the mechanical, thermal andchemical loadings as well as the design conditions to KTA3211.2.

(2) The materials shall safely withstand the loadings duringthe pressure test, during operation and all specified plantconditions. Any materials on which welding is to be performedshall be suitable for welding.

Note:The selection of material shall be made by the purchaser, ifnecessary after consultation with the material manufacturer.

3.2 Appraisal of the materials

(1) The materials shall be appraised to determine whetherthey are suitable for the intended use and the plannedprocessing conditions.

(2) Ferritic steels for service in material group W I shall beappraised in consultation with the authorized inspector.

(3) As regards nature and scope of appraisal tests, all othersteels shall be treated as steels for conventional pressurevessels subject to supervision. If these steels for use inconventional pressure vessels subject to supervision havealready been approved, they shall qualify as appraised.

(4) If in individual cases a material is used outside the scopeof validity of its approval, or if a different material is used, aspecial appraisal shall be required. The special appraisal shallbe mentioned in the acceptance test certificate.

3.3 General quality-assurance requirements

The stipulations in KTA 1401 shall apply to the general quality-assurance requirements.

3.4 Requirements to be met by the manufacturer

(1) The manufacturer shall possess facilities that permitproper and state-of-the-art production of materials and productforms.

(2) The manufacturer shall possess test and inspectionfacilities that permit testing and inspection of the materials andproduct forms in accordance with the applicable DINstandards or other rules pertinent to the conduct of materialstesting and inspection. The test equipment shall correspond toDIN 51 220 and be inspected in accordance with DIN 51 220.Within the measuring range of the test equipment, thepermitted measuring inaccuracy of the forces measuringequipment shall not exceed ± 1 %. Upon request, the testreports to DIN 51 220 shall be submitted to the authorizedinspector. If test facilities of other agencies are employed, theyshall be subject to the same stipulations.

(3) The manufacturer shall have access in its own works orat other agencies to facilities with which the non-destructiveexaminations required by this safety standard can beperformed.

(4) Mechanized or automated facilities to be employed forthe non-destructive examinations required by this safety stan-dard shall undergo an appraisal by the authorized inspector.

(5) Lists of necessary procedure instructions for the produc-tion and testing facilities shall be compiled.

(6) Through quality monitoring with corresponding recor-dings, the manufacturer shall ensure proper manufacture andprocessing of the materials and product forms as well asadherence to the governing technical rules.

(7) The manufacturer shall employ skilled personnel capableof performing the tests and examinations properly.

(8) The test supervisory personnel for the non-destructiveexaminations shall be part of the staff of the manufacturer’sworks. It shall be organisationally independent from thefabrication department and shall be named to the authorizedinspector.

(9) The test supervisory personnel shall be responsible thatthe test procedures are applied in accordance with therequirements under the product-form related Sections and thatthe individual steps of performing the tests are applied inaccordance with the corresponding regulations. The operatorsshall be employed by the test supervisory personnel. This alsoapplies to the employment of works-external personnel. Thetest supervisory personnel shall analyse the test results andsign the test report.

(10) The NDT operators carrying out the non-destructiveexaminations shall be part of the staff of the manufacurer'sworks. They shall have sufficient basic technical knowledgeand shall be capable of performing the examinations inaccordance with the requirements. These abilities shall bedemonstrated to the test supervisory personnel. The NDToperators shall have sufficient visual capacity which is to bechecked by an ophtalmologist, optician or another medicalperson in conjunction with DIN EN 473. A capacity of 1.0 (toDIN 58 220-3 and DIN 58 220-5) is required for the evaluationof radiographs and the evaluation of tests by means ofmagnetic particle and liquid penetrant methods at a distanceof 0.33 m with or without visual aids. The operator’s visualcapacity shall be checked yearly. NDT operators from outsidethe manufacturer's works may perform examination tasks onlywhen the radiographic method is being employed, but whenthe ultrasonic examination method is being employed theymay perform such tasks only in addition to inspectors of themanufacturer's works.

(11) The manufacturer shall be entitled to issue acceptancetest certificates only if he employs a works' inspector qualifiedin accordance with the conditions of DIN EN 10 204. Thename and stamp of the works' inspector shall be announced tothe authorized inspector.

(12) If welding work is performed on the product forms in thecourse of manufacture, the manufacturer shall employ his ownsupervisory staff and welders qualified to DIN EN 287-1 inconjunction with AD Merkblatt HP 3. Only qualified weldersshall be used for the welding jobs. The welding supervisorshall be a member of the staff of the manufacturer's works andbe named to the authorized inspector.

(13) A procedure by which all deviations from the qualityrequirements observed during production are reported to theresponsible agency shall be set forth in writing.

(14) The manufacturer shall have a quality department that isindependent of the production department.

(15) The organizational classification and assignment ofduties of the works' inspector, test supervisory personnel, NDToperators and quality department and, if applicable, thewelding supervisory personnel, shall be set forth in writing.

KTA 3211.1

Page 7

(16) The authorized inspector shall review whether therequirements have been met before production can be started.The review shall be repeated at intervals of about one to twoyears, unless the authorized inspector can be convinced byother means that the conditions are still being met.

3.5 Design approval

Unless otherwise stipulated in the following sections, materialtesting and sampling plans shall be required only for productforms for production of components from ferritic steels ofmaterial group WI. In fact, such plans shall be required only ifsampling is not clearly defined in the Sections relating toproduct forms. They shall be submitted to the authorizedinspector for design approval.

3.6 In-process inspection by the authorized inspector to§ 20 of the Atomic Energy Act

The authorized inspector shall have the right to be presentduring the manufacturing processes. However, he shall notimpair the manufacturing operations.

3.7 Verification of quality characteristics

(1) The quality characteristics of the materials and productforms shall be determined by tests and examinations, whichshall be performed in the manufacturer's works.

(2) The quality characteristics of the materials and productforms shall be verified by material test certificates to DIN EN10 204. The governing stipulations for the required type ofquality verification shall be those in the following Sectionsrelating to product forms. Confirmation that the requirementsof this safety standard have been met shall be required in thecertificates.

3.8 Marking

The product forms shall be clearly and durably marked, if at allpossible without notching, in accordance with the stipulationsin the following Sections relating to product forms. The use ofcode characters is permitted. The complete text of the markingshall be indicated in the test certificates. A clear correlationbetween the test certificates and product forms shall bepossible at all times.

3.9 Repairs

(1) Any necessary repairs shall be reported to the authorizedinspector. Further action shall be determined in consultationwith the authorized inspector.

(2) Repairs by welding shall be subject to the stipulations ofKTA 3211.3.

3.10 Material characteristic data for design analysis

The characteristic data critical to strength design analysis shallbe taken from Annex A, from the appropriate DIN standardsor, in the case of special steels, from the authorizedinspector's appraisal.

4 Generally applicable stipulations for materials andmaterial tests

4.1 General

(1) The requirements for material characteristics shall applyto the final condition of the components after the in-processinspection and pressure test. On the basis of the tests andexaminations to be performed on materials and product forms,

the material characteristics shall be verified on sufficientlylarge test coupons in the heat-treatment conditions requiredfor the particular purpose.

(2) The products shall have smooth surfaces consistent withthe forming method employed. Impermissible surface defectsshall be eliminated. The resulting depressions shall be groundflush. The wall thickness shall not be less than the allowableminimum nominal wall thickness.

4.2 Allowable materials

Materials shall be allowable if they fulfill the prerequisites ofSection 3.1 and their suitability has been established inaccordance with Section 3.2 of this safety standard.

4.3 Requirements for the materials and their product forms

4.3.1 Ferritic steels of material group W I

Ferritic steels of material group W I shall meet the followingconditions:

a) In the notched-bar impact bend test on Charpy V-notchtransverse specimens at the lowest operating temperature(including accidents) or at the temperature at which theprimary membrane stress is higher than 50 N/mm2, thesmallest individual value of energy absorbed of the basemetal, weld metal and heat-affected zone shall not be lessthan 68 J, and the smallest individual value of lateralexpansion shall not be less than 0.9 mm.

b) The smallest individual value of upper shelf energy,determined on Charpy V-notch transverse specimens, shallnot be less than 100 J. This only applies to the base metal.

c) The energy absorbed, determined on Charpy V-notchtransverse specimens, shall not be less than 41 J at thetest temperature of 0 °C. Only one individual value belowthe required mean value shall be permitted, and it shall notbe smaller than 29 J. This requirement applies to the basemetal, the weld metal and the heat-affected zone.

For cast steel the specimen direction is not specified.

4.3.2 Ferritic steels of material group W II

Ferritic steels of material group W II shall meet the followingconditions:

a) The values of the chemical composition determined in theladle analysis shall not exceed 0.020 % P and 0.015 % S.In addition, the processability shall be considered whendefining the chemical composition, especially thepermissible contents of microalloying elements.

b) In the notched-bar impact bend test on Charpy V-notchtransverse specimens, the mean value shall not be lessthan 41 J

ba) at the test temperature of 0 °C if the lowest loadingtemperature is lower than 20 °C, or

bb) at the test temperature of 20 °C if the lowest loadingtemperature is higher than or equal to than 20 °C.

Only one individual value below the required mean valueshall be permitted, and it shall not be smaller than 29 J.

The requirement applies for the base metal, the weld metaland the heat-affected zone.

For cast steel the specimen direction is not specified.

4.3.3 Austenitic steels

Austenitic steels shall meet the following conditions:

a) The steels shall be resistant to intergranular corrosion inthe production conditions in question.

KTA 3211.1

Page 8

b) Steels for hot (operating temperature ≥ 200 °C) reactorwater containing product forms and components in boilingwater reactor plants shall be resistant to IGSCC. Detailsare specified in the product-form related Sections.

c) The chemical composition shall be defined such that hotcracks do not develop during welding.

d) In the case of steels for product forms with a wall thicknessgreater than 16 mm or DN greater than 150 mm, theenergy-absorbed value of the base metal, weld metal andheat-affected zone, determined on Charpy V-notchtransverse specimens at the test temperature of 20 °C,shall not be less than 70 J (mean value of threespecimens, smallest individual value not less than 60 J) inthe solution-annealed and quenched condition, or 55 J(mean value of three specimens, smallest individual valuenot less than 40 J) in the annealed condition.

e) For parts on which welding work without weld filler metalwill be performed during further processing, the depositedbase metal shall have a delta ferrite content of 2 % to 10 %(ferrite number 2 to 11) to Annex D. For sheets on whichwelding work with weld filler metal will be performed duringfurther processing, the deposited base metal shall have adelta ferrite content of 1 % to 10 % (ferrite number 1 to 11)to Annex D. A close ferrite lattice structure is not permittedin either case. Deviations are permitted if the characte-ristics of the welded joint satisfy the stipulations of KTA3211.3.

f) For rolled and forged product forms made of austeniticsteels as well as parts made from such forms, the requiredultrasonic examinability, the further processability and thespecified mechanical and technological characteristicsshall not be impaired by coarse-grained microstructuralzones.

Note:Based on available experience, every effort should be made toachieve a grain size corresponding to a characterizing numberlarger than or equal to 4 to Euronorm 103-71.

4.3.4 Steels for special loads

If special loads such as erosion, corrosion and wear arepresent, materials matched to the requirements of theparticular application shall be employed. The conditions forsuch materials shall be defined on a case-by-case basis inconsultation with the authorized inspector.

4.4 Testing and examination of materials and productforms

4.4.1 Designation of specimen direction in product forms

The following designations shall be used to describe thedirection of specimens in product forms (see Figures 4-1and 4-2):

a) Designation based on direction relative to fibre:

Longitudinal specimens (L):Longitudinal axis of specimen in the main formingdirection; for notched-bar impact specimens, the notch axisshall be perpendicular to the plane of the transverse andlongitudinal directions.

Transverse specimens (Q):Longitudinal axis of specimen transverse to the mainforming direction; for notched-bar impact specimens, thenotch axis shall be perpendicular to the plane of thetransverse and longitudinal directions.

Perpendicular specimens (S):Longitudinal axis of specimen perpendicular to the plane ofthe transverse and longitudinal directions; for notched-bar

impact specimens, the notch axis shall be in the mainforming direction.

b) Designation based on direction relative to productgeometry:

Axial specimens (A):Longitudinal axis of specimen parallel to the axis ofrotational symmetry; for notched-bar impact specimens,the notch axis shall be perpendicular to the cylindricalsurface.

Tangential specimens (T):Longitudinal axis of specimen in the circumferentialdirection; for notched-bar impact specimens, the notch axisshall be perpendicular to the cylindrical surface.

Radial specimens (R):Longitudinal axis of specimen perpendicular to thecylindrical surface; for notched-bar impact specimens, thenotch axis shall be in the main forming direction.

4.4.2 Location of specimens in product forms

The specimen location shall be identified as follows: asregards depth below the surface, by the location of thespecimen axis; as regards distance from the edge, by thelocation of the cross section to be inspected. Furtherparticulars are defined in the following Sections relating toproduct forms.

4.4.3 Size of test coupons

(1) The quantity of material to be taken shall be largeenough to provide an adequate quantity of material forsubstitute specimens in addition to the material for verificationof mechanical and technological characteristics.

(2) If further specimen quantities are needed for additionaltests, the number and dimensions of the additional testcoupons shall be specified in the purchase order. In the caseof castings, additional test plates from the heats used forthese coupons shall be kept available if required.

HUR

1 1

2

23

3

Perpendicular specimen

Main forming direction

Longitudinal specimen2: 3:

1:

Transverse specimenHUR:

Figure 4-1: Designation of specimen directions for flatproducts

KTA 3211.1

Page 9

HUR axial

HUR tangential

1

22

3

31

Specimen direction relative to

Main forming direction (HUR)SpecimenNo.

Productgeometry

tangential axial

1 radial perpendicular perpendicular

2 axial transverse longitudinal

3 tangential longitudinal transverse

Figure 4-2: Designation of specimen directions forrotationally symmetric parts

4.4.4 Marking of test coupons and specimens

For the acceptance tests, the test coupons shall be markedlegibly and clearly before removal from the product form, andthe specimens shall be marked likewise before specimenremoval from the test coupon. The specimen marking shallpermit exact correlation with its location in the product form.

4.4.5 Heat-treatment conditions of specimens

(1) All test coupons shall be heat-treated on and togetherwith the product form (normalizing, quenching and tempering,solution annealing and quenching).

(2) If the product forms are not delivered in the heat-treatment condition governing establishment of thecharacteristics, but receive this heat treatment only in thecourse of further processing, the material manufacturer shallperform tests on specimens from test coupons subjected tocorresponding heat treatment.

Note:Unless otherwise stipulated in the appraisal, stress-reliefannealing shall not constitute the heat treatment governingestablishment of the mechanical and technological characteristics.

(3) Should simulated stress-relief annealing be required inAnnex A or in the authorized inspector’s appraisal, it shall beperformed in accordance with the conditions stipulatedtherein.

4.4.6 Tests and test methods to be employed

4.4.6.1 General

(1) The stipulations of clause 4.4.6 shall apply if perfor-mance of the tests cited in the following is required in theSections relating to product forms and if nothing to thecontrary is expressly stipulated there.

(2) The particulars needed for materials testing and takenfrom the classification into test and material groups per KTA3211.2 shall be announced to the material or product-formmanufacturer in the purchase order.

4.4.6.2 Chemical analysis

(1) The elements indicated for the corresponding material inAnnex A shall be determined during ladle and productanalyses.

(2) Specimen taking and preparation for product analysisshall be governed by SEP 1805 [Steel and Iron Test andExamination Data Sheet 1805].

(3) In case of doubt the chemical composition shall bedetermined by the test method developed by the ChemistsCommittee of the Association of German Ferrous Metallurgists(VDEh) (see Manual for the Ferrous Metallurgy Laboratory[1]).

4.4.6.3 Hardness test

(1) Hardness tests shall be performed to DIN EN ISO 6506-1or DIN EN ISO 6507-1.

(2) Other hardness test methods may also be used, subjectto approval of the authorized inspector.

4.4.6.4 Tensile test

Tensile tests shall be performed to DIN EN 10 002-1 andDIN EN 10 002-5, using specimens to DIN 50125.

4.4.6.5 Notched-bar impact bend test

Notched-bar impact bend tests shall be performed to DIN EN10 045-1 on Charpy V-notch specimens. One set consisting ofthree specimens shall be tested.

4.4.6.6 Energy absorbed vs. temperature curves

(1) Notched-bar impact bend tests to clause 4.4.6.5 shall betested at a minimum of four temperatures to plot energyabsorbed vs. temperature curves.

(2) The temperatures shall be chosen such that theyencompass the upper shelf energy, characterized by a dullfracture surface representing a proportion of about 100 % ofthe total fracture surface, as well as the transition to brittlefracture behaviour, characterized by a dull fracture surfacerepresenting a proportion of about 50% of the total fracturesurface.

(3) A set of three specimens shall be tested at each testtemperature. For all notched-bar specimens of ferritic steelsused to plot energy absorbed vs. temperature curves, thelateral expansion to DIN 50 115 and the proportion of dullfracture surface as a percentage of total fracture surface shallbe determined.

KTA 3211.1

Page 10

4.4.6.7 Technological tests on pipes

The technological tests on pipes shall be performed to:

DIN EN 10 233 - Flattening test

DIN EN 10 234 - Drift test

DIN EN 10 236 - Ring expanding test

DIN EN 10 237 - Ring tensile test

4.4.6.8 Metallographic examinations

(1) The microstructural condition shall be determined bypreparing micrographs at a magnification that permits anunequivocal evaluation.

(2) The grain-size characterizing number shall be deter-mined to Euronorm 103-71.

4.4.6.9 Determination of delta ferrite content

(1) If required in the Sections relating to product forms, thedelta ferrite content of products of austenitic steels oraustenitic cast steel as well as of composite pipes pressure-clad with austenitic cladding layers shall be determined by oneof the following methods:

a) metallographic determination in the as-delivered condition,

b) metallographic determination on the bead-on-plate testspecimen,

c) theoretical estimation from the chemical composition,using De Long’s method [2].

(2) The Sections relating to product forms specify which ofthe methods indicated under (1) a) to c) is to be employed.Other methods are also permitted, subject to agreement bythe authorized inspector. One such example is the physicalmeasurement method to DIN 32 514-1.

(3) If the theoretical estimate yields ferrite numbers lowerthan 3, the delta ferrite content shall also be determinedmetallographically on the bead-on-plate test specimen.

(4) Details on how to perform the methods cited under (1) a)to c) are described in Annex D.

(5) The particular method to be employed shall be indicatedin the quality certificate.

4.4.6.10 Corrosion-resistance testing

The resistance to intergranular corrosion shall be verified toDIN EN ISO 3651-2.

4.4.6.11 Materials identification check

(1) Materials identification checks shall be performed by asuitable method. Comparison of stamp markings shall not beadequate.

(2) For pieces that have undergone a product analysis, it ispermitted to acknowledge that analysis as the materialsidentification check.

4.4.6.12 Dimensional check

Before shipment of the products, the dimensions andtolerances specified in the purchase order shall be checked.

4.4.6.13 Visual inspection

During the acceptance procedure, the products shall besubjected to a visual inspection of their external finish.

4.4.7 Non-destructive examinations

4.4.7.1 General

(1) The stipulations of clause 4.4.7 shall apply unless otherstipulations are made in the Sections relating to product forms.

Note:Deviations from the requirements of clause 4.4.7 are permitted byagreement with the authorized inspector.

(2) The nature, extent and date of the examinations arestipulated in the Sections relating to product forms.

(3) Depending on machining location, the non-destructiveexaminations shall be performed by the product-form manu-facturer or component manufacturer. The ultrasonic exami-nation shall take place after the last forming step and heattreatment and in general shall be performed by the product-form manufacturer. If non-destructive examinations are notperformed completely by the product-form manufacture, acorresponding note shall be made in the acceptance testcertificate.

(4) Stipulations for automated or mechanized examinationmethods can be found in the respective Sections relating toproduct forms.

(5) Where automated or mechanized non-destructive testmethods are used, test instructions shall be prepared on thebasis of an evaluation of the test systems which demonstratethe equivalency of the test results with those obtained with thedescribed manual methods. The test instructions shall besubmitted to the authorized inspector within the course of thedesign approval procedure.

(6) Where weld edges and nozzles are dressed, thesedressed areas shall be subjected to an ultrasonic examinationprior to dressing the fusion faces. In this case, the conditionsof testing prior to welding shall be considered. In the case ofwall thicknesses or sections at the point of connection equal toor greater than 30 mm a section width equal to the wallthickness plus 10 mm is considered the weld edge or nozzlearea, in the case of greater wall thicknesses or sections at thepoint of connection, a section width equal to the wall thicknessplus 20 mm adjacent to the fusion face or nozzle hole.

4.4.7.2 Method-related stipulations

4.4.7.2.1 Manual ultrasonic examinations

(1) The general stipulations of Annex F as well as therequirements of the Sections relating to products shall apply.

(2) The root mean square roughness index Ra to DIN ENISO 4287 shall not exceed 20 µm on the examination surface.

(3) Should it be impossible to maintain the boundaryconditions for examination by the distance-gain-size method(DGS method) to Section F 4.2 or the DGS method cannot beapplied due to the sound attenuation of the material, thereference-echo method to Section F 4.3 shall be employed.

(4) When the DGS method is employed, the recording limitsgiven as a function of nominal wall thickness or of bar or roddiameter in the Sections relating to product forms shall apply.

(5) When the reference-echo method is employed, allindications with echo amplitudes equal to or greater than 50 %of the echo amplitude of the reference reflector shall beregistered.

(6) If in manual examination the coupling cannot be checkedby other means (e.g., by observing a back-wall echo), the gainshall be increased until the noise background becomes visible.

(7) The echo amplitudes to be registered and theacceptance limits are defined as a function of product formand dimensions in the Sections relating to product forms.

KTA 3211.1

Page 11

Should the permissible findings be exceeded, the furtheractions shall be determined by agreement between product-form manufacturer and authorized inspector.

(8) If indications can exhibit a longitudinal or areal extension,the reflector extension shall be given, unless otherwisestipulated, by that probe displacement for which, dependingon wall thickness:

a) the echo amplitudes correspond to the recording limit forwall thicknesses equal to or smaller than 10 mm, or

b) the echo amplitudes have dropped 6 dB below therecording limit for wall thicknesses greater than 10 mm andequal to or smaller than 40 mm, or

c) the echo amplitudes have dropped 12 dB below therecording limit for wall thicknesses greater than 40 mm.

(9) Should the noise background be reached in this process,reflector extensions shall be reported until they disappear inthe background. The accuracy in measurement of reflectorextension shall then be improved by additional investigations ifthese dimensions alone are critical for evaluation of accep-tability. Reflectors with extensions smaller than 10 mm shallqualify as local indications.

4.4.7.2.2 Surface-crack detection

(1) The general stipulations of Annex G as well as therequirements of the Sections relating to products shall apply.

(2) The root mean square roughness index Ra determined inaccordance with DIN EN ISO 4287 shall not exceed thefollowing values depending on the process of surfacetreatment:

a) unmachined surfaces Ra ≤ 20 µm

b) machined surfaces Ra ≤ 10 µm

(3) Examination for surface crack detection shall basically beperformed by the magnetic particle method unless specifiedotherwise by the product form-related sections.

(4) When subjecting large areas to a magnetic particleexamination, the yoke magnetization method shall preferablybe used. Small parts shall be examined, if practicable bymeans of the auxiliary or coil technique.

(5) Methods other than magnetic-particle or liquid-penetrantexamination are permitted, subject to approval by theauthorized inspector. They shall preferably be mechanizedmethods such as eddy-current examination or magnafluxmethod with probes for detection of surface defects.

4.4.7.2.3 Radiographic examination

The general stipulations of Annex B as well as therequirements of the Sections relating to products shall apply.

4.4.7.3 Organization of non-destructive examinations

(1) The manufacturer shall perform and verify all non-destructive examinations to the extent specified by this safetystandard.

(2) The authorized inspector shall perform or participate inthe non-destructive examinations to the extent specified bythis safety standard. The scope of random non-destructiveexaminations by the authorized inspector shall be 25 % in testgroup A 1 and 10 % in test group A 2. Examination by theauthorized inspector is not required in test group A 3.

(3) When equipment for mechanized or partly automatedexamination is used, the authorized inspector shall participateat random in the examinations and in the process and shall

check the sensitivity adjustments and whether the procedureis performed as stipulated in the initial appraisal

(4) The authorized inspector shall participate at random tothe extent stipulated in (2), in the surface-crack detections tobe performed in general by the manufacturer.

(5) When the ultrasonic-examination method is employed,the authorized inspector shall check the test reports. Theresults of the ultrasonic examinations performed by themanufacturer shall be randomly checked by the authorizedinspector to the extent stipulated in (2).

(6) When the radiographic-examination method is employed,the authorized inspector shall check the performance of theexaminations at random and shall evaluate the results on thebasis of the test report and the radiographs.

(7) If the authorized inspector has participated in the non-destructive examinations performed by the manufacturer, heshall include confirmation to this effect in the manufacturer’scertificates.

(8) If the authorized inspector has performed his ownexaminations, he shall check the manufacturer’s examinationresults for agreement within the error inherent to theexamination technique. Should agreement exist, he shallconfirm this in the manufacturer’s certificates.

(9) If substantial differences from the results of the manufac-turer’s examinations are found, the authorized inspector andmanufacturer together shall perform and document additionalchecks.

4.5 Re-examinations

(1) Test results that are based on incorrect taking orpreparation of the test specimens (test specimen sets), onincorrect performance of the test or on a random narrow flawlocation in one test specimen are invalid. The examinationshall be repeated.

(2) Should the results of a properly performed examinationfail to meet the above requirements, the following actions shallbe taken:

a) Lotwise examination

aa) The test coupon from which the unsatisfactoryspecimen (or specimen set) was taken shall beexcluded from the lot. It shall be replaced by twofurther test coupons from the lot, and the requiredexaminations shall be repeated on those coupons.

ab) The examination shall qualify as passed if the resultsof the re-examination meet the requirements.

ac) The lot shall be rejected if any result of the two re-examinations fails to meet the requirements. However,a check examination of the characteristic found to beout of specification is permitted on each individualpiece of the lot.

b) Individual examination

ba) For each unsatisfactory specimen (or specimen set),two further specimens (or specimen sets) from thesame sampling location shall be examined.

bb) The results of both examinations shall meet therequirements.

(3) Should it be impossible by appropriate heat treatment toeliminate the reason for the unsatisfactory result of anexamination, a new heat treatment shall be required, afterwhich the test unit shall be submitted again for examination.

(4) The cause of the unsatisfactory result of the firstexamination shall be investigated.

KTA 3211.1

Page 12

5 Product forms of ferritic steels of material group W I

5.1 Sheets and plates

5.1.1 Materials

(1) The following steel grades may be used:

a) steel grades to Section A 1

b) other steel grades meeting the prerequisites of Section 3 incombination with the stipulations in the authorizedinspector’s appraisal.

(2) The toughness requirements of clause 4.3.1 a) for thelowest operating temperature shall be considered in selectingmaterials.

5.1.2 Additional requirements for the materials

(1) Plates with nominal thicknesses equal to or larger than10 mm subjected to loading perpendicular to the rolled surfaceshall at least meet the requirements of quality class Z 35 toDIN EN 10 164. This shall be specified in the purchase order.

(2) For plates with nominal thicknesses equal to or greaterthan 150 mm, the smallest individual value of energy ab-sorbed (Charpy V-notch transverse specimens) at the middleof the plate thickness at 80 °C shall not be less than 68 J.

(3) The requirements of (1) shall apply when plates are usedfor tubesheets. In addition, the same requirements as forspecimens longitudinal to or transverse to the main rollingdirection shall apply for the room-temperature yield point or0.2 % proof stress and tensile strength of standard specimensperpendicular to the plate surface. This shall be specified inthe purchase order.

(4) The surface finish shall satisfy the stipulations of DIN EN10 163-2 Class B Subgroup 3. Elimination of surface defectsby welding is not permitted.

5.1.3 Tests and examinations

5.1.3.1 Sampling and specimen preparation

(1) The sampling locations are stipulated in Section A 1.

(2) The following specimens shall be taken for the tensiletest at room temperature:

a) For plates with nominal thicknesses equal to or larger than40 mm, flat tensile-test specimens containing both rolledsurfaces. Round tensile-test specimens may also be used.

b) For plates with nominal thicknesses larger than 40 mm, flattensile-test specimens at least 40 mm thick containing atleast one intact rolled surface. Round tensile-test speci-mens with the specimen axis at one quarter of nominalthickness under the rolled surface (test diameter equal toor larger than 10 mm) may also be used.

(3) The following specimens shall be taken for the tensiletest at elevated temperature:

a) For plates with nominal thicknesses smaller than 12 mm,flat tensile-test specimens or round tensile-test specimens.

b) For plates with nominal thicknesses equal to or larger than12 mm up to and including 40 mm, round tensile-testspecimens.

c) For plates with nominal thicknesses larger than 40 mm,round tensile-test specimens with the specimen axis at onequarter of nominal thickness under the rolled surface (testdiameter equal to or larger than 10 mm).

(4) The notched-bar impact bend test shall be subject to thefollowing requirements:

a) For plates with nominal thicknesses smaller than 5 mm, anotched-bar impact bend test is not required.

b) For plates with nominal thicknesses between 5 mm andsmaller than 10 mm, specimens with a width equal to theplate thickness shall be taken. The rolled surfaces shall beground. Dressing of the specimens is permitted, in whichcase specimens 5 or 7.5 mm wide are preferable.

c) For plates with nominal thicknesses equal to or larger than10 mm up to and including 40 mm, specimens shall betaken at the rolled surface.

d) For plates with nominal thicknesses larger than 40 mm,specimens with their axis at one quarter of the platethickness under the rolled surface shall be taken.

(5) Transverse specimens shall be used for the tensile andnotched-bar impact bend tests.

(6) Specimens for determination of the reduction of area atfracture on perpendicular specimens shall be taken and be pre-pared in accordance with the stipulations in DIN EN 10 164.

(7) Standard specimens shall be used for determination of theroom-temperature yield point or 0.2 % proof stress and tensilestrength on specimens perpendicular to the plate surface.

5.1.3.2 Extent of tests and examinations

(1) The chemical composition shall be determined by per-forming:

a) One ladle analysis per heat.

b) One product analysis on one sampling location in each oftwo rolled plates per heat.

(2) The mechanical and technological characteristics shallbe determined by performing:

a) One room-temperature tensile test per sampling location.

b) One elevated-temperature tensile test per heat, dimensio-nal range and at most 30 metric tons. The test temperatureis defined in Section A 1 or in the authorized inspector'sappraisal.

c) Three room-temperature tensile tests to DIN EN 10 164 atone sampling location per rolled plate for plates withnominal thicknesses equal to or larger than 10 mm, inorder to determine the reduction of area at fracture,whenever the requirement of clause 5.1.2 (1) is applicable.

d) One notched-bar impact bend test to clause 4.4.6.5 persampling location at 33 °C or at the lowest operatingtemperature, whichever is lower, for plates with nominalthicknesses equal to or larger than 5 mm. Notwithstandingthe foregoing, the energy absorbed for steel grade15 MnNi 6 3 shall be determined at 0 °C.

e) Notched-bar impact bend tests at one sampling location fordetermination of the energy absorbed vs. temperaturecurve to clause 4.4.6.6 per heat, dimensional range andidentical heat treatment for plates with nominal thicknessesequal to or larger than 10 mm and equal to or smaller than38 mm, and per rolled plate for plates with nominalthicknesses larger than 38 mm. At least four testtemperatures shall be used, of which two shall be 0 °C andthe lowest loading temperature. This test may be waivedfor plates of steel grade 15 MnNi 6 3.

f) One notched-bar impact bend test to clause 4.4.6.5 at onesampling location per rolled plate, to determine the uppershelf energy for plates with nominal thicknesses largerthan 16 mm. This test may be performed during determina-tion of the energy absorbed vs. temperature curves. Ingeneral, 80 °C shall be selected as the test temperature.The test shall be performed only in test group A 1, andmay be waived if the value of energy absorbed determinedper d) is equal to or greater than 100 J.

g) One notched-bar impact bend test to clause 4.4.6.5 at80 °C at one sampling location in the middle of the platethickness of each rolled plate for plates with nominal

KTA 3211.1

Page 13

thicknesses equal to or greater than 150 mm, unlessotherwise stipulated in the appraisal.

(3) The non-destructive examinations shall be subject to thefollowing requirements:

a) Each plate with nominal thickness equal to or larger than10 mm shall be subjected to an ultrasonic surface exami-nation to SEL 072 by the manufacturer. If the examinationis not performed with automated examination systems,10 % of the delivery shall additionally be examined by theauthorized inspector.

b) The requirements of Class 3 to SEL 072 shall apply to thesurface examination.

(4) Each rolled plate shall be subjected to a materialsidentification check.

(5) Each plate shall be subjected to a visual inspection of itsexternal finish.

(6) The thickness of each rolled plate shall be measured.

5.1.4 Marking

(1) Each plate shall be marked with the followinginformation:

a) manufacturer’s symbol,

b) steel grade (for steels with guaranteed reduction of area atfracture perpendicular to the product surface additionallyquality class to DIN EN 10 164),

c) heat number,

d) specimen number,

e) authorized inspector’s mark.

(2) The marking shall be applied such that it appears uprightwhen viewed in the main rolling direction of the rolled plate.

5.1.5 Verification of quality characteristics

(1) The results of the ladle analysis, product analysis,materials identification check and ultrasonic examination per-formed by the manufacturer shall be documented with anacceptance test certificate 3.1.B to DIN EN 10 204, and theresults of the visual inspection and dimensional check with anacceptance test certificate 3.1.C to DIN EN 10 204. The deli-very condition shall be indicated in the acceptance testcertificate 3.1.B.

(2) The results of all other tests and examinations shall becertified by the authorized inspector and combined with theabove-mentioned certificate as an acceptance test certificate3.1.C to DIN EN 10 204.

5.2 Dished or pressed product forms made from plate

5.2.1 Materials


a) steel grades to Section A 1,

b) other steel grades that the meet the prerequisites ofSection 3 in combination with the stipulations in theauthorized inspector’s appraisal.



(1) Product forms with nominal thicknesses equal to orlarger than 10 mm subjected to loading perpendicular to therolled surface shall at least meet the requirements of quality

class Z 35 to DIN EN 10 164. This shall be specified in thepurchase order.

(2) For product forms with nominal thicknesses greater than150 mm, the smallest individual value of energy absorbed(Charpy V-notch transverse specimens) at the middle of theproduct-form thickness at 80 °C shall not be less than 68 J.

5.2.3 Starting plates

(1) Starting plates shall be subject to the stipulations inSection 5.1.

(2) If the finished parts are tested individually in accordancewith clause 5.2.4.2, the tests to clause 5.1.3.2 (2) as well asthe corresponding verifications can be omitted.

(3) For the tests to clauses 5.1.3.2 (4) to (6), an acceptancetest certificate 3.1.B to DIN EN 10 204 will suffice.

Note:The stipulations of KTA 3211.3 shall apply to welded joints madewith the starting plates and remaining in the finished parts.

(4) If it is agreed in the purchase order that an ultrasonicexamination will be performed on the starting plates, thisexamination shall be performed to clause 5.1.3.2 (3) in theagreed delivery condition.

5.2.4 Tests and examinations of dished or pressed productforms made from plates


(1) For product forms with a diameter or length equal to orsmaller than 3000 mm, the tests or examinations shall beperformed on one part per rolled plate and heat-treatment lot.The maximum permissible lot size shall be 10 parts.

Note:Correlation of parts with the rolled plate can be achieved, forexample, through the specimen number of the starting plates.

(2) For product forms with a diameter or length greater than3000 mm, each part shall be tested. For lengths or diametersexceeding 6 m one test coupon each shall be taken at twoopposite sides.

(3) One test coupon shall be taken from each part to beexamined regardless of its diameter or length.

(4) The test coupons shall be taken such that transversespecimens can be machined. Deviations up to 20 degreesfrom the theoretical transverse direction are permitted for heads(ends) and similar parts. If this is not possible, a different wayof sampling shall be agreed with the authorized inspector.

(5) Round tensile-test specimens with a test diameter equalto or larger than 10 mm shall be made for both the room-temperature and elevated-temperature tensile tests. Fornominal thicknesses larger than 40 mm, the specimen axisshall be located at a distance of one quarter of the product-form thickness under the rolled surface.

For product-form thicknesses that do not permit a test diame-ter of 10 mm, the largest possible diameter shall be chosen.

(6) For nominal wall thicknesses equal to or smaller than40 mm, one side of the specimens for the notched-bar impactbend test shall be as close as possible to the rolled surface.For nominal wall thicknesses larger than 40 mm, the specimenaxis shall be located at a distance of one quarter of theproduct-form thickness under the rolled surface.



KTA 3211.1

Page 14


b) One elevated-temperature tensile test per heat, dimensio-nal range and at most 30 metric tons. The test temperatureis defined in Section A 1 or in the authorized inspector’sappraisal.

c) Three tensile tests (three perpendicular specimens toDIN EN 10 164) at one sampling location per rolled platefor product forms with nominal wall thicknesses equal to orlarger than 10 mm subject to loading perpendicular to therolled surface, in order to determine the reduction of areaat fracture. This test may be waived if it has already beenperformed on the rolled plate and documented with anacceptance test certificate 3.1.C to DIN EN 10 204.


d) One notched-bar impact bend test to clause 4.4.6.5 persampling location at 33 °C or at the lowest operating tem-perature, whichever is lower, for nominal wall thicknessesequal to or larger than 5 mm. Notwithstanding the fore-going, the energy absorbed for steel grade 15 MnNi 6 3shall be determined at 0 °C.

e) Notched-bar impact bend tests at one sampling location fordetermination of the energy absorbed vs. temperaturecurve to clause 4.4.6.6 per heat, dimensional range andheat-treatment lot for product forms with nominal wallthicknesses equal to or larger than 10 mm and equal to orsmaller than 38 mm, and per rolled plate for product formswith nominal wall thicknesses larger than 38 mm. At leastfour test temperatures shall be used, of which two shall be0 °C and the lowest loading temperature. This test may bewaived for product forms of steel grade 15 MnNi 6 3.

f) One notched-bar impact bend test to clause 4.4.6.5 at onesampling location of each part to be tested to determinethe upper shelf energy for product forms with nominal wallthicknesses larger than 16 mm. This test may be per-formed during determination of the energy absorbed vs.temperature curve. In general, 80 °C shall be selected asthe test temperature. The test shall be performed only intest group A 1, and may be waived if the value of energyabsorbed determined per d) is equal to or greater than100 J.

g) One notched-bar impact bend test to clause 4.4.6.5 persampling location at 80 °C in the middle of the product-form thickness for product forms with nominal wallthicknesses equal to or greater than 150 mm, unlessotherwise stipulated in the appraisal.


a) If agreed in the purchase order, the starting plates or thefinished parts with nominal wall thicknesses equal to orlarger than 10 mm shall be subjected to an ultrasonicsurface examination per clause 5.1.3.2 (3).

b) The flange and knuckle of each head (end) shall besubjected to a surface-crack detection in the finish-machined condition after the last heat treatment. Theacceptance criteria are defined in Table 5.2-1.

(3) Each product form shall be subjected to a materialsidentification check.

(4) Each product form shall be subjected to a visualinspection of its external finish.

(5) Each product form shall be checked for accuracyregarding dimensions and form.

5.2.5 Marking

(1) Each product form shall be marked with the followinginformation:

a) symbol of the manufacturer of the product form,


c) heat number,

d) specimen number and

e) authorized inspector's mark.

(2) In the case of lotwise examination, the product form fromwhich the specimens were taken shall additionally be marked.



(1) The results of the ladle analysis, product analysis,materials identification check and non-destructive examina-tions performed by the manufacturer, and of the heat-treatment condition shall be documented with an acceptancetest certificate 3.1.B and the results of the visual inspectionand dimensional check with an acceptance test certificate3.1.C to DIN EN 10 204. The delivery condition shall beindicated in the acceptance test certificate 3.1.B.

(2) The forming method shall be indicated in acceptance testcertificate 3.1.B to DIN EN 10 204.


Material groupAllowable actual extension of defect

in main forming direction, in mmInspectionon for wall

thicknesses≤ 10 mm

for wallthicknesses

> 10 mm

Allowable length ofnonmetallic

inclusions 1) in themain forming direction

in mm

Maximumallowable

frequency per10 x 10 cm2

StartingproductSteels with specified

yield point > 370 N/mm2 Formedproduct

≤ 1,5 ≤ 1,5 ≤ 6 10

Startingproduct ≤ 1,5 ≤ 3 ≤ 6 10Steels with specified

yield point ≤ 370 N/mm2 Formedproduct ≤ 1,5 ≤ 3 ≤ 10 10

1) For several similar indications, verification by a specimen randomly taken from the test coupon is permitted.

Table 5.2-1: Acceptance criteria for findings of the liquid-penetrant and magnetic-particle examinations

KTA 3211.1

Page 15

5.3 Forgings, bar steel and rolled rings

5.3.1 Materials






For products with heat-treatment thicknesses greater than150 mm and heat-treatment weights heavier than 500 kg, thesmallest individual value of energy absorbed (Charpy V-notchtransverse specimens) at the middle of the wall thickness at80 °C shall not be less than 68 J.

Note:Heat-treatment thickness and heat-treatment weight designate thewall thickness and piece weight of the product forms in thecondition in which the heat treatment governing establishment ofthe mechanical and technological characteristics is performed.



5.3.3.1.1 Test units

(1) Unless otherwise required in clause 5.3.3.2, the followingis required:

a) Pieces with heat-treatment weights lighter than or equal to100 kg may be grouped as test units of 1000 kg each.

b) Pieces with heat-treatment weights heavier than 100 kgand equal to or lighter than 500 kg from the same heat,with similar dimensions and from the same heat-treatmentlot shall be grouped as test units containing at most 10parts.

c) Pieces with heat-treatment weights heavier than 500 kgshall be tested individually.

5.3.3.1.2 Sampling locations

(1) For forged hollow parts, e.g., for shell courses, nozzlesor valve bodies, specimens shall be taken from one end as afunction of inside diameter Di as follows: from one samplinglocation for Di equal to or smaller than 500 mm; from twosampling locations separated by 180 degrees for Di between500 mm and 2000 mm; and from three sampling locationsseparated by 120 degrees for Di larger than 2000 mm.

(2) At the opposite end, specimens shall be taken from onesampling location for normalized or air quenched andtempered forgings having a finished length longer than5000 mm and for liquid quenched and tempered forgingshaving a finished length longer than 2000 mm. For pieces withinside diameters smaller than or equal to 500 mm, thissampling location shall be offset by 180 degrees relative tothat at the other end (see Figures 5.3-1 and 5.3-2).

Note:Finished length designates the length of the product form duringthe governing heat treatment, less the length of the test coupons.

(3) For seamless rolled or forged rings or flanges,specimens shall be taken from the circumference or end of theflange. They may also be taken from the end of the weldingend, if the heat-treatment wall thickness of the welding end isequal to that of the flange. Specimens shall be taken asfollows: from one sampling location for inside diameters Di

smaller than or equal to 1000 mm; from two samplinglocations separated by 180 degrees for Di between 1000 mmand 2000 mm; and from three locations separated by 120degrees for Di larger than 2000 mm (see Figure 5.3-3).

(4) For plates such as tubesheets, tube plates or blanking-off covers with heat-treatment weights lighter than 1000 kg,specimens shall be taken from one sampling location. Ifpermitted by the forging method employed, this location shallbe in the top or bottom zone (see Figure 5.3-4).

(5) For plates with heat-treatment weights equal to orheavier than 1000 kg, specimens shall be taken from twosampling locations. If permitted by the forging methodemployed, these locations shall be in the top and bottomzones (see Figure 5.3-4).

(6) For forged bars, specimens shall be taken at one end asa function of the diameter D of the bars: from one samplinglocation for D smaller than or equal to 500 mm; and from twosampling locations separated by 180 degrees for D larger than500 mm.

(7) At the opposite end, specimens shall be taken from onesampling location for normalized or air quenched andtempered bars having a finished length longer than 5000 mmand for liquid quenched and tempered bars having a finishedlength longer than 2000 mm. For bars having diameterssmaller than or equal to 500 mm, this location shall be offsetby 180 degrees relative to that at the other end.

5.3.3.1.3 Sampling depth

(1) For normalized and air quenched and tempered parts,the specimens shall be taken from at least one quarter of thegoverning heat-treatment thickness but at most 80 mm underthe heat-treatment surfaces.

(2) For liquid quenched and tempered parts, except forplates with heat-treatment thicknesses larger than 320 mm,the specimens shall be taken from at least one quarter of thegoverning heat-treatment thickness but at most 80 mm underthe governing heat-treatment surface and at least from themiddle of the governing heat-treatment thickness (s/2) and atmost 160 mm under the other surfaces.

(3) For liquid quenched and tempered plates with heat-treatment thicknesses larger than 320 mm, the specimensshall be taken from at least 80 mm under the heat-treatmentsurfaces.

(4) For parts with a governing heat-treatment thickness lar-ger than 150 mm and a heat-treatment weight heavier than500 kg, samples shall be taken additionally at one locationfrom the middle of the governing heat-treatment thickness(s/2).

Note:In the case of plates for tubesheets, the question of whether thisrequirement is met shall be verified in the appraisal by the energyabsorbed at the middle of the wall thickness.

5.3.3.1.4 Specimen direction

(1) Transverse specimens shall be taken for tensile testsand notched-bar impact bend tests if geometrically possibleand nothing to the contrary is stipulated in Section A 2 or inthe authorized inspector's appraisal.

(2) Notwithstanding the foregoing, longitudinal specimens oraxial specimens may be taken from bars, specifically fortensile tests if the diameter or greatest length of a cross-sectional edge is smaller than 160 mm, or for notched-barimpact bend tests if the diameter or the greatest length of across-sectional edge is smaller than 68 mm.

KTA 3211.1

Page 16


(1) The following procedures shall be performed for thechemical analysis:


b) One product analysis on one sampling location in each oftwo separately manufactured pieces per heat.

c) One product analysis on each piece for piece weightsequal to or heavier than 5000 kg.


a) One hardness test per piece to verify uniformity for piecesgrouped together in test units.

Note:Verification of uniformity shall be acknowledged if the differencebetween the highest and lowest hardness values in a test unitdoes not exceed 30 HB units.

b) One room-temperature tensile test per sampling location.

c) For pieces of similar dimension, one elevated-temperaturetensile test per heat and heat-treatment lot. The testtemperature is defined in Section A 2 or in the authorizedinspector’s appraisal.

d) One notched-bar impact bend test to clause 4.4.6.5 persampling location at 33 °C or at the lowest operatingtemperature, whichever is lower. Notwithstanding the fore-going, the energy absorbed for steel grade 15 MnNi 6 3shall be determined at 0 °C.

e) Notched-bar impact bend tests for determination of theenergy absorbed vs. temperature curve to clause 4.4.6.6.

ea) per heat and heat-treatment lot for pieces with heat-treatment weights equal to or lighter than 500 kg

eb) per piece, at one sampling location, for pieces withheat-treatment weights equal to or heavier than500 kg.

At least four test temperatures shall be used, of which twoshall be 0 °C and the lowest loading temperature. This testmay be waived for pieces of steel grade 15 MnNi 6 3 withwall thicknesses smaller than or equal to 150 mm.

f) One notched-bar impact bend test to clause 4.4.6.5 at onesampling location per test unit to verify the upper shelfenergy for pieces with heat-treatment weights equal to orheavier than 150 kg in the normalized or air quenched andtempered condition and equal to or heavier than 50 kg inthe liquid quenched and tempered condition. It shall bedemonstrated that the smallest individual value of uppershelf energy is equal to or larger than 100 J. This test maybe performed during determination of the energy absorbedvs. temperature curves. In general, 80 °C shall be selected

as the test temperature. The test shall be performed onlyin test group A 1, and may be waived if the value of energyabsorbed determined per d) is equal to or greater than100 J. This test may be waived for pieces of steel grade15 MnNi 6 3 with wall thicknesses smaller than or equal to150 mm.

g) One notched-bar impact bend test to clause 4.4.6.5 at80 °C at one sampling location in the middle of thethickness for products with heat-treatment weights heavierthan 500 kg and heat-treatment thicknesses larger than150 mm, unless otherwise stipulated in the appraisal.

(3) Each piece shall be subjected to a non-destructiveexamination to Annex H.

(4) Each piece shall be subjected to a materials identificationcheck.

(5) Each piece shall be subjected in the as-deliveredcondition to a visual inspection of its external finish.

(6) A dimensional check of each piece shall be performed.

5.3.4 Marking

(1) Each piece shall be marked with the followinginformation:

a) manufacturer's symbol,


c) heat number,

d) specimen number,

e) authorized inspector's mark and

f) mark of the non-destructive examinations performed.

(2) In the case of lotwise examination, the piece from whichthe specimens were taken shall additionally be marked.


(1) The results of the ladle analysis, product analysis,materials identification check and non-destructive examina-tions performed by the manufacturer, and if necessary of thehardness test shall be documented with an acceptance testcertificate 3.1.B to DIN EN 10 204, which shall include anindication of the delivery condition.


KTA 3211.1

Page 17

No. Finished length Inside diameter Di Examples for sampling

1 ≤ 500 mm

2

Normalized and air quenchedand tempered pieces:L ≤ 5000 mm

Pieces quenched andtempered in liquid:L ≤ 2000 mm

> 500 mm up to≤ 2000 mm

3 > 2000 mm

4 ≤ 500 mm

5

Normalized and air quenchedand tempered pieces:L > 5000 mm

Pieces quenched andtempered in liquid:L > 2000 mm

> 500 mm up to≤ 2000 mm

6 > 2000 mm

Figure 5.3-1: Examples for sampling from forged hollow parts

x

Example 3

s

x

s/4

x

s

x

s/4

ss/

4

L

Example 2

HUR

HU

R

HUR

Example 1

L

HUR: Main forming direction

ss/4

Example 4

L

HUR

L

for pieces quenched and tempered in liquid: x = s/2for normalized and air quenched and tempered pieces: x = s/4

Figure 5.3-2: Examples for sampling from forged valve bodies

i

x

s

D

Di

L

Di

x

s

Di

xs/

4s/

4s/

4s/

4s/

4s

s/4

L

Di

L

L

L

L

s

for normalized and airquenched and temperedpieces: x = s/4

x

iD

tempered in liquid: x = s/2

s

x

s

x

for pieces quenched and

KTA 3211.1

Page 18

<≤ >≤

i

1

2

1

1

1

1

i

1

iD D

s

s

x

/4

x

ii

s

i

/4

/4

x

s

s

1

s

D

1

s

D

s

2000 mm2000 mmD

/4s/2

b) Distribution of sampling locations on the circumference or at the end as a function of inside diameter

D

For normalized or air quenched and tempered parts: x =For parts quenched and tempered in liquid: x =

1000 mm

Example 3

a) Examples for sampling

Example 1 Example 2

1000 mm

Figure 5.3-3: Examples for sampling from seamless rolled or forged rings or flanges

>

≥

≤ >

s/2

80s

s/2 s

80

x 80

80

s/2

x

x

80

s/4

80

s

80

80

s/4

plates with s 320 mm

Sampling from top andSampling from top andbottom zones not possiblefor s 150 mm

b) Sampling for

Contour for quenchingand tempering

Test couponDelivery contour

bottom zones possible

plates with s 320 mmc) Sampling for

Sampling at s/2 only

For normalized or air quenched andin liquid: x = s/2 (max. 160 mm)For plates quenched and tempered

plates with s 320 mma) Sampling for

tempered plates: x = s/4 (max. 80 mm)

Figure 5.3-4: Examples for sampling from forged plates

KTA 3211.1

Page 19

5.4 Seamless pipes larger than DN 50

5.4.1 Scope

(1) The stipulations of this Section shall apply to seamless,rolled or pressed pipes larger than DN 50.

Note:For forged pipes Section 5.3 shall apply.

(2) The stipulations of this Section shall also apply to pipesequal to or smaller than DN 50 if pipe elbows larger thanDN 50 are made from such pipes.

(3) The stipulations of this Section shall not apply to pipesfor vessel shells.

5.4.2 Materials






Pipes with nominal wall thicknesses equal to or larger than10 mm and subject to loading perpendicular to the surfaceshall at least meet the requirements of quality class Z 35 toDIN EN 10 164. This shall be specified in the purchase order.



(1) The pipes shall be tested in manufacturing lengths.

(2) Specimens shall be taken from the ends of manufac-turing lengths.

(3) Transverse specimens shall be taken for tensile testsand notched-bar impact bend tests. If this is not possible, it ispermitted to take longitudinal specimens.

(4) Notched-bar impact bend tests shall be performed onlyfor pipes with nominal wall thicknesses equal to or larger than10 mm.

(5) Specimen forms to DIN EN 10 002-1 and DIN EN 10 002-5may also be used for tensile tests.

(6) For tensile tests other than those to DIN EN 10 002-1and DIN EN 10 002-5 and for notched-bar impact bend tests,the test coupons shall be taken such that the specimen axis islocated at one quarter of the wall thickness under the outsidesurface and at one half of the wall thickness under the endface or as close as possible to that location.

(7) Specimens for determination of reduction of area atfracture on perpendicular specimens shall be taken at thesame location as for the room-temperature tensile-testspecimens.




b) One product analysis on each of two manufacturinglengths per heat.


a) Room-temperature tensile tests for every 20 manufacturinglengths of the same heat, dimension and heat treatment

aa) at one end of one manufacturing length for pipes ofnormalized or air quenched and tempered steels

ab) at both ends of one manufacturing length for pipes ofliquid quenched and tempered steels.

b) One elevated-temperature tensile test per heat, dimensionand heat treatment if the design temperature is higher than100 °C. The test temperature is defined in Section A 3 or inthe authorized inspector's appraisal.

c) Tensile tests on three perpendicular specimens, takenfrom one sampling location every 20 manufacturinglengths of the same heat, dimension and heat treatment, todetermine the reduction of area at fracture for pipes withnominal wall thicknesses equal to or larger than 10 mmand subjected to loading perpendicular to the surface. Thistest may be waived for steel grades for which it wasdemonstrated in the material appraisal that the mean valueof reduction of area afire fracture of three perpendicularspecimens is at least 45 % and that none of the individualvalues is smaller than 35 %.

d) One notched-bar impact bend test to clause 4.4.6.5 at33 °C or at the lowest operating temperature, whichever islower, at one end of one manufacturing length per 20manufacturing lengths of the same heat, dimension andheat treatment for pipes of normalized or air quenched andtempered steels with nominal thicknesses equal to orsmaller than 38 mm, and at one end of each manufac-turing length for pipes with nominal thicknesses larger than38 mm. For pipes of steel grade 15 MnNi 6 3, the testtemperature shall be 0 °C.

e) One notched-bar impact bend test to clause 4.4.6.5 at33 °C or at the lowest operating temperature, whichever islower, at both ends of one manufacturing length per 20manufacturing lengths of the same heat, dimension andheat treatment for pipes of liquid quenched and temperedsteels with nominal wall thicknesses equal to or smallerthan 16 mm, and at both ends of each manufacturinglength for pipes with nominal wall thicknesses larger than16 mm.

f) Notched-bar impact bend tests for determination of anenergy absorbed vs. temperature curve to clause 4.4.6.6at one end of one manufacturing length per heat,dimension and heat treatment for pipes with nominal wallthicknesses equal to or larger than 10 mm. At least fourtest temperatures shall be used, of which two shall be 0 °Cand the lowest loading temperature. This test may bewaived for pipes of steel grade 15 MnNi 6 3.

g) One notched-bar impact bend test to clause 4.4.6.5 at oneend of each manufacturing length to determine the uppershelf energy for pipes of normalized or air quenched andtempered steels with nominal wall thicknesses larger than38 mm as well as for pipes of liquid quenched andtempered steels with nominal wall thicknesses larger than16 mm. This test may be performed during determinationof the energy absorbed vs. temperature curves. In general,80 °C shall be selected as the test temperature. This testshall be performed only in test group A 1, and may bewaived if the value of energy absorbed determined per d)or e) is equal to or greater than 100 J.

h) Technological tests per Table 5.4-1 at both ends of eachmanufacturing length for pipes with nominal wallthicknesses equal to or smaller than 40 mm.

KTA 3211.1

Page 20

Nominal wallthickness sof the pipes

Nominal outside diameterof the pipes

in mm

in mm ≤ 146 > 146

s < 2 Flattening test

2 ≤ s ≤ 16 Ring expanding test 1) Ring tensile test

16 < s ≤ 40 Flattening test Ring tensile test

1) The drift test also may be performed.

Table 5.4-1: Dimensional ranges for application of thetechnological tests to pipes

(3) Non-destructive examinations shall be subject to thefollowing requirements:

a) All pipes shall be examined ultrasonically for longitudinaldefects to SEP 1915. Pipes of test group A 1 equal to orlarger than DN 100 shall additionally be subjected to anultrasonic transverse-defect examination to SEP 1918 aswell as to an examination for laps to SEP 1919. Pipes oftest group A 2 equal to or larger than DN 100 shall beexamined for transverse defects to SEP 1918 if they werehot-pilger-rolled or subjected to hot pilger rolling during themanufacturing process.

b) One surface-crack detection shall be performed on everyfourth pipe of test group A 1. The outside surface shall beexamined completely and the inside surface shall beexamined over a length of 1 times the outside diameterfrom each end of the pipe. The acceptance criteria aredefined in Table 5.2-1.

c) Pipes with nominal wall thicknesses larger than 30 mmand diameters larger than DN 600 shall be examined toAnnex H as hollow forged or hollow rolled parts.

(4) Each pipe shall be subjected to a materials identificationcheck.

(5) The inside and outside surfaces of each pipe shall besubjected to a visual inspection.

(6) The diameter and wall thickness shall be checked fordimensional accuracy at both ends of each pipe.

(7) Each pipe shall be examined for leak tightness either byan internal hydrostatic pressure test or, at the manufacturer’sdiscretion, by an appropriate non-destructive examination toSEP 1925. For the internal hydrostatic pressure test, the testpressure shall generally be 8 MPa. The test pressure shall belimited such that the factor of safety relative to the yield pointat room temperature is never less than 1.1.

5.4.5 Marking

(1) Each pipe shall be marked at both ends, 300 mm fromthe ends, with the following information:


b) steel grade (for carbon steels additionally quality level, forsteels with guaranteed reduction of area at fractureperpendicular to the product surface additionally qualityclass to DIN EN 10 164) and

c) authorized inspector’s mark.

(2) Each pipe shall additionally be marked at one end withthe following information:

a) heat number,

b) pipe number and

c) mark of the non-destructive examinations performed.


(1) The results of the ladle analysis, product analysis,materials identification check, tightness test and non-destruc-tive examinations performed by the manufacturer shall bedocumented with acceptance test certificates 3.1.B to DIN EN10 204, which shall include an indication of the deliverycondition.

(2) The results of all other tests and examinations shall becertified by the authorized inspector and combined with theabove-mentioned certificates as an acceptance test certificate3.1.C to DIN EN 10 204.

5.5 Seamless pipe elbows larger than DN 50

5.5.1 Scope

(1) This Section shall apply to seamless pipe elbows (weld-in elbows) made from seamless rolled, extruded or forgedpipes by cold or hot forming followed by heat treatment(normalization; quenching and tempering).

(2) This Section shall not apply to pipe bends made withinductive bending machines or by cold forming with or withoutsubsequent heat treatment. These pipe bends are subject tothe requirements of KTA 3211.3 Section 6.

5.5.2 Materials


a) steel grades to Section A 3 and



(3) For finished pipe elbows, the values of the mechanicaland technological characteristics to Section A 3 shall applyeven if forged hollow parts are used as starting products.

5.5.3 Starting products

(1) Forged hollow parts to Section 5.3 and seamless pipesto Section 5.4 may be used as starting products.

(2) Starting products that have not been completelyexamined and heat-treated to the stipulations in Sections 5.3or 5.4 may also be used, provided the finished pipe elbowsare examined individually to clause 5.5.4.2. In this case thedetermination of mechanical and technological characteristicsand the corresponding verification may be waived for thestarting products. An acceptance test certificate 3.1.B toDIN EN 10 204 shall then be adequate for visual inspectionand dimensional check of the starting products.

5.5.4 Tests and examinations of pipe elbows


(1) Specimens shall be taken from the ends of the pipeelbows in conformity with the authorized inspector’s appraisal.

(2) The specimen axes shall be located at one quarter of thewall thickness under the outside surface and at one half of thewall thickness under the end face or as close as possible tothat location.

(3) Transverse specimens shall be taken for tensile testsand notched-bar impact bend tests. If this is not possible,longitudinal specimens shall be selected.

KTA 3211.1

Page 21

(4) Notched-bar impact bend tests shall be performed onlyfor pipe elbows with nominal wall thicknesses equal to orlarger than 10 mm.

(5) If starting products that have not been completelyexamined and heat-treated to the stipulations in Sections 5.3or 5.4 are used, test coupons shall be taken from both ends ofpipe elbows with an arc length greater than 3000 mm,measured along the outside of the bend.

(6) In all other cases, test coupons shall be taken from onlyone end of the pipe elbow.

(7) If the pipe elbows are not tested individually, test unitsconsisting of pipe elbows of the same heat, dimension andheat treatment shall be formed for determination ofmechanical and technological characteristics.

(8) For the room-temperature tensile tests and for thenotched-bar impact bend tests, the number of pipe elbows pertest unit shall not exceed:

a) 30 pieces for pipe elbows smaller than DN 200

b) 20 pieces for pipe elbows equal to or larger than DN 200and smaller than DN 350

c) 10 pieces for pipe elbows equal to or larger than DN 350.


(1) The chemical composition shall be verified on the basisof the starting product.


a) One room-temperature tensile test for each samplinglocation of one pipe elbow per test unit, and for eachsampling location of each pipe elbow in the case ofindividual testing.

b) One elevated-temperature tensile test for one samplinglocation of one pipe elbow per heat, dimension and heattreatment, and for one sampling location of each pipeelbow in the case of individual testing. The test tempera-ture is defined in Section A 3 or in the authorized inspec-tor’s appraisal.

c) One notched-bar impact bend test to clause 4.4.6.5 at33 °C or at the lowest operating temperature, whichever islower, for each sampling location of one pipe elbow pertest unit for pipe elbows of normalized or air quenched andtempered steels with nominal wall thicknesses equal to orsmaller than 38 mm, as well as for pipe elbows of liquidquenched and tempered steels with nominal wallthicknesses equal to or smaller than 16 mm. For greaterwall thicknesses as well as in the case of individual testing,this test shall be performed at each sampling location ofeach pipe elbow. For pipe elbows of steel grade15 MnNi 6 3, the test temperature shall be 0 °C.

d) Notched-bar impact bend tests for determination of anenergy absorbed vs. temperature curve to clause 4.4.6.6for one sampling location of one pipe elbow per heat,dimension and heat treatment for pipe elbows with nominalwall thicknesses equal to or larger than 10 mm. At leastfour test temperatures shall be used, of which two shall be0 °C and the lowest loading temperature. This test may bewaived for pipe elbows of steel grade 15 MnNi 6 3.

e) One notched-bar impact bend test to clause 4.4.6.5 todetermine the upper shelf energy at one sampling locationof each elbow for pipe elbows of normalized or airquenched and tempered steels with nominal wall thicknes-ses equal to or larger than 38 mm as well as for pipeelbows of liquid quenched and tempered steels withnominal wall thicknesses larger than 16 mm. This test maybe performed during determination of the energy absorbedvs. temperature curves. In general, 80 °C shall be selected

as the test temperature. This test shall be performed onlyin test group A 1, and may be waived if the value of energyabsorbed determined per d) or e) is equal to or greaterthan 100 J.

f) For pipe elbows grouped together as test units, onehardness test per pipe elbow to verify uniformity.



a) For pipe elbows equal to or larger than DN 100, the out-side and inside surfaces shall be subjected to a surface-crack detection. For pipe elbows smaller than DN 100, theoutside surface shall be subjected to a complete surface-crack detection and the inside surface shall be subjectedto a surface-crack detection wherever it is accessible. Theacceptance criteria are defined in Table 5.2-1.

b) All pipe elbows smaller than DN 100 shall be ultrasonicallyexamined to SEP 1915 and SEP 1918 for longitudinal andtransverse defects in the surface zones that are notaccessible to surface-crack detection.

c) Pipe elbows with nominal wall thicknesses larger than30 mm and diameters larger than DN 600 shall be exa-mined to Annex H as hollow forged or hollow rolled parts.

d) If an ultrasonic examination is performed on the pipeelbow, the corresponding examination on the startingproduct may be waived.

(4) Each pipe elbow shall be subjected to a materials identi-fication check.

(5) The inside and outside surfaces of each pipe elbow shallbe subjected to a visual inspection.

(6) For each pipe elbow, the wall thickness and, dependingon the purchase order, either the outside or inside diametershall be measured over the arc length, including the ends, andto a sufficient extent over the circumference. The smallest wallthickness as well as the ovality shall be determined.

5.5.5 Marking

(1) Each pipe elbow shall be marked with the followinginformation:



c) heat number,

d) pipe-elbow number




(1) The results of the ladle analysis, product analysis,materials identification check, hardness test and non-destruc-tive examinations performed by the manufacturer shall bedocumented with an acceptance test certificate 3.1.B toDIN EN 10 204, which shall include an indication of thedelivery condition.


KTA 3211.1

Page 22

5.6 Seamless fittings larger than DN 50

5.6.1 Scope

(1) This Section shall apply to the following seamlessfittings:

a) reducers made from seamless rolled, extruded or forgedpipes by cold or hot forming followed by heat treatment(normalization; quenching and tempering),

b) tees fabricated to the liqued bulge method.

Note:The nominal diameter of a reducer or of a tee shall refer to theend with the larger diameter.

5.6.2 Materials


a) steel grades to Section A 3 and

b) other steel grades meeting the prerequisites of Section 3 incombination with the stipulations in the authorized inspec-tor’s appraisal.


(3) For fabricated fittings, the values of the mechanical andtechnological characteristics to Section A 3 shall apply even ifforged hollow parts are used as starting products.


(1) Forged hollow parts to Section 5.3 and seamless pipesto Section 5.4 may be used as the starting product.

(2) Starting products that have not been completelyexamined and heat-treated to the stipulations in Sections 5.3or 5.4 may also be used, provided the fabricated fittings areexamined individually per clause 5.6.4.2. In this case thedetermination of mechanical and technological characteristicsand the corresponding verification may be waived for thestarting products. An acceptance test certificate 3.1.B toDIN EN 10 204 shall then be adequate for visual inspectionand dimensional check of the starting products.

5.6.4 Tests and examinations of fittings


(1) Specimens shall be taken from one end of the fittings inconformity with the authorized inspector’s appraisal.

(2) The specimen axes shall be located at one quarter of thewall thickness under the outside surface and at one half of thewall thickness under the end face or as close as possible tothat location.

(3) Where transverse specimens can be taken from non-directional test coupons they shall be taken for tensile testsand notched-bar impact bend tests. If this is not possible,longitudinal specimens shall be selected.

(4) Notched-bar impact bend tests shall be performed onlyfor fittings with nominal wall thicknesses equal to or largerthan 10 mm.

(5) If the fittings are not tested individually, test unitsconsisting of fittings of the same heat, dimension and heattreatment shall be formed for determination of mechanical andtechnological characteristics.

(6) For the room-temperature tensile tests and for thenotched-bar impact bend tests, the number of fittings per testunit shall not exceed:

a) 30 pieces for fittings smaller than DN 100

b) 10 pieces for fittings equal to or larger than DN 100.




a) One room-temperature tensile test per test unit.

b) One elevated-temperature tensile test per heat, dimensionand heat treatment, if the design temperature is higherthan 100 °C. The test temperature is defined in Section A 3or in the authorized inspector's appraisal.

c) One notched-bar impact bend test to clause 4.4.6.5 at33 °C or at the lowest operating temperature, whichever islower, on one piece per test unit for fittings of normalizedor air quenched and tempered steels with nominal wallthicknesses equal to or larger than 38 mm, as well as forfittings of liquid quenched and tempered steels withnominal wall thicknesses equal to or larger than 16 mm.For fittings of steel grade 15 MnNi 6 3, the test tempera-ture shall be 0 °C.

d) Notched-bar impact bend tests for determination of anenergy absorbed vs. temperature curve to clause 4.4.6.6on one piece per heat, dimension and heat-treatment lotfor fittings with nominal wall thicknesses equal to or largerthan 10 mm. At least four test temperatures shall be used,of which two shall be 0 °C and the lowest loadingtemperature. This test may be waived for fittings of steel15 MnNi 6 3.

e) One notched-bar impact bend test to clause 4.4.6.5 oneach piece to determine the upper shelf energy for fittingsof normalized or air quenched and tempered steels withnominal wall thicknesses larger than 38 mm as well as forfittings of liquid quenched and tempered steels withnominal wall thicknesses larger than 16 mm. In general,80 °C shall be selected as the test temperature. This testmay be performed during determination of the energyabsorbed vs. temperature curves. This test shall beperformed only in test group A 1, and may be waived if thevalue of energy absorbed determined per d) or e) is equalto or greater than 100 J.

f) For fittings grouped together as test units, one hardnesstest per fitting to verify uniformity.



a) For fittings larger than or equal to DN 100, the outside andinside surfaces shall be subjected to a surface-crackdetection. For fittings smaller than DN 100, the outsidesurface shall be examined completely and the insidesurface shall be examined wherever it is accessible. Theacceptance criteria are defined in Table 5.2-1.

b) All fittings smaller than DN 100 shall be ultrasonicallyexamined to SEP 1915 and SEP 1918 for longitudinal andtransverse defects in the surface zones that are notaccessible to surface-crack detection.

c) Fittings with nominal wall thicknesses larger than 30 mmshall be examined to Annex H as hollow forged parts.

d) If an ultrasonic examination is performed on the fitting, thecorresponding examination on the starting product may bewaived.

(4) Each fitting shall be subjected to a materials identificationcheck.

KTA 3211.1

Page 23

(5) The inside and outside surfaces of each fitting shall besubjected to a visual inspection.

(6) For each fitting, the ovality, diameter and thickness shallbe measured at the ends.

5.6.5 Marking

(1) Each fitting shall be marked with the following information:


b) steel grade (for carbon steels additionally quality level, forsteels with guaranteed reduction of area at fractureperpendicular to the product surface additionally qualityclass to DIN EN 10 164),

c) heat number,

d) fitting number or test lot number,

e) authorized inspector’s mark and



(1) The results of the ladle analysis, product analysis,materials identification check, hardness test and non-destruc-tive examinations performed by the manufacturer shall bedocumented with an acceptance test certificate 3.1.B toDIN EN 10 204, which shall include an indication of thedelivery condition.


5.7 Castings

5.7.1 Materials

(1) The following cast-steel grades may be used:

a) cast-steel grades to Section A 4 and

b) other cast-steel grades meeting the prerequisites ofSection 3 in combination with the stipulations in theauthorized inspector’s appraisal.


5.7.2 Requirements for casting condition

(1) As regards their general internal and external finish, thecastings shall meet the conditions of Table B-3 applicable totheir test group.

(2) Feeder heads and large casting-related thickenings thatimpair amenability of castings to heat treatment shall beeliminated before normalization or quenching and tempering.

(3) The casting technique shall be designed according to theprinciples of controlled solidification. For castings with nominalwidths equal to or larger than 200 mm, the gate and feedertechnique shall be explained on the basis of the saturationcalculation as well as drawings illustrating the position of thefeeders, feed zones and specimen location.

Note:The feature characterizing the dimensions of the body or caseshall be the nominal width, as follows:a) for pumps, the nominal width of the pressure nozzle,b) for valves, the largest nominal width involved,c) for safety valves, the nominal width of the inlet nozzle.

(4) For each casting model, the description of the castingtechnique shall be attached to the interim file (internal manu-facturer documentation) for retention by the manufacturer.

(5) Together with the drawing of the casting in the as-delivered condition, the following documents shall generally besubmitted as standard plans for the design approval:

a) test and inspection sequence plan and heat-treatmentplan, in case of differences from the standard productionscheme to Figure B-12,

b) for forgings of test group A 1 with nominal widths equal toor larger than 200 mm, instructions for the non-destructiveexaminations as well as a coordinate reference system(reference-point grid),

c) for prototypes of test groups A 2 and A 3 with nominalwidths equal to or greater than 200 mm a film location planand a radiation source plan,

d) welding procedure qualification and welding proceduresheet for production welds and if applicable constructionwelds (see Annex C),

e) test and inspection sequence plan for construction welds, ifnecessary.

f) list of planned production control tests.

(6) If changes are made compared with the conditionsstipulated in the welding procedure sheet, or if a differentwelding method is chosen, the welding procedure sheet shallbe amended accordingly and resubmitted for design approval.



(1) Castings with a delivery weight equal to or lighter than500 kg shall be tested in lots, and castings with a deliveryweight heavier than 500 kg shall be tested individually.

(2) The number of sampling locations shall be as indicatedin Table 5.7-1.

Product weight(delivery weight)

in kgTest unit

Number ofsamplinglocations

≤ 100 At most 2500 kg per heat,dimension and heat-treat-ment lot

1

> 100 up to ≤ 500 At most 10 pieces, but notmore than 2500 kg perheat, dimension and heat-treatment lot

1

> 500 up to ≤ 1000 Individual piece 1

> 1000 Individual piece 2

Table 5.7-1: Number of sampling locations on castings madeof ferritic steels of material group W I

(3) The specimens shall be taken from cast-on test couponsor from overlengths. Separately cast test coupons arepermitted only for castings with piece weights equal to orlighter than 150 kg.

(4) The test coupons shall be provided in sufficient numberand size that the prescribed specimens can be taken.

(5) The thickness of the cast-on test coupons shall be calcu-lated by comparison of volume/surface ratios at the governingwall thickness. However, it shall be at most 150 mm.

Note:In this connection, the governing wall thickness shall be thethickness of the wall subjected to pressure loading, and not thethickness of cast-on flanges or local thickenings.

KTA 3211.1

Page 24

(6) Cast-on test coupons at the gate system are notpermitted.

(7) The specimens shall be taken at a distance of half thethickness of the cast-on test coupons from the end and sidefaces as well as at one quarter from one of the other faces.

(8) For castings with piece weights heavier than 1000 kg,the position of the cast-on test coupons on the casting shall bedocumented by a photograph or in a sketch.




b) One product analysis for one sampling location per testunit.


a) One room-temperature tensile test per sampling location.The value of reduction of area at fracture shall also bedetermined for information.

b) One elevated-temperature tensile test per heat, dimensionand heat-treatment lot. The test temperature is defined inSection A 4 or in the authorized inspector’s appraisal. Thevalue of reduction of area at fracture shall also bedetermined for information.

c) One notched-bar impact bend test to clause 4.4.6.5 persampling location at 33 °C or at the lowest operatingtemperature, whichever is lower.

d) Notched-bar impact bend tests for determination of anenergy absorbed vs. temperature curve to clause 4.4.6.6at one sampling location per test unit. At least four testtemperatures shall be used, of which two shall be 33 C orthe lowest loading temperature and 0 °C.

e) One notched-bar impact bend test to clause 4.4.6.5 toverify the upper shelf energy at one sampling location pertest unit. In general, this test shall be performed at 80 °C.The test shall be performed only in test group A 1, andmay be waived if the notched-bar impact bend test at thelower of 33 °C or the lowest loading temperature hasalready verified that the requirements are met.

f) One hardness test on each piece to verify uniformity of thequenching and tempering treatment in the case of lotwiseexamination of castings of quenched and tempered steel.

(3) The non-destructive examinations of the castings shallbe subject to the requirements of Annex B.

(4) Each casting shall be subjected to a materials identifi-cation check.

(5) Each casting shall be subjected in the as-deliveredcondition to a visual inspection of its external finish.

(6) Each casting shall be subjected in the as-deliveredcondition to a dimensional check.

(7) Each casting shall be subjected in a condition suitable forthe purpose, generally by the further processor, to a tightnesstest in the form of an internal pressure test, which shall beperformed to DIN 50 104. Pressurizing fluid, test pressure andwithstand time shall be indicated in the purchase order. Thetest pressure shall never lead to a load higher than 90 % ofthe 0.2 % proof stress of the cast-steel grade.

5.7.4 Marking

(1) Each casting shall be marked with the followinginformation:


b) steel grade,

c) heat number,




(1) The results of the ladle analysis, product analysis, mate-rials identification check and non-destructive examinationsperformed by the manufacturer as well as of the hardness testshall be documented with an acceptance test certificate 3.1.Bto DIN EN 10 204. A certificate documenting the heat-treatmentcondition shall be attached to the acceptance test certificate.


(3) For castings with piece weights heavier than 1000 kg, aphotograph or a sketch of the location of the cast-on testcoupons on the casting shall be attached to the acceptancetest certificate.

6 Product forms of ferritic steels of material group W II


6.1.1 Materials


a) 15 MnNi 63 to Section A 1

b) WStB 255 to DIN 17 102

c) P275NH to DIN EN 10 028-3

d) WStE 285 to DIN 17 102

e) WStE 315 to DIN 17 102

f) P355NH to DIN EN 10 028-3

g) WStE 355 to DIN 17 102

h) 16Mo3 to DIN EN 10 028-2

i) 15 Mo 3 to DIN 17 155

j) S235J2G3 to DIN EN 10 025

k) St 37-3 to DIN 17 100

l) other steel grades meeting the prerequisites of Section 3 incombination with the stipulations in the authorizedinspector's appraisal.

(2) The selection of materials shall be based on therequirements of clause 4.3.2 and the lowest operatingtemperature.


(1) Plates with nominal thicknesses equal to or larger than10 mm which are subjected to loading perpendicular to therolled surface shall at least meet the requirements of qualityclass Z 25 to DIN EN 10 164. This shall be specified in thepurchase order.

(2) For steel grades b), d) and e) to clause 6.1.1 (1), thestipulations in the authorized inspector's appraisal forconventional pressure vessels subject to supervision shall betaken into consideration.

(3) The surface finish shall satisfy the stipulations of DIN EN10 163-2 Class B Subgroup 3. Elimination of surface defectsby welding is not permitted.

KTA 3211.1

Page 25



(1) Specimens shall be taken to the applicable DINstandards and, for steel grade 15 MnNi 6 3, to clause 5.1.3.

(2) Specimens for determination of the reduction of area atfracture on perpendicular specimens shall be taken to thestipulations of DIN EN 10 164.




b) One product analysis on one sampling location of onerolled plate per heat.



b) One tensile test at a temperature of 300 °C per heat,dimensional range and at most 30 metric tons.

c) Three room-temperature tensile tests to DIN EN 10 164 atone sampling location per rolled plate for plates withnominal thicknesses equal to or larger than 10 mm andsubject to loading perpendicular to the rolled surface, inorder to determine the reduction of area at fracture.

d) One notched-bar impact bend test to clause 4.4.6.5 persampling location at 0 °C or at 20 °C for nominalthicknesses equal to or larger than 5 mm.

e) Notched-bar impact bend tests for determination of anenergy absorbed vs. temperature curve to clause 4.4.6.6at one sampling location per heat, dimensional range andidentical heat treatment for plates with nominal thicknessesequal to or larger than 10 mm. At least four test tempera-tures shall be used, of which one shall be 0 °C or 20 °C.This test may be waived for plates of steel grade15 MnNi 6 3.


a) Each plate with a nominal thickness equal to or larger than10 mm shall be subjected to an ultrasonic surfaceexamination to SEL 072 by the manufacturer. If the exami-nation is not performed with automated examinationsystems, 10 % of the delivery shall additionally beexamined by the authorized inspector.

b) The stipulations of Class 3 to SEL 072 shall apply to thesurface examination.

(4) Each rolled plate shall be subjected to a materialsidentification check.


(6) The thickness of each rolled plate shall be measured.

6.1.4 Marking

(1) Each plate shall be marked with the followinginformation:



c) heat number,



(2) The marking shall be applied such that it appears uprightwhen viewed in the main rolling direction.


(1) The results of the ladle analysis, product analysis,materials identification check and ultrasonic examinationperformed by the manufacturer shall be documented with anacceptance test certificate 3.1.B to DIN EN 10 204, whichshall also indicate the delivery condition, and the results of thevisual inspection and dimensional check shall be documentedwith an acceptance test report 3.1.C to DIN EN 10 204.


6.2 Dished or pressed product forms made from plate

6.2.1 Materials


a) 15 MnNi 6 3 to Section A 1

b) WStE 255 to DIN 17102

c) P275NH to DIN EN 10 028-3



f) P355NH to DIN EN 10 028-3

g) WStE 355 to DIN 17 102

h) 16Mo3 to DIN EN 10 028-2

i) 15 Mo 3 to DIN 17 155

j) S235J2G3 to DIN EN 10 025

k) St 37-3 to DIN 17 100

l) other steel grades meeting the prerequisites of Section 3 incombination with the stipulations in the authorizedinspector's appraisal.

(2) The selection of materials shall be based on the require-ments of clause 4.3.2 and the lowest operating temperature.


(1) Product forms with nominal wall thicknesses equal to orlarger than 10 mm and subjected to loading perpendicular tothe rolled surface shall at least meet the requirements ofquality class Z 25 to DIN EN 10 164. This shall be specified inthe purchase order.

(2) For steel grades b), d) and f) per clause 6.2.1 (1), thestipulations in the authorized inspector's appraisal forconventional pressure vessels subject to supervision shall betaken into consideration.

6.2.3 Starting plates


(2) If the finished parts are tested individually to clause6.2.4.2, the tests to clause 6.1.3.2 as well as thecorresponding verifications can be omitted.

Note:The stipulations of KTA 3211.3 shall apply to welded joints madewith the starting plates and remaining in the finished parts.

(3) If it is agreed in the purchase order that the ultrasonicexamination will be performed on the starting plates, thisexamination shall be performed to clause 6.1.3.2 (3) in theagreed delivery condition.

KTA 3211.1

Page 26

6.2.4 Testing and examination of dished or pressedproduct forms made from plates


(1) For product forms with a diameter or length equal to orsmaller than 3000 mm, the tests or examinations shall beperformed on one part per rolled plate and heat-treatment lot.The maximum permissible lot size shall be 10 parts.


(2) For product forms with a diameter or length greater than3000 mm, each part shall be tested. For lengths or diametersexceeding 6 m one test coupon each shall be taken at twoopposite sides.

(3) One test coupon shall be taken from each part to beexamined regardless of its diameter or length.

(4) The test coupons shall be taken such that transversespecimens can be machined. Deviations up to 20 degreesfrom the theoretical transverse direction are permitted forheads (ends) and similar parts. If this is not possible, adifferent type of sampling shall be agreed with the authorizedinspector.

(5) Round tensile-test specimens with a test diameter equalto or larger than 10 mm shall be made for both the room-temperature and elevated-temperature tensile tests. Fornominal wall thicknesses larger than 40 mm, the specimenaxis shall be located at a distance of one quarter of theproduct-form thickness under the rolled surface.

For product-form thicknesses that do not permit a testdiameter of 10 mm, the largest possible diameter shall bechosen.

(6) For nominal wall thicknesses equal to or smaller than40 mm, one side of the specimens for the notched-bar impactbend test shall be as close as possible to the rolled surface.For nominal wall thicknesses larger than 40 mm, the specimenaxis shall be located at a distance of one quarter of theproduct-form thickness under the rolled surface.




b) One tensile test at a temperature of 300 °C per heat,dimensional range and at most 30 metric tons.

c) Three room-temperature tensile tests to DIN EN 10 164 atone sampling location per rolled plate for product formswith nominal wall thicknesses equal to or larger than10 mm and subject to loading perpendicular to the rolledsurface, in order to determine the reduction of area atfracture. This test may be waived if it has already beenperformed on the rolled plate and documented with anacceptance test certificate 3.1.C to DIN EN 10 204.

Note:Correlation of parts with the rolled plate can be achieved, forexample, through the specimen number.

d) One notched-bar impact bend test to clause 4.4.6.5 persampling location at 0 °C or at 20 °C for nominal wallthicknesses equal to or larger than 5 mm.

e) Notched-bar impact bend tests for determination of anenergy absorbed vs. temperature curve to clause 4.4.6.6at one sampling location per heat, dimensional range andheat-treatment lot for product forms with nominal wallthicknesses equal to or larger than 10 mm. At least fourtest temperatures shall be used, of which one shall be 0 °C

or 20 °C. This test may be waived for product forms ofsteel grade 15 MnNi 6 3.


a) If agreed in the purchase order, the starting plates or thefinished parts with nominal wall thicknesses equal to orlarger than 10 mm shall be subjected to an ultrasonicsurface examination to clause 6.1.3.2 (3).





6.2.5 Marking

(1) Each finished part shall be marked with the followinginformation:

a) symbol of the manufacturer of the product form,


c) heat number,



(2) In the case of lotwise examination, the product form fromwhich the specimens were taken shall also be marked.



(1) The results of the ladle analysis, product analysis,materials identification check and non-destructive examina-tions performed by the manufacturer shall be documented withan acceptance test certificate 3.1.B to DIN EN 10 204, whichshall also indicate the heat-treatment condition. The results ofthe visual inspection and dimensional check shall bedocumented with an acceptance test certificate 3.1.C toDIN EN 10 204. The forming method shall be indicated in theacceptance test certificate 3.1.B to DIN EN 10 204.



6.3.1 Materials



b) C22.8 to DIN 17 243

c) 15Mo3 to DIN 17 243


e) St 37-3 to DIN 17 100

f) other steel grades meeting the prerequisites of Section 3 incombination with the stipulations in the authorizedinspector's appraisal.

KTA 3211.1

Page 27



For steel grade WStE 355, the stipulations in the authorizedinspector’s appraisal for conventional pressure vessels subjectto supervision shall be taken into consideration.



6.3.3.1.1 Test units

(1) Unless otherwise stipulated in clause 6.3.3.2, pieces withheat-treatment weights between 100 kg and equal to or lighterthan 500 kg from the same heat, with similar dimensions andfrom the same heat-treatment lot shall be grouped as testunits containing at most 10 parts, while pieces with heat-treatment weights lighter than or equal to 100 kg may begrouped as test units of 1000 kg each.

(2) Pieces with heat-treatment weights heavier than 500 kgshall be tested individually.

6.3.3.1.2 Sampling locations

(1) For forged hollow parts, e.g., for shell courses, nozzlesor valve bodies, specimens shall be taken from one end as afunction of inside diameter Di as follows: from one samplinglocation for Di equal to or smaller than 500 mm; from twosampling locations separated by 180 degrees for Di between500 mm and 2000 mm; and from three sampling locationsseparated by 120 degrees for Di larger than 2000 mm.

(2) At the opposite end, specimens shall be taken from onesampling location for normalized or air quenched andtempered forgings having a finished length longer than5000 mm and for liquid quenched and tempered forgingshaving a finished length longer than 2000 mm. For pieces withinside diameters smaller than or equal to 500 mm, thissampling location shall be offset by 180 degrees relative tothat at the other end (according to Figures 5.3-1 and 5.3-2).

Note:Finished length designates the length of the product form duringthe governing heat treatment, less the length of the test coupons.

(3) For seamless rolled or forged rings or flanges,specimens shall be taken from the circumference or end of theflange. They may also be taken from the end of the weldingend, if the heat-treatment thickness of the welding end isequal to that of the flange. Specimens shall be taken asfollows: from one sampling location for inside diameters Dismaller than or equal to 1000 mm; from two samplinglocations separated by 180 degrees for Di between 1000 mmand 2000 mm; and from three sampling locations separatedby 120 degrees for Di larger than 2000 mm (according toFigure 5.3-3).

(4) For plates such as tubesheets, tube plates or blanking-off covers with heat-treatment weights lighter than 1000 kg,specimens shall be taken from one sampling location. Ifpermitted by the forging method employed, this location shallbe in the top or bottom zone (according to Figure 5.3-4).

(5) For plates with heat-treatment weights equal to orheavier than 1000 kg, specimens shall be taken from twosampling locations. If permitted by the forging methodemployed, these locations shall be in the top and bottomzones (according to Figure 5.3-4).

(6) For forged bars, specimens shall be taken at one end asa function of the diameter D of the bars: from one sampling

location for D smaller than or equal to 500 mm; and from twosampling locations separated by 180 degrees for D larger than500 mm.

(7) At the opposite end, specimens shall be taken from onesampling location for normalized or air quenched andtempered bars having a finished length longer than 5000 mmand for liquid quenched and tempered bars having a finishedlength longer than 2000 mm. For bars diameters smaller thanor equal to 500 mm, this sampling location shall be offset by180 degrees relative to that at the other end.


The specimens shall be taken from at least one quarter of thegoverning heat-treatment thickness but at most 80 mm underthe heat-treatment surfaces.


(1) Transverse specimens shall be taken for tensile testsand notched-bar impact bend tests if geometrically possibleand nothing to the contrary is stipulated in the authorizedinspector’s appraisal.

(2) Notwithstanding the foregoing, longitudinal specimens oraxial specimens taken from bars are permitted, specifically fortensile tests if the diameter or greatest length of a cross-sectional edge is smaller than 160 mm, or for notched-barimpact bend tests if the diameter or the greatest length of across-sectional edge is smaller than 68 mm.




b) One product analysis on in each of two separatelymanufactured products per heat. If possible, the top zoneof one piece and the bottom zone of the other shall betested. For piece weights equal to or heavier than 5000 kg,one product analysis shall be performed on one samplinglocation of each piece. It possible, the top or bottom of thestarting ingot shall be tested.


a) One hardness test per piece to verify uniformity for piecesgrouped together in test units.


b) One room-temperature tensile test per sampling location.

c) For pieces of similar dimension, one elevated-temperaturetensile test per heat and heat-treatment lot.

d) One notched-bar impact bend test to clause 4.4.6.5 persampling location at 0 °C or at 20 °C.

e) Notched-bar impact bend tests for determination of anenergy absorbed vs. temperature curve to clause 4.4.6.6at one sampling location per heat and heat-treatment lotfor pieces with heat-treatment weights greater than 150 kg.At least four test temperatures shall be used, of which oneshall be 0 °C or 20 °C.

(3) Each piece shall be subjected to a non-destructiveexamination to Annex H.


KTA 3211.1

Page 28

(5) Each piece shall be subjected in the as-deliveredcondition to a visual inspection of its external finish.

(6) A dimensional check of each piece shall be performed.

6.3.4 Marking

(1) Each piece shall be marked with the followinginformation:



c) heat number,

d) specimen number or test lot number,





(1) The results of the ladle analysis, product analysis,materials identification check and non-destructive examina-tions performed by the manufacturer, and if necessary of thehardness test shall be documented with an acceptance testcertificate 3.1.B to DIN EN 10 204, which shall include anindication of the delivery condition.



6.4.1 Scope




(3) The stipulations of this Section shall not apply to pipesfor vessel shells.

6.4.2 Materials



b) St 35.8 III to DIN 17 175

c) WStE 255 to DIN 17 179



f) 15 Mo 3 to DIN 17 175

g) other steel grades meeting the prerequisites of Section 3 incombination with the stipulations in the authorizedinspector’s appraisal.



Pipes with nominal wall thicknesses equal to or larger than10 mm and subjected to loading perpendicular to the rolledsurface shall at least meet the requirements of quality classZ 25 to DIN EN 10 164. This shall be specified in the purchaseorder.





(3) The specimens for tensile tests and notched-bar impactbend tests shall be taken to the applicable DIN standards and,for steel 15 MnNi 6 3, to clause 5.4.4.




b) One product analysis on each of two manufacturinglengths per heat.

(2) Where round or square bar steel blooms are used asstarting product for the fabrication of pipes of steel gradeSt 35.8 III, one disc of each round or square bar cut from thetop end, shall be subjected to a pickling test to ascertainwhether the head end was cut off far enough from the ingot. Atthe discretion of the manufacturer, an ultrasonic examinationfor detecting shrinkage cavities may substitute this picklingdisc test.


a) Room-temperature tensile tests for every 50 manufacturinglengths of the same heat, dimension and heat treatment, atone end of one manufacturing length for pipes ofnormalized or air quenched and tempered steels.

b) One tensile test at 300 °C per heat, dimension and heattreatment, if the design temperature is higher than 100 °C.

c) Tensile tests on perpendicular specimens per 50manufacturing lengths of the same heat, dimension andheat treatment, to determine the reduction of area atfracture for pipes with nominal wall thicknesses equal to orlarger than 10 mm and subjected to loading perpendicularto the surface. This test may be waived for steel grades forwhich it was demonstrated in the material appraisal thatthe mean value of reduction of area at fracture of threeperpendicular specimens per test set is at least 35 % andthat none of the individual values is smaller than 25 %.

d) One notched-bar impact bend test to clause 4.4.6.5 at 0 °Cor 20 °C at one end of one manufacturing length per 50manufacturing lengths of the same heat, dimension andheat treatment for pipes of normalized or air quenched andtempered steels with nominal wall thicknesses equal to orlarger than 10 mm up to and including 38 mm, and at oneend of each manufacturing length for nominal wallthicknesses larger than 38 mm. For pipes of steel grade15 MnNi 6 3, the test temperature shall be 0 °C.

e) Notched-bar impact bend tests for determination of theenergy absorbed vs. temperature curve to clause 4.4.6.6at one end of one manufacturing length per heat,dimension and heat treatment for pipes with nominal wallthicknesses equal to or larger than 16 mm for pipes ofnormalized or air quenched and tempered steels. At leastfour test temperatures shall be used, of which one shall be

KTA 3211.1

Page 29

0 °C or 20 °C. This test may be waived for pipes of steelgrade 15 MnNi 6 3.

f) Technological tests to Table 5.4-1 at both ends of eachmanufacturing length for pipes with nominal wallthicknesses equal to or smaller than 40 mm.


a) All pipes shall be examined ultrasonically for longitudinaldefects to SEP 1915.

b) Pipes of test group A 2 equal to or larger than DN 100shall additionally be subjected to an ultrasonic transverse-defect examination to SEP 1918 as well as to anexamination for laminations to SEP 1919, if they were hot-pilger-rolled or subjected to hot pilger rolling during themanufacturing process.

c) Pipes with nominal thicknesses larger than 30 mm anddiameters larger than DN 600 shall be examined as hollowforged or hollow rolled parts.




(8) Each pipe shall be examined for leak tightness either byan internal hydrostatic pressure test or, at the manufacturer'sdiscretion, by an appropriate non-destructive examination toSEP 1925. For the internal hydrostatic pressure test, the testpressure shall generally be 8 MPa. The test pressure shall belimited such that the factor of safety relative to the yield pointat room temperature is never less than 1.1.

6.4.5 Marking

(1) Each pipe shall be marked at both ends, 300 mm fromthe ends, with the following information:


b) steel grade (for carbon steels additionally quality level, forsteels with guaranteed reduction of area at fractureperpendicular to the product surface additionally qualityclass to DIN EN 10 164) and

c) authorized inspector's mark.

(2) Each pipe shall additionally be marked at one end withthe following information:

a) heat number,

b) pipe number and

c) mark of the non-destructive examinations performed.


(1) The results of the ladle analysis, product analysis,pickling disc test, if any, materials identification check,tightness test and non-destructive examinations performed bythe manufacturer shall be documented with an acceptancetest certificate 3.1.B to DIN EN 10 204, which shall include anindication of the delivery condition.



6.5.1 Scope

(1) This Section shall apply to seamless pipe elbows (weld-in elbows) made from seamless rolled, extruded or forgedpipes by cold or hot forming followed by heat treatment(normalization; quenching and tempering).

(2) This Section shall not apply to pipe bends made withinductive bending machines or by cold forming with or withoutsubsequent heat treatment. These pipe bends shall be subjectto the requirements of KTA 3211.3 Section 6.

6.5.2 Materials



b) St 35.8 III to DIN 17 175




f) 15 Mo 3 to DIN 17 175

g) other steel grades meeting the prerequisites of Section 3 incombination with the stipulations in the authorizedinspector's appraisal.


(3) For finished pipe elbows, the values of the mechanicaland technological characteristics for pipes shall apply even ifforged hollow parts are used as starting products.



(2) Starting products that have not been completelyexamined and heat-treated per the stipulations in Sections 6.3or 6.4 may also be used, provided the finished pipe elbowsare examined individually per clause 6.5.4.2. In this case, thedetermination of mechanical and technological characteristicsand the corresponding verification may be waived for thestarting products. An acceptance test certificate 3.1.B toDIN EN 10 204 shall then be adequate for visual inspectionand dimensional check of the starting products.



(1) Specimens shall be taken from the ends of the pipeelbows in conformity with the authorized inspector's appraisal.


(3) Transverse specimens shall be taken for tensile testsand notched-bar impact bend tests. If this is not possible,longitudinal specimens shall be used.

(4) If starting products that have not been completelyexamined and heat-treated to the stipulations in Sections 6.3or 6.4 are used, test coupons shall be taken from both ends ofpipe elbows with a chord length greater than 3000 mm,measured along the outside of the bend.

(5) In all other cases, test coupons shall be taken from onlyone end of the pipe elbow.

(6) If the pipe elbows are not tested individually, test unitsconsisting of pipe elbows of the same heat, dimension and

KTA 3211.1

Page 30

heat treatment shall be formed for determination ofmechanical and technological characteristics.



b) 25 pieces for pipe elbows equal to or larger than DN 200and smaller than DN 350

c) 10 pieces for pipe elbows equal to or larger than DN 350.




a) One room-temperature tensile test on one pipe elbow pertest unit.

b) One tensile test at 300 °C on one pipe elbow per heat,dimension and heat treatment, if the design temperature ishigher than 100 °C.

c) One notched-bar impact bend test to clause 4.4.6.5 at 0 °Cor at 20 °C on one pipe elbow per test unit for pipe elbowswith nominal wall thicknesses equal to or larger than10 mm. For pipe elbows of steel grade 15 MnNi 6 3, thetest temperature shall be 0 °C.

d) Notched-bar impact bend tests for determination of theenergy absorbed vs. temperature curve to clause 4.4.6.6on one pipe elbow per heat, dimension and heat treatmentfor pipe elbows of test group A 2 with nominal wallthicknesses equal to or larger than 16 mm. At least fourtest temperatures shall be used, of which one shall be 0 °Cor 20 °C. This test may be waived for pipe elbows of steelgrade 15 MnNi 6 3.

e) For pieces grouped together as test units, one hardnesstest per piece to verify uniformity.



a) For pipe elbows of test group A 2 equal to or larger thanDN 100, the outside and inside surfaces shall be subjectedto a surface-crack detection. For pipe elbows smaller thanDN 100, the outside surface shall be examined completelyand the inside surface shall be examined only where it isaccessible. The acceptance criteria are defined in Table5.2-1.

b) All pipe elbows of test group A 2 smaller than DN 100 shallbe ultrasonically examined for longitudinal defects toSEP 1915 and for transverse defects to SEP 1918 in thesurface zones that are not accessible to surface-crackdetection.

c) Pipe elbows with nominal wall thicknesses larger than30 mm shall be examined to Annex H as hollow forgedparts.

d) If an ultrasonic examination is performed on the pipeelbow, the corresponding examination on the starting pipemay be waived.

(4) Each pipe elbow shall be subjected to a materials identi-fication check.



6.5.5 Marking




c) heat number,

d) elbow number,




(1) The results of the ladle analysis, product analysis,materials identification check, hardness test and non-destructive examinations performed by the manufacturer shallbe documented with an acceptance test certificate 3.1.B toDIN EN 10 204, which shall include an indication of thedelivery condition.



6.6.1 Scope


a) reducers made from seamless rolled, extruded or forgedpipes by cold or hot forming followed by heat treatment(normalization; quenching and tempering),



6.6.2 Materials



b) St 35.8 III to DIN 17 175




f) 15 Mo 3 to DIN 17 175

g) other steel grades meeting the prerequisites of Section 3 incombination with the stipulations in the authorizedinspector's appraisal.


(3) For fabricated fittings, the values of the mechanical andtechnological characteristics for pipes shall apply even ifforged hollow parts are used as starting products.

KTA 3211.1

Page 31



(2) Starting products that have not been completelyexamined or heat-treated to the stipulations in Sections 6.3 or6.4 may also be used, provided the fabricated fittings areexamined individually to clause 6.6.4.2. In this case thedetermination of mechanical and technological characteristicsand the corresponding verification may be waived for thestarting products. An acceptance test certificate 3.1.B to DINEN 10 204 shall then be adequate for visual inspection anddimensional check of the starting products.



(1) Specimens shall be taken from the ends of the fittings inconformity with the authorized inspector’s appraisal.


(3) Where transverse specimens can be taken from non-directional test coupons they shall be taken for tensile testsand notched-bar impact bend tests. If this is not possible,longitudinal specimens shall be selected.

(4) If the fittings are not tested individually, test unitsconsisting of fittings of the same heat, dimension and heattreatment shall be formed for determination of mechanical andtechnological characteristics.


a) at most 50 pieces for fittings with nominal diameterssmaller than 100,

b) at most 25 pieces for fittings of unalloyed steels withnominal diameters equal to or larger than 100, or at most10 pieces for such fittings of alloyed steels.





b) One tensile test at 300 °C per heat, dimension and heattreatment, if the design temperature is higher than 100 °C.

c) One notched-bar impact bend test to clause 4.4.6.5 at 0 °Cor at 20 °C on one piece per test unit for fittings withnominal wall thicknesses equal to or larger than 10 mm.For fittings of steel grade 15 MnNi 6 3 the test temperatureshall be 0 °C.

d) Notched-bar impact bend tests for determination of theenergy absorbed vs. temperature curve to clause 4.4.6.6on one piece per heat, dimension and heat treatment forfittings with nominal wall thicknesses equal to or largerthan 16 mm. At least four test temperatures shall be used,of which one shall be 0 °C or 20 °C. This test may bewaived for pipe elbows of steel grade 15 MnNi 6 3.

e) One hardness test on each fitting to verify uniformity.



a) For fittings of test group A 2 equal to or larger thanDN 100, the outside and inside surfaces shall be subjectedto a surface-crack detection. For fittings smaller thanDN 100, the outside surface shall be examined completelyand the inside surface shall be examined only where it isaccessible. The acceptance criteria are defined in Table5.2-1.

b) All fittings of test group A 2 smaller than DN 100 shall beultrasonically examined for longitudinal defects toSEP 1915 and for transverse defects to SEP 1918 in thesurface zones that are not accessible to surface-crackdetection.

c) Fittings with nominal wall thicknesses larger than 30 mmshall be examined to Annex H as hollow forged parts.

d) If an ultrasonic examination is performed on the fitting, thecorresponding examination on the starting product may bewaived.



(6) For each fitting, the ovality, diameter and thickness shallbe measured at the ends.

6.6.5 Marking

(1) Each fitting shall be marked with the following information:



c) heat number,

d) authorized inspector's mark.

e) fitting number or test lot number,



(1) The results of the ladle analysis, product analysis,materials identification check, hardness test and non-destructive examination performed by the manufacturer shallbe documented with an acceptance test certificate 3.1.B toDIN EN 10 204, which shall include an indication of thedelivery condition.


6.7 Castings

6.7.1 Materials


a) GS-C25 to DIN 17 245,

b) other cast-steel grades meeting the prerequisites ofSection 3 in combination with the stipulations in theauthorized inspector's appraisal.


KTA 3211.1

Page 32

6.7.2 General requirements for casting finish

(1) As regards their general internal and external finish, thecastings shall satisfy the stipulations of Table B-2 applicableto their test group.

(2) Feeder heads and large casting-related thickenings thatimpair amenability of castings to heat treatment shall beeliminated before the heat treatment for establishment of themechanical and technological characteristics.

(3) The casting technique shall be designed according to theprinciples of controlled solidification. For castings with nominalwidths equal to or larger than 200 mm, the gate and feedertechnique shall be explained on the basis of the saturationcalculation as well as drawings illustrating the position of thefeeders, feed zones and specimen location.

(4) For each casting model, the description of the castingtechnique shall be attached to the interim file (internal manu-facturer documentation) for retention by the manufacturer.



a) test and inspection sequence plan and heat-treatmentplan, in case of differences from the standard productionscheme to Figure B-12,

b) for prototypes of test groups A 2 and A 3 with nominalwidths equal to or greater than 200 mm a film location planand a radiation source plan,

c) welding procedure qualification and welding proceduresheet for production welds and if applicable constructionwelds (see Annex C)

c) test and inspection sequence plan for construction welds, ifnecessary.

d) list of planned production control tests.

(6) If changes are made compared with the conditionsstipulated in the welding procedure sheet, or if a differentwelding method is chosen, the welding procedure sheet shallbe amended accordingly and resubmitted for design approval.



(1) Castings with a delivery weight equal to or lighter than500 kg shall be tested in lots, and castings with a delivery weightheavier than 500 kg shall be tested individually. The numberof sampling locations shall be as indicated in Table 6.7-1.


in kgTest unit



1


1



Table 6.7-1: Number of sampling locations on castings madeof ferritic steels of material group W II

(2) The specimens shall be taken from cast-on test couponsor from overlengths. Separately cast test coupons are permit-ted only for castings with piece weights equal to or lighter than50 kg. The test coupons shall be provided in sufficient numberand size that the prescribed specimens can be taken.

(3) The thickness of the cast-on test coupons shall be cal-culated by comparison of volume/surface ratios at the gover-ning wall thickness. However, it shall be at most 150 mm. Inthis connection, the governing wall thickness shall be thethickness of the wall subjected to pressure loading, and notthe thickness of cast-on flanges or local thickenings. Cast-ontest coupons at the gate system are not permitted. Thespecimens shall be taken at a distance of half the thickness ofthe cast-on test coupons from the end and side faces as wellas at one quarter from one of the other faces.








b) One tensile test at 350 °C per heat, dimension and heat-treatment lot, if the design temperature is higher than100 °C.

c) One notched-bar impact bend test to clause 4.4.6.5 persampling location at 0 °C or at 20 °C.

d) One hardness test on each piece to verify uniformity of thequenching and tempering treatment in the case of lotwiseexamination of castings of quenched and tempered steel.



(5) Each casting shall be subjected in the as-deliveredcondition to a visual inspection of its surface finish.


(7) Each casting shall be subjected in a condition suitable forthe purpose, generally by the further processor, to a tightnesstest in the form of an internal pressure test, which shall beperformed to DIN 50 104. Pressurizing fluid, test pressure andpressure-loading duration shall be indicated in the purchaseorder. However, the nominal pressure shall never lead to aload higher than 90 % of the 0.2 % proof stress of the cast-steel grade.

6.7.4 Marking

(1) Each casting shall be marked with the followinginformation:a) manufacturer's symbol,b) cast-steel grade,c) heat number,d) specimen number ande) authorized inspector's mark.

KTA 3211.1

Page 33


(1) The results of the ladle analysis, product analysis,materials identification check and non-destructive examina-tions performed by the manufacturer as well as of thehardness test shall be certified with an acceptance testcertificate 3.1.B to DIN EN 10 204. A certificate documentingthe heat-treatment condition shall be attached to theacceptance test certificate.

(2) The results of all other tests and examinations shall becertified by the authorized inspector and combined with theabove-mentioned certificates as an acceptance test certificate3.1.C to DIN EN 10 204. For castings with piece weightsheavier than 1000 kg, a photograph or a sketch of the locationof the cast-on test coupons on the casting shall be attached tothe acceptance test certificate.

7 Product forms of austenitic steels


7.1.1 Materials


a) X6CrNiNb18-10 to DIN 17 440

b) X6CrNiTi18-10 to DIN 17 440

c) X6CrNiMoTi17-12-2 to DIN 17 440

d) X6CrNiMoNb17-12-2 to DIN 17 440

e) other steel grades meeting the prerequisites of Section 3 incombination with the stipulations in the authorizedinspector’s appraisal.

(2) The stipulations of clause 4.3.3 shall be met.

(3) For hot (operating temperature T ≥ 200 °C) reactor watercontaining product form and components in BWR plants onlythe steel grade to clause (1) a), and only with the followingadditional requirements for the chemical composition shall beused:

C ≤ 0.03 %

Si ≤ 0.5 %

P ≤ 0.025 %

S ≤ 0.010 %

18.0 ≤ (% Cr) ≤ 19.0

13 x (% C) ≤ (% Nb) ≤ 0.65

The test certificate shall show the boron and nitrogen content.


(1) The surfaces shall be free of ferritic impurities. Scalelayers and tempering colours developed during hot forming orheat treatment shall be removed.

(2) The surface condition to DIN 17 740 shall be indicated inthe purchase order. The requirements of non-destructiveexamination shall be considered in this respect.



(1) Room-temperature tensile tests shall be performed using

a) for plates with nominal thicknesses equal to or smallerthan 30 mm, flat tensile-test specimens containing bothrolled surfaces,

b) for plates with nominal thicknesses larger than 30 mm andequal to or smaller than 75 mm, flat tensile-test specimensat least 30 mm thick, containing at least one intact rolledsurface.

(2) Elevated-temperature tensile tests shall be performedusing,

a) for plates with nominal thicknesses equal to or smallerthan 12 mm, flat tensile-test or round tensile-testspecimens,

b) for plates with nominal thicknesses larger than 12 mm,round tensile-test specimens.

(3) The notched-bar impact bend test shall be subject to thefollowing requirements:

a) For plates with nominal thicknesses smaller than or equalto 16 mm, a notched-bar impact bend test is not required.

b) For plates with nominal thicknesses larger than 16 mm andequal to or smaller than 30 mm, specimens shall be takenfrom 2 mm under the rolled surface.

c) For plates with nominal thicknesses larger than 30 mm andequal to or smaller than 75 mm, specimens shall be takenfrom 1/4 of the plate thickness under the rolled surface.

(4) The sampling depth for plates with nominal thicknessesgreater than 75 mm shall be subject to the stipulations in theauthorized inspector's appraisal.

(5) The specimens shall be taken as transverse specimenssuch that the specimens are located halfway between longedges and centerline of the plates.

(6) The number of sampling locations shall be as required inDIN 17 440.




b) One product analysis on one sampling location of oneplate per heat. The nitrogen content shall be shown if thedelta ferrite content is determined theoretically.



b) One tensile test at 350 °C per heat, dimensional range andheat-treatment lot, if the design temperature in test groupA 1 is higher than 200 °C and in test groups A 2 and A 3 ishigher than 300 °C.

c) One notched-bar impact bend test to clause 4.4.6.5 persampling location for plates with nominal thicknessesequal to or larger than 16 mm.

(3) One test for resistance to intergranular corrosion toDIN EN ISO 3651-2 with prior annealing (1/2 h at 650 °C) shallbe performed per heat, dimensional range and heat-treatmentlot.

(4) One bead-on-plate test to determine the delta ferritecontent to Annex D shall be performed per heat, if valuessmaller than 3 are found in calculation of the ferrite numberfrom the chemical composition in the ladle analysis.


a) Each plate with nominal thickness equal to or larger than10 mm shall be subjected to an ultrasonic surface exami-nation to SEL 072 by the manufacturer. If the examinationis not performed with automated examination systems,10 % of the delivery shall additionally be examined by theauthorized inspector.

b) The stipulations of Class 3 to SEL 072 shall apply to thesurface examination.

KTA 3211.1

Page 34

c) Where ultrasonic examination of the root area of welds toKTA 3211.3 Section 11 is required, the weld edges shallbe subject to an ultrasonic examination to Annex H.

(6) Each plate shall be subjected to a materials identificationcheck.


(8) The thickness of each plate shall be measured.

7.1.4 Marking

(1) Each plate shall be marked with the following information:


b) steel grade,

c) heat number,

d) specimen number,



(2) The marking shall be applied transverse to the rollingdirection. For plates cut from strip, roller stamping in thelongitudinal direction is also permitted.


(1) The heat-treatment condition as well as the results of theladle analysis, product analysis, test for intergranular corrosionresistance, determination of the delta ferrite content, materialsidentification check and non-destructive examinationsperformed by the manufacturer shall be documented with anacceptance test certificate 3.1.B to DIN EN 10 204.

(2) For plates of test groups A 1 and A 2, the results of allother tests and examinations shall be certified by the autho-rized inspector and combined with the above-mentionedcertificates as an acceptance test certificate 3.1.C toDIN EN 10 204. For plates of test group A 3, the stipulationsshall be the same as for steels for conventional pressurevessels subject to supervision to AD-Merkblatt W 2.

7.2 Dished or pressed product forms made from plates

7.2.1 Materials


a) X 6 CrNiNb 18 10 to DIN 17 440

b) X 6 CrNiTi 18 10 to DIN 17 440

c) X 6 CrNiMoTi 17 12 2 to DIN 17 440

d) X 6 CrNiMoNb 17 12 2 to DIN 17 440

e) other steel grades meeting the prerequisites of Section 3in combination with the stipulations in the authorized inspec-tor’s appraisal.



C ≤ 0.03 %

Si ≤ 0.5 %

P ≤ 0.025 %

S ≤ 0.010 %

18.0 ≤ (% Cr) ≤ 19.0

13 x (% C) ≤ (% Nb) ≤ 0.65




(2) The surface condition to DIN 17 740 shall be indicated inthe purchase order. The requirements of non-destructiveexamination shall be considered in this respect.

7.2.3 Tests and examinations of the starting plates


(2) If the finished parts are tested individually to clause7.2.4.2, the tests to clause 7.1.3.2 (2) as well as thecorresponding verifications shall not be required.

Note:The stipulations of KTA 321 1.3 shall apply to welded joints madewith the starting plates and remaining in the finished parts.

(3) If it is agreed in the purchase order that the ultrasonicexamination will be performed on the starting plates, thisexamination shall be performed in the agreed deliverycondition.

7.2.4 Tests and examinations of dished or pressed productforms made from plates


(1) For product forms with a diameter or length smaller thanor equal to 500 mm and a wall thickness smaller than or equalto 16 mm, the mechanical tests shall be performed on onepart per heat, thickness range and heat-treatment lot. Themaximum permissible lot size shall be 20 parts, but the lotweight shall not exceed 500 kg.

(2) For product forms with a diameter or length greater than500 mm or wall thickness greater than 16 mm, each part shallbe tested individually, in which case

a) for product forms with a diameter or length greater than500 mm and equal to or smaller than 6000 mm or a wallthickness greater than 16 mm one test coupon shall betaken,

b) for product forms with a diameter or length greater than6000 mm one test coupon each from two opposite sidesshall be taken.

(3) The test coupons shall be taken such that transversespecimens can be machined. Deviations up to 20 degreesfrom the theoretical transverse direction are permitted forheads (ends) and similar parts. In making the specimens,plastic deformation of the specimen in the zone of the gaugelength shall be avoided. If applicable, a different type ofsampling or procedure for making specimens shall be agreedwith the authorized inspector.

(4) The stipulations of clause 7.1.3.1 and of DIN 17 440 shallapply as relevant to sampling.

7.2.4.2 Extent of tests and examination



b) One tensile test at 350 °C per heat, thickness range andheat-treatment lot, if the design temperature in test groupA 1 is higher than 200 °C and in test groups A 2 and A 3 ishigher than 300 °C.

c) One notched-bar impact bend test to clause 4.4.6.5 atroom temperature per sampling location for product formswith nominal wall thicknesses larger than 16 mm.

KTA 3211.1

Page 35

(2) One test for resistance to intergranular corrosion toDIN EN ISO 3651-2 with prior annealing (1/2 h at 650 °C) shallbe performed per heat, dimensional range and heat-treatmentlot.

(3) One bead-on-plate test to determine the delta ferritecontent to Annex D shall be performed per heat, if valuessmaller than 3 are found in calculation of the ferrite numberfrom the chemical composition in the ladle analysis. This testmay be replaced by a corresponding test of the starting plates.


a) If agreed in the purchase order, the starting plates or theproduct forms with a nominal wall thickness equal to orlarger than 10 mm shall be subjected by the manufacturerto an ultrasonic surface examination to clause 7.1.3.2 (5).





7.2.5 Marking

(1) Each product form shall be marked with the followinginformation:


b) steel grade,

c) heat number,

d) specimen number



(2) In the case of lotwise examination, the product form fromwhich the specimens were taken shall additionally be marked.



(1) The heat-treatment condition as well as the results of theladle analysis, product analysis, test for intergranular corrosionresistance, determination of the delta ferrite content, materialsidentification check and non-destructive examinations per-formed by the manufacturer shall be documented with anacceptance test certificate 3.1.B to DIN EN 10 204. Theforming method shall be indicated in the acceptance test certi-ficate 3.1.B.

(2) For product forms of test groups A 1 and A 2, the resultsof all other tests and examinations shall be certified by theauthorized inspector and combined with the above-mentionedcertificates as an acceptance test certificate 3.1.C to DIN EN10 204. For product forms of test group A 3, the stipulationsshall be the same as for steels for conventional pressurevessels subject to supervision to AD-Merkblatt W 2.Certification of the forming method shall be attached to thequality verification.

7.3 Forgings, bar steel, rings and extrusions

7.3.1 Materials


a) X 6 CrNiNb 18 10 to DIN 17 440

b) X 6 CrNiTi 18 10 to DIN 17 440



e) other steel grades meeting the prerequisites of Section 3 incombination with the stipulations in the authorizedinspector's appraisal.



C ≤ 0.03 %

Si ≤ 0.5 %

P ≤ 0.025 %

S ≤ 0.010 %

18.0 ≤ (% Cr) ≤ 19.0

13 x (% C) ≤ (% Nb) ≤ 0.65




(2) The surface condition shall meet the requirements ofnon-destructive examination and be indicated in the purchaseorder.


7.3.3.1 Test units

(1) Pieces from the same heat, with similar dimensions andfrom the same heat-treatment lot shall be grouped as testunits weighing at most 500 kg.

(2) Pieces with heat-treatment weights heavier than 500 kgor governing dimensions exceeding 250 mm shall be testedindividually.

7.3.3.2 Sampling for forgings, rings and extrusions

7.3.3.2.1 Sampling location

Specimens shall be taken from one end face of the prices. Forheat treatment weights exceeding 2500 kg specimens shall betaken from both ends of the forging. At diameters exceeding1000 mm the specimens shall be taken offset by 180 degrees.Unless otherwise stipulated, specimens shall be taken fromone piece per test unit.


(1) The sampling location for longitudinal and transversespecimens shall be at least 25 mm from the end face.

(2) The sampling location shall also be at least one sixth ofthe heat-treatment thickness but not farther than 50 mm fromthe second surface, perpendicular to the end face. The heat-treatment thickness shall be defined as the nominal wall

KTA 3211.1

Page 36

thickness for hollow parts and as the outside diameter duringheat treatment for solid parts.

(3) If the exact sampling location cannot be given in advancefor any pieces, it shall be agreed with the authorized inspector.


(1) Specimens shall be taken transverse to the main formingdirection.

(2) Longitudinal specimens are permitted in the followingcases: tensile-test specimens for pieces with a cross-sectionalarea corresponding to solid parts with a diameter smaller than160 mm; and notched-bar impact-test specimens for pieceswith a cross-sectional area corresponding to solid parts with adiameter smaller than 100 mm.

7.3.3.3 Sampling for bars

7.3.3.3.1 Sampling location

(1) Specimens shall be taken from one end of the bars.

(2) Unless otherwise stipulated, specimens shall be takenfrom one piece per test unit.


(1) For bars with a diameter or heat-treatment thicknesssmaller than or equal to 25 mm, specimens shall be takenfrom the core of the bars.

(2) For bars with a diameter or heat-treatment thicknesslarger than 25 mm and smaller than or equal to 160 mm,specimens shall be taken at least 12.5 mm under the surface.

(3) The sampling depths for bars with larger diameter orlarger heat-treatment thickness shall be determined by thestipulations in the authorized inspector’s appraisal.

(4) The distance of the sampling location from the end facesshall be at least 25 mm.


Longitudinal specimens shall be taken for bars with a diameteror heat-treatment thickness smaller than or equal to 100 mm,and transverse specimens shall be taken for bars with adiameter or heat-treatment thickness larger than 100 mm.




b) One product analysis per heat. The nitrogen content shallbe shown if the delta ferrite content is determined toAnnex D.



b) One tensile test at 350 °C per heat, similar dimension andheat-treatment lot, if the design temperature in test groupA 1 is higher than 200 °C and in test groups A 2 and A 3 ishigher than 300 °C.

c) One notched-bar impact bend test to clause 4.4.6.5 atroom temperature per sampling location.

(3) One test for resistance to intergranular corrosion toDIN EN ISO 3651-2 with prior annealing (1/2 h at 650 °C) shallbe performed per heat, similar dimension and heat-treatmentlot.

(4) One bead-on-plate test to determine the delta ferritecontent shall be performed per heat, if values of ferrite numbersmaller than 3 are calculated by the procedure of Annex Dfrom the chemical composition in the ladle analysis.

(5) The non-destructive examinations shall be subject to thestipulations in Annex H.


(7) Each piece shall be subjected to a visual inspection of itsexternal finish.

(8) A dimensional check shall be performed for each piece.

7.3.4 Marking

(1) Each piece shall be marked durably with the followinginformation:


b) steel grade,

c) heat number,

d) specimen number,





(1) The heat-treatment condition, results of the ladleanalysis, product analysis, test for intergranular corrosionresistance, determination of the delta ferrite content, materialsidentification check and non-destructive examinationsperformed by the manufacturer shall be documented with anacceptance test certificate 3.1.B to DIN EN 10 204.

(2) For pieces of test groups A 1 and A 2, the results of allother tests and examinations shall be certified by theauthorized inspector and combined with the above-mentionedcertificates as an acceptance test certificate 3.1.C to DIN EN10 204. For pieces of test group A 3, the stipulations shall bethe same as for steels for conventional pressure vesselssubject to supervision to AD-Merkblatt W 2.


7.4.1 Scope




7.4.2 Materials


a) X 6 CrNiNb 18 10 to DIN 17 458

b) X 6 CrNiTi 18 10 to DIN 17 458





KTA 3211.1

Page 37


C ≤ 0.03 %

Si ≤ 0.5 %

P ≤ 0.025 %

S ≤ 0.010 %

18.0 ≤ (% Cr) ≤ 19.0

13 x (% C) ≤ (% Nb) ≤ 0.65




(2) The surface condition shall meet the requirements of thenon-destructive examination and be indicated in the purchaseorder.

7.4.4 Testing and examinations




(3) The distance between pipe end and sampling locationshall be at least equal to the nominal wall thickness but shallnot exceed 25 mm.

(4) Transverse specimens shall be taken, if possible. In thecase of outside diameters Da smaller than or equal to 200 mm,longitudinal specimens shall be taken for tensile tests.

(5) For pipes with wall thicknesses larger than or equal to20 mm, specimens shall be taken from the middle of the pipewall if at all possible. Specimen forms to DIN EN 10 002-1may also be used for tensile tests.




b) One product analysis per heat. The nitrogen content shallbe shown if the delta ferrite content is determined toAnnex D.


a) One room-temperature tensile test for every 50 manufac-turing lengths of the same heat, dimension and heat-treat-ment lot.

b) For pipes with nominal wall thicknesses greater than16 mm, one room-temperature tensile test at the end ofone pipe per manufacturing length.

c) For pipes for shells of pressure vessels with wallthicknesses greater than 10 mm or diameters larger than200 mm and smaller than or equal to 600 mm, one room-temperature tensile test at the end of one pipe permanufacturing length.

d) One tensile test at 350 °C per heat, dimensional range andheat-treatment lot, if the design temperature for pipes oftest group A 1 is higher than 200 °C and for pipes of test

groups A 2 and A 3 is higher than 300 °C. The test shall beperformed at 350 °C.

e) One notched-bar impact bend test to clause 4.4.6.5 atroom temperature at the end of one pipe per manufac-turing length for pipes with nominal wall thicknesses largerthan 16 mm.

f) For pipes for shells of pressure vessels with nominal wallthicknesses greater than 10 mm or diameters larger than200 mm and smaller than or equal to 600 mm, onenotched-bar impact bend test to clause 4.4.6.5 at roomtemperature at the end of one pipe per manufacturinglength.

g) For pipes with wall thicknesses smaller than or equal to40 mm, technological tests per Table 7.4-1 at both ends ofeach manufacturing length.

(3) One test for resistance to intergranular corrosion toDIN EN ISO 3651-2 with prior annealing (1/2 h at 650 °C) shallbe performed per heat, dimension and heat-treatment lot.

Nominal wallthickness sof the pipes

Nominal outside diameterof the pipes

in mmin mm ≤ 146 > 146

s < 2 Flattening test 2 ≤ s ≤ 16 Ring expanding test 1) Ring tensile test

16 < s ≤ 40 Flattening test Ring tensile test

1) The drift test also may be performed.

Table 7.4-1: Technological tests to be employed as afunction of pipe dimensions

(4) One bead-on-plate test to determine the delta ferritecontent shall be performed per heat, if the calculation toAnnex D yields values of ferrite number smaller than 3 fromthe chemical composition in the ladle analysis.


a) All pipes shall be examined ultrasonically for longitudinaldefects to SEP 1915.

b) Pipes of test group A 1 larger than or equal to DN 100 andpipes for shells of pressure vessels with design pressureshigher than 8 MPa shall be subjected to an ultrasonictransverse-defect examination to SEP 1918. Pipes of testgroup A 2 larger than or equal to DN 100 shall beexamined for transverse defects if they were hot-pilger-rolled or subjected to hot pilger rolling during themanufacturing process.

c) For hot-finished pipes of test group A 1 with outsidediameters larger than 100 mm and nominal wall thick-nesses larger than 16 mm, comparative sound attenuationmeasurements by means of angle-beam scanning shall bemade at both pipe ends and at the pipe center. Themeasurements shall be made at four places staggered by90 degrees, alternating between the circumferentialdirection and axial direction. They shall be performed withthe same nominal frequency as in the examination forlongitudinal and transverse defects. If the values deter-mined close to the test defects in the test pipe areexceeded by more than 6 dB, the maximum amounts inexcess of 6 dB shall be added on for sensitivity adjustmentfor the examination of longitudinal and transverse defects.If it is found in the course of the examinations thatadequate uniformity of sound attenuation exists for themanufacturing method, material and dimension, the extentof sound attenuation measurements may be reduced,subject to approval of the authorized inspector.

KTA 3211.1

Page 38

d) One surface-crack detection shall be performed on everyfourth pipe of test group A 1. The outside surface shall beexamined completely and the inside surface shall beexamined over a length of one times the outside diameterfrom each end of the pipe. The acceptance criteria aredefined in Table 5.2-1.




(9) Each pipe shall be examined for leak tightness either byan internal hydrostatic pressure test or by a non-destructiveexamination to SEP 1925. For the internal hydrostaticpressure test, the test pressure shall generally be 8 MPa. Ineach case the test pressure shall be limited such that thefactor of safety relative to the yield point at room temperatureis not less than 1.1.

7.4.5 Marking

(1) Each pipe shall be marked durably with the followinginformation at one end:


b) steel grade with abbreviation for the type of constructionand the designation „S“ for seamless products to DIN17 458,

c) heat number,

d) pipe number,




(1) The results of the ladle analysis, product analysis, testfor intergranular corrosion resistance, determination of thedelta ferrite content, materials identification check, tightnesstest and non-destructive examinations performed by themanufacturer shall be documented with an acceptance testcertificate 3.1.B to DIN EN 10 204.


(3) For pipes of test group A 3 and wall thicknesses smallerthan or equal to 5.6 mm, an acceptance test certificate 3.1.Bto DIN EN 10 204 will suffice.


7.5.1 Scope

(1) This Section shall apply to seamless pipe elbows (weld-in elbows) made from seamless rolled, extruded or forgedpipes by cold or hot forming followed by heat treatment(solution annealing and quenching).

(2) This Section shall not apply to pipe bends made withinductive bending machines or by cold forming with or withoutsubsequent heat treatment. These pipe bends shall be subjectto the requirements of KTA 3211.3 Section 6.

7.5.2 Materials


a) X6CrNiNb18-10 to DIN 17 440 or DIN 17 458

b) X6CrNiTi18-10 to DIN 17 440 or DIN 17 458

c) X6CrNiMoTi17-12-2 to DIN 17 440 or DIN 17 458

d) X6CrNiMoNb17-12-2 to DIN 17 440 or DIN 17 458




C ≤ 0.03 %

Si ≤ 0.5 %

P ≤ 0.025 %

S ≤ 0.010 %

18.0 ≤ (% Cr) ≤ 19.0

13 x (% C) ≤ (% Nb) ≤ 0.65


(4) For finished pipe elbows, the values of the mechanicaland technological characteristics for pipes shall apply even ifforged hollow parts are used as starting product.





(1) Forged hollow parts to Section 7.3 or seamless pipes toSection 7.4 may be used as starting products.

(2) If the starting products used are not in the solution-annealed and quenched condition or have not beencompletely examined to the stipulations in Sections 7.3 or 7.4,the finished pipe elbows shall be examined individually toclause 7.5.5.2.

(3) If the finished pipe elbows are examined individually toclause 7.5.5.2, the determination of mechanical and technolo-gical characteristics and the corresponding verification may bewaived for the starting products. An acceptance test certificate3.1.B to DIN EN 10 204 shall then be adequate for visualinspection and dimensional check of the starting products.



(1) Specimens shall be taken from the ends of the pipeelbows in conformity with the authorized inspector's appraisal.

(2) The distance between pipe-elbow end and samplinglocation shall be at least equal to the nominal wall thicknessbut shall not exceed 25 mm. Deviations from the foregoing arepermitted, subject to the authorized inspector's approval.

(3) Where transverse specimens can be taken from non-directional test coupons they shall be tested. In the case ofoutside diameters Da smaller than or equal to 200 mm,longitudinal specimens shall be taken for tensile tests.

KTA 3211.1

Page 39

(4) For pipe elbows with nominal wall thicknesses largerthan or equal to 20 mm, specimens shall be taken from themiddle of the pipe wall if at all possible.

(5) If the pipe elbows are not tested individually, test unitsconsisting of pipe elbows of the same heat, dimension andheat treatment shall be formed for determination ofmechanical and technological characteristics.



b) 25 pieces for pipe elbows larger than or equal to DN 200 tosmaller than DN 350

c) 10 pieces for pipe elbows larger than or equal to DN 350.




a) One room-temperature tensile test on one pipe elbow pertest unit or, in the case of individual testing, on each pipeelbow.

b) One tensile test at 350 °C on one pipe elbow per heat,dimension and heat-treatment lot, if the design tempera-ture for pipe elbows of test group A 1 is higher than 200 °Cand for pipe elbows of test groups A 2 and A 3 is higherthan 300 °C.

c) One notched-bar impact bend test to clause 4.4.6.5 atroom-temperature per test unit for wall thicknesses largerthan 16 mm.


(4) One bead-on-plate test to determine the delta ferritecontent to Annex D shall be performed per heat, if valuessmaller than 3 are found in calculation of the ferrite numberfrom the chemical composition in the ladle analysis. This testmay be replaced by a corresponding test on the startingproduct.


a) For pipe elbows larger than or equal to DN 100, the out-side and inside surfaces shall be subjected to a surface-crack detection. For pipe elbows smaller than DN 100, theoutside surface shall be examined completely and theinside surface shall be examined wherever it is accessible.The acceptance criteria are defined in Table 5.2-1.

b) All pipe elbows smaller than DN 100 shall be ultrasonicallyexamined for longitudinal and transverse defects toSEP 1915 and SEP 1918 in the surface zones that are notaccessible to surface-crack detection.

c) For hot-finished pipe elbows of test group A 1 with outsidediameters larger than 100 mm and nominal wall thick-nesses larger than 16 mm, comparative sound attenuationmeasurements by means of angle-beam scanning shall bemade at both elbow ends. The measurements shall bemade at four places staggered by 90 degrees, alternatingbetween the circumferential direction and axial direction.They shall be performed with the same nominal frequencyas in the examination for longitudinal and transversedefects. If the values determined close to the test defectsin the test elbow are exceeded by more than 6 dB, themaximum amounts in excess of 6 dB shall be added on forsensitivity adjustment for the examination of longitudinal

and transverse defects. If it is found in the course of theexaminations that adequate uniformity of sound attenua-tion exists for the manufacturing method, material anddimension, the extent of sound attenuation measurementsmay be reduced, subject to approval of the authorizedinspector.

d) If an ultrasonic examination is performed on the pipeelbow, the corresponding examination on the startingproduct may be waived.

(6) Each pipe elbow shall be subjected to a materialsidentification check.



7.5.6 Marking


à) manufacturer's symbol,

b) steel grade with abbreviation for the type of constructionand the designation „S“ for seamless products to DIN17 458 for the starting pipes,

c) heat number,

d) elbow number or test lot number and

e) authorized inspector's mark,

f) mark of the non-destructive examinations performed,

g) designation „X“ in the case of hot-finished elbows (of theHamburg type) from the steel grades X 6 CrNiTi 18 10 andX 6 CrNiMoTi 18 10 in accordance with the stipulations forhot-finished pipes to DIN 17 458.


(1) The results of the ladle analysis, test for intergranularcorrosion resistance, materials identification check and non-destructive examinations performed by the manufacturer shallbe documented with an acceptance test certificate 3.1.B toDIN EN 10 204.


(3) For pipe elbows of test group A 3 with wall thicknessessmaller than or equal to 5.6 mm, an acceptance test certificate3.1.B to DIN EN 10 204 will suffice.


7.6.1 Scope


a) reducers made from seamless rolled, extruded or forgedpipes by cold or hot forming followed by heat treatment(solution annealing and quenching),



KTA 3211.1

Page 40

7.6.2 Materials


a) X6CrNiNb18-10 to DIN 17 440 or DIN 17 458

b) X6CrNiTi18-10 to DIN 17 440 or DIN 17 458

c) X6CrNiMoTi17-12-2 to DIN 17 440 or DIN 17 458

d) X6CrNiMoNb17-12-2 to DIN 17 440 or DIN 17 458




C ≤ 0.03 %

Si ≤ 0.5 %

P ≤ 0.025 %

S ≤ 0.010 %

18.0 ≤ (% Cr) ≤ 19.0

13 x (% C) ≤ (% Nb) ≤ 0.65


(4) For the mechanical and technological characteristics offabricated fittings, the values of the mechanical and techno-logical characteristics for pipes shall apply even if forgedhollow parts are used as starting products.





The stipulations in Section 7.3 or 7.4 shall apply to the startingproducts.



(1) Specimens shall be taken from the ends of the fittings inconformity with the authorized inspector's appraisal.

(2) The specimen axes shall be located at one half of thewall thickness under the end face or as close as possible tothat location.

(3) Where transverse specimens can be taken from non-directional test coupons they shall be tested. In the case ofoutside diameters Da smaller than or equal to 200 mm,longitudinal specimens shall be taken for tensile tests.

(4) For fittings with nominal thicknesses larger than or equalto 20 mm, specimens shall be taken from the middle of thepipe wall if at all possible.

(5) If the fittings are not tested individually, test unitsconsisting of fittings of the same heat, dimension and heat-treatment lot shall be formed for determination of characte-ristics.


a) 50 pieces for fittings smaller than DN 100

b) 10 pieces for fittings larger than or equal to DN 100





b) One tensile test at 350 °C per heat, dimension and heat-treatment lot, if the design temperature for fittings of testgroup A 1 is higher than 200 °C and for fittings of testgroups A 2 and A 3 is higher than 300 °C.

c) One notched-bar impact bend test to clause 4.4.6.5 atroom-temperature per test unit for wall thicknesses largerthan 16 mm.


(4) One bead-on-plate test to determine the delta ferritecontent to Annex D shall be performed per heat, if valuessmaller than 3 are found in calculation of the ferrite numberfrom the chemical composition in the ladle analysis. This testmay be replaced by a corresponding test on the startingproduct.


a) For fittings larger than or equal to DN 100, the outside andinside surfaces shall be subjected to a surface-crackdetection. For fittings smaller than DN 100, the outsidesurface shall be examined completely and the insidesurface shall be examined wherever it is accessible. Theacceptance criteria are defined in Table 5.2-1.

b) All fittings smaller than DN 100 shall be ultrasonicallyexamined for longitudinal and transverse defects toSEP 1915 and SEP 1918 in the surface zones that are notaccessible to surface-crack detection.

c) For hot-finished fittings of test group A 1 with outsidediameters larger than 100 mm and nominal wall thicknes-ses larger than 16 mm, comparative sound attenuationmeasurements by means of angle-beam scanning shall bemade at both ends. The measurements shall be made atfour places staggered by 90 degrees, alternating betweenthe circumferential direction and axial direction. They shallbe performed with the same nominal frequency as in theexamination for longitudinal and transverse defects. If thevalues determined close to the test defects in the testelbow are exceeded by more than 6 dB, the maximumamounts in excess of 6 dB shall be added on for sensitivityadjustment for the examination of longitudinal and trans-verse defects. If it is found in the course of the examina-tions that adequate uniformity of sound attenuation existsfor the manufacturing method, material and dimension, theextent of sound attenuation measurements may bereduced, subject to approval of the authorized inspector.

d) If an ultrasonic examination is performed on the fitting, theexamination on the starting pipe may be waived.



KTA 3211.1

Page 41

(8) For each fitting the ovality, diameter and wall thicknessshall be measured at the ends.

7.6.6 Marking

(1) Each fitting shall be marked with the followinginformation:


b) steel grade with abbreviation for the type of constructionand the designation „S“ for seamless products to DIN17 458 for the starting pipes,

c) heat number,

d) number of the fitting or test lot number,

e) authorized inspector's mark,

f) mark of the non-destructive examinations performed,

g) designation „X“ in the case of hot-finished fittings from thesteel grades X 6 CrNiTi 18 10 and X 6 CrNiMoTi 18 10 inaccordance with the stipulations for hot-finished pipes toDIN 17 458.


(1) The results of the ladle analysis, test for intergranularcorrosion resistance, materials identification check and non-destructive examinations performed by the manufacturer shallbe documented with an acceptance test certificate 3.1.B toDIN EN 10 204.


(3) For fittings of test group A 3 with wall thicknesses smallerthan or equal to 5.6 mm, an acceptance test certificate 3.1.Bto DIN EN 10 204 will suffice.

7.7 Castings

7.7.1 Materials


a) G-X 5 CrNiNb 18 9 to DIN 17 445

b) GX5CrNiNb19-11 to DIN EN 10 213-4

c) G-X 5 CrNiMoNb 18 10 to DIN 17 445

d) GX5CrNiMoNb19-12 to DIN EN 10 213-4



7.7.2 General requirements for casting condition

(1) The base metal shall have a delta ferrite contentcorresponding to ferrite numbers of 2 to 12 to Annex D.


(3) Feeder heads and large casting-related thickenings thatimpair the heat treatment of the casting shall be eliminatedbefore the heat treatment for establishment of the mechanicaland technological characteristics.

(4) The casting technique shall be designed according to theprinciples of controlled solidification. For castings with nominalwidths larger than or equal to 200 mm, the gate and feedertechnique shall be explained on the basis of the saturationcalculation as well as drawings illustrating the position of thefeeders, feed zones and specimen location.

(5) For each casting model, the description of the castingtechnique shall be attached to the interim file (internalmanufacturer documentation) for retention by the manufac-turer.



a) test and inspection sequence plan and heat-treatmentplan, in case of differences from the standard productionscheme to Figure B-12.

b) for castings of test group A 1 with nominal widths equal toor larger than 200 mm, instructions for the non-destructiveexaminations as well as a coordinate reference system(reference-point grid).

c) for prototypes of test groups A 2 and A 3 with nominalwidths greater than 200 mm a film location plan and aradiation source plan,

d) welding procedure qualification and welding proceduresheet for production welds and if applicable constructionwelds (see Annex C)



(7) If changes are made compared with the conditionsstipulated in the welding procedure sheet, or if a differentwelding method is chosen, the welding procedure sheet shallbe resubmitted for design approval in this respect.



(1) Castings with a delivery weight lighter than or equal to500 kg shall be tested in lots, and castings with a deliveryweight heavier than 500 kg shall be tested individually.

(2) The number of sampling locations shall be as indicatedin Table 7.7-1.


in kgTest unit



1


1



Table 7.7-1: Number of sampling locations on castings madeof austenitic steels

(3) The specimens shall be taken from cast-on test couponsor from overlengths. Separately cast test coupons arepermitted only for castings with piece weights equal to orlighter than 50 kg. The test coupons shall be provided insufficient number and size that the prescribed specimens canbe taken.

KTA 3211.1

Page 42

(4) The thickness of the cast-on test coupons shall be calcu-lated by comparison of volume/surface ratios at the governingnominal wall thickness. However, it shall be at most 150 mm.In this connection, the governing nominal wall thickness shallbe the thickness of the wall subjected to pressure loading, andnot the thickness of cast-on flanges or local thickenings. Cast-on test coupons at the gate system are not permitted. Thespecimens shall be taken at a distance of half the thickness ofthe cast-on test coupons from the end and side faces as wellas at one quarter from one of the other faces.





b) One product analysis for one sampling location per testunit. The nitrogen content shall be shown if the delta ferritecontent is determined to Annex D.

(2) The mechanical and technological characteristics shallbe determined by performing:a) One room-temperature tensile test per sampling location.b) One tensile test at 350 °C per heat, dimension and heat-

treatment lot, if the design temperature for castings of testgroup A 1 is higher than 200 °C and for castings of testgroups A 2 and A 3 is higher than 300 °C.

c) One notched-bar impact bend test to clause 4.4.6.5 atroom-temperature per sampling location.


(4) The delta ferrite content shall be determined from thenitrogen content by the method of Annex D. If the value of theferrite number calculated from the chemical composition perthe ladle analysis is smaller than 3, the delta ferrite contentshall be determined metallographically per heat.



(7) Each casting shall be subjected in the as-deliveredcondition to a visual inspection of its external finish.


(9) Each casting shall be subjected in a condition suitable forthe purpose, generally by the further processor, to a tightnesstest in the form of an internal pressure test, which shall beperformed to DIN 50 104. Pressurizing fluid, pressure leveland pressure-loading duration shall be indicated in thepurchase order. However, the nominal pressure shall neverlead to a load higher than 90 % of the 0.2 % proof stress ofthe cast-steel grade.

7.7.4 Marking

(1) Each casting shall be marked with the followinginformation:a) manufacturer's symbol,b) cast-steel grade,c) heat number,d) specimen number ande) authorized inspector's mark.


(1) The results of the ladle analysis, product analysis, testfor resistance to intergranular corrosion, determination of thedelta ferrite content, materials identification check and non-destructive examinations performed by the manufacturer shallbe documented with an acceptance test certificate 3.1.B toDIN EN 10 204.

(2) The results of all other tests and examinations shall becertified by the authorized inspector and combined with theabove-mentioned certificate as an acceptance test certificate3.1.C to DIN EN 10 204. For castings with piece weightsheavier than 1000 kg, a photograph or a sketch of the locationof the cast-on test coupons on the casting shall be attached tothe acceptance test certificate.

8 Bolts and nuts

8.1 Scope

This Section shall apply to:

a) bolts and nuts made by machining from quenched andtempered ferritic bars,

b) bolts and nuts made by machining from solution-annealedand quenched austenitic bars,

c) bolts and nuts made by hot or cold forming from ferriticbars and then quenched and tempered,

d) bolts and nuts of unalloyed and alloyed ferritic steels of thestrength classes to DIN EN ISO 898-1, DIN EN 20 898-2and DIN EN ISO 898-6 as well as of austenitic steels ofsteel groups A 2, A 3, A 4 and A 5 to DIN EN ISO 3506-1and DIN EN ISO 3506-2 within the limits of Table 8-1.

Note:Thread rolling shall not be considered as cold forming thatrequires renewed heat treatment.

8.2 Materials



b) steel grades Ck 35, 24 CrMo 5 and 21 CrMoV 5 7 toDIN 17 240 as well as C35E and 21CrMoV5-7 to DIN EN10 269 in combination with the additional requirements ofSection 8.3 as well as the dimensional limits and otherstipulations in Section A 6,

c) steel grades X 22 CrMoV 12 1 and X 8 CrNiMoBNb 16 16to DIN 17 240 as well as X22CrMoV12-1 andX7CrNiMoBNb16-16 to DIN EN 10 269 in combination withthe dimensional limits and other stipulations in Section A 6,

d) ferritic and austenitic steel grades for bolts and nuts toTable 8-1, within the strength classes and limits ofapplication indicated therein,


(2) Locking by welding is not permitted.

8.3 Additional requirements for the materials

(1) For ferritic steels for bolts, except martensitic steelscontaining 12 % chromium and steel grades to clause 8.1 d),the following additional stipulations shall apply in the notched-bar impact bend test on Charpy V-notch longitudinalspecimens at room temperature:

a) for dimensions larger than M 24 and smaller than or equalto M 100, the smallest individual value of lateral expansionshall not be less than 0.6 mm and

KTA 3211.1

Page 43

b) for dimensions larger than M 100 the smallest individualvalue of energy absorbed shall not be less than 61 J andthe smallest individual value of lateral expansion shall notbe less than 0.6 mm.

8.4 Bolts and nuts made by machining from ferritic bars

8.4.1 Tests and examinations on the bars


(1) Longitudinal specimens shall be taken.

(2) The test cross section of the tensile-test and notched-barimpact-test specimens shall be located at least one half of thebar diameter from the end face, and the specimen axis shallbe located at the bar center for diameters equal to or smallerthan 40 mm and at a depth of one sixth of the diameter underthe surface for diameters larger than 40 mm.

8.4.1.2 Test units

The bars shall be tested in test units of at most 5000 kg,consisting of bars of the same dimension, same heat andsame heat-treatment lot.


(1) One ladle analysis shall be performed per heat.


a) Hardness test to DIN EN ISO 6506-1 as follows: with oneindentation at one end of each bar of the test unit for barswith diameter larger than 120 mm; and with oneindentation at one end of 10 % of the bars of the test unitfor bars with diameter equal to or smaller than 120 mm,except that at least 10 bars or, if the test unit consists offewer than 10 bars, every bar shall be tested.

b) One room-temperature tensile test on the bars exhibitingthe lowest and highest hardness values.

c) One additional tensile test at 350 °C on bars for fabricationof bolts of test group A 1, if the design temperature ishigher than 100 °C.

d) One notched-bar impact bend test to clause 4.4.6.5 atroom-temperature to determine the energy absorbed andlateral expansion for bars with diameters equal to or largerthan 14 mm on both bars that were subjected to the tensiletest.

(3) The ultrasonic examination of the bars shall be subject tothe following requirements:

a) All bars with diameters equal to or larger than 30 mm forbolts and nuts shall be examined in quenched andtempered condition by the manufacturer for internaldefects. During the acceptance procedure, 10 % of thebars for bolts or at least 10 of those bars per delivery and5 % of the bars for nuts or at least 2 of those bars perdelivery shall be examined by the authorized inspector.

b) The ultrasonic examination shall be performed as follows:along two scan paths separated by 90 degrees for roundbars; and along three scan paths separated by 60 degreesfor hexagonal bars. All echo amplitudes corresponding to acircular-disk reflector diameter of 1.5 mm and larger shallbe registered. To define the recording limit, a referencereflector in the form of a radial flat-bottomed hole with itsbottom located at the center of the bar shall be made. Thediameter of this hole shall be 4 to 6 mm. The cited sensiti-vity shall be adjusted by means of an appropriate gainincrease.

c) In the case of radial beam entry, indications up to 12 dBabove the recording limit and up to a maximum length

equal to the bar diameter of the bars for bolts and equal tohalf the bar diameter of the bars for nuts are permitted.The indication length shall be determined by the half-amplitude technique.

(4) Each bar shall be subjected to visual inspection of itsexternal finish.

(5) The marking on each bar shall be inspected.

(6) Each bar shall be inspected for dimensional accuracy.

(7) Each bar shall be subjected to a materials identificationcheck.

8.4.2 Tests and examinations on finished parts

(1) A surface-crack detection shall be performed randomlyon bolts and nuts. The extent of random examination and theacceptance levels shall be subject to the stipulations in Table8-3. Indications that prove the presence of cracks are notpermitted. Further findings shall be assessed to Table 8-10.

(2) The main and secondary features of randomly checkedbolts and nuts shall be examined to Table 8-2. The extent ofrandom examination and the acceptance levels shall besubject to the stipulations in Table 8-3. Subject to agreementof the authorized inspector, it is permitted to supplement orreplace the secondary features cited in Table 8-2 byapplication-specific requirements.

(3) The marking shall be checked at random. The extent ofrandom checking shall be subject to the stipulations in Table8-3.

(4) Bolts and nuts of alloyed steels shall randomly subjectedto a materials identification check. The extent of randomchecking shall be subject to the stipulations in Table 8-4. Theacceptance level shall be zero, regardless of the extent ofrandom checking.

8.5 Bolts and nuts made by machining from solution-annealed and quenched austenitic bars

8.5.1 Tests and examinations on the bars


(1) Longitudinal specimens shall be taken.

(2) The axis of the tensile-test and notched-bar impact-testspecimens shall be located at the center for sizes withdiameters smaller than or equal to 25 mm and at least12.5 mm under the surface for sizes with diameters largerthan 25 mm.

8.5.1.2 Test units

The bars shall be tested in test units of at most 500 kg,consisting of bars of the same dimension, same heat andsame heat-treatment lot.




a) One room-temperature tensile test on one bar per test unit.

b) One tensile test at 350 °C on bars for fabrication of bolts oftest group A 1, if the design temperature for test group A 1is higher than 200 °C.

c) One notched-bar impact bend test to clause 4.4.6.5 atroom-temperature for bars with diameters equal to orlarger than 14 mm on the same bar that was subjected tothe tensile test.

KTA 3211.1

Page 44

(3) One test for resistance to intergranular corrosion toDIN EN ISO 3651-2 shall be performed per heat and heat-treatment lot.

(4) The ultrasonic examination of the bars shall be subject tothe following requirements:

a) All bars with diameters equal to or larger than 30 mm forbolts and nuts shall be examined in solution-annealed andquenched condition by the manufacturer for internaldefects. During the acceptance procedure, 10 % of thebars for bolts or at least 10 of those bars per delivery and5 % of the bars for nuts or at least 2 of those bars perdelivery shall be examined by the authorized inspector.

b) The ultrasonic examination shall be performed as follows:along two scan paths separated by 90 degrees for roundbars; and along three scan paths separated by 60 degreesfor hexagonal bars. All echo amplitudes corresponding to acircular-disk reflector diameter of 2 mm and larger shall beregistered. To set the recording limit, a reference reflectorin the form of a radial flat-bottomed hole with its bottomlocated at the center of the bar shall be made. Thediameter of this hole shall be 4 to 6 mm. The citedexamination sensitivity shall be adjusted by means of anappropriate gain increase.

c) In the case of radial beam entry, indications up to 12 dBabove the recording limit and up to a maximum lengthequal to the bar diameter of the bars for bolts and equal tohalf the bar diameter of the bars for nuts are permitted.The indication length shall be determined by the half-amplitude technique.



(7) Each bar shall be inspected for dimensional accuracy.


8.5.2 Tests and examinations on finished parts

(1) A surface-crack detection shall be performed randomlyon the bolts and nuts. The extent of random examination andthe acceptance levels shall be subject to the stipulations inTable 8-3. Indications that prove the presence of cracks are notpermitted. Further findings shall be assessed per Table 8-10.

(2) The main and secondary features of randomly checkedbolts and nuts shall be examined per Table 8-2. The extent ofrandom examination and the acceptance levels shall besubject to the stipulations in Table 8-3. Subject to agreementof the authorized inspector, it is permitted to supplement orreplace the secondary features cited in Table 8-2 by applica-tion-specific requirements.

(3) The marking shall be checked at random. The extentof random checking shall be subject to the stipulations inTable 8-3.

(4) Bolts and nuts shall be randomly subjected to a materialsidentification check. The extent of random checking shall besubject to the stipulations in Table 8-4. The acceptance levelshall be zero, regardless of the extent of random checking.

8.6 Bolts and nuts made from ferritic bars by hot or coldforming and subsequently heat-treated


8.6.1.1 Tests and examinations on the bars





8.6.1.2 Tests and examinations on finished parts

The tests and examinations shall be performed on the boltsand nuts themselves. If this is not possible because of thedimensions of the bolts and nuts, specimens for tensile andnotched-bar impact bend tests shall be taken from barsegments that have been turned down to the heat-treatmentdiameter governing the heat treatment of the formed bolts andnuts and that have been heat-treated together with these boltsand nuts. In this case the stipulations of clause 8.4.1.1 shallapply to the sampling location.

8.6.1.3 Test units

(1) The test shall be performed after the final heat treatmenton test units consisting of parts of similar dimension andoriginating from the same heat and same heat-treatment lot.

(2) The number of pieces to be tested shall depend on thenumber of pieces in the test unit and on the test method. Thestipulations in Table 8-5 shall apply.



a) Hardness testing of the bolts and nuts of a test unit perTable 8-5 (DIN EN ISO 6506-1). If traveller bar segmentswere quenched and tempered for the tests to Sections 3and 4, the hardness shall also be determined on these barsegments.

b) One room-temperature tensile test on turned-downspecimens to DIN EN ISO 898-1 or, in the case of testingof quenched and tempered traveller bar segments, onspecimens to DIN 50 125. The piece for which the smallestvalue of hardness was determined in the hardness testshall also be subjected to this tensile test.

c) One notched-bar impact bend test to clause 4.4.6.5 atroom-temperature to determine the energy absorbed, forbolts larger than M 19 per Table 8-5; for bolts larger thanM 24, the lateral expansion shall additionally bedetermined. The piece for which the largest value ofhardness was determined in the hardness test shall alsobe subjected to this notched-bar impact bend test.

(2) A drift test to DIN EN 493 shall be performed on nuts perTable 8-5. The piece for which the largest value of hardnesswas determined shall also be subjected to this drift test.

(3) The non-destructive examinations shall be subject to thefollowing requirements: A surface-crack detection shall beperformed randomly on bolts and nuts. The extent of randomexamination and the acceptance levels shall be subject to thestipulations in Table 8-3. Indications that prove the presenceof cracks are not permitted. Further findings shall be evaluatedto Table 8-10.

(4) In the dimensional check, the main and secondaryfeatures shall be randomly examined to Table 8-2. The extentof random checking and the acceptance levels shall besubject to the stipulation in Table 8-3. Subject to agreement ofthe authorized inspector, it is permitted to supplement orreplace the secondary features cited in Table 8-2 by appli-cation-specific requirements.

(5) The marking shall be checked at random. The extentof random checking shall be subject to the stipulations inTable 8-3.

KTA 3211.1

Page 45

(6) Bolts and nuts of alloyed steels shall be randomlysubjected to a materials identification check. The extentof random checking shall be subject to the stipulations inTable 8-4. The acceptance level shall be zero, regardless ofthe extent of random checking.

8.7 Bolts and nuts of strength classes



(1) The tests and examinations shall normally be performedon the bolts themselves.

(2) If this is not possible because of the dimensions of thebolts:

a) specimens for tensile and notched-bar impact bend tests inthe case of ferritic steels shall be taken from bar segmentsthat have been turned down to the heat-treatment diametergoverning the quenching and tempering of the formedbolts and that have been heat-treated together with thesebolts. In this case the stipulations of clause 8.4.1.1 shallapply for the sampling location, and

b) bolts of correspondingly greater length shall be made forthe tensile tests of each test unit in the case of austeniticsteels.

8.7.1.2 Test units

The test shall be performed after the final heat treatment ontest units consisting of parts of similar dimension and thesame heat, originating from the same heat-treatment lot. Thenumber of pieces to be tested shall depend on the number ofpieces in the test unit. The stipulations in Table 8-6 shallapply.


(1) Bolts of ferritic steels shall be tested to DIN EN ISO 898-1,test program A. If test program A is not feasible, the tests shallbe performed per test program B. For dimensions larger thanM 19, verification of energy absorbed shall be required.

(2) For bolts of ferritic steels of strength class 8.8 forallowable operating temperatures higher than 50 °C, theelevated-temperature yield point shall be verified at designtemperature on specimens to DIN 50 125.

(3) Nuts of ferritic steels shall be tested to DIN EN 20 898-2or DIN EN ISO 898-6 in combination with DIN EN 493.

(4) Bolts and nuts of austenitic steels shall be tested toDIN EN ISO 3506-1 and DIN EN ISO 3506-2.

(5) Examinations and assessments for defect types perTable 8-7 shall be performed as follows: to DIN EN 26 157-3for bolts, and to DIN EN 493 for nuts.

(6) Bolts and nuts shall be subjected randomly to a dimen-sional check. The main and secondary features of Table 8-2shall be examined. Subject to agreement of the authorizedinspector, it is permitted to supplement or replace the secon-dary features cited in Table 8-2 by application-specific require-ments. The number of pieces to be inspected and the accep-tance levels shall be subject to the stipulations in Table 8-3.

8.8 Marking

8.8.1 Marking of the bars

(1) The marking shall be applied on labels for bars withdiameters equal to or smaller than 25 mm and on the barsthemselves for bars with diameters larger than 25 mm.

(2) The marking shall contain the following information:


b) steel grade,

c) heat number, if necessary abbreviation and

d) authorized inspector's mark.

8.8.2 Marking of the bolts and nuts

The marking shall contain the following information:


b) steel grade or strength class,

c) the heat number for dimensions larger than M 52, ifnecessary an abbreviation for nuts,

d) the authorized inspector's mark for bolts larger than M 52,

e) a mark of correlation to the certificate for bolts larger thanM 24, except for bolts of steels to Section 8.7.

8.9 Verification of quality characteristics

(1) The stipulations in Table 8-8 shall govern verification ofthe quality characteristics of parts as per Sections 8.4, 8.5 and8.6.

(2) The stipulations in Table 8-9 shall govern verification ofthe quality characteristics of bolts and nuts as per Section 8.7.

Steel grades Product form Strength class Limits of application

Unalloyed and alloyed ferritic steels Bolts 5.6 and 8.8per DIN EN ISO 898-1

≤ M 30 for the scope of application:≤ 2.5 MPa and ≤ 100 °C 1);strength class 8.8 only in combination withflanges ≤ DN 500

Nuts 5-2 and 8per DIN EN 20 898-2or DIN EN ISO 898-6

≤ M 30 for the scope of application:< 4 MPa and ≤ 300 °C; strength class 8only in combination with flanges ≤ DN 500

Austenitic steels of steel groups A 2 2),A 3, A 4 2) and A 5 to DIN EN ISO3506-1 and DIN EN ISO 3506-2

Bolts and nuts 50 and 70to DIN EN ISO 3506-1 toDIN EN ISO 3506-2

≤ M 39,strength class 70 only for ≤ M 30

1) Without verification of the elevated temperature proof stress, bolts made of the steels for strength class 8.8 shall only be used up to 50 °C.2) Bolts and nuts from non-stabilized austenitic steel grades of groups A 2 and A 4 shall not be used if in permanent contact with the fluid.

Exceptions shall be agreed between purchaser and authorized inspector.

Table 8-1: Limits of application of bolts and nuts to DIN EN ISO 898-1, DIN EN 20 898-2 and DIN EN ISO 898-6as well as DIN EN ISO 3506-1 and DIN EN ISO 3506-2

KTA 3211.1

Page 46

Main features

Thread limit dimensions (trueness to gauge size)Force-application areas for assemblyTransition under the bolt headThread root radius at the thread-to-shank transition

Secondary features

Lengths (bolt length, thread length)Deviations from shape and locationBearing surfacesHeights (head heights, nut heights)Diameters

Note:Further features as well as their classification can be defined in the purchase order.

Table 8-2: Features to be inspected during the dimensional check as well as their classification as main or secondaryfeatures

Extent of random checking Acceptance levels

Number of piecesin the test unit

Dimensional check formain features and

check of identificationmarking

Dimensional check forsecondary features andsurface crack detection

Check ofidentification

marking

Bolts Nuts Bolts Nuts

Dimensionalcheck for

main features

Dimensionalcheck for

secondaryfeatures andsurface crack

detection

up to 150 32 20 20 13 0 0 0

151 up to 280 32 20 80 50 0 1 0

281 up to 500 125 80 80 50 1 1 0

501 up to 1200 125 80 125 80 1 2 0

1201 up to 3200 200 125 200 125 2 3 0

3201 up to 10000 315 200 315 200 3 5 0

Table 8-3: Extent of random checking and acceptance levels for the dimensional check, surface-crack detection and checkof identification marking

Number of pieces in the test unit Extent of random checking 1)

up to 150 20

151 up to 280 32

281 up to 500 50

501 up to 1200 80

1201 up to 3200 125

3201 up to 10000 2001) The acceptance level is always zero, regardless of the extent of random checking.

Table 8-4: Extent of random materials identification checking on bolts and nuts

Hardness testTensile test

Notched-bar impact bend testDrift test

Number of pieces per test unit Number of pieces to be tested Number of pieces per test unit Number of pieces to be tested

up to 150 8151 up to 280 13

up to 300 1

281 up to 500 20

501 up to 1200 32301 up to 800 2

1201 up to 3200 50

3201 up to 10000 80more than 800 4

Table 8-5: Number of pieces to be subjected to the mechanical and technological tests of bolts and nuts to Section 8.6

KTA 3211.1

Page 47

Number of pieces per test unit (test lot) Number of pieces to be tested (extent of random checking)

up to 200 1

201 up to 400 2

401 up to 800 3

801 up to 1200 4

1201 up to 1600 5

1601 up to 3000 6

3001 up to 3500 7

If the bolts of one delivery verifiably originate from one heat with the same heat treatment, it will suffice to test 4 specimen sets regardless ofthe number of pieces.

Table 8-6: Number of pieces to be subjected to the mechanical and technological tests of bolts and nuts to Section 8.7

Examination ofType of defect bolts nuts

ferritic austenitic ferritic austenitic

Hardening cracks X X Crop cracking X X X X

Head cracks X X Shear cracks X X X X

Score marks X X X X

Pits X X X X

Cracks in the thread X X X XDamage(e.g., tool marks)

X X X X

Bursting X X

Wrinkling X X X X

Table 8-7: Defects of bolts and nuts of ferritic and austenitic steels per clause 8.7.1.3 (5) and testing for such defects (seeFigure 8-1 for visible manifestations and Table 8-10 for assessment)

Type of required certificate to DIN EN 10 204

Test Bars to Section 8.4and 8.5 for

Finished parts toSection 8.4 and 8.5

Bars forparts to

Finished parts toSection 8.6

Bolts Nuts Bolts 1) Nuts 1) Section 8.6 Bolts 1) Nuts 1)

Ladle analysis 2.2 2) 2.2 2) 2.2 2.2 2) 2.2 2)

Hardness test 3.1.B 3.1.B 3.1.B 3.1.B

Strength test 3.1.C 3.1.B 3.1.C 3.1.B

Notched-bar impacttoughness test 3.1.C 3.1.B 3.1.C

Drift test 3.1.B

Non-destructive examination 3.1.C 3.1.C 3.1.C 3.1.B 3.1.C 3.1.B

Resistance to intergranularcorrosion 3) 3.1.B 3.1.B 3.1.B

Visual inspection 3.1.C 3.1.B

Dimensional check 3.1.B 3.1.B 3.1.C 3.1.B 3.1.C 3.1.B

Inspection of the marking 3.1.C 3.1.B 3.1.C 3.1.B 3.1.B 3.1.C 3.1.B

Materials identification check 3.1.B 3.1.B 3.1.B 3.1.B 3.1.B 3.1.B 3.1.B

1) Certificates for the tests on the bars are additionally necessary.2) This verification may also be included in the acceptance test certificate.3) For products to Section 8.5.

Table 8-8: Review of required tests and test certificates for products to Sections 8.4, 8.5 and 8.6

KTA 3211.1

Page 48

Steel grades Product Strength class Certificate toDIN EN 10 204

Unalloyed and alloyed ferritic steels Bolts 4.6 and 5.6 3.1.B 1)

8.8 3.1.C 2)

Nuts 5 and 8 3.1.B 1)

Austenitic steel grades of steel groups A 2, A 3, A 4 and A 5 Bolts and nuts 50 and 70 3.1.B

1) The requirement of filling out an acceptance test certificate 3.1.B to DIN EN 10 204 may be waived if the manufacturer has constantlycarried out the tests necessary as basis for filling out an acceptance test certificate 3.1.B and has kept the results ready for review by theauthorized inspector at all times. In this case the marking to Section 8.8 will suffice as the quality verification.

2) For pressure vessels for which the product of capacity [I] in liters and pressure [p] in MPa is less than or equal to 500 (l x p ≤ 500) anacceptance test certificate 3.1.B to DIN EN 10 204 will suffice.

Table 8-9: Review of required test certificates for bolts and nuts to Section 8.7

Defect type Pits(shallowdepressions on thesurface)

Scoremarks(narrow, straight orslightly curveddepressions)

Tool marks Surface defects on thethread

Wrinkles Damage

Validity Full diameter boltsNuts

Full diameter boltsNuts

Full diameterboltsReduced-shank boltsNuts

Full diameter boltsReduced-shank bolts

Nuts Full diameterbolts

Visiblemanifesta-tions,location

a) Bolt shank,bearing surfacesof the bolts andnuts

b) Other surfaces ofthe bolt head, ofthe nut Figure 8-1(Sketch 1)

Figure 8-1(Sketch 3)



No definitegeometricform, locationor direction asexternal effect

Assess-mentcriteria

a) BoltsPermissible depth:≤ 0.02 d,max. 0.25 mmPercentage of pitarea ≤ 5%

NutsPermissible depth:≤ 0.25 mmPercentage of pitarea ≤ 5 % ofbearing surfaces

b) BoltsPermissible depth:≤ 0.03 d,max. 0.4 mm

NutsPermissible depth:≤ 0.02 D,max. 0.6 mm

BoltsPermissible depth:0.015 d + 0.1 mmmax. 0.4 mm

Permissible width:max. 0.13 mm

NutsPermissible depth:max. 0.3 mmPermissible scoredepth:≤ 0.02 D

BoltsPeak-to-valleyheight(RZ) ≤ 16 µm

Tool marks onthe transitionbetween headand shank aswell as on theshank are notpermitted.

NutsPeak-to-valleyheight(RZ) ≤ 16 µmon the bearingsurface

Shuts and laps are notpermissible at thefollowing places:- thread root- loaded thread flanks

The following defectsare permitted:- wrinkles with a depth

of max. 0.25 H1 atthe thread crests

- thread crests notcompletely rolled out

- shuts and laps, aslong as they runtoward the outsidediameter on theunloaded flank andare not deeper than0.25 H1 and at mostare 1/2 turn on onethread

Wrinkles inthe bearingsurfacesand wrinklespenetratinginto thebearingsurfaces arenotpermitted.

If damage ispresent, theusability of theparts shall bedecided on acase-by-casebasis.Damage dueto externaleffects shallnot impair thefunction andusability of theparts.

D : thread end diameter (nuts) RZ : averaged peak-to-valley heightd : thread end diameter (bolts) H1 : to DIN 13-19

Table 8-10: Assessment criteria for surface irregularities of bolts and nuts

KTA 3211.1

Page 49

Pits Pits

Pits

Score marks

Score marks

Excessive rolling or score mark,normally straight or slightly bent pathin longitudinal direction

Tool marks

Tool mark

Tool markdue to deburring

Figure 8-1: Visible manifestations and location of defects on bolts and nuts(Part 1)

Sketch 1

Sketch 2

Sketch 3

KTA 3211.1

Page 50

Surface defectson the thread

1

1

1

1

0.25

H

HH

0.25

H

Impermissible excessive rolling

Permissible excessive rolling

Pitch diameter

Loading direction

Outside diameter

Root diameter

Pitch diameter

Outside diameter

Pitch diameter

Root diameter

Permissible deviation from profile

Root diameter

Outside diameter

Wrinkles

bearing surface

Compression wrinkle of theCompression wrinkleof the side

Compression wrinkle on the end or

Compression wrinkles

perimeter of the bearing surfaceof flange nuts

Figure 8-1: Visible manifestations and location of defects on bolts and nuts(Part 2)

Sketch 4

Sketch 5

KTA 3211.1

Page 51

9 Product forms of steels for special loads


9.1.1 Materials


a) X 4 CrNi 13 4 per SEW 400,




(1) The surfaces shall be free of impurities. Scale layers andtempering colours developed during hot forming or heattreatment shall be removed.

(2) The surface condition shall meet the requirements ofnon-destructive examination and be indicated in the purchaseorder.


9.1.3.1 Sampling location and specimen preparation

(1) Specimens from the same heat, with similar dimensionsand from the same heat-treatment lot shall be grouped intotest units. One test unit shall contain at most 25 pieces butshall not weigh more than 500 kg.

(2) Pieces with heat-treatment weights heavier than 500 kg,open-die forged flanges with a piece weigth havier than 300 gand hollow parts with a diameter exceeding 600 mm shall betested individually.

(3) The specimens shall be taken at one end of the pieces.

(4) The specimens of each test unit shall be taken from onepiece. For bars or similar pieces that are longer than 3 m butare not heat-treated in the continuous furnace, specimensshall be taken from both ends of the piece selected for testing.

(5) The sampling locations shall be at least one sixth of thediameter or one sixth of the heat-treatment thickness but notmore than 30 mm under the heat-treatment surface. The testsshall be performed on transverse specimens. Longitudinalspecimens are permitted in the following cases: tensile-testspecimens for pieces with a cross-sectional area corresponingto solid parts with a diameter smaller than 160 mm; andnotched-bar impact-test specimens for pieces with a cross-sectional area corresponding to solid parts with a diametersmaller than 100 mm.

(6) If welding followed by heat treatment will be performedduring further processing, one test coupon shall be providedfor traveller specimens.




b) One product analysis at one sampling location on each oftwo separately manufactured pieces per heat. If possible,the top or bottom of the starting ingot shall be tested. Forpieces heavier than 5000 kg, the analysis shall be per-ormed on one sampling location of each piece. If possible,the top or bottom of the starting ingot shall be tested.



b) One tensile test at 350 °C per heat, similar dimension andheat-treatment lot, if the design temperature is higher than100 °C. For piece weights heavier than 3000 kg in testgroup A 1, each piece shall be tested.

c) One notched-bar impact bend test to clause 4.4.6.5 atroom temperature per sampling location.

d) One hardness test (at least 3 hardness indentations) toDIN EN ISO 6506-1 on each piece.

(3) The non-destructive examinations shall be subject to thestipulations in Annex H.


(5) Each piece shall be subjected to a visual inspection of itsexternal finish.

(6) A dimensional check shall be performed for each piece.

9.1.4 Marking

(1) Each piece shall be marked durably with the followinginformation:


b) steel grade,

c) heat number,





(1) The heat-treatment condition, results of the ladleanalysis, product analysis, materials identification check andnon-destructive examinations performed by the manufacturershall be documented with an acceptance test certificate 3.1.Bto DIN EN 10 204.


9.2 Castings

9.2.1 Materials


a) G-X 5 CrNi 13 4 to DIN 17 445

b) GX4CrNi13-4 to DIN EN 10 213-2

b) other steel grades meeting the prerequisites of Section 3 incombination with the stipulations in the authorizedinspector's appraisal.


9.2.2 General casting finish


(2) Feeder heads and large casting-related thickenings thatimpair amenability of the casting to the heat treatment shall beeliminated before the heat treatment for establishment of themechanical and technological characteristics.

(3) The casting technique shall be designed according to theprinciples of controlled solidification. For castings with nominalwidths equal to or larger than 200 mm, the gate and feeder

KTA 3211.1

Page 52

technique shall be explained on the basis of the saturationcalculation as well as drawings illustrating the position of thefeeders, feed zones and specimen location. For each castingmodel, the description of the casting technique shall beattached to the interim file (internal manufacturer documen-ation) for retention by the manufacturer.



a) test and inspection sequence plan and heat-treatmentplan, in case of differences from the standard productionscheme to Figure B-12.

b) for castings of test group A 1 with nominal widths largerthan 200 mm, instructions for the non-destructiveexaminations as well as a coordinate reference system(reference-point grid).

c) for prototypes of test groups A 2 and A 3 with nominalwidths greater than 200 mm a film location plan and aradiation source plan,

d) welding procedure qualification and welding proceduresheet for production welds and if applicable constructionwelds (see Annex C).



(5) Stipulations for production welds including procedureinspection and production control test are listed in Annex C.

(6) If changes are made compared with the conditionsstipulated in the welding procedure sheet, or if a differentwelding method is chosen, the welding procedure sheet shallbe resubmitted for design approval in this respect.



(1) Castings with a delivery weight equal to or lighter than500 kg shall be tested in lots, and castings with a deliveryweight heavier than 500 kg shall be tested individually.

(2) The number of sampling locations shall be as indicatedin the following table:

The number of sampling locations shall be as indicated inTable 9-1.


in kgTest unit



1


1



Table 9-1: Number of sampling locations on castings madeof steels for special loads

(3) The specimens shall be taken from cast-on test couponsor from overlengths. Separately cast test coupons arepermitted only for castings with piece weights equal to orlighter than 150 kg. The test coupons shall be provided insufficient number and size that the prescribed specimens canbe taken.

(4) The thickness of the cast-on test coupons shall becalculated by comparison of volume/surface ratios at thegoverning nominal wall thickness. However, it shall be at most150 m. In this connection, the governing nominal wall thick-ness shall be the thickness of the wall subjected to pressureloading, and not the thickness of cast-on flanges or localthickenings. Cast-on test coupons at the gate system are notpermitted. The specimens shall be taken at a distance of halfthe thickness of the cast-on test coupons from the end andside faces as well as at one quarter from one of the other faces.








b) One tensile test at 350 °C per heat, dimension and heat-treatment lot, if the design temperature is higher than100 C. The elevated-temperature tensile test is notrequired if the value of yield point determined in the room-temperature tensile test is 30 N/mm2 or more above therequired minimum value.

c) One notched-bar impact bend test to clause 4.4.6.5 atroom-temperature per sampling location.

d) One hardness test on each piece to verify uniformity of thequenching and tempering treatment in the case of lotwiseexamination of castings of quenched and tempered steel.

(3) The non-destructive examinations of the castings shallbe subject to the stipulations in Annex B.


(5) Each casting shall be subjected in the as-deliveredcondition to a visual inspection of its surface finish.


(7) Each casting shall be subjected in a condition suitable forthe purpose, generally by the further processor, to a tightnesstest in the form of an internal pressure test, which shall beperformed to DIN 50 104. Pressurizing fluid, pressure leveland pressure-loading duration shall be indicated in thepurchase order. However, the nominal pressure shall neverlead to a load higher than 90 % of the 0.2 % proof stress ofthe cast-steel grade.

9.2.4 Marking

(1) Each casting shall be marked with the followinginformation:


KTA 3211.1

Page 53

b) cast-steel grade,

c) heat number,


e) authorized inspector’s mark.


(1) The results of the ladle analysis, product analysis,materials identification check, non-destructive examinationsperformed by the manufacturer and hardness test shall bedocumented with an acceptance test certificate 3.1.B toDIN EN 10 204. A certificate documenting the heat-treatmentcondition shall be attached to the acceptance test certificate.

(2) The results of all other tests and examinations shall becertified by the authorized inspector and combined with theabove-mentioned certificates as an acceptance test certificate3.1.C to DIN EN 10 204. For castings with piece weightsheavier than 1000 kg, a photograph or a sketch of the locationof the cast-on test coupons on the casting shall be attached tothe acceptance test certificate.

10 Heat-exchanger tubes

10.1 Seamless straight heat-exchanger tubes of ferriticsteels with wall thicknesses smaller than or equal to4 mm and with outside diameters smaller than orequal to 38 mm

10.1.1 Materials


a) St 35.8 III to DIN 17 175

b) 15 Mo 3 to DIN 17 175

c) 13 CrMo 4 4 to DIN 17 175

d) 10 CrMo 9 10 to DIN 17 175




(1) The tubes shall be tested in manufacturing lengths.Every hundred manufacturing lengths of the same productionrun, heat, dimension and heat treatment shall be groupedtogether as one test unit.

(2) Specimens shall be taken from the ends ofmanufacturing lengths.

(3) Specimen forms to DIN EN 10 002-1 may also be usedfor tensile tests.

10.1.2.2 Extent of tests and examinationsNote:The extent of tests and examinations shall apply both to tubesused as straight tubes and to tubes that will subsequently be bent.



a) One pickling test on one disc of each round or square baroriginating from the top end of an ingot, for tubes manufac-tured from rough-rolled round or square steel. Alternative-ly, an ultrasonic examination for shrinkage cavities may beperformed at the manufacturer’s discretion.

b) For each production run, two tensile tests for each of thefirst two test units and one tensile test for the further testunits at one end of one manufacturing length.

c) One technological test to Table 10-1 at one end of eachmanufacturing length for tubes of test group A 1. For tubesof test groups A 2 and A 3, 20 % of every 100 manufactu-ring lengths of the same heat, dimension and heattreatment shall be subjected to a technological test toTable 10-1 at one end.

Nominal wall thickness sof the tubes

in mm

Nominal outsidediameter Da

in mms ≤ 2 2 < s ≤ 4

Da ≤ 21.3 Flattening test Flattening test

21.3 < Da ≤ 38 Flattening test Ring expandingtest

Table 10-1: Dimensional ranges for application of thetechnological tests

(3) Each tube shall be subjected to non-destructiveexamination to Annex E.

(4) Each tube shall be subjected to a materials identificationcheck.

(5) The inside and outside surfaces of each tube shall besubjected to a visual inspection.

(6) The diameter and wall thickness shall be checked fordimensional accuracy at both ends of each tube.

(7) Each tube shall be examined for leak tightness by aninternal hydrostatic pressure test. The test pressure shallchosen such that the factor of safety relative to the yield pointat room temperature is never less than 1.1; in general it shallbe 8 MPa. If the tube is bent, the tightness test shall beperformed on the bent tube. In this case the tightness test onthe straight tube is not required.

10.1.3 Marking

(1) Lists of tubes shall be maintained for tubes scheduled forbending. In this case the tubes shall be marked with heatnumber and tube number at one end. Other tubes may bemarked in the same way if lists of tubes are maintained. Theauthorized inspector’s mark shall be entered in the list oftubes.

(2) If lists of tubes are not maintained, the tubes shall bemarked at one end with the following information:


b) steel grade,

c) heat number,

d) tube number,


f) mark of the non-destructive examinations performed ifapplicable.


(1) The results of the ladle analysis and examination of thestarting material shall be documented with a manufacturer’stest certificate or with an acceptance test certificate 3.1.B toDIN EN 10 204.

(2) The results of the materials identification check, tightnesstest and non-destructive examinations shall be documentedwith an acceptance test certificate 3.1.B to DIN EN 10 204.

KTA 3211.1

Page 54

(3) The results of all other tests and examinations shall bedocumented for tubes of test group A 3 made of unalloyedsteels with an acceptance test certificate 3.1.B to DIN EN10 204, and for tubes of test groups A 1 and A 2 made ofunalloyed steels as well as for all tubes made of alloyed steelsshall be certified by the authorized inspector and combinedwith the above-mentioned certificates as an acceptance testcertificate 3.1.C to DIN EN 10 204.

10.2 Seamless bent heat-exchanger tubes of ferritic steelswith wall thicknesses smaller than or equal to 4 mmand with outside diameters smaller than or equal to38 mm

10.2.1 Materials


a) St 35.8 III to DIN 17 175

b) 15 Mo 3 to DIN 17 175

c) 13 CrMo 4 4 to DIN 17 175

d) 10 CrMo 9 10 to DIN 17 175


10.2.2 Starting tubes

Only tubes per Section 10.1 may be used. Lists of tubes perclause 10.1.3 (1) shall be maintained for the tubes.

10.2.2.1 Production methods

(1) The bends shall be made by cold bending.

(2) Smooth transition from the tube leg to the tube elbowshall be demonstrated to the authorized inspector on aspecimen bent prior to beginning bending work.

(3) For the case of partial heat treatment of the bent zone,the quality of the transition zone shall be verified by a one-timeappraisal of the authorized inspector.

10.2.2.2 Requirements for the geometric form of bent tubes

(1) Bulge-like transitions as well as any kind of wrinkles arenot permitted.

(2) The maximum allowable ovality shall be 0.10 x Di, whereDi is the tube inside diameter (nominal diameter).

(3) A ball of diameter DK = Di − (largest permissible negativetolerance on size + 0.1 Di + 2 mm) shall pass through freely.

10.2.2.3 Heat treatment

(1) Heat treatment is not required after cold bending of tubeswith bend radius rm equal to or larger than 1.3 x Da.

(2) Heat treatment of the bent zone or of the entire tube tothe instructions of DIN 17 175 for annealing after coldprocessing shall be performed after cold bending of tubes witha bend radius rm smaller than 1.3 x Da.


10.2.3.1 Heat-treatment condition of specimens

Verification of the mechanical and technological characte-ristics shall be required only if the entire tube was heat-treatedafter bending. In this case the test coupons shall be takenfrom the product after the last heat treatment.


(1) Test coupons shall be taken from the ends of tube legs.




a) One room-temperature tensile test at one end of one tubeper 100 bent tubes of the same heat, dimension and heattreatment for heat-treated tubes.

b) One technological test to Table 10-1 at both ends of onetube per 100 bent tubes of the same heat, dimension andheat treatment for heat-treated tubes.

(2) Each bent tube shall be subjected to a materials identifi-cation check.

(3) The outside surface and, wherever it is accessible, theinside surface of each bent tube shall be subjected to a visualinspection.

(4) A visual inspection and a magnetic-particle examinationof the inside surface shall be performed on two cut-openelbows from the series of tubes with the smallest bend radius.

(5) The diameter and wall thickness shall be checked fordimensional accuracy at both ends of each bent tube. Inaddition, the ovality, arc shape and leg length as well as thewall thickness shall be checked for dimensional accuracy ontwo cut-open elbows from the series of tubes with the smallestbend radius.

(6) Each bent tube shall be examined for leak tightness byan internal hydrostatic pressure test. The test pressure shallchosen such that the factor of safety relative to the yield pointat room temperature is never less than 1.1; in general it shallbe 8 MPa.

(7) The ball-pass test shall be performed on each bent tube.

10.2.4 Marking

(1) Lists of tubes shall be maintained for bent tubes. Eachbent tube shall be marked with heat number and tube numberat one end. The authorized inspector’s mark shall be enteredin the list of tubes.


(1) Certificates per clause 10.1.4 shall be provided for thestarting tubes.

(2) The results of the materials identification check, tightnesstest and ball-pass test shall be documented with an accep-tance test certificate 3.1.B to DIN EN 10 204, which shall alsoindicate the heat-treatment condition of the bent tubes.

(3) The results of all other tests and examinations shall bedocumented for bent tubes of test group A 3 made ofunalloyed steels with an acceptance test certificate 3.1.B toDIN EN 10 204, and for bent tubes of test groups A 1 and A 2made of unalloyed steels as well as for all tubes made ofalloyed steels shall be certified by the authorized inspectorand combined with the above-mentioned certificates as anacceptance test certificate 3.1.C to DIN EN 10 204.

KTA 3211.1

Page 55

10.3 Seamless straight heat-exchanger tubes of austeniticsteels with wall thicknesses smaller than or equal to3.6 mm and with diameters smaller than or equal to42.4 mm

10.3.1 Materials


a) X 6 CrNiTi 18 10 to DIN 17 458

b) X 6 CrNiNb 18 10 to DIN 17 458






(1) The tubes shall be tested in manufacturing lengths.




Note:The extent of tests and examinations shall apply both to tubesused as straight tubes and to tubes that will subsequently be bent.



a) One room-temperature tensile test per 100 manufacturinglengths of the same heat, dimension and heat treatment.

b) One technological test to Table 10-2 at one end of eachmanufacturing length for tubes of test group A 1. Theextent of testing shall be reduced to 25 % of the tubes fortest group A 2 and to 2 % of the tubes for test group A 3.

Diameter of the tubesin mm

Nominal wall thickness sof the tubes

in mm

outside (Da) inside (Di) s ≤ 2 2 < s ≤ 4

Di > 15 Flatteningtest

Ring expandingtest 1)

Da ≤ 21.3

Di ≤ 15 Flatteningtest

Flattening test

Di > 15 Flatteningtest

Ring expandingtest 1)

21.3 < Da ≤ 42.4

Di ≤ 15 Ring expandingtest 1)

1) At the manufacturer’s discretion, the ring expanding test maybe replaced by the drift test.

Table 10-2: Dimensional ranges for application oftechnological tests to tubes

(3) One test for resistance to intergranular corrosion toDIN EN ISO 3651-2 with prior annealing (1/2 h at 650 °C) shallbe performed per heat and heat treatment.

(4) Each tube shall be subjected to non-destructive exami-nation to Annex E.


(6) The inside and outside surfaces of each tube shall besubjected to a visual inspection.


(8) Each tube shall be examined for leak tightness by aninternal hydrostatic pressure test. The test pressure shallchosen such that the factor of safety relative to the yield pointat room temperature is never less than 1.1; in general it shallbe 8 MPa. If the tube is bent, the tightness test shall beperformed on the bent tube. In this case the tightness test onthe straight tube is not required.

10.3.3 Marking

(1) Lists of tubes shall be maintained for tubes scheduled forbending. In this case the tubes shall be marked with heatnumber and tube number at one end. Other tubes may bemarked in the same way if lists of tubes are maintained. Theauthorized inspector's mark shall be entered in the list oftubes.

(2) If lists of tubes are not maintained, the tubes shall bemarked with the following information:


b) steel grade with abbreviation for the type of constructionand the designation „S“ for seamless products to DIN17 458,

c) heat number,

d) tube number,


f) mark of the non-destructive examinations performed ifapplicable.


(1) The results of the ladle analysis shall be documentedwith a manufacturer's test certificate or with an acceptancetest certificate 3.1.B to DIN EN 10 204.

(2) The results of the materials identification check, tightnesstest, test for resistance to intergranular corrosion and non-destructive examinations shall be documented with anacceptance test certificate 3.1.B to DIN EN 10 204.

(3) The results of all other tests and examinations shall bedocumented for tubes of test group A 3 with an acceptancetest certificate 3.1.B to DIN EN 10 204, and for tubes of testgroups A 1 and A 2 shall be certified by the authorizedinspector and combined with the above-mentioned certificatesas an acceptance test certificate 3.1.C to DIN EN 10 204.

10.4 Seamless bent heat-exchanger tubes of austeniticsteels with wall thicknesses smaller than or equal to3.6 mm and with diameters smaller than or equal to42.4 mm

10.4.1 Materials


a) X 6 CrNiTi 18 10 to DIN 17 458

b) X 6 CrNiNb 18 10 to DIN 17 458




KTA 3211.1

Page 56

10.4.2 Starting tubes

Only tubes to Section 10.3 may be used. Lists of tubes shallbe maintained for the tubes.

10.4.2.1 Production methods

(1) The bends shall be made by cold bending.

(2) Smooth transition from the tube leg to the tube elbowshall be demonstrated to the authorized inspector on aspecimen bend prior to beginning bending work.

(3) For the case of partial heat treatment of the bent zone,the quality of the transition zone shall be verified by a one-timeappraisal of the authorized inspector.

10.4.2.2 Requirements for the geometric form of bent tubes

(1) Bulge-like transitions as well as any kind of wrinkles arenot permitted.

(2) The maximum permissible ovality shall be 0.10 x Di,where Di is the tube inside diameter (nominal diameter).

(3) A ball of diameter DK = Di − (largest permissible negativetolerance on size + 0.1 Di + 2 mm) shall pass through freely.

10.4.2.3 Heat treatment

(1) Heat treatment is not required after cold bending of tubeswith bend radius rm larger than or equal to 1.3 x Da.

(2) The bent zone or the entire tube shall be subjected tosolution annealing or to annealing in the temperature range ofstabilization annealing after cold bending of tubes with a bendradius rm smaller than 1.3 x Da.


10.4.3.1 Heat-treatment condition of specimens

Verification of the mechanical and technological characte-ristics shall be required only if the entire tube was heat-treatedafter bending. In this case the test coupons shall be takenfrom the product form after the heat treatment (solutionannealing and quenching).


(1) Test coupons shall be taken from the ends of tube legs.




a) One room-temperature tensile test per 100 bent tubes ofthe same heat, dimension and heat treatment for heat-treated tubes.

b) One technological test to Table 10-2 at the end of bothlegs of one tube per 100 tubes of the same heat,dimension and heat treatment for heat-treated tubes.


(3) Each bent tube shall be subjected to a materials identifi-cation check.

(4) The outside surface and, wherever it is accessible, theinside surface of each bent tube shall be subjected to a visual

inspection. A visual inspection and a liquid-penetrant exami-nation shall be performed on two cut-open elbows from theseries of tubes with the smallest bend radius.

(5) The diameter and wall thickness shall be checked fordimensional accuracy at both ends of each bent tube. Inaddition, the ovality, bend shape and leg length shall bechecked for dimensional accuracy and the wall thickness shallbe measured on two cut-open elbows from the series of tubeswith the smallest bend radius.

(6) Each bent tube shall be examined for leak tightness byan internal hydrostatic pressure test. The test pressure shallchosen such that the factor of safety relative to the yield pointat room temperature is never less than 1.1; in general it shallbe 8 MPa.

(7) One ball-pass test shall be performed on each bent tube.

10.4.4 Marking

The bent tubes shall be marked with heat number and tubenumber at one end. The authorized inspector's mark shall beentered in the list of tubes.


(1) Certificates per clause 10.3.4 shall be provided for thestarting tubes.

(2) The results of the materials identification check, tightnesstest, ball-pass test and test for resistance to intergranularcorrosion shall be documented with an acceptance testcertificate 3.1.B to DIN EN 10 204, which shall also indicatethe heat-treatment condition of the bent tubes.

(3) The results of all other tests and examinations shall bedocumented for bent tubes of test group A 3 with an accep-tance test certificate 3.1.B to DIN EN 10 204, and for benttubes of test groups A 1 and A 2 shall be certified by theauthorized inspector and combined with the above-mentionedcertificates as an acceptance test certificate 3.1.C to DIN EN10 204.

10.5 Longitudinally welded straight heat-exchanger tubes ofaustenitic steels with wall thicknesses smaller than2 mm and with diameters Da smaller than or equal to38 mm

10.5.1 Materials


a) X 6 CrNiTi 18 10 to DIN 17 457

b) X 6 CrNiMoTi 17 12 2 to DIN 17 457

c) other steel grades meeting the prerequisites of Section 3 incombination with the stipulations in the authorizedinspector's appraisal.

10.5.2 Additional requirements

(1) Only tubes drawn and sunsequently heat-treated afterwelding are permitted.

(2) The requirements of surface finish and dimensionaltolerances shall be determined per purchaser's specifications,but shall be at least as follows:

a) surface finish d2 to DIN 17 457,

b) thickness tolerances: ISO tolerance, class T3 toDIN EN ISO 1127 and

c) the allowable deviation of outside diameter and ovality asper ISO tolerance, class D2.

KTA 3211.1

Page 57



(1) The tubes shall be tested in manufacturing lengths.




(1) The chemical composition shall be determined byperforming one ladle analysis of the starting material per heat.


a) One room-temperature tensile test per 100 manufacturinglengths of the same heat, dimension and heat treatment.

b) One flattening test at both ends of each manufacturinglength.


(4) Each tube shall be subjected to non-destructiveexamination to Annex E.


(6) The outside and inside surfaces of each tube shall besubjected to a visual inspection.


(8) Each tube shall be examined for leak tightness by aninternal hydrostatic pressure test. The test pressure shallchosen such that the factor of safety relative to the yield pointat room temperature is never less than 1.1; in general it shallbe 8 MPa.

10.5.4 Marking

(1) If lists of tubes are not maintained, the tubes shall bemarked at one end with the following information:


b) steel grade with abbreviation for the type of constructionand the gesignation „W“ for welded construction,

c) heat number,

d) tube number,




(1) The results of the ladle analysis, materials identificationcheck, tightness test, test for resistance to intergranular corro-sion and non-destructive examinations shall be documentedwith an acceptance test certificate 3.1.B to DIN EN 10 204.

(2) The results of all other tests and examinations shall bedocumented for tubes of test group A 3 with an acceptancetest certificate 3.1.B to DIN EN 10 204, and for tubes of testgroups A 1 and A 2 shall be certified by the authorizedinspector and combined with the above-mentioned certificatesas an acceptance test certificate 3.1.C to DIN EN 10 204.

KTA 3211.1

Page 58

Annex A

Material characteristic data

A 1 Ferritic steels of material group W I for sheets andplates as well as parts made from sheets and plates

A 1.1 General

Section A 1 defines the details for manufacture, chemicalcomposition, characterizing mechanical and technologicalcharacteristics and heat treatment as well as for furtherprocessing of the following steel grades

a) 15 MnNi 6 3

b) 20 MnMoNi 5 5

c) 15 NiCuMoNb 5 S

d) WStE 255 S

e) WStE 285 S

f) WStE 315 S

g) WStE 355 S

for plates and parts made from plates.

A 1.2 Manufacture of the materials and delivery condition

A 1.2.1 Manufacture

(1) The steels shall be smelted by the basic oxygen processor in the electric furnace. If other processes are used, proof ofequivalence shall be furnished.

(2) The steels shall be made in particularly killed condition.

A 1.2.2 Delivery condition

(1) The usual delivery condition for the steel grades is asfollows:

a) 15 MnNi 6 3 normalized

b) 20 MnMoNi 5 5 quenched and tempered in liquid

c) 15 NiCuMoNb 5 S normalized and tempered

d) WStE 255 S normalized

e) WStE 285 S normalized

f) WStE 315 S normalized

g) WStE 355 S normalized

(2) If the governing heat treatment is performed duringfurther processing, the plates to be supplied in normalizedcondition may also be delivered in rolled condition, and theplates to be supplied in quenched and tempered conditionmay also be delivered in normalized or tempered condition or,in special cases, even in rolled condition.

(3) In special cases, a tempering treatment may benecessary for steel grades 15 MnNi 6 3 and WStB 355 S. Thistempering treatment shall be indicated in the certificate.

A 1.3 Material characteristic values

A 1.3.1 Chemical composition

The values stipulated in Table A 1-1 shall apply to thechemical composition per the ladle and product analyses.

A 1.3.2 Mechanical and technological characteristics

(1) The characteristic values of the mechanical andtechnological characteristics in the room-temperature tensiletest are stipulated in Table A 1-2.

(2) The characteristic values of the mechanical and techno-logical characteristics in the elevated-temperature tensile testare stipulated in Table A 1-3. The test temperatures forcarrying out the elevated-temperature tensile test shall be asfollows:

a) 15 MnNi 6 3 300 °C

b) 20 MnMoNi 5 5 350 °C

c) 15 NiCuMoNb 5 S 350 °C

d) WStE 255 S 300 °C

e) WStE 285 S 300 °C

f) WStE 315 S 300 °C

g) WStE 355 S 300 °C

(3) The characteristic values of energy absorbed and lateralexpansion of Charpy V-notch specimens are stipulated inTable A 1-4.

(4) The data for energy absorbed and lateral expansion shallapply to standard specimens with a specimen width of 10 mm.

(5) For nominal thicknesses smaller than 10 mm, thecharacteristic values of energy absorbed shall be reduced asa function of specimen width, moreover, the stipulations forlateral expansion shall be waived.

(6) The mechanical and technological characteristics shallbe verified on specimens subjected to simulated stress-reliefannealing. Unless otherwise agreed in the purchase order, theconditions for simulated stress-relief annealing shall be asfollows:

a) holding time: 900 minutes,

b) annealing temperature: 560 °C to 580 °C,

600 °C to 620 °C for steel grades 20 MnMoNi 5 5 and15 NiCuMoNb 5 S.

(7) The characteristic values shall apply to specimens takenand tested as per the stipulations in the Sections relating toproduct forms. The stipulations of Table A 1-5 shall be takeninto consideration for plates.

A 1.3.3 Grain size

(1) The steels listed below shall have ferrite grain sizes asshown by EURONORM 103-71:

a) 15 MnNi 6 3 at least grain size classification number 6,

b) 20 MnMoNi 5 5 at least grain size classification number 5,

c) 15 NiCuMoNb 5 S at least grain size classification number 6,

d) WStE 255 S at least grain size classification number 6,

e) WStE 285 S at least grain size classification number 6,

f) WStE 315 S at least grain size classification number 6,

g) WStE 355 S at least grain size classification number 6.

(2) For steels with contents of bainitic structure, therequirements shall apply only to the microstructuralproportions of polygonal ferrite.

A 1.3.4 Physical characteristics

Reference values for the physical characteristics can be foundin Annex AP.

KTA 3211.1

Page 59

A 1.4 Data on heat treatment

Reference values for heat treatment are presented in TableA 1-6.

A 1.5 Forming

A 1.5.1 Hot forming

Note:Hot forming shall designate forming at temperatures above thehighest temperature permissible for stress-relief annealing, even ifthe product forms are heated to the corresponding temperatureonly locally, in the forming zone. The term hot forming shall alsoinclude adaptation and straightening work at the correspondingtemperatures.

(1) For hot forming, the plates shall be heated above thelower limit temperature for normalization but not above1050 °C. Grain coarsening due to excessively long times or tooverheating shall be avoided.

(2) After hot forming, the complete product forms shall besubjected to renewed heat treatment as per the data in TableA 1-6.

(3) If the complete product form was heated above the lowerlimit temperature for normalization but not above 1000 C in thecase of one-time hot forming or before the last step of hotforming in the case of hot forming in several steps, and if theforming process was completed above 750 °C, or above700 °C in the case that the degree of forming in the last stepdid not exceed 5 %, subsequent normalization is not requiredfor steel grades 15 MnNi 6 3, WStE 255 S, WStE 285 S,WStE 315 S and WStE 355 S; steel grade 15 NiCuMoNb 5 Sshall merely require to be tempered. However, hot forming inseveral steps is subject to the condition that, before beingheated for the last step, the product form in the case of steelgrades 15 MnNi 6 3, WStE 255 S, WStE 285 S, WStE 315 S undWStE 355 S be cooled to a temperature below 550 °C and inthe case of steel grade 15 NiCuMoNb 5 S be cooled to atemperature below 350 °C.

(4) The temperature control program shall be monitored.

(5) If the procedures employed differ from stipulations (1) to(3), e.g., in the case of forming with local heating withoutsubsequent heat treatment of the complete product form,proof of equivalence shall be furnished.

A 1.5.2 Cold forming

Note:Cold forming shall designate forming at room temperature or withheating up to the highest temperature permissible for stress-reliefannealing.

(1) Heat treatment is not required after cold forming withdegrees of forming smaller than or equal to 2 %.

(2) Stress-relief annealing shall be required after formingwith degrees of cold forming between 2 % and smaller than orequal to 5 %,

(3) The governing heat treatment shall be performed aftercold forming with degrees of forming larger than 5 %.

(4) For plates with a degree of cold forming not exceeding10 %, stress-relief annealing may be performed instead of thegoverning heat treatment if it is proved on a case-by-casebasis that the stipulations for mechanical and technologicalcharacteristics are met.

(5) If different procedures are employed, proof ofequivalence shall be furnished.

A 1.6 Thermal cutting and welding

A 1.6.1 Thermal cutting

SEW 088 shall be taken into consideration for thermal cutting.Recommended preheating temperatures are presented inTable A 1-7.

A 1.6.2 Welding

(1) Use of the following welding methods has beenappraised as suitable for the steel grades to this Annex:

a) manual arc welding with basic-flux-coated rod electrodes,

b) submerged-are welding with basic fluxes,

c) inert-gas-shielded welding with wire electrodes or withbasic-flux-cored wire electrodes.

(2) The examined work areas for welding are listed in TableA 1-7. Other work areas for welding are permitted, providedprocedure qualification tests per KTA 3211.3 have beenperformed.

(3) The stipulations for welding per SEW 088 shall beobserved. The content of diffissible hydrogen, determined toDIN 8572-1 and DIN 8572-2, shall not exceed HD5 to DIN8572-E in manual arc welding or HD7 to DIN 8572-UP insubmerged-arc welding.

(4) Post-weld stress-relief annealing may be required,depending on wall thickness and geometry of the parts. Thenominal thicknesses at which stress-relief annealing may bewaived are listed in Table A 1-7.

(5) Post-weld non-destructive examinations shall beperformed after a waiting time of at least 48 hours aftercompletion of the welding work. The waiting time may bewaived for welds that are subjected to stress-relief annealing,hydrogen degassing or delayed cooling, or that were weldedunder shield gas.

KTA 3211.1

Page 60

Ste

elgr

ade

Ver

ifica

tion

Lim

itva

lue

Con

tent

bym

ass,

%1)

2)

byC

Si

Mn

PS

Al to

tal

NA

sC

uC

rM

oN

bN

iS

nT

iV

15M

nNi6

3m

in.

0.12

0.15

1.20

0.02

00.

50La

dle

anal

ysis

max

.0.

180.

351.

650.

015

0.00

50.

055

0.01

50.

015

0.06

0.15

0.05

0.00

40.

850.

010

0.02

00.

020

min

.0.

100.

151.

150.

015

0.50

Pro

duct

anal

ysis

max

.0.

200.

371.

700.

017

0.00

70.

065

0.01

60.

016

0.07

0.20

0.05

0.00

40.

900.

013

0.02

00.

020

20M

nMoN

i55

min

.0.

170.

151.

200.

010

0.40

0.50

Ladl

ean

alys

ism

ax.

0.23

0.30

1.50

0.01

20.

008

0.04

00.

013

0.02

50.

120.

200.

550.

800.

011

0.02

0m

in.

0.15

0.10

1.15

0.01

00.

403)

0.45

Pro

duct

anal

ysis

max

.0.

250.

351.

550.

0123

)0.

0123

)0.

050

0.01

33)

0.02

50.

123)

0.20

0.55

0.85

0.01

13)

0.02

0

15N

iCuM

oNb

5S

min

.0.

250.

800.

015

0.50

0.25

0.01

51.

00La

dle

anal

ysis

max

.0.

170.

501.

200.

016

0.00

50.

020

0.80

0.30

0.40

0.02

51.

300.

020

0.02

0m

in.

0.21

0.75

0.01

00.

450.

200.

010

0.95

Pro

duct

anal

ysis

max

.0.

190.

541.

250.

020

0.00

60.

022

0.85

0.35

0.45

0.03

01.

350.

020

0.02

0W

StE

255

Sm

in.

0.40

0.02

0La

dle

anal

ysis

max

.0.

180.

401.

300.

020

0.01

50.

020

0.18

4)0.

304)

0.08

4)0.

005

0.30

0.02

00.

020

min

.0.

300.

015

Pro

duct

anal

ysis

max

.0.

200.

451.

400.

025

0.02

00.

022

0.25

4)0.

344)

0.11

4)0.

005

0.35

0.02

00.

020

WS

tE28

5S

min

.0.

500.

020

Ladl

ean

alys

ism

ax.

0.18

0.40

1.40

0.02

00.

015

0.02

00.

184)

0.30

4)0.

084)

0.00

50.

300.

020

0.02

0m

in.

0.40

0.01

5P

rodu

ctan

alys

ism

ax.

0.20

0.45

1.50

0.02

50.

020

0.02

20.

254)

0.34

4)0.

114)

0.00

50.

350.

020

0.02

0W

StE

315

Sm

in.

0.60

0.02

0La

dle

anal

ysis

max

.0.

180.

451.

500.

020

0.01

50.

020

0.18

4)0.

304)

0.08

4)0.

005

0.30

0.02

00.

020

min

.0.

500.

015

Pro

duct

anal

ysis

max

.0.

200.

501.

600.

025

0.02

00.

022

0.25

4)0.

344)

0.11

4)0.

005

0.35

0.02

00.

020

WS

tE35

5S

min

.0.

100.

900.

020

Ladl

ean

alys

ism

ax.

0.20

0.50

1.65

0.02

00.

015

0.02

00.

184)

0.30

4)0.

084)

0.00

50.

305)

0.02

00.

020

min

.0.

050.

800.

015

Pro

duct

anal

ysis

max

.0.

220.

551.

750.

025

0.02

00.

022

0.25

4)0.

344)

0.11

4)0.

005

0.35

5)0.

020

0.02

01)

The

diffe

renc

esth

atth

eta

bula

ted

valu

esin

dica

tebe

twee

nch

emic

alco

mpo

sitio

nspe

rth

ela

dle

and

prod

uct

anal

yses

are

som

etim

essm

alle

rth

anw

ould

beex

pect

edfr

omth

em

etal

lurg

ical

rela

tions

hip.

The

reas

onis

that

the

limit

valu

esfo

rch

emic

alco

mpo

sitio

npe

rth

epr

oduc

tan

alys

isar

ein

this

case

base

don

lyon

the

heat

sco

vere

dby

the

appr

aisa

l.T

hus

the

valu

esw

illbe

revi

ewed

once

addi

tiona

ldo

cum

ents

beco

me

avai

labl

e.2)

Ifth

ein

dica

ted

limit

cont

ents

per

the

ladl

ean

alys

isar

eex

ceed

ed,t

helim

itco

nten

tspe

rth

epr

oduc

tana

lysi

ssh

allg

over

n.3)

Ifth

ese

valu

esar

eex

ceed

edan

dal

low

ance

mus

tbe

mad

ein

the

prod

uct

anal

ysis

for

cont

ents

upto

P≤

0.01

5%

,S

≤0.

015

%,

Mo

≤0.

63%

,C

u≤

0.18

%,

Sn

≤0.

016

%an

dN

tota

l≤0.

015

%,

the

auth

oriz

edin

spec

tor

shal

lche

ck,

until

furt

her

info

rmat

ion

beco

mes

avai

labl

e,as

tow

heth

erw

eldi

ngsi

mul

atio

nte

sts

and

ifne

cess

ary

tang

entia

lmic

rose

ctio

nex

amin

atio

nsar

ene

cess

ary.

Ifin

term

edia

tean

neal

ing

at55

0°C

ispl

anne

ddu

ring

furt

her

proc

essi

ng,t

hepe

rmis

sibi

lity

ofth

isan

neal

ing

tem

pera

ture

shal

lbe

verif

ied

durin

gth

esa

idte

sts

orex

amin

atio

ns.T

hesc

ope

and

cond

uct

ofth

ese

test

ssh

all

beag

reed

with

the

auth

oriz

edin

spec

tor.

The

test

sm

aybe

wai

ved

ifso

stip

ulat

edin

the

mat

eria

lapp

rais

al.

4)T

hesu

mof

the

cont

ents

ofch

rom

ium

,cop

per

and

mol

ybde

num

shal

lnot

exce

ed0.

45%

inth

ela

dle

anal

ysis

or0.

50%

inth

epr

oduc

tana

lysi

s.5)

Dep

endi

ngon

the

auth

oriz

edin

spec

tor's

appr

aisa

lrel

ativ

eto

the

indi

vidu

alm

anuf

actu

rer,

the

max

imum

perm

issi

ble

nick

elco

nten

tsha

llbe

0.85

%in

the

ladl

ean

alys

isan

d0.

90%

inth

epr

oduc

tana

lysi

s.

Tab

leA

1-1:

Che

mic

alco

mpo

sitio

nof

stee

lgra

des

per

the

ladl

ean

dpr

oduc

tana

lyse

s

KTA 3211.1

Page 61

Steel grade Nominalthickness s

in mm

Tensile strengthRm in N/mm2

Yield point 1)

ReH in N/mm2

at least

Elongation atfractureA in %at least

Specimendirection

Reduction of areaat fracture

Z in %(individual value)

at least15 MnNi 6 3 5 < s ≤ 38 510 to 630 370

38 < s ≤ 50 510 to 630 350 longitudinal50 < s ≤ 80 490 to 610 330 22 or 45

80 < s ≤ 100 470 to 600 320 transverse

100 < s ≤ 150 470 to 650 31015 MnNi 6 3 5 < s ≤ 38 490 to 610 330

38 < s ≤ 50 490 to 610 330 longitudinal50 < s ≤ 80 490 to 610 330 22 or 45

80 < s ≤ 100 470 to 600 320 transverse

normalizedand stress-relief-annealed

100 < s ≤ 150 470 to 600 31020 MnMoNi 5 5 30 < s ≤ 70 590 to 730 450 longitudinal 45 2)

70 < s ≤ 150 570 to 710 430 18 or 45150 < s ≤ 600 560 to 700 390 transverse 45

15 NiCuMoNb 5 S s ≤ 35 610 to 780 44035 < s ≤ 50 610 to 780 440

50 < s ≤ 70 600 to 760 430

70 < s ≤ 85 600 to 760 430 16

85 < s ≤ 100 600 to 760 430

100 < s ≤ 125 600 to 750 420

125 < s ≤ 150 590 to 740 410WStE 255 S s ≤ 35 360 to 480 255

35 < s ≤ 50 360 to 480 245

50 < s ≤ 70 360 to 480 235

70 < s ≤ 85 350 to 470 225 25

85 < s ≤ 100 340 to 460 215

100 < s ≤ 125 330 to 450 205

125 < s ≤ 150 320 to 440 195

150 < s ≤ 250 310 to 430 185 23WStE 285 S s ≤ 35 390 to 510 285

35 < s ≤ 50 390 to 510 275

50 < s ≤ 70 390 to 510 265

70 < s ≤ 85 380 to 500 255 24

85 < s ≤ 100 370 to 490 245

100 < s ≤125 360 to 480 235

125 < s ≤ 150 350 to 470 225

150 < s ≤ 250 340 to 470 215 22WStE 315 S s ≤ 35 440 to 560 315

35 < s ≤ 50 440 to 560 305

50 < s ≤ 70 440 to 560 295

70 < s ≤ 85 430 to 550 285 23

85 < s ≤ 100 420 to 540 275

100 < s ≤ 125 410 to 530 265

125 < s ≤ 150 400 to 520 255

150 < s ≤ 250 390 to 520 245 21WStE 355 S s ≤ 35 490 to 630 355

35 < s ≤ 50 490 to 630 345

50 < s ≤ 70 490 to 630 335

70 < s ≤ 85 480 to 620 325 22

85 < s ≤ 100 470 to 610 315

100 < s ≤ 125 460 to 600 305

125 < s ≤ 150 450 to 590 295

150 < s ≤ 250 440 to 590 285 20

1) If the yield point is not emphasized, the values shall be applicable for the 0.2 % proof stress.2) For the steel grade 20 MnMoNi 5 5, the reduction of area at fracture shall additionally be subject to a smallest individual value of 35 % and a mean

value of 45 % on perpendicular specimens.

Table A 1-2: Characteristic values of the mechanical and technological characteristics in the room-temperature tensile test onlongitudinal and transverse specimens

KTA 3211.1

Page 62

Ten

sile

stre

ngth

Rm

inN

/mm

2

atle

ast

0.2

%pr

oofs

tres

sR

p0.2

inN

/mm

2

atle

ast

Ste

elgr

ade

Tes

ttem

pera

ture

in°°C

for

nom

inal

thic

knes

ses

inm

mfo

rno

min

alth

ickn

esse

sin

mm

≥5

>50

>80

≥5

>50

>80

>10

0≤

50≤

80≤

150

≤50

≤80

≤10

0≤

150

Elo

ngat

ion

atfr

actu

reA

in%

atle

ast

15M

nNi6

310

047

046

044

034

031

530

529

5no

rmal

ized

145

450

440

420

320

290

280

270

200

440

430

410

290

260

250

240

250

440

430

410

270

250

240

230

300

440

430

410

250

230

220

210

350

440

430

410

230

210

200

190

15M

nNi6

310

042

042

042

030

030

029

028

014

541

041

041

029

029

028

027

020

041

041

041

026

026

025

024

025

040

040

040

025

025

024

023

0

norm

aliz

edan

dst

ress

-rel

ief-

anne

aled

300

400

400

400

230

230

220

210

350

400

400

400

210

210

200

190

for

nom

inal

thic

knes

ses

inm

mfo

rno

min

alth

ickn

esse

sin

mm

≥30

>70

>15

0>

30>

70>

150

>20

0>

320

≤70

≤15

0≤

600

≤70

≤15

0≤

200

≤32

0≤

600

20M

nMoN

i55

100

550

530

520

431

412

382

370

370

17

200

530

510

505

412

392

371

360

350

1630

053

051

050

539

237

135

335

033

016

350

530

510

505

382

363

343

343

315

1637

553

050

550

537

735

833

833

030

016

400

530

500

490

371

353

333

320

290

16

Tab

leA

1-3:

Cha

ract

eris

ticva

lues

ofth

em

echa

nica

land

tech

nolo

gica

lcha

ract

eris

tics

inth

eel

evat

ed-t

empe

ratu

rete

nsile

test

onlo

ngitu

dina

land

tran

sver

sesp

ecim

ens

(Par

t1)

KTA 3211.1

Page 63

Ten

sile

stre

ngth

Rm

inN

/mm

2

atle

ast

0.2

%pr

oofs

tres

sR

p0.2

inN

/mm

2

atle

ast

Ste

elgr

ade

Tes

ttem

pera

ture

in°C

for

nom

inal

thic

knes

ses

inm

mfo

rno

min

alth

ickn

esse

sin

mm

>70

>85

>10

0>

125

>15

0>

35>

70>

85>

100

>12

5>

150

≤70

≤85

≤10

0≤

125

≤15

0≤

250

≤35

≤70

≤85

≤10

0≤

125

≤15

0≤

250

Elo

ngat

ion

atfr

actu

reA

in%

atle

ast

15N

iCuM

oNb

5S

100

540

540

540

530

520

402

402

402

402

392

382

150

530

530

530

520

510

392

392

392

392

382

373

200

520

520

520

510

500

383

383

383

383

373

363

250

520

520

520

510

500

373

373

373

373

363

353

300

520

520

520

510

500

363

363

363

363

353

343

350

510

510

510

500

490

353

353

353

353

343

333

400

500

500

500

490

480

333

333

333

333

323

313

WS

tE25

5S

100

335

325

315

305

300

290

226

216

206

196

186

177

167

150

315

305

295

285

280

270

206

196

186

177

167

157

147

200

300

290

280

270

265

255

186

186

177

167

157

147

137

250

290

280

270

260

255

245

167

167

157

147

137

127

117

300

290

280

270

260

255

245

137

137

127

118

108

9888

350

280

270

260

250

245

235

118

118

108

9888

7868

400

270

260

250

240

235

225

108

108

9888

7869

59W

StE

285

S10

036

035

034

033

032

031

025

524

523

522

621

620

619

615

034

533

532

531

530

529

523

522

621

620

619

618

617

620

033

032

031

030

029

028

020

620

619

618

617

716

715

725

032

031

030

029

028

027

018

618

617

716

715

714

713

730

032

031

030

029

028

027

015

715

714

713

712

711

810

835

030

529

528

527

527

026

513

713

712

711

810

898

8840

029

528

527

526

526

025

511

811

810

898

8878

68W

StE

315

S10

040

039

038

037

036

035

027

526

525

524

523

522

621

615

038

537

536

535

534

533

525

524

523

522

621

620

619

620

037

036

035

034

033

032

022

622

621

620

619

618

617

625

036

035

034

033

032

031

020

620

619

618

617

716

715

730

036

035

034

033

032

031

017

717

716

715

714

713

712

735

035

034

033

032

031

030

015

715

714

713

712

711

810

840

034

033

032

031

030

029

013

712

711

811

810

898

88W

StE

355

S10

043

042

041

040

039

038

030

429

428

427

526

525

524

515

042

041

040

039

038

037

028

427

526

525

524

523

522

520

041

040

039

038

037

036

025

525

524

523

522

621

620

625

040

039

038

037

036

035

023

523

522

621

620

619

618

630

040

039

038

037

036

035

021

621

620

619

618

617

716

735

039

038

037

036

035

034

019

619

618

617

716

715

714

740

038

037

036

035

034

033

016

716

715

714

713

712

711

7

Tab

leA

1-3:

Cha

ract

eris

ticva

lues

ofth

em

echa

nica

land

tech

nolo

gica

lcha

ract

eris

tics

inth

eel

evat

ed-t

empe

ratu

rete

nsile

test

onlo

ngitu

dina

land

tran

sver

sesp

ecim

ens

(Par

t2)

KTA 3211.1

Page 64

Energy absorbed (Charpy-V) in Jat the temperature in °C

at least

Lateral expansion in mmat the temperature in °C

at least


in mm

Nature ofvalue 1)

-20 0 5 20 33 Uppershelf 2)

-20 5 33 Uppershelf 2)

15 MnNi 6 3 5 ≤ s 0≤ 150 MW 80 110 130 130 130 130

EW 68 90 100 100 100 100 0.9 1.3 1.3 1.3

20 MnMoNi 5 5 30 ≤ s ≤ 600 4) MW 41

EW 34 68 3) 100 0.9 3) 1.3

15 NiCuMoNb 5 S 10 ≤ s ≤ 150 MW 41

EW 34 68 3) 100 0.9 3) 1.3

10 ≤ s ≤ 150 MW 21 41

EW 15 34 68 3) 100 0.9 3) 1.3

150 ≤ s ≤ 250 4) MW 16 41

WStE 255 SWStE 285 SWStE 315 SWStE 355 S

EW 11 34 68 3) 100 0.9 3) 1.3

1) MW : mean value of 3 specimens, EW : individual value.2) The test is generally performed at 80 °C. The test may be waived if the requirements were already verified to be met at a lower

temperature.3) If agreed in the purchase order, this requirement shall also apply at lower temperature, but not below 0 °C.4) For nominal thicknesses exceeding 150 mm, the smallest individual value of energy absorbed (Charpy-V transverse specimens) at the

middle of the wall thickness at 80 °C shall not be less than 68 J.

Table A 1-4: Characteristic values of energy absorbed and lateral expansion in the notched-bar impact bend test on Charpy-V-notch specimens (transverse specimens)

Steel grade Nominalthickness in mm

Delivered product length lin m per rolled plate

Sampling and location of the test coupons relativeto the product width b

15 MnNi 6 3 l < 7 at one end at b/4all nominalthicknesses

l > 7 at both ends at b/4

20 MnMoNi 5 5 ≥ 30 to ≤ 600 all lengths at both ends at b/2 1)

l < 7 at one end at b/4WStE 255 SWStE 285 SWStE 315 SWStE 355 S15 NiCuMoNb 5 S

all nominalthicknesses

l > 7 at both ends at b/4

1) The test cross sections shall be located by at least half the product thickness under the end and side surfaces from the edgesstraightened for the heat treatment. Notwithstanding the foregoing, the test sections from plates with nominal thicknesses > 320 mm forpipe elbows shall be located at least 80 mm under the end and side surfaces from the edges straightened for the heat treatment.

Table A 1-5: Sampling and location of the test coupons (sampling locations)

KTA 3211.1

Page 65

Steel grade Normalization Temperature range in °C for

°C Quenching and tempering Stress-relief annealingAustenitization Tempering

15 MnNi 6 3 880 to 960 1) 530 to 580 2)

20 MnMoNi 5 5 870 to 930 2) 3) 630 to 690 2) 580 to 620 2) 4)

15 NiCuMoNb 5 S 900 to 980 1) 640 to 680 2) 580 to 620 2)

WStE 255 S 900 to 950 1) 530 to 580 2)

WStE 285 S 900 to 950 1) 530 to 580 2)

WStE 315 S 890 to 940 1) 530 to 580 2)

WStE 355 S 880 to 940 1) 530 to 580 2)

1) Cooling in stationary air after the temperature has been reached over the entire cross section.2) The heating and cooling rate, the temperature and the holding time shall be defined by the manufacturer and processor as a function of

dimensions of the part, chemical composition and preceding heat treatments such that the requirements for mechanical and technologicalcharacteristics are met even allowing for subsequent heat treatments for the final condition of the complete part. Claddings shall also betaken into consideration (corrosion resistance, ductility).

3) Water cooling.4) For multiple stress-relief annealing steps, the indicated temperature range shall be applicable for the last stress-relief annealing step.

Preceding stress-relief annealing steps can be performed at 530 °C to 570 °C.

Table A 1-6: Data for heat treatment

Welding 2)Steel grade Nominalthickness s

in mm

Thermal cutting

Preheatingtemperature TV

in °C

Preheatingtemperature TV and

interpasstemperature TZ

in °C

Holdingtemperature 1) TH

in °C

Coolingtime t8/5

inseconds

Limit wall thickness forwaiving stress-relief

annealing afterweldingin mm

s ≤ 15 RT ≤ TV RT ≤ T ≤ 150 RT ≤ TH

15 < s ≤ 30 RT ≤ TV 80 ≤ T ≤ 180 RT ≤ TH15 MnNi 6 3

30 < s ≤ 50 100 ≤ TV 100 ≤ T ≤ 220 RT ≤ TH

50 < s ≤ 150 120 ≤ TV 120 ≤ T ≤ 220 RT ≤ TH

8 to 25 38 3)

150 ≤ T ≤ 250 150 ≤ TH ≤ 250 5)20 MnMoNi 5 5 s > 15 150 ≤ TV ≤ 250

120 ≤ T ≤ 180 4) 120 ≤ TH ≤ 180 4) 5)7 to 25

s ≤ 15 RT ≤ TV RT ≤ T ≤ 150 RT ≤ TH

15 < s ≤ 30 RT ≤ TV 80 ≤ T ≤ 180 RT ≤ TH

30 < s ≤ 50 70 ≤ TV 100 ≤ T ≤ 220 200 ≤ TH15 NiCuMoNb 5 S

s > 50 120 ≤ TV 120 ≤ T ≤ 220 120 ≤ TH

8 to 35

Stress-relief annealingshall alwaysbe required

WStE 255 S s ≤ 15 RT ≤ TV RT ≤ T ≤ 150 RT ≤ TH

WStE 285 S 15 < s ≤ 50 RT ≤ TV RT ≤ T ≤ 180 RT ≤ TH

30 < s ≤ 50 RT ≤ TV 80 ≤ T ≤ 200 80 ≤ THWStE 315 S

s > 50 120 ≤ TV 120 ≤ T ≤ 220 120 ≤ TH

8 to 28 38 3)

s ≤ 15 RT ≤ TV RT ≤ T ≤ 150 RT ≤ TH

15 < s ≤ 30 RT ≤ TV 80 ≤ T ≤ 180 RT ≤ TH

30 < s ≤ 50 100 ≤ TV 100 ≤ T ≤ 220 200 ≤ THWStE 355 S

s > 50 120 ≤ TV 120 ≤ T ≤ 220 120 ≤ TH

8 to 25 38 3)

1) See DIN EN ISO 13 916 for definition.2) If welding tests per KTA 3211.3 prove that the characteristics required for the application are also achieved with adequate safety under

conditions other than those listed here, those conditions may be employed.3) In the case of simple geometric form and 100 % non-destructive examination of the welds, it is permitted to increase to ≤ 50 mm the limit

wall thickness up to which post-welded stress-relief annealing may be waived.4) For weld cladding.5) The part shall be subjected to post-weld heating at about 280 °C from the heat of welding for more than 2 hours or to delayed cooling,

unless stress-relief annealing is performed directly from the heat of welding or inert-gas-shielded welding is employed.

Table A 1-7: Particulars of thermal cutting and welding, together with limit wall thicknesses for stress-relief annealing

KTA 3211.1

Page 66

A 2 Ferritic steels of material group W I for forgings, barsteel and rolled rings

A 2.1 General


a) 15 MnNi 6 3

b) 20 MnMoNi 5 5

c) 15 NiCuMoNb 5 S

d) C 22.8 S

e) WStE 355 S

for forgings, bar steel and rolled rings.


A 2.2.1 Manufacture







c) 15 NiCuMoNb 5 S normalized and tempered (quenchedand tempered in air) or quenchedand tempered in liquid

d) C 22.8 S normalized, or also quenched andtempered in liquid for nominalthicknesses ≥ 150 mm

e) WStE 355 S normalized or quenched andtempered






(2) The characteristic values of the mechanical and techno-logical characteristics in the elevated-temperature tensile testare stipulated in Table A 2-3. The test temperatures forcarrying out the elevated-temperature tensile test for thevarious steel grades shall be as follows:

15 MnNi 6 3 300 °C

20 MnMoNi 5 5 350 °C

15 NiCuMoNb 5 S 350 °C

C 22.8 S 300 °C

WStE 355 S 300 °C



(5) The mechanical and technological characteristics shallbe verified on specimens subjected to simulated stress-reliefannealing. For product forms of steel 20 MnMoNi 5 5 withnominal thicknesses up to and including 50 mm that are to bewelded, the mechanical and technological characteristics shallbe verified in the delivery condition.

(6) For simulated stress-relief annealing the requirements ofTable A 2-7 shall apply.

(7) The characteristics shall apply to specimens taken andtested as per the stipulations in the Sections relating toproduct forms.

A 2.3.3 Grain size

(1) (1) The steels listed below shall have ferrite grain sizesas shown by EURONORM 103-71:



c) 15 NiCuMoNb 5 S at least grain size classification number 6,

d) C 22.8 S at least grain size classification number 4,

e) WStE 355 S at least grain size classification number 6.





Reference values for heat treatment are presented in TableA 2-5.

A 2.5 Forming

A 2.5.1 Hot forming


(1) For hot forming, the forgings shall be heated to at least750 °C but not above 1050 °C. For hot forming, the forgings of15 MnNi 6 3 shall be heated to at least 750 °C but not above1100 °C. Grain coarsening due to excessively long times or tooverheating shall be avoided. Hot forming of tubular forgings,e.g., for the manufacture of pipe elbows, shall be subject tothe stipulations in Section A 3.

(2) After hot forming, the complete product forms shall besubjected to renewed heat treatment per the data in TableA 2-5.

(3) If the procedures employed differ from stipulations (1)and (2), e.g., in the case of forming with local heating withoutsubsequent heat treatment of the complete product form,proof of equivalence shall be furnished.


KTA 3211.1

Page 67




A 2.6.2 Welding

(1) Use of the following welding methods has beenappraised as suitable for the steels per this Annex:


b) submerged-arc welding with basic fluxes,

c) inert-gas-shielded welding with wire electrodes or withbasic-flux-cored wire electrodes.

(2) The examined work areas for welding are listed in TableA 2-6. Other work areas for welding are permitted, provided

procedure qualification tests per KTA 3211.3 have beenperformed.

(3) The stipulations for welding per SEW 088 shall beobserved. The content of difflisible hydrogen, determined toDIN 8572-1 and DIN 8572-2, shall not exceed HD5 toDIN 8572-E in manual arc welding or HD7 to DIN 8572-UP insubmerged-arc welding.

(4) Post-weld stress-relief annealing may be required,depending on wall thickness and geometry of the parts. Thenominal thicknesses at which stress-relief annealing may bewaived are listed in Table A 2-6.

(5) Post-weld non-destructive examinations shall beperformed after a waiting time of at least 48 hours aftercompletion of the welding work. The waiting time may bewaived for welds that are subjected to stress-relief annealing,hydrogen degassing or delayed cooling, or that were weldedunder shield gas.

KTA 3211.1

Page 68

Ste

elgr

ade

Ver

ifica

tion

Lim

itva

lue

Con

tent

bym

ass,

%1)

2)

byC

Si

Mn

PS

Al to

tal

NA

sC

uC

rM

oN

bN

iS

nT

iV

15M

nNi6

3m

in.

0.12

0.15

1.20

0.02

00.

50La

dle

anal

ysis

max

.0.

180.

351.

650.

015

0.00

50.

055

0.01

50.

015

0.06

0.15

0.05

0.00

40.

850.

010

0.02

00.

020

min

.0.

100.

151.

150.

015

0.50

Pro

duct

anal

ysis

max

.0.

200.

371.

700.

017

0.00

70.

065

0.01

60.

016

0.07

0.20

0.05

0.00

40.

900.

013

0.02

00.

020

20M

nMoN

i55

min

.0.

170.

151.

200.

010

0.40

0.50

Ladl

ean

alys

ism

ax.

0.23

0.30

1.50

0.01

20.

008

0.04

00.

013

0.02

50.

120.

200.

550.

800.

011

0.02

0m

in.

0.15

0.10

1.15

0.01

00.

400.

45P

rodu

ctan

alys

ism

ax.

0.25

0.35

1.55

0.01

23)

0.01

23)

0.05

00.

0133

)0.

025

0.12

3)0.

200.

553)

0.85

0.01

13)

0.02

0

15N

iCuM

oNb

5S

min

.0.

100.

250.

800.

015

0.50

0.25

0.01

51.

00La

dle

anal

ysis

max

.0.

170.

501.

200.

016

0.00

50.

035

0.02

00.

800.

300.

400.

025

1.30

0.02

0m

in.

0.08

0.21

0.75

0.01

00.

450.

200.

010

0.95

Pro

duct

anal

ysis

max

.0.

190.

541.

250.

020

0.00

60.

040

0.02

20.

850.

350.

450.

030

1.35

0.02

0C

22.8

Sm

in.

0.18

0.15

0.40

0.01

5La

dle

anal

ysis

max

.0.

230.

350.

900.

016

0.01

00.

050

0.15

0.30

0.02

0m

in.

0.16

0.10

0.36

0.01

0P

rodu

ctan

alys

ism

ax.

0.25

0.40

0.95

0.02

00.

015

0.05

50.

180.

350.

020

WS

tE35

5S

min

.0.

100.

900.

020

Ladl

ean

alys

ism

ax.

0.20

0.50

1.65

0.02

00.

015

0.07

00.

020

0.18

4)0.

304)

0.08

4)0.

005

0.30

5)0.

020

0.02

0

min

.0.

050.

840.

015

Pro

duct

anal

ysis

max

.0.

220.

551.

750.

025

0.02

00.

075

0.02

20.

254)

0.34

4)0.

114)

0.00

60.

355)

0.02

00.

020

1)T

hedi

ffere

nces

that

the

tabu

late

dva

lues

indi

cate

betw

een

chem

ical

com

posi

tions

per

the

ladl

ean

dpr

oduc

tan

alys

esar

eso

met

imes

smal

ler

than

wou

ldbe

expe

cted

from

the

met

allu

rgic

alre

latio

nshi

p.T

here

ason

isth

atth

elim

itva

lues

for

chem

ical

com

posi

tion

per

the

prod

uct

anal

ysis

are

inth

isca

seba

sed

only

onth

ehe

ats

cove

red

byth

eap

prai

sal.

Thu

sth

eva

lues

will

bere

view

edon

cead

ditio

nal

docu

men

tsbe

com

eav

aila

ble.

2)If

the

indi

cate

dlim

itco

nten

tspe

rth

ela

dle

anal

ysis

are

exce

eded

,the

limit

cont

ents

per

the

prod

ucta

naly

sis

shal

lgov

ern.

3)If

thes

eva

lues

are

exce

eded

and

allo

wan

cem

ust

bem

ade

inth

epr

oduc

tan

alys

isfo

rco

nten

tsup

toP

≤0.

015

%,

S≤

0.01

5%

,M

o≤

0.63

%,

Cu

≤0.

18%

,S

n≤

0.01

6%

and

Nto

tal≤

0.01

5%

,th

eau

thor

ized

insp

ecto

rsh

allc

heck

,un

tilfu

rthe

rin

form

atio

nbe

com

esav

aila

ble,

asto

whe

ther

wel

ding

sim

ulat

ion

test

san

dif

nece

ssar

yta

ngen

tialm

icro

sect

ion

exam

inat

ions

are

nece

ssar

y.If

inte

rmed

iate

anne

alin

gat

550

°Cis

plan

ned

durin

gfu

rthe

rpr

oces

sing

,the

perm

issi

bilit

yof

this

anne

alin

gte

mpe

ratu

resh

allb

eve

rifie

ddu

ring

the

said

test

sor

exam

inat

ions

.The

scop

ean

dco

nduc

toft

hese

test

ssh

all

beag

reed

with

the

auth

oriz

edin

spec

tor.

The

test

sm

aybe

wai

ved

ifso

stip

ulat

edin

the

mat

eria

lapp

rais

al.

4)T

hesu

mof

the

cont

ents

ofch

rom

ium

,cop

per

and

mol

ybde

num

shal

lnot

exce

ed0.

45%

inth

ela

dle

anal

ysis

or0.

50%

inth

epr

oduc

tana

lysi

s.5)

Dep

endi

ngon

the

auth

oriz

edin

spec

tor's

appr

aisa

lrel

ativ

eto

the

indi

vidu

alm

anuf

actu

rer,

the

max

imum

perm

issi

ble

nick

elco

nten

tsha

llbe

0.85

%in

the

ladl

ean

alys

isan

d0.

90%

inth

epr

oduc

tana

lysi

s.

Tab

leA

2-1:

Che

mic

alco

mpo

sitio

nof

stee

lgra

des

per

the

ladl

ean

dpr

oduc

tana

lyse

s

KTA 3211.1

Page 69

Steel grade Yield point 1)

ReH in N/mm2Specimendirection

Reduction of area atfractureZ in %

Heat-treatmentwall thickness

s in mm

Tensilestrength

Rm in N/mm2

at least

Elongation atfractureA in %

at least Individualvalue

Meanvalue

15 MnNi 6 3s ≤ 70 470 to 590 320 longitudinal /

transverse22 45

70 < s ≤ 100 470 to 590 310 longitudinal / transverse

22 45


22 45


22 45

longitudinal / transverse

22 45 250 < s ≤ 350 440 to 580 275

perpendicular 35 45

20 MnMoNi 5 5 longitudinal / transverse

19 45 s ≤ 1000 560 to 700 390

perpendicular 35 45

15 NiCuMoNb 5 S longitudinal 20 s ≤ 400 580 to 740 430

transverse 18 C 22.8 S longitudinal 25 45

s ≤ 150 410 to 540 230transverse 20 45 longitudinal 25 45 150 < s ≤ 320 400 to 520 210transverse 19 45 longitudinal 25 45 320 < s ≤ 500 400 to 520 200transverse 19 45

WStE 355 S longitudinal 23 s ≤ 100 490 to 630 335transverse 21 longitudinal 21 100 < s ≤ 250 470 to 630 295transverse 19 longitudinal 21 250 < s ≤ 400 470 to 630 275transverse 19

1) If the yield point is not emphasized, the values shall be applicable for the 0.2 % proof stress.

Table A 2-2: Characteristic values of the mechanical and technological characteristics in the room-temperature tensile test

KTA 3211.1

Page 70

Steel grade Testtemperature


at least

0.2 % proof stress Rp0.2

in N/mm2

at least

Elongation at fracture Ain % at least

(longitudinal ortransverse)

in °C for heat-treatment wall thicknesses in mm

> 70 > 100 > 150 > 250

≤ 350 ≤ 70 ≤ 100 ≤ 150 ≤ 250 ≤ 350

15 MnNi 6 3 100 420 290 280 270 245 235145 410 280 270 260 225 215

200 400 250 240 230 205 195

250 400 240 230 220 185 175

300 400 220 210 200 165 155

350 400 200 190 180 145 135

for heat-treatment wall thicknesses in mm

> 320 > 320

≤ 1000 ≤ 320 ≤ 1000 ≤ 320 ≤ 1000

20 MnMoNi 5 5 100 520 370 370 17 16200 505 360 350 16 16

300 505 350 330 16 15

350 505 343 315 16 14

375 505 330 300 16 14

400 490 320 290 16 14


≤ 400 ≤ 400

15 NiCuMoNb 5 S 100 540 402150 530 389

200 520 376

250 510 363

300 500 350

350 490 337

400 480 324


> 150 > 320≤ 500 ≤ 150 ≤ 320 ≤ 500

C 22.8 S 100 360 220 200 190

150 350 200 180 170

200 340 175 160 155

250 335 155 140 135

300 335 135 125 115

350 335 115 105 100

400 300 90 85 80


> 100 > 250

≤ 400 ≤ 100 ≤ 250 ≤ 400

WStE 355 S 100 410 294 255 235150 400 275 235 215

200 390 255 216 197

250 380 235 196 179

300 380 216 177 160

350 370 196 157 142

400 360 167 127 117

Table A 2-3: Characteristic values of the mechanical and technological characteristics in the elevated-temperature tensile test

KTA 3211.1

Page 71


in mm

Nature ofvalue 1)


at least


at least

- 20 0 + 5 +20 +33 Uppershelf

2)

- 20 + 5 + 33 Uppershelf

2)

15 MnNi 6 3 s ≤ 150 MW 80 110 130 130 130 130

EW 68 90 100 100 100 100 0,9 1,3 1,3 1,3

150 < s ≤ 350 MW 70 90 110 130 130 130

EW 56 72 88 100 100 100 0,9 1,3 1,3 1,3

20 MnMoNi 5 5 s ≤ 1000 MW 41

EW 34 68 3) 100 0,9 3) 1,3

15 NiCuMoNb 5 S s ≤ 400 MW 60 80 95

EW 42 56 66 68 3) 100 0,9 3) 1,3

C 22.8 S s ≤ 500 MW 41 49

EW 34 42 68 3) 100 0,9 3) 1,3

WStE 355 S s ≤ 400 MW 41

EW 34 68 3) 100 0,9 3) 1,3


temperature.3) If agreed in the purchase order, this requirement shall also apply at lower temperature, but not below 0 °C.


Temperature range for

Steel grade Normalization Quenching and tempering Stress-relief annealing 3)

Austenitization Tempering

°C °C °C °C

15 MnNi 6 3 880 to 960 1) 530 to 580

20 MnMoNi 5 5 5) 870 to 940 2) 630 to 680 580 to 620

15 NiCuMoNb 5 S 900 to 980 1) 640 to 670 580 to 620

880 to 930 4) 640 to 690 4) 580 to 620

C 22.8 S 880 to 920 1) 870 to 910 2) 640 to 660 530 to 600

WStE 355 S 880 to 920 1) 880 to 940 4) 610 to 680 530 to 580

1) Cooling in stationary air after the temperature has been reached over the entire cross section.2) Cooling in water.3) For multiple stress-relief annealing steps, the indicated temperature range shall be applicable for the last stress-relief annealing step.

Preceding stress-relief annealing steps can be performed at 530 °C to 570 °C.4) Cooling in oil or water. This treatment shall be employed for relatively large heat-treatment wall thicknesses, in order to be able to

maintain the minimum temperature of 640 °C for tempering.5) Two-stage quenching and tempering are permitted, depending on the authorized inspector's appraisal.


KTA 3211.1

Page 72

Welding 2)


in mm

Thermalcutting

Preheatingtemperature

TVin °C

Preheatingtemperature TV and

interpass temperatureTZ

in °C

Holdingtemperature

TH 1)

in °C

Coolingtime t8/5

inseconds

Limit wall thicknessfor waiving stress-

relief annealing afterweldingin mm

15 MnNi 6 3 s ≤ 15 RT ≤ TV RT ≤ T ≤ 150 RT ≤ TH 8 to 25 38 5)

15 < s ≤ 30 RT ≤ TV 80 ≤ T ≤ 180 RT ≤ TH

30 < s ≤ 50 100 ≤ TV 100 ≤ T ≤ 220 3) 100 ≤ TH

50 < s ≤ 150 120 ≤ TV 120 ≤ T ≤ 220 3) 120 ≤ TH

20 MnMoNi 5 5 s > 15 150 ≤ TV ≤ 250 150 ≤ T ≤ 250 3) 150 ≤ TH ≤ 250 7 to 25

120 ≤ TH ≤ 180 4)


15 NiCuMoNb 5 S s ≤ 15 RT ≤ TV 80 ≤ T ≤ 180 RT ≤ TH 10 to 25

15 < s ≤ 30 RT ≤ TV 100 ≤ T ≤ 180 100 ≤ TH

30 < s ≤ 50 100 ≤ TV 120 ≤ T ≤ 220 120 ≤ TH


s > 50 120 ≤ TV 120 ≤ T ≤ 220

C 22.8 S s ≤ 30 RT ≤ TV 80 ≤ T ≤ 150 RT ≤ TH 8 to 25 30

30 < s ≤ 50 RT ≤ TV 80 ≤ T ≤ 200 3) RT ≤ TH

s > 50 120 ≤ TV 120 ≤ T ≤ 220 3) 120 ≤ TH

WStE 355 S s ≤ 15 RT ≤ TV RT ≤ T ≤ 150 RT ≤ TH 8 to 25 38 5)

15 < s ≤ 30 RT ≤ TV 80 ≤ T ≤ 180 RT ≤ TH

30 < s ≤ 50 100 ≤ TV 100 ≤ T ≤ 220 3) 100 ≤ TH

s > 50 120 ≤ TV 120 ≤ T ≤ 220 3) 120 ≤ TH


conditions other than those listed here, those conditions may be employed.3) At most 180 °C for weld cladding.4) The part shall be subjected to post-weld heating at about 280 °C from the heat of welding for more than 2 hours or to delayed cooling,

unless stress-relief annealing is performed directly from the heat of welding or inert-gas-shielded welding is employed.5) In the case of simple geometric form and 100 % non-destructive examination of the welds, it is permitted to increase the limit wall

thickness to ≤ 50 mm, unless special requirements of heat-treatment condition are imposed.


Simulated stress-relief annealingSteel grade Verification necessary

Temperature in °C Holding time 1) in minutes

15 MnNi 6 3 560 to 580

20 MnMoNi 5 5 600 to 620

15 NiCuMoNb 5 S yes 2) 600 to 620 900

C 22.8 S 580 to 600

WStE 355 S 560 to 580

1) These data shall apply only if no other particulars were required in the purchase order.2) See clause A 2.3.2 (5) for verification of product forms of the steel 20 MnMoNi 5 5.

Table A 2-7: Necessity for verification of mechanical characteristics in the simulated stress-relief-annealed condition, andperformance of the simulated stress-relief annealing process

KTA 3211.1

Page 73

A 3 Ferritic steels of material group W I for seamlesspipes, seamless pipe elbows and seamless reducers

A 3.1 General


a) 15 MnNi 6 3

b) 20 MnMoNi 5 5

c) 15 NiCuMoNb 5 S

for seamless pipes, seamless pipe elbows and seamlessreducers.


A 3.2.1 Manufacture







c) 15 NiCuMoNb 5 S normalized and tempered (quenchedand tempered in air) or quenchedand tempered in liquid

(2) If the governing heat treatment is performed duringfurther processing, the pipes to be supplied in normalizedcondition may also be delivered in rolled condition, and thepipes to be supplied in quenched and tempered condition mayalso be delivered in normalized or tempered condition or, inspecial cases, even in rolled condition.






(2) The characteristic values of the mechanical andtechnological characteristics in the elevated-temperaturetensile test are stipulated in Table A 3-3. The test temperaturefor carrying out the elevated-temperature tensile test for thevarious steel grades shall be as follows:

15 MnNi 6 3 300 °C

20 MnMoNi 5 5 350 °C

15 NiCuMoNb 5 S 350 °C



(5) For wall thicknesses between 5 and 10 mm, therequirements for energy absorbed shall be reduced as afunction of specimen width. For product-form thicknessessmaller than 10 mm, the stipulations on lateral expansion shallbe waived.

(6) The mechanical and technological characteristics shallbe verified on specimens subjected to simulated stress-reliefannealing (see Table A 3-5). For product forms of steel20 MnMoNi 5 5 with nominal thicknesses up to and including50 mm that are to be welded, the mechanical andtechnological characteristics shall be verified in the deliverycondition.

A 3.3.3 Grain size

(1) The steel grades listed below shall have ferrite grainsizes as shown by Euronorm 103:



c) 15 NiCuMoNb 5 S at least grain size classification number 6.





Reference values for heat treatment are presented inTable A 3-6.

A 3.5 Forming

A 3.5.1 Hot forming


(1) For hot forming, the pipes shall be heated to at least750 °C but not above 1050 °C. For hot forming, the pipes ofsteel 15 MnNi 6 3 shall be heated to at least 750 °C but notabove 1100 °C. Forging and upsetting shall be performed inthe upper portion of the temperature range at 1100 °C to900 °C. Hot bending of pipes and similar forming work shall beperformed in the lower portion of the temperature range. Graincoarsening due to excessively long times or to overheatingshall be avoided.

(2) After hot forming, the complete product forms shall besubjected to renewed heat treatment as per the data inTable A 3-5.

(3) If the procedures employed differ from stipulations (1) to(2), e.g., in the case of forming with local heating withoutsubsequent heat treatment of the complete product form,proof of equivalence shall be furnished.


KTA 3211.1

Page 74

A 3.5.2 Cold forming and cold bendingNote:Cold forming and cold bending shall designate forming at roomtemperature or with heating up to the highest temperaturepermissible for stress-relief annealing.

(1) Heat treatment is not required after cold forming withdegrees of forming smaller than or equal to 2 %.

(2) Stress-relief annealing shall be required after formingwith degrees of cold forming between 2 % and smaller than orequal to 5 %.

(3) The governing heat treatment shall be performed aftercold forming with degrees of forming larger than 5 %.

(4) If different procedures are employed, proof ofequivalence shall be furnished.

(5) For cold-bending processes, heat treatment after coldbending may be waived if appropriate proof is furnished.Weld-on work and straightening work shall not be permitted inthe zone of cold bends.

Note:Cold bends shall be defined as machine-made cold bends ofpipes with ≤ DN 150 and with bend radii Rm > 2.5 ⋅ Da.




A 3.6.2 Welding

(1) Use of the following welding methods has beenappraised as suitable:


b) submerged-arc welding with basic fluxes,

c) inert-gas-shielded welding with wire electrodes or withbasic-flux-cored wire electrodes

(2) The examined work areas for welding are listed inTable A 3-7. Other work areas for welding are permitted,provided procedure qualification tests per KTA 3211.3 havebeen performed.

(3) The stipulations for welding per SEW 088 shall beobserved. The content of diffusible hydrogen, determined toDIN 8572-1 and DIN 8572-2, shall not exceed HD5 toDIN 8572-E in manual arc welding or HD7 to DIN 8572-UP insubmerged-arc welding

(4) Post-weld stress-relief annealing may be required,depending on nominal thickness and geometry of the parts.The nominal thicknesses at which stress-relief annealing maybe waived are listed in Table A 3-7.

(5) Post-weld non-destructive examinations shall beperformed after a waiting time of at least 48 hours aftercompletion of the welding work, The waiting time may bewaived for welds that are subjected to stress-relief annealing,hydrogen degassing or delayed cooling, or that were weldedunder shield gas.

KTA 3211.1

Page 75

Ste

elgr

ade

Ver

ifica

tion

Lim

itva

lue

Con

tent

bym

ass,

%1)

2)

byC

Si

Mn

PS

Al to

tal

NA

sC

uC

rM

oN

bN

iS

nT

iV

15M

nNi6

3m

in.

0.12

0.15

1.20

0.02

00.

50La

dle

anal

ysis

max

.0.

180.

351.

650.

015

0.00

50.

055

0.01

50.

015

0.06

0.15

0.05

0.00

40.

850.

010

0.02

00.

020

min

.0.

100.

151.

150.

015

0.50

Pro

duct

anal

ysis

max

.0.

200.

371.

700.

017

0.00

70.

065

0.01

60.

016

0.07

0.20

0.05

0.00

40.

900.

013

0.02

00.

020

20M

nMoN

i55

min

.0.

174)

0.15

1.20

0.01

00.

400.

50La

dle

anal

ysis

max

.0.

230.

301.

500.

012

0.00

80.

040

0.01

30.

025

0.12

0.20

0.55

0.80

0.01

10.

020

min

.0.

154)

0.10

1.15

0.01

00.

400.

45P

rodu

ctan

alys

ism

ax.

0.25

0.35

1.55

0.01

23)

0.01

23)

0.05

00.

0133

)0.

025

0.12

3)0.

200.

553)

0.85

0.01

13)

0.02

0

15N

iCuM

oNb

5S

min

.0.

100.

250.

800.

015

0.50

0.25

0.15

1.00

Ladl

ean

alys

ism

ax.

0.17

0.50

1.20

0.01

60.

005

0.03

50.

020

0.80

0.30

0.40

0.02

51.

300.

020

min

.0.

080.

210.

750.

010

0.45

0.20

0.01

00.

95P

rodu

ctan

alys

ism

ax.

0.19

0.54

1.25

0.02

00.

006

0.04

00.

022

0.85

0.35

0.45

0.03

01.

350.

020

1)T

hedi

ffere

nces

that

the

tabu

late

dva

lues

indi

cate

betw

een

chem

ical

com

posi

tions

per

the

ladl

ean

dpr

oduc

tan

alys

esar

eso

met

imes

smal

ler

than

wou

ldbe

expe

cted

from

the

met

allu

rgic

alre

latio

nshi

p.T

here

ason

isth

atth

elim

itva

lues

for

chem

ical

com

posi

tion

per

the

prod

uct

anal

ysis

are

inth

isca

seba

sed

only

onth

ehe

ats

cove

red

byth

eap

prai

sal.

Thu

sth

eva

lues

will

bere

view

edon

cead

ditio

nal

docu

men

tsbe

com

eav

aila

ble.

2)If

the

indi

cate

dlim

itco

nten

tspe

rth

ela

dle

anal

ysis

are

exce

eded

,the

limit

cont

ents

per

the

prod

ucta

naly

sis

shal

lgov

ern.

3)If

thes

eva

lues

are

exce

eded

and

allo

wan

cem

ust

bem

ade

inth

epr

oduc

tan

alys

isfo

rco

nten

tsup

toP

≤0.

015

%,

S≤

0.01

5%

,M

o≤

0.63

%,

Cu

≤0.

18%

,S

n≤

0.01

6%

and

Nto

tal≤

0.01

5%

,th

eau

thor

ized

insp

ecto

rsh

allc

heck

,un

tilfu

rthe

rin

form

atio

nbe

com

esav

aila

ble,

asto

whe

ther

wel

ding

sim

ulat

ion

test

san

dif

nece

ssar

yta

ngen

tialm

icro

sect

ion

exam

inat

ions

are

nece

ssar

y.If

inte

rmed

iate

anne

alin

gat

550

°Cis

plan

ned

durin

gfu

rthe

rpr

oces

sing

,the

perm

issi

bilit

yof

this

anne

alin

gte

mpe

ratu

resh

allb

eve

rifie

ddu

ring

the

said

test

sor

exam

inat

ions

.The

scop

ean

dco

nduc

toft

hese

test

ssh

all

beag

reed

with

the

auth

oriz

edin

spec

tor.

The

test

sm

aybe

wai

ved

ifso

stip

ulat

edin

the

mat

eria

lapp

rais

al.

4)F

orqu

ench

edan

dte

mpe

red

wal

lthi

ckne

sses

smal

ler

than

oreq

ualt

o30

mm

,th

efo

llow

ing

Cco

nten

tssh

allb

epe

rmis

sble

:lar

ger

than

oreq

ualt

o0.

14%

and

smal

ler

than

oreq

ualt

o0.

18%

for

the

ladl

ean

alys

is;a

ndla

rger

than

oreq

ualt

o0.

12%

and

smal

ler

than

oreq

ualt

o0.

20%

for

the

prod

ucta

naly

sis.

Tab

leA

3-1:

Che

mic

alco

mpo

sitio

nof

stee

lgra

des

per

the

ladl

ean

dpr

oduc

tana

lyse

s

KTA 3211.1

Page 76

Steel grade Specimendirection

Reduction of area atfracture Z in %

at least

Heat-treatmentwall thickness

in mm

Tensilestrength

Rm in N/mm2

Yield point 1)

ReH in N/mm2

at least

Elongation atfractureA in %at least Individual

valueMeanvalue

longitudinal 24 45 ≤ 70 490 to 610 330

transverse 22 45

transverse 22 45

longitudinal 24 45

15 MnNi 6 3> 70

≤ 130 470 to 590 310

perpendicular 35 45

≥ 15≤ 100

570 to 710 430longitudinal /transverse 19 45

longitudinal /transverse 19 45

20 MnMoNi 5 5< 100≤ 200

560 to 700 390

perpendicular 35 45

longitudinal 19

transverse 17 15 NiCuMoNb 5 S ≤ 60 610 to 760 440

perpendicular 25 35

1) If the yield point is not emphasized, the values shall be applicable for the 0.2 % proof stress.



at least

0.2 % proof stressRp0.2 in N/mm2

at least


≤ 70 > 70 ≤ 70 > 70

Steel gradeTest

temperaturein °C

≤ 130 ≤ 130

Elongation at fractureA in %

at least(longitudinal or transverse)

100 420 400 285 260

145 415 375 275 240

200 400 375 245 22015 MnNi 6 3250 400 375 220 200

300 400 375 210 190

350 390 375 190 170


≥15 > 100 ≥ 15 > 100≤ 100 ≤ 200 ≤ 100 ≤ 200

100 530 530 412 370

200 513 510 392 360

300 513 510 371 35020 MnMoNi 5 5350 513 510 363 343

16

375 505 505 358 330

400 500 500 353 320


≤ 60 ≤ 60

100 540 422

150 530 412

200 520 402

15 NiCuMoNb 5 S 250 520 392

300 520 382

350 510 373

400 500 343

Table A 3-3: Characteristic values of the mechanical and technological characteristics in the elevated-temperature tensile test

KTA 3211.1

Page 77


at least


at least


in mm

Natureof

value 1)

-20 0 +5 +20 +33Uppershelf

2)

-20 +5 +33Uppershelf

2)

15 MnNi 6 3 ≤ 130 MW 80 110 130 130 130 130

EW 68 90 100 100 100 100 0,9 1,3 1,3 1,3

20 MnMoNi 5 5 ≤ 200 MW 41 4)

EW 34 4) 68 3) 100 0,9 1,3

15 NiCuMoNb 5 S ≤ 60 MW 60 80 95

EW 42 56 66 68 3) 100 0,9 1,3


temperature.3) If agreed in the purchase order, this requirement shall also apply at lower temperature, but not below 0 °C.4) For longitudinal specimens the minimum mean value shall be 60 J and the minimum individual value shall be 51 J.


Steel grade Verification necessary Simulated stress-relief annealingTemperature in °C Holding time 1) in minutes

15 MnNi 6 3 yes 560 to 580 900

20 MnMoNi 5 5 yes 600 to 620 900

15 NiCuMoNb 5 S yes 600 to 620 900

1) These data shall apply only if no other particulars were required in the purchase order.

Table A 3-5: Necessity for verification of mechanical characteristics in the simulated stress-relief-annealed condition, andperformance of the simulated stress-relief annealing process

Steel grade Normalization Temperature range for quenching and tempering Stress-reliefannealing 3)

Austenitization Tempering

°C °C °C °C

15 MnNi 6 3 880 to 960 1) 530 to 580

20 MnMoNi 5 5 870 to 930 2) 630 to 690 580 to 620

15 NiCuMoNb 5 S 900 to 980 1) 640 to 680 580 to 620

880 to 930 4) 640 to 690 4) 580 to 620

1) Cooling in stationary air after the temperature has been reached over the entire cross section.3) Cooling in water.3) For multiple stress-relief annealing steps, the indicated temperature range shall be applicable for the last stress-relief annealing step.

Preceding stress-relief annealing steps can be performed at 530 °C to 570 °C.4) Cooling in oil or water. This treatment shall be employed for relatively large heat-treatment wall thicknesses, in order to be able to

maintain the minimum temperature of 640 °C for tempering.


KTA 3211.1

Page 78

Welding 2)

Steel grade Nominalthickness

s

in mm

Thermalcutting

Preheatingtemperature

TVin °C

Preheating temperature TVand interpass temperature TZ

in °C

Holdingtemperature 1)

TH

in °C

Coolingtime t8/5

in seconds

Limit wallthickness for

waiving stress-relief annealing

after weldingin mm

15 MnNi 6 3 s ≤ 15 RT ≤ TV RT ≤ T ≤ 150 RT ≤ TH 8 to 25 38 5)

15 < s ≤ 30 RT ≤ TV 80 ≤ T ≤ 180 RT ≤ TH

30 < s ≤ 50 100 ≤ TV 100 ≤ T ≤ 220 3) 100 ≤ TH

s > 50 120 ≤ TV 120 ≤ T ≤ 220 3) 120 ≤ TH

20 MnMoNi 5 5 s ≥ 15 150 ≤ TV ≤ 250 150 ≤ T ≤ 250 3) 150 ≤ TH ≤ 250 4) 7 to 25

120 ≤ TH ≤ 180 6)

15 NiCuMoNb 5 S s ≤ 15 RT ≤ TV 80 ≤ T ≤ 150 RT ≤ TH 10 to 30

15 < s ≤ 30 RT ≤ TV 100 ≤ T ≤ 180 100 ≤ TH

30 < s ≤ 50 100 ≤ TV 120 ≤ T ≤ 220 3) 120 ≤ TH

s > 50 120 ≤ TV 120 ≤ T ≤ 220 3)

Stress-reliefannealing shallalwaysbe required


conditions other than those listed here, those conditions may be employed.3) At most 180 °C for weld cladding.4) The part shall be subjected to post-weld heating at about 280 °C from the heat of welding for more than 2 hours or to delayed cooling,

unless stress-relief annealing is performed directly from the heat of welding or inert-gas-shielded welding is employed.5) In the case of simple geometric form and 100 % non-destructive examination of the welds, it is permitted to increase the limit wall

thickness to ≤ 50 mm, unless special requirements of heat-treatment condition are imposed.6) For weld cladding.


KTA 3211.1

Page 79

A 4 Castings for cases and bodies of ferritic cast steel ofmaterial group W I

A 4.1 General


a) GS-18 NiMoCr 3 7

b) GS-C 25 S

for cases and bodies.

Note:The following stipulations are provisional, since the appraisal ofcast-steel grade GS-18 NiMoCr 3 7 and the supplementaryappraisal of cast-steel grade GS-C 25 S with regard to meetingthe requirements beyond those for cast-steel grade GS-C 25(material number 1.0619) to DIN 17 245 have not yet beencompleted.

A 4.2 Manufacture of the steels

The steels shall be smelted by the basic oxygen process or inthe electric furnace. If other processes are used, proof ofequivalence shall be furnished.



The values stipulated in Table A 4-1 shall apply to thechemical composition per the ladle and product analysis.


(1) The characteristic values of the mechanical andtechnological characteristics in the room-temperature tensiletest, including the minimum values of elongation at fracture,are stipulated in Table A 4-2.

(2) The characteristic values of the mechanical andtechnological characteristics at elevated temperatures arestipulated in Table A 4-3. Verification shall be required only ifthe design temperature is higher than 100 °C for cast-steelgrade GS-C 25 S and higher than 200 °C for cast-steel gradeGS-18 NiMoCr 3 7, unless otherwise stipulated in theauthorized inspector's appraisal.

(3) The characteristic values of energy absorbed arestipulated in Table A 4-4.

(4) The data for energy absorbed shall apply to standardspecimens with a specimen width of 10 mm.

(5) The mechanical and technological characteristics shallbe verified as per Table A 4-6.




Reference values for heat treatment are presented inTable A 4-5.

KTA 3211.1

Page 80

Ste

elgr

ade

Con

tent

bym

ass,

%V

erifi

catio

nby

Lim

itva

lue

CS

iM

nP

SA

l tota

lN

As

Cr

Cu

Mo

Ni

Sn

V

GS

-C25

Sm

in.

0.18

0.30

0.50

0.02

0La

dle

anal

ysis

max

.0.

220.

601.

100.

015

0.01

00.

070

0.01

50.

300.

180.

02m

in.

0.18

0.30

0.50

0.02

0P

rodu

ctan

alys

ism

ax.

0.22

0.60

1.10

0.01

50.

012

0.07

00.

015

0.30

0.18

0.02

GS

-18

NiM

oCr

37

min

.0.

170.

300.

700.

020

0.30

0.40

0.60

Ladl

ean

alys

ism

ax.

0.23

0.50

1.10

0.01

20.

010

0.05

00.

015

0.02

50.

500.

120.

601.

100.

011

0.02

min

.0.

160.

250.

700.

020

0.30

0.40

0.60

Pro

duct

anal

ysis

max

.0.

230.

501.

200.

012

1)0.

012

1)0.

050

0.01

51)

0.02

50.

500.

121)

0.60

1)1.

100.

011

1)0.

02

1)If

thes

eva

lues

are

exce

eded

and

allo

wan

cem

ust

bem

ade

inth

epr

oduc

tan

alys

isfo

rco

nten

tsup

toP

≤0.

015

%,

S≤

0.01

5%

,M

o≤

0.63

%,

Cu

≤0.

18%

,S

n≤

0.01

6%

and

Nto

tal≤

0.01

5%

,th

eau

thor

ized

insp

ecto

rsh

allc

heck

,un

tilfu

rthe

rin

form

atio

nbe

com

esav

aila

ble,

asto

whe

ther

wel

ding

sim

ulat

ion

test

san

dif

nece

ssar

yta

ngen

tialm

icro

sect

ion

exam

inat

ions

are

nece

ssar

y.If

inte

rmed

iate

anne

alin

gat

550

°Cis

plan

ned

durin

gfu

rthe

rpr

oces

sing

,the

perm

issi

bilit

yof

this

anne

alin

gte

mpe

ratu

resh

allb

eve

rifie

ddu

ring

the

said

test

sor

exam

inat

ions

.T

hesc

ope

and

cond

ucto

fth

ese

test

ssh

all

beag

reed

with

the

auth

oriz

edin

spec

tor.

The

test

sm

aybe

wai

ved

ifso

stip

ulat

edin

the

mat

eria

lapp

rais

al.

Tab

leA

4-1:

Che

mic

alco

mpo

sitio

nof

stee

lgra

des

per

the

ladl

ean

dpr

oduc

tana

lyse

s

Ste

elgr

ade

Nom

inal

thic

knes

sin

mm

0.2

%-p

roof

stre

ssR

p0.2

inN

/mm

2T

ensi

lest

reng

thR

min

N/m

m2

Elo

ngat

ion

atfr

actu

reA

in%

max

imum

atle

ast

atle

ast

GS

-C25

S10

024

544

0to

590

22G

S-1

8N

iMoC

r3

730

039

057

0to

735

16

Tab

leA

4-2:

Cha

ract

eris

ticva

lues

ofth

em

echa

nica

land

tech

nolo

gica

lcha

ract

eris

tics

inth

ero

om-t

empe

ratu

rete

nsile

test

Ste

elgr

ade

0.2

%-p

roof

stre

ss1)

Rp0

.2in

N/m

m2

Ten

sile

stre

ngth

1)R

min

N/m

m2

Elo

ngat

ion

atfr

actu

re1)

Ain

%

atle

ast

atle

ast

atle

ast

atte

mpe

ratu

rein

°Cat

tem

pera

ture

in°C

atte

mpe

ratu

rein

°C10

020

025

030

035

037

540

010

020

025

030

035

037

540

010

020

025

030

035

037

540

0

GS

-C25

(205

)17

5(1

60)

145

135

130

(410

)(4

00)

(400

)(3

90)

(375

)(3

55)

(21)

(20)

(19)

(18)

(20)

(25)

GS

-18

NiM

oCr

37

(370

)(3

60)

(350

)(3

45)

343

(338

)(5

70)

(550

)(5

35)

(520

)49

0(4

75)

(16)

(15)

(14)

(13)

12(1

1)

1)T

heva

lues

inpa

rent

hese

sm

usts

tillb

esu

bsta

ntia

ted

byst

atis

tics.

Tab

leA

4-3:

Cha

ract

eris

ticva

lues

ofth

em

echa

nica

land

tech

nolo

gica

lcha

ract

eris

tics

inth

eel

evat

ed-t

empe

ratu

rete

nsile

test

KTA 3211.1

Page 81

Energy absorbed (Charpy-V) in Jat least

Upper shelf 2) of theenergy absorbed (Charpy-V) in J

at 0 °C at 33 °C 1) at leastSteel grade

Mean value of 3 specimens Individual value Individual value Individual value

GS-C 25 S

GS-18 NiMoCr 3 741 34 68 100

1) If agreed in the purchase order, this requirement shall also apply at lower temperature, but not below + 5 °C for GS-C 25 S and not below+ 10 °C for GS-18 NiMoCr 3 7.

2) The test is generally performed at 80 °C.

Table A 4-4: Characteristic values of energy absorbed in the notched-bar impact bend test on Charpy-V-notch specimens

Quenching and tempering Preheating Stress-relief annealing 4)

Hardening TemperingSteel grade

°C °C °C °C

GS-C 25 S 900 to 940 1) 650 to 700 100 to 250 3) 580 to 620

GS-18 NiMoCr 3 7 880 to 950 2) 650 to 700 150 to 250 580 to 620

1) Quenching in oil or water.2) Hardening two times in water.3) Preheating may be waived if adequate experience is available.4) If applicable, higher temperatures up to 30 K below the actually employed tempering temperatures may be permissible for stress-relief

annealing.

Table A 4-5: Particulars of preweld heat treatment and preheating, of thermal cutting and of stress-relief annealing

Simulated stress-relief annealingSteel grade Verification necessary

Temperature in °C Holding time in minutes

GS-C 25 S

GS-18 NiMoCr 3 7yes 600 to 620 900

Table A 4-6: Necessity for verification of mechanical and technological characteristics in the simulated stress-relief-annealedcondition, and performance of the simulated stress-relief annealing process

KTA 3211.1

Page 82

A 5 High-tensile steels for quenching and tempering forbolts and nuts

A 5.1 General

Section A 5 defines the details for manufacture, chemicalcomposition, characterizing mechanical and technologicalcharacteristics and heat treatment as well as for furtherprocessing of high-tensile steels for quenching and temperingfor bolts and nuts. These stipulations shall apply not only torolled or forged bars but also to the bolts and nuts made fromthe bars.

A 5.2 Manufacture of the steels and delivery condition

A 5.2.1 Manufacture

Note:The steels shall be high-tensile steels for quenching andtempering with stipulated minimum values of elevated-temperature strength characteristics.

(1) The steels shall be smelted by the basic oxygen processor in the electric furnace. If other processes are used, proof ofequivalence shall be furnished. Steel grades 26 NiCrMo 14 6and 34 CrNiMo 6 S shall be subjected to metallurgical ladlepost-treatment or remelted in vacuum or by the electroslagrefining process.



The steels shall be delivered in the quenched and temperedcondition or in the quenched and tempered plus stress-relief-annealed condition.



The values stipulated in Table A 5-1 shall apply to thechemical composition per the ladle analysis. Table A 5-2

presents the allowable deviations of chemical composition perthe product analysis from the limit values of chemicalcomposition per the ladle analysis.


(1) The mechanical and technological characteristics shallapply to the delivery condition. The values shall be verified onlongitudinal specimens from the sampling locations as perSection 8.

(2) The characteristic values of the mechanical andtechnological characteristics in the room-temperature tensiletest, including the minimum values of reduction of area atfracture, are stipulated in Table A 5-3.

(3) The characteristic values of the mechanical andtechnological characteristics in the elevated-temperaturetensile test are stipulated in Table A 5-4.





Data for heat treatment are presented in Table A 5-6.

A 5.5 Further processing

Only machining is permitted.

Note:No provisions shall be made for hot or cold forming (thread rollingshall not qualify as cold forming).

Content by mass in %Steel grade Limit value

C Si Mn P S Cr Mo Ni V Altotal

min. 0.18 0.15 0.30 1.20 0.25 3.40 0.02020 NiCrMo 14 5

max. 0.25 0.40 0.50 0.020 0.010 1.50 0.50 4.00 0.050

min. 0.25 0.20 1.20 0.35 3.30 0.02026 NiCrMo 14 6

max. 0.30 0.30 0.50 0.020 0.010 1.70 0.55 3.80 0.08 1) 0.050

min. 0.30 0.15 0.40 1.40 0.15 1.40 34 CrNiMo 6 S

max. 0.38 0.40 0.70 0.020 0.010 1.70 0.35 1.70

1) Values larger than 0.08 and smaller than or equal to 0.12 % may be approved by appraisals on a case-by-case basis.

Table A 5-1: Chemical composition per the ladle analysis of high-tensile steels for quenching and tempering for bolts and nuts

KTA 3211.1

Page 83

Element Allowable limit deviation 1) of values per the product analysisContent by mass in %

C ± 0.02Si ± 0.03

Mn ± 0.04

P + 0.005

S + 0.005

Al ± 0.005

Cr ± 0.05

Mo ± 0.04

Ni ± 0.05 2)

V + 0.021) If several product analysis are performed for one heat and deviations of chemical composition per the product analysis are found from the

permissible values of chemical composition per the ladle analysis, these deviations for a given element shall be allowable only if they areeither all above or all below the limit values as per Table A 5-1.

2) For permissible nickel contents of 2.00 to 4.00 % per the ladle analysis, deviations of ± 0.07% Ni in the values per the product analysisshall be allowable.

Table A 5-2: Allowable deviations of chemical composition per the product analysis from the limit values of chemicalcomposition per the ladle analysis

Steel gradeDiameter

(bar steel), in mm0.2% proof stress

Rp0.2 in N/mm2

at least

Tensile strengthRm

in N/mm2

Elongation atfracture A in %

at least

Reduction of areaat fracture Z in %

at least

20 NiCrMo 14 5 (I) 940 1040 to 1240 14 55

20 NiCrMo 14 5 (II) 980 1080 to 1280 14 55

26 NiCrMo 14 6 940 1040 to 1240 14 50

34 CrNiMo 6 S

≤ 130

830 930 to 1130 16 45


Diameter(bar steel), in mm

0.2% proof stressRp0.2 in N/mm2 at

Tensile strengthRm in N/mm2 at

Elongation atfracture

A in % at

Reduction of areaat fractureZ in % at

Steel grade

in mm 300 °C 350 °C 300 °C 350 °C 300 °C 350 °C 300 °C 350 °C

20 NiCrMo 14 5 (I) 785 735 860 840 14 14 55 55

20 NiCrMo 14 5 (II) 830 785 900 880 14 14 55 55

26 NiCrMo 14 6 790 785 860 820 14 14 45 45

34 CrNiMo 6 S

≤ 130

630 560 760 735 16 16 45 45

Table A 5-4: Minimum values of the mechanical and technological characteristics in the elevated-temperature tensile test

Diameter(bar steel)

Energy absorbedin J

Lateral expansionin mmSteel grade

in mm Mean value Individual value Individual value

20 NiCrMo 14 5 (I) 76

20 NiCrMo 14 5 (II) 76

26 NiCrMo 14 6 72

34 CrNiMo 6 S

≤ 130

76

61 0.65

Table A 5-5: Characteristic values of energy absorbed and lateral expansion on Charpy V-notch longitudinal specimens at20 °C

Temperature range in °C Temperature range in °C forSteel grade for austenitization Cooling fluid Tempering Stress-relief annealing

20 NiCrMo 14 5 (I) 840 to 900 520 to 600 430 to 47020 NiCrMo 14 5 (II) 800 to 900 500 to 580 430 to 470

26 NiCrMo 14 6 840 to 870Water or oil

530 to 580 450 to 500

34 CrNiMo 6 S 820 to 870 550 to 640 450 to 500

Table A 5-6: Data for heat treatment of high-tensile steels for quenching and tempering for bolts and nuts

KTA 3211.1

Page 84

A 6 Bar steel for bolts and nuts; additional stipulationsto DIN 17 240 and DIN EN 10 269

A 6.1 General

Section A 6 shall apply in addition to the stipulations of DIN17 240 (7/76) and DIN EN 10 269 (11/99) for the steel gradeslisted in Table A 6-1 when used for bolts and nuts within thescope of validity of this safety standard.

(2) The stipulations shall apply to rolled or forged bar steeland to the bolts and nuts made from it.

A 6.2 Dimensional limits

The steel grades listed in Table A 6-1 may be used up to thedimensional limits indicated therein.

A 6.3 Notched-bar impact bend test

Table A 6-1 presents the values of energy absorbed andlateral expansion to be verified in the notched-bar impact bendtest at 20 °C with Charpy V-notch specimens (longitudinal),taking the stipulations of clause 8.2.2 into consideration.

A 6.4 Elevated-temperature tensile test

Table A 6-1 also presents the values of tensile strength atelevated temperatures.

Steel grade

Energy absorbed in J(Charpy-V specimens,

longitudinal)

Lateralexpansion

in mm


at leastDiameter

in mm

at room temperatureat the

temperature ofAbbreviated name Heat-

treatmentcondition

Standard

Mean value,

at least

Individualvalue,

at least

Individualvalue,

at least

300 °C 350 °C

Ck 35 V DIN 17 240 ≤ 60 55 39 0,60 400 390

C35E +QT DIN EN 10 269 ≤ 60 55 39 0,60 400 390

≤ 100 118 82 0,95 460 44024 CrMo 5 V DIN 17 240

> 100 to ≤ 130 102 70 0,85 460 440

21 CrMoV 5 7 V DIN 17 240 ≤ 100 63 52 0,60 590 560

21CrMoV5-7 +QT DIN EN 10 269 ≤ 100 63 52 0,60 590 560

≤ 60 52 37 620 600X 22 CrMoV 12 1 1) V DIN 17 240

> 60 to ≤ 100 2) 27 19 620 600

≤ 60 52 37 620 600X22CrMoV12-1 +QT1 DIN EN 10 269

> 60 to ≤ 100 2) 27 19 620 600

X 8 CrNiMoBNb 16 16 WK+AL DIN 17 240 ≤ 80 47 33 510 500

X7CrNiMoBNb16-16 +WW+P DIN EN 10 269 ≤ 80 50 35 530 505

1) Tensile strength at room temperature 800 N/mm2 to 950 N/mm2.2) Only for nuts.

Table A 6-1: Limits of permissible dimensions and additional stipulations for steels to DIN 17 240 and DIN EN 10 269for bolts and nuts

KTA 3211.1

Page 85

Annex AP

Reference data on physical characteristics

AP 1 Scope of application

This Annex contains reference data on

a) specific density,

b) dynamic modulus of elasticity,

c) mean coefficient of linear thermal expansion,

d) mean specific heat capacity and

e) thermal conductivity

for the steel grades cited in Sections A 1 through A 5.

AP 2 Characteristic values

AP 2.1 General

The characteristic values listed in Table AP-1 for physicalcharacteristicfs are reference data compiled on the basis ofmeasurements on individual heats and of literature data [3].

AP 2.2 Determination of characteristic values

At present a standardized method has not been defined fordetermination of the characteristic values presented here forphysical characteristics.

AP 2.3 Scatter band of characteristic values

(1) Changes in chemical composition and heat treatmentlead to a certain scatter band of physical characteristics. Anygrain orientation has a particularly strong influence on thevalues of modulus of elasticity.

(2) Differences between the measurement methodsemployed may lead to additional scattering.

(3) The documents available at present are not adequate forstatistical evaluation of reliability.

(4) The statements on the scatter band of characteristicvalues in footnotes 1 to 5 of Table AP-1 were taken from theliterature. They relate to the average scatter band of themeasured values acquired there.

KTA 3211.1

Page 86

Ste

elgr

ade

Spe

cific

dens

ity1)

in10

6g/

m3

Dyn

amic

mod

ulus

ofel

astic

ity2)

in10

3N

/mm

2

atth

ete

mpe

ratu

rein

°C

Mea

nco

effic

ient

oflin

ear

ther

mal

expa

nsio

n3)

in10

-6K

-1

betw

een

20°C

and

the

tem

pera

ture

in°C

Mea

nsp

ecifi

che

atca

paci

ty4)

inJ

g-1

K-1

betw

een

20°C

and

the

tem

pera

ture

in°C

The

rmal

cond

uctiv

ity5)

inW

m-1

K-1

atth

ete

mpe

ratu

rein

°C

at20

°C20

100

200

300

350

400

100

200

300

350

400

100

200

300

350

400

2010

020

030

035

040

0

15M

nNi6

37.

8521

120

619

819

118

712

.412

.913

.313

.642

4342

4140

15N

iCuM

oNb

5S

7.84

210

206

199

191

183

12.4

13.0

13.6

14.1

4444

4342

40

20M

nMoN

i55

7.86

211

206

199

192

184

12.7

13.2

13.6

14.0

4444

4341

39

20N

iMoC

r14

57.

8420

520

019

118

211

.211

.612

.112

.229

3031

3131

26N

iMoC

r14

67.

8420

520

019

118

211

.211

.612

.112

.229

3031

3131

34C

rNiM

o6

S7.

8020

520

019

118

212

.513

.213

.714

.234

3637

3736

C22

.8S

7.80

212

205

200

192

183

12.5

13.1

13.6

14.0

4343

4241

39

GS

-18

NiM

oCr

37

7.86

210

203

194

185

175

12.6

13.9

14.8

14.9

3837

3432

GS

-C25

S7.

8321

120

419

618

617

712

.212

.913

.413

.943

4342

4139

WS

tE25

5S

7.85

212

207

200

192

184

12.3

12.8

13.3

13.8

4243

4342

40

WS

tE28

5S

7.85

212

207

200

192

184

12.3

12.8

13.3

13.8

4243

4342

40

WS

tE31

5S

7.84

212

207

200

192

184

12.3

12.8

13.3

13.8

4243

4342

40

WS

tE35

5S

7.83

212

207

200

192

184

12.3

12.8

13.3

13.8

0.46

0.49

0.51

0.52

0.53

4243

4342

40

1)A

vera

geba

ndw

idth

ofm

easu

red

valu

es±

0.05

⋅106

g/m

3 .2)

Ave

rage

band

wid

thof

mea

sure

dva

lues

±5

⋅103

N/m

m2 .

3)A

vera

geba

ndw

idth

ofm

easu

red

valu

es±

0.8

⋅10-

6K

-1.

4)A

vera

geba

ndw

idth

ofm

easu

red

valu

es±

0.01

Jg-

1K

-1.

5)A

vera

geba

ndw

idth

ofm

easu

red

valu

es±

3.5

Wm

-1K

-1fo

rfe

rriti

c st

eels

; ±1.

5W

m-1

K-1

for

aust

eniti

c st

eels

.

Tab

leA

P-1

:R

efer

ence

dat

a on

spe

cific

den

sity

, dyn

amic

mod

ulus

of e

last

icity

and

mea

n co

effic

ient

of l

inea

r th

erm

al e

xpan

sion

of t

he s

teel

gra

des

as p

er S

ectio

ns A

1 th

roug

h A

5

KTA 3211.1

Page 87

Annex B

Non-destructive examinations of steel castings

B 1 General

This Annex shall apply to the non-destructive examinations ofcastings for cases and bodies to Sections 5.7, 6.7, 7.7 and9.2.

B 2 Type of examinations

B 2.1 Examination methods for cast steel

The examination methods for the different cast-steel gradesand part zones can be found in Table B-1.

B 2.2 Type and extent of ultrasonic examination

(1) In the zones listed below (see Figures B-1 throughB-11), the ultrasonic examination shall be employed as avolumetric examination:

a) on rough-turned flanges with nominal thickness equal to orlarger than 20 mm,

b) on machined seat portions with nominal thickness equal toor larger than 40 mm,

c) on ribs and cast-on parts with nominal thickness equal toor larger than 40 mm.

(2) These zones shall be examinable in at least two mutuallyperpendicular scanning directions.

(3) In addition, it is permitted to perform an ultrasonicexamination instead of the radiographic examination on thesmall production welds of test group A 2, provided therequirements of Section B 4.2 are met.

(4) If the ultrasonic examination is employed as a volumetricexamination in zones other than those illustrated in FiguresB-1 through B-11, the procedure shall be subject to theauthorized inspector’s approval on a part-by-part basis.

B 3 Point of time of examinations and participation inexaminations

(1) The point of time of non-destructive examinations in theproduction sequence as well as the participation inexaminations is defined for cast-steel cases and bodies inFigure B-12.

(2) If further machining is performed by the componentmanufacturer, a surface-crack detection shall additionally bemade of the surfaces produced by such machining.

B 4 Extent of examinations

B 4.1 Test group A 1

(1) All cast products including production welds shall becompletely radiographed. For ferritic and martensitic cast-steelgrades, it is permitted as an alternative to perform anultrasonic examination of the casting zones identified inFigures B-1 through B-11.

(2) All internal and external surfaces, including those ofproduction welds as well as the excavations for productionwelds, shall be subjected to a surface-crack detection.

B 4.2 Test groups A 2 and A 3

(1) The first three castings of a production lot (prototypes)shall be subjected completely to a volumetric examination.

(2) All further castings of the same production lot with thesame melting and casting technique shall be examined in thefollowing zones:

a) zones that are complex from the viewpoint of casting andstress,

b) welding ends,

c) relatively large production welds,

d) places at which defects with acceptable limit sizes wereobserved in the examination of the prototypes.

(3) The zones that are complex from the viewpoint of castingand stress shall be determined by decision among theparticipants, who shall also decide upon the consolidation ofproduction lots.

(4) For small production welds, it is also permitted, startingwith the fourth casting, to perform an ultrasonic examinationinstead of the radiographic examination.

(5) All internal and external surfaces, including those ofproduction welds as well as the excavations for productionwelds, shall be subjected to a surface-crack detection.

B 5 Method-related requirements

B 5.1 Surface finish

The surface prepared for the non-destructive examinationshall be evaluated to DIN EN 1370. The castings shall have asurface quality equal to or better than that of referencesamples BNIF 3S1 or 4S2. Castings to be examined by theliquid-penetrant method shall have a surface quality equal toor better than that of reference sample BNIF 3S2.

B 5.2 Radiographic examination

B 5.2.1 Procedure

(1) Radiographic examination shall be performed per testclass A of DIN 54 111-2 and DIN EN 462-3 image qualityclass A under consideration of DIN EN 444, in which case theimage quality indicator to DIN EN 462-1 shall be used, unlessotherwise stipulated in the following.

(2) The film processing shall be made to DIN EN 584-2.

(3) Welding ends and zones intended for construction weldsshall be radiographed in test class B of DIN 54 111-2.

B 5.2.2 Film locations

(1) Steel castings with an outside diameter equal to orsmaller than 200 mm shall be radiographed as per filmarrangement 7 of Table 1 to DIN 54 111-2.

(2) For steel castings with an outside diameter larger than200, film arrangement 7 of Table 1 to DIN 54 111-2 shall beselected only if film arrangements 3 or 4 are not feasible or ifthe assessment capabilities shall be improved.

KTA 3211.1

Page 88

B 5.2.3 Special conditions for overall filming

(1) Overall films shall be prepared preferably by using linearaccelerators. Notwithstanding the standard, total wallthicknesses of 2 x s equal to or larger than 40 mm may beradiographed under these conditions.

(2) The radiographic density shall be greater than 2.0.

(3) When the overall filming technique is employed, areference-point grid shall be required only if partial zones areradiographed and continuity with the adjoining zonesradiographed with internally disposed radiation sources shallbe demonstrated.

B 5.3 Ultrasonic examination of ferritic steel castings

(1) The ultrasonic examination shall be performed to SEP1922, test class I.

(2) If production welds with a depth of equal to or smallerthan 15 mm are examined from their own surface,examination with a normal probe (transmitter-receiver) willsuffice. In all other cases, production welds shall be examinedwhenever feasible by means of angle-beam scanning with anangle probe in four mutually perpendicular beam-entrypositions. In all cases the adjoining base-metal zones shall beincluded in the examination.

B 5.4 Magnetic-particle examination

B 5.4.1 Procedure

Magnetic-particle examination shall be performed to SEP1935 and Annex G.

B 5.5 Liquid-penetrant examination

B 5.5.1 Procedure

Liquid-penetrant examination shall be performed to SEP 1936and Annex G.

B 6 Acceptance limits

B 6.1 Cast products including production welds and weldingends

(1) The quality levels allocated to the test groups arepresented in Table B-2.

(2) The acceptance limits for the findings of the radiographic,ultrasonic, magnetic-particle and liquid-penetrant examina-tions shall be those to DIN 1690-2.

(3) If impermissible findings are observed in overall films,they shall be checked by additional selective films.

B 6.2 Excavations for production welds

(1) The only permissible indications shall be those that donot impair weldability and are not associated withimpermissible surface and volumetric defects that shall beeliminated.

(2) The welding supervisory agency and inspectionsupervisory agency of the manufacturer shall be required todecide jointly on potential impairment of weldability by findingsthat are left in place.

B 7 Documentation

The inspection reports shall contain all particulars and data(including radiation source plan and film location plan) thatpermit reproducible conduct of the examination. Thepresentation of findings of the volumetric examination shall beclear and unambiguous and shall permit correlation with thepart at every place.

KTA 3211.1

Page 89

Figure B-1: Valve body Figure B-2: Angle-valve body Figure B-3: Wedge-type gate-valve body

Figure B-4: Swing-check-valve body Figure B-5: Multi-way-valve body Figure B-6: Discharge casing

Figure B-7: Suction casing Figure B-8: Scroll casing Figure B-9: Double scroll casing

Figure B-10: Annular casing Figure B-11: Barrel-type-pump casing

Figures B-1 through B-11:

Examples of valve-body or pump-casing zones for which ultrasonicexamination is permissible

KTA 3211.1

Page 90

Casting zonesCast-steel

group Cast product Adjoining zones 1) Welding ends 6) Excavations Production weld 2)

Ferriticcast-steelgrades

Magnetic particleexamination 4)

Radiographicexamination 3)




Liquid-penetrantexaminationRadiographicexamination



Martensiticcast-steelgrades









Austeniticcast-steelgrades


Liquid-penetrantexamination




1) Adjoining zones are zones located outside the pressure-retaining wall, such as- feet,- brackets,- lugs,- external fins,- cams.

2) See DIN 17 245 for definition of relatively large production weld.3) Alternatively, it is permitted to perform an ultrasonic examination as per Section B 2.2.4) Magnetic-particle examination shall be preferred for magnetizable materials. However, liquid-penetrant examination may be employed:

a) in zones that are difficult to magnetize because of geometry or accessibility considerationsb) for cast-steel grade G-X 5 CrNi 13 4, material No.1.4313.

5) In test group A 2, it is permitted to replace the radiographic examination of small production welds by an ultrasonic examination, startingwith the 4th casting of a production lot.

6) Also applicable for zones of construction welds.

Table B-1: Examination methods for cast-steel grades and their casting zones

Quality levels to DIN 1690-2

Test group Case or body includingproduction welds

Welding ends Adjoining zones 1) 2)

A 1 S1-V2

A 2 S2-V3 S1-V1 S3-V3

A 3 S2-V3

1) Adjoining zones are zones located outside the pressure-retaining wall, such as

- feet,- brackets,- lugs.

2) For test groups A 1 through A 3 of materials to Sections 7.7 and 9.2, the quality level for the adjoining zones shall be S3-V4.

Table B-2: Quality levels as a function of test group and casting zones

KTA 3211.1

Page 91

4)

1)

3)

4)

2)

2)

4)

Grooving out and liquid-penetrant examination of the places

characteristics

Procedure 2

Production welds without subsequent heat treatmentfor establishing the mechanical and technological

prepared for welding by H

Permission for welding in W 1 by authorized inspector

Welding per Annex C

Grinding the welds smooth

in material group W 1, larger production welds in W 2Documentation, for the final file, of all production welds

and austenite

findings

no

Surface-crack detection and radiography

Impermissible

Acceptance

yesindications and

yes

Quenching and tempering or solution annealing

it becomes necessary for the component manufacturer

DIN 17 245 Annex B shall apply to cast-steel grade GS-C25.

Complete surface-crack detection

Impermissibleindications

no

Setting of the surface quality per Section B 5.1

Quenching and tempering or solution annealing

Casting

of the production weld by H


Ferrite: stress relief annealingMartensite: tempering

findings

See DIN 17 245 for definition of larger production weld.4)

Impermissible

Complete surface-crack detection by manufacturer (H)

no

indications and

Welding per Annex C

Volumetric examination by H

yes no

Surface-crack detection of the production welds by H

Ferrite: stress-relief annealingMartensite: temperingAustenite: none

Documentation, for the final file, of all production welds

and austenite

Permission for welding by authorized inspector in A 1

in material group W 1, larger production welds in W 2

Evaluation of the films by H and S

Grooving out and liquid-penetrant examination of the placesprepared for welding by H

yes

no

indications

yes

Impermissible

Ultrasonic re-examination by S if there is ferrite

prepared for welding by H



Volumetric examination by H

findings

Soaking, if required in Material Annex

interim file and informing of the authorized inspector (S)

Setting of the surface quality per Section B 5.1

Heat treatment to establish the mechanical and

Surface-crack detection of the production welds by H

indications andImpermissible

technological characteristics

Documentation of the larger production welds for the

Grooving out and liquid-penetrant examination of the places

Procedure 1

Mechanical and technological tests

Complete surface-crack detection by H and S

Applies only to material group W I, test group A 1.

Note when there are additional volumetric examinations:Radiographed welds and casting zones with

Compilation of the documentation

2)

1)

3)

Ultrasonic re-examination by S if there is ferrite


then deviations relative to the standard production scheme

indicationsImpermissible

Production welds with complete heat treatment

yes

Welding per Annex C

no

If, in exceptional cases in the course of further processing,

permissible findings need not be re-examined.

to perform production welds in order to eliminate

shall be permissible by agreement with the authorized inspector.

casting defects in an advanced state of processing,

Figure B-12: Production scheme for cast steel cases and bodies made of ferritic, austenitic or martensitic cast-steel grades

KTA 3211.1

Page 92

Annex C

Production welds of steel castings

C 1 General

This Annex shall apply in addition to the stipulations of DIN1690-2 and SEW 110 for production welds on steel castings.

Note:Production welds shall be employed only if the defect cannot berepaired in another way without reducing the thickness below thenominal value.

C 2 Prerequisites

(1) The general requirements per Section 3 shall be met.

(2) Production welds as well as their examination anddocumentation shall be classified as per the productionscheme of Figure B-12 in the process of casting manufacture.The individual production steps shall be completed in thedescribed sequence. In the event of deviations from thestandard production sequence, a design approval of thesequence of production steps shall be required. A distinctionshall be made between Procedure 1 (production welding withsubsequent quenching and tempering or solution annealingand quenching) on the one hand, and Procedure 2 (productionwelding without subsequent quenching and tempering orsolution annealing and quenching) on the other hand.

(3) If the castings are not quenched and tempered orsolution-annealed and quenched after production welding, forexample, because of the machining condition, the authorizedinspector’s consent regarding production welding shall beobtained if required in Annex B. In this case the productionwelds shall be documented as per Figure B-12.

(4) For relatively large production welds that willsubsequently be quenched and tempered or solution-annealed and quenched, the authorized inspector shall begiven adequate advance notification of the welding work.Suspension of the production sequence is not required.

Note:See DIN 17 245 for definition of relatively large production weld.

(5) For small production welds that will subsequently bequenched and tempered or solution-annealed and quenched,it is not required to notify the authorized inspector.

C 3 Weld filler metals and welding consumables

The weld filler metals and welding consumables shall meet therequirements of KTA 1408.1, KTA 1408.2 and KTA 1408.3Section 3.

C 4 Heat supply during welding and post-weld heattreatment

(1) The appropriately defined preheating temperature shallbe met for welding as well as for all cutting and joining work.

(2) The welding conditions and welding parameters forferritic and martensitic cast-steel grades shall be selectedsuch that the lowest possible hardness values are achievedfor the particular material. Work specimens shall be taken toverify that hardness values of 350 HV 10 are not exceeded.

(3) Production welds on castings of ferritic or martensiticsteels shall be heat-treated as per Figure B-12.

(4) Correlation of the castings with the heat-treatment lotshall be ensured.

C 5 Welding procedure qualifications

(1) For all materials to be welded and for all weldingmethods, a welding procedure qualification as per SEW 110and per the following stipulations shall be performed beforethe start of production welding for each planned heattreatment, welding position and wall thickness.

(2) The welding procedure qualification for a particular steelshall also be applicable for other steels within the limits set inKTA 3211.3.

(3) The duration of validity of a welding procedurequalification shall be 24 months after successful completion ofthe welding procedure qualification. This period shall beginwith the date of the written opinion of the authorized inspector.If production is started within these 24 months and productioncontrol tests to Section C 6 have been performed, the initialperiod shall be extended by a further 24 months, countingfrom the start of validity of the production control test.

(4) If production is not started within 24 months aftersuccessful completion of the welding procedure qualificationor is interrupted for longer than 24 months, the first productioncontrol test prior to starting or resuming production shall betreated as a repeat of the welding procedure qualification. Thestipulations of the original welding procedure qualification shallgovern the scope of this production control test, with regard toboth the start of validity and the duration of validity.

(5) Before the welding procedure qualification is performed,a welding procedure sheet and, if necessary, a heat-treatmentplan shall be submitted to the authorized inspector.

(6) It shall not be necessary to use for the welding procedurequalification the same heats of base metal or the samebatches of weld filler metals and welding consumables as areused for welding of parts.

(7) The welding shall be performed under constraintconditions.

(8) Welding records of welding procedure qualifications shallbe kept. Blank forms per KTA 3211.3 or sheets with identicalinformation content shall be used for this purpose.

(9) The scope of the welding procedure qualification as perSEW 110 is stipulated in Table C-1. Table C-2 additionallycontains stipulations on the technological bend test.

(10) Welding procedure qualifications that are still valid butare not fully in conformity with the stipulations of Table C-1regarding the scope of testing may be added to bysupplementary tests in a preliminary production control test.

C 6 Production control tests

(1) Depending on scope of validity of the welding procedurequalification, the manufacturer shall be required to performone production control test per year during production in thepresence of the authorized inspector. KTA 3211.3 Section 5shall apply in addition to the stipulations of this section.

(2) Production control tests on a steel of material group W Ishall also cover production control tests on the same steel foruse in material group W II.

(3) The test coupons for production control tests shall betaken from one of the heats involved.

(4) The weld filler metals and welding consumables shall betaken from one of the manufacturing lots involved.

KTA 3211.1

Page 93

(5) The test coupons shall be welded by welders whoparticipate in production.

(6) Production control tests shall be performed as full-penetration welds. They shall cover all partial penetrationweldings.

(7) The test pieces shall be subjected to simulated heattreatment approved by the authorized inspector or shall betraveller pieces subjected to the same heat treatment as thecasting.

(8) The extent of examination and requirements arestipulated in Table C-3.

C 7 Documentation

The documentation of welding procedure qualification andproduction control tests, including the associated designapproval documents, shall be organized per the stipulationsset forth for welding procedure qualification in SEW 110, andshall be attached to the acceptance test certificate.

Type of examination Number of specimens, specimen location, requirements

Non-destructive examinations 100 % surface-crack detection100 % volumetric examination, examination procedure and requirements as per thestipulations of SEW 110.

Tensile test(DIN EN 895 and DIN EN 10 002-1)

a) Base metal (DIN EN 10 002-1)1 specimen (DIN 50 125) at room temperatureRequirements to Sections 5.7, 6.7, 7.7 or 9.2

b) Welded joint (DIN EN 895)2 specimens (DIN EN 895, Figure 2a or 2b, parallel length Lc = weld width+ at least 60 mm) at room temperature.Rm and fracture location shall be tested (tensile-strength requirement as for the basemetal).

c) All-weld metal (DIN EN 10 002-1)1 specimen (DIN 50 125, L0 = 5 ⋅ d0) at room temperature.Requirements for Rp0.2, Rm, A, Z, as well as Rp1.0 for austenite, stipulated as for theweldability test.

Notched-bar impact bend test(DIN EN 10 045-1)on Charpy-V specimens

Ferritic steels of material group W IOne specimen set of base metal at 0 °C.One specimen set each of weld metal and heat-affected zone at 0 °C, 33 °C and 80 °C.Specimen location as per Figure C-1.See clause 4.3.1 for requirements. If the temperature at which 68 J (smallest individualvalue) and 0.9 mm lateral expansion (smallest individual value) is reached lies between0 °C and 33 °C, the exact value of this temperature may be determined by interpolationand used as the lowest permissible loading temperature.The ductile fracture percentage of the fractured area shall be determined.Ferritic steels of material group W IIOne specimen set of base metal at 0 °C (20 °C permissible if the lowest loadingtemperature exceeds 20 °C and the weld metal as well as the heat affected zone aretested at 20 °C).One specimen set each of weld metal and heat-affected zone at 0 °C (20 °C permis-sible if the lowest loading temperature exceeds 20 °C).Specimen location as per Figure C-1.See clause 4.3.2 for requirements.The ductile fracture percentage of the fractured area shall be determined.Austenitic steelsOne specimen set each of weld metal at room temperature.Specimen location as per Figure C-1.See clause 4.3.3 for requirements.Martensitic steelsOne specimen set of base metal at room temperature. Requirements as per Sections5.7 or 9.2.

One specimen set each of weld metal and heat-affected zone at room temperature.Specimen location as per Figure C-1.Requirements as for the base metal.

Technological bend test(DIN EN 910)

One specimen each with root and cover pass on the tension side; see Table C-2 forbending-mandrel diameter and requirements.

Chemical composition Weld metalNot required for unalloyed steels.Elements to be verified per weldability test of the weld filler metals.

Table C-1: Extent of examination and stipulations for procedure qualification for production welds on steel castings(Part 1)

KTA 3211.1

Page 94


Metallographic examinations withphotographic documentation

a) MacrographTo be evaluated: Weld buildup, penetration, slag, pores.Requirements: Satisfactory weld buildup, satisfactory penetration;

isolated slag inclusions and pores are permitted.

b) Micrograph, magnification at least 100 : 1 (not required for unalloyed steels).To be evaluated: Microstructure.For austenite, delta ferrite content in the weld metal shall additionally be determined.Requirement: A ferrite content of 4 to 10 % should be targeted; a closed lattice

structure is not permitted.

HV 10 hardness test(DIN EN ISO 6507-1)

as per SEW 110

Verification of intergranularcorrosion resistance(DIN EN ISO 3651-2)

Austenitic steelsSpecimen location: root side without additional sensitization.Requirement: freedom from cracks.

Table C-1: Extent of examination and stipulations for welding procedure qualification for production welds on steel castings(Part 2)

Steel group Tensile strengthRm in N/mm2

Bending mandreldiameter

Bend anglein degrees

Allowable deviation

Rm < 430 2 ⋅ a 180Ferritic andmartensiticsteels 430 ≤ Rm < 460 2.5 ⋅ a 180

Cracks shall not be longer than 1.6 mm.Bursting open due to pores or lack of fusionare permitted.

Rm ≥ 460 3 ⋅ a 180

Austeniticsteels

3 ⋅ a 180

As for ferritic and martensitic steels withRm < 460 N/mm2, but in addition:- If the specimen breaks at a bend angle

≥ 90°, the elongation of the gauge length(L0 = weld width + wall thickness) shallreach the minimum value of elongation atfracture A of the base metal.

- If the specimen breaks at a bend angle< 90°, the elongation over the weld widthshall reach at least 30 %. The fracturesurface appearance shall be free ofdefects.

Table C-2: Bending-mandrel diameter for the technological bend test to DIN EN 910 in connection with welding procedurequalification for production welds on cast steel

±0.3 ±0.3

d) only if b) is not feasibleHAZ or transition

a) Specimen location in theweld metal

c) Specimen location in the

b) Specimen location in the

0.50.5

HAZ or transition

Figure C-1: Location of the notch in notched-bar impact bend-test specimens

KTA 3211.1

Page 95


Non-destructiveexaminations

100 % surface-crack detection100% volumetric examination, examination procedure and requirements as per the stipulations forthe base metal.

Tensile test(DIN EN 895,DIN EN 10 002-1 andDIN EN 10 002-5)

a) Welded joint (DIN EN 895)2 specimens (DIN EN 895, Figure 2a or 2b, parallel length Lc = weld width + at least 60 mm)at room temperature.

Rm and fracture location shall be tested (tensile-strength requirement as for the base metal).

b) All-weld metal (DIN EN 10 002-1 and DIN EN 10 002-5)1 specimen (DIN 50 125, L0 = 5 ⋅ d0) at room temperature and design temperature 1).Requirements for Rp0.2, Rm, A, Z, as well as Rp1.0 for austenite, stipulated as for the weldabilitytest.

Notched-bar impactbend test(DIN EN 10 045-1)on Charpy-Vspecimens

Ferritic steels of material group W IOne specimen set each of weld metal and heat-affected zone at 0 °C and at the lowest loadingtemperature or at 33 °C, if correlation with a particular component is not possible.Specimen location per Figure C-1.See clause 4.3.1 for requirements. If the temperature at which 68 J (smallest individual value) and0.9 mm lateral expansion (smallest individual value) is reached lies between 0 °C and 33 °C, theexact value of this temperature may be determined by interpolation and used as the lowestpermissible loading temperature.If the requirement for minimum values of energy absorbed and lateral expansion at the lowestoperating temperature is already met at 0 °C, the test at higher temperature is not required.The ductile fracture percentage of the fractured area shall be determined.

Ferritic steels of material group W IIOne specimen set each of weld metal and heat-affected zone at 0 °C or at 20 °C, if the lowestloading temperature exceeds 20 °C.Specimen location as per Figure C-1.See clause 4.3.2 for requirements.The ductile fracture percentage of the fractured area shall be determined.

Austenitic steelsOne specimen set each of weld metal and heat-affected zone at room temperature.Specimen location as per Figure C-1.See clause 4.3.3 for requirements.

Martensitic steelsOne specimen set each of weld metal and heat-affected zone at room temperature.Specimen location as per Figure C-1.Requirements as for the base metal.

Metallographicexaminations withphotographicdocumentation

a) MacrographTo be evaluated: Weld buildup, penetration, slag, pores.Requirements: Satisfactory weld buildup, satisfactory penetration;

isolated slag inclusions and pores are permitted.

b) Micrograph, magnification at least 100 : 1 (not required for unalloyed steels).To be evaluated: Microstructure.For austenite, delta ferrite content in the weld metal shall additionally be determined.Requirement: A ferrite content of 4 to 10 % should be targeted; a closed lattice structure

is not permitted.

HV 10 hardness test(DIN EN ISO 6507-1)

Ferritic steelsOne hardness profile through base metal, heat-affected zone and weld metal, as close as possibleunder the surface.Requirement: 350 HV 10 shall not be exceeded.

Verification ofintergranularcorrosion resistance(DIN EN ISO 3651-2)

Austenitic steelsSpecimen location: root side without additional sensitization.Requirement: freedom from cracks.

1) The elevated-temperature tensile test shall be required if the operating temperature is higher than 200 °C (test groups A 1 and A 2) orhigher than 300 °C (test group A 3). In these cases, the elevated-temperature tensile test shall be performed at 350 °C for ferritic steels, at400 °C for austenitic steels and at 320 °C for martensitic steels.

Table C-3: Extent of examination and stipulations for production control tests for production welds on steel castings

KTA 3211.1

Page 96

Annex D

Procedure for determining the delta ferrite content

D 1 General

This annex specifies details for the procedures required for thedetermination of the products’ delta ferrite content under Sec.4.4.6.8 (1).

D 2 Metallographic determination on castings in theas-delivered condition

(1) A test specimen shall be taken from the product at thespecified sampling location, be ground and polished in theusual way and etched in accordance with Murakami [4]. Theetched surface shall have an area of at least 10 mm by10 mm.

(2) The evaluation shall be performed at a magnification of100:1.

(3) A representative location of the etched surface shall bedocumented as photograph at a magnification of 100:1.

(4) With regard to the quantitative evaluation it is recom-mended to compare the micrograph with a correspondingdelta ferrite reference sheet and classify it accordingly.Alternatively, the procedure of a quantitative microstructureanalysis may be employed.

(5) The test report shall state:

a) the shape, size and direction of the test specimen as wellas the sampling location,

b) the heat treatment condition,

c) the delta ferrite content in %.

A micrograph shall be contained in the test report.

D 3 Metallographic analysis of the bead-on-plate testspecimen

(1) A test specimen of the following size shall be taken fromthe product form at the specified sampling location:

length 200 mm, thickness 25 mm, width 40 mm.

(2) A melt run with a length of at least 180 mm shall bedeposited on the test specimen with a TIG burner without weldfiller metals, using the following weld parameters (guidancevalues):

voltage about 20 V,

current about 160 A,

feed rate about 20 cm/min.

(3) In the case of product forms that do not allow taking oftest specimens with a size as specified under (1) and wherethe weld parameters as specified under (2) cannot be applied,the specimen shape and heat input shall be adjusted asclosely as possible to the welding to be performed later on theproduct.

(4) A disc shall be taken from the middle of the melt runperpendicular to the surface of the test specimen and to theweld run axis; one side of this cross-section shall be groundand polished in the usual way and etched in accordance withMurakami [4].


(6) A representative location of the surface-deposited weldzone on the etched surface shall be documented asphotograph at a magnification of 1000:1.

(7) With regard to the quantitative evaluation it is recom-mended to compare the micrograph with a correspondingdelta ferrite reference sheet [5] and classify it accordingly.Alternatively, the procedure of a quantitative microstructureanalysis may be employed.


a) the shape, size and direction of the test specimen as wellas the sampling location,

b) the actual values of the welding parameters,


A micrograph with a specification of its location shall be addedto the test report.

D 4 Metallographic determination for weld material(during the procedure qualification and productionweld test for weldings on castings) production

(1) A slice through the entire cross-section shall be takenfrom the weld. For the metallographic examination, the sliceshall be ground and polished for on one side in the usual way,as well as etched in accordance with Murakami [4].

(2) An overall photograph shall be taken of the entire weldcross section.


(4) With regard to the quantitative evaluation it is recommen-ded to compare the micrograph with a corresponding deltaferrite reference sheet [5] and classify it accordingly.Alternatively, the procedure of a quantitative microstructureanalysis may be employed.

(5) Micrographs at a magnification of 1000:1 shall be madeof at least three zones representative of the delta ferritecontent.


a) the sampling location,

b) the heat treatment condition,


(7) The overall photograph as per (2) and the micrographsas per (5) shall be attached to the test report. The location ofthe zones as per (5) shall be marked in the overallphotograph.

D 5 Mathematical estimation according to De Long

Note:Figure D-1 in accordance with De Long [4] is used for the mathe-matical estimation of the delta ferrite content of the base metalmolten during welding as well as of the weld material. In this graphthe delta ferrite content is shown in relation to the chemicalcomposition, however, not in terms of its volumetric ratio but ratheron the basis of a special calibration (cf. DIN 32 514-1), in terms ofthe characteristic "ferrite number (FN)". In the range of small ferritenumbers up to FN 7, the ferrite number is identical to the deltaferrite content in %.

(1) The nickel equivalent NiE shall be calculated from thechemical composition of the base metal according to theequation

NiE = % Ni + 30 ⋅ (% C + % N) + 0.5 ⋅ % Mn (D 5-1)

and the chrome equivalent CrE according to the equation

CrE = % Cr + % Mo + 1.5 ⋅ % Si + 0.5 ⋅ % Nb (D 5-2)

KTA 3211.1

Page 97

(2) The calculated values of the nickel equivalent andchrome equivalent are the coordinates of a point in FigureD-1. The corresponding ferrite number is read from the graph.Where required, the values can be interpolated between thestraight lines of constant ferrite numbers.

(3) The documentation of the mathematical estimation shallcontain the following::

a) the chemical composition of the base metal,

b) the value of the nickel equivalent,

c) the value of the chrome equivalent,

d) the delta ferrite content in terms of the ferrite number.

0

1012

2

86

4

1618

14

Martensite

Austenite and

E

E

2221 23 25242016

10

17 1918

Austenite and Ferrite

20

SchäfflerFerrite

no.Austenite

18

26 27

12

16

14

Nic

kele

quiv

alen

tN

i

Chrome equivalent Cr

Figure D-1: Relationship between chemical composition andferrite numbers of molten base metal or weldmaterial (according to W.T. De Long [4])

KTA 3211.1

Page 98

Annex E

Non-destructive examinations of heat-exchanger tubes

E 1 Scope of application

This Annex shall apply to non-destructive examinations ofheat-exchanger tubes.

E 2 Type, extent and point of time of non-destructiveexaminations

Each tube shall be examined over its entire length and fullcross section. The type, extent and point of time of non-destructive examinations can be found in Table E-1.

E 3 Eddy-current examination

E 3.1 Method-related prerequisites

E 3.1.1 General

The eddy-current examination shall be performed to DIN54 141-3 in combination with the particulars of the followingSections.

E 3.1.2 Examination system

Encircling pass-through coils operating by the differentialmethod shall be employed for the examination. The tubesshall pass concentrically through the examination coils. Thecoils shall be constructed such that optimum resolution isachieved at the chosen examination frequency. The value ofthe amplitude of the signals caused by indications shall beevaluated.

E 3.1.3 Examination frequency

(1) To define appropriate examination frequencies as afunction of material, tube size and fabrication condition, sharp-edged notches with a length of 20 mm, a width of smaller thanor equal to 0.5 mm and a depth of less than or equal to 20 %of the nominal thickness but at least 0.15 mm shall be madeon the outside and inside in the longitudinal axis of the tube.

(2) For tubes of austenitic steels, the examinationfrequencies shall range from 10 to 50 kHz for wall thicknessesequal to or smaller than 1 mm and from 7 to 20 kHz for wallthicknesses larger than 1 mm and up to and including 2 mm.

(3) The notches shall be made such that they do not causeperceptible changes of the microstructural characteristics ofthe material.

(4) The geometry, shape and dimension of the notches shallbe verified.

(5) The examination frequency shall be selected such thatthe internal notch is verified with optimum signal-to-noise ratio.

(6) The examination parameters employed shall be logged.

E 3.1.4 Examination sensitivity

(1) If the theoretical load factor of the tube wall is equal to orsmaller than 30 %, examination sensitivity II to Figure E-1shall be employed. Otherwise examination sensitivity I shall berequired.

(2) The required examination sensitivity shall be specified inthe purchase order.

(3) Test tubes with identical examination-related charac-teristics and the same dimensions as the tubes to be

examined shall be used to set the examination sensitivity.Three holes separated by 120 degrees and having 0.8 mmdiameter shall be drilled in these tubes. The spacing of holesin the longitudinal direction of the tube should be sufficientlylarge that the holes yield separate and distinguishable signals.The smallest signal shall reach the response threshold of theindicating and recording instruments. The basic sensitivitysetting shall be made at the examination speed planned forthe examination, using the hole of 0.8 mm diameter. Thisbasic sensitivity setting shall be corrected by a tube-diameter-dependent dB value per Figure E-1.

+2

+1

+4

+3

20 30

0

10

+5

+12

+11

40+13

0

+6

+7

+8

+10

+9

dB

Tube outside diameter [ mm ]

Sensitivity II

Sensitivity I

Figure E-1: Sensitivity of the eddy-current examinationrelative to a hole diameter of 0.8 mm

E 3.2 Examination procedure and assessment of the results

E 3.2.1 Check of examination sensitivity

(1) Before the examination is started, the examination-sensitivity setting and the stability of the instrument settingsshall be verified by at least three passes of the test tube.

(2) After every 100 tubes examined, the examinationsensitivity shall be checked by another pass of the test tube. Ifa loss of more than 2 dB in examination sensitivity is noted,the examination shall be repeated on all tubes that wereexamined between the sensitivity setting to be corrected andthe preceding sensitivity setting.

E 3.2.2 Recording limits

All indications shall be recorded that reach or exceed thesignal amplitude of 0.8 mm diameter hole in accordance withclause E 3.1.4 (3), corrected by the diameter dependent dBvalue to Figure E-1.

KTA 3211.1

Page 99

E 3.2.3 Marking of indication sites

All sites on tubes with indications having amplitudes that reachor exceed the recording limit shall be marked with a colouredmarker.

E 3.2.4 Assessment of indications

(1) All tubes or tube sections with indications that reach orexceed the recording limit shall be sorted out.

(2) These tubes shall be repaired within the permissiblenominal thickness, after which they shall be subjected toanother examination. Indication sites on tubes that have beensorted out may be re-examined with a different non-destructive examination method (e.g., visual inspection,radiographic examination) for observation of defect type andsize. Verification that the indications are not objectionableshall be required.

E 4 Ultrasonic examination

E 4.2 Method-related prerequisites

E 4.1.1 General

An examination for longitudinal and transverse defects shallbe performed to SEP 1915 and SEP 1918. The stipulations inthe following sections shall apply in addition.

E 4.1.2 Reference reflectors

(1) Sharp-edged 60-degree V-notches or rectangularnotches made on the outside and inside surfaces shall beused as reference reflectors. The notch depth shall be at least10 % of the nominal thickness or at least 0.1 mm, with anallowable deviation of ± 20 µm.

(2) The length of the reference reflectors shall be matched tothe transducer size, but shall not exceed 10 mm. Thereference reflector for the transverse-defect examination maybe of circumferential nature if the effective transducer widthdoes not exceed 10 mm. Circular-segment notches with adepth of 20 % of nominal thickness but at least 0.2 mm mayalso be used on the tube outside for the transverse-defect

examination. The geometry, shape and size of the referencereflector shall be verified.

E 4.2 Examination procedure and assessment of the results

E 4.2.1 Check of examination sensitivity

(1) Before the examination is started, the examinationsensitivity and instrument stability shall be verified by severalpasses of the test tube.

(2) After every 2 hours, the examination sensitivity shall bechecked by another pass of the test tube. If a loss of morethan 2 dB in examination sensitivity is noted, the examinationshall be repeated on all tubes that were examined betweenthe sensitivity setting to be corrected and the precedingsensitivity setting.

E 4.2.2 Recording limits

(1) All indications shall be recorded that reach or exceed thereference echo amplitude.

(2) The reference echo amplitude is the echo amplitude of thereference reflectors to clause E 4.1.2.

E 4.2.3 Marking of indication sites

All sites on tubes with indications having amplitudes that reachor exceed the recording limit shall be marked with a colouredmarker.

E 4.2.4 Assessment of indications

(1) All tubes or tube sections with indications that reach orexceed the recording limit shall be sorted out.

(2) These tubes shall be repaired within the allowablenominal thickness, after which they shall be subjected toanother examination. Indication sites on tubes that have beensorted out may be re-examined with a different non-destructive examination method (e.g., visual inspection,radiographic examination) for observation of defect type andsize. Verification that the indications are not objectionableshall be required.

Type of tubes Extent of examinationin %

Examination method

Manufacture/material

Examinationpoint of time

Nominalthickness

in mm

Diameterin mm

H S US WS

X 4) XLongitudinally welded austenitictubes, stretch-reduced by rolldrawing 1)

As-deliveredcondition 2) ≤ 2 ≤ 38

alternatively

Longitudinally welded austenitictubes, sized

As-deliveredcondition

≤ 2 ≤ 38 X

Seamless tubes of austenitic orferritic steels


≤ 2 ≤ 42.4 X

Seamless tubes of austenitic orferritic steels


> 2 ≤ 3.6

≤ 42.4

100 St. 3)

X

1) Total deformation > 20 %2) Straight tube in final condition3) St. : spot check of examination system4) As an alternative, eddy-current examination with examination sensitivity II instead of US transverse-defect examination.

H : ManufacturerS : Authorized inspectorUS : Ultrasonic examinationWS : Eddy current examination

Table E-1: Extent of examination and examination methods

KTA 3211.1

Page 100

Annex F

Performance of manual ultrasonic examinations

(The wording of this Annex is identical in safety standards KTA 3201.1, KTA 3201.3, KTA 3211.1 and KTA 3211.3.)

F 1 General requirements

(1) This Annex covers the performance of manual non-destructive examinations.

(2) In this Annex, stipulations have been laid down for thecalibration of ultrasonic equipment for the pulse-echo methodwith reflectors or through-transmission and for the descriptionof indications.

F 2 Definitions, symbols, formulae

F 2.1 Definitions

The definitions of DIN 54 119 apply.

F 2.2 Symbols

In this Annex the following symbols are used:

Symbol Variable or designation Unit

A Scan path related to near field length inthe general DGS diagram

a, a’ Projected surface distance mm

AVG Distance / gain / size C Sound beam width, referred to dB echo

amplitude decreasemm

D0 Transducer dimension mm

Deff Effective transducer dimension mm

Dk Diameter of round bottom hole mm

DKSR Diameter of circular disk reflector mm

Dz Diameter of cylindrical bore mm

DS Beam diameter, referred to db echoamplitude decrease

mm

d Curvature diameter of test object mm

dref Curvature diameter of opposite face mm

∆f Band width (difference between upperand lower base frequency) referred to3 dB amplitude decrease

MHz

fN Nominal frequency MHz

G Reflector diameter referred to effectivetransducer diameter

GK Instrument gain when setting the refe-rence reflector for screen height level

dB

GT Instrument gain when setting thetransmission indication for screenheight level

dB

TG Arithmetical average of GT values dB

GR Instrument gain setting for recordinglimit

dB

γ6 Beam spread angle for 6 dB limit degree

H Echo amplitude referred to screenheight

HE Main echo

Symbol Variable or designation Unit

No. 1 Calibration block to DIN EN 12 223 No. 2 Calibration block to DIN EN 27 963 KSR Dimension of circular disk reflector mm

κ Sound attenuation coefficient (deviatingfrom DIN 54 119; sound attenuationreferred to sound path)

dB/mm

L Search unit dimension in direction ofcurvature

mm

λ Ultrasonic wave length mm

N Near field length NE1; NE2 Spurious echoes from wave mode

conversion

n Number of individually measuredvalues

p Projected surface distance for doubletraverse

mm

Ra Average roughness to DIN EN ISO 4287 µm

RL Recording length mm

RLK Corrected recording length mm

S Sound path (distance betweentransducer and reflector)

mm

S1 Sound path in reference block mm

S2 Sound path in component mm

SE Transmitter - receiver SEL Transmitter-receiver longitudinal waves s Wall thickness mm

sj Thickness of calibration block mm

V Gain in the general DGS diagram dB

∆V Sensitivity correction dB

∆Vκ Sound attenuation correction referredto a certain sound path

dB

∆Vkoppl Coupling correction dB

∆VS Beam spread correction of backreflection curve

dB

∆V~ Corrected gain for considering transfervariations

dB

∆VT Transfer correction dB

F 2.3 Formulae

The variables to be calculated shall be determined by meansof the following formulae:

a) The beam width C referred to a 20 dB echo amplitudedecrease:

0DS

2C ⋅λ⋅= (F-1)

KTA 3211.1

Page 101

b) Conversion of side-drilled hole echo amplitudes to circulardisk reflector echo amplitudes:

SD2

D ZKSR ⋅⋅λ⋅π

= , (F-2)

where S > 0.7 ⋅ N and DZ > 1.5 ⋅ λ.

c) Conversion of round bottom hole echo amplitudes tocircular disk reflector echo amplitude:

kKSR DD ⋅πλ= , (F-3)

where S > 0.7 ⋅ N and Dk > 1.5 ⋅ λ.

d) The beam diameter DS referred to a 6 dB echo amplitudedecrease:DS = 2 ⋅ S ⋅ tan γ6, (F-4)

e) Average value of instrument gain setting TG :

GG

nsum of ind

TT= =∑ ividual values

number of individual values, (F-5)

f) Corrected recording length RLK:

R R DDRLK L S

S

L= − ⋅ −

1 (F-6)

g) Sound path without lateral wall influence

λ⋅⋅=2Ds

S eff (F-7)

h) Corrected gain ∆V∼:

( )1n

Gn1

G7.1~V

2T

2T

−

⋅−⋅=∆

∑ ∑(F-8)

or

( )1n

GG7.1~V

2TT

−

−⋅=∆ ∑ (F-9)

i) Sensitivity correction ∆V:

1

2

SS

lg30V ⋅=∆ (F-10)

F 3 General requirements

F 3.1 Performance of examination

(1) For the calibration and examination the same couplantshall be used. Only such couplants shall be used which do notdamage the object (e.g. corrosion). Upon examination, allcouplant residues shall be removed from the test object.

(2) Test object, reference block and search units shallapproximately have the same temperature.

(3) When setting the sensitivity level and during theexamination only the gain control, but no other control element(e.g. for frequency range, pulse energy, resolution, thresholdvalue) shall be adjusted. A threshold value may only be usedin exceptional justified cases.

(4) Prior to the examination, the sensitivity level and rangeadjustments shall be made after the warm-up periods given bythe instrument manufacturer. Both adjustments shall bechecked at suitable intervals. Where in this check cleardeviations from the check made before are found, allexaminations performed after that check shall be repeatedwith a corrected adjustment.

(5) The nominal frequency shall be within a range of 1 to6 MHz. The selection of the nominal frequencies and

transducer dimensions to be used in the examination shall bebased both on the required sensitivity level (recording limit) forthe volume areas to be examined and the geometry of the part(sound path). In general, a frequency of 4 MHz shall be usedfor wall thicknesses ≤ 40 mm, and a frequency of 2 MHz forwall thicknesses > 40 mm.

(6) In the case of curved examination surfaces the searchunit probe shall be located with the probe index on the centreof the surface. At no point shall the probe shoes have adistance greater than 0.5 to the examination surface. Wherethe distance is greater, the probe shall be ground. This is thecase if L2 exceeds 2 x d.

(7) The use of auxiliary means for determining the echoamplitude (e.g. scales) is permitted if it is ensured that anevaluation as per F 4 is performed.

F 3.2 Test equipment

(1) The test equipment and accessories used including therequired auxiliary means shall show sufficient accuracy andstability for the intended use.

(2) The combination of equipment, cables and search unitsof various manufacturers is permitted if it is ensured (e.g. bymeasurements on reference reflectors) that the exactness ofresults is not affected.

F 3.3 Test object

(1) The test surfaces shall be free from discontinuities andimpurities (e.g. notches, scale, weld spatter, tool marks).

(2) Where an opposite face is used as reflecting surface itshall meet the same requirements as the test surface.

(3) The test surfaces‘ waviness shall be so little that theprobe shoe surface has sufficient contact. This is generally thecase if the distance between probe shoe surface and testsurface does not exceed 0.5 mm at any point.

F 3.4 Reference blocks and reference reflectors

(1) When using differing materials for search units and testobject the difference in sound velocity shall be into account forrange adjustment and for the angular deviation in case ofangle beam scanning.

(2) When calibration blocks No. 1 or No. 2 are not used forcalibration the following applies:

a) to the calibration block used:

aa) The sound beam shall not be impaired in itsdevelopment, i.e. all dimensions vertical to the mainbeam path for sound paths up to 2 x N shall be greaterthan the transducer dimension and for greater soundpaths exceed the beam width C.

ab) The dimensions of the coupling surface shall exceed1.5 times the effective probe shoe dimension.

ac) The location of the reference reflectors in thereference block shall be selected such that thereference echoes do no interfere with each other andcannot be confused with corner echoes.

ad) Claddings on the reference block shall be provided iftheir acoustic properties on the test object need not betaken into account.

b) to the calibration reflector used:

ba) the back walls shall be plane and vertical to the mainbeam as well as have dimensions exceeding the beamwidth C, but not less than the transducer dimension.

KTA 3211.1

Page 102

bb) Side-drilled holes shall be vertical to the main beamand parallel to the coupling surface. The lengths of theside-drilled holes shall be greater than the soundbeam width C, but not less than the transducerdimension. The diameter shall generally be 3 mm.

bc) The bottom of flat bottom holes shall be vertical to themain beam when applying the single-probe technique.

bd) Round bottom holes shall be oriented such that thedirections of hole axis and main beam deviate fromeach other as little as possible.

be) Rectangular notches shall be vertical (transverse) tothe main beam and the notch edges be vertical to thesurface. The notches shall have a rectangular cross-section, a width ≤ 10 mm and, if not specified for therespective product form, have a depth of 1.0 mm. Thelength of rectangular notches shall exceed the beamwidth C, but not be less than the transducerdimension.

bf) Where the echo amplitudes of side-drilled and roundbottom holes are to be converted to echo amplitudesof circular disk reflectors, the formulas (F-2) and (F-3)shall be considered additionally.

F 4 Calibration of test systems

F 4.1 Range adjustment

(1) The range shall be calibrated on the test object, thecalibration block No. 1, the calibration block No. 2 or on similarcalibration blocks.

(2) For longitudinal wave search units a calibration block(e.g. to Figure F-1) shall be used.

Two methods may be used

a) range calibration using a straight beam search unit on thetest object or on the calibration block and subsequentpulse zero-point correction with an angle beam search unit(delay path),

b) calibration on two far-distant holes.

In each case an advance calibration should be made oncalibration block No. 1 or No. 2 with a straight beam searchunit.

Note:This procedure is required due to the transverse wave portionoccurring under another beam angle.

F 4.2 Application of the DGS method

F 4.2.1 Criteria for the application of the DGS method

The following criteria apply:

a) Echoes shall not be influenced by the original pulse.

b) The sound path to be evaluated begins, for transceiverprobes, at S = 0.7 x N and for dual crystal search units atthe beginning of the focal area.

c) In the case of a lateral wall effect the DGS method mayonly be used up to the beam path given in Section F 2.3,formula (F-7).

d) In the case of angle-beam scanning the DGS method canonly be applied for wall thicknesses exceeding 5 x λ

e) Where probe-specific DGS diagrams are not available, aspecific diagram for the respective probe may be derivedfrom the general diagram (Figure F-2) where data on thenear field length are available.

f) In the case of highly attenuated search units the DGSmethod may only be used if the ratio of the band width (∆f)to the nominal frequency is less than 0.75.

<

≤

<

<

<

≥

>

≤

≥

≥

≤

≤

≥

≤

≥

≤

≥

≤

jj

j

j

j

j

jj

j

j

j

b =

b5

2

b

15

1

s

5s

10

b

s

s

1

sb =

s

1

10 15

c

b

s

b

Bore hole diameter = 3mm





10

c

b

s

1

20

c

b

s

b

b =s

s

s

3

b5

52

b5

5b

10

bb

b =

b5

b

80

c

5

b =

c

40

s

bb

s

40

20

10

10

s

4

s

s80

c

Figure F-1: Calibration blocks for sensitivity levelcalibration for angle beam scanning

g) For longitudinal wave dual angle beam search units andfocussing search units the DGS method shall not be used.

h) In the case of curved examination surfaces the conditionsof Table F-1 shall be satisfied for transceiver probes whenapplying the DGS method. Where the search units(probes) have to be adapted in accordance with clauseF 3.1 (7), the DGS method is applicable only if, in additionto the requirements of Table F-1, side-drilled, flat bottom

KTA 3211.1

Page 103

or round bottom holes in the test object or in a referenceblock (deviations from diameter a thickness 10 % atmaximum) are used as reference reflectors.

F 4.2.2 Reference reflectors to be used

(1) To generate a reference echo the following reflectorsshall be used unless back wall echoes can be generated fromthe test object:

a) calibration block No. 1 with a thickness of 25 mm andcalibration block No. 2 with a thickness of 12.5 mm,

b) calibration block No. 1 with a 100 mm arc of circle orcalibration block No. 2 with a 25 mm arc of circle if theprobe-specific correction factors (difference between theecho indications of the arc of a circle and plane back wall)are known or have been determined,

c) Side-drilled, flat bottom or round bottom holes.

(2) For the conversion of the echo amplitude of a side-drilledor round bottom bore into the echo amplitude of a circular diskreflector formulas (F-2) and (F-3) shall be used.

F 4.3 Adjustment of the sensitivity level by the referenceecho or DAC method

(1) In the reference echo method the indication from the testobject is directly compared to the reference reflector havingnearly the same sound path. This may be done with referencereflectors in the part or reference block.

(2) For comparison the reference reflector with the same ornext-longer sound path shall be used. In exceptional cases(e.g. for reflectors close to the opposite face) the referencereflector may be distanced from the opposite at a maximum of20 % of the wall thickness, but not to exceed 20 mm.(3) For simplifying the echo amplitude description it isrecommended to generate a DAC curve by means of one orseveral equal reflectors located at different depths in referenceblocks (e.g. step wedge or to Figure F-1) or by means ofreference reflectors in the test object located at differentdistances. Clause F 3.4.3 applies with regard to the require-ments for reference reflectors.

∞

5 6

G=0.10

10

G=0.3G=0.4

8

G=0.2

G=0.08

10040

G=

80

G=0.15

G=0.05

20 30

50

4

40

30

2 30.8 1

20

G=0.6G=0.8

0.5 50

0

10

60

G=1.0

KSR

effA = G =

V [ d

B ]

DDN

A

S

Figure F-2: Standard DGS Diagram

≥

Pos.3

3mm

Pos.1 Pos.2or

Pos.2

Pos.3

Bore hole diameter

Pos.1

Pos.1 Pos.2 Pos.3

Figure F-3: Generation of indications from side-drilled holeslocated at different positions

RR

Increased DAC curve( e.g. by 12 dB )

+ 12 dBG G

Figure F-4: Staged DAC curve

(4) The DAC curve shall be generated upon rangecalibration by at least three responses from the referencereflectors (e.g. side-drilled holes) in various positions (seeFigure F-3). The echo with the highest amplitude shall beadjusted for approximately 80 % of the screen height. Thecurve obtained may be extrapolated by a maximum of 20 %beyond the range limited by the reflector indications. The gainsetting of the equipment shall be selected such that the DACcurve is within the calibration range between 20 % and 100 %of the screen height. If this is not possible for the entirecalibration range, the gain shall be set as per Figure F-4.

F 4.4 Corrections of sensitivity level adjustment

F 4.4.1 Transfer correction

(1) The transfer correction shall be determined on at least 4points of the test object in the intended direction ofexamination.

(2) The transfer correction shall be determined in accor-dance with Figure F-5 by means of scanning on thecalibration beam and on the test object.

(3) To consider the general transfer correction in angle-beam scanning ∆VT with Vee or W path shall be used.

F 4.4.2 Sound attenuation correction

(1) The sound attenuation for straight-beam scanning shallbe determined as per Figure F-6 and for angle-beamscanning as per Figure F-7 in consideration of ∆VS.

(2) The determination of the sound attenuation may beomitted if it is considered by an allowance independent fromthe sound path (e.g. by a general transfer correction).

KTA 3211.1

Page 104

κκ1

1 2

21

2

2211

S

2S

40%

Calibration block ( )

S

S

2S

2S

S

40%

2S

Test object ( )

G dBT1 = . . . G dBT2 = . . .

∆ ∆ ∆ ∆V G G V V VT T T S koppl= − − = +2 1 κ

( )∆V S Sκ κ κ= ⋅ ⋅ − ⋅2 2 2 1 1

∆V V VS S S= −2 1

Figure F-5: Determination of transfer correction for straight-beam scanning or for angle-beam scanning withVee or W path

2

1

2

1

H

S STest object

H

S

( ) ( )κ =− −

⋅ −==

G G V

S SdB mm

G dBG dB

T T S T

T

2 1

2 1

1

22/

. . .. . .

Figure F-6: Determination of sound attenuation for straight-beam scanning

F 4.4.3 Coupling and sound attenuation variations

(1) For the transfer correction the average value of thescanning values obtained from the test object shall be used ifthe range of variation does not exceed 6 dB. Where the rangeexceeds 6 dB, the average value from 20 scanning valuesplus an allowance ~V∆ = 1.7 x standard deviations to be calcu-lated in accordance with clause F 2.3 (h) shall be used.

(2) Where the ~V∆ value thus determined is greater than6 dB, the test object shall be subdivided into sections wherethe transfer correction of each section shall be consideredseparately. This subdivision shall be such that in each section

~V∆ is equal to or smaller than 6 dB.

2

1 2

1

S

2S

W-pathV-path

40%

2S

S

40%

G dBT1 = . . . G dBT2 = . . .

( ) ( )κ =− −

⋅ −G G V

S SdB mmT T S2 1

2 12/

Figure F-7: Determination of sound attenuation for angle-beam scanning

∆∆

∆

∆∞

κ

κ κ

κ

κ0.4

1.0

0.8

Reference echo

1

2

0

10

50 500300

20

60

100

50

30

40

1000

0.2

200

0.6

2000

considerationof soundattanuation

Calibration block ( )

Circular diskreflector with

Vkorr

.V

V

Test object ( )

V

just

G

s

V[d

B]

V[d

B]

s

s [ mm ]

( ) [ ]∆V S S dBjustκ κ κ= ⋅ ⋅ − ⋅2 2 1

Figure F-8: Consideration of sound attenuation in the DGSdiagram for κ2 > κ1

F 4.4.4 Consideration of corrections

(1) Taking the aforementioned sensitivity level correctioninto account, the following recording limit is obtained for theequipment sensitivity

GR = GK + ∆VT + ∆V∼, (F-11)

where

∆VT = ∆Vkoppl + ∆Vκ (F-12)

(2) Where sound attenuation in dependence of the soundpath is taken into account this shall be made with theattenuation portion ∆Vκ contained in ∆VT as per Figure F-8

KTA 3211.1

Page 105

when using the DGS method or as per Figure F-9 when usingthe DAC method.

(3) If it is not necessary to consider the sound attenuation independence of the sound path, ∆VT shall contain a constantsound attenuation portion ∆Vκ independent of the sound path.

(4) Where an additional correction for considering greatervariations as per clause F 4.4.3 is required, this shall be doneby means of ~V∆ . Otherwise, the correction value in theabove equation shall be omitted.

∆κ

V

DAC curve upon

Transferred orset-up DAC curve

sound attenuation correction

( ) [ ]∆V S dBκ κ κ= ⋅ ⋅ −2 2 1

Figure F-9: Consideration of sound attenuation for the DACmethod for the case κ2 > κ1

F 4.5 Setting of instrument gain

Taking the coupling and attenuation losses into account theinstrument gain shall be adjusted such that the recording limitfor the respective calibration range attains at least 20 % of thescreen height.

F 5 Description of indications

F 5.1 Echo amplitude

The maximum echo amplitude of a reflector referred to therespective valid recording limit is to be indicated in dB.

Note:The reproduceability of the echo amplitude determination isgenerally ± 3 dB.

F 5.2 Extension of reflectors

F 5.2.1 General requirements

Recording lengths equal to or greater than 10 mm shall bemeasured. The measured lengths shall be given as integralmultiple rounded up or down to 5 mm (e.g. 10, 15, 20 etc.).Shorter recording lengths shall be recorded as „< 10“.

F 5.2.2 Determination of the recording length

The extension of reflector (see Figure F-10) shall be given bythe search unit displacement range. This range is determinedas the distance between locations where the echo amplitudeis lower by either 0 dB, 6 dB or 12 dB. Where the noise levellimit is reached, the recording length shall be documented asthe distance between the points where the signal disappearsin the noise level.

F 5.2.3 Determination of half-amplitude and quarter-amplitude length

When measuring the half-amplitude or quarter-amplitude lengthof reflectors, the search unit displacements at echo amplitudedecreases of 6 dB or 12 dB compared to the maximum echoamplitude shall be determined. Here, for dual search units theacoustic separating line and for line focussing search units theline focus shall be vertical to the reflector direction of extension.

12dB

Recording length

Recording limit

6dB

displacement

displacementRecording length

Search unit

Search unit

Recording limit

Ech

oam

plitu

deE

cho

ampl

itude

Reflector

Search unit

Ech

oam

plitu

de

Recording length

Recording limit

Search unitdisplacement

Figure F-10: Determination of recording length

F 5.2.4 Methods for the exact determination of reflectorextension

(1) The determination of the reflector extension may beoptimized by one of the following additional corrections orexaminations if this measurement alone is decisive for theassessment of the acceptability of an indication.

(2) The reflector shall be measured from the scan position orangle of incidence at which the scan path shows the slightestdeviation from 1.0 x near field length however is greater than0.7 x near field length. In such a case, another frequency thanthat for generating the maximum echo amplitude may be used.

(3) The beam diameter shall be determined at the reflectorlocation. If the measured length exceeds this measured beamdiameter the recording length shall be the corrected recordinglength calculated as per formula (F-6).

(4) The beam diameter shall be determined by calculation orexperimental analysis. It may be calculated according toformula (F-4) if non-adapted search units are used.

(5) In the case of angle beam scanning the horizontalincluded angle shall be inserted for γ6. The included angleshall be taken from the data sheets on the search units used.

(6) Where the included angle has to be determined byexperimental analysis, measurements shall be made on areference block to correspond to the test object.

KTA 3211.1

Page 106

(7) To this end, reference reflectors shall be bored into thisreference block at the same depth location like for theindication to be corrected. As reference reflector a cylindricalhole or flat bottom hole of 3 mm diameter or a round bottomhole with a diameter exceeding 1.5 x λ may be suited.

(8) The half-amplitude length shall be determined on thereference reflector on the same sound path as for the reflectorto be corrected. The value determined such shall correspondto the beam diameter at the respective depth of indication.

(9) By means of suitable dual search units or focused beamsearch units the reflector shall be measured in the focal areaand be evaluated as follows:

a) Where the difference between the quarter-amplitude andhalf-amplitude length is ≤ 1.5 times the beam diameter, thehalf-amplitude length shall be the recording length.

b) Where the difference between the quarter-amplitude andhalf-amplitude length exceeds 1.5 times the beam

diameter, the quarter-amplitude length minus the beamdiameter shall be the recording length.

c) Where the half-amplitude length is smaller than the beamdiameter, the beam diameter or the focal width at thedepth location shall be the recording length.

(10) In a measurement of lengths with focused beam searchunits several echo volumes shall be recorded to increase themeasuring accuracy and to improve the reproduceability on agrid pattern. The grid-line distances should be smaller than thediameter of the focusing beam. A typical set-up of measuringequipment to record echo volumes is shown in Figure F-11.

F 5.2.5 Determination of depth extension

Note:Stipulations in course of preparation.

Search unit guiding mechanism ( schematic )

Noise

Signal Signal

Ultrasonic instrument

Monitor

Distance of adjacent ( Puls amplitude )

Rotary potentiometer with

Reflector

friction-wheel drive

Echo

am

plitu

de

Displacement

Search unit

grid lines of grid pattern

Figure F-11: Set-up of measuring equipment when using focused-beam search units for measuring reflector extensions

Classification as to geometry Type of scanning Range of application

Straight-beam, radial d > 5 ⋅ N

angle-beam, axial and incircumferential direction

d > 2.5 ⋅ NEvaluation up to p/2

Straight-beam, radial d > 5 ⋅ N

Straight-beam, axial and incurcumferential direction

d > 2.5 ⋅ N for evaluation up to p/2;dref > 10 ⋅ N for evaluation beyond p/2

Straight-beam, in thicknessdirection

d > 10 ⋅ N

angle-beam, tangentiallyd > 5 ⋅ N for evaluation up to p/2;dref > 20 ⋅ N for evaluation beyond p/2

Table F-1: Range of application of DGS method for transceiver probe techniques

Curved-surface full material (e.g. bars)

Concentric, uniaxial curved surface(e.g. pipes)

Concentric, biaxial curved surface (e.g.dished heads, tube-sheets)

KTA 3211.1

Page 107

F 5.3 Structural discontinuities

(1) Where indications from the root area of a weld are to beclassified as geometric discontinuities, control measurementsshall be made to determine the cause of indication.

(2) If it is to be proved that the echos reflected from the twoweld sides arise on the two flanks of the excess penetrationand are not caused by weld defects, the control measurementshall be made by measuring the projected-surface distance onthe test piece. The exact projected-surface distances shall bedetermined on rectangular notches with a depth and width of 1mm each on a reference block (see Figure F-12). Where it isfound out that the projected-surface distances of the respec-tive indications clearly overlaps [(2a - a’) equal to or greaterthan 2 mm], the echo amplitudes are considered to be causedby geometric discontinuities. Where a smaller distance than2 mm is found, the reflectors shall no more be treatedseparately.

F 6 Creeping wave method

F 6.1 Description of method

(1) Longitudinal wave probes with usual angles of incidenceof 75 to 80 degrees generate additionally to the longitudinalmain wave a longitudinal wave propagating in parallel to theexamination surface (primary creeping waves).

(2) By the propagation of the creeping wave along theexamination face transverse waves are permanently radiatedso that the intensity of the creeping wave rapidly decreaseswith the sound path. In the case of creeping wave twin probeswith transducer dimensions of e.g. D0 ≈ 6 x 13 mm2 the focaldistance will be approximately 10 mm.

(3) Where, for geometric reasons, the creeping wave will dipinto the volume, e.g. in the case of attachment welds, it willpropagate as normal longitudinal wave without radiation. Thisleads to greater usable sound paths of 30 mm toapproximately 50 mm.

F 6.2 Reference blocks

(1) For the calibration of creeping wave probes the referenceblocks as shown in Figure F-13 shall be taken.

(2) When examining with adapted probes, the curvatures ofthe examination faces of the reference block and the testobject shall match, if possible.

′ ≥

′

ss

a 3 mm

1

a

2a -

a

a

1

a

Figure F-12: Proof of indications cause by structural disconti-nuities from the root area of single-side welds

Section A-A

∅3

≈ 15

1.5

≈ 45°

≈ 25

≈5

≈ 45

≈ 35

≈12

5

≈50

≈25

≈10

0

≈75

≈ 70

>10

≈ 150

of the flat bottom hole indications

Flat bottom holes

The recording limit corresponds to the echo height

∅ 3 mm

AA

Figure F-13: Reference block and recording limit for thecalibration of creeping wave probes

F 6.3 Adjustment of sensitivity

For the examination area a DAC curve shall be generated tomeet the requirements of Section F 4.3 by means of scanningthe respective reference reflectors in the reference blocks inaccordance with Section F 6.2.

F 6.4 Adaptation of probes

(1) When examining on convex curved examination faceswith d equal to or greater than L2/2 , the adaption of theprobes may be waived.

(2) In the case of examination faces with L2/3 ≤ d < L2/2 anadaptation by shaped refracting prisms (wedges) or byshaping of the probe shoe is permitted.

(3) In the case of examination faces with d < L2/3 speciallydesigned probes shall be used.

F 7 Wave mode conversion method

F 7.1 Description of method

(1) When transverse waves hit an opposite face at an angleof approximately 31 degrees, a longitudinal wave (secondarycreeping wave) is generated which is nearly parallel to thesurface (Figure F-14). The angle of incidence of 31 degrees isobtained, in the case of plane-parallel test objects, by the

KTA 3211.1

Page 108

accompanying transverse wave of a 70-degree longitudinalprobe.

(2) Due to its scattered propagation the secondary creepingwave is e.g. used to examine the root area of a welded jointwithout being influenced by the excess penetration (FigureF-15). In this case it shall be taken into account that theintensity of the secondary creeping wave will rapidly decreasewith the sound path subject to the permanent radiation oftransverse waves.

(3) During scanning with the longitudinal wave probe onplane-parallel test objects a sequence of echoes is generatedthe individual echoes of which are called NE 1 and NE 2(Figure F-16). For the detection of reflectors the echo NE 2 isused. The echo NE 1 may be used for reflector depthestimation.

(4) When scanning thin test objects (8 mm < s ≤ 20 mm) withthe longitudinal wave probe (Type 70 degree SEL) an echoamplitude is generated which contains both the longitudinalwave portion (main echo-HE) and the converted transversewave portion (sequence of secondary echoes-NE) (FigureF-17).

Note:Spurious echoes may be generated due to the transverse wavegenerated simultaneously with the beam entry into the test object,since the transverse wave entering at a very steep angle is highlysensitive to irregularities of the probe-remote surface, such asgauge marks, identification markings, etc. and reacts to deviationsfrom shape. Therefore, it is especially important to- consider the probe position in relation to the centre of the

welded joint,- know the sound velocities and the related angle of incidence of

the transverse wave,- know the various echo dynamics.

When exactly allocating the indication to the welded joint andconsidering the fact that a reflector has a great dynamic effectwhen being scanned with longitudinal waves - contrary to theaccompanying transverse wave of approx. 31 degrees- a distinc-tion between such spurious echoes and real defects is possible.

Scanning with secondary creeping waves in accordance withsubpara (2) and (3) is purposeful beginning with a wall thickness> 15 mm. In the case of wall thicknesses 8 mm < s ≤ 20 mm theexamination shall be performed with longitudinal wave probes(Type 70 degree SEL). The presence of the main echo HE andthe secondary echo NE shows that the sound waves are reflectedat deep material discontinuities. Indications of root notches of littledepth are distinguished from deep defects due to the fact thatsecondary echoes are not obtained (Figure F-17).

F 7.2 Probe

In the case of plane-parallel surfaces 70 degree longitudinalwave probes are used as single transducer or transceiverdesign which besides the longitudinal wave below 70 degreestransmit an accompanying transverse wave of approx. 31degrees to generate a secondary creeping wave on theinternal surface.

Note:For the selection of the probe its dependency on the echoamplitude from the groove depth related to the echo NE 2 and tothe wall thickness to be examined shall be known.

F 7.3 Range calibration

(1) The range shall be calibrated for longitudinal waves.

(2) A precalibration for sound velocity adjustment (velocityrange) shall be made by means of straight beam scanning onthe test object or on a similar reference block.

(3) A correction of the precalibration (zero point displace-ment) by taking the transverse wave portions in the soundpath into account shall be made on the test object or referenceblock by the scanning of a rectangular groove according to thewave conversion method. Here, the secondary echo NE 2 isoptimized. „a“ is determined on the coupling surface. With „a“and in consideration of the above formula the zero pointdisplacement can be made (SEL probe). A marking on thescreen is purposeful. At one edge the calibration can bechecked by means of secondary echoes NE 1 and NE 2(Figure F-16).

S = 1.5 ⋅ s + a (F-13)

F 7.4 Adjustment of sensitivity levels

(1) The sensitivity shall be adjusted on a similar referenceblock with regard to material and geometry.

(2) To generate a reference echo rectangular grooves as perclause F 3.4 (2) be) shall be used.

(3) When examining with the secondary creeping wave thesecondary echo NE 2 reflected from the groove is optimizedand thus the sensitivity level is obtained.

(4) In the case of examination as per clause F 7.1 (4) thesensitivity shall be adjusted on corresponding rectangulargrooves with longitudinal waves. The recording limit is thereference echo amplitude of the direct longitudinal wave minus6 dB. The indication of the edge on the reference block shallexceed the recording limit by at least 10 dB. Otherwise, therecording limit shall be reduced accordingly.

F 7.5 Corrections during sensitivity level adjustment

F 7.5.1 Transfer correction

The transfer correction shall be made with two transversewave angle probes of the same kind (angle of incidencegreater than 35 degrees) with V-transmission through thebase metal of the component and the reference block. In thiscase, the frequency of the longitudinal wave probe shall beused.

F 7.5.2 Correction of sound attenuation caused by thewelded joint

Different sensitivity levels caused by the filler metal shall bedetermined by suitable means and be taken into account.

F 7.6 Performance of examination

The examination is usually performed by displacing the probeon a small area parallel to the welded joint. Here, the probeposition is optimized by moving the probe vertically to thewelded joint. This has to be done on several tracks so that thetotal area to be examined is completely covered.

s

Figure F-14: Reflexion with wave mode conversion forlongitudinal wave angle probe

KTA 3211.1

Page 109

70°

Beaming characteristics

70°

≈31°

≈31°

Figure F-15: Examination of internal near-surface area of welded joints by means of secondary creeping waves

2 4 6

NE2NE1

0

NE2

NE1

a

8 10a

Figure F-16: Sound field geometry during transverse wave conversion

64 1082

NE

HE

0

HE

NE

0

HE

HE

2 8 104 6

HE: Main echo, NE: Secondary echo

Figure F-17: Examination of components with wall thicknesses 8 mm < s ≤ 20 mm by means of longitudinal waves(70 degree SEL probe)

KTA 3211.1

Page 110

Annex G

Performance of surface crack detection by magnetic particle and liquid penetrant methods

(The wording of this Annex is identical in safety standards KTA 3201.1, KTA 3201.3, KTA 3211.1 and KTA 3211.3.)

G 1 General requirements

G 1.1 Surface condition

(1) The surfaces to be examined shall show a conditionsuitable for the examination.

(2) They shall be free from scale, weld spatter or otherdisturbing impurities.

(3) Grooves and notches affecting the test result shall beremoved.

G 1.2 Visibility conditions

G 1.2.1 Fluorescent tests fluids

(1) When using fluorescent test fluids the inspection shall bemade under ultraviolet light with a wave length maximum of365 nm ± 10 nm.

(2) The ultraviolet light incident on the examination surfaceshall have an intensity of at least 10 W/m2.

(3) The ultraviolet lamps shall have attained their fullluminous intensity prior to using it.

(4) The eyes of the operator shall have at least 5 minutes toadapt to the light conditions.

(5) The examination shall be performed in a darkened roomwithout disturbing incidence of light, in which case theilluminance shall be limited to 20 lx.

G 1.2.2 Non-fluorescent agents

(1) For the evaluation, the examination surfaces shall beilluminated by daylight or artificial light with an illuminance ofat least 500 lux.

(2) During examination, disturbing reflections and incidentlight shall be avoided.

G 1.2.3 Auxiliary means for evaluation

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

G 1.3 Post-cleaning

Upon completion of examination, the parts shall be properlycleaned to remove residues from the test fluid.

G 2 Magnetic particle examination

G 2.1 Magnetisation

G 2.1.1 Methods

(1) The possibilities of magnetisation are given in DIN 54 130.

(2) Where magnetisation is achieved in partial areas byinherent direct magnetisation or yoke magnetisation, ACmagnetisation shall normally be used.

(3) The DC magnetisation method shall only be used uponagreement by the authorized inspector.

(4) The residual magnetic field strength shall principally notexceed 103 A/m (12.5 Oe) unless a lower value is required forthe fabrication. Where the specified value is exceeded, thepart shall be demagnetised and the value of the residualmagnetic field strength be recorded.

G 2.1.2 Contact areas in case of direct magnetisation

(1) Where the examination is performed by inherentmagnetic flux, consumable electrodes (e.g. lead fin alloys)shall be used, if possible. It shall be ensured that in thecontact areas overheating of the material to be examined isavoided.

(2) Where overheating has occurred the overheated areasshall be marked, ground over after the examination and beexamined for surface cracks, preferably by a magnetic particlemethod using yoke magnetisation.

G 2.1.3 Direction of magnetisation

Each location on the surface shall be examined from twodirections of magnetisation offset by approximately 90degrees.

G 2.1.4 Magnetic field strength

Note:a) The magnetic flux in the test object surface governs the

quality of the examination. The required minimum flux densityis 1 T.

b) Due to the difficulties in measuring the magnetic field strengthin the part, the tangential field strength is used as auxiliaryvariable.

c) Tangential field strength is the tangential component of themagnetic field strength on the test object surface. In low-carbon steels the required flux density is obtained at a fieldstrength of 2 k/A.

d) Possibilities of checking whether the magnetisation of the testobject suffices are given in the guideline of the DeutscheGesellschaft für Zerstörungsfreie Prüfverfahren e.V. (DGZfP),Berlin, DGZfP-EM-3, Instruction sheet for the checking ofexamination parameters during magnetic particle examination.

(1) In the case of AC magnetisation the tangential fieldstrength on the surface shall be at least 2 x 103 A/m (approx.25 Oe) and shall not exceed 6.5 x 103 A/m (approx. 80 Oe).

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

G 2.1.5 Magnetisation times

(1) The following guide values apply with respect to theapplication of the magnetic particles and magnetisation:

a) Magnetisation and application: at least 3 seconds

b) Subsequent magnetisation: at least 5 seconds

(2) The evaluation shall be made during subsequentmagnetisation.

KTA 3211.1

Page 111

G 2.2 Inspection medium

G 2.2.1 Wet particle inspection method

(1) Only such particles shall be used as vehicle which do notcause corrosive damage on the test object even afterprolonged application. The examination surface shall bewettable by the vehicle fluid. For example, water is permittedwith respective anti-corrosion and low-surface tensionadditives.

(2) Only fine-grained iron oxide shall be used as magneticparticles. Depending on application, black, fluorescent orcoloured powders may be used.

(3) Prior to bathing the surface care shall be taken to ensurethat the magnetic powder is distributed uniformly in the vehiclefluid and is kept in suspension. Prior to and during theexamination the powder suspension shall be spot-checked bysuitable test units. When using the Berthold test unit the cross-recessions shall be oriented at an angle of approximately 45°to the direction of magnetisation and be wetted during thecheck. The concentration of the magnetic powder will suffice ifthe cross-recession can be clearly and completely identified.

G 2.2.2 Dry particle method

(1) The dry particle method is subject to agreement by theauthorized inspector except for the intermediate check inwarm condition. Care shall be exercised to ensure that thepower used is sufficiently dry.

(2) The device for applying the powder shall make possiblesuch a fine spraying that no accumulations of powder occurs.It shall be ensured that the powders used do not agglomerateunder the influence of the workpiece temperature.

G 2.2.3 Contrast

Sufficient contrast shall be provided to improve thedetectability of defects by using suitable means (e.g.fluorescent inspection medium or application of a thin colourcoating just covering the surface).

Note:Sufficient contrast is obtained if black magnetic powder is used onmetallic bright surfaces.

G 3 Liquid penetrant examination

G 3.1 Examination system

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

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

(3) Only wet developers suspended in an aqueous solventshall be used. Dry developers may only be applied on theexamination surface by electrostatic charging.

(4) For the examination system at least sensitivity class 3 toDIN 54 152-3 shall be adhered to.

(5) The suitability of the examination system (penetrant,solvent remover and developer) shall be demonstrated to theauthorized inspector by means of a sample examination as toDIN 54 152-2.

(6) In the case of multiple use or storage of the penetrants inopen containers, the effectiveness of the examination systemshall be verified on reference block B to DIN 54 152-3 prior tobeginning the examination. In this test the maximumpenetration and development times shall not exceed theminimum times specified for the evaluation. The examinationsensitivity obtained shall be recorded.

G 3.2 Performance

(1) Liquid penetrant examinations shall be performed toDIN 54 152-1 to meet the following requirements.

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

(3) As soon as possible after drying of the developer a firstevaluation shall be made. A further evaluation shall not bemade before half an hour after the first evaluation has passed.

(4) Further evaluation times are required if during thesecond evaluation crack-like indications are detected whichwere not visible during the first evaluation.

Note:Further evaluation times are required if during the secondevaluation crack-like indications are detected which were notvisible during the first evaluation.

(5) The evaluation shall be made in consideration of theresults of all evaluations.

KTA 3211.1

Page 112

Annex H

Additional stipulations for non-destructive examinationof forgings, bar steel, rings and extrusions

H1 Forgings, bar steel and rolled rings of ferritic steels

H 1.1 Scope

This Annex shall apply in addition to the stipulations of clause4.4.7 and to Annexes F and G to the performance andevaluation of non-destructive examinations for forgings, barsteel and rolled rings of ferritic steels.

H 1.2 General

(1) The ultrasonic examination shall be performed after thegoverning heat treatment for establishment of the mechanicaland technological characteristics, while the materials have theminimum possible of contours.

(2) If, during the ultrasonic examination, indications that shallbe registered are found in zones that will be removed duringfurther processing of the piece being examined, they need notbe considered in the evaluation. All indications due tostructural condition of the piece shall not be covered by theevaluation, but be indicated in the test report.

(3) If, for material-related reasons (e.g., reduction of theheat-treatment cross section), the geometry after heattreatment does not allow the entire volume to be examinedwith the required ultrasonic scanning directions, the zones thatwill subsequently have restricted examinability shall beadditionally examined prior to the heat treatment, while thegeometric condition is appropriately favorable, subject toapproval of the authorized inspector.

(4) The entire surface shall be subjected to a surface-crackdetection while it is in the finish-machined, unbored condition.The parts made from bars shall be subjected to a surface-crack detection when they are in the finish-machinedcondition. When the magnetic particle method is used, minorredressing without further examination is allowable if theresults of the original examination are not impaired.

Note:Surfaces that have been prepared for final assembly or pressuretesting and that will not be subjected to further machining areconsidered to be finish-machined.

H 1.3 Ultrasonic examination of forged flat plates

H 1.3.1 General

Ultrasonic examination shall be performed by straight-beamscanning in thickness direction, with complete scanning of oneend face. If necessary, examination shall be performed fromthe opposite end face in order to maintain the requiredexamination sensitivity.

H 1.3.2 Recording limits

(1) All echo amplitudes reaching or exceeding the valuespresented in Table H-1 shall be registered.

(2) If the nominal thickness in the finished condition is notknown during the examination, the following recording limitsshall be selected regardless of scanning direction; that ofcircular-disk reflector 2 for nominal thicknesses equal to orsmaller than 60 mm in the examination condition, and that ofcircular-disk reflector 3 for nominal thicknesses larger than60 mm.

(3) For product forms with nominal thicknesses equal to orlarger than 100 mm, all sites shall be registered at which theexpected back-wall echo decreases in the region of therecording limit as per (1).

(4) All sites shall be registered with clusters of echoindications that are 6 dB below the recording limit and cannotbe resolved into individual echo indications in one probeposition or during probe travel or that cannot be clearlyclassified or correlated with the scanning directions to beemployed.

(5) All sites shall be registered where the signal-to-noiseratio to the recording limit is less than 6 dB.

Nominal thickness sin final condition

in mm

Diameter in mm of thecorresponding circular-disk

reflectorStraight-beam

scanningAngle-beam

scanning

s ≤ 40 2 2

40 < s ≤ 120 3 3

120 <s ≤ 250 4 1) 3

s > 250 6 1) 3

1) These values shall be applicable only if the back-wall echo isobservable, otherwise the same values as for angle-beamscanning shall apply.

Table H-1: Recording limits

H 1.3.3 Evaluation of the examination results

(1) If the back-wall echo vanishes or becomes very weak, orif the signal-to-noise ratio to the recording limit is less than6 dB, the manufacturer shall perform investigations such assound attenuation measurements, by agreement with theauthorized inspector, aimed at permitting a decision onusability.

(2) If the acceptance limits are exceeded or if clusters ofreflection sites are found with echo amplitudes that are asmuch as 6 dB below the recording limit and cannot beseparated into individual echo indications in one probeposition or resolved during probe travel or that cannot beclearly classified or correlated, additional investigations suchas through-transmission in several directions shall beperformed. If these investigations reveal signs of areal separa-tions, e.g., loss of intensity of a sound-transmission signal bycomparison with indication-free zones of the product form,these sites are not permitted.

(3) Local indications with echo amplitudes up to 18 dBabove the recording limit are permitted. Indications with lengthextent under curve 1 presented in Figure H-1 are alsopermitted.

(4) Zonal indications observed in nominal thicknesses largerthan 250 mm are permitted if the back-wall echo is notattenuated by more than 6 dB relative to indication-free zones.Sporadic local indications up to 12 dB above the recordinglimits are permitted in such zones. Zonal indications shall be

KTA 3211.1

Page 113

defined as a cluster of reflection sites appearing on the screenas a large number of amplitudes that are no longer resolvable.

(5) The frequency of individual indications that shall beregistered, when projected on one end face, shall not exceed10 per square meter locally and 5 per square meter relative tothe total area of the end face.

1.0

+24

+12

+6

+18

0.5

[dB]

nominal wall thickness in finished condition

abov

e re

gist

ratio

n lim

it

Curve 1

Indication length relative to

Max

imum

ech

o am

plitu

de

regionPermissible

Curve 2

Figure H-1: Allowable indication lengths and echoamplitudes in the ultrasonic examination

H 1.4 Surface-crack detection of forged flat plates

The following shall apply to the evaluation of the examinationresults: The frequency of allowable indications shall notexceed 10 per square decimeter locally or 5 per squaredecimeter relative to the total area. The stipulations of TablesH-2 and H-3 shall also apply.

Note:A liquid-penetrant indication shall be considered to have alongitudinal extension (linear indication) if its dimension in thedirection of maximum extension is at least three times as large asits smallest dimension transverse to that direction.

Indications≤ 3 mm

individual

Roundindications

> 3 mmup to ≤ 6 mm

Roundindications

> 6 mm

Linearindications

> 3 mm

Acceptable

not to beincluded intheevaluation

Acceptable

to beincluded infrequency

Unacceptable Unacceptable

Where it isshown that theindications arecaused by non-metallic inclu-sions, indications≤ 6 mm areacceptable andshall be includedin the frequency.

Table H-2: Acceptance standards for liquid-penetrantexamination

Indications≤ 1.5 mmindividual

Indications> 1.5 mm upto ≤ 6 mm,caused bynon-metallicinclusions

Indications> 6 mm

LinearIndications> 1.5 mm

Acceptable

not to beincluded intheevaluation

Acceptable

to beincluded inthefrequency

Unacceptable Unacceptable

Table H-3: Acceptance standards for magnetic-particleexamination

H 1.5 Ultrasonic examination of hollow parts

H 1.5.1 Scanning directions

(1) Products with a length-to-diameter ratio equal to or largerthan 3 shall be examined by straight-beam scanning from thecylindrical surface. Products of material group W I shalladditionally be examined by angle-beam scanning in bothcircumferential directions from the cylindrical surface.

(2) Products with a length-to-diameter ratio smaller than 3shall be examined by straight-beam scanning in radial andaxial direction.

(3) In straight-beam scanning, examination shall beperformed from both cylindrical surfaces and end faces ifnecessary, in order to maintain the required examinationsensitivity.



(2) If the nominal thickness in the finished condition is notknown during the examination, the following recording limitsshall be selected regardless of scanning direction: that ofcircular-disk reflector 2 for wall thicknesses equal to or smallerthan 60 mm in the examination condition, and that of circular-disk reflector 3 for wall thicknesses larger than 60 mm.

(3) For product forms with nominal thicknesses equal to orlarger than 100 mm, all sites shall be registered at which theexpected back-wall echo decreases in the region of therecording limit as per (1).

(4) All sites shall be registered with clusters of echoindications that are 6 dB below the recording limit and cannotbe resolved into individual echo indications in one probeposition or during probe travel or that cannot be clearlyclassified or correlated with the scanning directions to beemployed.

(5) All sites shall be registered where the signal-to-noiseratio to the recording limit is less than 6 dB.


(1) If echo indications that shall be registered are observedfrom reflection sites in the zone with lateral wall influenceduring straight-beam scanning, they shall be evaluated bymeans of angle-beam scanning.

(2) If the back-wall echo vanishes or becomes very weak, orif the signal-to-noise ratio to the recording limit is less than6 dB, the manufacturer shall perform investigations such assound-attenuation measurements, by agreement with the

KTA 3211.1

Page 114

authorized inspector, aimed at permitting a decision onusability.

(3) If the acceptance limits are exceeded or if clusters ofreflection sites are found with echo amplitudes that are asmuch as 6 dB below the recording limit and cannot beseparated into individual echo indications in one probeposition or resolved during probe travel or that cannot bedearly classified or correlated, additional investigations suchas through-transmissions in several directions shall beperformed. If these investigations reveal signs of arealseparations, e.g., loss of intensity of a sound-transmissionsignal by comparison with indication-free zones of the productform, these sites are not permitted.

(4) For hollow parts with length-to-diameter ratio larger than3, indications below curve 2 of Figure H-1 are permitted bothin straight-beam and angle-beam scanning. In straight-beamscanning, indications below curve 1 in Figure H-1 are alsopermitte echo amplitudes reaching 6 dB or more above therecording limit are not observed at these sites during angle-beam scanning. However, the largest allowable reflectorlength shall be limited to 120 mm.

(5) For rings with length-to-diameter ratio smaller than orequal to 3, indications below curve 2 in Figure H-1 arepermitted. However, the largest allowable reflector length shallbe limited to 60 mm.

(6) Reflection sites with extensions in the thickness directionare not permitted. The frequency of reflection sites relative tothe external surface shall not exceed 10 per square meterlocally and 5 per square meter overall.

H 1.6 Surface-crack detection of hollow parts

For the evaluation of the examination results the stipulationsof Section H 1.4 shall apply.

H 1.7 Ultrasonic examination of open-die forgings for casesand bodies

H 1.7.1 General

The ultrasonic examination shall be performed after thegoverning heat treatment for establishment of the mechanicaland technological characteristics, while the materials have theminimum possible of contours. If the contour after the heattreatment permits only restricted examination, an examinationas per clause H 1.7.2.1 shall be performed before the heattreatment and an examination per clause H 1.7.2.3 shall beperformed after the heat treatment.


H 1.7.2.1 Forgings not containing bored holes

(1) The forgings shall be examined by straight-beamscanning as follows:

a) cylindrical forgings from the external cylindrical surface,

b) square forgings from two faces oriented at 90 degrees toeach other and running parallel to the longitudinal axis,and

c) hexagonal forgings from 3 faces adjoining each other andrunning parallel to the longitudinal axis.

(2) If indications under the respective evaluation criterionwith echo amplitudes larger than 50 % of the maximumallowable echo amplitude are observed during examination ofsquare and hexagonal forgings, these zones shall be re-examined from the respective opposite faces.

(3) For parts of material group W I, the ultrasonicexamination shall additionally be performed by straight-beam

scanning from both ends. Furthermore, cylindrical zones shallbe examined by angle-beam scanning in both circumferentialdirections.

H 1.7.2.2 Forgings containing bored holes

(1) The entire volume shall be examined by straight-beamscanning from all external surfaces running parallel to thehole.

(2) For parts of material group W I, the ultrasonicexamination shall additionally be performed axially by straight-beam scanning from the ends. Furthermore, cylindrical zonesshall be examined by angle-beam scanning in bothcircumferential directions.

H 1.7.2.3 Scanning directions for restricted examination afterthe heat treatment

(1) Straight-beam scanning shall be performed from allexternal surfaces with radii of curvature larger than 30 mm.

(2) For parts of material group W I, angle-beam scanning inboth circumferential directions in the cylindrical zones of open-die forgings may be performed as an alternative to straight-beam scanning.

H 1.7.2.4 Recording limits


(2) If the nominal thickness in the finished condition is notknown during the examination, the following recording limitsshall be selected regardless of scanning direction: that ofcircular-disk reflector 2 for wall thicknesses equal to or smallerthan 60 mm in the examination condition, and that of circular-disk reflector 3 for wall thicknesses larger than 60 mm.

H 1.7.2.5 Evaluation of the examination results

(1) The stipulations of clauses H 1.5.3 (1) to (3) shall apply,together with the stipulations of the following paragraphs.

(2) Local indications that shall be registered but that haveecho amplitudes less than or equal to 12 dB above therecording limit are permitted in all volume zones and for allscanning directions. Indications with longitudinal extension butwith values below curve 2 in Figure H-1 are permitted,provided the direction of extent of the indication does notcoincide with the thickness direction of the part to be madefrom the object of examination.

(3) The frequency of indications relative to the externalsurface of the piece being examined shall not exceed 10 persquare meter locally and 5 per square meter overall.

(4) For smaller forgings with an external surface area of lessthan one square meter, 3 indications per forging are permitted.

H 1.8 Surface-crack detection of open-die forgings for casesand bodies

The stipulations of Section H 1.4 shall apply to the evaluationof the examination results.

H 1.9 Ultrasonic examination of bar steel


(1) For diameters or widths across flats larger than 30 mm,straight-beam scanning in radial direction shall be performed.For parts of material group W I, the examination shall beperformed by angle-beam scanning in both circumferential

KTA 3211.1

Page 115

directions for round bars with diameters larger than 120 mm.The scanning angle for angle-beam scanning shall be 35degrees.

(2) Straight-beam scanning from the lateral surface shall beperformed over the entire circumference of round bars andover half the periphery for square or hexagonal bars.

(3) If indications under the respective evaluation criteria withecho amplitudes larger than 50 % of the maximum allowableecho amplitude are observed during examination of square orhexagonal forgings, these zones shall be re-examined fromthe respective opposite faces.


For diameters or widths across flats smaller than or equal to60 mm, indications with echo amplitudes not exceedingcircular-disk reflector 2 are permitted. For diameters or widthsacross flats larger than 60 mm, indications with echoamplitudes not exceeding circular-disk reflector 3 arepermitted. For diameters or widths across flats larger than 120mm, indications up to circular-disk reflector 4 are permitted.

H 1.10 Surface-crack detection of bar steel

The stipulations of Section H 1.4 shall apply to the evaluationof the examination results.

H 1.11 Ultrasonic examination of drop-forged parts andhot-formed extrusions

H 1.11.1 General

(1) For drop-forged parts and hot-formed extrusions, theultrasonic examination on stock material with diameters orwidths across flats larger than 50 mm shall be performed toSEP 1920 test group 4. The stock material shall meet therequirements of size class C.

(2) For drop-forged parts and hot-formed extrusions withnominal values larger than 150 mm, an ultrasonic examinationshall additionally be performed, if permitted by the geometry,after the governing heat treatment for establishment of themechanical and technological material characteristics, whilethe materials have the minimum possible of contours.


(1) The examination of drop-forged parts and hot-formedextrusions shall be performed with straight-beam scanningfrom the external surface. Ultrasonic examination is notrequired in zones with radii of curvature smaller than 30 mm.


(1) For drop-forged parts and hot-formed extrusions, allindications with echo amplitudes reaching or exceeding thevalues presented in Table H-1 shall be registered.

(2) If the nominal thickness in the finished condition is notknown during the examination, the following recording limitsshall be selected regardless of scanning direction: that ofcircular-disk reflector 2 for nominal thicknesses equal to orsmaller than 60 mm in the examination condition, and that ofcircular-disk reflector 3 for nominal thicknesses larger than60 mm.


For drop-forged parts and hot-formed extrusions examinedwith straight-beam scanning, indications without length extent

and with echo amplitudes smaller than or equal to 12 dBabove the recording limit are permitted in all volume zones.

H 1.12 Surface-crack detection of drop-forged parts andhot-formed extrusions

H 1.12.1 Extent and point of time

Prior to delivery, the entire surface of drop-forged parts andhot-formed extrusions shall be subjected to surface-crackdetection in the forging shop. All mechanically machined andaccessible surfaces of the finish-machined part shall also besubjected to surface-crack detection. Examination of surfacesof blind holes and through holes equal to or smaller than50 mm and of threaded holes is not required.


The stipulations of Section H 1.4 shall apply.

H 2 Forgings, bar steel, rings and extrusions ofaustenitic steels

H 2.1 Scope of application

This Annex shall apply in addition to the stipulations of clause4.4.7 the performance and evaluation of non-destructiveexaminations for forgings, bar steel, rings and extrusions ofaustenitic steels

H 2.2 Ultrasonic examination


(1) For bars with diameters or widths across flats larger than30 mm, straight-beam scanning in radial direction shall beperformed. For parts with diameters or widths across flatslarger than 120 mm, an examination shall be additionallyperformed by angle-beam scanning in both circumferentialdirections, in which case the scanning angle for angle-beamscanning in the circumferential direction shall be 35 degrees.

(2) The stock material for drop-forged parts with diametersor widths across flats larger than 50 mm shall be examined bystraight-beam scanning from the lateral surface. Examinationin the condition that has not been solution-annealed is alsopermitted.

(3) For drop-forged parts larger than DN 150, straight-beamscanning shall be performed from the external surface,provided the radius of curvature is larger than 30 mm.

(4) The entire volume of free-forged valve bodies shall beexamined by straight-beam scanning from all externalsurfaces. In addition, angle-beam scanning in both circumfe-rential directions shall be performed in the cylindrical zones inthe rough-turned or finish-machined condition. In this case therecording limit shall be related to the wall thickness in theexamination condition.

(5) Hollow parts with a length-to-outside-diameter ratio equalto or larger than 3 shall be examined by straight-beamscanning from the cylindrical surface and by angle-beamscanning in both circumferential directions. Hollow parts with alength-to-outside-diameter ratio smaller than 3 shall beexamined by straight-beam scanning in radial and axialdirection. In straight-beam scanning, examination shall beperformed from both cylindrical surfaces and from both endfaces if necessary, in order to maintain the requiredexamination sensitivity.

KTA 3211.1

Page 116

H 2.2.2 Examination prerequisites and procedure

H 2.2.2.1 Examination technique and examinability

H 2.2.2.1.1 Examination technique

(1) For the straight-beam method frequencies between 2and 5 MHz and for the angle-beam method a frequency of2 MHz shall be selected where during the examination of weldedges and nozzle areas miniature transverse wave probesshall basically be used. The examination shall be performed todetect longitudinal defects (defect orientation parallel to thedirection of welding progress). Here, the incidence angle shallbe selected such that the angle at the inner surface lies withinthe usable range of the corner effect (impinging angle possibly35 degrees to 55 degrees).

(2) The examination technique for examining the weld edgeand nozzle areas shall be determined on a similar referencereflector or if practicable (e.g. where excess lengths areavailable) on the test object. When using a reference reflectorit shall be representative for the test object with respect togeometry, acoustic properties and surface condition.

(3) To obtain a sufficient signal-to-noise ratio of at least 6 dBor to be within the recording limits the examination techniquemay be optimised upon agreement with the authorizedinspector, e.g. by the following measures:

a) probes with a low nominal frequency,

b) use of frequency selective equipments,

c) use of twin probes,

d) use of highly attenuated probes,

e) use of longitudinal waves also for the angle beam method.

H 2.2.2.1.2 Determination of examinability

(1) The examinabilty shall be determined for each testobject.

(2) The examinabilty shall be determined jointly by theparties involved in the examination.

(3) The wave lengths used for determining the examinabilityshall not be greater than those used for the straight and anglebeam examinations that follow.

(4) For plates the back wall echo shall be determined in allcentre ranges of a grid of 200 mm and at the border line bymeans of straight-beam scanning and at intended frequency.

(5) For all other product forms a grid of 200 mm shall beprovided on each test object in the area of parallel orconcentric walls to determine the examinability. In all centreranges of this grid and additionally on all border lines offorgings the back wall echoes shall be determined by straight-beam scanning in wall thickness direction. In areas of nonparallel or non-concentric walls reference reflectors shall beused (e.g. boreholes, edges or through-transmission) for thisexamination.

(6) The number and density of examination points requiredto determine the examinability shall be in a reasonablerelationship to the size and geometry of the test object. Here,the absolute number of measuring points may be limited to 50.

(7) Where the examination has to be performed by straight-beam scanning, the sound wave attenuation in areas with aback wall echo attenuation greater than 6 dB shall also bedetermined by means of angle-beam scanning, e.g. byV-scanning.

(8) Areas with a high sound wave attenuation (back wallecho variation greater than 12 dB) shall be identified and beenveloped by a narrow measuring point grid in which case theabsolute number of measuring points shall be increased

accordingly. The maximum sound attenuation shall berecorded for each required scanning direction.

(9) For the weld edges and nozzle areas the examinabilityshall be determined for the conditions of weld examination.This shall be done, like for the examination to follow, bymeans of angle-beam scanning. A circumferential groove asreference reflector shall be provided on the test object in thearea where the weld will be laid, however, at a sufficientdistance to the edge. The grooves shall not exceed a width of1.5 mm, the reflection area shall be perpendicular to thesurface. The depth of the reference reflector shall bedetermined in dependence of the wall thickness of the finishedpart in accordance with Table H-4. Where the reflector cannotbe provided on the test object, a reference reflector inaccordance with clause H 2.2.2.1.1 (2) with a circumferentialgroove (if practicable over the full circumference, but at leastwith a length of 50 mm) shall be provided. On the test objectwith circumferential groove the groove shall be scanned overthe full circumference. By observation of the groove echo thearea with the greatest sound attenuation will be determined.

Where using a reference reflector, the test object areas withthe greatest sound attenuation shall be determined byobserving the edge reflection. By comparison of the edgereflexion at the test object and the reference reflector thedifferences in amplification referred to the reference echoamplitude shall be determined in accordance with clauseH 2.2.2.5 (4) and be taken into account.

Wall thickness s, mm 8 < s ≤ 20 20 < s ≤ 40 40 < s

Groove depth, mm 1.5 2 3

Table H-4: Depth of reference reflector for the examinationof weld edges end nozzle areas

H 2.2.2.1.3 Unrestricted examinability

If it can be proved for the area under examination with thegreatest sound attenuation that

a) for plates the required recording limits to 7.1.3.2 (5) c)

b) for all the other product forms with respect to the straightand each angle beam scanning method the recordinglimits to clause H 2.2.2.5

can be satisfied, the test object has unrestricted examinability.

H 2.2.2.1.4 Restricted examinability

(1) Where for one or more sound beam entry directions in asound attenuation region the recording limit according toclause H 2.2.2.5 or the required signal-to-noise ratio of 6 dBcannot be maintained even with an optimised examinationtechnique (see clause H 2.2.2.1.1 (2)), these volumetricregions with restricted examinability and the correspondingdegree of restriction shall be determined.

(2) If, in the course of subsequent mechanical processing,more favourable conditions with regard to ultrasonicexaminations are created for these regions (e.g. reduction ofthe wall thickness, shorter sound paths, removal of the regionsof restricted examinability), then the ultrasonic examination ofthe regions in question may be carried out for the missingbeaming directions in this subsequent fabrication condition.This examination may also be carried out by the subsequentmanufacturer, provided the producer of the forging and thesubsequent manufacturer agree. If the required testingsensitivity is achieved in the subsequent fabrication condition,these regions shall also be considered to be unrestrictedlyexaminable.

KTA 3211.1

Page 117

H 2.2.2.2 Sensitivity adjustment

(1) During the sensitivity adjustment the largest sound waveattenuation values shall be considered for all probes andbeaming directions.

(2) The evaluation of the echo indications shall be carriedout with respect to the sound wave attenuation determined inthe immediate vicinity of the echo indications.

(3) When examining the weld edge and nozzle areas thesensitivity shall be adjusted to the reference echo method. Inaddition to the requirements of Annex F the following applies.The sensitivity shall be adjusted on a rectangular groove witha width not to exceed 1.5 mm and the reflection area of whichis perpendicular to the surface. The groove depth shall befixed in dependence of the wall thickness of the finished partin accordance with Table H-4. Where an equivalent referencereflector is used, the groove length shall be 50 mm with thegroove run-out not being taken into account. The run-outradius shall not exceed 50 mm. Where the sensitivity isadjusted on the test object, the groove shall be provided onthe circumference with sufficient distance to the edge.

H 2.2.2.3 Size of reflectors

Deviating from clause 4.4.7.2.1 (8) the reflector size is givenby the probe movement at which the echo amplitude hasdropped by 6 dB under the maximum echo amplitude (half-amplitude technique according to clause F 5.2.3).

H 2.2.2.4 Types of examination

(1) The test objects shall be subjected either to an overallultrasonic examination or to a selective ultrasonic exami-nation.

Whether an overall or selective ultrasonic examination is to beperformed shall be agreed between the forging manufacturerand the manufacturer and be recorded in the design reviewdocuments.

The type of examination shall be indicated in the test recordas „overall US“ or „selective US“.

(2) In the overall ultrasonic examination a detailedknowledge of the components to be fabricated from the testobject is not required. In this examination the acceptance limitis equal to the recording limit.

(3) In the selective ultrasonic examination it is required toknow the shape and final dimensions of the components to befabricated from the test object. To be able to correctly applythe recording limits and evaluation criteria on the nominal wallthickness, shape and location of the walls of the finishedcomponent it is required that at the point of time ofexamination drawings of the components to be fabricated fromthe test object are available. These drawings shall besubmitted by the purchaser of the test object.

Note:The nominal wall thickness is the wall thickness indicated in thedrawing of the finished component (used in the power plant).

H 2.2.2.5 Recording limits

(1) For all forgings the following shall be recorded:

a) all echo indications the amplitude of which is equal to orgreater than the values indicated in Tables H-5 or H-6,

b) locations on forgings with wall thicknesess, diameters orside lengths equal to or exceeding 100 mm where the backwall echo to be expected drops to a value near therecording limit.

(2) In an overall ultrasonic examination in accordance withclause H 2.2.2.4 (2) and in the examination of bars as well as

of stock material for drop forgings the recording limit of TableH-5 shall be used.

(3) In the selective ultrasonic examination in accordancewith clause H 2.2.2.4 (3) the recording limits of Table H-6apply.

To obtain a sufficient signal-to-noise ratio (6 dB from therecording limit) the recording limit may partially be raised by6 dB for the respective sound beam entry positions andvolumetric regions. These regions as well as the recordinglimits obtained for the different beam entry directions shall berecorded.

However, the evaluation criteria according to clause H 2.2.3.2refer to the originally prescribed recording limit to Table H-6.

Where the raised recording limit cannot be obtained inconsideration of the extent of restrictions (number and type ofbeam entry directions, number and size of volumetric regions),substitute measures shall be agreed with the authorizedinspector.

(4) When examining the weld edge and nozzle areas allindications shall be recorded which are equal to or greaterthan the reference echo amplitude. The reference echoamplitude is the echo amplitude of the reference reflector toTable H-4 reduced by 12 dB. In addition, regions shall berecorded where the signal-to-noise ratio is less than 6 dB.


H 2.2.3.1 General requirements

All indications liable to record during angle-beam scanningwhich are not liable to record during straight-beam scanningshall be thoroughly examined with respect to their orientation.Indications with a size in thickness direction are not permitted.

H 2.2.3.2 Bars and stock material for drop-forged parts

Echo amplitudes up to the recording limits cited in Table H-5are permitted.

H 2.2.3.3 Forgings and extrusions

(1) When referring the echo amplitude to the dimension inthe test condition, echo indications up to the recording limitsspecified in Table H-5 are permitted.

(2) When referring the echo amplitude to the nominal wallthickness of the finished product, the following requirementsapply:

a) In the case of straight and angle-beam scanning echoindications exceeding the recording limits specified inTable H-6 by up to 12 dB are permitted.

b) The allowable frequency of recorded reflections shall be, inthe case of nominal wall thicknesses or diameters of:

ba) s or d ≤ 60 mm 3 per m2 locally and

2 per m2 overall,

bb) s or d > 60 mm 5 per m2 locally and

3 per m2 overall.

In the case of an examination with raised recording limit inaccordance with clause H 2.2.2.5 (3) only half the numberof recorded reflexions is permitted.

c) In the case of straight-beam scanning in wall thicknessdirection reflexions with a length smaller or equal to thenominal wall thickness are permitted.

d) For the other scanning direction reflexions with a lengthsmaller than or equal to the nominal wall thickness, but atmaximum 50 mm, are permitted.

KTA 3211.1

Page 118

Scanningdirections

Wallthickness

in testconditions (mm)

Reference Echo MethodRecordable echo

amplitudes referenced toa 4 mm cylindrical bore

hole

DGSMethodCircular

diskreflector

all ≤ 60 50 % (-6 dB) 3

> 60 100 % 4

Table H-5: Recording limits and acceptance standards forultrasonic examination on forgings with referenceto the dimensions in the test condition and stockmaterial for drop-forged parts

a) Recording limits for DGS method. Recordable echoamplitudes referred to circular disk reflector (mm)

Scanningdirection

Nominal wall thickness of finished product(mm)

s ≤ 15 15 < s ≤ 30 30 < s ≤ 60 s > 60

Straight beamscanning

2 3 3 4

Angle-beamscanning

1) 2 3 4

b) Recording limits for distance gain size or referenceecho method. Recordable echo amplitudes referred tothe echo amplitudes of cylindrical bore holes ∅ 4 mm

Scanningdirection

Nominal wall thickness of finished product(mm)

s ≤ 30 s > 30

all 50 % = (- 6 dB) 100 %

1) Where scanning is performed on the nominal wall thickness,the recording limit is the echo amplitude of a rectangulargroove at the end of the second path to be evaluated with thefollowing dimensions:

Depth ≤ 1.0 mmWidth ≤ 1.5 mmLength > Sound beam width

When scanning with full skip distance reference echoamplitudes from the inner and outer groove can be used for therespective sound path regions.Regions scanned in the pre-fabricated condition which have awall thickness s > 15 mm at the point of time of test, may beexamined with a recording limit: circular disk reflector 2 mm.

Table H-6: Recording limits for ultrasonic examination onforgings with reference to the nominal wallthickness of the finished product

H 2.2.3.4 Regions of weld edges and nozzles

(1) Indications exceeding the recording limit by up to 6 dBare permitted if their number per meter of weld edge length ata minimum recording length of 10 mm is limited to 3indications, and at a maximum recording length of 20 mm toone indication.

(2) Where these limits are exceeded or areas are presentwhere the groove or weld edge signal-to-noise ratio is lessthan 6 dB, further steps shall be agreed with the authorizedinspector.

H 2.3 Surface crack detection

H 2.3.1 Extent and point of time

All accessible surfaces on the finished product shall besubjected to a liquid penetrant examination.


(1) The requirements specified in Table H-7 apply.

(2) The frequency of acceptable indications shall, locally, notexceed 10 per square decimetre and, relative to the entiresurface, 5 per square decimetre.

Indications≤ 3 mm

individual

Circularindications> 3 mm to

≤ 6 mm

Circularindications

> 6 mm

Linearindications 1)

> 3 mm

allowable,shall notbeincluded intheevaluation

allowable,shall beincluded inthefrequency

notallowable

not allowable.If it is shown that theindications are due tocarbon nitrideinclusions, indicationsup to ≤ 6 mm areallowed and shall beincluded in thefrequency.

1) A liquid penetrant indication is considered to be linear (linearindication) if the length of its longest dimension is at least threetimes larger than the length in transverse direction.

Table H-7: Acceptance standards for liquid penetrantexamination

KTA 3211.1

Page 119

Annex I

Regulations and literature referred to in this Safety Standard

(The references exclusively refer to the version given in this annex. Quotations of regulations referred totherein refer to the version available when the individual reference below was established or issued.)

AtG Act on the Peaceful Utilization of Atomic Energy and the Protectionagainst 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 the Act of April 6, 1998 (BGbl. I,p. 694)

StrlSchV Ordinance on the Protection against Damage and Injuries Caused byIonizing Radiation (Radiological Protection Ordinance) as promulgatedon June 30, 1989 and corrected on Oct. 16, 1989, at last amended bythe Act of August 18, 1997 (BGBl. I, Page 2113)

KTA 1401 (6/96) General Requirements Regarding Quality Assurance

KTA 1408.1 (6/85) Quality Assurance for Weld Filler Materials and Weld Additives forPressure and Activity Retaining System in Nuclear Power Plants;Part 1: Suitability Testing

KTA 1408.2 (6/85) Quality Assurance for Weld Filler Materials and Weld Additives forPressure and Activity Retaining System in Nuclear Power Plants;Part 2: Manufacturing

KTA 1408.3 (6/85) Quality Assurance for Weld Filler Materials and Weld Additives forPressure and Activity Retaining System in Nuclear Power Plants;Part 3: Processing

KTA 3211.2 (6/92) Pressure and Activity Retaining Components of Systems outside thePrimary Circuit; Part 2: Design and Analysis

KTA 3211.3 (6/90) Pressure and Activity Retaining Components of Systems outside thePrimary Circuit; Part 3: Manufacture

DIN 13-19 (11/99) ISO general purpose metric screw threads - Part 19: Nominal profiles

DIN EN 287-1 (8/97) Approval testing of welders - Fusion welding - Part 1: Steels (includesAmendment A1:1997); German version EN 287-1:1992 + A1:1997

DIN EN 444 (4/94) Non-destructive testing; general principles for the radiographicexamination of metallic materials using X-rays and gamma-rays;German version EN 444:1994

DIN EN 462-1 (3/94) Non-destructive testing; image quality of radiographs; Part 1: Imagequality indicators (wire type); determination of image quality values;German version EN 462-1:1994

DIN EN 462-3 (11/96) Non-destructive testing - Image quality of radiogrammes - Part 3: Imagequality classes for ferrous metals; German version EN 462-3:1996

DIN EN 473 (7/93) Qualification and certification of NDT personnel; general principles;German version EN 473:1992

DIN EN 493 (7/92) Fasteners; surface discontinuities; nuts; German version EN 493:1992

DIN EN 584-2 (1/97) Non-destructive testing - Industrial radiographic film - Part 2: Control offilm processing by means of reference values; German versionEN 584-2:1996

DIN EN 895 (5/99) Destructive tests on welds in metallic materials - Transverse tensiletest; German version EN 895:1995

DIN EN ISO 898-1 (11/99) Mechanical properties of fasteners made of carbon steel and alloy steel- Part 1: Bolts, screws and studs (ISO 898-1:1999); German versionEN ISO 898-1:1999

DIN EN ISO 898-6 (2/96) Mechanical properties of fasteners - Part 6: Nuts with specified proofload values; fine pitch thread (ISO 898-6:1994); German versionEN ISO 898-6:1995

KTA 3211.1

Page 120

DIN EN 910 (5/96) Destructive test on welds in metallic materials - Bend tests; Germanversion EN 910:1996

DIN EN ISO 1127 (3/97) Stainless steel tubes - Dimensions, tolerances and conventionalmasses per unit length (ISO 1127:1992); German version EN ISO1127:1996

DIN EN 1370 (2/97) Founding - Surface roughness inspection by visual tactile comparators;German version EN 1370:1996

DIN 1690-2 (6/85) Technical delivery conditions for castings made from metallic materials;steel castings; classification into severity levels on the basis of non-destructive testing

DIN EN ISO 3506-1 (3/98) Mechanical properties of corrosion-resistant stainless steel fasteners -Part 1: Bolts, screws and studs (ISO 3506-1:1997); German versionEN ISO 3506-1:1997

DIN EN ISO 3506-2 (3/98) Mechanical properties of corrosion-resistant stainless steel fasteners -Part 2: Nuts (ISO 3506-2:1997); German version EN ISO 3506-2:1997

DIN EN ISO 3651-2 (8/98) Determination of resistance to intergranular corrosion of stainless steels- Part 2: Ferritic, austenitic and ferritic-austenitic (duplex) stainlesssteels - Corrosion test in media containing sulfuric acid(ISO 3651-2:1998); German version EN ISO 3651-2:1998

DIN EN ISO 4287 (10/98) Geometrical Product Specifications (GPS) - Surface texture: Profilemethod - Terms, definitions and surface texture parameters(ISO 4287:1997); German version EN ISO 4287:1998

DIN EN ISO 6506-1 (10/99) Metallic materials - Brinell hardness test - Part 1: Test method(ISO 6506-1:1999); German version EN ISO 6506-1:1999

DIN EN ISO 6507-1 (1/98) Metallic materials - Vickers hardness test - Part 1: Test method(ISO 6507-1:1997); German version EN ISO 6507-1:1997

DIN 8572-1 (3/81) Determination of diffusible hydrogen in weld metal; manual arc welding

DIN 8572-2 (3/81) Determination of diffusible hydrogen in weld metal; submerged arcwelding

DIN EN 10 002-1 (4/91) Tensile testing of metallic materials; method of test at ambienttemperature (including Corrigendum AC1:1990); German versionEN 10002-1:1990 and AC 1:1990

DIN EN 10 002-5 (2/92) Tensile testing of metallic materials; method of testing at elevatedtemperature; German version EN 10002-5:1991

DIN EN 10 025 (3/94) Hot rolled products of non-alloy structural steels; technical deliveryconditions (includes amendment A1:1993); German VersionEN 10025:1990

DIN EN 10 028-2 (4/93) Flat products made from steel for pressure purposes; Part 2: Non-alloyand alloy steels with specified elevated temperature properties; Germanversion EN 10028-2:1992

DIN EN 10 028-3 (4/93) Flat products made from steel for pressure purposes; Part 3: Weldablefine grain steels, normalized; German version EN 10028-3:1992

DIN EN 10 045-1 (4/91) Charpy impact test on metallic materials; Part 1: Test method; Germanversion EN 10045-1:1990

DIN EN 10 163-2 (10/91) Technical delivery conditions for the surface condition of hot rolled steelplate, wide flats and sections; Part 2: Plate and wide flats; Germanversion EN 10163-2:1991

DIN EN 10 164 (8/93) Steel products with improved deformation properties perpendicular tothe surface of the product; technical delivery conditions; Germanversion of EN 10164:1993

DIN EN 10 204 (8/95) Metallic products - Types of inspection documents (includesAmendment A1:1995); German version EN 10204:1991 + A1:1995

DIN EN 10 213-2 (1/96) Technical delivery conditions for steel castings for pressure purposes -Part 2: Steel grades for use at room temperature and elevatedtemperatures; German version EN 10213-2:1995

DIN EN 10 213-4 (1/96) Technical delivery conditions for steel castings for pressure purposes -Part 4: Austenitic and austenitic-ferritic steel grades; German versionEN 10213-4:1995

KTA 3211.1

Page 121

DIN EN 10 233 (1/94) Metallic materials; tube; flattening test; German version EN 10233:1993

DIN EN 10 234 (1/94) Metallic materials; tube; drift expanding test; German version EN10234:1993

DIN EN 10 236 (1/94) Metallic materials; tube; ring expanding test; German version EN10236:1993

DIN EN 10 237 (1/94) Metallic materials; tube; ring tensile test; German version EN10237:1993

DIN EN 10 269 (11/99) Steels and nickel alloys for fasteners with specified elevated and/or lowtemperature properties; German version EN 10269:1999

DIN EN 12 223 (1/00) Non-destructive testing - Ultrasonic examination - Specification forcalibration block No. 1; German version EN 12223:1999

DIN EN ISO 13 916 (11/96) Welding - Guidance on the measurement of preheating temperature,interpass temperature and preheat maintenance temperature(ISO 13916:1996); German version EN ISO 13916:1996

DIN 17 100 (1/80) Steels for general structural purposes; quality standard

DIN 17 102 (10/83) Weldable normalized fine grain structural steels; technical deliveryconditions for plate, strip, wide flats, sections and bars

DIN 17 103 (10/89) Weldable fine grain structural steel forgings; technical deliveryconditions

DIN 17 155 (10/83) Creep resistant steel plate and strip; technical delivery conditions

DIN 17 175 (5/79) Seamless tubes of heat-resistant steels; technical conditions of delivery

DIN 17 179 (5/86) Seamless circular fine grain steel tubes subject to special requirements;technical delivery conditions

DIN 17 240 (7/76) Heat resisting and highly heat resisting materials for bolts and nuts;quality specifications

DIN 17 243 (1/87) Weldable heat resisting steel forgings and rolled or forged steel bars;technical delivery conditions

DIN 17 245 (12/87) Ferritic steel castings with elevated temperature properties; technicaldelivery conditions

DIN 17 440 (9/96) Stainless steels - Technical delivery conditions for plates, hot rolledstrip and bars for pressure purposes, drawn wire and forgings

DIN 17 445 (11/84) Stainless steel castings; technical delivery conditions

DIN 17 457 (7/85) Welded circular austenitic stainless steel tubes subject to specialrequirements; technical delivery conditions

DIN 17 458 (7/85) Seamless circular austenitic stainless steel tubes subject to specialrequirements; technical delivery conditions

DIN EN 20 898-2 (2/94) Mechanical properties of fasteners; Part 2: Nuts with specified proofload values; coarse thread (ISO 898-2:1992); German versionEN 20898-2:1993

DIN EN 26 157-3 (12/91) Fasteners; surface discontinuities; bolts, screws and studs subject tospecial requirements (ISO 6157-3:1988); German version EN 26157-3:1991

DIN EN 27 963 (6/92) Welds in steel; calibration block No. 2 for ultrasonic examination ofwelds (ISO 7963:1985); German version EN 27963:1992

DIN 32 514-1 (6/90) Determination of ferrite number in austenitic weld metal; measurementmethod

DIN 50 104 (11/83) Testing of hollow bodies by internal pressure; leak detection up to acertain pressure value; general specifications

DIN 50 115 (4/91) Notched bar impact testing of metallic materials using test pieces otherthan ISO test pieces

DIN 50 125 (4/91) Test pieces for the tensile testing of metallic materials

DIN 51 220 (1/96) Materials testing machines - Generals for requirements and forverification and calibration of materials testing machines

DIN 54 111-2 (6/82) Non-destructive testing; testing of metallic materials by X-rays orgamma rays; radiographic techniques for castings of ferrous materials

KTA 3211.1

Page 122

DIN 54 119 (8/81) Non-destructive testing; ultrasonic inspection; terms

DIN 54 130 (4/74) Non-destructive testing; magnetic leakage flux testing, general

DIN 54 141-3 (2/87) Non-destructive testing; eddy current testing of pipes and tubes;procedure

DIN 54 152-1 (7/89) Non-destructive testing; penetrant inspection; procedure

DIN 54 152-2 (7/89) Non-destructive testing; penetrant inspection; verification of penetrantinspection materials

DIN 54 152-3 (7/89) Non-destructive testing; penetrant inspection; reference blocks fordetermination of the sensitivity of penetrant systems

DIN 58 220-3 (1/97) Visual acuity testing - Part 3: Test for use in expertise

DIN 58 220-5 (1/97) Visual acuity testing - Part 5: Vision screening test for general use

EURONORM 103-71 (11/71) Microscopic determination of the ferritic or austenitic grain size of steels

SEL 072 (12/77) Ultrasonically tested heavy plate; technical delivery specifications

SEP 1805 (3/76) Sampling and sample preparation for the product analysis in the case ofsteel

SEP 1915 (9/94) Ultrasonic testing of pipes for longitudinal defects

SEP 1918 (1/92) Ultrasonic testing of pipes for transverse defects

SEP 1919 (6/77) Ultrasonic testing for laminations of pipes of creep-resistant steels

SEP 1920 (12/84) Ultrasonic testing of rolled semi-finished products on internal materialdiscontinuities

SEP 1922 (7/85) Ultrasonic testing of forgings of ferritic steel

SEP 1925 (1/80) Electromagnetic testing of pipes for the proof of impermeability

SEP 1935 (6/82) Seam testing of castings of steel; magnetic powder test

SEP 1936 (6/82) Seam testing of castings of steel; penetration testing

SEW 088 (10/93) Weldable fine-grained structural steels; guidelines for processing, inparticular for fusion welding (incl. supplementary sheets 1 and 2)

SEW 110 (7/86) Procedure test for production welding at cast steel

SEW 400 (2/97) Stainless rolled and forged steels

AD HP 3 (4/96) Welding systems - Welders

AD W 2 (1/00) Austenitic steels

Literature

[1] Handbuch für das Loseblattsammlung (Loose-leaf edition); Verlag Stahleisen, DüsseldorfEisenhüttenlaboratorium

[2] De Long, W. T. Welding Research Supplement 53 (1974), S. 273/286

[3] Richter, F. Physikalische Eigenschaften von Stählen und ihreTemperaturabhängigkeit, Stahleisen-Sonderberichte Heft 10, 1983,Verlag Stahleisen, Düsseldorf.

[4] Petzow, G. Metallkundliche technische Reihe; Metallographisches Ätzen,6. Auflage; Berlin, Stuttgart, Borntraeger, 1994

[5] Reference-Atlas for a comparative evaluation of ferrite percentage inthe fused zone of austenitic stainless steel welded joints;Internationales Institut für Schweißtechnik: Istituto Italiano dellaSaldatura, Genova, 1972

KTA 3211.1

Page 123

Annex K (informative)

Changes with respect to the edition 6/91

(1) The wording of the requirements regarding the accuracyof the test and inspection facilities and their testing to clause3.4 (2) was adapted to DIN 51 220, edition 1/96 withoutchange in contents.

(2) The procedural requirements for ultrasonic examinationin clause 4.4.7, in correspondence with clause 3.3.8 of KTA3201.1 (6/98), as well as the requirements for the ultrasonicexamination of product forms made of austenitic steels wereadapted to the actual state of knowledge.

(3) In Section 4.3 it was pointed out that for steel castings nosampling direction for notched-bar impact test specimens isspecified due to the directional independence of mechanicalcharacteristics.

(4) For hot (T ≥ 200 °C) reactor water containing piping andcomponents to be fabricated anew for boiling-water reactorsonly the steel grade X 6 CrNiNb 18 10 with a restrictedchemical composition compared to that of the standardcomposition shall be used. Corresponding stipulations havebeen included in clauses 4.3.3, 7.1.1, 7.2.1, 7.3.1, 7.4.1, 7.5.1and 7.6.1.

(5) Sections 5, 6, 8 and 9 were adapted to the actual state ofstandardisation.

(6) The scope of Sections 5.6, 6.6 and 7.6 was extended tocover tees fabricated to the liquid-bulge method.

(7) The test certificates required by Sections 6 and 7 for testgroup A 3 were adapted to the requirement of PmB ≤ 50 N/mm2

defined for test group A 2.

(8) The requirements of Table 8-1 were adapted to Annex 1of AD Merkblatt W 7 (2/98).

(9) In Annexes B and C it was pointed out that for the term"large production weld" the definition of DIN 17 245 willgovern. According to the actual standard DIN EN 10 213-1 alarge production weld is meant if its depth exceeds 40 % ofthe effective wall thickness. DIN 17 245 additionally specifiesthat for grades 1 and 2 (e.g. welding ends) the depth shall notexceed 25 mm. For wall thickneses over 60 mm the definitionto DIN 17 245 therefore is more stringent. The more stringent

requirements of DIN 17 245 shall be adhered to for the scopeof KTA 3211.1.

(10) Annex D "Procedure for determining the delta ferritecontent" was changed in correpondence with KTA 3201.1(6/98).

(11) In Annex E the term "recording limit" not defined up tonow was clarified by inclusion of supplementary stipulations.

(12) Annex F "Performance of manual ultrasonicexaminations" and Annex G "Performance of surface crackdetection by magnetic particle and liquid penetrant methods"were replaced by the respective Annexes of KTA 3201.1(6/98).

(13) In Annex G requirements regarding the sensitivity of theexamination system as per DIN 54 152-3 wer taken over.

(14) In Section H 1.2 it was pointed out that when using themagnetic particle method minor redressing without furtherexamination is allowable if the test result of the originalexamination is not impaired.

(15) Annex I was adapted to the actual state of standardi-sation. The references to the material standards DIN 17 100(1/80), DIN 17 102 (10/83), DIN 17 103 (10/89), DIN 17 155(10/83), DIN 17 240 (7/76), DIN 17 243 (1/87), DIN 17 245(12/87) and DIN 17 445 (11/84) as well as to DIN 54 152-1(7/89) and DIN 54 152-3 (7/89) for the performance ofpenetrant examination were maintained for the followingreasons, although they have been withdrawn in the meantime:- the withdrawn standards are further needed as

specification for some allowable materials. For thesematerials no other standards covering the actual range ofapplication exist.

- the application of DIN EN 571-1 (3/97) (documentsubstituting DIN 54 152-1) and DIN ISO 3452-3 (documentsubsituting DIN 54 152-3) is at present not practicallyfeasible, as long as the stipulations contained in the otherparts of DIN 54 152 regarding the calibration blocks to beused, the checking of penetrant fluids etc. will not bereplaced by DIN EN Standards in a manner compatiblewith DIN EN 571-1.

Date post:	27-Oct-2015
Category:	Documents
Upload:	smallik3
View:	17 times
Download:	1 times

3211_1e

Documents