Safety Standards

of the
Nuclear Safety Standards Commission (KTA)

KTA 3211.1 (2017-11)

Pressure- and activity-retaining components of systems

outside the primary circuit
Part 1: Materials
(Druck- und aktivitätsführende Komponenten von Systemen
außerhalb des Primärkreises; Teil 1: Werkstoffe)

Please note:
This translation includes the correction
published in BAnz of April 24th, 2019.

Previous versions of this Safety Standard

were issued 1991-06, 2000-06 and 2015-11

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

Editor:

KTA-Geschaeftsstelle c/o Bundesamt fuer kerntechnische Entsorgungs-

sicherheit (BfE)  Willy-Brandt-Strasse 5  38226 Salzgitter  Germany
Telephone +49-30-18-333-1621  Telefax +49-30-18-333-1625
 KTA SAFETY STANDARD
November Pressure- and activity-retaining components of systems out-
KTA 3211.1
2017 side the primary circuit; Part 1: Materials

CONTENTS

Fundamentals ........................................................................... 5 7 Product forms of austenitic steels .................................... 31

1 Scope ................................................................................ 5 7.1 Flat products ............................................................ 31
2 Definitions .......................................................................... 5 7.2 Dished or pressed product forms made from flat
products ................................................................... 32
3 General principles .............................................................. 6
7.3 Forgings, bars and rolled rings ................................. 33
3.1 Selection of materials.................................................. 6
7.4 Seamless pipes larger than DN 50 ........................... 34
3.2 Appraisal of the materials ........................................... 6 7.5 Seamless pipe elbows larger than DN 50 ................. 35
3.3 General quality-assurance requirements .................... 6 7.6 Seamless fittings larger than DN 50 ......................... 36
3.4 Requirements to be met by the manufacturer ............. 6 7.7 Castings ................................................................... 37
3.5 Design approval .......................................................... 7 8 Bolts and nuts.................................................................. 39
3.6 In-process inspection by the authorized 8.1 Scope ....................................................................... 39
inspector to § 20 of the Atomic Energy Act ................. 7 8.2 Materials................................................................... 39
3.7 Verification of quality characteristics ........................... 7 8.3 Additional requirements for the materials ................. 39
3.8 Marking ....................................................................... 7 8.4 Bolts and nuts made by machining from
quenched and tempered bars or from hot-cold
3.9 Repairs ....................................................................... 7
work hardened austenitic bars .................................. 39
3.10 Material characteristic data for design analysis ........... 7
8.5 Bolts and nuts made by machining from
4 Generally applicable stipulations for materials and solution-annealed and quenched austenitic bars ...... 41
material tests ..................................................................... 7 8.6 Bolts and nuts made by hot or cold forming and
4.1 General ....................................................................... 7 then quenched and tempered ................................... 41
4.2 Allowable materials ..................................................... 7 8.7 Bolts and nuts of strength classes or steel
grades ...................................................................... 42
4.3 Requirements for the materials and their
product forms .............................................................. 7 8.8 Marking .................................................................... 43
4.4 Testing and examination of materials and 8.9 Verification of quality characteristics......................... 43
product forms .............................................................. 8 9 Product forms of steels for special loads ......................... 44
4.5 Re-examinations ....................................................... 10 9.1 Forgings, bars and rolled rings ................................. 44
9.2 Castings ................................................................... 45
5 Product forms of ferritic steels of material group W I ........ 10
10 Heat-exchanger tubes ..................................................... 46
5.1 Flat products ............................................................. 10 10.1 Seamless straight heat-exchanger tubes of
5.2 Dished or pressed product forms made from flat ferritic steels with wall thicknesses smaller than
products .................................................................... 12 or equal to 4 mm and with outside diameters
5.3 Forgings, bars and rolled rings.................................. 13 smaller than or equal to 38 mm ................................ 46
5.4 Seamless pipes larger than DN 50 ........................... 17 10.2 Seamless bent heat-exchanger tubes of ferritic
steels with wall thicknesses smaller than or
5.5 Seamless pipe elbows larger than DN 50 ................. 18 equal to 4 mm and with outside diameters
5.6 Seamless fittings larger than DN 50 .......................... 20 smaller than or equal to 38 mm ................................ 46
5.7 Castings.................................................................... 21 10.3 Seamless straight heat-exchanger tubes of
austenitic steels with wall thicknesses smaller
6 Product forms of ferritic steels of material group W II ....... 23
than or equal to 3.6 mm and with diameters
6.1 Flat products ............................................................. 23 smaller than or equal to 42.4 mm ............................. 47
6.2 Dished or pressed product forms made from flat 10.4 Seamless bent heat-exchanger tubes of
products .................................................................... 24 austenitic steels with wall thicknesses smaller
6.3 Forgings, bars and rolled rings.................................. 25 than or equal to 3.6 mm and with diameters
6.4 Seamless pipes larger than DN 50 ........................... 27 smaller than or equal to 42.4 mm ............................. 48
6.5 Seamless pipe elbows larger than DN 50 ................. 28 10.5 Longitudinally welded straight heat-exchanger
tubes of austenitic steels with wall thicknesses
6.6 Seamless fittings larger than DN 50 .......................... 29 smaller than 2 mm and with diameters Da
6.7 Castings.................................................................... 30 smaller than or equal to 38 mm ................................ 49

(Continued next page)

PLEASE NOTE: Only the original German version of this safety standard represents the joint resolution of the
35-member Nuclear Safety Standards Commission (Kerntechnischer Ausschuss, KTA). The German version was made pub-
lic in Bundesanzeiger of May 17th 2018. Copies of the German versions of the KTA safety standards may be mail-ordered
through the Wolters Kluwer Deutschland GmbH (info@wolterskluwer.de). Downloads of the English translations are available
at the KTA website (http://www.kta-gs.de).
All questions regarding this English translation should please be directed to the KTA office:
KTA-Geschaeftsstelle c/o BfE, Willy-Brandt-Strasse 5, D-38226 Salzgitter, Germany or kta-gs@bfe.bund.de
 CONTENTS
(Continued)

11 Non-destructive tests and examinations ...........................50 Annex A: Material characteristic data .................................. 69
11.1 General requirements ...............................................50
Annex AP: Reference data on physical characteristics .......... 94
11.2 Flat products .............................................................52
11.3 Dished or pressed product forms made from flat Annex B: Production welds of steel castings ....................... 96
products ....................................................................53
11.4 Forgings, bars and rings............................................53 Annex C: Procedure for determining the delta ferrite
content ............................................................... 100
11.5 Seamless pipes larger than DN 50 ............................56
11.6 Seamless pipe elbows larger than DN 50..................57 Annex D: Performance of manual ultrasonic testing .......... 102
11.7 Seamless fittings larger than DN 50 ..........................57
11.8 Castings ....................................................................58 Annex E: Performance of surface inspections by
magnetic particle and penetrant methods .......... 119
11.9 Bolts and nuts ...........................................................64
11.10 Product forms of steels for special loads ...................65 Annex F: Regulations and literature referred to in this
11.11 Heat-exchanger tubes ...............................................65 Safety Standard ................................................. 121

Comments by the editor:

Taking into account the meaning and usage of auxiliary verbs in the German language, in this translation the follow-
ing agreements are effective:
shall indicates a mandatory requirement,
shall basically is used in the case of mandatory requirements to which specific exceptions (and only
those!) are permitted. It is a requirement of the KTA that these exceptions - other than
those in the case of shall normally - are specified in the text of the safety standard,
shall normally indicates a requirement to which exceptions are allowed. However, the exceptions used,
shall be substantiated during the licensing procedure,
should indicates a recommendation or an example of good practice,
may indicates an acceptable or permissible method within the scope of this safety standard.
 KTA 3211.1 Page 5

Fundamentals safety provisions to an extent that is acceptable for nuclear

safety.
(1) The safety standards of the Nuclear Safety Standards
Commission (KTA) have the objective to specify safety-related c) Failure of the plant section can lead directly or via a chain
requirements, compliance of which provides the necessary of conceivable subsequent events to an accident as de-
precautions in accordance with the state of the art in science fined by § 49 of the Radiation Protection Ordinance.
and technology against damage arising from the construction (2) The following components fall within the scope of appli-
and operation of the facility (Sec. 7 para. 2 subpara. 3 Atomic cation of this safety standard:
Energy Act - AtG) in order to achieve the fundamental safety
functions specified in the Atomic Energy Act and the Radiolog- a) pressure vessels,
ical Protection Ordinance (StrlSchV) and further detailed in the b) piping systems and piping-system parts,
Safety Requirements for Nuclear Power Plants as well as in
c) pumps and
the Interpretations on the Safety Requirements for Nuclear
Power Plants. d) valves and fittings
(2) No. 3.1 of the Safety Requirements for Nuclear Power including the integral zones of the component support struc-
Plants requires the use of qualified materials as well as the tures.
assurance and maintenance of the quality features during (3) This safety standard shall not apply to:
manufacturing. The safety requirement no. 3.4 sets forth fur-
ther design and fabrication requirements for the pressure- a) piping systems and to valves and fittings of DN 50 size or
retaining walls of components outside the primary circuit. KTA smaller,
safety standard 3211.1 defines provisions to be made to meet b) internals of components (that are not part of the pressure-
these requirements within their scope of application. For this containing wall) and accessories,
purpose it also draws upon numerous individually cited rules c) systems and plant sections that perform auxiliary functions
from conventional engineering, especially DIN Standards. For for the systems in question here,
the pressure- and activity-retaining components of systems
outside the primary circuit the requirements of the aforemen- d) system parts in which the system pressure is determined
tioned safety requirements are further concretised with the exclusively by the geodetic pressure head in the suction
following safety standards zone,
KTA 3211.2 Design and Analysis, e) parts for force and power transmission to pumps and to
valves and fittings as well as inspections for verification of
KTA 3211.3 Manufacture functional capability,
KTA 3211.4 In-service Inspections and Operational Monito- f) weld filler metals and welding consumables,
ring, as well as with
g) small parts.
KTA 3206 Break Preclusion Verifications for Pressure-Re-
taining Components in Nuclear Power Plants. Note:
Small parts are subject to the stipulations of Section 10 and of
(3) KTA 3211.1 specifically defines the requirements to be Table 2-3 of KTA 3211.3.
imposed on:
a) organizations involved in manufacturing,
b) manufacture of materials and product forms as well as 2 Definitions
their chemical composition, mechanical and technological
(1) Loading temperature, lowest
characteristics, physical characteristics, heat treatment
and further processing, The lower of the pressure-test temperature or lowest operating
c) methods for testing and verifying the required quality of temperature is designated the lowest loading temperature.
materials and product forms, such as destructive and non- (2) Production welding
destructive examinations,
Production welding means welding performed prior to delivery
d) provision of documents for documentation of the test and to the customer to ensure the stipulated quality of cast pieces.
inspection results.
(3) Construction welding
Construction welding is a welded joint between two cast piec-
1 Scope es performed prior to delivery to the customer to produce a
complete unit.
(1) This safety standard shall apply to the materials and
product forms of the pressure-retaining walls of pressure- and (4) Test groups A1, A2 and A3
activity-containing light-water-reactor systems and compo- The components in the scope of application of this safety
nents that do not belong to the reactor-coolant pressure standard shall be classified in test groups A1, A2 or A3 de-
boundary but have relevance specifically to reactor engi- pending on design data and dimensions, with consideration of
neered safety. This definition shall include systems and com- the planned materials and stresses. KTA 3211.2 defines the
ponents meeting one of the following criteria: criteria for classification of a component.
a) The plant section is necessary for accident control by
Note:
means of shutdown, maintenance of long-term subcriti-
The allocation to the test groups is made by the licence holder by
cality and direct residual heat removal. Requirements for agreement with the authorized inspector.
components in systems involved only indirectly in residual
heat removal - in other words the closed cooling-water sys- (5) Room temperature
tems and secondary cooling-water systems which do not The temperature range for the room temperature is (23 ± 5) °C
carry activity - shall be established on a plant-specific ba- for the mechanical tests laid down in this safety standard.
sis with consideration of the multiple design (e.g., redun-
dancy-type, diversity-type). (6) Noise
b) Considerable energy is released in the event of failure of Depending on the test conditions, randomly distributed addi-
the plant section, and the consequences of failure are not tional signals in the screen image due to reflections from the
limited by structural provisions, spatial separation or other structure of the material, its surface condition or the electronics.
KTA 3211.1 Page 6

(7) Noise level (2) Ferritic steels for service in material group W I shall be
Noise level means the 95 % value of the cumulative fre- appraised with reference to the manufacturer and to the pro-
quency of the echo heights of the noise in the examined vol- duct form by agreement with the authorized inspector.
ume free from defects. (3) As regards nature and scope of appraisal tests, all other
(8) Authorized inspector steels shall be treated as steels for conventional pressure
vessel plants subject to supervision. If these steels for use in
The authorized inspector for the tests and inspections to be
conventional pressure vessel plants subject to supervision
conducted in accordance with this safety standard is the au-
have already been approved, they shall qualify as appraised.
thorized inspector called in by the licensing or supervisory
authority in accordance with Section 20 of the Atomic Energy (4) If in individual cases a material is used outside the scope
Act. The inspections/reviews required by this safety standard of validity of its approval, or if a different material is used, a
shall be performed on the basis of applications made by the special appraisal shall be required. The special appraisal shall
competent authority. be mentioned in the inspection certificate.
(9) Ultrasonic testing, selected
Selected ultrasonic testing means testing where the ac- 3.3 General quality-assurance requirements
ceptance criteria refer to the finished component. To this end, The stipulations in KTA 1401 shall apply to the general quality-
it is required to know the shape and final dimensions of the assurance requirements.
components to be fabricated from the test object as well as
their location in the test object.
3.4 Requirements to be met by the manufacturer
(10) Ultrasonic testing, global
Global ultrasonic testing means testing where the acceptance (1) The manufacturer shall possess facilities that permit
criteria have been determined globally without reference to a proper and state-of-the-art production of materials and product
finished component. forms.

(11) Reference block (2) The manufacturer shall possess test and inspection
A reference block is a block corresponding to the test object facilities that permit testing and inspection of the materials and
with respect to test-relevant characteristics (e.g. material, product forms in accordance with the applicable DIN stand-
forging direction, shape, wall thickness) and that contains ards or other rules pertinent to the conduct of materials testing
reference flaws (e.g. notches, bores) adapted to the individual and inspection. The test equipment shall correspond to DIN
testing task. 51 220 and be inspected in accordance with DIN 51 220.
Within the measuring range of the test equipment, the permit-
(12) Material group W I or W II ted measuring inaccuracy of the forces measuring equipment
The ferritic materials for manufacturing components within the shall not exceed  1 %. Upon request, the test reports to DIN
scope of application of this safety standard are classified in 51 220 shall be submitted to the authorized inspector. If test
material groups W I or W II according to their quality features, facilities of other agencies are employed, they shall be subject
especially chemical composition and toughness characteris- to the same stipulations.
tics. The allocation of materials to test groups is defined in
KTA 3211.2. (3) The manufacturer shall have access in its own works or
at other agencies to facilities with which the non-destructive
(13) Acceptance criteria for non-destructive testing examinations required by this safety standard can be per-
Non-destructive testing acceptance criteria refer to the sum of formed.
all stipulations used to determine whether an indication can be
evaluated to be acceptable without taking further measures (4) Mechanized or automated facilities to be employed for
(requirements of test instruction have been met) or whether the non-destructive examinations required by this safety stan-
further measures need be taken. The acceptance criteria dard shall undergo an appraisal by the authorized inspector.
contain both quantitative stipulations in form of acceptance (5) Lists of necessary procedure instructions for the produc-
limits (e.g. amplitude height, extension of indication, frequen- tion and testing facilities shall be compiled.
cy, and distance between indications) and descriptive stipula-
tions (e.g. linear or rounded indication, indication on surface or (6) Through quality monitoring with corresponding recor-
across volume, accumulation of indications). dings, the manufacturer shall ensure proper manufacture and
processing of the materials and product forms as well as ad-
herence to the governing technical rules.
3 General principles
(7) The manufacturer shall employ skilled personnel capable
3.1 Selection of materials of performing the tests and examinations properly. Personnel
(1) Materials appropriate for the intended use shall be se- performing visual inspections shall be informed on the manu-
lected, with consideration of the mechanical, thermal and che- facturing process and have vision to comply with the require-
mical loadings as well as the design conditions to KTA 3211.2. ments of DIN EN ISO 9712, which shall be checked every 12
months. For personnel performing non-destructive tests the
(2) The materials shall safely withstand the loadings during requirements of Section 11.1.3 apply.
the pressure test, during operation and all specified plant
conditions. Any materials on which welding is to be performed (8) The manufacturer shall be entitled to issue inspection
shall be suitable for welding. certificates only if he employs an authorized inspection repre-
Note: sentative qualified in accordance with the conditions of DIN
The selection of material shall be made by the purchaser, if nec- EN 10204. The name and stamp of the manufacturer's author-
essary after consultation with the material manufacturer. ized inspection representative shall be announced to the au-
thorized inspector.

3.2 Appraisal of the materials (9) If welding work is performed on the product forms in the
course of manufacture, the manufacturer shall employ his own
(1) The materials shall be appraised to determine whether supervisory staff and welders qualified to DIN EN ISO 9606-1
they are suitable for the intended use and the planned pro- in conjunction with AD-2000 Merkblatt HP 3. Only qualified
cessing conditions. welders shall be used for the welding jobs. The revalidation of
 KTA 3211.1 Page 7

welder qualification must be acquired to clause 9.3 a) or (2) Repairs by welding shall be subject to the stipulations of
clause 9.3 b) of DIN EN ISO 9606-1. The welding supervisor KTA 3211.3.
shall be a member of the staff of the manufacturer's works and
be named to the authorized inspector. (3) Production weldings on cast pieces are not repairs within
the meaning of this safety standard.
(10) A procedure by which all deviations from the quality
requirements observed during production are reported to the
responsible agency shall be set forth in writing. 3.10 Material characteristic data for design analysis
(11) The manufacturer shall have a quality department that is The characteristic data critical to strength design analysis shall
independent of the production department. be taken from Annex A, from the appropriate DIN standards,
VdTÜV material sheets or, in the case of special steels, from
(12) The organizational classification and assignment of du-
ties of the manufacturer's authorized inspection represen- the authorized inspector's appraisal.
tative, test supervisory personnel, NDT operators and quality
department and, if applicable, the welding supervisory per-
sonnel, shall be set forth in writing. 4 Generally applicable stipulations for materials and
material tests
(13) The authorized inspector shall review whether the re-
quirements have been met before production can be started. 4.1 General
The review shall be repeated at intervals of about one to two (1) The requirements for material characteristics shall apply
years, unless the authorized inspector can be convinced by to the final condition of the components after the in-process
other means that the conditions are still being met. inspection and pressure test. On the basis of the tests and
examinations to be performed on materials and product forms,
3.5 Design approval the material characteristics shall be verified on sufficiently
large test coupons in the heat-treatment conditions required
Subject to design approval by the authorized inspector are for the particular purpose.
a) test instructions for non-destructive testing procedures RT,
UT and ET, (2) The products shall have smooth surfaces consistent with
b) material testing and sampling plans for product forms for the forming method employed. Impermissible surface irregula-
production of components from ferritic steels of material rities shall be eliminated. The resulting depressions shall be
group WI, if sampling is not clearly defined in the Sections ground flush. The wall thickness shall not be less than the
relating to product forms, and allowable minimum nominal wall thickness.
c) documents for cast pieces according to the stipulations in (3) Finish and surface quality of the products shall be speci-
Sections 5.7.2, 6.7.2, 7.7.2 and 9.2.2. fied in the purchase order. In this regard, the surface require-
ments according to Section 11.1 shall be taken into account.
3.6 In-process inspection by the authorized inspector to
§ 20 of the Atomic Energy Act 4.2 Allowable materials
The authorized inspector shall have the right to be present
during the manufacturing processes. However, he shall not Materials shall be allowable if they fulfill the prerequisites of Sec-
impair the manufacturing operations. tion 3.1 and their suitability has been established in accordance
with Section 3.2 of this safety standard. Materials approved for
the individual products are given in Sections 5 to 10.
3.7 Verification of quality characteristics
(1) The quality characteristics of the materials and product 4.3 Requirements for the materials and their product forms
forms shall be determined by tests and examinations, which
shall be performed in the manufacturer's works. 4.3.1 Ferritic steels of material group W I

(2) The quality characteristics of the materials and product Ferritic steels of material group W I shall meet the following
forms shall be verified by inspection certificates to DIN EN conditions:
10204. The governing stipulations for the required type of a) In the notched-bar impact test on transverse specimens at
quality verification shall be those in the following Sections the lowest operating temperature (including accidents) or
relating to product forms. Confirmation that the requirements at the temperature at which the primary membrane stress
of this safety standard have been met shall be required in the is higher than 50 N/mm2, the smallest individual value of
certificates.
impact energy of the base metal, weld metal and heat-
(3) inspection certificates 3.2 shall be confirmed or be estab- affected zone shall not be less than 68 J, and the smallest
lished by the authorized inspector to § 20 of the Atomic Ener- individual value of lateral expansion shall not be less than
gy Act. 0.9 mm.
b) The smallest individual value of upper shelf impact energy,
3.8 Marking determined on transverse specimens, shall not be less than
100 J. This only applies to the base metal.
The product forms shall be clearly and durably marked, if at all
possible without notching, in accordance with the stipulations c) The impact energy, determined on transverse specimens,
in the following Sections relating to product forms. The use of shall not be less than 41 J at the test temperature of 0 °C.
code characters is permitted. The complete text of the marking Only one individual value below the required mean value
shall be indicated in the inspection certificates. A clear correla- shall be permitted, and it shall not be smaller than 29 J.
tion between the inspection certificates and product forms This requirement applies to the base metal, the weld metal
shall be possible at all times. and the heat-affected zone.
For cast steel the specimen direction is not specified.
3.9 Repairs
4.3.2 Ferritic steels of material group W II
(1) Any necessary repairs shall be reported to the authorized
inspector. Further action shall be determined in consultation Ferritic steels of material group W II shall meet the following
with the authorized inspector. conditions:
KTA 3211.1 Page 8

a) The values of the chemical composition determined in the 4.4 Testing and examination of materials and product
ladle analysis shall not exceed 0.020 % P and 0.015 % S. forms
In addition, the processability shall be considered when
4.4.1 Designation of specimen direction in product forms
defining the chemical composition, especially the permis-
sible contents of microalloying elements. The following designations shall be used to describe the direc-
b) In the notched-bar impact bend test on transverse speci- tion of specimens in product forms (see Figures 4-1 and 4-2):
mens, the mean value shall not be less than 41 J
ba) at the test temperature of 0 °C if the lowest loading
temperature is lower than 20 °C, or
bb) at the test temperature of 20 °C if the lowest loading 3 HUR 2
temperature is higher than or equal to than 20 °C.
Only one individual value below the required mean value
shall be permitted, and it shall not be smaller than 29 J. 2
The requirement applies for the base metal, the weld metal 3 1 1
and the heat-affected zone.
For cast steel the specimen direction is not specified.

4.3.3 Austenitic steels 1: Perpendicular specimen

2: Longitudinal specimen
Austenitic steels shall meet the following conditions:
3: Transverse specimen
a) The steels shall be resistant to intergranular corrosion in
the production conditions in question. HUR: Main forming direction
b) Steels for hot (operating temperature  200 °C during
continuous operation) reactor water containing product Figure 4-1: Designation of specimen directions for flat prod-
forms and components in boiling water reactor plants shall ucts
be resistant to IGSCC and have a cobalt content not ex-
ceeding 0.2 %. Details are specified in the product-form re-
lated Sections.
c) The chemical composition shall be defined such that hot
cracks do not develop during welding. ial
ax
d) In the case of steels for product forms with a wall thickness 2 UR
H
greater than 16 mm or DN greater than 150 mm, the im- 2
pact energy value of the base metal, weld metal and heat- HUR tangential
affected zone, determined on transverse specimens at the
test temperature of 20 °C, shall not be less than 70 J
1
(mean value of three specimens, smallest individual value
not less than 60 J) in the solution-annealed and quenched
condition, or 55 J (mean value of three specimens, small-
est individual value not less than 40 J) in the annealed
condition. 3
1
e) For parts on which welding work without weld filler metal
will be performed during further processing, the deposited
base metal shall have a delta ferrite content of 2 % to 10 %
(ferrite number 2 to 11) to Annex C. For parts on which
welding work with weld filler metal will be performed during
further processing, the deposited base metal shall have a
3
delta ferrite content of 1 % to 10 % (ferrite number 1 to 11)
to Annex C. A close ferrite lattice structure is not permitted
in either case. Deviations are permitted if the characte-
ristics of the welded joint satisfy the stipulations of KTA Specimen direction relative to
3211.3.
Specimen
f) For rolled and forged product forms made of austenitic Product Main forming direction (HUR)
No.
steels as well as parts made from such forms, the required geometry tangential axial
ultrasonic examinability, the further processability and the
specified mechanical and technological characteristics 1 radial perpendicular perpendicular
shall not be impaired by coarse-grained microstructural
2 axial transverse longitudinal
zones.
Note: 3 tangential longitudinal transverse
Based on available experience, every effort should be made to
achieve a grain size corresponding to a characterizing number Figure 4-2: Designation of specimen directions for rotation-
larger than or equal to 4 to DIN EN ISO 643. ally symmetric product forms

4.3.4 Steels for special loads a) Designation based on direction relative to fibre:
If special loads such as erosion, corrosion and wear are pre- Longitudinal specimens (L):
sent, materials matched to the requirements of the particular Longitudinal axis of specimen in the main forming direc-
application shall be employed. The conditions for such materi- tion; for notched-bar impact specimens, the notch axis
als shall be defined on a case-by-case basis by agreement shall be perpendicular to the plane of the transverse and
with the authorized inspector. longitudinal directions.
 KTA 3211.1 Page 9

Transverse specimens (Q): (3) Should simulated stress-relief annealing be required in

Longitudinal axis of specimen transverse to the main form- Annex A or in the authorized inspector's appraisal, it shall be
ing direction; for notched-bar impact specimens, the notch performed in accordance with the conditions stipulated there-
axis shall be perpendicular to the plane of the transverse in.
and longitudinal directions.
Perpendicular specimens (S): 4.4.6 Tests and test methods to be employed
Longitudinal axis of specimen perpendicular to the plane of
4.4.6.1 General
the transverse and longitudinal directions; for notched-bar
impact specimens, the notch axis shall be in the main (1) The stipulations of clause 4.4.6 shall apply if perfor-
forming direction. mance of the tests cited in the following is required in the
Sections relating to product forms and if nothing to the contra-
b) Designation based on direction relative to product geometry: ry is expressly stipulated there.
Axial specimens (A):
(2) The particulars needed for materials testing and taken
Longitudinal axis of specimen parallel to the axis of rota-
from the classification into test and material groups per KTA
tional symmetry; for notched-bar impact specimens, the
3211.2 shall be announced to the material or product-form
notch axis shall be perpendicular to the cylindrical surface.
manufacturer in the purchase order.
Tangential specimens (T):
Longitudinal axis of specimen in the circumferential direc-
4.4.6.2 Chemical analysis
tion; for notched-bar impact specimens, the notch axis
shall be perpendicular to the cylindrical surface. (1) The content by mass of elements specified for the re-
spective material shall be determined during ladle and product
Radial specimens (R):
analyses.
Longitudinal axis of specimen perpendicular to the cylindri-
cal surface; for notched-bar impact specimens, the notch (2) DIN EN ISO 14284 shall apply to the specimen taking
axis shall be in the main forming direction. and preparation.
(3) In case of doubt the chemical composition shall be deter-
4.4.2 Location of specimens in product forms mined by the test method developed by the Chemists Commit-
tee of the Association of German Ferrous Metallurgists (VDEh)
The specimen location shall be identified as follows: as re-
(see Manual for the Ferrous Metallurgy Laboratory [1]).
gards depth below the surface, by the location of the speci-
men axis; as regards distance from the edge, by the location
of the cross section to be inspected. Further particulars are 4.4.6.3 Hardness test
defined in the following Sections relating to product forms.
(1) Hardness tests shall be performed to DIN EN ISO 6506-1
and DIN EN ISO 6506-4 or to DIN EN ISO 6507-1 and DIN EN
4.4.3 Size of test coupons ISO 6507-4.
(1) The quantity of material to be taken shall be large (2) Other hardness test methods may also be used, subject
enough to provide an adequate quantity of material for substi- to approval of the authorized inspector.
tute specimens in addition to the material for verification of
mechanical and technological characteristics.
4.4.6.4 Tensile test
(2) If further specimen quantities are needed for additional
Tensile tests shall be performed to DIN EN ISO 6892-1 and
tests, the number and dimensions of the additional test cou-
DIN EN ISO 6892-2. Where method A is used, the strain rates
pons shall be specified in the purchase order. In the case of
recommended by the standard shall be used. Tensile test
castings, additional test plates from the heats used for these
specimens to DIN 50125 may also be used.
coupons shall be kept available if required.

4.4.6.5 Notched-bar impact bend test

4.4.4 Marking of test coupons and specimens
Notched-bar impact bend tests shall be performed to DIN EN
For the acceptance tests, the test coupons shall be marked ISO 148-1 on specimens with V-notch using a striker with
legibly and clearly before removal from the product form, and 2 mm radius (KV2). One set consisting of three specimens
the specimens shall be marked likewise before specimen shall be tested. Where specimens with a width less than
removal from the test coupon. The specimen marking shall 10 mm are used, the impact energy determined shall be con-
permit exact correlation with its location in the product form. verted proportionally to the specimen width to the standard
specimen if the test has been conducted at the upper shelf of
4.4.5 Heat-treatment conditions of specimens impact energy. Otherwise, the conversion factor of impact
energy to the standard specimen value shall be decided in
(1) All test coupons shall be heat-treated on and together each individual case.
with the product form (normalizing, quenching and tempering,
solution annealing and quenching).
4.4.6.6 Impact energy vs. temperature curves
(2) If the product forms are not delivered in the heat-
treatment condition governing establishment of the charac- (1) In the case of product forms belonging to test group A 1
teristics, but receive this heat treatment only in the course of or A 2 notched-bar impact bend tests to clause 4.4.6.5 shall
further processing, the material manufacturer shall perform be performed at a minimum of four temperatures to plot im-
tests on specimens from test coupons subjected to corre- pact energy vs. temperature curves.
sponding heat treatment. (2) The temperatures shall be chosen such that they en-
Note: compass the upper shelf of impact energy, characterized by a
Unless otherwise stipulated in the appraisal, stress-relief annea- dull fracture surface representing a proportion of about 100 %
ling shall not constitute the heat treatment governing establish- of the total fracture surface, as well as the transition to brittle
ment of the mechanical and technological characteristics. fracture behaviour, characterized by a dull fracture surface
KTA 3211.1 Page 10

representing a proportion of about 50% of the total fracture 4.4.6.13 Visual inspection
surface.
During the acceptance procedure, all products shall be sub-
(3) A set of three specimens shall be tested at each test jected to a visual inspection in which case the following shall
temperature. For all notched-bar specimens of ferritic steels be checked:
used to plot impact energy vs. temperature curves, the lateral a) the compliance of the product surface with the required
expansion and the proportion of dull fracture surface as a surface condition in due consideration of subsequent sur-
percentage of total fracture surface shall be determined ac- face coating, if any,
cording to DIN EN ISO 148-1. b) the surface condition with regard to surface irregularities,
c) the compliance of the products with the number of items
4.4.6.7 Technological tests on pipes given and the identification marking, and
The technological tests on pipes shall be performed to: d) the product surface for compliance with the given clean-
liness requirements.
DIN EN ISO 8492 - Flattening test or
DIN EN ISO 8493 - Drift test or 4.4.6.14 Non-destructive tests and examinations
DIN EN ISO 8495 - Ring expanding test or
The stipulations of Section 11 shall apply.
DIN EN ISO 8496 - Ring tensile test

4.5 Re-examinations
4.4.6.8 Metallographic examinations
(1) Test results that are based on incorrect taking or prepa-
(1) The microstructural condition shall be determined by ration of the test specimens (test specimen sets), on incorrect
preparing micrographs at a magnification that permits an une- performance of the test or on a random narrow flaw location in
quivocal evaluation. one test specimen are invalid. The examination shall be re-
peated.
(2) The grain-size characterizing number shall be deter-
mined to DIN EN ISO 643. (2) Should the results of a properly performed examination
fail to meet the above requirements, the following actions shall
be taken:
4.4.6.9 Determination of delta ferrite content
a) Lotwise examination
(1) If required in the Sections relating to product forms, the aa) The test coupon from which the unsatisfactory speci-
delta ferrite content of products of austenitic steels or auste- men (or specimen set) was taken shall be excluded
nitic cast steel shall be determined by one of the following from the lot. It shall be replaced by two further test
methods: coupons from the lot, and the required examinations
a) metallographic determination in the as-delivered condition, shall be repeated on those coupons.
b) metallographic determination on the bead-on-plate test ab) The examination shall qualify as passed if the results
specimen, of the re-examination meet the requirements.
ac) The lot shall be rejected if any result of the two re-
c) theoretical estimation from the chemical composition,
examinations fails to meet the requirements. However,
using De Long's method [2].
a check examination of the characteristic found to be
(2) The Sections relating to product forms specify which of out of specification is permitted on each individual
the methods indicated under (1) a) to c) is to be employed. piece of the lot.
(3) If the theoretical estimate yields ferrite numbers lower b) Individual examination
than 3, the delta ferrite content shall also be determined ba) For each unsatisfactory specimen (or specimen set),
metallographically on the bead-on-plate test specimen. two further specimens (or specimen sets) from the
same sampling location shall be examined.
(4) Details on how to perform the methods cited under (1) a)
to c) are described in Annex C. bb) The results of both examinations shall meet the re-
quirements.
(5) The particular method to be employed shall be indicated
(3) Should it be impossible by appropriate heat treatment to
in the inspection certificate.
eliminate the reason for the unsatisfactory result of an exami-
nation, a new heat treatment shall be required, after which the
4.4.6.10 Corrosion-resistance testing test unit shall be submitted again for examination.
The resistance to intergranular corrosion shall be verified to (4) The cause of the unsatisfactory result of the first exami-
DIN EN ISO 3651-2. nation shall be investigated.

4.4.6.11 Materials identification check

5 Product forms of ferritic steels of material group W I
(1) The materials identification check shall be carried out
5.1 Flat products
using a spectrometric method.
5.1.1 Materials
(2) For pieces that have undergone a product analysis, it is
permitted to acknowledge that analysis as the materials identi- (1) The following steel grades may be used:
fication check. a) steel grades to Section A 1
b) other steel grades meeting the prerequisites of Section 3 in
4.4.6.12 Dimensional check combination with the stipulations in the authorized inspec-
tor's appraisal.
Before shipment of the products, the dimensions and toler-
ances specified in the purchase order shall be checked. (2) The materials shall meet the requirements of clause 4.3.1.
 KTA 3211.1 Page 11

5.1.2 Additional requirements for the materials a) One ladle analysis per heat.
(1) Flat products with nominal thicknesses equal to or larger b) One product analysis on one sampling location in each of
than 15 mm subjected to loading perpendicular to the rolled two rolled plates per heat.
surface shall at least meet the requirements of quality class (2) The mechanical and technological characteristics shall
Z35 to DIN EN 10164. This shall be specified in the purchase be determined by performing:
order.
a) One room-temperature tensile test per sampling location.
(2) For flat products with nominal thicknesses equal to or b) One elevated-temperature tensile test per heat, dimensio-
greater than 150 mm, the smallest individual value of impact nal range and a total weight of at most 30 metric tons. The
energy absorbed (transverse specimens) at the middle of the test temperature is defined in Section A 1 or in the autho-
flat product thickness at 80 °C shall not be less than 68 J. rized inspector's appraisal.
(3) When flat products are used for tubesheets, the same c) Room-temperature tensile tests to DIN EN 10164 per rolled
requirements as for specimens longitudinal to or transverse to plate for flat products with nominal thicknesses equal to or
the main rolling direction shall apply for the room-temperature larger than 15 mm, in order to determine the reduction of
yield point or 0.2 % proof stress and tensile strength of stand- area at fracture, whenever the quality class Z35 is required
ard specimens perpendicular to the flat product surface. This acc. to clause 5.1.2 (1).
shall be specified in the purchase order. d) One notched-bar impact bend test to clause 4.4.6.5 per
(4) The surface finish shall satisfy the stipulations of DIN EN sampling location at 33 °C or at the lowest operating tem-
10163-2 Class B Subgroup 3. perature, whichever is lower, for flat products with nominal
thicknesses equal to or larger than 5 mm. Notwithstanding
the foregoing, the impact energy for steel grade 15 MnNi 6 3
5.1.3 Tests and examinations shall be determined at 0 °C.
5.1.3.1 Sampling and specimen preparation e) Notched-bar impact bend tests at one sampling location for
determination of the impact energy vs. temperature curve
(1) The sampling locations are stipulated in Section A 1. to clause 4.4.6.6 per heat, dimensional range and identical
(2) The following specimens shall be taken for the tensile heat treatment for flat products with nominal thicknesses
test at room temperature: equal to or larger than 10 mm and not exceeding 38 mm,
a) For flat products with nominal thicknesses not exceeding and per rolled plate for plates with nominal thicknesses ex-
40 mm, flat tensile-test specimens containing both rolled ceeding 38 mm. At least four test temperatures shall be
surfaces. used, of which two shall be 0 °C and the lowest loading
temperature. This test may be waived for flat products of
b) For flat products with nominal thicknesses larger than steel grade 15 MnNi 6 3.
40 mm, flat tensile-test specimens at least 40 mm thick
containing at least one intact rolled surface. f) One notched-bar impact bend test to clause 4.4.6.5 at one
sampling location per rolled plate, to determine the upper
(3) The following specimens shall be taken for the tensile shelf impact energy for flat products with nominal thick-
test at elevated temperature: nesses larger than 16 mm. This test may be performed
a) for flat products with nominal thicknesses smaller than during determination of the impact energy absorbed vs.
12 mm, flat tensile-test specimens or round tensile-test temperature curves. In general, 80 °C shall be selected as
specimens, the test temperature. The test shall be performed only in
test group A 1, and may be waived if the value of impact
b) for flat products with nominal thicknesses equal to or larger
energy absorbed determined per d) is equal to or greater
than 12 mm up to and including 40 mm, round tensile-test
than 100 J.
specimens,
g) One notched-bar impact bend test to clause 4.4.6.5 at
c) for flat products with nominal thicknesses larger than
80 °C at one sampling location in the middle of the flat
40 mm, round tensile-test specimens with the specimen
product thickness of each rolled plate for plates with nomi-
axis at one quarter of nominal thickness under the rolled
nal thicknesses equal to or greater than 150 mm, unless
surface (test diameter equal to or larger than 10 mm).
otherwise stipulated in the appraisal.
(4) The notched-bar impact bend test shall be subject to the (3) Each rolled plate shall be subjected to a materials identi-
following requirements: fication check.
As regards the specimens for notched-bar impact testing one
side of the specimen shall be located as close as possible to (4) Each flat product shall be subjected to a visual inspection
the rolling surface in case of wall thicknesses ≤ 40 mm. In of its external finish.
case of nominal thicknesses exceeding 40 mm the specimen (5) The dimensional and shape accuracy of each rolled plate
axis shall be located at a distance of one quarter of the thick- shall be measured.
ness of the product form below the rolling surface.
(6) The Sections 11.1 and 11.2 as well as the Sections 11.1
(5) Transverse specimens shall be used for the tensile and and 11.4 in the case of flat products for tube sheets shall ap-
notched-bar impact bend tests. ply to the non-destructive tests and examinations.
(6) Specimens for determination of the reduction of area at
fracture on perpendicular specimens shall be taken and be pre- 5.1.4 Marking
pared in accordance with the stipulations in DIN EN 10164.
(1) Each flat product shall be marked with the following
(7) Standard specimens shall be used for determination of the information:
room-temperature yield point or 0.2 % proof stress and tensile a) manufacturer's symbol,
strength on specimens perpendicular to the flat product sur-
b) steel grade (for steels with guaranteed reduction of area at
face.
fracture perpendicular to the product surface additionally
quality class to DIN EN 10164),
5.1.3.2 Extent of tests and examinations c) heat number,
(1) The chemical composition shall be determined by per- d) specimen number,
forming: e) authorized inspector's mark.
KTA 3211.1 Page 12

(2) The marking shall be applied such that it appears upright (4) The test coupons shall be taken such that transverse
when viewed in the main rolling direction of the rolled plate. specimens can be machined. Deviations up to 20 degrees
from the theoretical transverse direction are permitted for heads
(ends) and similar parts. If this is not possible, a different way
5.1.5 Verification of quality characteristics of sampling shall be agreed with the authorized inspector.
(1) The results of the ladle analysis, product analysis, ma- (5) Round tensile-test specimens with a test diameter equal
terials identification check and non-destructive tests and exa- to or larger than 10 mm shall be made for both the room-
minations performed by the manufacturer shall be documen- temperature and elevated-temperature tensile tests. For nom-
ted with an inspection certificate 3.1 to DIN EN 10204. The inal thicknesses larger than 40 mm, the specimen axis shall
steel making process, the delivery condition of the product be located at a distance of one quarter of the product-form
form stating heat treatment temperatures, holding times and thickness under the rolled surface.
cooling conditions as well as simulated stress-relief annealing For product-form thicknesses that do not permit a test diame-
temperature and holding time of test coupons shall be indicat- ter of 10 mm, the largest possible diameter shall be chosen.
ed in the inspection certificate 3.1.
(6) For nominal wall thicknesses equal to or smaller than
(2) The results of mechanical and technological tests, visual 40 mm, one side of the specimens for the notched-bar impact
inspection, dimensional check and non-destructive tests and bend test shall be as close as possible to the rolled surface.
examinations shall be confirmed by the authorized inspector For nominal wall thicknesses larger than 40 mm, the specimen
and combined with inspection certificate 3.1 as inspection axis shall be located at a distance of one quarter of the prod-
certificate 3.2 to DIN EN 10204 issued by him. Alternatively, uct-form thickness under the rolled surface.
these tests shall be confirmed by the authorized inspector on
an inspection certificate 3.2 established by the manufacturer. 5.2.4.2 Extent of tests and examinations
(1) The mechanical and technological characteristics shall
5.2 Dished or pressed product forms made from flat prod- be determined by performing:
ucts
a) One room-temperature tensile test per sampling location.
5.2.1 Materials b) One elevated-temperature tensile test per heat, dimensio-
nal range and total weight of at most 30 metric tons. The
(1) The following steel grades may be used:
test temperature is defined in Section A 1 or in the autho-
a) steel grades to Section A 1, rized inspector's appraisal.
b) other steel grades that the meet the prerequisites of Sec- c) Room-temperature tensile tests to DIN EN 10164 in order
tion 3 in combination with the stipulations in the authorized to determine the reduction of area at fracture in the case of
inspector's appraisal. product forms with nominal wall thicknesses equal to or
(2) The materials shall meet the requirements of clause 4.3.1. larger than 15 mm, if as per clause 5.1.2 (1) quality class
Z35 is required. This test may be waived if it has already
been performed on the rolled plate and documented with
5.2.2 Additional requirements for the materials an inspection certificate 3.2 to DIN EN 10204.
Note:
The requirements of clauses 5.1.2 (1), (2) and (4) shall apply.
Correlation of parts with the rolled plate can be achieved, for
example, through the specimen number of the starting products.
5.2.3 Starting products d) One notched-bar impact bend test to clause 4.4.6.5 per
sampling location at 33 °C or at the lowest operating tem-
(1) Starting products shall be subject to the stipulations in
perature, whichever is lower, for nominal wall thicknesses
Section 5.1.
equal to or larger than 5 mm. Notwithstanding the fore-
(2) If the finished parts are tested individually in accordance going, the impact energy for steel grade 15 MnNi 6 3 shall
with clause 5.2.4.2, the tests to clause 5.1.3.2 (2) as well as be determined at 0 °C.
the corresponding verifications can be omitted. e) Notched-bar impact bend tests at one sampling location for
(3) For the tests to clauses 5.1.3.2 (3) to (5), an inspection determination of the impact energy vs. temperature curve
certificate 3.1 to DIN EN 10204 will suffice. to clause 4.4.6.6 per heat, dimensional range and heat-
treatment lot for product forms with nominal wall thick-
Note:
nesses equal to or larger than 10 mm and not exceeding
The stipulations of KTA 3211.3 shall apply to welded joints made 38 mm, and per rolled plate for product forms with nominal
with the starting products and remaining in the finished parts.
wall thicknesses exceeding 38 mm. At least four test tem-
peratures shall be used, of which two shall be 0 °C and the
5.2.4 Tests and examinations of dished or pressed product lowest loading temperature. This test may be waived for
forms made from flat products product forms of steel grade 15 MnNi 6 3.
5.2.4.1 Sampling and specimen preparation f) One notched-bar impact bend test to clause 4.4.6.5 at one
sampling location of each part to be tested to determine
(1) For product forms with a diameter or length equal to or the upper shelf impact energy for product forms with nomi-
smaller than 3000 mm, the tests or examinations shall be nal wall thicknesses larger than 16 mm. This test may be
performed on one part per rolled plate and heat-treatment lot. performed during determination of the impact energy vs.
The maximum permissible lot size shall be 10 parts. temperature curve.
Note: In general, 80 °C shall be selected as the test temperature.
Correlation of parts with the rolled plate can be achieved, for ex- The test shall be performed only in test group A 1, and
ample, through the specimen number of the starting products. may be waived if the value of impact energy determined
per d) is equal to or greater than 100 J.
(2) For product forms with a diameter or length greater than
3000 mm, each part shall be tested. g) One notched-bar impact bend test to clause 4.4.6.5 per
sampling location at 80 °C in the middle of the product-
(3) One test coupon shall be taken from each part to be form thickness for product forms with nominal wall thick-
examined. In the case of length or diameter exceeding 6 m an nesses equal to or greater than 150 mm, unless otherwise
additional test coupon shall be taken at the opposite side. stipulated in the appraisal.
 KTA 3211.1 Page 13

(2) Each product form shall be subjected to a materials iden- Note:

tification check. Heat-treatment thickness and heat-treatment weight designate the
wall thickness and piece weight of the product forms in the condi-
(3) Each product form shall be subjected to a visual inspec- tion in which the heat treatment governing establishment of the
tion of its external finish. mechanical and technological characteristics is performed.
(4) The dimensional and shape accuracy of each product
form shall be measured.
5.3.3 Tests and examinations
(5) The Sections 11.1 and 11.3 shall apply to the non-
destructive tests and examinations. 5.3.3.1 Sampling and specimen preparation
5.3.3.1.1 Test units
5.2.5 Marking (1) Unless otherwise required in clause 5.3.3.2, the following
(1) Each product form shall be marked with the following is required:
information: a) Pieces with heat-treatment weights lighter than or equal to
a) symbol of the manufacturer of the product form, 100 kg may be grouped as test units of 1000 kg each.
b) steel grade (for steels with guaranteed reduction of area at b) Pieces with heat-treatment weights heavier than 100 kg
fracture perpendicular to the product surface additionally and equal to or lighter than 500 kg from the same heat,
quality class to DIN EN 10164), with similar dimensions and from the same heat-treatment
c) heat number, lot shall be grouped as test units containing at most 10
parts.
d) specimen number and
c) Pieces with heat-treatment weights heavier than 500 kg
e) authorized inspector's mark. shall be tested individually.
(2) In the case of lotwise examination, the product form from
which the specimens were taken shall additionally be marked. 5.3.3.1.2 Sampling locations
(3) The marking shall be applied such that it appears upright
when viewed in the main rolling direction of the rolled plate. (1) For forged hollow parts, e.g., for shell courses, nozzles
or valve bodies, specimens shall be taken from one end as a
function of inside diameter Di as follows: from one sampling
5.2.6 Verification of quality characteristics location for Di equal to or smaller than 500 mm; from two
(1) The results of the materials identification check and non- sampling locations separated by 180 degrees for Di between
destructive tests and examinations performed by the manufac- 500 mm and 2000 mm; and from three sampling locations
turer shall be documented with an inspection certificate 3.1 to separated by 120 degrees for Di larger than 2000 mm.
DIN EN 10204. The delivery condition of the product form (2) At the opposite end, specimens shall be taken from one
stating heat treatment temperatures, holding times and cooling sampling location for normalized or air quenched and tem-
conditions as well as simulated stress-relief annealing tem- pered forgings having a finished length longer than 5000 mm
perature and holding time of test coupons shall be indicated in and for liquid quenched and tempered forgings having a fin-
the inspection certificate 3.1. ished length longer than 2000 mm. For pieces with inside
(2) The forming method shall be indicated in inspection diameters smaller than or equal to 500 mm, this sampling
certificate 3.1 to DIN EN 10204. location shall be offset by 180 degrees relative to that at the
other end (see Figures 5.3-1 and 5.3-2).
(3) The results of mechanical and technological tests, visual
Note:
inspection, dimensional check and non-destructive tests and
Finished length designates the length of the product form during
examinations shall be confirmed by the authorized inspector
the governing heat treatment, less the length of the test coupons.
and combined with the inspection certificate 3.1 as an inspec-
tion certificate 3.2 to DIN EN 10204 issued by him. Alterna- (3) For seamless rolled or forged rings or flanges, speci-
tively, these tests shall be confirmed by the authorized inspec- mens shall be taken from the circumference or end of the
tor on an inspection certificate 3.2 established by the manu- flange. They may also be taken from the end of the welding
facturer. end, if the heat-treatment wall thickness of the welding end is
(4) The inspection certificate of the starting product shall be equal to that of the flange. Specimens shall be taken as fol-
attached to the inspection certificate 3.2. lows: from one sampling location for inside diameters Di
smaller than or equal to 1000 mm; from two sampling loca-
tions separated by 180 degrees for Di between 1000 mm and
5.3 Forgings, bars and rolled rings 2000 mm; and from three locations separated by 120 degrees
5.3.1 Materials for Di larger than 2000 mm (see Figure 5.3-3).

(1) The following steel grades may be used: (4) For plates such as tubesheets, tube plates or blanking-
off covers with heat-treatment weights lighter than 1000 kg,
a) steel grades to Section A 2,
specimens shall be taken from one sampling location. If per-
b) other steel grades meeting the prerequisites of Section 3 in mitted by the forging method employed, this location shall be
combination with the stipulations in the authorized inspec- in the top or bottom zone (see Figure 5.3-4).
tor's appraisal.
(5) For plates with heat-treatment weights equal to or heavi-
(2) The materials shall meet the requirements of clause 4.3.1. er than 1000 kg, specimens shall be taken from two sampling
locations. If permitted by the forging method employed, these
5.3.2 Additional requirements for the materials locations shall be in the top and bottom zones (see Figure
5.3-4).
For products with heat-treatment thicknesses greater than
150 mm and heat-treatment weights heavier than 500 kg, the (6) For bars, specimens shall be taken at one end as a func-
smallest individual value of impact energy (transverse speci- tion of the diameter D of the bars: from one sampling location
mens) at the middle of the wall thickness at 80 °C shall not be for D smaller than or equal to 500 mm; and from two sampling
less than 68 J. locations separated by 180 degrees for D larger than 500 mm.
KTA 3211.1 Page 14

(7) In the case of b) One room-temperature tensile test per sampling location.
a) normalized or air quenched and tempered bars having a c) For pieces of similar dimension, one elevated-temperature
finished length longer than 5000 mm tensile test per heat and heat-treatment lot. The test tem-
perature is defined in Section A 2 or in the authorized in-
b) liquid quenched and tempered bars having a finished
spector's appraisal.
length longer than 2000 mm
d) One notched-bar impact bend test to clause 4.4.6.5 per
specimens shall be taken from one sampling location at the sampling location at 33 °C or at the lowest operating tem-
opposite end. For bars having diameters smaller than or equal perature, whichever is lower. Notwithstanding the fore-
to 500 mm, this location shall be offset by 180 degrees relative going, the impact energy absorbed for steel grade
to that at the other end. 15 MnNi 6 3 shall be determined at 0 °C.
e) Notched-bar impact bend tests for determination of the
5.3.3.1.3 Sampling depth impact energy vs. temperature curve to clause 4.4.6.6.
(1) For normalized and air quenched and tempered parts, ea) per heat and heat-treatment lot for pieces with heat-
the specimens shall be taken from at least one quarter of the treatment weights equal to or lighter than 500 kg
governing heat-treatment thickness but at most 80 mm under eb) per piece, at one sampling location, for pieces with
the heat-treatment surfaces. heat-treatment weights equal to or heavier than
500 kg.
(2) For liquid quenched and tempered parts, except for
At least four test temperatures shall be used, of which two
plates with heat-treatment thicknesses larger than 320 mm,
shall be 0 °C and the lowest loading temperature. This test
the specimens shall be taken from at least one quarter of the
may be waived for pieces of steel grade 15 MnNi 6 3 with
governing heat-treatment thickness but at most 80 mm under
wall thicknesses smaller than or equal to 150 mm.
the governing heat-treatment surface and at least from the
middle of the governing heat-treatment thickness (s/2) and at f) One notched-bar impact bend test to clause 4.4.6.5 at one
most 160 mm under the other surfaces. sampling location per test unit to verify the upper shelf
impact energy for pieces with heat-treatment weights
(3) For liquid quenched and tempered plates with heat- equal to or heavier than 150 kg in the normalized or air
treatment thicknesses larger than 320 mm, the specimens quenched and tempered condition and equal to or heavier
shall be taken from at least 80 mm under the heat-treatment than 50 kg in the liquid quenched and tempered condition.
surfaces. It shall be demonstrated that the smallest individual value
of upper shelf impact energy is equal to or larger than
(4) For parts with a governing heat-treatment thickness lar-
100 J. This test may be performed during determination of
ger than 150 mm and a heat-treatment weight heavier than
the impact energy vs. temperature curves. In general,
500 kg, samples shall be taken additionally at one location from
80 °C shall be selected as the test temperature. The test
the middle of the governing heat-treatment thickness (s/2).
shall be performed only in test group A 1, and may be
Note: waived if the value of impact energy determined per d) is
In the case of plates for tubesheets, the question of whether this equal to or greater than 100 J. This test may be waived for
requirement is met shall be verified in the appraisal by the impact pieces of steel grade 15 MnNi 6 3 with wall thicknesses
energy at the middle of the wall thickness. smaller than or equal to 150 mm.
g) One notched-bar impact bend test to clause 4.4.6.5 at
5.3.3.1.4 Specimen direction 80 °C at one sampling location in the middle of the thick-
ness for products with heat-treatment weights heavier than
(1) Transverse specimens shall be taken for tensile tests 500 kg and heat-treatment thicknesses larger than
and notched-bar impact bend tests if geometrically possible 150 mm, unless otherwise stipulated in the appraisal.
and nothing to the contrary is stipulated in Section A 2 or in
the authorized inspector's appraisal. (3) Each piece shall be subjected to a materials identification
check.
(2) Notwithstanding the foregoing, longitudinal specimens or
axial specimens may be taken from bars, specifically for ten- (4) Each piece shall be subjected in the as-delivered condi-
sile tests if the diameter or greatest length of a cross-sectional tion to a visual inspection of its external finish.
edge is smaller than 160 mm, or for notched-bar impact bend (5) A dimensional check of each piece shall be performed.
tests if the diameter or the greatest length of a cross-sectional
edge is smaller than 68 mm. (6) The Sections 11.1 and 11.4 shall apply to the non-
destructive tests and examinations.

5.3.3.2 Extent of tests and examinations

5.3.4 Marking
(1) The following procedures shall be performed for the che-
mical analysis: (1) Each piece shall be marked with the following infor-
mation:
a) One ladle analysis per heat.
a) manufacturer's symbol,
b) One product analysis on one sampling location in each of
two separately manufactured pieces per heat. b) steel grade,
c) One product analysis on each piece for piece weights c) heat number,
equal to or heavier than 5000 kg. d) specimen number,
(2) The mechanical and technological characteristics shall e) authorized inspector's mark.
be determined by performing: (2) In the case of lotwise examination, the piece from which
a) One hardness test per piece to verify uniformity for pieces the specimens were taken shall additionally be marked.
grouped together in test units.
Note:
5.3.5 Verification of quality characteristics
Verification of uniformity shall be acknowledged if the difference
between the highest and lowest hardness values in a test unit (1) The results of the ladle analysis, product analysis, mate-
does not exceed 30 HB units. rials identification check and non-destructive tests and exami-
 KTA 3211.1 Page 15

nations performed by the manufacturer, and if necessary of (2) The results of mechanical and technological tests, vis-
the hardness test shall be documented with an inspection ual inspection, dimensional check and non-destructive tests
certificate 3.1 to DIN EN 10204. The steel making process, and examinations shall be confirmed by the authorized in-
the delivery condition of the product form stating heat treat- spector and combined with inspection certificate 3.1 as in-
ment temperatures, holding times and cooling conditions as spection certificate 3.2 to DIN EN 10204 issued by him.
well as simulated stress-relief annealing temperature and Alternatively, these tests shall be confirmed by the authorized
holding time of test coupons shall be indicated in the inspec- inspector on an inspection certificate 3.2 established by the
tion certificate 3.1. manufacturer.

No. Finished length Inside diameter Di Examples for sampling

Normalized and air quenched

and tempered pieces: for normalized and air
L  5000 mm  500 mm

Di
1 quenched and tempered

s/4
pieces: x = s/4
Pieces quenched and tem-

s
pered in liquid: x L
L  2000 mm

for pieces quenched and

> 500 mm up to

Di
2 tempered in liquid: x = s/2

s/4
 2000 mm

s
x L

s/4

Di
3 > 2000 mm

s
x L

Normalized and air quenched

and tempered pieces:
 500 mm

Di
L > 5000 mm
s/4

4
Pieces quenched and tem-
s

pered in liquid: x L
L > 2000 mm

Di
> 500 mm up to
s/4

5
 2000 mm
s

x L
s/4

Di

6 > 2000 mm
s

x L

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

KTA 3211.1 Page 16

s/4 s x
HUR

s/4
x

HUR

s
L
L
Example 3 s
s/4

Example 1

x
x HUR: Main forming direction
s/4

HUR
HUR
s

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

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

s1
s1
s1 /4
s1 /4
x

x
x

s1 /4
s2

s1
Di

Di

Di

Example 1 Example 2 Example 3

For parts quenched and tempered in liquid: x = s1/2
For normalized or air quenched and tempered parts: x = s1/4
a) Examples for sampling

Di £ 1000 mm 1000 mm < Di £ 2000 mm Di > 2000 mm

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

Figure 5.3-3: Examples for sampling from seamless rolled or forged rings or flanges
 KTA 3211.1 Page 17

80
80

80
s/4
s/2

80

s
s

s
s/2

s/2
s/4
80 80
For plates quenched and tempered
in liquid: x = s/2 (max. 160 mm)
For normalized or air quenched and
tempered plates: x = s/4 (max. 80 mm)
x

80
x x 80

Sampling at s/2 only Sampling from top and Sampling from top and
for s 150 mm bottom zones possible bottom zones not possible

a) Sampling for b) Sampling for c) Sampling for

plates with s £ 320 mm plates with s > 320 mm plates with s > 320 mm

Contour for quenching Delivery contour Test coupon

and tempering

Figure 5.3-4: Examples for sampling from forged plates

5.4 Seamless pipes larger than DN 50 (3) Transverse specimens shall be taken for tensile tests
and notched-bar impact bend tests. If this is not possible, it is
5.4.1 Scope
permitted to take longitudinal specimens.
(1) The stipulations of this Section shall apply to seamless, (4) Notched-bar impact bend tests shall be performed only
rolled or pressed pipes larger than DN 50. for pipes with nominal wall thicknesses equal to or larger than
Note: 10 mm.
For forged pipes Section 5.3 shall apply.
(5) For tensile tests carried out on round tensile test speci-
(2) The stipulations of this Section shall also apply to pipes mens and for notched-bar impact bend tests, the test coupons
equal to or smaller than DN 50 if pipe elbows larger than shall be taken such that they are located at one quarter of the
DN 50 are made from such pipes. wall thickness under the outside surface and at one half of the
(3) The stipulations of this Section shall not apply to pipes wall thickness under the end face or as close as possible to
for vessel shells. that location.
(6) Specimens for determination of reduction of area at frac-
5.4.2 Materials ture on perpendicular specimens shall be taken at the same
location as for the room-temperature tensile-test specimens.
(1) The following steel grades may be used:
a) steel grades to Section A 3, 5.4.4.2 Extent of tests and examinations
b) other steel grades meeting the prerequisites of Section 3 in
combination with the stipulations in the authorized inspec- (1) The following procedures shall be performed for the che-
tor's appraisal. mical analysis:
a) One ladle analysis per heat.
(2) The materials shall meet the requirements of clause 4.3.1.
b) One product analysis on each of two manufacturing
lengths per heat.
5.4.3 Additional requirements for the materials
(2) The mechanical and technological characteristics shall
Pipes with nominal wall thicknesses equal to or larger than be determined by performing:
15 mm and subject to loading perpendicular to the surface a) Room-temperature tensile tests for every 20 manufacturing
shall at least meet the requirements of quality class Z35 to lengths of the same heat, dimension and heat treatment
DIN EN 10164. This shall be specified in the purchase order.
aa) at one end of one manufacturing length for pipes of
normalized or air quenched and tempered steels
5.4.4 Tests and examinations ab) at both ends of one manufacturing length for pipes of
5.4.4.1 Sampling and specimen preparation liquid quenched and tempered steels.
b) One elevated-temperature tensile test per heat, dimension
(1) The pipes shall be tested in manufacturing lengths. and heat treatment if the design temperature is higher than
(2) Specimens shall be taken from the ends of manufac- 100 °C. The test temperature is defined in Section A 3 or in
turing lengths. the authorized inspector's appraisal.
KTA 3211.1 Page 18

c) Room-temperature tensile tests to DIN EN 10164 in order (3) The Sections 11.1 and 11.5.1 shall apply to the non-
to determine the reduction of area at fracture on perpen- destructive tests and examinations.
dicular specimens from one sampling location every 20
(4) Each pipe shall be subjected to a materials identification
manufacturing lengths of the same heat, dimension and
check.
heat treatment for pipes with nominal wall thicknesses
equal to or larger than 15 mm, if as per clause 5.1.2 (1) (5) The inside and outside surfaces of each pipe shall be
quality class Z35 is required. This test may be waived for subjected to a visual inspection.
steel grades for which it was demonstrated in the material
appraisal that the mean value of reduction of area at frac- (6) The diameter and wall thickness shall be checked for
ture is at least 45 % and that none of the individual values dimensional accuracy at both ends of each pipe.
is smaller than 35 %. (7) Each pipe shall be examined for leak tightness in ac-
d) One notched-bar impact bend test to clause 4.4.6.5 at cordance with DIN EN 10216-2.
33 °C or at the lowest operating temperature, whichever is
lower, at one end of one manufacturing length per 20 5.4.5 Marking
manufacturing lengths of the same heat, dimension and
heat treatment for pipes of normalized or air quenched and (1) Each pipe shall be marked at both ends, 300 mm from
tempered steels with nominal thicknesses not exceeding the ends, with the following information:
38 mm, and at one end of each manufacturing length for a) manufacturer's symbol,
pipes with nominal thicknesses exceeding 38 mm. For b) steel grade, for steels with guaranteed reduction of area at
pipes of steel grade 15 MnNi 6 3, the test temperature fracture perpendicular to the product surface additionally
shall be 0 °C. quality class to DIN EN 10164) and
e) One notched-bar impact bend test to clause 4.4.6.5 at c) authorized inspector's mark.
33 °C or at the lowest operating temperature, whichever is
lower, at both ends of one manufacturing length per 20 (2) Each pipe shall additionally be marked at one end with
manufacturing lengths of the same heat, dimension and the following information:
heat treatment for pipes of liquid quenched and tempered a) heat number,
steels with nominal wall thicknesses equal to or smaller b) pipe number.
than 16 mm, and at both ends of each manufacturing
length for pipes with nominal wall thicknesses larger than
16 mm. 5.4.6 Verification of quality characteristics
f) Notched-bar impact bend tests for determination of an (1) The results of the ladle analysis, product analysis, mate-
impact energy vs. temperature curve to clause 4.4.6.6 at rials identification check, tightness test and non-destructive
one end of one manufacturing length per heat, dimension tests and examinations performed by the manufacturer shall
and heat treatment for pipes with nominal wall thicknesses be documented with inspection certificates 3.1 to DIN EN
equal to or larger than 10 mm. At least four test tempera- 10204. The steel making process, the delivery condition of the
tures shall be used, of which two shall be 0 °C and the product form stating heat treatment temperatures, holding
lowest loading temperature. This test may be waived for times and cooling conditions as well as simulated stress-relief
pipes of steel grade 15 MnNi 6 3. annealing temperature and holding time of test coupons shall
be indicated in the inspection certificate 3.1.
g) One notched-bar impact bend test to clause 4.4.6.5 at one
end of each manufacturing length to determine the upper (2) The results of mechanical and technological tests, visual
shelf impact energy for pipes of normalized or air inspection, dimensional check and non-destructive tests and
quenched and tempered steels with nominal wall thick- examinations shall be confirmed by the authorized inspector
nesses larger than 38 mm as well as for pipes of liquid and combined with inspection certificate 3.1 as inspection
quenched and tempered steels with nominal wall thick- certificate 3.2 to DIN EN 10204 issued by him. Alternatively,
nesses larger than 16 mm. This test may be performed these tests shall be confirmed by the authorized inspector on
during determination of the impact energy vs. temperature an inspection certificate 3.2 established by the manufacturer.
curves. In general, 80 °C shall be selected as the test tem-
perature. This test shall be performed only in test group 5.5 Seamless pipe elbows larger than DN 50
A 1, and may be waived if the value of impact energy de-
termined per d) or e) is equal to or greater than 100 J. 5.5.1 Scope
h) Technological tests per Table 5.4-1 at both ends of each (1) This Section shall apply to seamless pipe elbows (weld-
manufacturing length for pipes with nominal wall thick- in elbows) made by cold or hot forming followed by heat
nesses equal to or smaller than 40 mm. treatment (normalization; quenching and tempering).
(2) This Section shall not apply to pipe bends made with
inductive bending machines or by cold forming with or without
Nominal wall Nominal outside diameter subsequent heat treatment. These pipe bends are subject to
thickness s of the pipes the requirements of KTA 3211.3 Section 6.
of the pipes in mm
in mm  146 > 146 5.5.2 Materials
(1) The following steel grades may be used:
s< 2 Flattening test 
a) steel grades to Section A 3 and
2  s  16 Ring expanding test 1) Ring tensile test b) other steel grades meeting the prerequisites of Section 3 in
combination with the stipulations in the authorized inspec-
16 < s  40 Flattening test Ring tensile test
tor's appraisal.
1) The drift test also may be performed.
(2) The materials shall meet the requirements of clause 4.3.1.
(3) For finished pipe elbows, the values of the mechanical
Table 5.4-1: Dimensional ranges for application of the tech- and technological characteristics to Section A 3 shall apply
nological tests to pipes even if forged hollow parts are used as starting products.
 KTA 3211.1 Page 19

5.5.3 Starting products b) One elevated-temperature tensile test for one sampling
location of one pipe elbow per heat, dimension and heat
(1) Forged hollow parts to Section 5.3 or seamless pipes to treatment, and for one sampling location of each pipe el-
Section 5.4 shall basically be used as starting products. bow in the case of individual testing. The test temperature
(2) Starting products that have not been completely exam- is defined in Section A 3 or in the authorized inspector's
ined and heat-treated to the stipulations in Sections 5.3 or 5.4 appraisal.
may also be used, provided c) One notched-bar impact bend test to clause 4.4.6.5 at
a) the finished pipe elbows are examined individually to 33 °C or at the lowest operating temperature, whichever is
clause 5.5.4.2 and lower, for each sampling location of one pipe elbow per
test unit for pipe elbows of normalized or air quenched and
b) the non-destructive tests and examinations of the starting
tempered steels with nominal wall thicknesses not exceed-
products have been carried out according to the require-
ing 38 mm, as well as for pipe elbows of liquid quenched
ments in Section 11.4 or Section 11.5.1 prior to forming.
and tempered steels with nominal wall thicknesses not ex-
In this case the determination of mechanical and technological ceeding 16 mm. For greater wall thicknesses as well as in
characteristics and the corresponding verification may be the case of individual testing, this test shall be performed
waived for the starting products. An inspection certificate 3.1 at each sampling location of each pipe elbow. For pipe el-
to DIN EN 10204 shall then be adequate for visual inspection bows of steel grade 15 MnNi 6 3, the test temperature
and dimensional check of the starting products. shall be 0 °C.
d) Notched-bar impact bend tests for determination of an
5.5.4 Tests and examinations of pipe elbows impact energy vs. temperature curve to clause 4.4.6.6 for
one sampling location of one pipe elbow per heat, dimen-
5.5.4.1 Sampling and specimen preparation sion and heat treatment for pipe elbows with nominal wall
thicknesses equal to or larger than 10 mm. At least four
(1) Specimens shall be taken from the ends of the pipe el- test temperatures shall be used, of which two shall be 0 °C
bows in conformity with the authorized inspector's appraisal. and the lowest loading temperature. This test may be
(2) The test coupons shall be located at one quarter of the waived for pipe elbows of steel grade 15 MnNi 6 3.
wall thickness under the outside surface and at one half of the e) One notched-bar impact bend test to clause 4.4.6.5 to
wall thickness under the end face or as close as possible to determine the upper shelf impact energy at one sampling
that location. location of each elbow for pipe elbows of normalized or air
quenched and tempered steels with nominal wall thicknes-
(3) Transverse specimens shall be used for tensile tests and ses exceeding 38 mm as well as for pipe elbows of liquid
notched-bar impact bend tests, provided that they can be quenched and tempered steels with nominal wall thicknes-
taken from unstraightened test coupons. If this is not possible, ses exceeding 16 mm. This test may be performed during
longitudinal specimens shall be tested. determination of the impact energy vs. temperature curves.
In general, 80 °C shall be selected as the test temperature.
(4) Notched-bar impact bend tests shall be performed only
This test shall be performed only in test group A 1, and
for pipe elbows with nominal wall thicknesses equal to or larg-
may be waived if the value of impact energy determined
er than 10 mm.
per d) or e) is equal to or greater than 100 J.
(5) If starting products that have not been completely exam- f) For pipe elbows grouped together as test units, one hard-
ined and heat-treated to the stipulations in Sections 5.3 or 5.4 ness test per pipe elbow to verify uniformity.
are used, test coupons shall be taken from both ends of pipe Note:
elbows with an arc length greater than 3000 mm, measured Verification of uniformity shall be acknowledged if the difference
along the outside of the bend. between the highest and lowest hardness values in a test unit
does not exceed 30 HB units.
(6) In all other cases, test coupons shall be taken from only
one end of the pipe elbow. (3) The Sections 11.1 and 11.6.1 shall apply to the non-
destructive tests and examinations.
(7) If the pipe elbows are not tested individually, test units
consisting of pipe elbows of the same heat, dimension and (4) Each pipe elbow shall be subjected to a materials identi-
heat treatment shall be formed for determination of mechani- fication check.
cal and technological characteristics. (5) The inside and outside surfaces of each pipe elbow shall
(8) For the room-temperature tensile tests and for the be subjected to a visual inspection.
notched-bar impact bend tests, the number of pipe elbows per (6) For each pipe elbow, the wall thickness and, depending
test unit shall not exceed: on the purchase order, either the outside or inside diameter
a) 30 pieces for pipe elbows smaller than DN 200 shall be measured over the arc length, including the ends, and
b) 20 pieces for pipe elbows equal to or larger than DN 200 to a sufficient extent over the circumference. The smallest wall
and smaller than DN 350 thickness as well as the ovality shall be determined.
c) 10 pieces for pipe elbows equal to or larger than DN 350.
5.5.5 Marking
5.5.4.2 Extent of tests and examinations (1) Each pipe elbow shall be marked with the following in-
formation:
(1) The chemical composition shall be verified on the star-
ting product. a) manufacturer's symbol,
b) steel grade (for steels with guaranteed reduction of area at
(2) The mechanical and technological characteristics shall fracture perpendicular to the product surface additionally
be determined by performing: quality class to DIN EN 10164),
a) One room-temperature tensile test for each sampling loca- c) heat number,
tion of one pipe elbow per test unit, and for each sampling
location of each pipe elbow in the case of individual test- d) pipe-elbow number,
ing. e) authorized inspector's mark.
KTA 3211.1 Page 20

5.5.6 Verification of quality characteristics 5.6.4 Tests and examinations of fittings

(1) The results of the materials identification check and of 5.6.4.1 Sampling and specimen preparation
non-destructive tests and examinations performed by the
manufacturer as well as of hardness test, if any, shall be doc- (1) Specimens shall be taken from one end of the fittings in
umented with an inspection certificate 3.1 to DIN EN 10204. conformity with the authorized inspector's appraisal.
The delivery condition of the product form stating heat treat- (2) The test coupons shall be located at one quarter of the
ment temperatures, holding times and cooling conditions as wall thickness under the outside surface and at one half of the
well as simulated stress-relief annealing temperature and wall thickness under the end face or as close as possible to
holding time of test coupons shall be indicated in the inspec- that location.
tion certificate 3.1.
(3) Transverse specimens shall be used for tensile tests and
(2) The forming process used shall be indicated in the in- notched-bar impact bend tests, provided that they can be
spection certificate 3.1 to DIN EN 10204. taken from unstraightened test coupons. If this is not possible,
(3) The results of mechanical and technological tests, visual longitudinal specimens shall be tested.
inspection, dimensional check and non-destructive tests and (4) Notched-bar impact bend tests shall be performed only
examinations shall be confirmed by the authorized inspector for fittings with nominal wall thicknesses equal to or larger
and combined with inspection certificate 3.1 as inspection than 10 mm.
certificate 3.2 to DIN EN 10204 issued by him. Alternatively,
these tests shall be confirmed by the authorized inspector on (5) If the fittings are not tested individually, test units consist-
an inspection certificate 3.2 established by the manufacturer. ing of fittings of the same heat, dimension and heat treatment
shall be formed for determination of mechanical and techno-
(4) The inspection certificate of the starting product shall be logical characteristics.
attached to the inspection certificate 3.2.
(6) For the room-temperature tensile tests and for the
notched-bar impact bend tests, the number of fittings per test
5.6 Seamless fittings larger than DN 50 unit shall not exceed:
Note: a) 30 pieces for fittings smaller than DN 100
The nominal diameter of a reducer or of a tee shall refer to the
end with the larger diameter.
b) 10 pieces for fittings equal to or larger than DN 100.

5.6.1 Scope
5.6.4.2 Extent of tests and examinations
(1) This Section shall apply to the following seamless fittings:
(1) The chemical composition shall be verified on the star-
a) reducers made by cold or hot forming, ting product.
b) tees fabricated to the liqued bulge method (2) The mechanical and technological characteristics shall
followed by heat treatment (normalization; quenching and be determined by performing:
tempering) a) One room-temperature tensile test per test unit.
b) One elevated-temperature tensile test per heat, dimension
5.6.2 Materials and heat treatment, if the design temperature is higher
(1) The following steel grades may be used: than 100 °C. The test temperature is defined in Section A 3
or in the authorized inspector's appraisal.
a) steel grades to Section A 3 and
c) One notched-bar impact bend test to clause 4.4.6.5 at
b) other steel grades meeting the prerequisites of Section 3 in 33 °C or at the lowest operating temperature, whichever is
combination with the stipulations in the authorized inspec- lower, on one piece per test unit for fittings of normalized
tor's appraisal. or air quenched and tempered steels with nominal wall
(2) The materials shall meet the requirements of clause 4.3.1. thicknesses not exceeding 38 mm, as well as for fittings of
liquid quenched and tempered steels with nominal wall
(3) For fabricated fittings, the values of the mechanical and thicknesses not exceeding 16 mm. For fittings of steel
technological characteristics to Section A 3 shall apply even if grade 15 MnNi 6 3, the test temperature shall be 0 °C.
forged hollow parts are used as starting products.
d) Notched-bar impact bend tests for determination of an
impact energy vs. temperature curve to clause 4.4.6.6 on
5.6.3 Starting products one piece per heat, dimension and heat-treatment lot for
fittings with nominal wall thicknesses equal to or larger
(1) Forged hollow parts to Section 5.3 or seamless pipes to than 10 mm. At least four test temperatures shall be used,
Section 5.4 shall basically be used as starting products. of which two shall be 0 °C and the lowest loading tempera-
(2) Starting products that have not been completely exam- ture. This test may be waived for fittings of steel
ined and heat-treated to the stipulations in Sections 5.3 or 5.4 15 MnNi 6 3.
may also be used, provided e) One notched-bar impact bend test to clause 4.4.6.5 on
a) the finished pipe elbows are examined individually to each piece to determine the upper shelf impact energy for
clause 5.6.4.2 and fittings of normalized or air quenched and tempered steels
with nominal wall thicknesses exceeding 38 mm as well as
b) the non-destructive tests and examinations of the starting for fittings of liquid quenched and tempered steels with
products have been carried out according to the require- nominal wall thicknesses exceeding 16 mm. In general,
ments in Section 11.4 or Section 11.5.1 prior to forming. 80 °C shall be selected as the test temperature. This test
In this case the determination of mechanical and technological may be performed during determination of the energy ab-
characteristics and the corresponding verification may be sorbed vs. temperature curves. This test shall be per-
waived for the starting products. An inspection certificate 3.1 formed only in test group A 1, and may be waived if the
to DIN EN 10204 shall then be adequate for visual inspection value of energy absorbed determined per d) or e) is equal
and dimensional check of the starting products. to or greater than 100 J.
 KTA 3211.1 Page 21

f) For fittings grouped together as test units, one hardness (2) Feeder heads and large casting-related thickenings that
test per fitting to verify uniformity. impair amenability of castings to heat treatment shall be elimi-
Note: nated before normalization or quenching and tempering.
Verification of uniformity shall be acknowledged if the difference (3) The casting technique shall be designed according to the
between the highest and lowest hardness values in a test unit principles of controlled solidification. For castings with nominal
does not exceed 30 HB units.
widths equal to or larger than 200 mm, the gate and feeder
(3) Each fitting shall be subjected to a materials identification technique shall be explained on the basis of the saturation
check. calculation as well as drawings illustrating the position of the
feeders, feed zones and specimen location.
(4) The inside and outside surfaces of each fitting shall be Note:
subjected to a visual inspection. The feature characterizing the dimensions of the body or case
(5) For each fitting, the ovality, diameter and thickness shall shall be the nominal width, as follows:
be measured at the ends. a) for pumps, the nominal width of the pressure nozzle,
b) for valves, the largest nominal width involved,
(6) The Sections 11.1 and 11.7.1 shall apply to the non- c) for safety valves, the nominal width of the inlet nozzle.
destructive tests and examinations.
(4) For each casting model, the description of the casting
technique shall be attached to the interim file (internal manu-
5.6.5 Marking facturer documentation) for retention by the manufacturer.
(1) Each fitting shall be marked with the following information: (5) Together with the drawing of the casting in the as-
a) manufacturer's symbol, delivered condition, the following documents shall generally be
submitted as standard plans for the design approval:
b) steel grade (for steels with guaranteed reduction of area at
fracture perpendicular to the product surface additionally a) test and inspection sequence plan and heat-treatment
quality class to DIN EN 10164), plan, in case of differences from the standard production
scheme to Figure 5.7-1,
c) heat number,
b) for forgings of test group A 1 with nominal widths equal to
d) fitting number or test lot number, or larger than 200 mm, instructions for the non-destructive
e) authorized inspector's mark. examinations as well as a coordinate reference system
(reference-point grid),
c) for prototypes of test groups A 2 and A 3 with nominal
5.6.6 Verification of quality characteristics widths equal to or greater than 200 mm a film location plan
(1) The results of the materials identification check and of and a radiation source plan,
non-destructive tests and examinations performed by the d) welding procedure qualification and welding procedure
manufacturer as well as of hardness test, if any, shall be doc- sheet for production welds and if applicable construction
umented with an inspection certificate 3.1 to DIN EN 10204. welds (see Annex B),
The delivery condition of the product form stating heat treat- e) test and inspection sequence plan for construction welds, if
ment temperatures, holding times and cooling conditions as necessary.
well as simulated stress-relief annealing temperature and f) list of planned production control tests.
holding time of test coupons shall be indicated in the inspec-
tion certificate 3.1. (6) If changes are made compared with the conditions stipu-
lated in the welding procedure sheet, or if a different welding
(2) The forming process used shall be indicated in the in- method is chosen, the welding procedure sheet shall be
spection certificate 3.1 to DIN EN 10204. amended accordingly and resubmitted for design approval.
(3) The results of mechanical and technological tests, visual
inspection, dimensional check and non-destructive tests and 5.7.3 Tests and examinations
examinations shall be confirmed by the authorized inspector
and combined with inspection 3.1 as inspection certificate 3.2 5.7.3.1 Sampling and specimen preparation
to DIN EN 10204 issued by him. Alternatively, these tests shall (1) Castings with a delivery weight equal to or lighter than
be confirmed by the authorized inspector on an inspection 500 kg shall be tested in lots, and castings with a delivery
certificate 3.2 established by the manufacturer. weight heavier than 500 kg shall be tested individually.
(4) The inspection certificate of the starting product shall be (2) The number of sampling locations shall be as indicated
attached to the inspection certificate 3.2. in Table 5.7-1.

Product weight Number of

5.7 Castings
(delivery weight) Test unit sampling
5.7.1 Materials in kg locations
(1) The following cast-steel grades may be used: At most 2500 kg per heat,
 100 dimension and heat-treat- 1
a) GS-C 25 S to Section A 4 and
ment lot
b) other cast-steel grades meeting the prerequisites of Sec-
At most 10 pieces, but not
tion 3 in combination with the stipulations in the authorized
more than 2500 kg per
inspector's appraisal. > 100 up to  500 1
heat, dimension and heat-
(2) The materials shall meet the requirements of clause 4.3.1. treatment lot
> 500 up to  1000 Individual piece 1
5.7.2 Requirements for casting condition > 1000 Individual piece 2
(1) As regards their general internal quality and external
finish, the castings shall meet the conditions of Table 11-6 Table 5.7-1: Number of sampling locations on castings made
applicable to their test group. of ferritic steels of material group W I
KTA 3211.1 Page 22

Casting
Quenching and tempering or solution annealing
Setting of the surface quality per Section 11.8.4

Complete surface inspection by manufacturer (H)

yes Impermissible yes

indications

no

Procedure 1 Volumetric testing by H Procedure 2

Production welds with complete heat treatment Evaluation of the films by H and S Production welds without subsequent heat treatment
for establishing the mechanical and technological
characteristics

Grooving out and penetrant testing of the places

Grooving out and penetrant testing of the places prepared for welding by H
prepared for welding by H
Documentation, for the final file, of all production
Documentation of the larger production welds 1) for the welds in material group W I and in the case of
interim file and informing of the authorized inspector (S) yes materials to Section 9.2 as well as in the case of
yes larger production welds 1) in W II and austenite
Impermissible
Welding per Annex C indications Permission 2) for welding by S
Welding per Annex C
Soaking, if required in Material Annex Grinding the welds smooth
no
Ferrite: stress-relief annealing
Grinding the welds smooth Martensite: tempering

Surface inspection of the production welds by H

Surface inspection of the production welds by H

yes Impermissible no
yes Impermissible no
indications
indications

Volumetric testing 3) by H
Volumetric testing 2) by H
Evaluation of the films by H and S
Evaluation of the films by H and S
Ultrasonic re-testing by S if there is ferrite or martensite
yes Impermissible no
indications
yes Impermissible no
indications
Grooving out and penetrant testing of the places
prepared for welding by H
Heat treatment to establish the mechanical and Documentation, for the final file, of all production
technological characteristics welds in material group W I and in the case of
Quenching and tempering or solution annealing materials to Section 9.2 as well as in the case of
larger production welds 1) in W II and austenite
Setting of the surface quality per Section 11.8.4 Permission 2) for welding by S
Complete surface inspection Welding per Annex B
Grinding the welds smooth
Ferrite: stress relief annealing
Martensite: tempering
no Impermissible yes
indications
Surface inspection and radiography
of the production weld by H
Evaluation of the films by H and S
1)
Ultrasonic testing of larger production welds by H Ultrasonic re-testing by S if there is ferrite
and S if there is ferrite or martensite

yes Impermissible no
yes indications
Impermissible
indications

no Acceptance 4)
Complete surface inspection by H and S
Mechanical and technological tests
1) See Annex B, clause B 2 (4) for definition Compilation of the documentation
of larger production weld. 4) If, in exceptional cases in the course of further processing, it becomes
2) Applies only to material group W I, test group A 1 and in the case of materials to Section 9.2.
necessary for the component manufacturer to perform production welds in order
3) Note when there are additional volumetric examinations: to eliminate casting defects in an advanced state of processing, then deviations
Radiographed welds and casting zones with permissible relative to the standard production scheme shall be permissible by agreement with
indications need not be re-tested. the authorized inspector.

Figure 5.7-1: Production scheme for cast steel cases and bodies made of ferritic, austenitic or martensitic cast-steel grades
 KTA 3211.1 Page 23

(3) The specimens shall be taken from cast-on test blocks to order. The test pressure has to be limited to ensure that a
DIN EN 1559-2 or from overlengths. Separately cast test safety margin against the yield point or 0.2 % proof stress at
blocks are permitted only for castings with piece weights equal room temperature of at least 1.1 is achieved.
to or lighter than 150 kg.
(4) The test blocks shall be provided in sufficient number 5.7.4 Marking
and size that the prescribed specimens can be taken.
(1) Each casting shall be marked with the following infor-
(5) The thickness of the cast-on test blocks shall correspond mation:
to the governing wall thickness. In this connection, the govern- a) manufacturer's symbol,
ing wall thickness shall be the thickness of the wall subjected
to pressure loading, and not the thickness of cast-on flanges b) steel grade,
or local thickenings. c) heat number,
(6) Cast-on test blocks at the gate system are not permitted. d) specimen number and
e) authorized inspector's mark.
(7) For castings with piece weights heavier than 1000 kg,
the position of the cast-on test coupons on the casting shall be
documented by a photograph or in a sketch. 5.7.5 Verification of quality characteristics
(1) The results of the ladle analysis, product analysis, mate-
5.7.3.2 Extent of tests and examinations rials identification check and non-destructive tests and exami-
nations performed by the manufacturer as well as of the hard-
(1) The following procedures shall be performed for the che- ness test, if any, shall be documented with an inspection cer-
mical analysis: tificate 3.1 to DIN EN 10204. The delivery condition of the
a) One ladle analysis per heat. product form stating heat treatment temperatures, holding
b) One product analysis for one sampling location per test times and cooling conditions as well as simulated stress-relief
unit. annealing temperature and holding time of test coupons shall
be indicated in the inspection certificate 3.1.
(2) The mechanical and technological characteristics shall
be determined by performing: (2) The results of mechanical and technological tests, visual
inspection, dimensional check, tightness test and non-destruc-
a) One room-temperature tensile test per sampling location. tive tests and examinations shall be confirmed by the autho-
The value of reduction of area at fracture shall also be de- rized inspector and combined with the inspection certificate
termined for information. 3.1 as an inspection certificate 3.2 to DIN EN 10204 issued by
b) One elevated-temperature tensile test per heat, dimension him. Alternatively, these tests shall be confirmed by the au-
and heat-treatment lot. The test temperature is defined in thorized inspector on an inspection certificate 3.2 established
Section A 4 or in the authorized inspector's appraisal. The by the manufacturer.
value of reduction of area at fracture shall also be deter-
mined for information. (3) For castings with piece weights heavier than 1000 kg, a
photograph or a sketch of the location of the cast-on test
c) One notched-bar impact bend test to clause 4.4.6.5 per blocks on the casting shall be attached to the inspection certif-
sampling location at 33 °C or at the lowest operating tem- icate.
perature, whichever is lower.
d) Notched-bar impact bend tests for determination of an
impact energy vs. temperature curve to clause 4.4.6.6 at 6 Product forms of ferritic steels of material group W II
one sampling location per test unit. At least four test tem-
peratures shall be used, of which two shall be 33 C or the 6.1 Flat products
lowest loading temperature and 0 °C. 6.1.1 Materials
e) One notched-bar impact bend test to clause 4.4.6.5 to
verify the upper shelf impact energy at one sampling loca- (1) The following steel grades may be used:
tion per test unit. In general, this test shall be performed at a) 15 MnNi 6 3 to Section A 1
80 °C. The test shall be performed only in test group A 1, b) P275NH (1.0486) to DIN EN 10028-3 in conjunction
and may be waived if the notched-bar impact bend test at with VdTÜV material sheet 352/1
the lower of 33 °C or the lowest loading temperature has
already verified that the requirements are met. c) P355NH (1.0565) to DIN EN 10028-3 in conjunction
with VdTÜV material sheet 354/1
f) One hardness test on each piece to verify uniformity of the
quenching and tempering treatment in the case of lotwise d) 16Mo3 (1.5415) to DIN EN 10028-2
examination of castings of quenched and tempered steel. e) P235GH (1.0345) to DIN EN 10028-2
(3) The Sections 11.1 and 11.8 shall apply to the non- f) other steel grades meeting the prerequisites of Section 3 in
destructive tests and examinations. combination with the stipulations in the authorized inspec-
tor's appraisal.
(4) Each casting shall be subjected to a materials identifi-
cation check. (2) The materials shall meet the requirements of clause 4.3.1.

(5) Each casting shall be subjected in the as-delivered con- (3) The selection of materials shall be based on the lowest
dition to a visual inspection. operating temperature.
(6) Each casting shall be subjected in the as-delivered con-
dition to a dimensional check. 6.1.2 Additional requirements for the materials
(7) Each casting shall be subjected in a condition suitable for (1) Flat products with nominal thicknesses equal to or larger
the purpose, generally by the further processor, to a tightness than 15 mm which are subjected to loading perpendicular to
test in the form of an internal pressure test, which shall be the rolled surface shall at least meet the requirements of quali-
performed to DIN 50104. Pressurizing fluid, test pressure and ty class Z25 to DIN EN 10164. This shall be specified in the
pressure-loading duration shall be indicated in the purchase purchase order.
KTA 3211.1 Page 24

(2) When flat products are used for tubesheets, the same c) heat number,
requirements as for specimens longitudinal to or transverse to d) specimen number and
the main rolling direction shall apply for the room-temperature
e) authorized inspector's mark.
yield point or 0.2 % proof stress and tensile strength of stand-
ard specimens perpendicular to the flat product surface. This (2) The marking shall be applied such that it appears upright
shall be specified in the purchase order. when viewed in the main rolling direction.
(3) The surface finish shall satisfy the stipulations of DIN EN
10163-2 Class B Subgroup 3. 6.1.5 Verification of quality characteristics
(1) The results of the ladle analysis, product analysis, mate-
6.1.3 Tests and examinations rials identification check and non-destructive tests and exami-
nations performed by the manufacturer shall be documented
6.1.3.1 Sampling and specimen preparation with an inspection certificate 3.1 to DIN EN 10204. The steel
(1) Specimens shall be taken in accordance with the DIN making process, the delivery condition of the product form
standards and VdTÜV material sheets referred to in 6.1.1 (1). stating heat treatment temperatures, holding times and cooling
For steel grade 15 MnNi 6 3 clause 5.1.3 shall apply. conditions as well as simulated stress-relief annealing tem-
perature and holding time of test coupons, if any, shall be
(2) Specimens for determination of the reduction of area at indicated in the inspection certificate 3.1.
fracture on perpendicular specimens shall be taken and pre-
(2) The results of mechanical and technological tests, visual
pared to the stipulations in DIN EN 10164.
inspection, dimensional check and non-destructive tests and
examinations shall be confirmed by the authorized inspector
6.1.3.2 Extent of tests and examinations and combined with inspection certificate 3.1 as inspection
certificate 3.2 to DIN EN 10204 issued by him. Alternatively,
(1) The following procedures shall be performed for the these tests shall be confirmed by the authorized inspector on
chemical analysis: an inspection certificate 3.2 established by the manufacturer.
a) One ladle analysis per heat.
b) One product analysis on one sampling location of one 6.2 Dished or pressed product forms made from flat prod-
rolled plate per heat. ucts
(2) The mechanical and technological characteristics shall 6.2.1 Materials
be determined by performing:
Section 6.1.1 shall apply to the materials.
a) One room-temperature tensile test per sampling location.
b) One tensile test at a temperature of 300 °C per heat, dimen- 6.2.2 Additional requirements for the materials
sional range and total weight of at most 30 metric tons.
c) Room-temperature tensile tests to DIN EN 10164 per rolled The requirements of Section 6.1.2 shall apply.
plate for flat products with nominal thicknesses equal to or
larger than 15 mm, in order to determine the reduction of 6.2.3 Starting products
area at fracture, whenever the quality class Z25 is required
acc. to clause 6.1.2 (1). (1) Starting products shall be subject to the stipulations in
Section 6.1.
d) One notched-bar impact bend test to clause 4.4.6.5 per
sampling location at 0 °C or at 20 °C for nominal thick- (2) If the finished parts are tested individually to clause
nesses equal to or larger than 5 mm. 6.2.4.2, the tests to clause 6.1.3.2 (2) as well as the corres-
e) Notched-bar impact bend tests for determination of an ponding verifications can be omitted.
impact energy vs. temperature curve to clause 4.4.6.6 at Note:
one sampling location per heat, dimensional range and The stipulations of KTA 3211.3 shall apply to welded joints made
identical heat treatment for flat products with nominal thick- with the starting plates and remaining in the finished parts.
nesses equal to or larger than 10 mm. At least four test
temperatures shall be used, of which one shall be 0 °C or 6.2.4 Testing and examination of dished or pressed prod-
20 °C. This test may be waived for flat products of steel uct forms made from flat products
grade 15 MnNi 6 3.
6.2.4.1 Sampling and specimen preparation
(3) Each rolled plate shall be subjected to a materials identi-
fication check. (1) For product forms with a diameter or length equal to or
smaller than 3000 mm, the tests or examinations shall be
(4) Each flat product shall be subjected to a visual inspection. performed on one part per rolled plate and heat-treatment lot.
The maximum permissible lot size shall be 10 parts.
(5) The dimensional and shape accuracy of each rolled plate
shall be measured. Note:
Correlation of parts with the rolled plate can be achieved, for ex-
(6) The Sections 11.1 and 11.2 shall apply to the non- ample, through the specimen number of the starting products.
destructive tests and examinations, the Sections 11.1 and
11.4 in the case of flat products for tubesheets. (2) For product forms with a diameter or length greater than
3000 mm, each part shall be tested. For lengths or diameters
6.1.4 Marking exceeding 6 m one test coupon each shall be taken at two
opposite sides.
(1) Each flat product shall be marked at least with the follow-
ing information: (3) One test coupon shall be taken from each part to be
a) manufacturer's symbol, examined regardless of its diameter or length.
b) steel grade (for steels with guaranteed reduction of area at (4) The test coupons shall be taken such that transverse
fracture perpendicular to the product surface additionally specimens can be machined. Deviations up to 20 degrees
quality class to DIN EN 10164), from the theoretical transverse direction are permitted for
 KTA 3211.1 Page 25

heads (ends) and similar parts. If this is not possible, a differ- (2) In the case of lotwise examination, the product form from
ent type of sampling shall be agreed with the authorized in- which the specimens were taken shall also be marked.
spector.
(3) The marking shall be applied such that it appears upright
(5) Round tensile-test specimens with a test diameter equal when viewed in the main rolling direction of the rolled plate.
to or larger than 10 mm shall be made for both the room-
temperature and elevated-temperature tensile tests. For nom-
6.2.6 Verification of quality characteristics
inal wall thicknesses larger than 40 mm, the specimen axis
shall be located at a distance of one quarter of the product- (1) The results of the materials identification check and non-
form thickness under the rolled surface. destructive tests and examinations performed by the manu-
For product-form thicknesses that do not permit a test diame- facturer shall be documented with an inspection certificate 3.1
ter of 10 mm, the largest possible diameter shall be chosen. to DIN EN 10204. The delivery condition of the product form
stating heat treatment temperatures, holding times and cooling
(6) For nominal wall thicknesses equal to or smaller than conditions as well as simulated stress-relief annealing tem-
40 mm, one side of the specimens for the notched-bar impact perature and holding time of test coupons, if any, shall be
bend test shall be as close as possible to the rolled surface. indicated in the inspection certificate 3.1.
For nominal wall thicknesses larger than 40 mm, the specimen
axis shall be located at a distance of one quarter of the prod- (2) The forming method shall be indicated in the inspection
uct-form thickness under the rolled surface. certificate 3.1 to DIN EN 10204.
(3) The results of mechanical and technological tests, visual
inspection, dimensional check and non-destructive tests and
6.2.4.2 Extent of tests and examinations examinations shall be confirmed by the authorized inspector
(1) The mechanical and technological characteristics shall and combined with inspection certificate 3.1 as inspection
be determined by performing: certificate 3.2 to DIN EN 10204 issued by him. Alternatively,
these tests shall be confirmed by the authorized inspector on
a) One room-temperature tensile test per sampling location. an inspection certificate 3.2 established by the manufacturer.
b) One tensile test at a temperature of 300 °C per heat, di-
mensional range and total weight of at most 30 metric tons. (4) The inspection certificate of the starting product shall be
attached to the inspection certificate 3.2.
c) Room-temperature tensile tests to DIN EN 10164 per rolled
plate for product forms with nominal thicknesses equal to
or larger than 15 mm, in order to determine the reduction 6.3 Forgings, bars and rolled rings
of area at fracture, whenever the quality class Z25 is re- 6.3.1 Materials
quired acc. to clause 6.1.2 (1). This test may be waived if it
has already been performed on the rolled plate and docu- (1) The following steel grades may be used:
mented with an inspection certificate 3.2 to DIN EN 10204. a) 15 MnNi 6 3 to Section A 2
Note:
b) P250GH (1.0460) to DIN EN 10273 or DIN EN 10222-2
Correlation of parts with the rolled plate can be achieved, for
example, through the specimen number. c) 16Mo3 (1.5415) to DIN EN 10273 or DIN EN 10222-2
d) One notched-bar impact bend test to clause 4.4.6.5 per d) P355NH (1.0565) to DIN EN 10273 in conjunction with
sampling location at 0 °C or at 20 °C for nominal wall VdTÜV material sheet 354/1 or DIN
thicknesses equal to or larger than 5 mm. EN 10222-4 in conjunction with
e) Notched-bar impact bend tests for determination of an VdTÜV material sheet 354/3
impact energy vs. temperature curve to clause 4.4.6.6 at e) P355QH1 (1.0571) to DIN EN 10222-4 in conjunction
one sampling location per heat, dimensional range and with VdTÜV material sheet 354/3
heat-treatment lot for product forms with nominal wall f) P235GH (1.0345) to DIN EN 10273
thicknesses equal to or larger than 10 mm. At least four
g) other steel grades meeting the prerequisites of Section 3 in
test temperatures shall be used, of which one shall be 0 °C
combination with the stipulations in the authorized inspec-
or 20 °C. This test may be waived for product forms of
tor's appraisal.
steel grade 15 MnNi 6 3.
(2) The materials shall meet the requirements of clause 4.3.2.
(2) Each product form shall be subjected to a materials
identification check. (3) The selection of materials shall be based on the lowest
operating temperature.
(3) Each product form shall be subjected to a visual inspec-
tion.
6.3.2 Tests and examinations
(4) The dimensional and shape accuracy of each product
form shall be measured. 6.3.2.1 Sampling and specimen preparation

(5) The Sections 11.1 and 11.3 shall apply to the non- 6.3.2.1.1 Test units
destructive tests and examinations. (1) Unless otherwise stipulated in clause 6.3.2.2, pieces with
heat-treatment weights between 100 kg and equal to or lighter
than 500 kg from the same heat, with similar dimensions and
6.2.5 Marking
from the same heat-treatment lot shall be grouped as test
(1) Each finished part shall be marked at least with the fol- units containing at most 10 parts, while pieces with heat-
lowing information: treatment weights lighter than or equal to 100 kg may be
grouped as test units of 1000 kg each.
a) symbol of the manufacturer of the product form,
b) steel grade (for steels with guaranteed reduction of area at (2) Pieces with heat-treatment weights heavier than 500 kg
fracture perpendicular to the product surface additionally shall be tested individually.
quality class to DIN EN 10164),
c) heat number, 6.3.2.1.2 Sampling locations
d) specimen number and (1) For forged hollow parts, e.g., for shell courses, nozzles
e) authorized inspector's mark. or valve bodies, specimens shall be taken from one end as a
KTA 3211.1 Page 26

function of inside diameter Di as follows: from one sampling tensile tests if the diameter or greatest length of a cross-
location for Di equal to or smaller than 500 mm; from two sectional edge is smaller than 160 mm, or for notched-bar
sampling locations separated by 180 degrees for Di between impact bend tests if the diameter or the greatest length of a
500 mm and 2000 mm; and from three sampling locations cross-sectional edge is smaller than 68 mm.
separated by 120 degrees for Di larger than 2000 mm.
(2) At the opposite end, specimens shall be taken from one 6.3.2.2 Extent of tests and examinations
sampling location for normalized or air quenched and tem- (1) The following procedures shall be performed for the
pered forgings having a finished length longer than 5000 mm chemical analysis:
and for liquid quenched and tempered forgings having a fin-
a) One ladle analysis per heat.
ished length longer than 2000 mm. For pieces with inside
diameters smaller than or equal to 500 mm, this sampling b) One product analysis on in each of two separately manu-
location shall be offset by 180 degrees relative to that at the factured products per heat. If possible, the top zone of one
other end (according to Figures 5.3-1 and 5.3-2). piece and the bottom zone of the other shall be tested. For
piece weights equal to or heavier than 5000 kg, one prod-
Note:
uct analysis shall be performed on one sampling location
Finished length designates the length of the product form during
the governing heat treatment, less the length of the test coupons.
of each piece. It possible, the top or bottom of the starting
ingot shall be tested.
(3) For seamless rolled or forged rings or flanges, speci-
mens shall be taken from the circumference or end of the (2) The mechanical and technological characteristics shall
flange. They may also be taken from the end of the welding be determined by performing:
end, if the heat-treatment thickness of the welding end is a) One hardness test per piece to verify uniformity for pieces
equal to that of the flange. Specimens shall be taken as fol- grouped together in test units.
lows: from one sampling location for inside diameters Di Note:
smaller than or equal to 1000 mm; from two sampling loca- Verification of uniformity shall be acknowledged if the difference
tions separated by 180 degrees for Di between 1000 mm and between the highest and lowest hardness values in a test unit
2000 mm; and from three sampling locations separated by does not exceed 30 HB units.
120 degrees for Di larger than 2000 mm (according to Figure b) One room-temperature tensile test per sampling location.
5.3-3). c) For pieces of similar dimension, one elevated-temperature
(4) For plates such as tubesheets, tube plates or blanking- tensile test per heat and heat-treatment lot.
off covers with heat-treatment weights lighter than 1000 kg, d) One notched-bar impact bend test to clause 4.4.6.5 per
specimens shall be taken from one sampling location. If per- sampling location at 0 °C or at 20 °C.
mitted by the forging method employed, this location shall be e) Notched-bar impact bend tests for determination of an
in the top or bottom zone (according to Figure 5.3-4). impact energy vs. temperature curve to clause 4.4.6.6 at
(5) For plates with heat-treatment weights equal to or heavi- one sampling location per heat and heat-treatment lot for
er than 1000 kg, specimens shall be taken from two sampling pieces with heat-treatment weights greater than 150 kg. At
locations. If permitted by the forging method employed, these least four test temperatures shall be used, of which one
locations shall be in the top and bottom zones (according to shall be 0 °C or 20 °C.
Figure 5.3-4). (3) The Sections 11.1 and 11.4 shall apply to the non-
(6) For bars, specimens shall be taken at one end as a func- destructive tests and examinations.
tion of the diameter D of the bars: from one sampling location (4) Each piece shall be subjected to a materials identification
for D smaller than or equal to 500 mm; and from two sampling check.
locations separated by 180 degrees for D larger than 500 mm.
(5) Each piece shall be subjected in the as-delivered condi-
(7) In the case of tion to a visual inspection.
a) normalized or air quenched and tempered bars having a (6) A dimensional check of each piece shall be performed.
finished length longer than 5000 mm and
b) liquid quenched and tempered bars having a finished
length longer than 2000 mm 6.3.3 Marking
specimens shall be taken from one sampling location at the (1) Each piece shall be marked at least with the following
opposite end. For bars having diameters smaller than or equal information:
to 500 mm, this location shall be offset by 180 degrees relative a) manufacturer's symbol,
to that at the other end.
b) steel grade,
c) heat number,
6.3.2.1.3 Sampling depth
d) specimen number or test lot number,
The requirements of the DIN standards or VdTÜV material
sheets applicable for the respective product form shall apply. e) authorized inspector's mark.
In the case of steel 15 MnNi 6 3 the specimens shall be taken (2) In the case of lotwise examination, the piece from which
from at least one quarter of the governing heat-treatment thick- the specimens were taken shall additionally be marked.
ness but at most 80 mm under the heat-treatment surfaces.

6.3.4 Verification of quality characteristics

6.3.2.1.4 Specimen direction
(1) The results of the ladle analysis, product analysis, mate-
(1) Transverse specimens shall be taken for tensile tests rials identification check and non-destructive tests and exami-
and notched-bar impact bend tests if geometrically possible nations performed by the manufacturer, and if necessary of
and nothing to the contrary is stipulated in the authorized the hardness test shall be documented with an inspection
inspector's appraisal. certificate 3.1 to DIN EN 10204. The steel making process, the
(2) Notwithstanding the foregoing, longitudinal specimens or delivery condition of the product form stating heat treatment
axial specimens taken from bars are permitted, specifically for temperatures, holding times and cooling conditions as well as
 KTA 3211.1 Page 27

simulated stress-relief annealing temperature and holding time (2) The mechanical and technological characteristics shall
of test coupons, if any, shall be indicated in the inspection be determined by performing:
certificate 3.1. a) Room-temperature tensile tests in compliance with the re-
(2) The results of mechanical and technological tests, visual quirements for test category 2 in the DIN standards refer-
inspection, dimensional check and non-destructive tests and red to in 6.4.2, but in the case of steel grade 15 MnNi 6 3
examinations shall be confirmed by the authorized inspector one room-temperature tensile test for every 50 manufac-
and combined with inspection certificate 3.1 as inspection turing lengths of the same heat, dimension and heat treat-
certificate 3.2 to DIN EN 10204 issued by him. Alternatively, ment at one end of one manufacturing length.
these tests shall be confirmed by the authorized inspector on b) One tensile test at 300 °C per heat, dimension and heat
an inspection certificate 3.2 established by the manufacturer. treatment, if the design temperature is higher than 100 °C.
c) Room-temperature tensile tests to DIN EN 10164 per
6.4 Seamless pipes larger than DN 50 tensile test specimen to a) on perpendicular specimens in
order to determine the reduction of area at fracture for
6.4.1 Scope pipes with nominal wall thicknesses equal to or larger than
15 mm, whenever the quality class Z25 is required acc. to
(1) The stipulations of this Section shall apply to seamless,
clause 6.4.3. This test may be waived for steel grades for
rolled or pressed pipes larger than DN 50.
which it was demonstrated in the material appraisal that
Note: the mean value of reduction of area at fracture is at least
For forged pipes Section 6.3 shall apply. 35 % and that none of the individual values is smaller than
(2) The stipulations of this Section shall also apply to pipes 25 %.
equal to or smaller than DN 50 if pipe elbows larger than d) One notched-bar impact bend test to clause 4.4.6.5 at 0 °C
DN 50 are made from such pipes. or 20 °C
(3) The stipulations of this Section shall not apply to pipes da) per tensile test specimen to a) for pipes of normalized
for vessel shells. or air quenched and tempered steels with nominal wall
thicknesses equal to or larger than 10 mm up to and
including 38 mm,
6.4.2 Materials db) at one end of each manufacturing length for pipes of
(1) The following steel grades may be used: normalized or air quenched and tempered steels with
nominal wall thicknesses exceeding 38 mm,
a) 15 MnNi 6 3 to Section A 3
dc) per tensile test specimen to a) for pipes of liquid
b) P235GH (1.0345) to DIN EN 10216-2, quenched and tempered steels at both ends of one
c) P275NL1 (1.0488) to DIN EN 10216-3 in conjunction manufacturing length in the case of nominal wall thick-
with VdTÜV material sheet 352/2, nesses equal to or larger than 10 mm up to and includ-
ing 16 mm and at both ends of each manufacturing
d) P355NH (1.0565) to DIN EN 10216-3 in conjunction length for pipes exceeding 16 mm.
with VdTÜV material sheet 354/2,
For pipes of steel grade 15 MnNi 6 3, the test temperature
e) 16Mo3 (1.5415) to DIN EN 10216-2 and shall be 0 °C.
f) other steel grades meeting the prerequisites of Section 3 in e) Notched-bar impact bend tests for determination of the
combination with the stipulations in the authorized inspec- impact energy vs. temperature curve to clause 4.4.6.6 at
tor's appraisal. one end of one manufacturing length per heat, dimension
(2) The materials shall meet the requirements of clause 4.3.2. and heat treatment for pipes with nominal wall thicknesses
exceeding 16 mm. At least four test temperatures shall be
(3) The selection of materials shall be based on the lowest used, of which one shall be 0 °C or 20 °C. This test may
operating temperature. be waived for pipes of steel grade 15 MnNi 6 3.
f) Technological tests for pipes with nominal wall thicknesses
6.4.3 Additional requirements for the materials equal to or smaller than 40 mm per tensile test specimen
to a) using test methods in compliance with the DIN stand-
Pipes with nominal wall thicknesses equal to or larger than ards referred to in 6.4.2. In the case of pipes made of steel
15 mm and subjected to loading perpendicular to the rolled grade 15 MnNi 6 3 at both ends of each manufacturing
surface shall at least meet the requirements of quality class length using test methods to Table 5.4-1.
Z25 to DIN EN 10164. This shall be specified in the purchase
order. (4) The Sections 11.1 and 11.5.2 shall apply to the non-
destructive tests and examinations.
6.4.4 Tests and examinations (5) Each pipe shall be subjected to a materials identification
check.
6.4.4.1 Sampling and specimen preparation
(6) The inside and outside surfaces of each pipe shall be
Specimens shall be taken in accordance with the DIN stan- subjected to a visual inspection.
dards and VdTÜV material sheets referred to in 6.4.2 and in
the case of steel grade 15 MnNi 6 3 in accordance with Sec- (7) The diameter and wall thickness shall be checked for
tion 5.4.4. dimensional accuracy at both ends of each pipe.
(8) Each pipe shall be examined for leak tightness to DIN
6.4.4.2 Extent of tests and examinations EN 10216-2 or DIN EN 10216-3.
(1) The following procedures shall be performed for the
chemical analysis: 6.4.5 Marking
a) One ladle analysis per heat. (1) Each pipe shall be marked at both ends at least with the
b) One product analysis on each of two manufacturing following information:
lengths per heat. a) manufacturer's symbol,
KTA 3211.1 Page 28

b) steel grade and number of the DIN standard, for steels 6.5.4 Tests and examinations of pipe elbows
with guaranteed reduction of area at fracture perpendicular
6.5.4.1 Sampling and specimen preparation
to the product surface additionally quality class to DIN EN
10164, (1) Specimens shall be taken from the ends of the pipe
c) heat number, elbows in conformity with the authorized inspector's appraisal.
d) pipe number, (2) Transverse specimens shall be tested in the tensile tests
e) test category and and notched-bar impact bend tests, provided that they can be
f) authorized inspector's mark. taken from unstraightened test coupons. If this is not possible,
longitudinal specimens shall be tested.

6.4.6 Verification of quality characteristics (3) If starting products that have not been completely exam-
ined and heat-treated to the stipulations in Sections 6.3 or 6.4
(1) The results of the ladle analysis, product analysis, mate- are used, test coupons shall be taken from both ends of pipe
rials identification check, tightness test and non-destructive elbows with a chord length greater than 3000 mm, measured
tests and examinations performed by the manufacturer shall along the outside of the bend.
be documented with an inspection certificate 3.1 to DIN EN
(4) In all other cases, test coupons shall be taken from only
10204. The steel making process, the delivery condition of the one end of the pipe elbow.
product form stating heat treatment temperatures, holding
times and cooling conditions as well as simulated stress-relief (5) If the pipe elbows are not tested individually, test units
annealing temperature and holding time of test coupons, if consisting of pipe elbows of the same heat, dimension and
any, shall be indicated in the inspection certificate 3.1. heat treatment shall be formed for determination of mechani-
cal and technological characteristics.
(2) The results of mechanical and technological tests, visual
inspection, dimensional check and non-destructive tests and (6) For the room-temperature tensile tests and for the
examinations shall be confirmed by the authorized inspector notched-bar impact bend tests, the number of pipe elbows per
and combined with inspection certificate 3.1 as inspection test unit shall not exceed:
certificate 3.2 to DIN EN 10204 issued by him. Alternatively, a) 50 pieces for pipe elbows smaller than DN 200
these tests shall be confirmed by the authorized inspector on b) 25 pieces for pipe elbows equal to or larger than DN 200
an inspection certificate 3.2 established by the manufacturer. and smaller than DN 350
c) 10 pieces for pipe elbows equal to or larger than DN 350.
6.5 Seamless pipe elbows larger than DN 50
6.5.1 Scope 6.5.4.2 Extent of tests and examinations

(1) This Section shall apply to seamless pipe elbows (weld- (1) The chemical composition shall be verified on the basis
in elbows) made by cold or hot forming followed by heat of the starting product.
treatment (normalization; quenching and tempering). (2) The mechanical and technological characteristics shall
be determined by performing:
(2) This Section shall not apply to pipe bends made with
inductive bending machines or by cold forming with or without a) One room-temperature tensile test on one pipe elbow per
subsequent heat treatment. These pipe bends shall be subject test unit.
to the requirements of KTA 3211.3 Section 6. b) One tensile test at 300 °C on one pipe elbow per heat,
dimension and heat treatment, if the design temperature is
higher than 100 °C.
6.5.2 Materials
c) One notched-bar impact bend test to clause 4.4.6.5 at 0 °C
(1) The Sections 6.3.1 and 6.4.2 apply to the materials. or at 20 °C on one pipe elbow per test unit for pipe elbows
with nominal wall thicknesses equal to or larger than
(2) For finished pipe elbows, the values of the mechanical 10 mm. For pipe elbows of steel grade 15 MnNi 6 3, the
and technological characteristics for pipes shall apply even if test temperature shall be 0 °C.
forged hollow parts are used as starting products.
d) Notched-bar impact bend tests for determination of the
impact energy vs. temperature curve to clause 4.4.6.6 on
6.5.3 Starting products one pipe elbow per heat, dimension and heat treatment for
pipe elbows with nominal wall thicknesses exceeding
(1) Forged hollow parts to Section 6.3 or seamless pipes to 16 mm. At least four test temperatures shall be used, of
Section 6.4 shall basically be used as starting products. which one shall be 0 °C or 20 °C. This test may be waived
(2) Starting products that have not been completely exa- for pipe elbows of steel grade 15 MnNi 6 3.
mined and heat-treated per the stipulations in Sections 6.3 or e) For pipe elbows grouped together as test units, one hard-
6.4 may also be used, provided ness test per pipe elbow to verify uniformity.
Note:
a) the finished pipe elbows are examined individually per
Verification of uniformity shall be acknowledged if the difference
clause 6.5.4.2 and
between the highest and lowest hardness values in a test unit
b) the non-destructive tests and examinations of the starting does not exceed 30 HB units.
products have been carried out according to the require- (3) The Sections 11.1 and 11.6.2 shall apply to the non-
ments in Section 11.4 or Section 11.5.1 prior to forming. destructive tests and examinations.
In this case, the determination of mechanical and technolo-
(4) Each pipe elbow shall be subjected to a materials identi-
gical characteristics and the corresponding verification may be
fication check.
waived for the starting products. An inspection certificate 3.1
to DIN EN 10204 shall then be adequate for visual inspection (5) The inside and outside surfaces of each pipe elbow shall
and dimensional check of the starting products. be subjected to a visual inspection.
 KTA 3211.1 Page 29

(6) For each pipe elbow, the wall thickness and, depending (2) Starting products that have not been completely exa-
on the purchase order, either the outside or inside diameter mined or heat-treated to the stipulations in Sections 6.3 or 6.4
shall be measured over the arc length, including the ends, and may also be used, provided
to a sufficient extent over the circumference. The smallest wall a) the finished fittings are examined individually per clause
thickness as well as the ovality shall be determined. 6.6.4.2 and
b) the non-destructive tests and examinations of the starting
6.5.5 Marking products have been carried out according to the require-
ments in Section 11.4 or Section 11.5.2 prior to forming.
(1) Each pipe elbow shall be marked at least with the follow-
In this case the determination of mechanical and technological
ing information:
characteristics and the corresponding verification may be
a) manufacturer's symbol, waived for the starting products. An inspection certificate 3.1
b) steel grade (for steels with guaranteed reduction of area at to DIN EN 10204 shall then be adequate for visual inspection
fracture perpendicular to the product surface additionally and dimensional check of the starting products.
quality class to DIN EN 10164),
c) heat number, 6.6.4 Tests and examinations of fittings
d) elbow number, 6.6.4.1 Sampling and specimen preparation
e) authorized inspector's mark. (1) Specimens shall be taken from the ends of the fittings in
conformity with the authorized inspector's appraisal.
6.5.6 Verification of quality characteristics (2) Transverse specimens shall be tested in the tensile tests
and notched-bar impact bend tests, provided that they can be
(1) The results of the materials identification check and non-
taken from unstraightened test coupons. If this is not possible,
destructive tests and examinations performed by the manufac-
longitudinal specimens shall be tested.
turer as well as the hardness test, if any, shall be documented
with an inspection certificate 3.1 to DIN EN 10204. The deli- (3) If the fittings are not tested individually, test units consist-
very condition of the product form stating heat treatment tem- ing of fittings of the same heat, dimension and heat treatment
peratures, holding times and cooling conditions as well as shall be formed for determination of mechanical and techno-
simulated stress-relief annealing temperature and holding time logical characteristics.
of test coupons, if any, shall be indicated in the inspection
certificate 3.1. (4) For the room-temperature tensile tests and for the
notched-bar impact bend tests, the number of fittings per test
(2) The forming process used shall be indicated in the in- unit shall not exceed:
spection certificate 3.1 to DIN EN 10204. a) at most 50 pieces for fittings with nominal diameters small-
(3) The results of mechanical and technological tests, visual er than 100,
inspection, dimensional check and non-destructive tests and b) at most 25 pieces for fittings of unalloyed steels with nomi-
examinations shall be confirmed by the authorized inspector nal diameters equal to or larger than 100, or at most 10
and combined with inspection certificate 3.1 as inspection pieces for such fittings of alloyed steels.
certificate 3.2 to DIN EN 10204 issued by him. Alternatively,
these tests shall be confirmed by the authorized inspector on
an inspection certificate 3.2 established by the manufacturer. 6.6.4.2 Extent of tests and examinations

(4) The inspection certificate of the starting product shall be (1) The chemical composition shall be verified on the basis
attached to the inspection certificate 3.2. of the starting product.
(2) The mechanical and technological characteristics shall
6.6 Seamless fittings larger than DN 50 be determined by performing:
Note: a) One room-temperature tensile test per test unit.
The nominal diameter of a reducer or of a tee shall refer to the b) One tensile test at 300 °C per heat, dimension and heat
end with the larger diameter. treatment, if the design temperature is higher than 100 °C.
6.6.1 Scope c) One notched-bar impact bend test to clause 4.4.6.5 at 0 °C
or at 20 °C on one piece per test unit for fittings with nomi-
(1) This Section shall apply to the following seamless fittings: nal wall thicknesses equal to or larger than 10 mm. For fit-
a) reducers made by cold or hot forming, tings of steel grade 15 MnNi 6 3 the test temperature shall
b) tees fabricated to the liqued bulge method be 0 °C.
followed by heat treatment (normalization; quenching and d) Notched-bar impact bend tests for determination of the
tempering). impact energy vs. temperature curve to clause 4.4.6.6 on
one piece per heat, dimension and heat treatment for fit-
tings with nominal wall thicknesses exceeding 16 mm. At
6.6.2 Materials least four test temperatures shall be used, of which one
shall be 0 °C or 20 °C. This test may be waived for pipe
(1) The Sections 6.3.1 and 6.4.2 apply to the materials. elbows of steel grade 15 MnNi 6 3.
(2) For fabricated fittings, the values of the mechanical and e) For fittings grouped together as test units, one hardness
technological characteristics for pipes shall apply even if test on each fitting to verify uniformity.
forged hollow parts are used as starting products. Note:
Verification of uniformity shall be acknowledged if the difference
between the highest and lowest hardness values in a test unit
6.6.3 Starting products does not exceed 30 HB units.
(1) Forged hollow parts to Section 6.3 or seamless pipes to (3) The Sections 11.1 and 11.7.2 shall apply to the non-
Section 6.4 shall basically be used as starting products. destructive tests and examinations.
KTA 3211.1 Page 30

(4) Each fitting shall be subjected to a materials identification (3) The casting technique shall be designed according to the
check. principles of controlled solidification. For castings with nominal
widths equal to or larger than 200 mm, the gate and feeder
(5) The inside and outside surfaces of each fitting shall be technique shall be explained on the basis of the saturation
subjected to a visual inspection. calculation as well as drawings illustrating the position of the
(6) For each fitting, the ovality, diameter and thickness shall feeders, feed zones and specimen location.
be measured at the ends. (4) For each casting model, the description of the casting
technique shall be attached to the interim file (internal manu-
6.6.5 Marking facturer documentation) for retention by the manufacturer.
Note:
(1) Each fitting shall be marked at least with the following
information: The feature characterizing the dimensions of the body or case
shall be the nominal width, as follows:
a) manufacturer's symbol, a) for pumps, the nominal width of the pressure nozzle,
b) steel grade (for steels with guaranteed reduction of area at b) for valves, the largest nominal width involved,
fracture perpendicular to the product surface additionally c) for safety valves, the nominal width of the inlet nozzle.
quality class to DIN EN 10164),
(5) Together with the drawing of the casting in the as-
c) heat number, delivered condition, the following documents shall generally be
d) fitting number or test lot number, submitted as standard plans for the design approval:
e) authorized inspector's mark. a) test and inspection sequence plan and heat-treatment
plan, in case of differences from the standard production
scheme to Figure 5.7-1,
6.6.6 Verification of quality characteristics
b) for prototypes of test groups A 2 and A 3 with nominal
(1) The results of the materials identification check and non- widths equal to or greater than 200 mm a film location plan
destructive tests and examinations performed by the manufac- and a radiation source plan,
turer as well as the hardness test, if any, shall be documented c) welding procedure qualification and welding procedure
with an inspection certificate 3.1 to DIN EN 10204. The deli- sheet for production welds and if applicable construction
very condition of the product form stating heat treatment tem- welds (see Annex B),
peratures, holding times and cooling conditions as well as d) test and inspection sequence plan for construction welds, if
simulated stress-relief annealing temperature and holding time necessary.
of test coupons, if any, shall be indicated in the inspection
certificate 3.1. e) list of planned production control tests.
(6) If changes are made compared with the conditions stipu-
(2) The forming process used shall be indicated in the in-
lated in the welding procedure sheet, or if a different welding
spection certificate 3.1 to DIN EN 10204.
method is chosen, the welding procedure sheet shall be
(3) The results of mechanical and technological tests, visual amended accordingly and resubmitted for design approval.
inspection, dimensional check and non-destructive tests and
examinations shall be confirmed by the authorized inspector 6.7.3 Tests and examinations
and combined with inspection certificate 3.1 as inspection
certificate 3.2 to DIN EN 10204 issued by him. Alternatively, 6.7.3.1 Sampling and specimen preparation
these tests shall be confirmed by the authorized inspector on (1) Castings with a delivery weight equal to or lighter than
an inspection certificate 3.2 established by the manufacturer. 500 kg shall be tested in lots, and castings with a delivery weight
heavier than 500 kg shall be tested individually. The number
(4) The inspection certificate of the starting product shall be of sampling locations shall be as indicated in Table 5.7-1.
attached to the inspection certificate 3.2.
(2) The specimens shall be taken from cast-on test blocks to
DIN EN 1559-2 or from overlengths. Separately cast test
6.7 Castings blocks are permitted only for castings with piece weights equal
6.7.1 Materials to or lighter than 50 kg. The test blocks shall be provided in
sufficient number and size that the prescribed specimens can
(1) The following cast-steel grades may be used: be taken.
a) GP240GH+QT (1.0619+QT) to DIN EN 10213, (3) The thickness of the cast-on test blocks shall correspond
b) other cast-steel grades meeting the prerequisites of Sec- to the governing wall thickness. In this connection, the govern-
tion 3 in combination with the stipulations in the authorized ing wall thickness shall be the thickness of the wall subjected
inspector's appraisal. to pressure loading, and not the thickness of cast-on flanges
or local thickenings.
(2) The materials shall meet the requirements of clause 4.3.2.
(4) Cast-on test blocks at the gate system are not permitted.
(3) The selection of materials shall be based on the lowest
operating temperature. (5) For castings with piece weights heavier than 1000 kg,
the position of the cast-on test blocks on the casting shall be
6.7.2 General requirements for casting finish documented by a photograph or in a sketch.

(1) As regards their general internal and external finish, the

6.7.3.2 Extent of tests and examinations
castings shall satisfy the stipulations of Table 11-6 applicable
to their test group. (1) The following procedures shall be performed for the
(2) Feeder heads and large casting-related thickenings that chemical analysis:
impair amenability of castings to heat treatment shall be elimi- a) One ladle analysis per heat.
nated before the heat treatment for establishment of the me- b) One product analysis for one sampling location per test
chanical and technological characteristics. unit.
 KTA 3211.1 Page 31

(2) The mechanical and technological characteristics shall a) X6CrNiNb18-10 (1.4550) to DIN EN 10028-7,
be determined by performing: b) X6CrNiTi18-10 (1.4541) to DIN EN 10028-7,
a) One room-temperature tensile test per sampling location.
c) X6CrNiMoTi17-12-2 (1.4571) to DIN EN 10028-7,
The value of reduction of area at fracture shall also be de-
termined for information. d) X6CrNiMoNb17-12-2 (1.4580) to DIN EN 10028-7 and
b) One tensile test at 350 °C per heat, dimension and heat- e) other steel grades meeting the prerequisites of Section 3 in
treatment lot, if the design temperature is higher than combination with the stipulations in the authorized inspec-
100 °C. tor's appraisal.
c) One notched-bar impact bend test to clause 4.4.6.5 per
(2) The materials shall meet the requirements of clause 4.3.3.
sampling location at 0 °C or at 20 °C.
d) One hardness test on each piece to verify uniformity of the (3) For hot (operating temperature T  200 °C during conti-
quenching and tempering treatment in the case of lotwise nuous operation) reactor water containing product form and
examination of castings of quenched and tempered steel. components in BWR plants only the steel grade to clause
(3) The Sections 11.1 and 11.8 shall apply to the non-de- (1) a), and only with the following additional requirements for
structive tests and examinations. the chemical composition shall be used:
C  0,03 %
(4) Each casting shall be subjected to a materials identifi-
cation check. Si  0,5 %
(5) Each casting shall be subjected in the as-delivered con- P  0,025 %
dition to a visual inspection. S  0,010 %
(6) Each casting shall be subjected in the as-delivered con- 18,0 %  % Cr  19,0 %
dition to a dimensional check.
13  % C  % Nb  0,65 %
(7) Each casting shall be subjected in a condition suitable for Co  0,2 %
the purpose, generally by the further processor, to a tightness
test in the form of an internal pressure test, which shall be The inspection certificate shall show the nitrogen content.
performed to DIN 50104. Pressurizing fluid, test pressure and
pressure-loading duration shall be indicated in the purchase
order. The test pressure has to be limited to ensure that a 7.1.2 Additional requirements for the materials
safety margin against the yield point or 0.2 % proof stress at The surfaces shall be free of ferritic impurities which are rele-
room temperature of at least 1.1 is achieved. vant for the corrosions resistance of the product form. Scale
layers from hot forming or heat treatment shall be removed.
6.7.4 Marking Tempering colours from hot forming or heat treatment shall be
avoided by taking appropriate measures. Decision on the
(1) Each casting shall be marked at least with the following permissibility of tempering colours up to and including “yellow”
information: shall be made in each individual case.
a) manufacturer's symbol,
b) cast-steel grade,
7.1.3 Tests and examinations
c) heat number,
d) specimen number and 7.1.3.1 Sampling and specimen preparation
e) authorized inspector's mark. (1) Room-temperature tensile tests shall be performed using
a) for flat products with nominal thicknesses equal to or
6.7.5 Verification of quality characteristics smaller than 30 mm, flat tensile-test specimens containing
(1) The results of the ladle analysis, product analysis, mate- both rolled surfaces,
rials identification check and non-destructive tests and exami- b) for flat products with nominal thicknesses exceeding
nations performed by the manufacturer as well as of the hard- 30 mm and equal to or smaller than 75 mm, flat tensile-test
ness test, if any, shall be certified with an inspection certificate specimens at least 30 mm thick, containing at least one in-
3.1 to DIN EN 10204. The delivery condition of the product tact rolled surface.
form stating heat treatment temperatures, holding times and
cooling conditions as well as simulated stress-relief annealing (2) Elevated-temperature tensile tests shall be performed
temperature and holding time of test coupons, if any, shall be using,
indicated in the inspection certificate 3.1. a) for flat products with nominal thicknesses equal to or
(2) The results of mechanical and technological tests, visual smaller than 12 mm, flat tensile-test or round tensile-test
inspection, dimensional check, tightness test and non-destruc- specimens,
tive tests and examinations shall be confirmed by the author- b) for flat products with nominal thicknesses exceeding
ized inspector and combined with inspection certificate 3.1 as 12 mm, round tensile-test specimens.
inspection certificate 3.2 to DIN EN 10204 issued by him.
Alternatively, these tests shall be confirmed by the authorized (3) The notched-bar impact bend test shall be subject to the
inspector on an inspection certificate 3.2 established by the following requirements:
manufacturer. For castings with piece weights heavier than
a) For flat products with nominal thicknesses smaller than or
1000 kg, a photograph or a sketch of the location of the cast-
equal to 30 mm, specimens shall be taken from 2 mm un-
on test blocks on the casting shall be attached to the inspec-
tion certificate. der the rolled surface.
b) For flat products with nominal thicknesses exceeding
30 mm and equal to or smaller than 75 mm, specimens
7 Product forms of austenitic steels shall be taken from 1/4 of the flat product thickness under
the rolled surface.
7.1 Flat products
(4) The sampling depth for flat products with nominal thick-
7.1.1 Materials nesses exceeding 75 mm shall be subject to the stipulations in
(1) The following steel grades may be used: the authorized inspector's appraisal.
KTA 3211.1 Page 32

(5) The specimens shall be taken as transverse specimens tures, holding times and cooling conditions shall be indicated
such that the specimens are located halfway between long in the inspection certificate 3.1.
edges and centerline of the flat products.
(2) For flat products of test groups A 1 and A 2, the results of
(6) The number of sampling locations shall be as required in mechanical and technological tests, visual inspection, dimen-
DIN EN 10028-7. sional check and non-destructive tests and examinations shall
be confirmed by the authorized inspector and combined with
inspection certificate 3.1 as inspection certificate 3.2 to DIN
7.1.3.2 Extent of tests and examinations
EN 10204 issued by him. Alternatively, these tests shall be
(1) The following procedures shall be performed for the confirmed by the authorized inspector on an inspection cer-
chemical analysis: tificate 3.2 established by the manufacturer. For flat products
a) One ladle analysis per heat. of test group A 3, the stipulations shall be the same as for
steels for conventional pressure vessel plants subject to su-
b) One product analysis on one sampling location of one flat pervision to AD 2000-Merkblatt W 2.
product per heat. The nitrogen content shall be documen-
ted.
7.2 Dished or pressed product forms made from flat prod-
(2) The mechanical and technological characteristics shall ucts
be determined by performing:
a) One room-temperature tensile test per sampling location. 7.2.1 Materials
b) One tensile test at 350 °C per heat, dimensional range and The materials shall meet the requirements of clause 7.1.1.
heat-treatment lot, if the design temperature in test group
A 1 is higher than 200 °C and in test groups A 2 and A 3 is
7.2.2 Additional requirements for the materials
higher than 300 °C.
c) One room-temperature notched-bar impact bend test to The requirements of clause 7.1.2 shall apply.
clause 4.4.6.5 per sampling location for flat products with
nominal thicknesses exceeding 16 mm.
7.2.3 Tests and examinations of the starting products
(3) One test for resistance to intergranular corrosion to
DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 °C) shall (1) Starting products shall be subject to the stipulations in
be performed per heat, dimensional range and heat-treatment Section 7.1.
lot. (2) If the finished parts are tested individually to clause
(4) One bead-on-plate test to determine the delta ferrite 7.2.4.2, the tests to clause 7.1.3.2 (2) as well as the corre-
content to Annex C shall be performed per heat, if values sponding verifications shall not be required.
smaller than 3 are found in calculation of the ferrite number Note:
from the chemical composition in the ladle analysis. The stipulations of KTA 3211.3 shall apply to welded joints made
with the starting products and remaining in the finished parts.
(5) Each flat product shall be subjected to a materials identi-
fication check.
7.2.4 Tests and examinations of dished or pressed product
(6) Each flat product shall be subjected to a visual inspection. forms made from flat products
(7) The dimensional and shape accuracy of each flat product 7.2.4.1 Sampling and specimen preparation
shall be measured.
(1) For product forms with a diameter or length smaller than
(8) The Sections 11.1 and 11.2 as well as the Sections 11.1
or equal to 500 mm and a wall thickness smaller than or equal
and 11.4 in the case of flat products for tube sheets shall ap-
to 16 mm, the mechanical tests shall be performed on one
ply to the non-destructive tests and examinations.
part per heat, thickness range and heat-treatment lot. The
maximum permissible lot size shall be 20 parts, but the lot
7.1.4 Marking weight shall not exceed 500 kg.
(1) Each flat product shall be marked at least with the follow- (2) For product forms with a diameter or length greater than
ing information: 500 mm or wall thickness greater than 16 mm, each part shall
a) manufacturer's symbol, be tested individually, in which case
b) steel grade, a) for product forms with a diameter or length greater than
c) heat number, 500 mm and equal to or smaller than 6000 mm or a wall
thickness greater than 16 mm one test coupon shall be
d) specimen number, taken,
e) authorized inspector's mark. b) for product forms with a diameter or length greater than
(2) The marking shall be applied transverse to the rolling 6000 mm one test coupon each from two opposite sides
direction. For flat products cut from strip, roller stamping in the shall be taken.
longitudinal direction is also permitted. (3) The test coupons shall be taken such that transverse
specimens can be machined. Deviations up to 20 degrees
7.1.5 Verification of quality characteristics from the theoretical transverse direction are permitted for
heads (ends) and similar parts. In making the specimens,
(1) The results of the ladle analysis, product analysis, test plastic deformation of the specimen in the zone of the gauge
for resistance to intergranular corrosion, determination of the length shall be avoided. If applicable, a different type of sam-
delta ferrite content, materials identification check and non- pling or procedure for making specimens shall be agreed with
destructive tests and examinations performed by the manufac- the authorized inspector.
turer shall be documented with an inspection certificate 3.1 to
DIN EN 10204. The steel making process and the delivery (4) The stipulations of clause 7.1.3.1 and of DIN EN 10028-7
condition of the product form stating heat treatment tempera- shall apply as relevant to sampling.
 KTA 3211.1 Page 33

7.2.4.2 Extent of tests and examination certificate 3.2 established by the manufacturer. For product
forms of test group A 3, the stipulations shall be the same as
(1) The mechanical and technological characteristics shall
for steels for conventional pressure vessel plants subject to
be determined by performing:
supervision to AD 2000-Merkblatt W 2.
a) One room-temperature tensile test per sampling location.
b) One tensile test at 350 °C per heat, thickness range and
7.3 Forgings, bars and rolled rings
heat-treatment lot, if the design temperature in test group
A 1 is higher than 200 °C and in test groups A 2 and A 3 is 7.3.1 Materials
higher than 300 °C.
(1) The following steel grades may be used:
c) One notched-bar impact bend test to clause 4.4.6.5 at
room temperature per sampling location for product forms a) X6CrNiNb18-10 (1.4550) to DIN EN 10222-5 or
with nominal wall thicknesses larger than 16 mm. DIN EN 10272,
b) X6CrNiTi18-10 (1.4541) to DIN EN 10222-5 or
(2) One test for resistance to intergranular corrosion to DIN EN 10272,
DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 °C) shall
be performed per heat, dimensional range and heat-treatment c) X6CrNiMoTi17-12-2 (1.4571) to DIN EN 10222-5 or
lot. DIN EN 10272,
d) X6CrNiMoNb17-12-2 (1.4580) to DIN EN 10272 and
(3) One bead-on-plate test to determine the delta ferrite
content to Annex C shall be performed per heat, if values e) other steel grades meeting the prerequisites of Section 3 in
smaller than 3 are found in calculation of the ferrite number combination with the stipulations in the authorized inspec-
from the chemical composition in the ladle analysis. This test tor's appraisal.
may be replaced by a corresponding test of the starting prod- (2) The materials shall meet the requirements of clause 4.3.3.
ucts.
(3) For hot (operating temperature T  200 °C during conti-
(4) Each product form shall be subjected to a materials nuous operation) reactor water containing product form and
identification check. components in BWR plants only the steel grade to clause
(5) Each product form shall be subjected to a visual inspec- (1) a), and only with the following additional requirements for
tion. the chemical composition shall be used:
C  0,03 %
(6) The dimensional and shape accuracy of each product
form shall be measured. Si  0,5 %
(7) The Sections 11.1 and 11.3 shall apply to the non-de- P  0,025 %
structive tests and examinations. S  0,010 %
18,0  (% Cr)  19,0
7.2.5 Marking 13 x (% C)  (% Nb)  0,65
(1) Each product form shall be marked at least with the Co  0,2 %
following information:
The inspection certificate shall show the nitrogen content.
a) manufacturer's symbol,
b) steel grade,
7.3.2 Additional requirements for the materials
c) heat number,
The surfaces shall be free of ferritic impurities which are rele-
d) specimen number,
vant for the corrosions resistance of the product form. Scale
e) authorized inspector's mark. layers from hot forming or heat treatment shall be removed.
(2) In the case of lotwise examination, the product form from Tempering colours from hot forming or heat treatment shall be
which the specimens were taken shall additionally be marked. avoided by taking appropriate measures. Decision on the
permissibility of tempering colours up to and including “yellow”
(3) The marking shall be applied such that it appears upright shall be made in each individual case.
when viewed in the main rolling direction of the rolled plate.
7.3.3 Tests and examinations
7.2.6 Verification of quality characteristics
7.3.3.1 Test units
(1) The results of the test for resistance to intergranular cor-
rosion, determination of the delta ferrite content, materials (1) Pieces from the same heat, with similar dimensions and
identification check and non-destructive tests and examina- from the same heat-treatment lot shall be grouped as test
tions performed by the manufacturer shall be documented with units weighing at most 500 kg.
an inspection certificate 3.1 to DIN EN 10204. The delivery
(2) Pieces with heat-treatment weights heavier than 500 kg
condition of the product form stating heat treatment tempera-
or governing dimensions exceeding 250 mm shall be tested
tures, holding times and cooling conditions shall be indicated
individually.
in the inspection certificate 3.1.
(2) The forming method shall be indicated in the inspection
7.3.3.2 Sampling for forgings and rings
certificate 3.1.
7.3.3.2.1 Sampling location
(3) For product forms of test groups A 1 and A 2, the results
of mechanical and technological tests, visual inspection, di- Specimens shall be taken from one end face of the prices. For
mensional check and non-destructive tests and examinations heat treatment weights exceeding 2500 kg specimens shall be
shall be confirmed by the authorized inspector and combined taken from both ends of the forging. At diameters exceeding
with inspection certificate 3.1 as inspection certificate 3.2 to 1000 mm the specimens shall be taken offset by 180 degrees.
DIN EN 10204 issued by him. Alternatively, these tests shall Unless otherwise stipulated, specimens shall be taken from
be confirmed by the authorized inspector on an inspection one piece per test unit.
KTA 3211.1 Page 34

7.3.3.2.2 Sampling depth (4) One bead-on-plate test to determine the delta ferrite
content shall be performed per heat, if values of ferrite number
(1) The requirements of the DIN standards applicable for the
smaller than 3 are calculated by the procedure of Annex C
respective product form shall apply.
from the chemical composition in the ladle analysis.
(2) If the exact sampling location cannot be given in advance
(5) The Sections 11.1 and 11.4 shall apply to the non-de-
for any pieces, it shall be specified by agreement with the
structive tests and examinations.
authorized inspector.
(6) Each piece shall be subjected to a materials identification
check.
7.3.3.2.3 Specimen direction
(7) Each piece shall be subjected to a visual inspection.
(1) Specimens shall be taken transverse to the main forming
direction. (8) A dimensional check shall be performed for each piece.
(2) Longitudinal specimens are permitted in the following
cases: tensile-test specimens for pieces with a cross-sectional 7.3.4 Marking
area corresponding to solid parts with a diameter smaller than
(1) Each piece shall be marked durably at least with the
160 mm; and notched-bar impact-test specimens for pieces
following information:
with a cross-sectional area corresponding to solid parts with a
diameter smaller than 100 mm. a) manufacturer's symbol,
b) steel grade,
c) heat number,
7.3.3.3 Sampling for bars
d) specimen number,
7.3.3.3.1 Sampling location e) authorized inspector's mark.
(1) Specimens shall be taken from one end of the bars. (2) In the case of lotwise examination, the piece from which
(2) Unless otherwise stipulated, specimens shall be taken the specimens were taken shall additionally be marked.
from one piece per test unit.
7.3.5 Verification of quality characteristics
7.3.3.3.2 Sampling depth (1) The results of the ladle analysis, product analysis, test
(1) For bars with a diameter or heat-treatment thickness for resistance to intergranular corrosion, determination of the
smaller than or equal to 25 mm, specimens shall be taken delta ferrite content, materials identification check and non-
from the core of the bars. destructive tests and examinations performed by the manufac-
turer shall be documented with an inspection certificate 3.1 to
(2) For bars with a diameter or heat-treatment thickness DIN EN 10204. The delivery condition of the product form
larger than 25 mm and smaller than or equal to 160 mm, spec- stating heat treatment temperatures, holding times and cooling
imens shall be taken at least 12.5 mm under the surface. conditions shall be indicated in the inspection certificate 3.1.
(3) The sampling depths for bars with larger diameter or (2) For pieces of test groups A 1 and A 2, the results of me-
larger heat-treatment thickness shall be determined by the chanical and technological tests, visual inspection, dimensio-
stipulations in the authorized inspector's appraisal. nal check and non-destructive tests and examinations shall be
(4) The distance of the sampling location from the end faces confirmed by the authorized inspector and combined with
shall be at least 25 mm. inspection certificate 3.1 as inspection certificate 3.2 to DIN EN
10204 issued by him. Alternatively, these tests shall be con-
firmed by the authorized inspector on an inspection certificate
7.3.3.3.3 Specimen direction 3.2 established by the manufacturer. For pieces of test group
Longitudinal specimens shall be taken for bars with a diameter A 3, the stipulations shall be the same as for steels for con-
or heat-treatment thickness smaller than or equal to 100 mm, ventional pressure vessel plants subject to supervision to
and transverse specimens shall be taken for bars with a diam- AD 2000-Merkblatt W 2
eter or heat-treatment thickness larger than 100 mm.
7.4 Seamless pipes larger than DN 50
7.3.3.4 Extent of tests and examinations 7.4.1 Scope
(1) The following procedures shall be performed for the (1) The stipulations of this Section shall apply to seamless,
chemical analysis: rolled or pressed pipes larger than DN 50.
a) One ladle analysis per heat. Note:
For forged pipes Section 7.3 shall apply.
b) One product analysis per heat. The nitrogen content shall
be documented. (2) The stipulations of this Section shall also apply to pipes
equal to or smaller than DN 50 if pipe elbows larger than
(2) The mechanical and technological characteristics shall
DN 50 are made from such pipes.
be determined by performing:
a) One room-temperature tensile test per sampling location.
b) One tensile test at 350 °C per heat, similar dimension and 7.4.2 Materials
heat-treatment lot, if the design temperature in test group (1) The following steel grades may be used:
A 1 is higher than 200 °C and in test groups A 2 and A 3 is
a) X6CrNiNb18-10 (1.4550) to DIN EN 10216-5,
higher than 300 °C.
c) One notched-bar impact bend test to clause 4.4.6.5 at b) X6CrNiTi18-10 (1.4541) to DIN EN 10216-5,
room temperature per sampling location. c) X6CrNiMoTi17-12-2 (1.4571) to DIN EN 10216-5,
(3) One test for resistance to intergranular corrosion to d) X6CrNiMoNb17-12-2 (1.4580) to DIN EN 10216-5 and
DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 °C) shall e) other steel grades meeting the prerequisites of Section 3 in
be performed per heat, similar dimension and heat-treatment combination with the stipulations in the authorized inspec-
lot. tor's appraisal.
 KTA 3211.1 Page 35

(2) The materials shall meet the requirements of clause 4.3.3. (6) The inside and outside surfaces of each pipe shall be
subjected to a visual inspection.
(3) For hot (operating temperature T  200 °C during conti-
nuous operation) reactor water containing product form and (7) The dimensional and shape accuracy of each pipe shall
components in BWR plants only the steel grade to clause be measured at both ends.
(1) a), and only with the following additional requirements for (8) The Sections 11.1 and 11.5.3 shall apply to the non-de-
the chemical composition shall be used: structive tests and examinations.
C  0,03 %
(9) Each pipe shall be examined for leak tightness to DIN
Si  0,5 % EN 10216-5.
P  0,025 %
S  0,010 % 7.4.5 Marking
18,0  (% Cr)  19,0 (1) Each pipe shall be marked durably at least with the fol-
13 x (% C)  (% Nb)  0,65 lowing information at one end:
Co  0,2 % a) manufacturer's symbol,
b) dimensions of the pipe,
The inspection certificate shall show the nitrogen content.
c) steel grade and number of the DIN standard,
d) heat number,
7.4.3 Additional requirements for the materials
e) test category,
The surfaces shall be free of ferritic impurities which are rele- f) mark of the delivery condition,
vant for the corrosions resistance of the product form. Scale
layers from hot forming or heat treatment shall be removed. g) pipe number,
Tempering colours from hot forming or heat treatment shall be h) authorized inspector's mark.
avoided by taking appropriate measures. Decision on the
permissibility of tempering colours up to and including “yellow” 7.4.6 Verification of quality characteristics
shall be made in each individual case.
(1) The results of the ladle analysis, product analysis, test
for resistance to intergranular corrosion, determination of the
7.4.4 Testing and examinations delta ferrite content, materials identification check, tightness
7.4.4.1 Sampling and specimen preparation test and non-destructive tests and examinations performed by
the manufacturer shall be documented with an inspection
Specimens shall be taken in compliance with the requirements certificate 3.1 to DIN EN 10204. The steel making process and
in DIN EN 1026-5. The distance between pipe end and samp- the delivery condition of the product form stating heat treat-
ling location of tensile and notched-bar impact bend test spec- ment temperatures, holding times and cooling conditions shall
imens shall be at least equal to the nominal wall thickness but be indicated in the inspection certificate 3.1.
shall not exceed 25 mm.
(2) The results of mechanical and technological tests, visual
inspection, dimensional check and non-destructive tests and
7.4.4.2 Extent of tests and examinations examinations shall be confirmed by the authorized inspector
and combined with inspection certificate 3.1 as inspection
(1) The following procedures shall be performed for the
certificate 3.2 to DIN EN 10204 issued by him. Alternatively,
chemical analysis:
these tests shall be confirmed by the authorized inspector on
a) One ladle analysis per heat. an inspection certificate 3.2 established by the manufacturer.
b) One product analysis per heat. The nitrogen content shall (3) For pipes of test group A 3 and wall thicknesses smaller
be documented. than or equal to 5.6 mm, an inspection certificate 3.1 to DIN
(2) The mechanical and technological characteristics shall EN 10204 will suffice.
be determined by performing:
a) Room-temperature tensile tests in compliance with the re- 7.5 Seamless pipe elbows larger than DN 50
quirements for test category 2 in DIN EN 10216-5.
7.5.1 Scope
b) One tensile test at 350 °C per heat, dimensional range and
heat-treatment lot, if the design temperature for pipes of (1) This Section shall apply to seamless pipe elbows (weld-
test group A 1 is higher than 200 °C and for pipes of test in elbows) made by cold or hot forming followed by heat
groups A 2 and A 3 is higher than 300 °C. treatment (solution annealing and quenching).
c) One room-temperature notched-bar impact bend test to (2) This Section shall not apply to pipe bends made with
clause 4.4.6.5 per tensile test specimen to a) for pipes with inductive bending machines or by cold forming with or without
nominal wall thicknesses exceeding 16 mm. subsequent heat treatment. These pipe bends shall be subject
d) For pipes with wall thicknesses smaller than or equal to to the requirements of KTA 3211.3 Section 6.
40 mm, technological tests in compliance with the require-
ments in DIN EN 1026-5. 7.5.2 Materials
(3) One test for resistance to intergranular corrosion to (1) The materials shall meet the requirements of clauses
DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 °C) shall 7.3.1 and 7.4.2.
be performed per heat, dimension and heat-treatment lot.
(2) For finished pipe elbows, the values of the mechanical
(4) One bead-on-plate test to determine the delta ferrite and technological characteristics for pipes shall apply even if
content shall be performed per heat, if the calculation to An- forged hollow parts are used as starting product.
nex C yields values of ferrite number smaller than 3 from the
chemical composition in the ladle analysis.
7.5.3 Additional requirements for the materials
(5) Each pipe shall be subjected to a materials identification
check. The requirements of clauses 7.3.2 and 7.4.3 shall apply.
KTA 3211.1 Page 36

7.5.4 Starting products (4) One bead-on-plate test to determine the delta ferrite
content to Annex C shall be performed per heat, if values
(1) Forged hollow parts to Section 7.3 or seamless pipes to
Section 7.4 shall basically be used as starting products. smaller than 3 are found in calculation of the ferrite number from
the chemical composition in the ladle analysis. This test may
(2) Starting products that have not been completely exa- be replaced by a corresponding test on the starting product.
mined per the stipulations in Sections 7.3 or 7.4 may also be
used, provided (5) Each pipe elbow shall be subjected to a materials iden-
tification check.
a) the finished pipe elbows are examined individually per
clause 7.5.5.2 and (6) The inside and outside surfaces of each pipe elbow shall
b) the non-destructive tests and examinations of the starting be subjected to a visual inspection.
products have been carried out according to the require- (7) For each pipe elbow, the wall thickness and, depending
ments in Section 11.4 or Section 11.5.3 prior to forming. on the purchase order, either the outside or inside diameter
(3) If the finished pipe elbows are examined individually to shall be measured over the arc length, including the ends, and
clause 7.5.5.2, the determination of mechanical and technolo- to a sufficient extent over the circumference. The smallest wall
gical characteristics and the corresponding verification may be thickness as well as the ovality shall be determined.
waived for the starting products. An inspection certificate 3.1 (8) The Sections 11.1 and 11.6.3 shall apply to the non-de-
to DIN EN 10204 shall then be adequate for visual inspection structive tests and examinations.
and dimensional check of the starting products.

7.5.6 Marking
7.5.5 Tests and examinations of pipe elbows
7.5.5.1 Sampling and specimen preparation (1) Each pipe elbow shall be marked at least with the follow-
ing information:
(1) Specimens shall be taken from the ends of the pipe
à) manufacturer's symbol,
elbows in conformity with the authorized inspector's appraisal.
b) steel grade with abbreviation for the type of construction in
(2) The distance between pipe-elbow end and sampling compiance with the requirements in the DIN standard for
location shall be at least equal to the nominal wall thickness the starting product,
but shall not exceed 25 mm. Deviations from the foregoing are
permitted by agreement with the authorized inspector. c) heat number,
d) elbow number or test lot number and
(3) Transverse specimens shall be tested in the tensile tests
and notched-bar impact bend tests, provided that they can be e) authorized inspector's mark,
taken from unstraightened test coupons. If this is not possible, f) designation „X“ in the case of hot-finished elbows (of the
longitudinal specimens shall be tested. Hamburg type) from the steel grades X6CrNiTi18-10 and
X6CrNiMoTi18-10.
(4) For pipe elbows with nominal wall thicknesses larger
than or equal to 20 mm, specimens shall be taken from the
middle of the pipe wall if at all possible. 7.5.7 Verification of quality characteristics
(5) If the pipe elbows are not tested individually, test units (1) The results of the test for resistance to intergranular cor-
consisting of pipe elbows of the same heat, dimension and rosion, determination of the delta ferrite content, materials
heat treatment shall be formed for determination of mechani- identification check and non-destructive tests and examina-
cal and technological characteristics. tions performed by the manufacturer shall be documented with
(6) For the room-temperature tensile tests and for the an inspection certificate 3.1 to DIN EN 10204. The delivery
notched-bar impact bend tests, the number of pipe elbows per condition of the product form stating heat treatment tempera-
test unit shall not exceed: tures, holding times and cooling conditions shall be indicated
in the inspection certificate 3.1.
a) 50 pieces for pipe elbows smaller than DN 200
b) 25 pieces for pipe elbows larger than or equal to DN 200 to (2) The results of mechanical and technological tests, visual
smaller than DN 350 inspection, dimensional check and non-destructive tests and
examinations shall be confirmed by the authorized inspector
c) 10 pieces for pipe elbows larger than or equal to DN 350. and combined with inspection certificate 3.1 as inspection
certificate 3.2 to DIN EN 10204 issued by him. Alternatively,
7.5.5.2 Extent of tests and examinations these tests shall be confirmed by the authorized inspector on
an inspection certificate 3.2 established by the manufacturer.
(1) The chemical composition shall be verified on the basis
of the starting product. (3) The acceptance inspection certificate of the starting
product shall be attached to the inspection certificate 3.2.
(2) The mechanical and technological characteristics shall
be determined by performing: (4) For pipe elbows of test group A 3 with wall thicknesses
a) One room-temperature tensile test on one pipe elbow per smaller than or equal to 5.6 mm, an inspection certificate 3.1
test unit or, in the case of individual testing, on each pipe to DIN EN 10204 will suffice.
elbow.
b) One tensile test at 350 °C on one pipe elbow per heat, 7.6 Seamless fittings larger than DN 50
dimension and heat-treatment lot, if the design tempera- Note:
ture for pipe elbows of test group A 1 is higher than 200 °C The nominal diameter of a reducer or of a tee shall refer to the
and for pipe elbows of test groups A 2 and A 3 is higher end with the larger diameter.
than 300 °C.
7.6.1 Scope
c) One notched-bar impact bend test to clause 4.4.6.5 at
room-temperature per test unit for wall thicknesses excee- (1) This Section shall apply to the following seamless fit-
ding 16 mm. tings:
(3) One test for resistance to intergranular corrosion to a) reducers made by cold or hot forming,
DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 °C) shall b) tees fabricated to the liqued bulge method
be performed per heat, dimension and heat-treatment lot. followed by heat treatment (solution annealing and quenching).
 KTA 3211.1 Page 37

7.6.2 Materials group A 1 is higher than 200 °C and for fittings of test
groups A 2 and A 3 is higher than 300 °C.
(1) The materials shall meet the requirements of clauses
7.3.1 and 7.4.2. c) One notched-bar impact bend test to clause 4.4.6.5 at
room-temperature per test unit for wall thicknesses excee-
(2) For the mechanical and technological characteristics of ding 16 mm.
fabricated fittings, the values of the mechanical and techno-
logical characteristics for pipes shall apply even if forged hol- (3) One test for resistance to intergranular corrosion to
low parts are used as starting products. DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 °C) shall
be performed per heat, dimension and heat-treatment lot.

7.6.3 Additional requirements for the materials (4) One bead-on-plate test to determine the delta ferrite
content to Annex C shall be performed per heat, if values
The requirements of clauses 7.3.2 and 7.4.3 shall apply. smaller than 3 are found in calculation of the ferrite number from
the chemical composition in the ladle analysis. This test may
be replaced by a corresponding test on the starting product.
7.6.4 Starting products
(5) Each fitting shall be subjected to a materials identification
(1) Forged hollow parts to Section 7.3 or seamless pipes to
check.
Section 7.4 shall basically be used as starting products.
(6) The inside and outside surfaces of each fitting shall be
(2) Starting products that have not been completely exa-
subjected to a visual inspection.
mined per the stipulations in Sections 7.3 or 7.4 may also be
used, provided (7) For each fitting the ovality, diameter and wall thickness
a) the finished pipe elbows are examined individually per shall be measured at the ends.
clause 7.6.5.2 and
(8) The Sections 11.1 and 11.7.3 shall apply to the non-
b) the non-destructive tests and examinations of the starting destructive tests and examinations.
products have been carried out according to the require-
ments in Section 11.4 or Section 11.5.3 prior to forming.
7.6.6 Marking
(3) If the finished pipe elbows are examined individually to
clause 7.6.5.2, the determination of mechanical and technolo- (1) Each fitting shall be marked at least with the following
gical characteristics and the corresponding verification may be information:
waived for the starting products. An inspection certificate 3.1 a) manufacturer's symbol,
to DIN EN 10204 shall then be adequate for visual inspection
b) steel grade with abbreviation for the type of construction in
and dimensional check of the starting products.
compiance with the requirements in the DIN standard for
the starting product,
7.6.5 Tests and examinations of fittings c) heat number,
7.6.5.1 Sampling and specimen preparation d) number of the fitting or test lot number,
(1) Specimens shall be taken from the ends of the fittings in e) authorized inspector's mark,
conformity with the authorized inspector's appraisal. f) designation „X“ in the case of hot-finished fittings from the
steel grades X6CrNiTi18-10 and X6CrNiMoTi18-10.
(2) The test coupons shall be located at one half of the wall
thickness under the end face or as close as possible to that
location. 7.6.7 Verification of quality characteristics
(3) Transverse specimens shall be tested in the tensile tests (1) The results of the test for resistance to intergranular cor-
and notched-bar impact bend tests, provided that they can be rosion, determination of the delta ferrite content, materials
taken from unstraightened test coupons. If this is not possible, identification check and non-destructive tests and examina-
longitudinal specimens shall be tested. tions performed by the manufacturer shall be documented with
an inspection certificate 3.1 to DIN EN 10204. The delivery
(4) For fittings with nominal thicknesses larger than or equal condition of the product form stating heat treatment tempe-
to 20 mm, specimens shall be taken from the middle of the ratures, holding times and cooling conditions shall be indica-
pipe wall if at all possible. ted in the inspection certificate 3.1.
(5) If the fittings are not tested individually, test units con- (2) The results of mechanical and technological tests, visual
sisting of fittings of the same heat, dimension and heat- inspection, dimensional check and non-destructive tests and
treatment lot shall be formed for determination of characte- examinations shall be confirmed by the authorized inspector
ristics. and combined with inspection certificate 3.1 as inspection
(6) For the room-temperature tensile tests and for the certificate 3.2 to DIN EN 10204 issued by him. Alternatively,
notched-bar impact bend tests, the number of fittings per test these tests shall be confirmed by the authorized inspector on
unit shall not exceed: an inspection certificate 3.2 established by the manufacturer.
a) 50 pieces for fittings smaller than DN 100 (3) The inspection certificate of the starting product shall be
b) 10 pieces for fittings larger than or equal to DN 100 attached to the inspection certificate 3.2.
(4) For fittings of test group A 3 with wall thicknesses smaller
7.6.5.2 Extent of tests and examinations than or equal to 5.6 mm, an inspection certificate 3.1 to DIN
(1) The chemical composition shall be verified on the basis EN 10204 will suffice.
of the starting product.
(2) The mechanical and technological characteristics shall 7.7 Castings
be determined by performing: 7.7.1 Materials
a) One room-temperature tensile test per test unit.
b) One tensile test at 350 °C per heat, dimension and heat- (1) The following cast-steel grades may be used:
treatment lot, if the design temperature for fittings of test a) GX5CrNiNb19-11 (1.4552) to DIN EN 10213,
KTA 3211.1 Page 38

b) GX5CrNiMoNb19-11-2 (1.4581) to DIN EN 10213 and (3) The specimens shall be taken from cast-on test blocks to
c) other steel grades meeting the prerequisites of Section 3 in DIN EN 1559-2 or from overlengths. Separately cast test
combination with the stipulations in the authorized inspec- blocks are permitted only for castings with piece weights equal
tor's appraisal. to or lighter than 50 kg. The test blocks shall be provided in
sufficient number and size that the prescribed specimens can
(2) The materials shall meet the requirements of clause 4.3.3. be taken.
(4) The thickness of the cast-on test blocks shall correspond
7.7.2 General requirements for casting condition to the governing wall thickness. In this connection, the gover-
ning nominal wall thickness shall be the thickness of the wall
(1) The base metal shall have a delta ferrite content corre- subjected to pressure loading, and not the thickness of cast-
sponding to ferrite numbers of 2 to 12 to Annex C. on flanges or local thickenings.
(2) As regards their general internal and external finish, the (5) Cast-on test blocks at the gate system are not permitted.
castings shall satisfy the stipulations of Table 11-6 applicable
to their test group. (6) For castings with piece weights heavier than 1000 kg,
the position of the cast-on test blocks on the casting shall be
(3) Feeder heads and large casting-related thickenings that documented by a photograph or in a sketch.
impair the heat treatment of the casting shall be eliminated
before the heat treatment for establishment of the mechanical
7.7.3.2 Extent of tests and examinations
and technological characteristics.
(1) The following procedures shall be performed for the
(4) The casting technique shall be designed according to the
chemical analysis:
principles of controlled solidification. For castings with nominal
widths larger than or equal to 200 mm, the gate and feeder a) One ladle analysis per heat.
technique shall be explained on the basis of the saturation b) One product analysis for one sampling location per test
calculation as well as drawings illustrating the position of the unit. The nitrogen content shall be documented.
feeders, feed zones and specimen location. (2) The mechanical and technological characteristics shall
(5) For each casting model, the description of the casting be determined by performing:
technique shall be attached to the interim file (internal manu- a) One room-temperature tensile test per sampling location.
facturer documentation) for retention by the manufacturer. b) One tensile test at 350 °C per heat, dimension and heat-
Note: treatment lot, if the design temperature for castings of test
group A 1 is higher than 200 °C and for castings of test
The feature characterizing the dimensions of the body or case
shall be the nominal width, as follows: groups A 2 and A 3 is higher than 300 °C.
a) for pumps, the nominal width of the pressure nozzle, c) One notched-bar impact bend test to clause 4.4.6.5 at
b) for valves, the largest nominal width involved,
room-temperature per sampling location.
c) for safety valves, the nominal width of the inlet nozzle. (3) One test for resistance to intergranular corrosion to
DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 °C) shall
(6) Together with the drawing of the casting in the as- be performed per heat, dimension and heat-treatment lot.
delivered condition, the following documents shall generally be
submitted as standard plans for the design approval: (4) The delta ferrite content shall be determined from the
nitrogen content by the method of Annex C. If the value of the
a) test and inspection sequence plan and heat-treatment
ferrite number calculated from the chemical composition per
plan, in case of differences from the standard production
the ladle analysis is smaller than 3, the delta ferrite content
scheme to Figure 5.7-1.
shall be determined metallographically per heat.
b) for castings of test group A 1 with nominal widths equal to
(5) The Sections 11.1 and 11.8 shall apply to the non-de-
or larger than 200 mm, instructions for the non-destructive
structive tests and examinations.
examinations as well as a coordinate reference system
(reference-point grid). (6) Each casting shall be subjected to a materials identifi-
c) for prototypes of test groups A 2 and A 3 with nominal cation check.
widths greater than 200 mm a film location plan and a ra- (7) Each casting shall be subjected in the as-delivered con-
diation source plan, dition to a visual inspection.
d) welding procedure qualification and welding procedure (8) Each casting shall be subjected in the as-delivered con-
sheet for production welds and if applicable construction dition to a dimensional check.
welds (see Annex B)
(9) Each casting shall be subjected in a condition suitable for
e) test and inspection sequence plan for construction welds, if
necessary. the purpose, generally by the further processor, to a tightness
test in the form of an internal pressure test, which shall be
f) list of planned production control tests. performed to DIN 50104. Pressurizing fluid, pressure level and
(7) If changes are made compared with the conditions stipu- pressure-loading duration shall be indicated in the purchase
lated in the welding procedure sheet, or if a different welding order. The test pressure has to be limited to ensure that a
method is chosen, the welding procedure sheet shall be re- safety margin against the 0.2 % proof stress at room tempe-
submitted for design approval in this respect. rature of at least 1.1 is achieved.

7.7.4 Marking
7.7.3 Tests and examinations
(1) Each casting shall be marked at least with the following
7.7.3.1 Sampling and specimen preparation
information:
(1) Castings with a delivery weight lighter than or equal to a) manufacturer's symbol,
500 kg shall be tested in lots, and castings with a delivery b) cast-steel grade,
weight heavier than 500 kg shall be tested individually. c) heat number,
(2) The number of sampling locations shall be as indicated d) specimen number and
in Table 5.7-1. e) authorized inspector's mark.
 KTA 3211.1 Page 39

7.7.5 Verification of quality characteristics 8 Bolts and nuts

(1) The results of the ladle analysis, product analysis, test 8.1 Scope
for resistance to intergranular corrosion, determination of the
delta ferrite content, materials identification check and non- This Section shall apply to:
destructive tests and examinations performed by the manufac- a) bolts and nuts made by machining from quenched and
turer shall be documented with an inspection certificate 3.1 to tempered bars,
DIN EN 10204. The steel making process and the delivery b) bolts and nuts made by machining from hot-cold work
condition of the product form stating heat treatment tempera- hardened austenitic bars,
tures, holding times and cooling conditions shall be indicated
c) bolts and nuts made by machining from solution-annealed
in the inspection certificate 3.1.
and quenched austenitic bars,
(2) The results of mechanical and technological tests, visual d) bolts and nuts made by hot or cold forming ___ and then
inspection, dimensional check, tightness test and non-destruc- quenched and tempered,
tive tests and examinations shall be confirmed by the autho-
e) bolts and nuts of unalloyed and alloyed ferritic steels of the
rized inspector and combined with inspection certificate 3.1 as
strength classes to DIN EN ISO 898-1 and DIN EN ISO
inspection certificate 3.2 to DIN EN 10204 issued by him.
898-2 as well as of austenitic steels of steel grades A 2,
Alternatively, these tests shall be confirmed by the authorized
A 3, A 4 and A 5 to DIN EN ISO 3506-1 and DIN EN ISO
inspector on an inspection certificate 3.2 established by the
3506-2 within the limits of Table 8-1.
manufacturer. For castings with piece weights heavier than
1000 kg, a photograph or a sketch of the location of the cast- Note:
on test blocks on the casting shall be attached to the inspec- Thread rolling shall not be considered as cold forming that re-
tion certificate. quires renewed heat treatment.

Steel group Product form Strength class Limits of application

Bolts 5.6 and 8.8  M 30 for the scope of application:
per DIN EN ISO 898-1  2.5 MPa and  100 ° C 2);
strength class 8.8 only in combination with
Unalloyed and alloyed ferritic flanges  DN 500
steels 1)
Nuts 5-2 and 8  M 30 for the scope of application: < 4 MPa
per DIN EN ISO 898-2 and  300 ° C ; strength class 8 only in com-
bination with flanges  DN 500
Austenitic steels of steel grades Bolts and nuts 50 and 70  M 39,
A 2 3), A 3, A 4 3) and A 5 to per DIN EN ISO 3506-1 strength class 70 only for  M 30
DIN EN ISO 3506-1 and and DIN EN ISO 3506-2
DIN EN ISO 3506-2
1) Permitted in test group A3 only.
2) 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.
3) Bolts and nuts from non-stabilized austenitic steels of steel groups A 2 and A 4 shall not be used if in permanent contact with the fluid. Ex-
ceptions shall be agreed between purchaser and authorized inspector.

Table 8-1: Application limits of bolts and nuts to DIN EN ISO 898-1 and DIN EN ISO 898-2 as well as to DIN EN ISO 3506-1
and DIN EN ISO 3506-1

8.2 Materials e) ferritic and austenitic steels for bolts and nuts to Table 8-1,
(1) The following steel grades may be used: f) other steels meeting the prerequisites of Section 3 in com-
a) steels to Section A 5, bination with the stipulations in the authorized inspector's
appraisal.
b) steels C35E+QT (1.1181+QT), 25CrMo4 (1.7218) and
21CrMoV5-7 (1.7709) to DIN EN 10269 in combination (2) Locking by welding is not permitted.
with the additional requirements of Section 8.3 as well as
the dimensional limits and other stipulations in Section A 6,
8.3 Additional requirements for the materials
c) steels
ca) X6CrNiNb18-10 (1.4550) to DIN EN 10222-5 or (1) For ferritic steels for bolts, except X22CrMoV12-1+QT1
DIN EN 10272, (1.4923+QT1) and bolts of strength classes, the following
cb) X6CrNiTi18-10 (1.4541) to DIN EN 10222-5 or additional stipulations shall apply in the notched-bar impact
DIN EN 10272, bend test on longitudinal specimens at room temperature:
cc) X6CrNiMoTi17-12-2 (1.4571) to DIN EN 10222-5 or a) for dimensions larger than M 24 and smaller than or equal
DIN EN 10272, to M 100, the smallest individual value of lateral expansion
cd) X6CrNiMoNb17-12-2 (1.4580) to DIN EN 10272, shall not be less than 0.6 mm and
d) steels X22CrMoV12-1+QT1 (1.4923+QT1) to DIN EN 10269 b) for dimensions larger than M 100 the smallest individual
and X 8 CrNiMoBNb 16-16 +wk (1.4986+wk) to VdTÜV ma- value of impact energy shall not be less than 61 J and the
terial sheet 113/2 in combination with the dimensional limits smallest individual value of lateral expansion shall not be
and other stipulations in Section A 6, less than 0.6 mm.
KTA 3211.1 Page 40

8.4 Bolts and nuts made by machining from quenched and (7) The following requirements shall apply to the non-de-
tempered bars or from hot-cold work hardened auste- structive tests and examinations:
nitic bars a) Sections 11.1 and 11.9.2.1 in the case of ferritic and mar-
8.4.1 Tests and examinations on the bars tensitic quenched and tempered bars,
8.4.1.1 Sampling and specimen preparation b) Sections 11.1 and 11.9.3.1 in the case of bars made of the
steel X 8 CrNiMoBNb 16-16 +wk (1.4986+wk).
(1) Longitudinal specimens shall be taken.
(2) The test cross section of the tensile-test and notched-bar 8.4.2 Tests and examinations on finished parts
impact-test specimens shall be located at least one half of the
bar diameter from the end face, and the specimen axis shall (1) In the course of inspection for dimensional accuracy the
be located at the bar center for diameters equal to or smaller main and secondary features shall be examined to Table 8-2.
than 40 mm and at a depth of one sixth of the diameter under The extent of random examination and the acceptance levels
the surface for diameters larger than 40 mm. shall be subject to the stipulations in Table 8-3. Subject to
agreement of the authorized inspector, it is permitted to sup-
plement or replace the secondary features cited in Table 8-2
8.4.1.2 Test units by application-specific requirements.
The bars shall be tested in test units of at most 5000 kg, con- (2) The marking shall be checked at random. The extent of ran-
sisting of bars of the same dimension, same heat and same dom checking shall be subject to the stipulations in Table 8-3.
heat-treatment lot. (3) Bolts and nuts of alloyed steels shall randomly subjected
For steel grade X 8 CrNiMoBNb 16-16 +wk (1.4986+wk) the to a materials identification check. The extent of random
stipulations in VdTÜV material sheet 113/2 shall apply. checking shall be subject to the stipulations in Table 8-4. The
acceptance level shall be zero, regardless of the extent of
8.4.1.3 Extent of tests and examinations random checking.

(1) One ladle analysis shall be performed per heat. (4) The Sections 11.1 and 11.9.2.2 shall apply to the non-
destructive tests and examinations.
(2) The mechanical and technological characteristics shall
be determined by performing:
a) Hardness test to DIN EN ISO 6506-1 as follows: with one Main features
indentation at one end of each bar of the test unit for bars Thread limit dimensions (trueness to gauge size)
with diameter larger than 120 mm; and with one indenta-
tion at one end of 10 % of the bars of the test unit for bars Force-application areas for assembly
with diameter equal to or smaller than 120 mm, except that
at least 10 bars or, if the test unit consists of fewer than 10 Transition under the bolt head
bars, every bar shall be tested. Thread root radius at the thread-to-shank transition
b) One room-temperature tensile test on the bars exhibiting
the lowest and highest hardness values. Secondary features
c) One tensile test at 350 °C on bars for fabrication of bolts of Lengths (bolt length, thread length)
test group A 1 as well as on bars made of 20 NiCrMo 14 5
and 26 NiCrMo 14 6 for fabrication of bolts of test groups Deviations from shape and location
A 1, A 2 and A 3, if the design temperature is higher than Bearing surfaces
100 °C.
d) One notched-bar impact bend test to clause 4.4.6.5 at room- Heights (head heights, nut heights)
temperature to determine the impact energy and lateral Diameters
expansion for bars with diameters equal to or larger than
14 mm on both bars that were subjected to the tensile test. Note:
Further features as well as their classification can be defined in the
(3) Each bar shall be subjected to visual inspection.
purchase order.
(4) The marking on each bar shall be inspected.
(5) Each bar shall be inspected for dimensional accuracy. Table 8-2: Features to be inspected during dimensional check
(6) Each bar shall be subjected to a materials identification as well as their classification as main or secondary
check. features

Extent of random checking Acceptance levels

Dimensional check for Dimensional check for sec- Dimensional Dimensional check Check of
Number of
main features and ondary features and surface check for for secondary fea- identification
pieces in the
check of identification inspection main fea- tures and surface marking
test unit
marking tures inspection
Bolts Nuts Bolts Nuts
up to 150 32 20 20 13 0 0 0
151 up to 280 32 20 80 50 0 1 0

Table 8-3: Extent of random checking and acceptance levels for the dimensional check, surface inspection and check of identi-
fication marking
 KTA 3211.1 Page 41

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 200
1) 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

8.5 Bolts and nuts made by machining from solution- (3) Bolts and nuts shall be randomly subjected to a materials
annealed and quenched austenitic bars identification check. The extent of random checking shall be
subject to the stipulations in Table 8-4. The acceptance level
8.5.1 Tests and examinations on the bars
shall be zero, regardless of the extent of random checking.
8.5.1.1 Sampling and specimen preparation
(4) The Sections 11.1 and 11.9.3.2 shall apply to the non-
(1) Longitudinal specimens shall be taken. destructive tests and examinations.
(2) The axis of the tensile-test and notched-bar impact-test
specimens shall be located at the center for sizes with diame- 8.6 Bolts and nuts made by hot or cold forming and then
ters smaller than or equal to 25 mm and at least 12.5 mm quenched and tempered
under the surface for sizes with diameters larger than 25 mm.
8.6.1 Tests and examinations
8.6.1.1 Tests and examinations on the bars
8.5.1.2 Test units
(1) One ladle analysis shall be performed per heat.
The bars shall be tested in test units of at most 500 kg, con-
sisting of bars of the same dimension, same heat and same (2) Each bar shall be subjected to visual inspection.
heat-treatment lot.
(3) Each bar shall be subjected to a materials identification
check.
8.5.1.3 Extent of tests and examinations
(4) The marking on each bar shall be inspected.
(1) One ladle analysis shall be performed per heat.
(2) The mechanical and technological characteristics shall 8.6.1.2 Tests and examinations on finished parts
be determined by performing:
The tests and examinations shall be performed on bolts and
a) One room-temperature tensile test on one bar per test unit. nuts of the production lot. If this is not possible because of the
b) One tensile test at 350 °C on bars for fabrication of bolts of dimensions of the bolts and nuts, specimens for tensile and
test group A 1, if the design temperature for test group A 1 notched-bar impact bend tests shall be taken from bar seg-
is higher than 200 °C. ments that have been turned down to the heat-treatment di-
c) One notched-bar impact bend test to clause 4.4.6.5 at ameter governing the heat treatment of the formed bolts and
room-temperature for bars with diameters equal to or larg- nuts and that have been heat-treated together with these bolts
er than 14 mm on the same bar that was subjected to the and nuts. In this case the stipulations of clause 8.4.1.1 shall
tensile test. apply to the sampling location.
(3) One test for resistance to intergranular corrosion to
DIN EN ISO 3651-2 shall be performed per heat and heat- 8.6.1.3 Test units
treatment lot.
(1) The test shall be performed after the final heat treatment
(4) Each bar shall be subjected to visual inspection. on test units consisting of parts of similar dimension and origi-
(5) The marking on each bar shall be inspected. nating from the same heat and same heat-treatment lot.
(6) Each bar shall be inspected for dimensional accuracy. (2) The number of pieces to be tested shall depend on the
number of pieces in the test unit and on the test method. The
(7) Each bar shall be subjected to a materials identification
stipulations in Table 8-5 shall apply.
check.
(8) The Sections 11.1 and 11.9.3.1 shall apply to the non-
8.6.1.4 Extent of tests and examinations
destructive tests and examinations.
(1) The mechanical and technological characteristics shall
be determined by performing:
8.5.2 Tests and examinations on finished parts
a) Hardness testing of the bolts and nuts of a test unit per
(1) In the course of inspection for dimensional accuracy the Table 8-5 (DIN EN ISO 6506-1). If traveller bar segments
main and secondary features shall be examined per Table 8-2. were quenched and tempered for the tests to (3) and (4),
The extent of random examination and the acceptance levels the hardness shall also be determined on these bar seg-
shall be subject to the stipulations in Table 8-3. Subject to ments.
agreement of the authorized inspector, it is permitted to sup-
b) One room-temperature tensile test on turned-down speci-
plement or replace the secondary features cited in Table 8-2
mens to DIN EN ISO 898-1 or, in the case of testing of
by application-specific requirements.
quenched and tempered traveller bar segments, on speci-
(2) The marking shall be checked at random. The extent mens to DIN 50 125. The piece for which the smallest val-
of random checking shall be subject to the stipulations in ue of hardness was determined in the hardness test shall
Table 8-3. also be subjected to this tensile test.
KTA 3211.1 Page 42

c) One notched-bar impact bend test to clause 4.4.6.5 at (4) In the dimensional check, the main and secondary fea-
room-temperature to determine the impact energy, for tures shall be examined to Table 8-2. The extent of random
bolts larger than M 19 per Table 8-5; for bolts larger than checking and the acceptance levels shall be subject to the
M 24, the lateral expansion shall additionally be deter- stipulation in Table 8-3. Subject to agreement of the author-
ized inspector, it is permitted to supplement or replace the
mined. The piece for which the largest value of hardness
secondary features cited in Table 8-2 by application-specific
was determined in the hardness test shall also be subject- requirements.
ed to this notched-bar impact bend test.
(5) The marking shall be checked at random. The extent
(2) A drift test to DIN EN ISO 10484 shall be performed on of random checking shall be subject to the stipulations in Ta-
nuts per Table 8-5. The piece for which the largest value of ble 8-3.
hardness was determined shall also be subjected to this drift (6) Bolts and nuts of alloyed steels shall be randomly sub-
test. jected to a materials identification check. The extent
of random checking shall be subject to the stipulations in Ta-
(3) The Sections 11.1 and 11.9.4 shall apply to the non- ble 8-4. The acceptance level shall be zero, regardless of the
destructive tests and examinations. extent of random checking.

Tensile test
Hardness test Notched-bar impact bend test
Drift 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 8
up to 300 1
151 up to 280 13
281 up to 500 20
301 up to 800 2
501 up to 1200 32
1201 up to 3200 50
more than 800 4
3201 up to 10000 80

Table 8-5: Number of pieces to be subjected to the mechanical and technological tests of bolts and nuts to Section 8.6

8.7 Bolts and nuts of strength classes or steel grades b) test series MP1 (Table 12 in DIN EN ISO 898-1) including
notched bar impact bend test in the case of bolts greater
8.7.1 Tests and examinations
than M14.
8.7.1.1 Sampling and specimen preparation The following requirements shall apply to the impact ener-
(1) The tests and examinations shall normally be performed gy with only one individual value may fall short of the re-
on bolts and nuts of the production lot. quired minimum value by not more than 30 %:
strength class 5.6: not less than 40 J
(2) If this is not possible because of the dimensions of the
bolts: strength class 8.8: not less than 52 J.
a) specimens for tensile and notched-bar impact bend tests in (2) For bolts of ferritic steels of strength class 8.8 for allowa-
the case of ferritic steels shall be taken from bar segments ble operating temperatures higher than 50 °C, the elevated-
that have been turned down to the heat-treatment diameter temperature yield point shall be verified at design temperature
governing the quenching and tempering of the formed on specimens to DIN 50 125.
bolts and that have been heat-treated together with these
bolts. In this case the stipulations of clause 8.4.1.1 shall (3) Nuts of ferritic steels shall be tested to DIN EN ISO 898-2
apply for the sampling location, and in combination with DIN EN ISO 6157-2.
b) bolts of correspondingly greater length shall be made for (4) Bolts and nuts of austenitic steels shall be tested to
the tensile tests of each test unit in the case of austenitic DIN EN ISO 3506-1 and DIN EN ISO 3506-2.
steels.
(5) The Sections 11.1 and 11.9.5 shall apply to the non-de-
structive tests and examinations.
8.7.1.2 Test units
The test shall be performed after the final heat treatment on test (6) Bolts and nuts shall be subjected to a dimensional check.
units consisting of parts of similar dimension and the same a) In the case of austenitic steels in test groups A 1 and A 2
heat, originating from the same heat-treatment lot. The num- the main and secondary features of Table 8-2 shall be ex-
ber of pieces to be tested shall depend on the number of piec- amined. Subject to agreement of the authorized inspector,
es in the test unit. The stipulations in Table 8-6 shall apply. it is permitted to supplement or replace the secondary fea-
tures cited in Table 8-2 by application-specific require-
ments. The stipulations in Table 8-3 apply to the number
8.7.1.3 Extent of tests and examinations
of pieces to be inspected and the acceptance levels.
(1) Bolts of ferritic steels shall be tested to DIN EN ISO 898-1 b) The requirements of AD 2000-Merkblatt W 7 shall apply
as follows: in the case of ferritic steels and the requirements of
a) test series FF1 (Table 8 in DIN EN ISO 898-1) in the case AD 2000-Merkblatt W 2 in the case of austenitic steels in
of bolts equal to or smaller than M14 or test group A 3.
 KTA 3211.1 Page 43

8.8 Marking a) manufacturer's symbol,

8.8.1 Marking of the bars b) steel grade or strength class,
(1) The marking shall be applied on labels for bars with c) the heat number for dimensions larger than M 52, if neces-
diameters equal to or smaller than 25 mm and on the bars sary an abbreviation for nuts,
themselves for bars with diameters larger than 25 mm. d) the authorized inspector's mark for bolts larger than M 52,
(2) The marking shall contain the following information: e) a mark of correlation to the inspection certificate for bolts
larger than M 24, except for bolts of steels to Section 8.7.
a) manufacturer's symbol,
b) steel grade,
8.9 Verification of quality characteristics.
c) heat number, if necessary abbreviation and
d) authorized inspector's mark. (1) The stipulations in Table 8-7 shall govern verification of
the quality characteristics of parts as per Sections 8.4, 8.5 and
8.6.
8.8.2 Marking of the bolts and nuts
(2) The stipulations in Table 8-8 shall govern verification of
The marking shall contain the following information: the quality characteristics of bolts and nuts as per Section 8.7.

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 and nuts of one delivery originate from one heat with the same heat treatment, it will suffice to test 4 specimen sets regardless of
the 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

Type of required certificate to DIN EN 10204

Test Bars to Section 8.4 Finished parts to Sec- Bars for Finished parts to Sec-
and 8.5 for tion 8.4 and 8.5 parts to tion 8.6
Bolts Nuts Bolts 1) Nuts 1) Section 8.6 Bolts 1) Nuts 1)
Ladle analysis 3.1 3.1   3.1 3.1 3.1
Hardness test 3.1 3.1    3.1 3.1
Strength test 3.2 3.1    3.2 3.1
Notched-bar impact tough- 3.2 3.1    3.2 
ness test
Drift test       3.1
Non-destructive examination 3.2 3.2 3.2 3.1  3.2 3.1
Resistance to intergranular 3.1 3.1   3.1  
corrosion 2)
Visual inspection 3.2 3.1     
Dimensional check 3.1 3.1 3.2 3.1  3.2 3.1
Inspection of the marking 3.2 3.1 3.2 3.1 3.1 3.2 3.1
Materials identification check 3.1 3.1 3.1 3.1 3.1 3.1 3.1
1) Certificates for the tests on the bars are additionally necessary.
2) For products to Section 8.5.

Table 8-7: Review of required tests and test certificates for products to Sections 8.4, 8.5 and 8.6
KTA 3211.1 Page 44

Steel grades Product Strength class Certificate to

DIN EN 10204
Unalloyed and alloyed ferritic steels Bolts 5.6 3.1 1)

8.8 3.2 2)

Nuts 5 and 8 3.1 1)

Austenitic steels of steel grades A 2, A 3, A 4 and A 5 Bolts and nuts 50 and 70 3.1 3)
1) The requirement of filling out an inspection certificate 3.1 to DIN EN 10204 may be waived if the manufacturer has constantly carried out
the tests necessary as basis for filling out an inspection certificate 3.1 and has kept the results ready for review by the authorized inspec-
tor 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) an in-
spection certificate 3.1 to DIN EN 10204 will suffice.
3) In test group A 3 the requirement of filling out an inspection certificate 3.1 to DIN EN 10204 may be waived if the manufacturer has con-
stantly carried out the tests necessary as basis for filling out an inspection certificate 3.1 and has kept the results ready for review by the
authorized inspector at all times. In this case the marking to Section 8.8 will suffice as quality verification.

Table 8-8: Review of required inspection certificates for bolts and nuts to Section 8.7

9 Product forms of steels for special loads 100 °C. For piece weights heavier than 3000 kg in test
group A 1, each piece shall be tested.
9.1 Forgings, bars and rolled rings
c) One notched-bar impact bend test to clause 4.4.6.5 at
9.1.1 Materials room temperature per test unit on 2 parts in the case of
The following steel grades may be used: thicknesses exceeding 10 mm.
a) X3CrNiMo13-4 (1.4313) to VdTÜV material d) One hardness test (at least 3 hardness indentations) to
sheet 395/3, DIN EN ISO 6506-1 on each piece.
b) other steel grades meeting the prerequisites of Section 3 (3) The Sections 11.1 and 11.10.1 shall apply to the non-
and subsection 4.3.4 in in consideration of the stipulations destructive tests and examinations.
in the authorized inspector's appraisal.
(4) Each piece shall be subjected to a materials identification
check.
9.1.2 Additional requirements for the materials
(5) Each piece shall be subjected to a visual inspection.
The surfaces shall be free of ferritic impurities which are rele-
vant for the corrosions resistance of the product form. Scale (6) A dimensional check shall be performed for each piece.
layers from hot forming or heat treatment shall be removed.
Tempering colours from hot forming or heat treatment shall be 9.1.4 Marking
avoided by taking appropriate measures. Decision on the
permissibility of tempering colours up to and including “yellow” (1) Each piece shall be marked durably with the following
shall be made in each individual case. information:
a) manufacturer's symbol,
9.1.3 Tests and examinations b) steel grade,
9.1.3.1 Sampling locations and specimen preparation c) heat number,
The requirements of VdTÜV material sheet 395/3 apply to the d) specimen number and
sampling location and specimen preparation. Deviating here e) authorized inspector's mark.
from the lot size for pieces with partial-weights not exceeding
(2) In the case of lotwise examination, the pieces from which
1000 kg is limited to 25 pieces from the same heat treatment
the specimens were taken shall additionally be marked.
lot.

9.1.3.2 Extent of tests and examinations 9.1.5 Verification of quality characteristics

(1) The following procedures shall be performed for the (1) The results of the ladle analysis, product analysis, mate-
chemical analysis: rials identification check, hardness test and non-destructive
tests and examinations performed by the manufacturer shall
a) One ladle analysis per heat.
be documented with an inspection certificate 3.1 to DIN EN
b) One product analysis at one sampling location on each of 10204. The steel making process and the delivery condition of
two separately manufactured pieces per heat. If possible, the product form stating heat treatment temperatures, holding
the top or bottom of the starting ingot shall be tested. For times and cooling conditions shall be indicated in the inspec-
pieces heavier than 5000 kg, the analysis shall be per- tion certificate 3.1.
ormed on one sampling location of each piece. If possible,
the top or bottom of the starting ingot shall be tested. (2) The results of mechanical and technological tests, visual
inspection, dimensional check and non-destructive tests and
(2) The mechanical and technological characteristics shall
examinations shall be confirmed by the authorized inspector
be determined by performing:
and combined with inspection certificate 3.1 as inspection
a) One room-temperature tensile test per test unit on 2 parts. certificate 3.2 to DIN EN 10204 issued by him. Alternatively,
b) One tensile test at 350 °C per heat, similar dimension and these tests shall be confirmed by the authorized inspector on
heat-treatment lot, if the design temperature is higher than an inspection certificate 3.2 established by the manufacturer.
 KTA 3211.1 Page 45

9.2 Castings 9.2.3 Tests and examinations

9.2.1 Materials 9.2.3.1 Sampling and specimen preparation
(1) The following cast-steel grades may be used: (1) Castings with a delivery weight equal to or lighter than
500 kg shall be tested in lots, and castings with a delivery
a) G-X4 CrNi 13 4 (1.4317) to VdTÜV material sheet 452 and
weight heavier than 500 kg shall be tested individually.
meeting the additional require-
ments according to Annex A 7 (2) The number of sampling locations shall be as indicated
b) other steel grades meeting the prerequisites of Section 3 in Table 5.7-1.
and subsection 4.3.4 in combination with the stipulations in (3) The specimens shall be taken from cast-on test blocks
the authorized inspector's appraisal. according to DIN EN 1559-2 or from overlengths. Separately
cast test blocks are permitted only for castings with piece
(2) The stipulations of clause 4.3.4 shall be met.
weights equal to or lighter than 150 kg.
(4) The test blocks shall be provided in sufficient number
9.2.2 General casting finish
and size that the prescribed specimens can be taken.
(1) As regards their general internal and external finish, the (5) The thickness of the cast-on test blocks shall correspond
castings shall satisfy the stipulations of Table 11-6 applicable to the governing wall thickness. In this connection, the govern-
to their test group. ing nominal wall thickness shall be the thickness of the wall
(2) Feeder heads and large casting-related thickenings that subjected to pressure loading, and not the thickness of cast-
impair amenability of the casting to the heat treatment shall be on flanges or local thickenings.
eliminated before the heat treatment for establishment of the (6) Cast-on test blocks at the gate system are not permitted.
mechanical and technological characteristics.
(7) For castings with piece weights heavier than 1000 kg,
(3) The casting technique shall be designed according to the the position of the cast-on test blocks on the casting shall be
principles of controlled solidification. For castings with nominal documented by a photograph or in a sketch.
widths equal to or larger than 200 mm, the gate and feeder
(8) For simulation-heat treated specimens and travelling
technique shall be explained on the basis of the saturation
specimens the requirements of VdTÜV material sheet 452, cl.
calculation as well as drawings illustrating the position of the
10.7.1 shall apply.
feeders, feed zones and specimen location. For each casting
model, the description of the casting technique shall be at-
tached to the interim file (internal manufacturer documenation) 9.2.3.2 Extent of tests and examinations
for retention by the manufacturer.
(1) The following procedures shall be performed for the
Note: chemical analysis:
The feature characterizing the dimensions of the body or case
a) One ladle analysis per heat.
shall be the nominal width, as follows:
a) for pumps, the nominal width of the pressure nozzle, b) One product analysis for one sampling location per test
b) for valves, the largest nominal width involved, unit.
c) for safety valves, the nominal width of the inlet nozzle. (2) The mechanical and technological characteristics shall
be determined by performing:
(4) Together with the drawing of the casting in the as-
delivered condition, the following documents shall generally be a) One room-temperature tensile test per sampling location.
submitted as standard plans for the design approval: b) One tensile test at 350 °C per heat, dimension and heat-
treatment lot, if the design temperature is higher than
a) test and inspection sequence plan and heat-treatment
100 °C.
plan, in case of differences from the standard production
scheme to Figure 5.7-1, c) One notched-bar impact bend test to clause 4.4.6.5 at
room-temperature per sampling location.
b) for castings of test group A 1 with nominal widths larger
than 200 mm, instructions for the non-destructive examina- d) One hardness test on each piece to verify uniformity of the
tions as well as a coordinate reference system (reference- quenching and tempering treatment in the case of lotwise
point grid), examination of castings of quenched and tempered steel.
c) for prototypes of test groups A 2 and A 3 with nominal (3) The Sections 11.1 and 11.10.2 shall apply to the non-de-
widths greater than 200 mm a film location plan and a ra- structive tests and examinations.
diation source plan, (4) Each casting shall be subjected to a materials identifi-
d) welding procedure qualification and welding procedure cation check.
sheet for production welds and if applicable construction (5) Each casting shall be subjected in the as-delivered con-
welds (see Annex B). dition to a visual inspection.
e) test and inspection sequence plan for construction welds, if (6) Each casting shall be subjected in the as-delivered con-
necessary. dition to a dimensional check.
f) list of planned production control tests. (7) Each casting shall be subjected in a condition suitable for
(5) Stipulations for production welds including procedure the purpose, generally by the further processor, to a tightness
inspection and production control test are listed in Annex B. test in the form of an internal pressure test, which shall be
performed to DIN 50104. Pressurizing fluid, test pressure and
(6) If changes are made compared with the conditions stipu- pressure-loading duration shall be indicated in the purchase
lated in the welding procedure sheet, or if a different welding order. The test pressure has to be limited to ensure that a
method is chosen, the welding procedure sheet shall be re- safety margin against the yield point or 0.2 % proof stress at
submitted for design approval in this respect. room temperature of at least 1.1 is achieved.
KTA 3211.1 Page 46

9.2.4 Marking b) One technological test to DIN EN 10216-2 at one end of

each manufacturing length for heat-exchanger tubes of test
(1) Each casting shall be marked with the following infor- group A 1. For heat-exchanger tubes of test groups A 2 and
mation: A 3, 20 % of every 100 manufacturing lengths of the same
a) manufacturer's symbol, heat, dimension and heat treatment shall be subjected to a
b) cast-steel grade, technological test to DIN EN 10216-2 at one end.
c) heat number, (3) The Sections 11.1 and 11.11.1.1 shall apply to the non-
d) specimen number and destructive tests and examinations.
e) authorized inspector's mark. (4) Each tube shall be subjected to a materials identification
check.
9.2.5 Verification of quality characteristics
(5) The inside and outside surfaces of each tube shall be
(1) The results of the ladle analysis, product analysis, mate- subjected to a visual inspection.
rials identification check and non-destructive tests and exami-
nations performed by the manufacturer as well as hardness (6) The diameter and wall thickness shall be checked for
test, if any, shall be documented with an inspection certificate dimensional accuracy at both ends of each tube.
3.1 to DIN EN 10204. The steel making process and the deli- (7) Each tube shall be examined for leak tightness by an
very condition of the product form stating heat treatment tem- internal hydrostatic pressure test to DIN EN 10216-2. If the
peratures, holding times and cooling conditions shall be indi- tube is bent, the tightness test shall be performed on the bent
cated in the inspection certificate 3.1. tube. In this case the tightness test on the straight tube is not
(2) The results of mechanical and technological tests, visual required.
inspection, dimensional check, tightness test and non-destruc-
tive tests and examinations shall be confirmed by the author- 10.1.3 Marking
ized inspector and combined with inspection certificate 3.1 as
inspection certificate 3.2 to DIN EN 10204 issued by him. (1) Lists of tubes shall be maintained for tubes scheduled for
Alternatively, these tests shall be confirmed by the authorized bending. In this case the tubes shall be marked with heat
inspector on an inspection certificate 3.2 established by the number and tube number at one end. Other tubes may be
manufacturer. For castings with piece weights heavier than marked in the same way if lists of tubes are maintained. The
1000 kg, a photograph or a sketch of the location of the cast- authorized inspector's mark shall be entered in the list of
on test blocks on the casting shall be attached to the inspec- tubes.
tion certificate.
(2) If lists of tubes are not maintained, the tubes shall be
marked at one end with the following information:
10 Heat-exchanger tubes a) manufacturer's symbol,
b) steel grade,
10.1 Seamless straight heat-exchanger tubes of ferritic
steels with wall thicknesses smaller than or equal to c) heat number,
4 mm and with outside diameters smaller than or d) tube number,
equal to 38 mm e) authorized inspector's mark.
10.1.1 Materials
(1) The following steel grades may be used: 10.1.4 Verification of quality characteristics
a) P235GH (1.0345) to DIN EN 10216-2,
(1) The results of the ladle analysis, materials identification
b) 16Mo3 (1.5415) to DIN EN 10216-2, check, leak tightness test and non-destructive tests and exam-
c) 13CrMo4-5 (1.7335) to DIN EN 10216-2, inations shall be documented with an inspection certificate 3.1
d) 10CrMo9-10 (1.7380) to DIN EN 10216-2 and to DIN EN 10204. The steel making process and the delivery
e) other steel grades meeting the prerequisites of Section 3 in condition of the product form stating heat treatment tempera-
combination with the stipulations in the authorized inspec- tures, holding times and cooling conditions as well as simulat-
tor's appraisal. ed stress-relief annealing temperature and holding time of test
coupons, if any, shall be indicated in the inspection certificate
3.1.
10.1.2 Tests and examinations
(2) The results of mechanical and technological tests, visual
10.1.2.1 Sampling and specimen preparation
inspection, dimensional check and non-destructive tests and
Specimens shall be taken in compliance with DIN EN 10216-2. examinations shall be confirmed by the authorized inspector
and combined with inspection certificate 3.1 as inspection
certificate 3.2 to DIN EN 10204 issued by him. Alternatively,
10.1.2.2 Extent of tests and examinations these tests shall be confirmed by the authorized inspector on
Note: an inspection certificate 3.2 established by the manufacturer.
The extent of tests and examinations shall apply both to tubes
used as straight tubes and to tubes that will subsequently be bent. (3) For heat-exchanger tubes of test group A 3 made of
unalloyed steels an inspection certificate 3.1 to DIN EN 10204
(1) One ladle analysis shall be performed per heat. will suffice.
(2) The mechanical and technological characteristics shall
be determined by performing: 10.2 Seamless bent heat-exchanger tubes of ferritic steels
a) For each production run, two tensile tests at room-tempe- with wall thicknesses smaller than or equal to 4 mm and
rature for each of the first two test units to DIN EN 10216-2 with outside diameters smaller than or equal to 38 mm
and one tensile test at room-temperature for each further 10.2.1 Materials
test unit to DIN EN 10216-2 at one end of one manufactur-
ing length. Section 10.1.1 shall apply to the materials.
 KTA 3211.1 Page 47

10.2.2 Starting tubes thickness shall be checked for dimensional accuracy on two
cut-open elbows from the series of tubes with the smallest
Only tubes per Section 10.1 may be used. Lists of tubes per bend radius.
clause 10.1.3 (1) shall be maintained for the tubes.
(6) Each bent tube shall be examined for leak tightness by
an internal hydrostatic pressure test to DIN EN 10216-2.
10.2.2.1 Production methods
(7) The ball-pass test shall be performed on each bent tube.
(1) The bends shall be made by cold bending.
(2) Smooth transition from the tube leg to the tube elbow 10.2.4 Marking
shall be demonstrated on a specimen bent prior to beginning
bending work. Lists of tubes shall be maintained for bent tubes. Each bent
tube shall be marked with heat number and tube number at
(3) For the case of partial heat treatment of the bent zone, one end. The authorized inspector's mark shall be entered in
the quality of the transition zone shall be verified by a one-time the list of tubes.
appraisal of the authorized inspector.

10.2.5 Verification of quality characteristics

10.2.2.2 Requirements for the geometric form of bent tubes
(1) The results of the materials identification check, tightness
(1) Bulge-like transitions as well as any kind of wrinkles are test and ball-pass test shall be documented with an inspection
not permitted. test certificate 3.1 to DIN EN 10204. The delivery condition of
(2) The maximum allowable ovality shall be 0.10 x Di, where the product form stating heat treatment temperatures, holding
Di is the tube inside diameter (nominal diameter). times and cooling conditions shall be indicated in the inspec-
tion certificate 3.1.
(3) A ball of diameter DK = Di  (largest permissible negative
tolerance on size + 0.1 Di + 2 mm) shall pass through freely. (2) The results of mechanical and technological tests, visual
inspection, dimensional check and non-destructive tests and
examinations shall be confirmed by the authorized inspector
10.2.2.3 Heat treatment and combined with inspection certificate 3.1 as inspection
certificate 3.2 to DIN EN 10204 issued by him. Alternatively,
(1) Heat treatment is not required after cold bending of tubes these tests shall be confirmed by the authorized inspector on
with bend radius rm equal to or larger than 1.3 x Da. an inspection certificate 3.2 established by the manufacturer.
(2) Heat treatment of the bent zone or of the entire tube to (3) For bent tubes of test group A 3 made of unalloyed
the instructions of DIN EN 10216-2 for annealing after cold steels an inspection certificate 3.1 to DIN EN 10204 will suf-
processing shall be performed after cold bending of tubes with fice.
a bend radius rm smaller than 1.3 x Da.
(4) The inspection certificate of the starting product shall be
attached to the inspection certificate of the bent tube.
10.2.3 Tests and examinations
10.2.3.1 Heat-treatment condition of specimens 10.3 Seamless straight heat-exchanger tubes of austenitic
Verification of the mechanical and technological characte- steels with wall thicknesses smaller than or equal to
ristics shall be required only if the entire tube was heat-treated 3.6 mm and with diameters smaller than or equal to
after bending. In this case the test coupons shall be taken 42.4 mm
from the product after the last heat treatment. 10.3.1 Materials
(1) The following steel grades may be used:
10.2.3.2 Sampling and specimen preparation
a) X6CrNiTi18-10 (1.4541) to DIN EN 10216-5,
Test coupons shall be taken from the ends of tube legs. b) X6CrNiNb18-10 (1.4550) to DIN EN 10216-5,
c) X6CrNiMoTi17-12-2 (1.4571) to DIN EN 10216-5,
10.2.3.3 Extent of tests and examinations d) X6CrNiMoNb17-12-2 (1.4580) to DIN EN 10216-5 and
(1) The mechanical and technological characteristics shall e) other steel grades meeting the prerequisites of Section 3 in
be determined by performing: combination with the stipulations in the authorized inspec-
a) One room-temperature tensile test at one end of one tube tor's appraisal.
per 100 bent tubes of the same heat, dimension and heat
treatment for heat-treated tubes. 10.3.2 Tests and examinations
b) One technological test to DIN EN 10216-2 at both ends of
10.3.2.1 Sampling and specimen preparation
one tube per 100 bent tubes of the same heat, dimension
and heat treatment for heat-treated tubes. Specimens shall be taken in compliance with DIN EN 10216-5.
(2) Each bent tube shall be subjected to a materials identifi-
cation check. 10.3.2.2 Extent of tests and examinations
(3) The outside surface and, wherever it is accessible, the Note:
inside surface of each bent tube shall be subjected to a visual The extent of tests and examinations shall apply both to tubes
inspection. used as straight tubes and to tubes that will subsequently be bent.

(4) The Sections 11.1 and 11.11.1.2 shall apply to the non- (1) One ladle analysis shall be performed per heat.
destructive tests and examinations. (2) The mechanical and technological characteristics shall
(5) The diameter and wall thickness shall be checked for be determined by performing:
dimensional accuracy at both ends of each bent tube. In addi- a) One room-temperature tensile test per 100 manufacturing
tion, the ovality, arc shape and leg length as well as the wall lengths of the same heat, dimension and heat treatment.
KTA 3211.1 Page 48

b) One technological test to DIN EN 10216-5 at one end of 10.4 Seamless bent heat-exchanger tubes of austenitic
each manufacturing length for tubes of test group A 1. The steels with wall thicknesses smaller than or equal to
extent of testing shall be reduced to 25 % of the tubes for 3.6 mm and with diameters smaller than or equal to
test group A 2 and to 2 % of the tubes for test group A 3. 42.4 mm
(3) One test for resistance to intergranular corrosion to 10.4.1 Materials
DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 °C) shall
be performed per heat and heat treatment. Section 10.3.1 shall apply to the materials.

(4) The Sections 11.1 and 11.11.1.1 shall apply to the non-
10.4.2 Starting tubes
destructive tests and examinations.
(5) Each tube shall be subjected to a materials identification Only tubes to Section 10.3 may be used. Lists of tubes shall
check. be maintained for the tubes.

(6) The inside and outside surfaces of each tube shall be

10.4.2.1 Production methods
subjected to a visual inspection.
(7) The diameter and wall thickness shall be checked for (1) The bends shall be made by cold bending.
dimensional accuracy at both ends of each tube. (2) Smooth transition from the tube leg to the tube elbow
(8) Each tube shall be examined for leak tightness by an shall be demonstrated on a specimen bent prior to beginning
internal hydrostatic pressure test to DIN EN 10216-5. If the bending work.
tube is bent, the tightness test shall be performed on the bent (3) For the case of partial heat treatment of the bent zone,
tube. In this case the tightness test on the straight tube is not the quality of the transition zone shall be verified by a one-time
required. appraisal of the authorized inspector.

10.3.3 Marking 10.4.2.2 Requirements for the geometric form of bent tubes
(1) Lists of tubes shall be maintained for tubes scheduled for (1) Bulge-like transitions as well as any kind of wrinkles are
bending. In this case the tubes shall be marked with heat not permitted.
number and tube number at one end. Other tubes may be
marked in the same way if lists of tubes are maintained. The (2) The maximum permissible ovality shall be 0.10 x Di,
authorized inspector's mark shall be entered in the list of where Di is the tube inside diameter (nominal diameter).
tubes.
(3) A ball of diameter DK = Di  (largest permissible negative
(2) If lists of tubes are not maintained, the tubes shall be tolerance on size + 0.1 Di + 2 mm) shall pass through freely.
marked with the following information:
a) manufacturer's symbol, 10.4.2.3 Heat treatment
b) number of the DIN standard and short name or material
number with mark of the delivery condition, (1) Heat treatment is not required after cold bending of tubes
with bend radius rm larger than or equal to 1.3 x Da.
c) heat number,
d) tube number, (2) The bent zone or the entire tube shall be subjected to
solution annealing or to annealing in the temperature range of
e) authorized inspector's mark. stabilization annealing after cold bending of tubes with a bend
radius rm smaller than 1.3 x Da.

10.3.4 Verification of quality characteristics

10.4.3 Tests and examinations
(1) The results of the ladle analysis, materials identification
check, tightness test, test for resistance to intergranular corro- 10.4.3.1 Heat-treatment condition of specimens
sion and non-destructive examinations shall be documented Verification of the mechanical and technological characte-
with an inspection certificate 3.1 to DIN EN 10204. The steel ristics shall be required only if the entire tube was heat-treated
making process and the delivery condition of the product form after bending. In this case the test coupons shall be taken
stating heat treatment temperatures, holding times and cooling from the product form after the heat treatment (solution an-
conditions shall be indicated in the inspection certificate 3.1. nealing and quenching).
(2) For tubes of test groups A 1 and A 2 the results of me-
chanical and technological tests, visual inspection, dimension- 10.4.3.2 Sampling and specimen preparation
al check and non-destructive tests and examinations shall be
confirmed by the authorized inspector and combined with Test coupons shall be taken from the ends of tube legs.
inspection certificate 3.1 as inspection certificate 3.2 to DIN
EN 10204 issued by him. Alternatively, these tests shall be
10.4.3.3 Extent of tests and examinations
confirmed by the authorized inspector on an inspection certifi-
cate 3.2 established by the manufacturer. (1) The mechanical and technological characteristics shall
(3) For tubes of test group A 3 the results of mechanical and be determined by performing:
technological tests, visual inspection, dimensional check and a) One room-temperature tensile test per 100 bent tubes of
non-destructive tests and examinations shall be documented the same heat, dimension and heat treatment for heat-
with inspection certificate 3.1 to DIN EN 10204. treated tubes.
 KTA 3211.1 Page 49

b) One technological test to DIN EN 10216-5 at the end of (2) The requirements of surface finish and dimensional tol-
both legs of one tube per 100 tubes of the same heat, di- erances shall be determined per purchaser's specifications,
mension and heat treatment for heat-treated tubes. but shall be at least as follows:
(2) One test for resistance to intergranular corrosion to a) surface finish WCR to DIN EN 10217-7,
DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 °C) shall b) thickness tolerances: ISO tolerance, class T3 to
be performed per heat and heat treatment. DIN EN ISO 1127 and
(3) Each bent tube shall be subjected to a materials identifi- c) the allowable deviation of outside diameter and ovality as
cation check. per ISO tolerance, class D2.
(4) The outside surface and, wherever it is accessible, the
inside surface of each bent tube shall be subjected to a visual 10.5.3 Tests and examinations
inspection.
10.5.3.1 Sampling and specimen preparation
(5) The Sections 11.1 and 11.11.1.2 shall apply to the non-
destructive tests and examinations. (1) The tubes shall be tested in manufacturing lengths.
(6) The diameter and wall thickness shall be checked for (2) Specimens shall be taken from the ends of manufac-
dimensional accuracy at both ends of each bent tube. In addi- turing lengths.
tion, the ovality, bend shape and leg length shall be checked
for dimensional accuracy and the wall thickness shall be
10.5.3.2 Extent of tests and examinations
measured on two cut-open elbows from the series of tubes
with the smallest bend radius. (1) The chemical composition shall be determined by per-
forming one ladle analysis of the starting material per heat.
(7) Each bent tube shall be examined for leak tightness by
an internal hydrostatic pressure test to DIN EN 10216-5. (2) The mechanical and technological characteristics shall
(8) One ball-pass test shall be performed on each bent tube. be determined by performing:
a) One room-temperature tensile test per 100 manufacturing
lengths of the same heat, dimension and heat treatment.
10.4.4 Marking
b) One flattening test at both ends of each manufacturing
The bent tubes shall be marked with heat number and tube length.
number at one end. The authorized inspector's mark shall be
entered in the list of tubes. (3) One test for resistance to intergranular corrosion to
DIN EN ISO 3651-2 with prior annealing (1/2 h at 650 °C) shall
be performed per heat and heat treatment.
10.4.5 Verification of quality characteristics
(4) The Sections 11.1 and 11.11.1.1 shall apply to the non-
(1) The results of the materials identification check, tightness destructive tests and examinations.
test, ball-pass test and test for resistance to intergranular
corrosion shall be documented with an inspection certificate (5) Each tube shall be subjected to a materials identification
3.1 to DIN EN 10204. The delivery condition of the product check.
form stating heat treatment temperatures, holding times and (6) The outside and inside surfaces of each tube shall be
cooling conditions shall be indicated in the inspection certifi- subjected to a visual inspection.
cate 3.1.
(7) The diameter and wall thickness shall be checked for
(2) The results of mechanical and technological tests, visual
dimensional accuracy at both ends of each tube.
inspection, dimensional check and non-destructive tests and
examinations shall be confirmed by the authorized inspector (8) Each tube shall be examined for leak tightness by an
and combined with inspection certificate 3.1 as inspection internal hydrostatic pressure test to DIN EN 10217-7.
certificate 3.2 to DIN EN 10204 issued by him. Alternatively,
these tests shall be confirmed by the authorized inspector on
an inspection certificate 3.2 established by the manufacturer. 10.5.4 Marking

(3) For bent tubes of test group A 3 an inspection certificate (1) If lists of tubes are not maintained, the tubes shall be
3.1 to DIN EN 10204 will suffice. marked at one end with the following information:
(4) The inspection certificate of the starting product shall be a) manufacturer's symbol,
attached to the inspection certificate of the bent tube. b) number of the DIN standard and short name or material
number with mark of the delivery condition,
c) heat number,
10.5 Longitudinally welded straight heat-exchanger tubes of
austenitic steels with wall thicknesses smaller than 2 mm d) tube number,
and with diameters Da smaller than or equal to 38 mm e) test category to DIN EN 10217-7
f) authorized inspector's mark.
10.5.1 Materials
(1) The following steel grades may be used:
10.5.5 Verification of quality characteristics
a) X6CrNiTi18-10 (1.4541) to DIN EN 10217-7,
b) X6CrNiMoTi17-12-2 (1.4571) to DIN EN 10217-7 and (1) The results of the ladle analysis, materials identification
check, tightness test, test for resistance to intergranular corro-
c) other steel grades meeting the prerequisites of Section 3 in sion and non-destructive examinations shall be documented
combination with the stipulations in the authorized inspec- with an inspection certificate 3.1 to DIN EN 10204. The deli-
tor's appraisal. very condition of the product form stating heat treatment tem-
peratures, holding times and cooling conditions shall be indi-
10.5.2 Additional requirements cated in the inspection certificate 3.1.

(1) Only tubes drawn and sunsequently heat-treated after (2) The results of mechanical and technological tests, visual
welding are permitted. inspection, dimensional check and non-destructive tests and
KTA 3211.1 Page 50

examinations shall be confirmed by the authorized inspector detection sensitivity of testing, including periodic (in-service)
and combined with inspection certificate 3.1 as inspection inspections, is not impaired.
certificate 3.2 to DIN EN 10204 issued by him. Alternatively,
(3) The arithmetical mean deviation of the assessed profile
these tests shall be confirmed by the authorized inspector on
(average roughness) Ra to DIN EN ISO 4287 on the areas to
an inspection certificate 3.2 established by the manufacturer. be examined shall not exceed 20 µm in the case of ultrasonic
(3) For tubes of test group A 3 an inspection certificate 3.1 to testing and 10 µm in the case of eddy-current testing. For the
DIN EN 10204 will suffice. surface condition of casings the requirements laid down in
clause 11.8.4 shall apply.
(4) In addition, the following shall apply to ultrasonic testing:
11 Non-destructive tests and examinations a) In the case of waviness of the scanning surfaces the wavi-
11.1 General requirements ness shall be so little as to provide sufficient probe shoe
contact. This is generally the case if the distance between
11.1.1 Test instructions probe shoe surface and scanning surface does not exceed
(1) Test instructions shall be established by the manufactur- 0.5 mm at any point.
ers for non-destructive tests and examinations. b) In relation to a reference surface of 40 mm x 40 mm, the
deviation from the specified contour of the scanning sur-
(2) Independently of the project these instructions may be faces shall not exceed 0.5 mm. When selecting other di-
established for identical test objects in standardized form. mensions of reference surfaces, the allocated deviation
from the specified contour shall be linearly converted in
(3) For surface inspection the manufacturer‘s own test in-
accordance with the side length of the reference surface
structions may be used independently of the project and test selected.
object.
c) Where the opposite surface is used as reflection surface,
(4) The test instructions shall contain detailed information on: the same requirements as for the scanning surface apply
a) Assignment to the individual test objects, to the reflection surface.
b) time of testing as far as it will influence the extent and
performance of testing according to the test and inspection 11.1.2.4 Proof of required surface condition
sequence plan,
(1) It shall be proved that the requirements for the surface
c) test requirements, test methods and test facilities/equip- condition have been met.
ment, type of testing level adjustment or check of sensitivity,
d) if required, additional explanations regarding the perfor- (2) The proof of the surface condition may be omitted if it is
mance of the test (e.g. drawing to scale), ensured by the surface processing method used that the re-
quired surface condition has been obtained.
e) intended substitute measures to be taken if the applicabil-
ity of the requirements of this Section is restricted,
f) system of coordinates (reference system and counting 11.1.3 Requirements to be met by the testing personnel
direction) for a description of indications or irregularities (1) Non-destructive testing supervisors shall
assigned to a test object and
a) have the technical knowledge required to perform their
g) where required, supplementary data as regards the record- tasks and know the possibilities of application as well as
ing and evaluation of indications or irregularities (e.g. in limits of test procedures,
case of substitute measures as regards the test require-
ments). b) have basic knowledge of fabrication processes and of the
characteristic appearance of fabrication irregularities.
The test supervisory personnel shall normally be independent
11.1.2 Requirements for surfaces from the fabrication department and the authorized inspector
11.1.2.1 Radiographic testing shall be notified of their names. The test supervisory person-
nel is responsible for the application of the test procedure, for
For radiographic testing, the surfaces shall be such that the the details of the implementation of the test and for the evalua-
evaluation is in no way impaired. tion in accordance with the relevant specifications. They are
responsible for the employment of qualified and certified oper-
11.1.2.2 Surface inspection by magnetic particle, penetrant ators. This applies also to the employment of personnel not
or magnetic flux leakage testing belonging to the works.
(2) The test supervisory personnel shall have been qualified
(1) For the surface inspection by magnetic particle, pene- and certified for the testing procedures in the relevant product
trant or magnetic flux leakage testing, the surfaces shall be or industrial sectors at least with level 2 to DIN EN ISO 9712.
free from scale or any other contaminants. Any grooves or For radiographic, ultrasonic and eddy-current testing level 3
notches affecting the test result shall be eliminated. qualification and certification is required.
(2) The arithmetical mean deviation of the assessed profile (3) The NDT operators shall be capable of conducting the
(average roughness) Ra to DIN EN ISO 4287 shall not exceed tests described in this safety standard. They shall have been
10 µm on the areas to be examined. For the surface condition qualified and certified at least with level 2 to DIN EN ISO 9712
of casings the requirements laid down in clause 11.8.4 shall for the applicable testing procedure in the relevant product or
apply. industrial sector.

11.1.2.3 Ultrasonic and eddy-current testing 11.1.4 Extent and time of testing
(1) The scanning surfaces shall be free from disturbing un- (1) The type, extent and time of testing are stipulated relat-
eveness and contaminants (e.g. notches, scale, machining ing to product forms in Sections 11.2 to 11.11.
grooves).
(2) Depending on the machining location, the non-
(2) Residual notches and deviations from the specified con- destructive testing shall be performed by the product-form
tour due to processing or fabrication are only permitted if the manufacturer or component manufacturer. The tests shall take
 KTA 3211.1 Page 51

place after the last forming step and heat treatment and in a) The requirements of class B to DIN EN ISO 5579 shall be
general shall be performed by the product-form manufacturer. met. The substitute solution of Section 4 of DIN EN ISO
If non-destructive tests are not performed completely by the 5579 shall not be applied in this case.
product-form manufacturer, a corresponding note shall be b) The image quality values of image quality class B to DIN
made in the inspection certificate. EN ISO 19232-3 shall be adhered to in which case the im-
age quality indicators to DIN EN ISO 19232-1 shall be
11.1.5 Procedural requirements used.
The stipulations of clause 11.8.6.2 shall apply to the perfor-
11.1.5.1 Manual ultrasonic testing
mance of radiographic testing on castings.
(1) The general specifications laid down in Annex D as well
as the requirements laid down in Sections 11.1.8 and 11.2 to 11.1.5.4 Visual inspection
11.11 shall apply.
Note: The inspection shall be performed locally according to DIN EN
The beam angles specified in this safety standard refer to the re- 13018.
spective probe nominal angles.
(2) Should it be impossible to maintain the boundary condi- 11.1.5.5 Eddy-current testing
tions for examination by the distance-gain-size method (DGS
method) to Section D 6.2 or the DGS method cannot be ap- The stipulations of clause 11.11.2 shall apply.
plied due to the sound attenuation of the material, then the
reference block method or DAC method to Section D 6.3 shall 11.1.5.6 Mechanized or automated testing
be employed.
(1) Mechanized or automated testing systems to be em-
(3) When the DGS method is employed, the recording levels ployed for non-destructive testing shall undergo an appraisal
given as a function of nominal wall thickness or of bar diame- by the authorized inspector.
ter in Sections 11.2 to 11.11 shall apply.
(2) The requirements of the non-destructive testing standard
(4) When the reference block method or DAC method is em- applicable to the respective product form as well as the re-
ployed, all indications with echo amplitudes equal to or greater quirements under Sec. 11.2 to 11.11 shall apply provided, the
than 50 % of the echo amplitude of the reference reflector tests are performed by means of mechanized or automated
shall be registered. testing.
(5) If in manual examination the coupling cannot be checked
by other means (e.g., by observing a back-wall echo), the gain 11.1.6 Evaluation of the test results
shall be increased until the noise signals becomes visible.
(1) For the evaluation of the test results obtained by the
(6) The echo amplitudes to be registered and the accep- various test methods the criteria as per Sections 11.1.8 and
tance criteria are defined depending on the product form and 11.2 to 11.11 apply.
its dimensions in Sections 11.2 to 11.11. Should the permissi-
ble indications be exceeded, the further actions shall be de- (2) The evaluation of the test results shall normally always
termined by agreement between product-form manufacturer take into consideration the measuring tolerances of the test
and authorized inspector. procedure as well as the properties of the tested material or
material area.
(7) The size of indications shall be determined in accord-
ance with Section D 11.2.3 (half-amplitude method). The ac- (3) If several test procedures are employed in order to detect
curacy in measurement of the reflector extension shall then be internal or external irregularities, the final evaluation of the test
improved by additional investigations if these dimensions object shall be effected on the basis of the test results of all
alone are critical for evaluation of acceptability. Reflectors with test procedures.
extensions smaller than 10 mm shall qualify as point-type
indications.
11.1.7 Organization of non-destructive testing
11.1.7.1 Performance
11.1.5.2 Surface inspections
(1) The manufacturer shall perform and verify all non-
(1) The general specifications laid down in Annex E as well
destructive examinations to the extent specified by this safety
as the requirements laid down in Sections 11.2 to 11.11 shall
standard.
apply.
(2) Surface inspections of sufficiently magnetizable materials (2) The authorized inspector shall perform or participate in
shall basically be performed by the magnetic particle method, the non-destructive testing to the extent specified by this safe-
unless specified otherwise in Sections 11.2 to 11.11. ty standard. The scope of random non-destructive testing by
the authorized inspector shall be 25 % in test group A 1 and
(3) When subjecting large areas to a magnetic particle ex- 10 % in test group A 2. In test group A 3 the testing is per-
amination, the yoke magnetization method shall preferably be formed without participation of the authorized inspector.
used. Small parts shall be examined, if practicable by means
of the auxiliary or coil technique. (3) The following shall apply to the attendence of the author-
ized inspector in the performance of non-destructive tests:
(4) Methods other than magnetic-particle or penetrant test-
a) Ultrasonic, eddy-current and magnetic flux leakage testing
ing are permitted. They shall preferably be mechanized meth-
ods such as eddy-current examination or magnetic flux leak- aa) In the case of manual testing the authorized inspector
age method with probes for detection of surface defects. The shall check the test reports established by the manu-
acceptance criteria shall be specified in the test instruction. facturer. The manual tests shall be performed and be
evaluated by the authorized inspector in the scope of
random testing specified in (2) independently of the
11.1.5.3 Radiographic testing tests made by the manufacturer.
The testing shall basically be performed to DIN EN ISO 5579. ab) In the case of mechanized or automated testing the
In addition, the following requirements shall apply: authorized inspector shall attend the sensitivity calibra-
KTA 3211.1 Page 52

tion of the test equipment, spot-check the performance 11.1.8 Testing of weld edges and nozzles areas
of testing and evaluate the test results obtained. Note:
b) Radiographic testing Further tests prior to welding are specified in KTA 3211.3.
The results obtained by radiography (images) to be per- (1) Where weld edges and nozzles are dressed on ferritic
formed by the manufacturer shall be evaluated by the au- product forms, these dressed areas shall be subjected to an
thorized inspector. The performance of radiography shall ultrasonic testing prior to dressing the fusion faces.
be spot-checked by the authorized inspector.
(2) Where weld edges and nozzles are dressed on austenitic
c) Surface inspection (magnetic particle and penetrant test-
product forms, these dressed areas shall be subjected to an
ing) and visual inspection
ultrasonic testing prior to dressing the fusion faces, if accord-
The authorized inspector shall attend the test to be per- ing to KTA 3211.3 Section 11 an ultrasonic testing of the inner
formed by the manufacturer and evaluate the result ob- surface of weld seams is required.
tained.
(3) For the ultrasonic testing of weld edges and nozzle are-
(4) Where the test results obtained by the authorized inspec- as, the following requirements apply:
tor, in consideration of the scattering subject to test method
variations, do not match the test results obtained by the manu- a) For flat products made of ferritic steels the test to DIN EN
facturer, additional tests shall commonly be conducted by the 10160 and for flat products made of austenitic steels the
authorized inspector and the manufacturer. test to DIN EN 10307 shall be performed. The tested areas
shall meet the requirements of quality class E4 to Table 5
of these standards.
11.1.7.2 Recording of test results b) For all other product forms the requirements for the testing
11.1.7.2.1 General after welding laid down in KTA 3211.3, Section 11, shall
apply.
(1) The tests performed shall be recorded in test reports.
The performance of tests and the test result obtained shall be (4) In the case of wall thicknesses or sections at the point of
confirmed by signature of the persons attending the test connection equal to or greater than 30 mm a section width
(manufacturer’s NDT operator and - when participating - oper- equal to the wall thickness plus 10 mm is considered the weld
ator of the authorized inspector). edge or nozzle area, in the case of greater wall thicknesses or
sections at the point of connection, a section width equal to
(2) Test results obtained from similar test objects for which the wall thickness plus 20 mm adjacent to the fusion face or
identical test instructions have been established, may be nozzle hole.
comprised in overall records.
(5) In the case of forgings, rings and hollow parts made from
(3) The test report shall document indications and irregulari- austenitic steels the testability of the weld edges and nozzle
ties to be recorded in a traceable manner, stating the location, areas shall be determined additionally for the conditions of
orientation and size by means of the coordinate system de- weld seam testing. This shall be done, like for the testing to
scribed in the test instruction. follow, by means of angle-beam scanning. A circumferential
(4) The test supervisor shall confirm the test result by sign- notch as reference reflector shall basically be provided on the
ing it in which case this confirmation may be comprised on test object in the area where the weld will be laid, however, at
each test report or for several tests (e.g. on a cover sheet). a sufficient distance to the edge. The notch shall normally not
exceed a width of 1.0 mm, the reflection area shall be perpen-
dicular to the surface. The depth of the reference reflector
11.1.7.2.2 Manual ultrasonic and eddy-current testing shall be determined in dependence of the nominal wall thick-
Recording shall be performed by means of individual test ness of the finished part in accordance with Table 11-1.
reports of the parties involved. The results obtained by several
participants shall be evaluated (e.g. on a common cover
sheet). Nominal wall thick-
8 < s ≤ 20 20 < s ≤ 40 40 < s
ness s, mm

11.1.7.2.3 Mechanized or automated ultrasonic, eddy- Notch depth, mm 1.5 2 3

current and magnetic flux leakage testing
Recording shall be performed by means of a test report estab- Table 11-1: Depth of reference reflector for testing of weld
lished by the manufacturer. As regards the attendance at the edges end nozzle areas
testing level adjustment, spot-check control of the perfor-
mance of the test and the test results obtained the authorized Where for design reasons no oversize for the notch to be
inspector shall countersign the manufacturer’s report. inserted on the product front face is possible, the wall thick-
ness oversize shall be provided such that the notch at the
11.1.7.2.4 Surface inspection (magnetic particle and pene- inner surface can be completely dressed upon determination
trant testing) and visual inspection of testability. The test method shall follow the method for de-
tecting longitudinal defects on the weld and shall be described
Recording shall be performed by means of a test report estab- in the test instruction. The notch shall be scanned over the full
lished by the manufacturer. As regards the attendance and the circumference. The resulting notch echo height dynamics shall
test results obtained the authorized inspector shall countersign be recorded by indicating the individual positions on the cir-
the manufacturer’s report. cumference and the dB values. Where variations exceeding 6
dB are found, the further procedure shall be agreed upon with
the authorized inspector.
11.1.7.2.5 Radiographic testing
Recording shall be performed by means of a test report estab- 11.2 Flat products
lished by the manufacturer. As regards the spot-check control
of the performance of the test and the test results obtained the (1) Each flat product with nominal thickness equal to or
authorized inspector shall countersign the manufacturer’s re- larger than 10 mm shall be subjected to an ultrasonic testing
port. of the flat product body by the manufacturer.
 KTA 3211.1 Page 53

(2) The following requirements shall apply to the testing of 11.3 Dished or pressed product forms made from flat prod-
the flat product body: ucts
a) quality class S2 to DIN EN 10160 for flat products made The formed area of each dished or pressed product form
from ferritic steels and made from flat products shall be subjected to a surface in-
spection in the finish-machined condition after the last heat
b) quality class S2 to DIN EN 10307 for flat products made treatment. The acceptance criteria are defined in Tables 11-2
from austenitic steels. and 11-3.

Indications > 3 mm up to  6 mm
Linear 1) indications,
Indications caused by non-metallic inclusions 2) in the Other Indications
 3 mm Rounded > 6 mm
indications
case of ferritic steels or by carbides or linear 1)
nitrides or carbonitrides 2) in the case of indications
austenitic steels
Permitted as isolated indica-
Permitted up to 10 indications on a reference area of Not Not
tions and not to be included in
100 mm  150 mm acceptable acceptable
frequency 3)
1) In penetrant testing an indication shall be considered to have a longitudinal extension (linear indication) if its dimension in the direction of
maximum extension is at least three times as large as its smallest dimension transverse to that direction.
2) Non-metallic inclusions, carbides, nitrides and carbonitrides shall be proved to be present. This proof may be made by spot checking for
several similar indications in the tested area.
3) In the case of indications appearing systematically, the usability of the parts shall be decided jointly with the authorized inspector.

Table 11-2: Acceptance criteria for penetrant testing

Indications Indications > 1.5 mm up to  6 mm Indications

 1.5 mm Indications caused by non-metallic inclusions 1) Other indications > 6 mm

Permitted as isolated indica-

Permitted up to 10 indications on a reference area of Not Not
tions and not to be included in
100 mm  150 mm acceptable acceptable
frequency 2)
1) Non-metallic inclusions shall be proved to be present. This proof may be made by spot checking for several similar indications in the tested
area.
2) In the case of indications appearing systematically, the usability of the parts shall be decided jointly with the authorized inspector.

Table 11-3: Acceptance criteria for magnetic-particle testing

11.4 Forgings, bars and rings (2) The magnetic particle test shall be performed and evalu-
ated in compliance with the requirements of DIN EN 10228-1,
11.4.1 General
quality class 4. In addition, the stipulations laid down in An-
(1) Each piece shall be subjected to a non-destructive testing. nex E shall apply.

(2) When performing manual ultrasonic tests, the require- (3) The penetrant test shall be performed and evaluated in
ments laid down in Annex D shall be taken into account. compliance with the requirements of DIN EN 10228-2, quality
class 4. In addition, the stipulations laid down in Annex E shall
(3) The tests shall be performed and evaluated on the basis apply.
of the DIN EN 10228 standard series along with the deviations
(4) In addition to the requirements as per quality class 4 to
and supplements made in (4) and in clauses 11.4.2 and
DIN EN 10228-1 and DIN EN 10228-2 the following shall ap-
11.4.3.
ply: The frequency of allowable indications shall not exceed 10
Note: per square meter relative to the total area.
In case of the selected ultrasonic test the “forging thicknesses t”
mentioned in DIN EN 10228-4 correspond to the nominal wall (5) For areas which are not accessible for magnetic particle
thicknesses s of the final product. or penetrant testing, the procedure shall be laid down in the
test instruction.
(4) The surfaces of the parts to be examined shall be condi-
tioned and cleaned such that testing is possible without re-
strictions. Deviating from the stipulations of the DIN EN 10228 11.4.3 Ultrasonic testing
standard series the stipulations of clauses 11.1.2.2 and 11.4.3.1 Procedural requirements
11.1.2.3 apply to the arithmetical mean deviation of the as-
sessed profile (average roughness) Ra. (1) The ultrasonic testing shall be performed after the gov-
erning heat treatment for establishment of the mechanical and
technological characteristics, while the materials have the
11.4.2 Surface inspection minimum possible of contours.
(1) The entire surface shall be subjected to a surface inspec- (2) The ultrasonic testing shall basically be performed as
tion in the final machined condition. selected ultrasonic testing. If no detailed knowledge of the
KTA 3211.1 Page 54

components to be fabricated from the test object is available the test instruction. In this case at least the following require-
at the time of testing, the test may be performed as global ments shall be met.
ultrasonic testing.
(2) The testability shall be determined jointly by the parties
(3) Testing of ferritic parts shall basically be performed by involved in the test.
100 % scanning to DIN EN 10228-3, testing of austenitic parts
by 100 % scanning to DIN EN 10228-4. The stipulations of (3) The wave lengths used for determining the testability
clauses 11.4.3.3.4 and 11.4.3.3.5 shall apply to drop-forged shall not be greater than those used for the straight and angle
parts and to the stock material for drop-forged parts. Testing beam scanning that follow.
of stock material for drop-forged parts from polygonal bars (4) For plates and discs a grid of 200 mm shall be provided.
shall be performed by complete scanning to DIN EN 10308. The back wall echo height shall be determined in all centre
(4) The testing level adjustment shall either be effected ranges of the grid and additionally at the border line of the
using the DGS method or using the DAC or the reference plates and discs by means of straight-beam scanning and at
block method. The method to be used shall be fixed in the test intended frequency.
instruction. (5) For all other product forms a grid of 200 mm shall be
(5) Deviating from the stipulations of the standards refer- provided on each test object in the area of parallel or concen-
enced for the performance of ultrasonic tests the test frequen- tric walls to determine the testability. In all centre ranges of
cies shall be equal to or greater than 2 MHz. The test frequen- this grid and additionally on all border lines of forgings or
cy to be used shall be laid down in the test instruction. rolled rings the back wall echoes shall be determined by
straight-beam scanning in wall thickness direction. In areas of
(6) During ultrasonic testing the total volume shall be non parallel or non-concentric walls reference reflectors shall
scanned. For the testing of sub-surface areas scanning shall be used (e.g. boreholes, edges or through-transmission) for
be performed either from the opposite surface or a dual-ele- this examination.
ment probe shall be used. The technique to be used shall be
laid down in the test instruction. (6) The number and density of examination points required
to determine the testability shall be in a reasonable relation-
(7) Where during ultrasonic testing indications up to 6 dB be- ship to the size and geometry of the test object. Here, the
low recording level are ascertained these areas shall purpose- absolute number of measuring points may be limited to 50.
fully be tested again from the respective opposite direction.
(7) Where the test has to be performed by straight-beam
(8) If, during ultrasonic testing, indications that are to be
scanning, the sound wave attenuation in areas with a back
registered are found in zones that will be removed during
wall echo attenuation greater than 6 dB shall also be deter-
further processing of the piece being tested, they need not be
mined by means of angle-beam scanning, e.g. by V-scanning.
considered in the evaluation but shall be documented. All
indications due to structural condition of the piece shall not be (8) Areas with a high sound wave attenuation (back wall
covered by the evaluation, but be indicated in the test report. echo variation greater than 12 dB) shall be identified and be
(9) If, for material-related reasons (e.g., reduction of the enveloped by a narrow measuring point grid in which case the
heat-treatment cross section), the geometry after heat treat- absolute number of measuring points shall be increased ac-
ment does not allow the entire volume to be examined with the cordingly. The maximum sound attenuation shall be recorded
required ultrasonic scanning directions, the zones that will for each required scanning direction.
subsequently have restricted examinability shall be additional-
ly examined prior to the heat treatment, while the geometric 11.4.3.2.2 Unrestricted testability
condition is appropriately favorable.
If it can be proved for the area with the greatest sound attenu-
(10) For the purpose of documenting and correcting the test ation that with respect to the straight and each angle beam
conditions during ultrasonic testing the sound attenuation and scanning a distance of at least 6 dB between recording levels
transfer correction shall be determined to the extent such that to clause 11.4.3.4.1.2 and noise level can be satisfied, the test
a complete evaluation of the test object is possible. The loca- object has unrestricted testability.
tion and number of measurements shall be laid down in the
test instruction. In the case of product forms made of austenit-
ic steels clause 11.4.3.2 shall be considered. 11.4.3.2.3 Restricted testability
(11) Depending on the intended use, the sound beam entry (1) Where for one or more sound beam entry directions in a
positions shall be laid down in accordance with the purchas- sound attenuation region the distance of at least 6 dB between
er’s data, however at least the sound beam entry positions laid recording levels to clause 11.4.3.4.1.2 and noise level cannot
down in clause 11.4.3.3 shall be used. Where during ultrason- be maintained in a certain area, the volumetric regions with
ic testing with straight beam scanning in axial component restricted testability and the corresponding degree of restric-
direction the volume cannot be evaluated completely (side- tion shall be determined and be documented.
wall influence, sound attenuation), additional tests with angle
(2) If, in the course of subsequent mechanical processing,
beam scanning from the lateral surface shall be made in both
more favourable conditions with regard to ultrasonic testing
axial directions.
are created for these regions (e.g. reduction of the wall thick-
(12) Deviating from the stipulations in DIN EN 10228-3 and ness, shorter sound path travel distances, removal of the
DIN EN 10228-4 (section 12.1 in each standard), angle-beam regions of restricted testability), then the ultrasonic testing of
scanning in circumferential direction on hollow parts is re- the regions in question may be carried out for the missing
quired independently from the outside-to-inside diameter ratio. beaming directions in this subsequent fabrication condition.
The incidence angle for angle-beam scanning in circumferen- This testing may also be carried out by the subsequent manu-
tial direction shall be between 35 and 45 degrees. facturer, provided the producer of the forging and the subse-
quent manufacturer agree. If the required testing level is
11.4.3.2 Testability of product forms made of austenitic steel achieved in the subsequent fabrication condition, these re-
gions shall also be considered to be unrestrictedly testable.
11.4.3.2.1 Determination of testability
(3) For areas of restricted testability additional examinations
(1) The testability shall be determined for each test object. (e.g. fracture mechanics analyses) shall be performed which
Location and number of measurements shall be specified in make a decision of usability possible.
 KTA 3211.1 Page 55

11.4.3.3 Performance of testing Straight-beam scanning shall be performed from all outer
surfaces if their radius of curvature exceeds 30 mm. On parts
11.4.3.3.1 Forged or rolled bars
of test group A1 and parts with nominal widths exceeding
(1) On bars with diameters or side lengths exceeding 30 mm DN 300 of test group A2 angel-beam scanning in both circum-
ultrasonic testing shall be performed to DIN EN 10228-3 or ferential directions shall be performed in cylindrical regions of
DIN EN 10228-4 in due considerations of the stipulations open-die forgings.
mentioned in (2).
Note: 11.4.3.3.4 Stock material for drop-forged parts
For straight-beam scanning the requirements of DIN EN 10228-3
are also met by DIN EN 10308. (1) The stock material for drop-forged parts with diameters
or edge lengths exceeding 50 mm shall be subjected to
(2) In case of bars for parts of test group A1 the following ultrasonic testing to DIN EN 10308, DIN EN 10228-3 or
shall be performed additionally: DIN EN 10228-4.
a) In case of diameters or side lengths exceeding 60 mm
(2) Stock material made of austenitic steel may also be
straight-beam scanning in axial direction; where in this
tested in the not solution-annealed condition, provided that no
case no distance between recording level and noise level
restrictions as to their testability exist.
of at least 6 dB can be adhered to over the entire length of
the bar, the test shall be performed in the cut-to-length
condition or with 45° angle-beam scanning in both axial di- 11.4.3.3.5 Drop-forged parts
rections.
(1) For drop-forged parts with nominal values larger than
b) In case of round bars with diameters exceeding 120 mm 150 mm, an ultrasonic examination shall be performed, if
angle-beam scanning in both circumferential directions; the permitted by the geometry, after the governing heat treatment
incidence angle shall be 35°. for establishment of the mechanical and technological material
The incidence angles to a) and b) shall also be used for bars characteristics, while the materials have the minimum possible
used for components with nominal widths exceeding DN 300 of contours.
of test group A2.
(2) The examination shall be performed by straight-beam
scanning from the external surfaces.
11.4.3.3.2 Forged flat plates, disks and cylindrical hollow
parts as well as forged or rolled rings (3) Ultrasonic testing is not required in zones with radii of
curvature smaller than 30 mm.
(1) Ultrasonic testing shall be performed to DIN EN 10228-3
or DIN EN 10228-4 with the requirements for types 2 and 3 in
due consideration of the stipulations hereafter. 11.4.3.4 Recording levels and acceptance criteria
11.4.3.4.1 Selected testing
(2) Hollow parts and rings of test group A1 as well as hollow
parts and rings with diameters exceeding DN 300 of test group 11.4.3.4.1.1 Product forms of ferritic steel
A2 shall additionally be tested by straight-beam scanning from
(1) For the testing of forgings, bars and rings the quality
both front edges. classes as per Table 11-4 and the resulting recording levels
and acceptance criteria to DIN EN 10228-3 apply.
11.4.3.3.3 Open-die forgings Note:
For straight-beam scanning the requirements of DIN EN 10228-3
(1) Ultrasonic testing shall be performed to DIN EN 10228-3
are also met by DIN EN 10308.
or to DIN EN 10228-4 in compliance with the specifications
laid down in (2) in the case of forgings not containing bored (2) For the testing of stock material used for drop-forged
holes and the specifications laid down in (3) in the case of parts the recording levels and acceptance criteria as per quali-
forgings containing bored holes. It shall be performed after the ty class 4 to DIN EN 10308 or DIN EN 10228-3 apply.
governing heat treatment for establishment of the mechanical
(3) In addition, the following requirements apply to the test-
and technological characteristics, while the materials have the
ing of forging, bars and rings as well as stock material for
minimum possible of contours.
drop-forged parts:
If the contour after machining and heat treatment permits only
a) Clusters of echo indications shall be registered that are up
restricted testability, testing per (2) or (3) shall be performed
to 6 dB below the recording level and cannot be resolved
before machining and heat treatment and testing per (4) shall into individual echo indications in one probe position or
be performed after machining and heat treatment. during probe travel. In these regions additional investiga-
(2) For forgings not containing bored holes the following tions (e.g. through-transmission in several directions) shall
shall apply: be performed to be able to make a statement on the reflec-
tor type (planar or volumetric).
The requirements for types 1a or 1b to DIN EN 10228-3 or
DIN EN10228-4 shall be met. On parts of test group A1 and The indications are not permitted, if these investigations
parts with nominal widths exceeding DN 300 of test group A2 reveal signs of areal separations, e.g., loss of intensity of a
ultrasonic testing shall additionally be performed from the front sound-transmission signal by comparison with indication-
edges by straight-beam scanning and in cylindrical regions in free zones of the product form.
both circumferential directions by angle-beam scanning. b) All sites shall be registered where
(3) For hollow-bored forgings the following shall apply: ba) the distance between the recording level and the noise
level is less than 6 dB,
The requirements for type 3a to DIN EN 10228-3 or DIN EN
10228-4 shall be met. On parts of test group A1 and parts with bb) the back-wall echo drops to reach the recording level
nominal widths exceeding DN 300 of test group A2 ultrasonic for no apparent reason or where back-wall echo atten-
testing shall additionally be performed from the front edges by uations equal to or greater 6 dB occur in the area of
straight-beam scanning. indications liable to recording.
For these areas examinations shall be laid down jointly
(4) In case of restricted testability upon heat treatment the with the authorized inspector to make possible a decision
following applies to the scanning directions: on the usability of the product form.
KTA 3211.1 Page 56

(4) When testing drop-forged parts with nominal values a) the distance of the recording level to the noise level attains
exceeding 150 mm, the quality classes given in Table 11-4 or is less than 6 dB,
and the resulting according to DIN EN 10228-3 recording b) the back-wall echo drops to reach the recording level for
levels and acceptance criteria shall apply. no apparent reason or where back-wall echo attenuations
equal to or greater 6 dB occur in the area of indications li-
Nominal wall thickness s
Quality class able to recording,
of the final produkt, mm
c) clusters of indications up to 6 dB below recording level
s  60 4 occur.
s > 60 3 1)
1) Quality class 2 is permitted for straight-beam scanning of nomi- 11.5 Seamless pipes larger than DN 50
nal wall thicknesses s > 250 mm, provided that monitoring of the
backwall echo is possible. 11.5.1 Seamless pipes larger than DN 50 of ferritic steels of
material group W I
Table 11-4: Quality classes to DIN EN 10228-3 for selected (1) The following shall apply to pipes with nominal wall
ultrasonic testing thicknesses not exceeding 30 mm:
a) All pipes shall be subjected to an ultrasonic testing for
longitudinal defects to DIN EN ISO 10893-10, acceptance
11.4.3.4.1.2 Product forms of austenitic steel
class U2 subclass B.
(1) For straight-beam scanning the recording levels and b) Pipes of test group A 1 shall additionally be subjected to
acceptance criteria as per quality class 3 to DIN EN 10228-4 an ultrasonic testing for transverse defects to DIN EN ISO
apply. 10893-10, acceptance class U2 subclass C as well as in
Note: the case of nominal wall thicknesses equal to or larger
For straight-beam scanning the requirements of DIN EN 10228-4 than 8 mm to an examination for laminar-type discontinui-
are also met by DIN EN 10308. ties to DIN EN ISO 10893-8, acceptance class U0. Pipes
(2) For angle-beam scanning the following recording levels of test group A 2 shall be examined for transverse defects
and acceptance criteria shall apply: to DIN EN ISO 10893-10, acceptance class U2 sub-
class C if they were hot-pilger-rolled or subjected to hot
a) the recording levels and acceptance criteria to Table 6 of pilger rolling during the manufacturing process.
DIN EN 10228-4 when using the DGS method,
c) One surface inspection shall be performed on every fourth
b) the recording levels and acceptance criteria to Table 7 of pipe of test group A 1. The outside surface shall be exam-
DIN EN 10228-4 when using the DAC method or the refer- ined completely and the inside surface shall be examined
ence block method. over a length of 1 times the outside diameter from each
(3) In addition, the following requirements shall apply: end of the pipe. The acceptance class M1 to DIN EN ISO
10893-5 shall apply.
a) Clusters of echo indications shall be registered that are up
to 6 dB below the recording level and cannot be resolved (2) Pipes with nominal wall thicknesses exceeding 30 mm
into individual echo indications in one probe position or shall be tested to Section 11.4 as forged hollow parts.
during probe travel. In these regions additional investiga-
tions such as through-transmissions in several directions
shall be performed to be able to make a statement about 11.5.2 Seamless pipes larger than DN 50 of ferritic steels of
the reflector type (planar or voluminous). material group W II
The indications are not permitted, if these investigations (1) The following shall apply to pipes with nominal wall
reveal signs of areal separations, e.g., loss of intensity of a thicknesses not exceeding 30 mm:
sound-transmission signal by comparison with indication- a) All pipes shall be subjected to an ultrasonic testing for
free zones of the product form. longitudinal defects to DIN EN ISO 10893-10, acceptance
b) All sites shall be registered where class U2 subclass B, calibration on reference tube with “N”-
type notch at the inside and at the outside.
ba) the distance between recording level and noise level is
6 dB or less, b) Pipes of test group A 2, which were hot-pilger-rolled or
subjected to hot pilger rolling during the manufacturing
bb) the back-wall echo drops to reach the recording level
process, shall additionally be subjected to
for no apparent reason or where back-wall echo atten-
uations equal to or greater 6 dB occur in the area of ba) an examination for laminar-type discontinuities to DIN
indications liable to recording. EN ISO 10893-8, acceptance class U0 and
For these areas examinations shall be laid down jointly bb) an ultrasonic testing for transverse defects examina-
with the authorized inspector to make possible a decision tion to DIN EN ISO 10893-10, acceptance class U2
on the usability of the product form. subclass C, calibration on reference tube with notch at
the outside or on reference tube with notch at the inside
and at the outside.
11.4.3.4.2 Global testing of product forms made of ferritic or
austenitic steel (2) Pipes with nominal wall thicknesses exceeding 30 mm
shall be tested to Section 11.4 as forged hollow parts .
(1) In case of global ultrasonic testing the required quality
class to DIN EN 10228-3 or DIN EN 10228-4 shall be laid
down by the purchaser prior to the beginning of fabrication. 11.5.3 Seamless pipes larger than DN 50 of austenitic steels
Where the globally tested test object is used further it shall be
(1) The following shall apply to pipes with nominal wall
ensured that the final product meets the requirements of se-
thicknesses not exceeding 30 mm:
lected ultrasonic testing. Where required, supplementary se-
lected ultrasonic tests shall be performed. a) All pipes shall be subjected to an ultrasonic testing for
longitudinal defects to DIN EN ISO 10893-10, acceptance
(2) In addition to the stipulations of DIN EN 10228-3 or DIN class U2 subclass B, calibration on reference tube with “N”-
EN 10228-4 such locations shall be documented where type notch at the inside and at the outside.
 KTA 3211.1 Page 57

b) Pipes with nominal wall thicknesses exceeding 5.6 mm b) Where a surface inspection is not possible on the inner
and pipes larger than or equal to DN 100 shall be subject- surface, the inspection on all elbows of test class A2 shall
ed to an ultrasonic testing for transverse defects to DIN EN be replaced by ultrasonic or radiographic testing to DIN EN
ISO 10893-10, acceptance class U2 subclass C, calibra- ISO 5579, class B. A combination of the UT and RT meth-
tion on reference tube with notch at the outside or on refer- ods is permitted. The test conditions shall be laid down in
ence tube with notch at the inside and at the outside. the test instruction. Where the UT method is applied, test-
c) For the purpose of correcting the test conditions the sound ing for longitudinal and transverse defects to DIN EN ISO
attenuation and transfer correction shall be determined at 10893-10 shall be performed. The calibration shall be
four measuring points offset by 90° each at both ends and made on a reference tube with “N“ type notch at the inside.
over the entire length at a distance of not more than For the testing for longitudinal defects acceptance class
200 mm. The measurements shall be made with the same U2, subclass B applies. For the testing for transverse de-
probes and test equipment as used during the test for lon- fects acceptance class U2, subclass C applies.
gitudinal and transverse defects. Where the values deter- (2) Pipe elbows with nominal wall thicknesses exceeding
mined differ from the values determined adjacent to the 30 mm shall be tested to Section 11.4 as forged hollow parts.
reference reflectors, this difference shall be considered in
the test. In case of differing surface qualities the number of
measuring points shall be doubled. Where the variation of 11.6.3 Seamless pipe elbows larger than DN 50 of
measured values determined under same incidence condi- austenitic steels
tions exceeds 6 dB (referred to the sound path to be eval- (1) The following shall apply to pipe elbows with nominal
uated), the number of measuring points shall be doubled. wall thicknesses not exceeding 30 mm:
Where it is ascertained during the tests that sufficiently
equal test conditions are obtained in dependence of the a) The outside and inside surfaces shall basically be subject-
manufacturing process, the material and the dimensions, ed to a surface inspection. The acceptance criteria are de-
the extent of measuring points may be reduced to half the fined in Table 11-2.
number upon agreement by the authorized inspector. b) Where a surface inspection is not possible on the inner
d) One surface inspection shall be performed on every fourth surface, the inspection on all elbows shall be replaced by
pipe of test group A 1. The outside surface shall be exam- ultrasonic or radiographic testing to DIN EN ISO 5579,
ined completely and the inside surface shall be examined class B. A combination of the UT and RT methods is per-
over a length of 1 times the outside diameter from each mitted. The test conditions shall be laid down in the test in-
end of the pipe. The acceptance class P1 to DIN EN ISO struction. Where the UT method is applied, testing for lon-
10893-4 shall apply. gitudinal and transverse defects to DIN EN ISO 10893-10
shall be performed. The calibration shall be made on a ref-
(2) Pipes with nominal wall thicknesses exceeding 30 mm erence tube with “N“ type notch at the inside. For the test-
shall be tested to Section 11.4 as forged hollow parts. ing for longitudinal defects acceptance class U2, subclass
B applies. For the testing for transverse defects ac-
11.6 Seamless pipe elbows larger than DN 50 ceptance class U2, subclass C applies.
c) For the purpose of correcting the test conditions the sound
11.6.1 Seamless pipe elbows larger than DN 50 of ferritic attenuation and transfer correction shall be determined at
steels of material group W I four measuring points offset by 90° each at both ends and
(1) The following shall apply to pipe elbows with nominal over the entire length at a distance of not more than
wall thicknesses not exceeding 30 mm: 200 mm. The measurements shall be made with the same
probes and test equipment as used during the test for lon-
a) The outside and inside surfaces shall basically be subject- gitudinal and transverse defects. Where the values deter-
ed to a surface inspection. The acceptance criteria are de- mined differ from the values determined adjacent to the
fined in Tables 11-2 and 11-3.
reference reflectors, this difference shall be considered in
b) Where a surface inspection is not possible on the inner the test. In case of differing surface qualities the number of
surface, it shall be replaced by ultrasonic or radiographic measuring points shall be doubled. Where the variation of
testing to DIN EN ISO 5579, class B. A combination of the measured values determined under same incidence condi-
UT and RT methods is permitted. The test conditions shall tions exceeds 6 dB (referred to the sound path to be eval-
be laid down in the test instruction. Where the UT method uated), the number of measuring points shall be doubled.
is applied, testing for longitudinal and transverse defects to Where it is ascertained during the tests that sufficiently
DIN EN ISO 10893-10 shall be performed. The calibration equal test conditions are obtained in dependence of the
shall be made on a reference tube with “N“ type notch at manufacturing process, the material and the dimensions,
the inside. For the testing for longitudinal defects accep- the extent of measuring points may be reduced to half the
tance class U2, subclass B applies. For the testing for number upon agreement by the authorized inspector.
transverse defects acceptance class U2, subclass C ap-
plies. (2) Pipe elbows with nominal wall thicknesses exceeding
30 mm shall be tested to Section 11.4 as forged hollow parts.
(2) Pipe elbows with nominal wall thicknesses exceeding
30 mm shall be tested to Section 11.4 as forged hollow parts.
11.7 Seamless fittings larger than DN 50

11.6.2 Seamless pipe elbows larger than DN 50 of ferritic 11.7.1 Seamless fittings larger than DN 50 of ferritic steels
steels of material group W II of material group W I

(1) The following shall apply to pipe elbows with nominal (1) The outside and inside surfaces of fittings with nominal
wall thicknesses not exceeding 30 mm: wall thicknesses not exceeding 30 mm shall be subjected to a
surface inspection. The acceptance criteria are defined in
a) For pipe elbows of test group A 2, the outside and inside Tables 11-2 and 11-3.
surfaces shall basically be subjected to a surface inspec-
tion. The acceptance criteria are defined in Tables 11-2 (2) Fittings with nominal wall thicknesses exceeding 30 mm
and 11-3. shall be tested to Section 11.4 as forged hollow parts.
KTA 3211.1 Page 58

11.7.2 Seamless fittings larger than DN 50 of ferritic steels c) on ribs and cast-on parts,
of material group W II where complete observation of the back-wall echo is possible
(1) For fittings of test group A 2 with nominal wall thickness- at at least one beam incidence direction. For straight-beam
es not exceeding 30 mm, the outside and inside surfaces scanning it shall be possible to test these regions in opposite
completely shall be subjected to a surface inspection. The direction (see Figures 11.8-1 to 11.8-11) at at least two inci-
acceptance criteria are defined in Tables 11-2 and 11-3. dence directions being vertical to each other.

(2) Fittings with nominal wall thicknesses exceeding 30 mm (3) If ultrasonic testing is employed as volumetric testing in
shall be tested to Section 11.4 as forged hollow parts. zones other than those illustrated in Figures 11.8-1 through
11.8-11, it shall be ensured that complete observation of the
back-wall echo at at least one beam incidence direction and
11.7.3 Seamless fittings larger than DN 50 of austenitic angle-beam scanning in opposite direction at two incidence
steels directions being vertical to each other are possible. Regions
that cannot be ultrasonically tested, shall be subject to radio-
(1) The outside and inside surfaces of fittings with nominal graphic testing as per section B 7.1. The procedure to be
wall thicknesses not exceeding 30 mm completely shall be followed shall be laid down in the test instruction with refer-
subjected to a surface inspection. The acceptance criteria are ence to the respective part.
defined in Table 11-2.
(4) Volumetric testing shall be supplemented by angle-beam
(2) Fittings with nominal wall thicknesses exceeding 30 mm ultrasonic testing in regions where hot cracking may occur,
shall be tested to Section 11.4 as forged hollow parts. e.g. regions of risers and chill casting, cross-sectional transi-
tions. The regions shall be laid down in the test instruction with
11.8 Castings reference to the respective part.

11.8.1 Test methods to be used

11.8.2 Point of time of testing and participation in testing
(1) The test methods for the different cast-steel grades and
casting zones can be found in Table 11-5. (1) The point of time of non-destructive testing in the produc-
tion sequence as well as the participation in testing is defined
(2) The ultrasonic testing may be employed as volumetric for cast-steel cases and bodies in Figure 5.7-1.
testing
(2) If further machining is performed by the component
a) on rough-turned flanges, manufacturer, a surface inspection shall additionally be made
b) on machined seat portions, of the surfaces produced by such machining.

Cast-steel Casting zones

group Cast body Adjoining zones 1) Welding ends Welded joints Excavations Production weld

Ferritic and Magnetic particle Magnetic particle Magnetic particle Magnetic particle Magnetic particle
martensitic testing 2) Magnetic particle testing 2) testing 2) testing 2) testing 2)
cast-steel Radiographic testing 2) Radiographic Radiographic Radiographic Radiographic
grades testing 3) 4) testing 3) testing 3) testing 3) testing 5)
Austenitic Penetrant testing Penetrant testing Penetrant testing Penetrant testing Penetrant testing
Penetrant
cast-steel Radiographic Radiographic Radiographic Radiographic Radiographic
testing
grades testing testing testing testing testing
1) Adjoining zones are zones located outside the pressure-retaining wall, such as

- feet,
- brackets,
- lugs,
- external fins,
- cams.
2) Magnetic-particle testing shall be preferred for magnetizable materials. However, penetrant testing may be employed:

a) in zones that are difficult to magnetize because of geometry or accessibility considerations and
b) for cast-steel grade G X4 CrNi 13 4, material No. 1.4317.
3) Alternatively, it is permitted to perform an ultrasonic testing as per clauses 11.8.1 (2) and (3).

4) A supplementary ultrasonic test with angle-beam scanning as per sub-clause 11.8.1 (4) shall be performed for detecting hot cracking. The
procedure to be followed shall be laid down in the test instruction with reference to the respective part.
5) In test groups A 2 and A 3, it is permitted to replace the radiographic testing of small production welds by an ultrasonic testing, starting
with the 4th casting of a production lot. See Annex B, section B 2 (4) as regards the differentiation between small and relatively large pro-
duction welds.

Table 11-5: Testing methods for cast-steel grades and their casting zones
 KTA 3211.1 Page 59

Figure 11.8-1: Straight way valve body Figure 11.8-2: Angle-valve body Figure 11.8-3: Wedge-type gate-valve body

Figure 11.8-4: Swing-check-valve body Figure 11.8-5: Multi-way-valve body Figure 11.8-6: Discharge casing

Figure 11.8-7: Suction casing Figure 11.8-8: Scroll casing Figure 11.8-9: Double scroll casing

Figures 11.8-1 through 11.8-11:

Examples of valve-body or pump-
casing zones for which ultrasonic
Figure 11.8-10: Annular casing Figure 11.8-11: Annular casing testing is permissible
KTA 3211.1 Page 60

Angle-valve body Straight way valve body Multi-way-valve body

Swing-check-valve body Wedge-type gate-valve body Angle seat valve body

Figure 11.8-12: Examples of valve-casing zones that are complex from the viewpoint of casting (black)

Barrel-type-pump casing Annular casing Double scroll casing

Scroll casing Suction casing Discharge casing

Figure 11.8-13: Examples of pump-casing zones that are complex from the viewpoint of casting (black)
 KTA 3211.1 Page 61

11.8.3 Extent of testing 11.8.4 Surface quality

11.8.3.1 Test group A 1 The surface prepared for the non-destructive testing shall be
evaluated to DIN EN 1370 using the comparison specimens
(1) All cast bodies, welding ends, welded joints and produc- referred to therein. The surfaces shall have a surface quality
tion welds shall be completely radiographed. For ferritic and equal to or better than that of BNIF-visualtactile comparators
martensitic cast-steel grades, it is permitted as an alternative 3 S1 or 4 S2. Castings to be tested by the ultrasonic method
to perform an ultrasonic testing in accordance with clause shall have a surface quality equal to or better than that of
11.8.1. BNIF-visualtactile comparators 3 S1 or 3 S2. Castings to be
tested by the penetrant method shall have a surface quality
(2) All internal and external surfaces, including those of equal to or better than that of BNIF-visualtactile compara-
excavations for production welds, shall be subjected to a sur- tors 2 S1 or 3 S2.
face inspection. For inaccessible areas the alternative
measures shall be laid down in the design review documents.
11.8.5 Surface inspection

11.8.3.2 Test groups A 2 and A 3 11.8.5.1 Procedural requirements

(1) Penetrant testing shall be performed by magnetic particle
(1) Cast body, welding ends, welded joints and production
or penetrant testing according to Table 11-5.
welds of the first three castings of a production lot (prototypes)
shall be subjected completely to a volumetric testing. (2) The requirements of DIN EN 1369 shall apply to the
performance of magnetic particle testing. In addition, the stipu-
(2) All further castings of the same production lot with the lations of Annex E apply.
same melting and casting technique shall be tested in the
following zones: (3) The requirements of DIN EN 1371-1 shall apply to the
performance of penetrant testing. In addition, the stipulations
a) zones that are complex from the viewpoint of casting and of Annex E apply.
stress,
b) welding ends,
11.8.5.2 Acceptance criteria
c) relatively large production welds,
(1) For the evaluation of magnetic particle and penetrant
d) places at which defects with acceptable limit sizes were testing the severity levels shown in Table 11-6 and the result-
observed in the testing of the prototypes. ing acceptance criteria to DIN EN 1369 or DIN EN 1371-1
apply in dependence of the casting area and test class. In
(3) The zones that are complex from the viewpoint of casting
addition, the following applies:
and stress shall be determined by agreement with the author-
ized inspector. Where it is intended to combine production a) Linear indications suggesting cracks are not permitted.
lots, the decision shall also be made by agreement with the b) The evaluation of the test results obtained by penetrant
authorized inspector. Examples of zones that are complex testing shall be made in due consideration of all indications
from the viewpoint of casting are shown in Figures 11.8-12 and points in time of inspection.
and 11.8-13. (2) For production welds and welded joints the same severi-
(4) For small production welds, it is also permitted, starting ty levels as for the respective casting areas apply.
with the fourth casting, to perform an ultrasonic testing instead (3) Where excavations are subject to magnetic particle or pe-
of the radiographic testing. netrant testing only such indications are permitted that do not
impair weldability and are not associated with inadmissible sur-
(5) All internal and external surfaces, including those of face and volumetric defects that are to be eliminated. In case of
excavations for production welds as well as the production doubt it shall be proved by radiographic testing that no inad-
welds, shall be subjected to a surface inspection. missible indications are present in the adjacent base metal.

Severity level to be applied

Casting Area Test group
PT 1) MT 2) RT 3) UT 4)
Welding ends Any SP1, CP1 5) SM1 5) 1 1
A1 SP1, CP1, LP1, AP1 SM1, LM1, AM1, 2 2
Cast body
A2 and A3 SP2, CP2, LP2, AP2 SM2, LM2, AM2, 2 6) 2 6)
A1 SP2, CP2, LP2, AP2 SM2, LM2, AM2,  
Adjoining zones 7)
A2 and A3 SP3, CP3, LP3, AP3 SM3, LM3, AM3,  
1) Penetrant testing PT to DIN EN 1371-1.
2) Magnetic particle testing MT to DIN EN 1369.
3) Radiographic testing RT to DIN EN 12681; acceptance criteria to Annex 1 of AD 2000-Merkblatt W 5.
4) Ultrasonic testing UT to DIN EN 12680-2.
5) During surface inspection linear indications or indications grouped in a chain are not permitted.
6) Severity level 3 will suffice if
a) DN ≤ 150 or
b) in the case of DN > 150 the product of nominal width DN and allowable operating pressure, MPa, does not exceed 2000.
7) Adjoining zones are zones located outside the pressure-retaining wall, e.g. feet, brackets, lugs.

Table 11-6: Severity levels to be applied depending on the test group

KTA 3211.1 Page 62

11.8.6 Volumetric testing 11.8.6.1.2 Determination of testability

11.8.6.1 Ultrasonic testing (1) The testability shall be determined for each test object in
11.8.6.1.1 Procedural requirements accordance with DIN EN 12680-2. The location and number of
measurements shall be laid down in the test instruction.
(1) For the performance of ultrasonic testing the stipulations
of DIN EN 12680-2 apply. (2) The testability shall be determined jointly by the parties
involved in the test.
(2) Deviating from the stipulations in DIN EN 12680-2 test
frequencies equal to or greater than 2 MHz shall be applied. (3) The wave lengths used to determine the testability shall
The test frequency to be applied shall be laid down in the test not be greater than those used in tests with straight-beam and
instruction. angle-beam scanning following thereafter.
(3) For the testing of sub-surface regions the test shall be
performed either from the opposite face or dual-element 11.8.6.1.3 Performance of test
probes shall be used up to a depth of 50 mm. The technique
to be applied shall be laid down in the test instruction. (1) The regions to be tested, the test technique to be applied
and the incidence conditions shall be taken from Table 11-7.
(4) The extension of indications shall be determined in ac-
cordance with DIN EN 12680-2, clause 5.5.7. (2) Testing with dual-element probes shall not exceed a sub-
surface depth of 50 mm.
(5) As regards the description of reflectors which cause
echoes liable to recording the identification system (reference (3) The casting shall be tested such that the regions to be
point grid) established for radiographic testing shall be used. tested are completely covered.

Serial. Extent of testing and

Test area Probe
no. sound entry positions
1 Welding ends
Straight beam probe 100 % from both surfaces
Welding ends with s > 50 mm
1.1 and accessibility from both Dual-element angle-beam probe 60° 100 % from two sides using two beam an-
sides gles which are perpendicular to each other
Angle-beam probe 45°
Straight beam probe
100 % from one surface
Welding ends with s > 50 mm Dual-element straight beam probe
1.2
and Welding ends with acces-
sibility from one side Dual-element angle-beam probe 60° 100 % from two sides using two beam an-
Angle-beam probe 45° gles which are perpendicular to each other
Dual-element straight beam probe 100 % from one surface
1.3 Welding ends with s ≤ 50 mm 100 % from two sides using two beam an-
Dual-element angle-beam probe 60°
gles which are perpendicular to each other
2 Other casting areas
Accessibility from both sides
2.1 Straight beam probe 100 % from both surfaces
in the case of s > 50 mm
Accessibility from one side in Straight beam probe
2.2 100 % from one surface
the case of s > 50 mm Dual-element straight beam probe
2.3 In the case of s ≤ 50 mm Dual-element straight beam probe 100 % from one surface
Regions where hot cracking Dual-element angle-beam probe 60°
may occur, e.g. regions of ris- Angle-beam probe 45° or angle-beam 100 % from two sides using two beam an-
2.4
ers, chill casting and cross- probe 60° in the case of long sound gles which are perpendicular to each other
sectional transitions 1) path travel distances
3 Production weldings
Production weldings with a
3.1 Dual-element straight beam probe 100 % from one surface
depth of  15 mm
Production weldings with a Dual-element straight beam probe 100 % from one surface
3.2 depth of > 15 mm and 100 % from two sides using two beam an-
 30 mm Dual-element angle-beam probe 60°
gles which are perpendicular to each other
Dual-element straight beam probe 100 % from one surface
Production weldings with a
3.3 Dual-element angle-beam probe 60° 100 % from two sides using two beam an-
depth of > 30 mm
Angle-beam probe 45° gles which are perpendicular to each other

1) Where no detailed date on the casting technique are available which allow conclusion on the occurrence of hot cracks, all castings, where
practicable, shall be subject to a 100% testing in opposite direction at two incidence directions vertical to each other with a dual-element
60 degrees angle beam probe.

Table 11-7: Test conditions for ultrasonic testing

 KTA 3211.1 Page 63

(4) The casting regions shall be subjected to straight-beam (2) The test results shall be evaluated according to DIN EN
scanning from all accessible surfaces. 12680-2 in dependence of the severity level to be adhered to.
(5) Regions where the traceability of the back-wall echo is not (3) Indications suggesting cracks or lack of fusion are not
possible with straight-beam scanning, however an echo from a permitted.
discontinuity can be traced, shall be subject to angle-beam
scanning. Details shall be laid down in the test instruction. (4) The finale evaluation shall be made in due consideration
of the results of all tests.
(6) In the case of welding ends angle-beam scanning shall
be performed on cylindrical casting areas accessible from the
outside only. 11.8.6.2 Radiographic testing
(7) Testing for hot cracks: 11.8.6.2.1 Procedural requirements
a) The test shall be performed upon quenching and tempering. (1) The castings shall be tested in accordance with DIN EN
b) Angel-beam scanning shall be performed in regions where 12681 in connection with DIN EN ISO 5579.
hot cracking may occur, e.g. regions of risers and chill
(2) The following applies additionally:
casting, cross-sectional transitions.
c) The regions shall be scanned up to a depth of 50 mm. a) Image quality indicators to DIN EN ISO 19232-1 shall be
used.
d) The procedure shall be agreed with the authorized inspec-
tor with reference to the respective part. b) The image quality shall be examined on each radiograph.
c) Welding ends, regions intended for welded joints and diffi-
(8) Testing of production welds:
cult-to-cast regions shall be radiographed in accordance
a) Where heat treatments are performed, the test shall be with DIN EN ISO 5579, test class B; in this case image
performed upon the last heat treatment. quality class B to DIN EN ISO 19232-3 shall be adhered
b) In the case of production welds with a thickness not ex- to. The other radiographs shall correspond at least to test
ceeding 15 mm (except for penetrations) testing shall be class A of DIN EN ISO 5579 and to image quality class A
performed with a dual-element straight-beam probe from to DIN EN ISO 19232-3.
the weld metal surface. In all other cases production welds Note:
shall be tested at two incidence directions vertical to each See Figures 11.8-12 and 11.8-13 showing examples for diffi-
other, where practicable. This shall be done by straight- cult-to-cast regions.
beam scanning and opposite angle-beam scanning. The
d) Linear accelerators with a radiation energy E ≥ 4 MeV may
transition from base metal to weld metal shall be scanned
be used at a radiographed wall thickness s ≥ 40 mm in
as vertically as possible.
which case this value may be somewhat less than re-
quired. At a radiographed wall thickness s < 60 mm a min-
11.8.6.1.4 Recording levels and acceptance criteria imum density of 3.0 shall be adhered to as per DIN EN
ISO 11699-1 when using films of film system classes C3
11.8.6.1.4.1 Recording level to C5.
(1) All locations shall be recorded where the back-wall echo e) If a region is radiographed using multiple-film techniques, it
drop reaches or exceeds a value of dB 12 (see DIN EN shall be checked during the control of the individual radio-
12680-2, Table 3). graphs whether in the region to be evaluated the required
(2) All reflectors with measurable extensions shall be rec- density (test class A: minimum density 1.5; test class B:
orded the echo heights of which reach or exceed the values minimum density 2.0) is adhered to.
shown in Table 3 of DIN EN 12680-2 if the criteria given in
Figures 3 and 4 of DIN EN 12680-2 are also reached or ex- 11.8.6.2.2 Performance of test
ceeded.
(1) The test shall be performed in accordance with DIN EN
(3) In severity level 1 regions all reflectors without measura- 12681.
ble extension (point-type indication) shall be recorded the
echo heights of which reach or exceed the values shown in (2) Steel castings with an outer diameter not exceeding
Table 1 of DIN EN 12680-2. 200 mm shall normally be radiographed as per DIN EN 12681,
Figure 7.
(4) Where angle-beam probes are used which show an echo
dynamic or clear extension in wall thickness direction shall be (3) In the case of steel castings with an outer diameter
recorded independently of the echo height. greater than 200 mm, the master shot to DIN EN 12681, Fig-
ure 7 shall only be selected when the arrangement of radio-
graphs to DIN EN 12681, Figures 3 or 4 cannot be used or the
11.8.6.1.4.2 Examination of indications liable to recording
evaluation possibilities have to be improved.
(1) The locations where indications liable to recording were
(4) Production welds shall be tested in due consideration of
detected shall be examined more detailed with respect to the
their geometry and location.
type, shape, size and position. This may be done by means of
ultrasonic testing with reference to Table 4 and Annex C of
DIN EN 12680-2 or by additional radiographic testing as per 11.8.6.2.3 Acceptance criteria
clause 11.8.7.
(1) The severity levels assigned to the test groups and cast-
(2) Indications liable to recording that have been ascertained ing regions shall be taken from Table 11-6 and the ac-
upon quenching and tempering shall be re-examined and be ceptance criteria to be applied be taken from Annex 1 to AD
evaluated with the same test method after the last heat treat- 2000-Merkblatt W5.
ment.
(2) The following stipulations apply additionally:
a) In case of double-wall radiography the acceptance criteria
11.8.6.1.4.3 Acceptance criteria
apply to the smaller of the individual wall thicknesses un-
(1) The severity levels assigned to the test groups and cast- less additional radiographs make the assignment of indica-
ing regions shall be taken from Table 11-6. tions to a specific wall possible.
KTA 3211.1 Page 64

b) Where the master shots do not provide clearly evaluable using probes with nominal frequencies greater than or equal to
indications, they shall be re-examined by additional select- 4 MHz. The sensitivity shall be adjusted by means of the DGS
ed radiographs. method or DAC method. The technique to be applied shall be
c) For production weld and welded joints the same require- laid down in the test instruction. The reflectors’ extension shall
ments as for the respective casting regions apply. Cracks be determined by means of the half-amplitude technique to
and lack of fusion as well as systematically occurring pores clause D 11.2.3.
and inclusion are not permitted. (4) In case of bars for nuts, straight-beam scanning to DIN
EN 10308 may be omitted. Instead of this, the circumferential
11.9 Bolts and nuts face shall be completely scanned by angle-beam scanning in
both circumferential directions using a 35° angle-beam probe.
11.9.1 Procedural requirements
(5) During straight-beam scanning from the circumferential
11.9.1.1 General surface all echo heights shall be recorded which correspond to
a circular disk diameter equal to or greater than 1.5 mm. Indi-
The procedural requirements laid down in sub-section 11.1.5
cations up to 12 dB in excess of the recording level and up to
shall apply. In addition, the procedural requirements specified
a maximum length equal to the bar diameter are permitted.
in sub-sections 11.9.1.2 and 11.9.1.3 hereinafter apply.
(6) When scanning from the front faces and in circumferen-
11.9.1.2 Surface inspections tial direction all echo heights shall be recorded which corre-
spond to a circular disk diameter equal to or greater than
Surface inspections shall be performed by means of penetrant 2.0 mm. Indications attaining or exceeding the recording level
testing to Annex E. are not permitted.
(7) For the material X22CrMoV12-1, magnetic particle test-
11.9.1.3 Ultrasonic testing ing shall additionally be performed on the bar upon final heat
treatment. Table 11-3 lays down the acceptance criteria.
(1) Ultrasonic testing of the bars shall be performed by
means of grid scanning to DIN EN 10308.
11.9.2.2 Tests and examinations on finished parts
(2) For the testing of sub-surface areas ultrasonic testing
shall be performed either from the opposite surface or dual (1) A surface inspection shall be performed randomly on
element probes shall be used. The technique to be applied bolts and nuts. The maximum lot size is 150 pieces and the
shall be laid down in the test instruction. number of spot-check samples shall be 20. The acceptance
(3) In addition, the stipulations of 11.4.3.1 (1), (4), (5), (7), criterion = zero defects.
(8), (10), and (11) shall be observed. (2) Bolts shall be evaluated to DIN EN 26157-3 and nuts to
DIN EN ISO 6157-2 where deviating from these standards,
11.9.2 Bolts and nuts made by machining from solution- indications suggesting cracks are not permitted.
annealed and quenched bars
11.9.2.1 Test on the bars 11.9.3 Bolts and nuts made by machining from hot-cold
work hardened or from solution-annealed and
(1) All bars for bolts and nuts with diameters, widths across quenched austenitic bars
flats or side lengths equal to or larger than 30 mm and addi-
11.9.3.1 Test on the bars
tionally all bars made of the material X22CrMoV12-1 with
diameters, widths across flats or side lengths smaller than (1) All bars with diameters, widths across flats or side
30 mm shall be subject to ultrasonic testing in solution- lengths equal to or larger than 30 mm for bolts and nuts shall
annealed and quenched condition by the manufacturer for be tested in solution-annealed and quenched condition by the
internal defects. During the acceptance procedure, 10 % of manufacturer for internal defects. During the acceptance pro-
the bars for bolts or at least 10 of those bars per delivery and cedure, 10 % of the bars for bolts, but at least 10 of those bars
5 % of the bars for nuts or at least 2 of those bars per delivery per delivery, and 5 % of the bars for nuts, but at least 2 of
shall be tested by the authorized inspector. those bars per delivery, shall be tested by the authorized in-
(2) The following shall apply to bars for bolts and nuts with spector.
diameters, widths across flats or side lengths equal to or larg- (2) In case of bars for bolts and nuts, ultrasonic testing to
er than 30 mm: DIN EN 10308 shall be performed with the recording levels
An ultrasonic testing to DIN EN 10308 or to DIN EN 10228-3 and acceptance criteria to sub-clauses (4) and (5).
shall basically be performed. Straight-beam scanning in
(3) In case of bars for nuts, straight-beam scanning to DIN
axial direction shall additionally be performed on bars for
EN 10308 may be omitted. Instead of this, the circumferential
bolts; where in this case no distance between recording
face shall be scanned completely by angle-beam scanning in
level and noise level of at least 6 dB can be adhered to
both circumferential directions using a 35° angle-beam probe.
over the entire length of the bar, the test shall be performed
in the cut-to-length condition. (4) During straight-beam scanning from the circumferential
surface all echo heights shall be recorded which correspond to
(3) The following shall apply to bars of the material a circular disk diameter equal to or greater than 2.0 mm. Indi-
X22CrMoV12-1 with diameters, widths across flats or side cations up to 6 dB in excess of the recording level and up to a
lengths smaller than 30 mm: maximum length equal to the bar diameter are permitted.
Ultrasonic testing shall be performed by
(5) When scanning in circumferential direction all echo
a) complete scanning to DIN EN 10308, quality class 4 heights shall be recorded which correspond to a circular disk
or diameter equal to or greater than 3.0 mm. Indication attaining
b) 100 % scanning to DIN EN 10228-3, quality class 4. or exceeding the recording level are not permitted.
The total volume shall be scanned. For the testing of sub-
surface areas, ultrasonic testing shall be performed either 11.9.3.2 Tests and examinations on finished parts
from the opposite surface or dual element probes shall be
used. The test shall be performed manually or mechanized The requirements of clause 11.9.2.2 shall apply.
 KTA 3211.1 Page 65

11.9.4 Bolts and nuts made by hot or cold forming and then extent and point of time of non-destructive tests and examina-
quenched and tempered tions can be found in Table 11-8.
The requirements of clause 11.9.2.2 shall apply. (2) The test shall be performed by means of automated test
equipment. The test equipment shall be capable of distin-
11.9.5 Bolts and nuts of strength classes or steel grades guishing between tubes that have passed the test and tubes
being suspect by means of a trigger/alarm level in connection
Bolts shall be tested and evaluated to DIN EN 26157-3, nuts with a marking system. A recording device shall make as-
shall be tested and evaluated to DIN EN ISO 6157-2. For the signment of measured values to their exact location possible.
lot size, extent of spot-check samples and acceptance criteria The authorized inspector shall have inspected the test equip-
the following applies: ment. Ends that have not been tested shall either be cut off or
a) for ferritic steels the stipulations of AD 2000-Merkblatt W 7, be tested manually on the basis of the same requirements
b) for austenitic steels of test class A 1 and A 2 the stipula- applied before.
tions in sub-clause 11.9.2.2 (1), (3) Eddy-current tests shall be performed to Section 11.11.2,
c) for austenitic steels of test class A 3 the stipulations of ultrasonic tests to Section 11.11.3 and magnetic flux leakage
AD 2000-Merkblatt W 2. tests to Section 11.11.4.

11.10 Product forms of steels for special loads 11.11.1.2 Bent heat-exchanger tubes
11.10.1 Forgings, bars and rolled rings
(1) In the case of seamless bent heat-exchanger tubes of
The Sections 11.1.8 and 11.4 shall apply to the non-destruc- ferritic steels to Section 10.2 a visual inspection and a mag-
tive tests and examinations. netic-particle test of the inside surface shall be performed on
two cut-open elbows from the series of tubes with the smallest
bend radius.
11.10.2 Castings
Section 11.8 shall apply to the non-destructive tests and ex- (2) In the case of seamless bent heat-exchanger tubes of
aminations on castings. austenitic steels to Section 10.4 a visual inspection and a
penetrant test of the inside surface shall be performed on two
cut-open elbows from the series of tubes with the smallest
11.11 Heat-exchanger tubes bend radius.
11.11.1 Type, extent and time of testing (3) The stipulations in Section 11.1.5 shall apply to the per-
11.11.1.1 Straight heat-exchanger tubes formance of testing.
(1) Each tube to Section 10.1, 10.3, 10.5 or 10.6 shall be (4) For the evaluation of the test results obtained the follow-
tested over its entire length and full cross section. The type, ing shall apply: no abnormalities or indications are permitted.

Type of tubes Nominal Diameter Extent of testing Test method

Point in time thickness in mm in %
of testing in mm
Manufacture/material H S ET UT MT 1)
Longitudinally welded austenitic tubes, X X
on straight
stretch-reduced by roll drawing 2) and heat-  2.0  38.0 
tube alternatively
treated, straight or bent

Seamless austenitic tubes, straight or cold on straight X X

 3.6  42.4 100 St. 3) 
bent tube alternatively

on straight X X
Seamless ferritic tubes, straight or cold bent ≤ 4.0 ≤ 38.0 X 4)
tube alternatively
1) Magnetic flux leakage technique
2) Total deformation > 20 %
3) St. : In test classes A1 and A2 the authorized inspector shall check the test system during his spot attendance on the test.
4) Where s ≤ 2 mm the test for transverse defects may be performed by ET alternatively to UT or MT.

H : Manufacturer
S : Authorized inspector
UT : Ultrasonic testing
ET : Eddy current testing

Table 11-8: Extent of testing and test methods

KTA 3211.1 Page 66

11.11.2 Eddy-current testing reach the response threshold of the indicating and recording
instruments. The basic sensitivity setting shall be made at the
11.11.2.1 Procedural prerequisites testing speed planned for the test, using the hole of 0.8 mm
11.11.2.1.1 General diameter. This basic sensitivity setting shall be corrected by a
tube-diameter-dependent dB value per Figure 11.1-1.
The eddy-current testing shall be performed to DIN EN ISO
(2) If the theoretical load factor of the tube wall is equal to or
10893-2 using concentric coil technique in combination with
smaller than 30 %, testing sensitivity II to Figure 11.1-1 shall
the particulars of the following subsections.
be employed. Otherwise testing sensitivity I shall be required.

11.11.2.1.2 Testing system

0
Encircling coils shall be employed for the test
a) using differential probes for testing seamless tubes +1

b) using differential and absolute probes for testing longitudi- +2

nally welded tubes,
+3
The tubes shall pass concentrically through the test coils. The
coils shall be constructed such that the test sensitivity required +4
in subsection 11.11.2.1.4 is achieved at the chosen excitation +5
frequency. The value of the amplitude of the signals caused

dB
by indications shall be evaluated. +6

+7
11.11.2.1.3 Excitation frequency Sensitivity II
+8
(1) To define appropriate excitation frequencies as a func-
tion of material, tube size and fabrication condition, a refer- +9
ence tube of the same test-relevant characteristics and the
+10
same dimensions as the tubes to be tested shall be used.
Sharp-edged notches with a length of 20 mm, a width of +11
smaller than or equal to 0.5 mm and a depth of less than or Sensitivity I
equal to 20 % of the nominal wall thickness but at least +12
0.15 mm shall be produced on the outside and inside in the
longitudinal axis of this reference tube. +13
0 10 20 30 40
(2) The notches shall be made such that they do not cause
changes of the microstructural characteristics of the material Tube outside diameter [ mm ]
that influence the eddy-current distribution.
(3) The geometry, shape and dimension of the notches shall Figure 11.11-1: Testing sensitivity of eddy-current testing
be verified. relative to a hole diameter of 0.8 mm

(4) The excitation frequency shall be selected such that the

notch on the surface distant from the probe is verified with a (3) The required testing sensitivity shall be specified in the
distance to the noise level of at least 6 dB. When selecting purchase order.
the excitation frequency particular consideration shall be given
(4) Prior to adjusting the testing sensitivity a running-in peri-
to the physical parameters of the tube (e.g. conductivity, per-
od of the eddy-current test device of at least half an hour shall
meability, wall thickness).
be observed unless otherwise provided by the respective
Notes: operating instruction.
(1) For tubes of austenitic steels, excitation frequencies from
30 kHz up to 400 kHz are used for wall thicknesses not exceed-
ing 1 mm, excitation frequencies from 20 kHz up to 80 kHz for wall 11.11.2.2 Testing procedure and assessment of the results
thicknesses larger than 1 mm and up to and including 2 mm, exci-
tation frequencies from 5 kHz up to 40 kHz for wall thicknesses 11.11.2.2.1 Check of testing sensitivity
larger than 2 mm and up to and including 4 mm.
(1) Before starting the test, the testing sensitivity setting and
(2) For tubes of ferritic steels, excitation frequencies from 15 kHz the stability of the instrument settings shall be verified by at
up to 100 kHz are used for wall thicknesses not exceeding 1 mm,
excitation frequencies from 4 kHz up to 25 kHz for wall thickness-
least three passes of the reference tube.
es larger than 1 mm and up to and including 2 mm, excitation fre- (2) After every 100 tubes tested or maximum four hours as
quencies from 1 kHz up to 15 kHz for wall thicknesses larger than
well as after completing the test, the testing sensitivity shall be
2 mm and up to and including 4 mm.
checked by another pass of the reference tube. If a loss of
(5) The test parameters to be used shall be laid down in the more than 2 dB in testing sensitivity is noted, the test shall be
test instruction. repeated on all tubes that were tested between the sensitivity
setting to be corrected and the preceding sensitivity setting.
The repetition of the test shall be performed using the correct-
11.11.2.1.4 Testing sensitivity ed testing sensitivity setting.
(1) Test tubes with identical test-related characteristics and
the same dimensions as the tubes to be tested shall be used 11.11.2.2.2 Recording levels
to set the testing sensitivity level. Three holes separated by
120 degrees and having 0.8 mm diameter shall be drilled in All indications shall be recorded that reach or exceed the
these tubes. The spacing of holes in the longitudinal direction signal amplitude of the reference drill hole to clause
of the tube should be sufficiently large that the holes yield 11.11.2.1.4 (1), corrected by the diameter dependent dB value
separate and distinguishable signals. The smallest signal shall to Figure 11.11-1.
 KTA 3211.1 Page 67

11.11.2.2.3 Marking of indication sites sure scanning of the entire tube surface without interruption.
This is usually the case, if during tube surface scanning a 10%
All sites on tubes with indications having amplitudes that reach
overlap of the scanned partial surface areas referred to the
or exceed the recording level shall be marked by a permanent
transducer diameter is ensured.
marking.
(2) Multiple transducers where the distance between the
individual transducers is less than 1 mm, are considered to be
11.11.2.2.4 Admissibility of indications
one transducer.
(1) All tubes or tube sections with indications that reach or
exceed the recording level shall be sorted out being suspect.
11.11.3.2.3 Check of testing sensitivity
(2) Indication sites on tubes being suspect that have been
(1) Before the test is started, the testing sensitivity and sta-
sorted out may be re-tested with a different non-destructive
bility of the device settings shall be verified by several passes
testing method (e.g., visual inspection, radiographic testing)
of the reference tube.
for observation of defect type and size. Verification that the
indications are not objectionable shall be required. (2) After every 2 hours, the testing sensitivity shall be
checked by another pass of the reference tube. If a loss of
(3) Tubes being suspect may be mechanically reworked
more than 2 dB in testing sensitivity is noted, the test shall be
within the permissible dimensional tolerances, after which they
repeated on all tubes that were tested between the sensitivity
shall be subjected to another test.
setting to be corrected and the preceding sensitivity setting.
The repetition of the test shall be performed using the correct-
11.11.2.3 Test report ed testing sensitivity setting.
In addition to the information required according to DIN EN
ISO 10893-2, the test report shall shall contain the following 11.11.3.2.4 Recording levels
data:
(1) All indications shall be recorded that reach or exceed the
a) relative motion of tube and probe unit (rotation frequency, reference echo amplitude.
translation velocity),
b) sorting and marking device, (2) The reference echo amplitude is the echo amplitude of
the reference reflectors to clause 11.11.3.1.
c) adjustment and testing sensitivity level,
d) untested tube sites as well as
e) place of the test, test supervisory personnel and operators. 11.11.3.2.5 Marking of indication sites
All sites on tubes with indications having amplitudes that reach
11.11.3 Ultrasonic testing or exceed the recording level shall be marked by a permanent
marking.
11.11.3.1 Procedural prerequisites
(1) Ultrasonic tests for longitudinal and transverse defects 11.11.3.2.6 Admissibility of indications
shall be performed. These tests shall be performed to (2) and
(3) in combination with the particulars of the following subsec- (1) All tubes or tube sections with indications that reach or
tions. exceed the recording level shall be sorted out being suspect.
(2) Test for longitudinal defects (2) Indication sites on tubes being suspect that have been
sorted out may be re-tested with a different non-destructive
The test for longitudinal defects shall be performed to DIN EN
testing method (e.g., visual inspection, radiographic testing)
ISO 10893-10, acceptance level U3 subclass A. The testing
sensitivity adjustment shall be made on a reference tube with for observation of defect type and size. Verification that the
“N“ type notch at the outside and at the inside. indications are not objectionable shall be required.
(3) Tubes being suspect may be mechanically reworked
(3) Test for transverse defects
within the permissible dimensional tolerances, after which they
The test for transverse defects shall be performed to DIN EN shall be subjected to another test.
ISO 10893-10, acceptance level U3 subclass A. The testing
sensitivity adjustment shall be made on a reference tube with
notches at the outside and at the inside, which shall be per- 11.11.3.3 Test report
formed as partial circumferential or full circumferential notch-
In addition to the information required according to DIN EN
es.
ISO 10893-10, the test report shall shall contain the following
(4) Tolerances on the notch depth data:
Deviating from the stipulations in DIN EN ISO 10893-10 the a) relative motion of tube and probe unit (rotation frequency,
tolerance on the notch depth shall be ± 0.02 mm. translation velocity),
b) sorting and marking device,
11.11.3.2 Test procedure and assessment of the results c) adjustment and testing sensitivity level,
11.11.3.2.1 Adjustment of the testing sensitivity d) untested tube sites as well as
e) place of the test, test supervisory personnel and operators.
The testing sensitivity shall be set by adjusting the trig-
ger/alarm level according to DIN EN ISO 10893-10, Section 7.
In this case, the distance to the noise level derived from the 11.11.4 Magnetic flux leakage technique
respective reference reflector shall not be less than 6 dB.
11.11.4.1 General

11.11.3.2.2 Relative movement of tube and probe unit The magnetic flux leakage testing shall be performed to
DIN EN ISO 10893-3, acceptance level F2, in combination
(1) For the test the beam width, scanning pitch, pulse repeti- with the particulars of the following subsections for longitudinal
tion frequency and test speed shall be tuned such as to en- and transverse defects.
KTA 3211.1 Page 68

11.11.4.2 Test system b) circular reference drill holes shall not be used for the ad-
For the test for longitudinal defects a technique with fixed or justment of the test equipment
rotating magnetic field probes shall be used, and for the test c) All locations on tubes where the trigger/alarm level is at-
for transverse defects a technique with multiple magnetic field tained or exceeded, shall be identified with a permanent
probes. marking.
d) In addition to the information required according to DIN EN
11.11.4.3 Performance of test and evaluation of results ISO 10893-3, the test report shall shall contain the follow-
For the performance of the flux leakage test and the accep- ing data:
tance criteria the stipulations of DIN EN ISO 10893-3, accep- da) relative motion of tube and probe unit (rotation fre-
tance class F2 apply. In addition, the following applies: quency, translation velocity),
a) Each probe of the flux leakage test equipment shall be
adjusted with the following reference notches for the test db) sorting and marking device,
for both longitudinal and transverse defects: dc) adjustment and testing sensitivity level,
aa) reference notch on outer surface with a depth of
dd) untested tube sites as well as
0.3 mm,
ab) reference notch on the inner surface with a depth of de) place of the test, test supervisory personnel and oper-
0.4 mm. ators.
 KTA 3211.1 Page 69

Annex A

Material characteristic data

A1 Ferritic steels of material group W I for flat products as well as parts made from flat products.......................... 69
A2 Ferritic steels of material group W I for forgings, bars and rolled rings .............................................................. 77
A3 Ferritic steels of material group W I for seamless pipes, seamless pipe elbows and seamless reducers .......... 84
A4 Castings for cases and bodies of ferritic cast steel of material group W I.......................................................... 89
A5 High-tensile steels for quenching and tempering for bolts and nuts .................................................................. 91
A6 Bars for bolts and nuts; additional stipulations .................................................................................................. 93
A7 Castings of the martensitic steel G-X4 CrNi 13 4 (1.4317); additional stipulations ............................................ 94

A 1 Ferritic steels of material group W I for flat products (3) In special cases, a tempering treatment may be neces-
as well as parts made from flat products sary for steel grades 15 MnNi 6 3 and WStB 355 S. This tem-
pering treatment shall be indicated in the certificate.
A 1.1 General
Section A 1 defines the details for manufacture, chemical A 1.3 Material characteristic values
composition, characterizing mechanical and technological
characteristics and heat treatment as well as for further pro- A 1.3.1 Chemical composition
cessing of the following steel grades
The values stipulated in Table A 1-1 shall apply to the chemi-
a) 15 MnNi 6 3 cal composition per the ladle and product analyses.
b) 20 MnMoNi 5 5
c) 15 NiCuMoNb 5 S A 1.3.2 Mechanical and technological characteristics
d) WStE 255 S (1) The characteristic values of the mechanical and techno-
e) WStE 285 S logical characteristics in the room-temperature tensile test are
stipulated in Table A 1-2.
f) WStE 315 S
g) WStE 355 S (2) The characteristic values of the mechanical and techno-
logical characteristics in the elevated-temperature tensile test
for flat products and parts made from flat products. are stipulated in Table A 1-3. The test temperatures for carry-
ing out the elevated-temperature tensile test shall be as fol-
lows:
A 1.2 Manufacture of the materials and delivery condition
a) 15 MnNi 6 3 300 °C
A 1.2.1 Manufacture
b) 20 MnMoNi 5 5 350 °C
(1) The steels shall be smelted by the basic oxygen process c) 15 NiCuMoNb 5 S 350 °C
or in the electric furnace. If other processes are used, proof of
d) WStE 255 S 300 °C
equivalence shall be furnished.
e) WStE 285 S 300 °C
(2) The steels shall be made in particularly killed condition.
f) WStE 315 S 300 °C
g) WStE 355 S 300 °C
A 1.2.2 Delivery condition
(3) The characteristic values of impact energy and lateral
(1) The usual delivery condition for the steel grades is as expansion are stipulated in Table A 1-4.
follows:
(4) The data for impact energy and lateral expansion shall
a) 15 MnNi 6 3 normalized apply to standard specimens with a specimen width of 10 mm.
b) 20 MnMoNi 5 5 quenched and tempered in liquid
(5) The mechanical and technological characteristics shall
c) 15 NiCuMoNb 5 S normalized and tempered be verified on specimens subjected to simulated stress-relief
d) WStE 255 S normalized annealing. Unless otherwise agreed in the purchase order, the
conditions for simulated stress-relief annealing shall be as
e) WStE 285 S normalized follows:
f) WStE 315 S normalized a) holding time: 900 minutes,
g) WStE 355 S normalized b) annealing temp.: 560 °C to 580 °C,
600 °C to 620 °C for steel grades
(2) If the governing heat treatment is performed during fur-
20 MnMoNi 5 5 and 15 NiCuMoNb 5 S.
ther processing, the flat products to be supplied in normalized
condition may also be delivered in rolled condition, and the flat (6) The characteristic values shall apply to specimens taken
products to be supplied in quenched and tempered condition and tested as per the stipulations in the Sections relating to
may also be delivered in normalized or tempered condition or, product forms. The stipulations of Table A 1-5 shall be taken
in special cases, even in rolled condition. into consideration for flat products.
KTA 3211.1 Page 70

A 1.3.3 Grain size A 1.5.2 Cold forming

(1) The ferrite grain size at least shall comply with the follow- Note:
ing grain size index to DIN EN ISO 643: Cold forming shall designate forming at room temperature or with
heating up to the highest temperature permissible for stress-relief
a) 15 MnNi 6 3 grain size index 6, annealing.
b) 20 MnMoNi 5 5 grain size index 5,
(1) Heat treatment is not required after cold forming with
c) 15 NiCuMoNb 5 S grain size index 6, degrees of forming smaller than or equal to 2 %.
d) WStE 255 S grain size index 6, (2) Stress-relief annealing shall be required after forming
e) WStE 285 S grain size index 6, with degrees of cold forming between 2 % and smaller than or
equal to 5 %,
f) WStE 315 S grain size index 6,
g) WStE 355 S grain size index 6. (3) The governing heat treatment shall be performed after
cold forming with degrees of forming larger than 5 %.
(2) For steels with contents of bainitic structure, the require-
ments shall apply only to the microstructural proportions of (4) For flat products with a degree of cold forming not excee-
polygonal ferrite. ding 10 %, stress-relief annealing may be performed instead
of the governing heat treatment if it is proved on a case-by-
case basis that the stipulations for mechanical and technologi-
A 1.3.4 Physical characteristics cal characteristics are met.
Reference values for the physical characteristics can be found (5) If different procedures are employed, proof of equiva-
in Annex AP. lence shall be furnished.

A 1.4 Data on heat treatment A 1.6 Thermal cutting and welding

Reference values for heat treatment are presented in Table A 1.6.1 Thermal cutting
A 1-6.
SEW 088 shall be taken into consideration for thermal cutting.
Recommended preheating temperatures are presented in
A 1.5 Forming Table A 1-7.
A 1.5.1 Hot forming
Note: A 1.6.2 Welding
Hot forming shall designate forming at temperatures above the
highest temperature permissible for stress-relief annealing, even if (1) Use of the following welding methods has been ap-
the product forms are heated to the corresponding temperature praised as suitable for the steel grades to this Annex:
only locally, in the forming zone. The term hot forming shall also a) manual arc welding with basic-flux-coated rod electrodes,
include adaptation and straightening work at the corresponding
temperatures. b) submerged-are welding with basic fluxes,
c) inert-gas-shielded welding with wire electrodes or with
(1) For hot forming, the flat products shall be heated above basic-flux-cored wire electrodes.
the lower limit temperature for normalization but not above
1050 °C. Grain coarsening due to excessively long times or to (2) The examined work areas for welding are listed in Table
overheating shall be avoided. A 1-7. Other work areas for welding are permitted, provided
procedure qualification tests per KTA 3211.3 have been per-
(2) After hot forming, the complete product forms shall be formed.
subjected to renewed heat treatment as per the data in Table
A 1-6. (3) The stipulations for welding per SEW 088 shall be ob-
served. Basic coated rod electrodes or fluxes of basic charac-
(3) If the complete product form was heated above the lower teristics shall preferably be used. Moreover, welding filler
limit temperature for normalization but not above 1000 C in the metals with the following diffusible hydrogen content shall be
case of one-time hot forming or before the last step of hot provided for steels if Rp0.2RT is equal to or greater than
forming in the case of hot forming in several steps, and if the
370 N/mm2:
forming process was completed above 750 °C, or above
700 °C in the case that the degree of forming in the last step a) rod electrode weld metal:
did not exceed 5 %, subsequent normalization is not required equal to or smaller than 5 ml/100 g in the molten weld
for steel grades 15 MnNi 6 3, WStE 255 S, WStE 285 S, metal (H 5 to DIN EN ISO 2560);
WStE 315 S and WStE 355 S; steel grade 15 NiCuMoNb 5 S b) submerged arc weld metal:
shall merely require to be tempered. However, hot forming in equal to or smaller than 5 ml/100 g in the molten weld
several steps is subject to the condition that, before being metal (H 5 to DIN EN ISO 14174).
heated for the last step, the product form in the case of steel
grades 15 MnNi 6 3, WStE 255 S, WStE 285 S, WStE 315 S und (4) Post-weld stress-relief annealing may be required, de-
WStE 355 S be cooled to a temperature below 550 °C and in pending on wall thickness and geometry of the parts. The limit
the case of steel grade 15 NiCuMoNb 5 S be cooled to a tem- wall thickness values up to which stress-relief annealing may
perature below 350 °C. be waived are listed in Table A 1-7.

(4) The temperature control program shall be monitored. (5) Post-weld non-destructive examinations shall be per-
formed after a waiting time of at least 48 hours after com-
(5) If the procedures employed differ from stipulations (1) to pletion of the welding work. The waiting time may be waived
(3), e.g., in the case of forming with local heating without sub- for welds that are subjected to stress-relief annealing, hydro-
sequent heat treatment of the complete product form, proof of gen degassing or delayed cooling, or that were welded under
equivalence shall be furnished. shield gas.
 Verification Content by mass, % 1) 2)
Steel grade by Limit value
C Si Mn P S Altotal N As Cu Cr Mo Nb Ni Sn Ti V
Ladle min. 0.12 0.15 1.20 0.020 0.50
analysis max. 0.18 0.35 1.65 0.015 0.005 0.055 0.015 0.015 0.06 0.15 0.05 0.004 0.85 0.010 0.020 0.020
15 MnNi 6 3
Product min. 0.10 0.15 1.15 0.015 0.50
analysis max. 0.20 0.37 1.70 0.017 0.007 0.065 0.016 0.016 0.07 0.20 0.05 0.004 0.90 0.013 0.020 0.020
Ladle min. 0.17 0.15 1.20 0.010 0.40 0.50
analysis max. 0.23 0.30 1.50 0.012 0.008 0.040 0.013 0.025 0.12 0.20 0.55 0.80 0.011 0.020
20 MnMoNi 5 5
Product min. 0.15 0.10 1.15 0.010 0.403) 0.45
analysis max. 0.25 0.35 1.55 0.0123) 0.0123) 0.050 0.0133) 0.025 0.123) 0.20 0.55 0.85 0.0113) 0.020
Ladle min. 0.25 0.80 0.015 0.50 0.25 0.015 1.00
analysis max. 0.17 0.50 1.20 0.016 0.005 0.020 0.80 0.30 0.40 0.025 1.30 0.020 0.020
15 NiCuMoNb 5 S
Product min. 0.21 0.75 0.010 0.45 0.20 0.010 0.95
analysis max. 0.19 0.54 1.25 0.020 0.006 0.022 0.85 0.35 0.45 0.030 1.35 0.020 0.020
Ladle min. 0.40 0.020
analysis max. 0.18 0.40 1.30 0.020 0.015 0.020 0.184) 0.304) 0.084) 0.005 0.30 0.020 0.020
WStE 255 S
Product min. 0.30 0.015
analysis max. 0.20 0.45 1.40 0.025 0.020 0.022 0.254) 0.344) 0.114) 0.005 0.35 0.020 0.020
Ladle min. 0.50 0.020
WStE 285 S analysis max. 0.18 0.40 1.40 0.020 0.015 0.020 0.184) 0.304) 0.084) 0.005 0.30 0.020 0.020
Product min. 0.40 0.015
analysis max. 0.20 0.45 1.50 0.025 0.020 0.022 0.254) 0.344) 0.114) 0.005 0.35 0.020 0.020
Ladle min. 0.60 0.020
analysis max. 0.18 0.45 1.50 0.020 0.015 0.020 0.184) 0.304) 0.084) 0.005 0.30 0.020 0.020
WStE 315 S
Product min. 0.50 0.015
analysis max. 0.20 0.50 1.60 0.025 0.020 0.022 0.254) 0.344) 0.114) 0.005 0.35 0.020 0.020
Ladle min. 0.10 0.90 0.020
analysis max. 0.20 0.50 1.65 0.020 0.015 0.020 0.184) 0.304) 0.084) 0.005 0.305) 0.020 0.020
WStE 355 S
Product min. 0.05 0.80 0.015
analysis max. 0.22 0.55 1.75 0.025 0.020 0.022 0.254) 0.344) 0.114) 0.005 0.355) 0.020 0.020
1) The differences that the tabulated values indicate between chemical compositions per the ladle and product analyses are sometimes smaller than would be expected from the metallurgical relationship.
The reason is that the limit values for chemical composition per the product analysis are in this case based only on the heats covered by the appraisal. Thus the values will be reviewed once additional
documents become available.
2) If the indicated limit contents per the ladle analysis are exceeded, the limit contents per the product analysis shall govern.
3) If these values are exceeded and allowance must be made in the product analysis for contents up to P  0.015 %, S  0.015 %, Mo  0.63 %, Cu  0.18 %, Sn  0.016 % and N
total  0.015 %, the author-
ized inspector shall check, until further information becomes available, as to whether welding simulation tests and if necessary tangential microsection examinations are necessary. If intermediate anneal-
ing at 550 °C is planned during further processing, the permissibility of this annealing temperature shall be verified during the said tests or examinations. The scope and conduct of these tests shall be

KTA 3211.1 Page 71

agreed with the authorized inspector. The tests may be waived if so stipulated in the material appraisal.
4) The sum of the contents of chromium, copper and molybdenum shall not exceed 0.45 % in the ladle analysis or 0.50 % in the product analysis.
5) Depending on the authorized inspector's appraisal relative to the individual manufacturer, the maximum permissible nickel content shall be 0.85 % in the ladle analysis and 0.90 % in the product analysis.

Table A 1-1: Chemical composition of steel grades per the ladle and product analyses
KTA 3211.1 Page 72

Elongation at Specimen Reduction of area

Nominal Yield point 1)
Tensile strength fracture direction at fracture Z
thickness ReH
Steel grade Rm A %
s N/mm2 (individual value)
mm N/mm2 %
at least at least
at least
5 < s  38 510 to 630 370
38 < s  50 510 to 630 350 longitudinal
15 MnNi 6 3 50 < s  80 490 to 610 330 22 or 45
80 < s  100 470 to 600 320 transverse
100 < s  150 470 to 650 310
5 < s  38 490 to 610 330
15 MnNi 6 3
38 < s  50 490 to 610 330 longitudinal
normalized
and stress-relief- 50 < s  80 490 to 610 330 22 or 45
annealed 80 < s  100 470 to 600 320 transverse
100 < s  150 470 to 600 310
30 < s  70 590 to 730 450 longitudinal 45 2)
20 MnMoNi 5 5 70 < s  150 570 to 710 430 18 or 45
150 < s  600 560 to 700 390 transverse 45
s  35 610 to 780 440
35 < s  50 610 to 780 440
50 < s  70 600 to 760 430
15 NiCuMoNb 5 S 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 740 410
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
WStE 255 S
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 23
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
WStE 285 S
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 22
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
WStE 315 S
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 21
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
WStE 355 S
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 val-
ue of 45 % on perpendicular specimens.

Table A 1-2: Characteristic values of the mechanical and technological characteristics in the room-temperature tensile test on
longitudinal and transverse specimens
 Tensile strength Rm 0.2 % proof stress Rp0.2 Elongation at
Steel grade Test temperature N/mm2 N/mm2 fracture A
°C at least at least %

for nominal thicknesses in mm for nominal thicknesses in mm at least

5 > 50 > 80 5 > 50 > 80 > 100

 50  80  150  50  80  100  150
100 470 460 440 340 315 305 295
145 450 440 420 320 290 280 270
15 MnNi 6 3 200 440 430 410 290 260 250 240
normalized 250 440 430 410 270 250 240 230
300 440 430 410 250 230 220 210
350 440 430 410 230 210 200 190
100 420 420 420 300 300 290 280
15 MnNi 6 3 145 410 410 410 290 290 280 270
normalized and 200 410 410 410 260 260 250 240
stress-relief-
annealed 250 400 400 400 250 250 240 230
300 400 400 400 230 230 220 210
350 400 400 400 210 210 200 190
for nominal thicknesses in mm for nominal thicknesses in mm
 30 > 70 > 150 > 30 > 70 > 150 > 200 > 320
 70  150  600  70  150  200  320  600
100 550 530 520 431 412 382 370 370 17
20 MnMoNi 5 5 200 530 510 505 412 392 371 360 350 16
300 530 510 505 392 371 353 350 330 16
350 530 510 505 382 363 343 343 315 16
375 530 505 505 377 358 338 330 300 16
400 530 500 490 371 353 333 320 290 16

Table A 1-3: Characteristic values of the mechanical and technological characteristics in the elevated-temperature tensile test on longitudinal and transverse specimens (Part 1)

KTA 3211.1 Page 73

 KTA 3211.1 Page 74
Tensile strength Rm, N/mm2 0.2 % proof stress Rp0.2, N/mm2 Elongation at
Steel grade Test temperature at least at least fracture A
°C for nominal thicknesses in mm for nominal thicknesses in mm %
> 70 > 85 > 100 > 125 > 150 > 35 > 70 > 85 > 100 > 125 > 150 at least
 70  85  100  125  150  250  35  70  85  100  125  150  250
15 NiCuMoNb 5 S 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
WStE 255 S 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 98 88
350 280 270 260 250 245 235 118 118 108 98 88 78 68
400 270 260 250 240 235 225 108 108 98 88 78 69 59
WStE 285 S 100 360 350 340 330 320 310 255 245 235 226 216 206 196
150 345 335 325 315 305 295 235 226 216 206 196 186 176
200 330 320 310 300 290 280 206 206 196 186 177 167 157
250 320 310 300 290 280 270 186 186 177 167 157 147 137
300 320 310 300 290 280 270 157 157 147 137 127 118 108
350 305 295 285 275 270 265 137 137 127 118 108 98 88
400 295 285 275 265 260 255 118 118 108 98 88 78 68
WStE 315 S 100 400 390 380 370 360 350 275 265 255 245 235 226 216
150 385 375 365 355 345 335 255 245 235 226 216 206 196
200 370 360 350 340 330 320 226 226 216 206 196 186 176
250 360 350 340 330 320 310 206 206 196 186 177 167 157
300 360 350 340 330 320 310 177 177 167 157 147 137 127
350 350 340 330 320 310 300 157 157 147 137 127 118 108
400 340 330 320 310 300 290 137 127 118 118 108 98 88
WStE 355 S 100 430 420 410 400 390 380 304 294 284 275 265 255 245
150 420 410 400 390 380 370 284 275 265 255 245 235 225
200 410 400 390 380 370 360 255 255 245 235 226 216 206
250 400 390 380 370 360 350 235 235 226 216 206 196 186
300 400 390 380 370 360 350 216 216 206 196 186 177 167
350 390 380 370 360 350 340 196 196 186 177 167 157 147
400 380 370 360 350 340 330 167 167 157 147 137 127 117

Table A 1-3: Characteristic values of the mechanical and technological characteristics in the elevated-temperature tensile test on longitudinal and transverse specimens (continued)
 KTA 3211.1 Page 75

Impact energy in J Lateral expansion in mm

Nominal at the temperature, °C at the temperature, °C
Nature of at least at least
Steel grade thickness s
value 1)
mm Upper Upper
-20 0 5 20 33 -20 5 33
shelf 2) shelf 2)
MW 80 110 130 130 130 130
15 MnNi 6 3 5  s 0 150
EW 68 90 100 100 100 100 0.9 1.3 1.3 1.3
MW 41
20 MnMoNi 5 5 30  s  600 4)
EW 34 68 3) 100 0.9 3) 1.3
MW 41
15 NiCuMoNb 5 S 10  s  150
EW 34 68 3) 100 0.9 3) 1.3
MW 21 41
WStE 255 S 10  s  150
WStE 285 S EW 15 34 68 3) 100 0.9 3) 1.3
WStE 315 S MW 16 41
WStE 355 S 150  s  250 4)
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 tempera-
ture.
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 impact energy (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 impact energy and lateral expansion in the notched-bar impact bend test on transverse
specimens

Nominal thick- Delivered product length l Sampling and location of the test coupons relative
Steel grade
ness in mm in m per rolled plate to the product width b

all nominal thick- l<7 at one end at b/4

15 MnNi 6 3
nesses l>7 at both ends at b/4
20 MnMoNi 5 5  30 to  600 all lengths at both ends at b/2 1)
WStE 255 S
l<7 at one end at b/4
WStE 285 S
all nominal thick-
WStE 315 S
nesses
WStE 355 S l>7 at both ends at b/4
15 NiCuMoNb 5 S
1) The test cross sections shall be located by at least half the product thickness under the end and side surfaces from the edges straight-
ened for the heat treatment. Notwithstanding the foregoing, the test sections from flat products with nominal thicknesses > 320 mm for
pipe 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 76

Temperature range in °C for

Normalization
Steel grade Quenching and tempering
°C Stress-relief annealing
Austenitization 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 technological
characteristics are met even allowing for subsequent heat treatments for the final condition of the complete part. Claddings shall also be
taken 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) Limit wall thick-

Nominal Thermal cutting ness for waiving
thickness s Cooling stress-relief
Steel grade Preheating temperature time
Preheating Holding annealing after
TV and interpass tem- t8/5
mm temperature TV temperature 1) TH welding
perature TZ
sec. in mm
s  15 Room temp.  TV Room temp.  T  150 °C Room temp.  TH
15 < s  30 Room temp.  TV 80 °C  T  180 °C Room temp.  TH
15 MnNi 6 3 8 to 25 38 3)
30 < s  50 100 °C  TV 100 °C  T  220 °C Room temp.  TH
50 < s  150 120 °C  TV 120 °C  T  220 °C Room temp.  TH
150 °C  T  250 °C 150 °C  TH  250 5)
20 MnMoNi 5 5 s > 15 150 °C  TV  250 °C 7 to 25
120 °C  T  180 °C 4) 120 °C  TH  180 4) 5)
s  15 Room temp.  TV Room temp.  T  150 °C Room temp.  TH Stress-relief
annealing shall
15 < s  30 Room temp.  TV 80 °C  T  180 °C Room temp.  TH always
15 NiCuMoNb 5 S 8 to 35
30 < s  50 70 °C  TV 100 °C  T  220 °C 200 °C  TH be required
s > 50 120 °C  TV 120 °C  T  220 °C 120 °C  TH
WStE 255 S s  15 Room temp.  TV RT  T  150 °C Room temp.  TH
WStE 285 S 15 < s  50 Room temp.  TV RT  T  180 °C Room temp.  TH
8 to 28 38 3)
30 < s  50 Room temp.  TV 80 °C  T  200 °C 80 °C  TH
WStE 315 S
s > 50 120 °C  TV 120 °C  T  220 °C 120 °C  TH
s  15 Room temp.  TV RT  T  150 °C Room temp.  TH
15 < s  30 Room temp.  TV 80 °C  T  180 °C Room temp.  TH
WStE 355 S 8 to 25 38 3)
30 < s  50 100 °C  TV 100 °C  T  220 °C 200 °C  TH
s > 50 120 °C  TV 120 °C  T  220 °C 120 °C  TH
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 77

A 2 Ferritic steels of material group W I for forgings, bars (4) The data for impact energy and lateral expansion shall
and rolled rings apply to standard specimens with a specimen width of 10 mm.
A 2.1 General (5) The mechanical and technological characteristics shall
be verified on specimens subjected to simulated stress-relief
Section A 2 defines the details for manufacture, chemical
annealing. For product forms of steel 20 MnMoNi 5 5 with
composition, characterizing mechanical and technological
nominal thicknesses up to and including 50 mm that are to be
characteristics and heat treatment as well as for further pro-
welded, the mechanical and technological characteristics shall
cessing of the following steel grades
be verified in the delivery condition.
a) 15 MnNi 6 3
(6) For simulated stress-relief annealing the requirements of
b) 20 MnMoNi 5 5 Table A 2-7 shall apply.
c) 15 NiCuMoNb 5 S
(7) The characteristics shall apply to specimens taken and
d) C 22.8 S tested as per the stipulations in the Sections relating to prod-
e) WStE 355 S uct forms.
for forgings, bars and rolled rings.
A 2.3.3 Grain size
A 2.2 Manufacture of the materials and delivery condition (1) The ferrite grain size at least shall comply with the follow-
A 2.2.1 Manufacture ing grain size index to DIN EN ISO 643:
a) 15 MnNi 6 3 grain size index 6,
(1) The steels shall be smelted by the basic oxygen process
or in the electric furnace. If other processes are used, proof of b) 20 MnMoNi 5 5 grain size index 5,
equivalence shall be furnished. c) 15 NiCuMoNb 5 S grain size index 6,
(2) The steels shall be made in particularly killed condition. d) C 22.8 S grain size index 4,
e) WStE 355 S grain size index 6.
A 2.2.2 Delivery condition
(2) For steels with contents of bainitic structure, the require-
(1) The usual delivery condition for the steel grades is as ments shall apply only to the microstructural proportions of
follows: polygonal ferrite.
a) 15 MnNi 6 3 normalized
b) 20 MnMoNi 5 5 quenched and tempered in liquid A 2.3.4 Physical characteristics
c) 15 NiCuMoNb 5 S normalized and tempered (quenched Reference values for the physical characteristics can be found
and tempered in air) or quenched in Annex AP.
and tempered in liquid
d) C 22.8 S normalized, or also quenched and
tempered in liquid for nominal thick- A 2.4 Data on heat treatment
nesses  150 mm Reference values for heat treatment are presented in Table
e) WStE 355 S normalized or quenched and tem- A 2-5.
pered
A 2.5 Forming
A 2.3 Material characteristic values
A 2.5.1 Hot forming
A 2.3.1 Chemical composition
Note:
The values stipulated in Table A 2-1 shall apply to the chemi- Hot forming shall designate forming at temperatures above the
cal composition per the ladle and product analyses. highest temperature permissible for stress-relief annealing, even if
the product forms are heated to the corresponding temperature
only locally, in the forming zone. The term hot forming shall also
A 2.3.2 Mechanical and technological characteristics include adaptation and straightening work at the corresponding
temperatures.
(1) The characteristic values of the mechanical and techno-
logical characteristics in the room-temperature tensile test are (1) For hot forming, the forgings shall be heated to at least
stipulated in Table A 2-2. 750 °C but not above 1050 °C. For hot forming, the forgings of
15 MnNi 6 3 shall be heated to at least 750 °C but not above
(2) The characteristic values of the mechanical and techno-
1100 °C. Grain coarsening due to excessively long times or to
logical characteristics in the elevated-temperature tensile test
overheating shall be avoided. Hot forming of tubular forgings,
are stipulated in Table A 2-3. The test temperatures for carry-
e.g., for the manufacture of pipe elbows, shall be subject to
ing out the elevated-temperature tensile test for the various
the stipulations in Section A 3.
steel grades shall be as follows:
15 MnNi 6 3 300 °C (2) After hot forming, the complete product forms shall be
subjected to renewed heat treatment per the data in Table
20 MnMoNi 5 5 350 °C A 2-5.
15 NiCuMoNb 5 S 350 °C
(3) If the procedures employed differ from stipulations (1)
C 22.8 S 300 °C and (2), e.g., in the case of forming with local heating without
subsequent heat treatment of the complete product form,
WStE 355 S 300 °C
proof of equivalence shall be furnished.
(3) The characteristic values of impact energy and lateral ex- (4) The temperature control program shall be monitored.
pansion are stipulated in Table A 2-4.
KTA 3211.1 Page 78

A 2.6 Thermal cutting and welding teristics shall preferably be used. Moreover, welding filler
metals with the following diffusible hydrogen content shall be
A 2.6.1 Thermal cutting
provided for steels if Rp0.2RT is equal to or greater than
SEW 088 shall be taken into consideration for thermal cutting. 370 N/mm2:
Recommended preheating temperatures are presented in a) rod electrode weld metal:
Table A 2-6.
equal to or smaller than 5 ml/100 g in the molten weld
metal (H 5 to DIN EN ISO 2560);
A 2.6.2 Welding
b) submerged arc weld metal:
(1) Use of the following welding methods has been ap- equal to or smaller than 5 ml/100 g in the molten weld
praised as suitable for the steels per this Annex: metal (H 5 to DIN EN ISO 14174).
a) manual arc welding with basic-flux-coated rod electrodes,
(4) Post-weld stress-relief annealing may be required, de-
b) submerged-arc welding with basic fluxes, pending on wall thickness and geometry of the parts. The
c) inert-gas-shielded welding with wire electrodes or with nominal thicknesses at which stress-relief annealing may be
basic-flux-cored wire electrodes. waived are listed in Table A 2-6.
(2) The examined work areas for welding are listed in Table (5) Post-weld non-destructive examinations shall be per-
A 2-6. Other work areas for welding are permitted, provided formed after a waiting time of at least 48 hours after comple-
procedure qualification tests per KTA 3211.3 have been per- tion of the welding work. The waiting time may be waived for
formed. welds that are subjected to stress-relief annealing, hydrogen
(3) The stipulations for welding per SEW 088 shall be ob- degassing or delayed cooling, or that were welded under
served. Basic coated rod electrodes or fluxes of basic charac- shield gas.
 Verification Content by mass, % 1) 2)
Steel grade by Limit value
C Si Mn P S Altotal N As Cu Cr Mo Nb Ni Sn Ti V
Ladle min. 0.12 0.15 1.20 0.020 0.50
analysis max. 0.18 0.35 1.65 0.015 0.005 0.055 0.015 0.015 0.06 0.15 0.05 0.004 0.85 0.010 0.020 0.020
15 MnNi 6 3
Product min. 0.10 0.15 1.15 0.015 0.50
analysis max. 0.20 0.37 1.70 0.017 0.007 0.065 0.016 0.016 0.07 0.20 0.05 0.004 0.90 0.013 0.020 0.020
Ladle min. 0.17 0.15 1.20 0.010 0.40 0.50
analysis max. 0.23 0.30 1.50 0.012 0.008 0.040 0.013 0.025 0.12 0.20 0.55 0.80 0.011 0.020
20 MnMoNi 5 5
Product min. 0.15 0.10 1.15 0.010 0.40 0.45
analysis max. 0.25 0.35 1.55 0.0123) 0.0123) 0.050 0.0133) 0.025 0.12 3) 0.20 0.55 3) 0.85 0.0113) 0.020
Ladle min. 0.10 0.25 0.80 0.015 0.50 0.25 0.015 1.00
analysis max. 0.17 0.50 1.20 0.016 0.005 0.035 0.020 0.80 0.30 0.40 0.025 1.30 0.020
15 NiCuMoNb 5 S
Product min. 0.08 0.21 0.75 0.010 0.45 0.20 0.010 0.95
analysis max. 0.19 0.54 1.25 0.020 0.006 0.040 0.022 0.85 0.35 0.45 0.030 1.35 0.020
Ladle min. 0.18 0.15 0.40 0.015
analysis max. 0.23 0.35 0.90 0.016 0.010 0.050 0.15 0.30 0.020
C 22.8 S
Product min. 0.16 0.10 0.36 0.010
analysis max. 0.25 0.40 0.95 0.020 0.015 0.055 0.18 0.35 0.020
Ladle min. 0.10 0.90 0.020
analysis max. 0.20 0.50 1.65 0.020 0.015 0.070 0.020 0.18 4) 0.30 4) 0.084) 0.005 0.30 5) 0.020 0.020
WStE 355 S
Product min. 0.05 0.84 0.015
analysis max. 0.22 0.55 1.75 0.025 0.020 0.075 0.022 0.25 4) 0.34 4) 0.114) 0.006 0.35 5) 0.020 0.020
1) The differences that the tabulated values indicate between chemical compositions per the ladle and product analyses are sometimes smaller than would be expected from the metallurgical relationship.
The reason is that the limit values for chemical composition per the product analysis are in this case based only on the heats covered by the appraisal. Thus the values will be reviewed once additional
documents become available.
2) If the indicated limit contents per the ladle analysis are exceeded, the limit contents per the product analysis shall govern.
3) If these values are exceeded and allowance must be made in the product analysis for contents up to P  0.015 %, S  0.015 %, Mo  0.63 %, Cu  0.18 %, Sn  0.016 % and N
total  0.015 %, the author-
ized inspector shall check, until further information becomes available, as to whether welding simulation tests and if necessary tangential microsection examinations are necessary. If intermediate anneal-
ing at 550 °C is planned during further processing, the permissibility of this annealing temperature shall be verified during the said tests or examinations. The scope and conduct of these tests shall be
agreed with the authorized inspector. The tests may be waived if so stipulated in the material appraisal.
4) The sum of the contents of chromium, copper and molybdenum shall not exceed 0.45 % in the ladle analysis or 0.50 % in the product analysis.
5) Depending on the authorized inspector's appraisal relative to the individual manufacturer, the maximum permissible nickel content shall be 0.85 % in the ladle analysis and 0.90 % in the product analysis.

Table A 2-1: Chemical composition of steel grades per the ladle and product analyses

KTA 3211.1 Page 79

KTA 3211.1 Page 80

Reduction of area at
Tensile Yield point 1) Elongation at
Heat-treatment fracture Z
strength ReH Specimen fracture A
Steel grade wall thickness s %
Rm N/mm2 direction %
mm Individual Mean
N/mm2 at least at least
value value
longitudinal /
s  70 470 to 590 320 22 45 
transverse
longitudinal /
70 < s  100 470 to 590 310 22 45 
transverse
longitudinal /
100 < s  150 470 to 590 300 22 45 
15 MnNi 6 3 transverse
longitudinal /
150 < s  250 440 to 580 285 22 45 
transverse
longitudinal /
22 45 
250 < s  350 440 to 580 275 transverse
perpendicular  35 45
longitudinal /
19 45 
20 MnMoNi 5 5 s  1000 560 to 700 390 transverse
perpendicular  35 45
longitudinal 20  
15 NiCuMoNb 5 S s  400 580 to 740 430
transverse 18  
longitudinal 25 45 
s  150 410 to 540 230
transverse 20 45 
longitudinal 25 45 
C 22.8 S 150 < s  320 400 to 520 210
transverse 19 45 
longitudinal 25 45 
320 < s  500 400 to 520 200
transverse 19 45 
longitudinal 23  
s  100 490 to 630 335
transverse 21  
longitudinal 21  
WStE 355 S 100 < s  250 470 to 630 295
transverse 19  
longitudinal 21  
250 < s  400 470 to 630 275
transverse 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 81

Tensile strength Elongation at fracture A

Rm 0.2 % proof stress Rp0.2 %
N/mm2 at least
N/mm2 (longitudinal or trans-
Test tem- at least at least
Steel grade perature verse)
°C for heat-treatment wall thicknesses in mm
> 70 > 100 > 150 > 250
 350  70  100  150  250  350
100 420 290 280 270 245 235
145 410 280 270 260 225 215
200 400 250 240 230 205 195
15 MnNi 6 3
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
100 520 370 370 17 16
20 MnMoNi 5 5 200 505 360 350 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
for heat-treatment wall thicknesses in mm
 400  400
100 540 402
150 530 389
15 NiCuMoNb 5 S 200 520 376
250 510 363
300 500 350
350 490 337
400 480 324
for heat-treatment wall thicknesses in mm
> 150 > 320
 500  150  320  500
100 360 220 200 190
150 350 200 180 170
C 22.8 S
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
for heat-treatment wall thicknesses in mm
> 100 > 250
 400  100  250  400
100 410 294 255 235
150 400 275 235 215
WStE 355 S
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 82

Impact energy Lateral expansion in mm

Nominal at the temperature, °C at the temperature, °C
Nature of at least at least
Steel grade thickness s
value 1)
mm - 20 0 +5 +20 +33 Upper - 20 +5 + 33 Upper
shelf 2) shelf 2)
MW 80 110 130 130 130 130
s  150
EW 68 90 100 100 100 100 0,9 1,3 1,3 1,3
15 MnNi 6 3
MW 70 90 110 130 130 130
150 < s  350
EW 56 72 88 100 100 100 0,9 1,3 1,3 1,3
MW 41
20 MnMoNi 5 5 s  1000
EW 34 68 3) 100 0,9 3) 1,3
MW 60 80 95
15 NiCuMoNb 5 S s  400
EW 42 56 66 68 3) 100 0,9 3) 1,3
MW 41 49
C 22.8 S s  500
EW 34 42 68 3) 100 0,9 3) 1,3
MW 41
WStE 355 S s  400
EW 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 tempera-
ture.
3) If agreed in the purchase order, this requirement shall also apply at lower temperature, but not below 0 °C.

Table A 2-4: Characteristic values of impact energy and lateral expansion in the notched-bar impact bend test on transverse
specimens

Temperature range for

Normalization Quenching and tempering Stress-relief annealing 3)
Steel grade
°C Austenitization Tempering
°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
900 to 980 1) 640 to 670 580 to 620
15 NiCuMoNb 5 S
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 main-
tain the minimum temperature of 640 °C for tempering.
5) Two-stage quenching and tempering are permitted, depending on the authorized inspector's appraisal.

Table A 2-5: Data for heat treatment

 KTA 3211.1 Page 83

Welding 2) Limit wall

thickness for
Nominal Thermal cutting Cooling waiving
thickness s Preheating temperature Holding temperature
Steel grade time t8/5 stress-relief
Preheating tem- TV and interpass temper- annealing
mm perature TV ature TZ TH 1)
seconds after welding
mm
s  15 Room temp.  TV Room temp.  T  150 °C Room temp.  TH
15 < s  30 Room temp.  TV 80 °C  T  180 °C Room temp.  TH
15 MnNi 6 3 30 < s  50 100 °C  TV 100 °C  T  220 °C 3) 100 °C  TH 8 to 25 38 5)

50 < s  120 °C  TV 120 °C  T  220 °C 3) 120 °C  TH

150
150 °C  TH  250 °C Stress-relief
annealing
20 MnMoNi 5 5 s > 15 150 °C  TV  250 °C 150 °C  T  250 °C 3) 7 to 25
120 °C  TH  180 °C 4) shall always
be required
s  15 Room temp.  TV 80 °C  T  180 °C Room temp.  TH
Stress-relief
15 < s  30 Room temp.  TV 100 °C  T  180 °C 100 °C  TH annealing
15 NiCuMoNb 5 S 10 to 25
30 < s  50 100 °C  TV 120 °C  T  220 °C 120 °C  TH shall always
be required
s > 50 120 °C  TV 120 °C  T  220 °C
s  30 Room temp.  TV 80 °C  T  150 °C Room temp.  TH
C 22.8 S 30 < s  50 Room temp.  TV 80 °C  T  200 °C 3) Room temp.  TH 8 to 25 30
s > 50 120 °C  TV 120 °C  T  220 °C 3) 120 °C  TH
s  15 Room temp.  TV Room temp.  T  150 °C Room temp.  TH
15 < s  30 Room temp.  TV 80 °C  T  180 °C Room temp.  TH
WStE 355 S 8 to 25 38 5)
30 < s  50 100 °C  TV 100 °C  T  220 °C 3) 100 °C  TH
s > 50 120 °C  TV 120 °C  T  220 °C 3) 120 °C  TH
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) 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 thick-
ness to  50 mm, unless special requirements of heat-treatment condition are imposed.

Table A 2-6: Particulars of thermal cutting and welding, together with limit wall thicknesses for stress-relief annealing

Simulated stress-relief annealing

Steel 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, and per-
formance of the simulated stress-relief annealing process
KTA 3211.1 Page 84

A 3 Ferritic steels of material group W I for seamless annealing (see Table A 3-5). For product forms of steel
pipes, seamless pipe elbows and seamless reducers 20 MnMoNi 5 5 with nominal thicknesses up to and including
50 mm that are to be welded, the mechanical and technologi-
A 3.1 General
cal characteristics shall be verified in the delivery condition.
Section A 3 defines the details for manufacture, chemical
composition, characterizing mechanical and technological A 3.3.3 Grain size
characteristics and heat treatment as well as for further pro-
cessing of the following steel grades (1) The ferrite grain size at least shall comply with the follow-
a) 15 MnNi 6 3 ing grain size index to DIN EN ISO 643:
b) 20 MnMoNi 5 5 a) 15 MnNi 6 3 grain size index 6,
c) 15 NiCuMoNb 5 S b) 20 MnMoNi 5 5 grain size index 5,
c) 15 NiCuMoNb 5 S grain size index 6.
for seamless pipes, seamless pipe elbows and seamless
reducers. (2) For steels with contents of bainitic structure, the require-
ments shall apply only to the microstructural proportions of
polygonal ferrite.
A 3.2 Manufacture of the materials and delivery condition
A 3.2.1 Manufacture A 3.3.4 Physical characteristics
(1) The steels shall be smelted by the basic oxygen process Reference values for the physical characteristics can be found
or in the electric furnace. If other processes are used, proof of in Annex AP.
equivalence shall be furnished.
(2) The steels shall be made in particularly killed condition. A 3.4 Data on heat treatment
Reference values for heat treatment are presented in Ta-
A 3.2.2 Delivery condition ble A 3-6.
(1) The usual delivery condition for the steel grades is as
follows: A 3.5 Forming
a) 15 MnNi 6 3 normalized
A 3.5.1 Hot forming
b) 20 MnMoNi 5 5 quenched and tempered in liquid
Note:
c) 15 NiCuMoNb 5 S normalized and tempered (quenched Hot forming shall designate forming at temperatures above the
and tempered in air) or quenched highest temperature permissible for stress-relief annealing, even if
and tempered in liquid the product forms are heated to the corresponding temperature
only locally, in the forming zone. The term hot forming shall also
(2) If the governing heat treatment is performed during fur- include adaptation and straightening work at the corresponding
ther processing, the pipes to be supplied in normalized condi- temperatures.
tion may also be delivered in rolled condition, and the pipes to
be supplied in quenched and tempered condition may also be (1) For hot forming, the pipes shall be heated to at least
delivered in normalized or tempered condition or, in special 750 °C but not above 1050 °C. For hot forming, the pipes of
cases, even in rolled condition. steel 15 MnNi 6 3 shall be heated to at least 750 °C but not
above 1100 °C. Forging and upsetting shall be performed in
the upper portion of the temperature range at 1100 °C to
A 3.3 Material characteristic values 900 °C. Hot bending of pipes and similar forming work shall be
A 3.3.1 Chemical composition performed in the lower portion of the temperature range. Grain
coarsening due to excessively long times or to overheating
The values stipulated in Table A 3-1 shall apply to the chemi- shall be avoided.
cal composition per the ladle and product analyses.
(2) After hot forming, the complete product forms shall be
subjected to renewed heat treatment as per the data in Ta-
A 3.3.2 Mechanical and technological characteristics ble A 3-5.
(1) The characteristic values of the mechanical and techno- (3) If the procedures employed differ from stipulations (1) to
logical characteristics in the room-temperature tensile test are (2), e.g., in the case of forming with local heating without sub-
stipulated in Table A 3-2. sequent heat treatment of the complete product form, proof of
equivalence shall be furnished.
(2) The characteristic values of the mechanical and techno-
logical characteristics in the elevated-temperature tensile test (4) The temperature control program shall be monitored.
are stipulated in Table A 3-3. The test temperature for carry-
ing out the elevated-temperature tensile test for the various
steel grades shall be as follows: A 3.5.2 Cold forming and cold bending
15 MnNi 6 3 300 °C Note:
Cold forming and cold bending shall designate forming at room
20 MnMoNi 5 5 350 °C temperature or with heating up to the highest temperature permis-
sible for stress-relief annealing.
15 NiCuMoNb 5 S 350 °C
(1) Heat treatment is not required after cold forming with
(3) The characteristic values of impact energy and lateral degrees of forming smaller than or equal to 2 %.
expansion are stipulated in Table A 3-4.
(2) Stress-relief annealing shall be required after forming
(4) The data for impact energy and lateral expansion shall with degrees of cold forming between 2 % and smaller than or
apply to standard specimens with a specimen width of 10 mm. equal to 5 %.
(5) The mechanical and technological characteristics shall (3) The governing heat treatment shall be performed after
be verified on specimens subjected to simulated stress-relief cold forming with degrees of forming larger than 5 %.
 KTA 3211.1 Page 85

(4) If different procedures are employed, proof of equiva- (2) The examined work areas for welding are listed in Ta-
lence shall be furnished. ble A 3-7. Other work areas for welding are permitted, provid-
ed procedure qualification tests per KTA 3211.3 have been
(5) For cold-bending processes, heat treatment after cold performed.
bending may be waived if appropriate proof is furnished.
Weld-on work and straightening work shall not be permitted in (3) The stipulations for welding per SEW 088 shall be ob-
the zone of cold bends. served. Basic coated rod electrodes or fluxes of basic charac-
Note:
teristics shall preferably be used. Moreover, welding filler
metals with the following diffusible hydrogen content shall be
Cold bends shall be defined as machine-made cold bends of
provided for steels if Rp0.2RT is equal to or greater than
pipes with  DN 150 and with bend radii Rm > 2.5  Da.
370 N/mm2:
a) rod electrode weld metal:
A 3.6 Thermal cutting and welding equal to or smaller than 5 ml/100 g in the molten weld
A 3.6.1 Thermal cutting metal (H 5 to DIN EN ISO 2560);
b) submerged arc weld metal:
SEW 088 shall be taken into consideration for thermal cutting. equal to or smaller than 5 ml/100 g in the molten weld
Recommended preheating temperatures are presented in metal (H 5 to DIN EN ISO 14174).
Table A 3-7.
(4) Post-weld stress-relief annealing may be required, de-
pending on nominal thickness and geometry of the parts. The
A 3.6.2 Welding nominal thicknesses at which stress-relief annealing may be
(1) Use of the following welding methods has been ap- waived are listed in Table A 3-7.
praised as suitable: (5) Post-weld non-destructive examinations shall be per-
a) manual arc welding with basic-flux-coated rod electrodes, formed after a waiting time of at least 48 hours after comple-
tion of the welding work, The waiting time may be waived for
b) submerged-arc welding with basic fluxes,
welds that are subjected to stress-relief annealing, hydrogen
c) inert-gas-shielded welding with wire electrodes or with degassing or delayed cooling, or that were welded under
basic-flux-cored wire electrodes shield gas.
 KTA 3211.1 Page 86
Verification Content by mass, % 1) 2)
Steel grade Limit value
by C Si Mn P S Altotal N As Cu Cr Mo Nb Ni Sn Ti V

Ladle min. 0.12 0.15 1.20 0.020 0.50

analysis max. 0.18 0.35 1.65 0.015 0.005 0.055 0.015 0.015 0.06 0.15 0.05 0.004 0.85 0.010 0.020 0.020
15 MnNi 6 3
Product min. 0.10 0.15 1.15 0.015 0.50
analysis max. 0.20 0.37 1.70 0.017 0.007 0.065 0.016 0.016 0.07 0.20 0.05 0.004 0.90 0.013 0.020 0.020
min. 0.17 4) 0.15 1.20 0.010 0.40 0.50
Ladle
analysis max. 0.23 0.30 1.50 0.012 0.008 0.040 0.013 0.025 0.12 0.20 0.55 0.80 0.011 0.020
20 MnMoNi 5 5
min. 0.15 4) 0.10 1.15 0.010 0.40 0.45
Product
analysis max. 0.25 0.35 1.55 0.0123) 0.0123) 0.050 0.0133) 0.025 0.12 3) 0.20 0.55 3) 0.85 0.0113) 0.020
Ladle min. 0.10 0.25 0.80 0.015 0.50 0.25 0.15 1.00
analysis max. 0.17 0.50 1.20 0.016 0.005 0.035 0.020 0.80 0.30 0.40 0.025 1.30 0.020
15 NiCuMoNb 5 S
Product min. 0.08 0.21 0.75 0.010 0.45 0.20 0.010 0.95
analysis max. 0.19 0.54 1.25 0.020 0.006 0.040 0.022 0.85 0.35 0.45 0.030 1.35 0.020
1) The differences that the tabulated values indicate between chemical compositions per the ladle and product analyses are sometimes smaller than would be expected from the metallurgical relationship.
The reason is that the limit values for chemical composition per the product analysis are in this case based only on the heats covered by the appraisal. Thus the values will be reviewed once additional
documents become available.
2) If the indicated limit contents per the ladle analysis are exceeded, the limit contents per the product analysis shall govern.

3) If these values are exceeded and allowance must be made in the product analysis for contents up to P  0.015 %, S  0.015 %, Mo  0.63 %, Cu  0.18 %, Sn  0.016 % and Ntotal  0.015 %, the author-
ized inspector shall check, until further information becomes available, as to whether welding simulation tests and if necessary tangential microsection examinations are necessary. If intermediate anneal-
ing at 550 °C is planned during further processing, the permissibility of this annealing temperature shall be verified during the said tests or examinations. The scope and conduct of these tests shall be
agreed with the authorized inspector. The tests may be waived if so stipulated in the material appraisal.
4) For quenched and tempered wall thicknesses smaller than or equal to 30 mm, the following C contents shall be permissble: larger than or equal to 0.14 % and smaller than or equal to 0.18 % for the ladle
analysis; and larger than or equal to 0.12 % and smaller than or equal to 0.20 % for the product analysis.

Table A 3-1: Chemical composition of steel grades per the ladle and product analyses
 KTA 3211.1 Page 87

Reduction of area at
Heat-treatment Elongation at fracture Z
Tensile Yield point 1) ReH %
wall thickness Specimen fracture A
Steel grade strength Rm N/mm2 % at least
direction
mm N/mm2 at least Individual Mean val-
at least
value ue
longitudinal 24 45 
 70 490 to 610 330
transverse 22 45 
15 MnNi 6 3 transverse 22 45 
> 70
470 to 590 310 longitudinal 24 45 
 130
perpendicular  35 45
 15 longitudinal /
570 to 710 430 19 45 
 100 transverse
20 MnMoNi 5 5 longitudinal /
< 100 19 45 
560 to 700 390 transverse
 200
perpendicular  35 45
longitudinal 19  
15 NiCuMoNb 5 S  60 610 to 760 440 transverse 17  
perpendicular  25 35
1) If the yield point is not emphasized, the values shall be applicable for the 0.2 % proof stress.

Table A 3-2: Characteristic values of the mechanical and technological characteristics in the room-temperature tensile test

Tensile strength Rm 0.2 % proof stress Rp0.2 Elongation at fracture A

Test
N/mm2 N/mm2 %
Steel grade temperature
at least
°C at least at least (longitudinal or transverse)
for heat-treatment wall thicknesses in mm
 70 > 70  70 > 70
 130  130
100 420 400 285 260
15 MnNi 6 3 145 415 375 275 240
200 400 375 245 220
250 400 375 220 200
300 400 375 210 190
350 390 375 190 170
for heat-treatment wall thicknesses in mm
15 > 100  15 > 100
 100  200  100  200
100 530 530 412 370
20 MnMoNi 5 5 200 513 510 392 360 16
300 513 510 371 350
350 513 510 363 343
375 505 505 358 330
400 500 500 353 320
for heat-treatment wall thicknesses in mm
 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 88

Impact energy in J Lateral expansion in mm

Nominal wall Nature at the temperature, °C at the temperature. °C
Steel grade thickness s of at least at least
mm value 1) Upper Upper
-20 0 +5 +20 +33 -20 +5 +33
shelf 2) shelf 2)
MW 80 110 130 130 130 130
15 MnNi 6 3  130
EW 68 90 100 100 100 100 0,9 1,3 1,3 1,3
MW 41 4)
20 MnMoNi 5 5  200
EW 34 4) 68 3) 100 0,9 1,3
MW 60 80 95
15 NiCuMoNb 5 S  60
EW 42 56 66 68 3) 100 0,9 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 tempera-
ture.
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.

Table A 3-4: Characteristic values of impact energy and lateral expansion in the notched-bar impact bend test on transverse
specimens

Simulated stress-relief annealing

Steel grade Verification necessary
Temperature 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, and per-
formance of the simulated stress-relief annealing process

Temperature range for quenching and tempering

Steel grade Normalization
Austenitization Tempering Stress-relief annealing 3)
°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

900 to 980 1) 640 to 680 580 to 620

15 NiCuMoNb 5 S
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 main-
tain the minimum temperature of 640 °C for tempering.

Table A 3-6: Data for heat treatment

 KTA 3211.1 Page 89

Nominal Thermal cutting Welding 1) Limit wall

wall thick- Preheating tem- Preheating temperature Holding temperature 2) Cooling thickness for
ness s perature TV TV and interpass tem- time waiving
Steel grade TH stress-relief
perature TZ t8/5
mm annealing
seconds after welding
mm
s  15 Room temp.  TV Room temp.  T  150 °C Room temp.  TH

15 < s  30 Room temp.  TV 80 °C  T  180 °C Room temp.  TH

15 MnNi 6 3 8 to 25 38 5)
30 < s  50 100 °C  TV 100 °C  T  220 °C 3) 100 °C  TH

s > 50 120 °C  TV 120 °C  T  220 °C 3) 120 °C  TH

150 °C  TH  250 °C 4)
20 MnMoNi 5 5 s  15 150 °C  TV  250 °C 150 °C  T  250 °C 3) 7 to 25
120 °C  TH  180 °C 6)
Stress-relief
s  15 Room temp.  TV 80  T  150 °C Room temp.  TH annealing
15 < s  30 Room temp.  TV 100 °C  T  180 °C 100 °C  TH shall always
15 NiCuMoNb 5 S 10 to 30 be required
30 < s  50 100 °C  TV 120 °C  T  220 °C 3) 120 °C  TH

s > 50 120 °C  TV 120 °C  T  220 °C 3) 120 °C  TH

1) 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.
2) See DIN EN ISO 13916 for definition.
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 thick-
ness to  50 mm, unless special requirements of heat-treatment condition are imposed.
6) For weld cladding.

Table A 3-7: Particulars of thermal cutting and welding, together with limit wall thicknesses for stress-relief annealing

A 4 Castings for cases and bodies of ferritic cast steel of A 4.3.2 Mechanical and technological characteristics
material group W I
(1) The characteristic values of the mechanical and techno-
A 4.1 General logical characteristics in the room-temperature tensile test,
including the minimum values of elongation at fracture, are
Section A 4 defines the details for manufacture, chemical stipulated in Table A 4-2.
composition, characterizing mechanical and technological
characteristics and heat treatment as well as for further pro- (2) The characteristic values of the mechanical and techno-
cessing of the following cast-steel grade logical characteristics at elevated temperatures are stipulated
in Table A 4-3. Verification shall be required only if the design
GS-C 25 S temperature is higher than 100 °C for cast-steel grade GS-C
for cases and bodies. 25 S, unless otherwise stipulated in the authorized inspector's
Note: appraisal.
The following stipulations are provisional, since the supplementary (3) The characteristic values of impact energy are stipulated
appraisal of cast-steel grade GS-C 25 S with regard to meeting in Table A 4-4.
the requirements beyond those for cast-steel grade GP240GH
(material number 1.0619) to DIN 10213 have not yet been com- (4) The data for impact energy shall apply to standard spec-
pleted and an individual appraisal is required. imens with a specimen width of 10 mm.
(5) The mechanical and technological characteristics shall
A 4.2 Manufacture of the steels be verified as per Table A 4-6.
The steels shall be smelted by the basic oxygen process or in
the electric furnace. If other processes are used, proof of A 4.3.3 Physical characteristics
equivalence shall be furnished. Reference values for the physical characteristics can be found
in Annex AP.
A 4.3 Material characteristic values
A 4.3.1 Chemical composition A 4.4 Data on heat treatment
The values stipulated in Table A 4-1 shall apply to the chemi- Reference values for heat treatment are presented in Ta-
cal composition per the ladle and product analysis. ble A 4-5.
 KTA 3211.1 Page 90
Verification Content by mass, %
Steel grade Limit value
by C Si Mn P S Altotal N As Cr Cu Mo Ni Sn V

Ladle min. 0.18 0.30 0.50   0.020        

analysis max. 0.22 0.60 1.10 0.015 0.010 0.070 0.015  0.30 0.18    0.02
GS-C 25 S
Product min. 0.18 0.30 0.50   0.020        
analysis max. 0.22 0.60 1.10 0.015 0.012 0.070 0.015  0.30 0.18    0.02

Table A 4-1: Chemical composition per the ladle and product analyses

Nominal thickness in mm 0.2 %-proof stress Rp0.2, N/mm2 Tensile strength Rm, N/mm2 Elongation at fracture A, %
Steel grade
maximum at least at least
GS-C 25 S 100 245 440 up to 590 22

Table A 4-2: Characteristic values of the mechanical and technological characteristics in the room-temperature tensile test

0.2 %-proof stress 1) Rp0.2, N/mm2 Tensile strength 1) Rm, N/mm2 Elongation at fracture 1) A, %
Steel grade at least at least at least
at temperature, °C at temperature, °C at temperature, °C
100 200 250 300 350 400 100 200 250 300 350 400 100 200 250 300 350 400
GS-C 25 (205) 175 (160) 145 135 130 (410) (400) (400) (390) (375) (355) (21) (20) (19) (18) (20) (25)
1) The values in parentheses must still be substantiated by statistics.

Table A 4-3: Characteristic values of the mechanical and technological characteristics in the elevated-temperature tensile test

Impact energy in J Upper shelf 2) of the impact energy

at least in J
Stahlsorte at least
at 0 °C at 33 °C 1)
Mean value of 3 specimens Individual value Mean value of 3 specimens Individual value
GS-C 25 S 41 34 68 100
1) If agreed in the purchase order, this requirement shall also apply at lower temperature, but not below + 5 °C.

2) The test is generally performed at 80 °C.

Table A 4-4: Characteristic values of impact energy

 KTA 3211.1 Page 91

Quenching and tempering Preheating Stress-relief annealing 3)

Steel grade Hardening Tempering
°C °C °C °C
GS-C 25 S 900 to 940 1) 650 to 700 100 to 250 2) 580 to 620
1) Quenching in oil or water.
2) Preheating may be waived if adequate experience is available.
3) 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 annealing

Steel grade Verification necessary
Temperature Holding time
°C minutes
GS-C 25 S yes 600 to 620 900

Table A 4-6: Necessity for verification of mechanical and technological characteristics in the simulated stress-relief-annealed
condition, and performance of the simulated stress-relief annealing process

A 5 High-tensile steels for quenching and tempering for sents the allowable deviations of chemical composition per the
bolts and nuts product analysis from the limit values of chemical composition
per the ladle analysis.
A 5.1 General
Section A 5 defines the details for manufacture, chemical
composition, characterizing mechanical and technological A 5.3.2 Mechanical and technological characteristics
characteristics and heat treatment as well as for further pro- (1) The mechanical and technological characteristics shall
cessing of high-tensile steels for quenching and tempering for apply to the delivery condition. The values shall be verified on
bolts and nuts. These stipulations shall apply not only to rolled longitudinal specimens from the sampling locations as per
or forged bars but also to the bolts and nuts made from the Section 8.
bars.
(2) The characteristic values of the mechanical and techno-
A 5.2 Manufacture of the steels and delivery condition logical characteristics in the room-temperature tensile test,
including the minimum values of reduction of area at fracture,
A 5.2.1 Manufacture are stipulated in Table A 5-3.
Note:
The steels shall be high-tensile steels for quenching and temper- (3) The characteristic values of the mechanical and techno-
ing with stipulated minimum values of elevated-temperature logical characteristics in the elevated-temperature tensile test
strength characteristics. are stipulated in Table A 5-4.
(1) The steels shall be smelted by the basic oxygen process (4) The characteristic values of impact energy and lateral
or in the electric furnace. If other processes are used, proof of expansion are stipulated in Table A 5-5.
equivalence shall be furnished. Steel grades 26 NiCrMo 14 6
and 34 CrNiMo 6 S shall be subjected to metallurgical ladle
post-treatment or remelted in vacuum or by the electroslag A 5.3.3 Physical characteristics
refining process.
Reference values for the physical characteristics can be found
(2) The steels shall be made in particularly killed condition. in Annex AP.

A 5.2.2 Delivery condition A 5.4 Data on heat treatment

The steels shall be delivered in the quenched and tempered Data for heat treatment are presented in Table A 5-6.
condition or in the quenched and tempered plus stress-relief-
annealed condition.
A 5.5 Further processing
A 5.3 Material characteristic values Only machining is permitted.
A 5.3.1 Chemical composition Note:
The values stipulated in Table A 5-1 shall apply to the chemi- No provisions shall be made for hot or cold forming (thread rolling
cal composition per the ladle analysis. Table A 5-2 pre- shall not qualify as cold forming).
KTA 3211.1 Page 92

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  0.020

20 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  0.020
26 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

Element Allowable limit deviation 1) of values per the product analysis

Content by mass, %
C ± 0.02
Si ± 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 + 0.02
1) 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 are
either 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 analysis
shall be allowable.

Table A 5-2: Allowable deviations of chemical composition per the product analysis from the limit values of chemical composi-
tion per the ladle analysis

Diameter 0.2% proof stress Tensile strength Elongation at frac- Reduction of area
Steel grade (bars) Rp0.2, N/mm2 Rm ture A, % at fracture Z, %
mm at least N/mm2 at least at least
20 NiCrMo 14 5 (I) 940 1040 to 1240 14 55
20 NiCrMo 14 5 (II) 980 1080 to 1280 14 55
 130
26 NiCrMo 14 6 940 1040 to 1240 14 50
34 CrNiMo 6 S 830 930 to 1130 16 45

Table A 5-3: Characteristic values of the mechanical and technological characteristics in the room-temperature tensile test

0.2% proof stress Tensile strength Elongation at frac- Reduction of area

Diameter
Rp0.2, N/mm2 Rm, N/mm2 ture A, % at fracture Z, %
Steel grade (bars) at at
at at
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
 130
26 NiCrMo 14 6 790 785 860 820 14 14 45 45
34 CrNiMo 6 S 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
 KTA 3211.1 Page 93

Diameter Impact energy Lateral expansion

Steel grade (bars) J mm
mm Mean value Individual value Individual value
20 NiCrMo 14 5 (I) 76
20 NiCrMo 14 5 (II) 76
 130 61 0.65
26 NiCrMo 14 6 72
34 CrNiMo 6 S 76

Table A 5-5: Characteristic values of impact energy and lateral expansion on longitudinal specimens at 20 °C

Temperature range, °C Temperature range, °C for

Steel grade for austenitization Cooling fluid Tempering Stress-relief annealing
20 NiCrMo 14 5 (I) 840 to 900 520 to 600 430 to 470
20 NiCrMo 14 5 (II) 800 to 900 500 to 580 430 to 470
Water or oil
26 NiCrMo 14 6 840 to 870 530 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

A 6 Bars for bolts and nuts; additional stipulations A 6.3 Notched-bar impact bend test
A 6.1 General Table A 6-1 presents the values of impact energy and lateral
Section A 6 shall apply additionally for the steel grades listed expansion to be verified in the notched-bar impact bend test
in Table A 6-1 when used for bolts and nuts within the scope at 20 °C with longitudinal specimens, taking the stipulations
of validity of this safety standard. of section 8.3 into consideration.
(2) The stipulations shall apply to rolled or forged bars and
to the bolts and nuts made from it.
A 6.4 Elevated-temperature tensile test

A 6.2 Dimensional limits Table A 6-1 also presents the values of tensile strength at
elevated temperatures.
The steel grades listed in Table A 6-1 may be used up to the
dimensional limits indicated therein.

Impact energy in J Lateral Tensile strength

(longitudinal specimens) expansion Rm, N/mm2
Steel grade
mm at least
Abbreviated name Heat- Requirements Diameter at the temperature
treatment in addition to mm at room temperature of
condition Mean value, Individual Individual 300 ° C 350 ° C
at least value, value,
at least at least
C35E +QT  60 55 39 0.60 400 390
25CrMo4 +QT  100 60 42 0.60 460 440
DIN EN 10269
21CrMoV5-7 +QT  100 63 52 0.60 590 560

X22CrMoV12-1 +QT1  60 52 36  620 600

VdTÜV material
X 8 CrNiMoBNb 16 -16 + wk + wk  80 52 36  530 505
sheet 113/2

Table A 6-1: Limits of permissible dimensions and additional stipulations for steels for bolts and nuts
KTA 3211.1 Page 94

A 7 Castings of the martensitic steel G-X4 CrNi 13 4 A 7.3 Mechanical and technological characteristics
(1.4317); additional stipulations
In test group A 1 deviating from the values given in VdTÜV
A 7.1 General material sheet 452 the minimum requirements for the impact
Section A 7 shall apply in addition to the requirements of energy to be verified in the notched-bar impact bend test
VdTÜV material sheet 452 when castings of the martensitic specified in Table A 7-2 shall apply, however only one individ-
steel G-X4 CrNi 13 4 (1.4317) are within the scope of validity ual value of the specimen set below the specified mean value
of this safety standard. shall be permitted.

A 7.2 Chemical composition Mean value of Smallest

(1) Deviating from the values given in VdTÜV material sheet Test area three specimens individual value
452 the restricted values specified in Table A 7-1 shall apply J J
to the ladle and product analyses. Base metal,
70 50
(2) In the case of operating temperatures exceeding 300 °C Heat-affected zone 1)
during continuous operation, the ratio chrom equivalent to
nickel equivalent shall be set less than 2.0. Weld metal 1)
(quenched and tem- 70 50
Cr equivalent = % Cr + % Mo + 1.5  % Si pered)
Ni equivalent = % Cr + % Mo + 1.5  % Si Weld metal 1)
(tempered/stress relief 50 35
Ladle analysis Product analysis heat treated)
Element
max. weight-% max. weight-%
1) Proof has to be provided in the course of welding procedure quali-
P 0.020 0.025 fications or production control tests.
S 0.015 0.020
Table A 7-2: Impact energy at room temperature verified in
Table A 7-1: Restricted values for the chemical composition the notched-bar impact bend test (minimum
as compared to the VdTÜV material sheet 452 requirements) for castings in test group A 1

Annex AP
Reference data on physical characteristics

AP 1 Scope of application AP 2.2 Determination of characteristic values

This Annex contains reference data on At present a standardized method has not been defined for
determination of the characteristic values presented here for
a) specific density, physical characteristics.
b) dynamic modulus of elasticity,
AP 2.3 Scatter band of characteristic values
c) mean coefficient of linear thermal expansion,
(1) Changes in chemical composition and heat treatment
d) mean specific heat capacity and lead to a certain scatter band of physical characteristics. Any
grain orientation has a particularly strong influence on the
e) thermal conductivity
values of modulus of elasticity.
for the steel grades cited in Sections A 1 through A 5. (2) Differences between the measurement methods em-
ployed may lead to additional scattering.
AP 2 Characteristic values (3) The documents available at present are not adequate for
statistical evaluation of reliability.
AP 2.1 General
(4) The statements on the scatter band of characteristic
The characteristic values listed in Table AP-1 for physical values in footnotes 1 to 5 of Table AP-1 were taken from the
characteristicfs are reference data compiled on the basis of literature. They relate to the average scatter band of the
measurements on individual heats and of literature data [3]. measured values acquired there.
 Specific Dynamic modulus of elasticity 2) Mean coefficient of linear thermal Mean specific Thermal conductivity 5)
density 1) 103 N/mm2 expansion 3) heat capacity 4) W m-1 K-1
106 g/m3 10-6 K-1 in J g-1 K-1
Steel grade at temperature in °C between 20 °C and between 20 °C and at the temperature in °C
the temperature in °C the temperature in °C
at 20 ° C 20 100 200 300 350 400 100 200 300 350 400 100 200 300 350 400 20 100 200 300 350 400

15 MnNi 6 3 7.85 211 206 198 191 187 12.4 12.9 13.3 13.6 42 43 42 41 40

15 NiCuMoNb 5 S 7.84 210 206 199 191 183 12.4 13.0 13.6 14.1 44 44 43 42 40

20 MnMoNi 5 5 7.86 211 206 199 192 184 12.7 13.2 13.6 14.0 44 44 43 41 39

20 NiMoCr 14 5 7.84 205 200 191 182 11.2 11.6 12.1 12.2 29 30 31 31 31

26 NiMoCr 14 6 7.84 205 200 191 182 11.2 11.6 12.1 12.2 29 30 31 31 31

34 CrNiMo 6 S 7.84 205 200 191 182 12.5 13.2 13.7 14.2 34 36 37 37 36
0.46 0.49 0.51 0.52 0.53
C 22.8 S 7.80 212 205 200 192 183 12.5 13.1 13.6 14.0 43 43 42 41 39

GS-C 25 S 7.83 211 204 196 186 177 12.2 12.9 13.4 13.9 43 43 42 41 39

WStE 255 S 7.85 212 207 200 192 184 12.3 12.8 13.3 13.8 42 43 43 42 40

WStE 285 S 7.85 212 207 200 192 184 12.3 12.8 13.3 13.8 42 43 43 42 40

WStE 315 S 7.84 212 207 200 192 184 12.3 12.8 13.3 13.8 42 43 43 42 40

WStE 355 S 7.83 212 207 200 192 184 12.3 12.8 13.3 13.8 42 43 43 42 40

1) Average bandwidth of dispersion of measured values ± 0.05  106 g/m3.

2) Average bandwidth of dispersion of measured values ± 5  103 N/mm2.

3) Average bandwidth of dispersion of measured values ± 0.8  10-6 K-1.

4) Average bandwidth of dispersion of measured values ± 0.01 J g-1 K-1.

5) Average bandwidth of dispersion of measured values ± 3.5 W m-1 K-1 for ferritic steels, ± 1.5 W m-1 K-1 for austenitic steels.

KTA 3211.1 Page 95

Table AP-1: Reference data on specific density, dynamic modulus of elasticity and mean coefficient of linear thermal expansion of the steel grades as per Sections A 1 through A 5
KTA 3211.1 Page 96

Annex B

Production welds of steel castings

B 1 General (3) Production welds shall be heat-treated as per Figure 5.7-1.

This Annex shall apply in addition to the stipulations of DIN EN (4) Correlation of the castings with the heat-treatment lot
1559-2 and DIN EN ISO 11970 for production welds on steel shall be ensured.
castings.
Note:
Production welds shall be employed only if the defect cannot be B 5 Welding procedure qualifications
repaired in another way without reducing the thickness below the
nominal value.
(1) For all materials to be welded and for all welding meth-
ods, a welding procedure qualification as per DIN EN ISO
11970 and per the following stipulations shall be performed
before the start of production welding for each planned heat
B 2 Prerequisites
treatment, welding position and wall thickness.
(1) The general requirements per Section 3 shall be met. (2) The welding procedure qualification for a particular steel
(2) Production welds as well as their examination and doc- shall also be applicable for other steels within the limits set in
umentation shall be classified as per the production scheme of KTA 3211.3.
Figure 5.7-1 in the process of casting manufacture. The indi- (3) The duration of validity of a welding procedure qualifica-
vidual production steps shall be completed in the described tion shall be 24 months after successful completion of the
sequence. In the event of deviations from the standard pro- welding procedure qualification. This period shall begin with
duction sequence, a design approval of the sequence of pro- the date of the written opinion of the authorized inspector. If
duction steps shall be required. A distinction shall be made production is started within these 24 months and production
between Procedure 1 (production welding with subsequent control tests to Section C 6 have been performed, the initial
quenching and tempering or solution annealing and quench- period shall be extended by a further 24 months, counting
ing) on the one hand, and Procedure 2 (production welding from the start of validity of the production control test.
without subsequent quenching and tempering or solution an-
nealing and quenching) on the other hand. (4) If production is not started within 24 months after suc-
cessful completion of the welding procedure qualification or is
(3) If the castings are not quenched and tempered or solu- interrupted for longer than 24 months, the first production
tion-annealed and quenched after production welding, for control test prior to starting or resuming production shall be
example, because of the machining condition, the authorized treated as a repeat of the welding procedure qualification. The
inspector's consent regarding production welding shall be stipulations of the original welding procedure qualification shall
obtained if required in Section 11.8. In this case the production govern the scope of this production control test, with regard to
welds shall be documented as per Figure 5.7-1. both the start of validity and the duration of validity.
(4) Each area prepared for welding shall be assumed to be a (5) Before the welding procedure qualification is performed,
“relatively large production weld” if its depth exceeds 40 % of a welding procedure sheet and, if necessary, a heat-treatment
the wall thickness or the following values: plan shall be submitted to the authorized inspector.
a) for welding ends and cast bodies: 25 mm,
(6) It shall not be necessary to use for the welding procedure
b) for adjoining zones: 40 mm. qualification the same heats of base metal or the same batch-
(5) For relatively large production welds that will subse- es of weld filler metals and welding consumables as are used
quently be quenched and tempered or solution-annealed and for welding of parts.
quenched, the authorized inspector shall be given adequate (7) The welding shall be performed under constraint condi-
advance notification of the welding work. Suspension of the tions.
production sequence is not required.
(8) Welding records of welding procedure qualifications shall
(6) For small production welds that will subsequently be be kept. Blank forms per KTA 3211.3 or sheets with identical
quenched and tempered or solution-annealed and quenched, information content shall be used for this purpose.
it is not required to notify the authorized inspector.
(9) The scope of the welding procedure qualification as per
DIN EN ISO 11970 is stipulated in Table B-1. Table B-2 addi-
tionally contains stipulations on the technological bend test.
B 3 Weld filler metals and welding consumables
(10) Welding procedure qualifications that are still valid but
The weld filler metals and welding consumables shall meet the are not fully in conformity with the stipulations of Table B-1
requirements of KTA 1408.1, KTA 1408.2 and KTA 1408.3 regarding the scope of testing may be added to by supple-
Section 3. mentary tests in a preliminary production control test.

B 4 Heat supply during welding and post-weld heat B 6 Production control tests
treatment
(1) Depending on scope of validity of the welding procedure
(1) The appropriately defined preheating temperature shall qualification, the manufacturer shall be required to perform
be met for welding as well as for all cutting and joining work. one production control test per year during production in the
presence of the authorized inspector. KTA 3211.3 Section 5
(2) The welding conditions and welding parameters for ferrit- shall apply in addition to the stipulations of this section.
ic and martensitic cast-steel grades shall be selected such
that the lowest possible hardness values are achieved for the (2) Production control tests on a steel of material group W I
particular material. Work specimens shall be taken to verify shall also cover production control tests on the same steel for
that hardness values of 350 HV 10 are not exceeded. use in material group W II.
 KTA 3211.1 Page 97

(3) The test coupons for production control tests shall be eller pieces subjected to the same heat treatment as the cast-
taken from one of the heats involved. ing.
(4) The weld filler metals and welding consumables shall be (8) The extent of examination and requirements are stipulat-
taken from one of the manufacturing lots involved. ed in Table B-3.
(5) The test coupons shall be welded by welders who partic-
ipate in production. B 7 Documentation
(6) Production control tests shall be performed as full-
The documentation of welding procedure qualification and
penetration welds. They shall cover all partial penetration
production control tests, including the associated design ap-
weldings.
proval documents, shall be organized per the stipulations set
(7) The test pieces shall be subjected to simulated heat forth for welding procedure qualification in DIN EN ISO 11970,
treatment jointly with the authorized inspector or shall be trav- and shall be attached to the inspection certificate.

Type of examination Number of specimens, specimen location, requirements

100 % surface inspection
Non-destructive tests and examina-
100 % volumetric testing, test procedure and requirements as per the stipulations of
tions
Section 11.8.
a) Base metal (DIN EN ISO 6892-1)
1 specimen (DIN 50125) at room temperature
Requirements to Sections 5.7, 6.7, 7.7 or 9.2
b) Welded joint (DIN EN ISO 4136)
2 specimens (DIN EN ISO 4136, Figure 2a or 2b, parallel length Lc = weld width
Tensile test + at least 60 mm) at room temperature.
(DIN EN ISO 4136 and Rm and fracture location shall be tested (tensile-strength requirement as for the base
DIN EN ISO 6892-1)
metal).
c) All-weld metal (DIN EN ISO 6892-1)
1 specimen (DIN 50125, L0 = 5  d0) at room temperature.
Requirements for Rp0.2, Rm, A, Z, as well as Rp1.0 for austenite, stipulated as for the
weldability test.
Ferritic steels of material group W I
One 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 B-1.
See clause 4.3.1 for requirements. If the temperature at which 68 J (smallest individual
value) and 0.9 mm lateral expansion (smallest individual value) is reached lies between
0 °C and 33 °C, the exact value of this temperature may be determined by interpolation
and used as the lowest permissible loading temperature.
The ductile fracture percentage of the fractured area shall be determined.
Ferritic steels of material group W II
One specimen set of base metal at 0 °C (20 °C permissible if the lowest loading tem-
perature exceeds 20 °C and the weld metal as well as the heat affected zone are tested
at 20 °C).
Notched-bar impact bend test One specimen set each of weld metal and heat-affected zone at 0 °C (20 °C permis-
(DIN EN ISO 148-1) sible if the lowest loading temperature exceeds 20 °C).
Specimen location as per Figure B-1.
See clause 4.3.2 for requirements.
The ductile fracture percentage of the fractured area shall be determined.
Austenitic steels
One specimen set each of weld metal at room temperature.
Specimen location as per Figure B-1.
See clause 4.3.3 for requirements.
Martensitic steels
One specimen set of base metal at room temperature. Requirements as per Sections
5.7 or 9.2.
One specimen set each of weld metal and heat-affected zone at room temperature.
Specimen location as per Figure B-1.
Requirements as for the base metal.
Technological bend test One specimen each with root and cover pass on the tension side; see Table B-2 for
(DIN EN ISO 5173) bending-mandrel diameter and requirements.
Weld metal
Chemical composition Not required for unalloyed steels.
Elements to be verified per weldability test of the weld filler metals.

Table B-1: Extent of examination and stipulations for procedure qualification for production welds on steel castings
(continued on next page)
KTA 3211.1 Page 98

Type of examination Number of specimens, specimen location, requirements

a) Macrograph
To be evaluated: Weld buildup, penetration, slag, pores.
Requirements: Satisfactory weld buildup, satisfactory penetration;
isolated slag inclusions and pores are permitted.
Metallographic examinations with
photographic documentation 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 and as per DIN EN ISO 11970
DIN EN ISO 6507-4)
Verification of intergranular corro- Austenitic steels
sion resistance Specimen location: root side without additional sensitization.
(DIN EN ISO 3651-2) Requirement: freedom from cracks.

Table B-1: Extent of examination and stipulations for welding procedure qualification for production welds on steel castings
(continued)

Steel group Tensile strength Bending mandrel Bend angle Allowable deviation
Rm in N/mm2 diameter in degrees

Rm < 430 2  specimen Cracks shall not be longer than 1.6 mm.
180
thickness a Bursting open due to pores or lack of fusion
Ferritic and are permitted.
2.5  specimen
martensitic 430  Rm < 460 180
thickness a
steels
3  specimen As for ferritic and martensitic steels with
Rm  460 180
thickness a Rm < 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) shall
reach the minimum value of elongation at
Austenitic 3  specimen fracture A of the base metal.
180
steels thickness a - If the specimen breaks at a bend angle
< 90°, the elongation over the weld width
shall reach at least 30 %. The fracture
surface appearance shall be free of de-
fects.

Table B-2: Bending-mandrel diameter for the technological bend test to DIN EN ISO 5173 in connection with welding proce-
dure qualification for production welds on cast steel

a) Specimen location in the c) Specimen location in the

weld metal HAZ or transition

0.5 ±0.3
0.5 ±0.3

b) Specimen location in the d) only if b) is not feasible

HAZ or transition

Figure B-1: Location of the notch in notched-bar impact bend-test specimens

 KTA 3211.1 Page 99

Type of examination Number of specimens, specimen location, requirements

100 % surface inspection

Non-destructive tests
100% volumetric testing, test procedure and requirements as per the stipulations for the base metal
and examinations
(see Section 11.8.
a) Welded joint (DIN EN ISO 4136)
2 specimens (DIN EN ISO 4136, Figure 2a or 2b, parallel length Lc = weld width + at least
Tensile test
60 mm) at room temperature.
(DIN EN ISO 4136,
DIN EN ISO 6892-1 Rm and fracture location shall be tested (tensile-strength requirement as for the base metal).
and
b) All-weld metal (DIN EN ISO 6892-1 and DIN EN ISO 6892-2)
DIN EN ISO 6892-2)
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 weldability
test.
Ferritic steels of material group W I
One specimen set each of weld metal and heat-affected zone at 0 °C and at the lowest loading tem-
perature or at 33 °C, if correlation with a particular component is not possible.
Specimen location per Figure B-1.
See clause 4.3.1 for requirements. If the temperature at which 68 J (smallest individual value) and
0.9 mm lateral expansion (smallest individual value) is reached lies between 0 °C and 33 °C, the ex-
act value of this temperature may be determined by interpolation and used as the lowest permissible
loading temperature.
If the requirement for minimum values of impact energy and lateral expansion at the lowest operat-
ing 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.
Notched-bar impact Ferritic steels of material group W II
bend test
One specimen set each of weld metal and heat-affected zone at 0 °C or at 20 °C, if the lowest load-
(DIN EN ISO 148-1)
on Charpy-V speci- ing temperature exceeds 20 °C.
mens Specimen location as per Figure B-1.
See clause 4.3.2 for requirements.
The ductile fracture percentage of the fractured area shall be determined.
Austenitic steels
One specimen set each of weld metal and heat-affected zone at room temperature.
Specimen location as per Figure B-1.
See clause 4.3.3 for requirements.
Martensitic steels
One specimen set each of weld metal and heat-affected zone at room temperature.
Specimen location as per Figure B-1.
Requirements as for the base metal.
a) Macrograph
To be evaluated: Weld buildup, penetration, slag, pores.
Requirements: Satisfactory weld buildup, satisfactory penetration;
Metallographic exam- isolated slag inclusions and pores are permitted.
inations with photo-
graphic documenta- b) Micrograph, magnification at least 100 : 1 (not required for unalloyed steels).
tion 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.
Ferritic steels
HV 10 hardness test One hardness profile through base metal, heat-affected zone and weld metal, as close as possible
(DIN EN ISO 6507-1) under the surface.
Requirement: 350 HV 10 shall not be exceeded.
Verification of inter- Austenitic steels
granular corrosion Specimen location: root side without additional sensitization.
resistance Requirement: freedom from cracks.
(DIN EN ISO 3651-2)

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) or
higher than 300 °C (test group A 3). In these cases, the elevated-temperature tensile test shall be performed at 350 °C for ferritic steels, at
400 °C for austenitic steels and at 320 °C for martensitic steels.

Table B-3: Extent of examination and stipulations for production control tests for production welds on steel castings
KTA 3211.1 Page 100

Annex C

Procedure for determining the delta ferrite content

C 1 General (7) With regard to the quantitative evaluation it is recom-

mended to compare the micrograph with a corresponding
This annex specifies details for the procedures required for the
delta ferrite reference sheet [5] and classify it accordingly.
determination of the products' delta ferrite content under
Alternatively, the procedure of a quantitative microstructure
clause 4.4.6.9 (1).
analysis may be employed.

C 2 Metallographic determination on castings in the (8) The test report shall state:
as-delivered condition a) the shape, size and direction of the test specimen as well
as the sampling location,
(1) A test specimen shall be taken from the product at the
specified sampling location, be ground and polished in the b) the actual values of the welding parameters,
usual way and etched in accordance with Murakami [4]. The c) the delta ferrite content in %.
etched surface shall have an area of at least 10 mm by
10 mm. A micrograph with a specification of its location shall be added
to the test report.
(2) The evaluation shall be performed at a magnification of
100:1.
C 4 Metallographic determination for weld material (dur-
(3) A representative location of the etched surface shall be ing the procedure qualification and production con-
documented as photograph at a magnification of 100:1. trol test for production weldings on castings)
(4) With regard to the quantitative evaluation it is recom- (1) A slice through the entire cross-section shall be taken
mended to compare the micrograph with a corresponding from the weld. For the metallographic examination, the slice
delta ferrite reference sheet and classify it accordingly. Alter-
shall be ground and polished for on one side in the usual way,
natively, the procedure of a quantitative microstructure analy-
as well as etched in accordance with Murakami [4].
sis may be employed.
(2) An overall photograph shall be taken of the entire weld
(5) The test report shall state:
cross section.
a) the shape, size and direction of the test specimen as well
as the sampling location, (3) The evaluation shall be performed at a magnification of
b) the heat treatment condition, 1000:1.
c) the delta ferrite content in %. (4) With regard to the quantitative evaluation it is recommen-
ded to compare the micrograph with a corresponding delta
A micrograph shall be contained in the test report.
ferrite reference sheet [5] and classify it accordingly. Alterna-
tively, the procedure of a quantitative microstructure analysis
C 3 Metallographic analysis of the bead-on-plate test may be employed.
specimen
(5) Micrographs at a magnification of 1000:1 shall be made
(1) A test specimen of the following size shall be taken from of at least three zones representative of the delta ferrite con-
the product form at the specified sampling location: tent.
length 200 mm, thickness 25 mm up to 30 mm, width 40 mm.
(6) The test report shall state:
(2) A melt run with a length of at least 180 mm shall be de- a) the sampling location,
posited on the test specimen with a TIG burner without weld
filler metals, using the following weld parameters (guidance b) the heat treatment condition,
values): c) the delta ferrite content in %.
voltage about 20 V,
(7) The overall photograph as per (2) and the micrographs
current about 160 A, as per (5) shall be attached to the test report. The location of
feed rate about 20 cm/min. the zones as per (5) shall be marked in the overall photo-
graph.
(3) In the case of product forms that do not allow taking of
test specimens with a size as specified under (1) and where
the weld parameters as specified under (2) cannot be applied, C 5 Mathematical estimation according to De Long
the specimen shape and heat input shall be adjusted as close- Note:
ly as possible to the welding to be performed later on the Figure C-1 in accordance with De Long [4] is used for the mathe-
product. matical estimation of the delta ferrite content. In this graph the del-
ta ferrite content is shown in relation to the chemical composition,
(4) A disc shall be taken from the middle of the melt run however, not in terms of its volumetric ratio but rather on the basis
perpendicular to the surface of the test specimen and to the of a special calibration (cf. DIN EN ISO 8249), in terms of the
weld run axis; one side of this cross-section shall be ground characteristic "ferrite number (FN)". In the range of small ferrite
and polished in the usual way and etched in accordance with numbers up to FN 7, the ferrite number is identical to the delta fer-
Murakami [4]. rite content in %.

(5) The evaluation shall be performed at a magnification of (1) The nickel equivalent NiE shall be calculated from the
1000:1. chemical composition of the base metal (content by mass)
(6) A representative location of the surface-deposited weld according to the equation
zone on the etched surface shall be documented as photo-
graph at a magnification of 1000:1. NiE = % Ni + 30  (% C + % N) + 0.5  % Mn (C 5-1)
 KTA 3211.1 Page 101

and the chrome equivalent CrE according to the equation

20

Fe
rri
CrE = % Cr + % Mo + 1.5  % Si + 0.5  % Nb

te
(C 5-2) Austenite

no
.
18 0
2
4
(2) The calculated values of the nickel equivalent and 6

Nickel equivalent NiE

8 0
chrome equivalent are the coordinates of a point in Figure 16 1 2
1 4
1 6
C-1. The corresponding ferrite number is read from the graph. 1 8
1
Sc
Where required, the values can be interpolated between the 14 Aus häffl
e
M a e n i te r
t
straight lines of constant ferrite numbers. rten and
site
12
(3) The documentation of the mathematical estimation shall Austenite and Ferrite
contain the following: 10
16 17 18 19 20 21 22 23 24 25 26 27
a) the chemical composition of the base metal,
b) the value of the nickel equivalent, Chrome equivalent CrE

c) the value of the chrome equivalent, Figure C-1: Relationship between chemical composition and
ferrite numbers of molten base metal or weld
d) the delta ferrite content in terms of the ferrite number. material (according to W.T. De Long [4])
KTA 3211.1 Page 102

Annex D

Performance of manual ultrasonic testing

D1 General requirements ............................................................................................................................. 103

D2 Definitions, symbols, formulae ................................................................................................................ 103
D 2.1 Definitions ............................................................................................................................................... 103
D 2.2 Symbols .................................................................................................................................................. 103
D 2.3 Formulae ................................................................................................................................................ 103
D3 Requirements to be met by the test object .............................................................................................. 104
D4 Requirements to be met by the testing system ....................................................................................... 104
D 4.1 Test equipment ....................................................................................................................................... 104
D 4.2 Calibration blocks, reference blocks and reference reflectors ................................................................. 105
D5 Optimization of the testing technique for ultrasonic testing of austenitic steels or nickel alloys ............... 106
D6 Adjustment of test system ....................................................................................................................... 106
D 6.1 Range adjustment ................................................................................................................................... 106
D 6.2 Adjustment of the testing level when applying the DGS method ............................................................. 106
D 6.3 Adjustment of the testing level for the reference block method and DAC method ................................... 107
D 6.4 Corrections of testing level adjustment ................................................................................................... 108
D 6.5 Setting of the ultrasonic instrument ......................................................................................................... 108
D7 Creeping wave method ........................................................................................................................... 110
D 7.1 Description of method ............................................................................................................................. 110
D 7.2 Reference block ...................................................................................................................................... 110
D 7.3 Testing level adjustment ......................................................................................................................... 110
D 7.4 Adaptation of probes ............................................................................................................................... 111
D8 Wave conversion method  (secondary creeping wave)............................................................................ 111
D 8.1 Description of method ............................................................................................................................. 111
D 8.2 Probe ...................................................................................................................................................... 111
D 8.3 Range calibration .................................................................................................................................... 112
D 8.4 Testing level adjustment ......................................................................................................................... 112
D 8.5 Corrections during testing level adjustment ............................................................................................ 113
D 8.6 Performance of testing ............................................................................................................................ 113
D9 Wave conversion method II (LLT technique) ........................................................................................... 114
D 9.1 General ................................................................................................................................................... 114
D 9.2 Probes, scanning zones, reference blocks, LLT sensitivity diagrams ...................................................... 114
D 9.3 Range adjustment ................................................................................................................................... 114
D 9.4 Testing level adjustment ......................................................................................................................... 114
D 9.5 Transfer correction.................................................................................................................................. 115
D 9.6 Performance of testing ............................................................................................................................ 115
D 10 Performance of testing ............................................................................................................................ 117
D 10.1 Overlap ................................................................................................................................................... 117
D 10.2 Rate of probe movement ........................................................................................................................ 117
D 10.3 Adjustment and check of the test system ................................................................................................ 117
D 11 Description of indications ........................................................................................................................ 117
D 11.1 Echo amplitude ....................................................................................................................................... 117
D 11.2 Extension of indications .......................................................................................................................... 117
D 11.3 Indications due to geometric discontinuities ............................................................................................ 118
 KTA 3211.1 Page 103

D 1 General requirements Symbol Variable or designation Unit

(1) This Annex covers the performance of manual ultrasonic G Reflector diameter referred to effective 
testing. transducer diameter
(2) In this Annex, stipulations have been laid down for the GK Instrument gain when setting the refe- dB
calibration of ultrasonic equipment for the pulse-echo method rence reflector for reference screen
used in the multiple-echo or through transmission technique height level
and for the description of indications. GT Instrument gain when setting the dB
transmission indication for reference
screen height level
D 2 Definitions, symbols, formulae
GT Arithmetical average of GT values dB
D 2.1 Definitions
GR Instrument gain setting for recording dB
The definitions of DIN EN ISO 5577 apply. level
6 Beam spread angle at 6 dB limit degree
D 2.2 Symbols H Echo amplitude referred to screen 
In this Annex the following symbols are used: height
HE Main echo in testing using wave con- 
Symbol Variable or designation Unit version technique
A Sound path length related to near field  KSR Diameter of disc shaped reflector mm
length in the general DGS diagram  Sound attenuation coefficient (deviating dB/mm
a Projected surface distance mm from DIN EN ISO 5577; sound attenua-
tion referred to sound path length)
a’ Reduced projected surface distance mm
L Probe scanning surface dimension in mm
aLLT Reduced projected surface distance in mm direction of curvature
the case of LLT-technique
LLT „Long-Long-Trans“ wave conversion 
AVG Distance / gain / size  technique
LW Angle of refraction of longitudinal wave degree LW Longitudinal wave 
TW Angle of incidence of transverse wave  Wave length mm
degree
on scanning surface of test object N Near field length mm
C Required width of the reference block mm NE1; NE2 Neighbour echoes in testing using 
cLW Sound velocity of longitudinal wave m/s wave conversion technique
cTW Sound velocity of transverse wave m/s n Number of individually measured 
values
Deff Effective transducer dimension accord- mm p Projected surface distance for indirect mm
ing to probe data sheet scan
DFBB Diameter of the flat bottom hole mm p’ Projected surface distance in testing mm
DKon Diameter of contact surface of a mm using wave conversion technique in the
straight beam probe case of neighbour echo optimization
DKSR Diameter of disc shaped reflector mm p’’ Projected surface distance in testing mm
using wave conversion technique in the
DQ Effective transducer dimension per- mm case of main echo optimization
pendicular to the scanning direction
Ra Arithmetical mean deviation of the as- m
DS-6dB Beam width for 6 dB decrease of sound mm sessed profile (average roughness) Ra
pressure relating to central beam to DIN EN ISO 4287
DS-20dB Beam width for 20 dB decrease of mm RL Recording length mm
sound pressure relating to central beam
RLK Corrected recording length mm
Dz Diameter of side-drilled hole mm
S (with and Sound path length mm
d Curvature diameter of the scanning mm without index)
surface on the test object SEL Transmitter-receiver longitudinal waves 
dref Curvature diameter of opposite surface mm SE Transmitter - receiver 
on the test object
s Wall thickness, nominal wall thickness mm
f Band width (difference between upper MHz
and lower frequency limit) referred to sj Thickness of reference block mm
3 dB amplitude decrease S/N Signal-to-noise ratio is the ratio of the 
SE Distance of points of incidence mm echo amplitude of an ultrasonic signal
from a reflector to the amplitude of the
ES Receiving transducer  noise level (noise level means the 95 %
fN Nominal frequency MHz value of the cumulative frequency of the
heights of the noise signals in the tested
LW Angle of incidence of longitudinal wave degree
volume free from defects)
on reflector
TLL „Trans-Long-Long“ wave conversion 
TW Angle of refraction of transverse wave degree
on reflector TW Transverse wave 
KTA 3211.1 Page 104

Symbol Variable or designation Unit i) Sensitivity correction VZ:

S2
V Gain in the general DGS diagram dB VZ  30  lg (D-10)
YFBB mm S1
Reflector depth position
Ys Distance of scanning zone centre to mm k) Resultant instrument sensitivity for adjustment of recording
scanning surface level:
ZH Depth of scanning zone mm G = G + V + V
R K T (D-11)
V Sensitivity correction dB with
V Sound attenuation correction referred
dB VT = Vkoppl + V (D-12)
to a certain sound path length
l) Zero point displacement at longitudinal wave dual-element
Vkoppl Coupling correction dB probes:
VLLT Echo height difference between refer- dB
S = 1.5  s + a (D-13)
ence level of front face and maximum
of sensitivity curve m) Sound path travel distance to scanning zone centre with
LLT probes:
VS Divergence correction of back reflec-
dB
tion curve SJust  SLW  2  STW (D-14)
V~ Gain correction for considering trans-
dB 2  s  Ys
fer variations with SLW  (D-15)
cos αLW
VT Transfer correction dB Ys
and STW  (D-16)
VZ Gain correction for considering different dB cos αTW
sound path travel distances when
scanning a cylindrical hole or approximated for steel
s  Ys
S Just  2  (D-17)
cos αLW
D 2.3 Formulae
The variables to be calculated shall be determined by means
of the following equations:
D 3 Requirements to be met by the test object
a) Required width of the reference block
C  DS-20dB (D-1) (1) The scanning surfaces of the test object and its reflecting
surfaces shall be large enough to completely cover the exami-
b) The beam width DS-20dB referred to a 20 dB echo ampli- nation volume.
tude decrease:
S (2) The scanning surfaces shall be free from disturbing un-
DS 20dB  2    (D-2) eveness and contaminants (e.g. notches, scale, weld spatters,
DQ
machining grooves). Where the opposite surface is used as
c) Conversion of side-drilled hole echo amplitudes to disc reflection surface, the same requirements as for the scanning
shaped reflector echo amplitudes: surface apply to the reflection surface.
2 (3) The arithmetical mean deviation of the assessed profile
DKSR     DZ  S , (D-3) (average roughness) Ra to DIN EN ISO 4287 shall not exceed

20 µm on the surfaces to be tested.
where S > 1.5  N and DZ > 1.5  .
(4) In the case of waviness of the scanning surfaces the
d) The beam diameter DS-6dB referred to a 6 dB echo ampli- waviness shall be so little as to provide sufficient probe shoe
tude decrease: contact. This is generally the case if the distance between
probe shoe surface and scanning surface does not exceed 0.5
DS-6dB = 2  S  tan 6, (D-4)
mm at any point.
e) Average value of instrument gain setting GT : (5) In relation to a reference surface of 40 mm x 40 mm, the

GT 
 GT  sum of individual values
, (D-5)
deviation from the specified contour of the scanning surfaces
shall not exceed 0.5 mm. When selecting other dimensions of
n number of individual values reference surfaces, the allocated deviation from the specified
f) Corrected recording length RLK: contour shall be linearly converted in accordance with the side
length of the reference surface selected.
 D 
RLK  RL  DS 6dB   1  S 6dB  (D-6)
 RL 
D 4 Requirements to be met by the testing system
g) Sound path length without lateral wall influence:
s  Deff D 4.1 Test equipment
S  (D-7)
2 (1) The test equipment used including the required measur-
h) Gain correction V ~ : ing instruments and auxiliary equipment shall show appropri-
ate exactness and stability suited for the intended use.
1
 G2T  n   GT 
2

V ~  1.7  (D-8) (2) Test instruments and probes shall normally meet the
n 1 requirements of DIN EN 12668-1 or DIN EN 12668-2. The
requirements of DIN EN 12668-3 shall apply to checking the
or
properties of the entire test equipment.
 GT  GT 
2

V ~  1.7  (D-9) (3) The combination of equipment, cables and probes of

n 1 various manufacturers is permitted if it is ensured (e.g. by
 KTA 3211.1 Page 105

measurements on reference reflectors) that the exactness of (6) The scanning surfaces of transverse wave angle-beam
results is not affected. probes shall
a) always be contoured when scanning into concave test
(4) Probes with sound fields shall be used which ensure the
object scanning surfaces unless sufficient coupling can be
observance of the required testing level (recording level) in the obtained due to large radii of curvature,
area to be examined.
b) be contoured when scanning into convex test object scan-
Note: ning surfaces if according to Figure D-1 for test object di-
In general, a nominal frequency of 4 MHz and a transducer size ameters up to 200 mm the scanning surface dimension in
DQ of approx. 10 mm is used for nominal wall thicknesses equal to the direction of curvature is L > d/10 and for diameters ex-
or less than 40 mm, and a nominal frequency of 2 MHz and a ceeding 200 this dimension is L > 2d .
transducer size DQ of approx. 20 mm is used for nominal wall
thicknesses exceeding 40 mm. (7) For adjustment of the time base range and the testing
level as well as for testing the same couplant shall be used.
(5) Straight-beam probes shall be selected such that the Only such couplants shall be used which do not damage the
distance between the scanning surfaces of the probe and of object (e.g. corrosion). Upon testing, all couplant residues
the test object does not exceed 0.5 mm (DKon < 2d ). By the shall be removed from the test object.
use of protective foils the coupling of a straight-beam trans- (8) Test object, calibration block, reference block and probes
ceiver probe may be improved. shall approximately have the same temperature.

60

56
Dimension (L) of contact surface of the probe in direction of curvature, in mm

52 Adjustment of plane
contact surfaces required
48

44

40 L= 2d

36

32

28

24 Adjustment of plane contact

surfaces not required
20

16
d
L=
12 10
8

0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Curvature diameter (d) of test object, in mm
Figure D-1: Conditions for adjusting plane contact surfaces of angle-beam probes when scanning into convex scanning sur-
faces of the test object

D 4.2 Calibration blocks, reference blocks and reference component to be tested. When using contoured
reflectors probes or if the curvature of the opposite surface im-
pairs the reflection behaviour (ratio of wall thickness s
(1) When using differing materials for calibration block or
to outer diameter da of the test objet to exceed 0.2),
reference block and test object the difference in sound veloci-
ties shall be taken into account for range adjustment and for the deviation of the test object diameter shall not ex-
the angular deviation in case of angle beam scanning. ceed 10 % of the diameter of the component to be
tested. Deviating here from plane reference blocks
(2) When calibration blocks No. 1 to DIN EN ISO 2400 or may be used in case of pulse-echo probes if the test
No. 2 to DIN EN ISO 7963 are not used for adjusting the test- object diameter does not require the use of contoured
ing level, the following applies: probes, the reflection behaviour is not impaired by the
a) to the reference block used: curvature of the opposite surface (ratio of wall thick-
aa) The reference block shall correspond to the test object ness s to outer diameter da of the test objet less than
as regards the test-relevant characteristics (material, or equal to 0.2) and no wave conversion technique is
design, shape, wall thickness, cladding if any, heat used.
treatment). The wall thickness of the reference block ab) Reference blocks for testing of welds on austenitic
shall deviate not more than 10 % from that of the steels, on nickel alloys or dissimilar welds shall be
KTA 3211.1 Page 106

similar to the test object. The similar reference block (2) As far as the optimization of the testing technique as per
(e.g. from a production control test piece), must corre- (1) does not lead to a sufficient signal-to-noise ratio, testing
spond to the test object as regards geometry, material, techniques providing images of the test results shall be used
weld design, welding process and surface condition. to make evaluation possible, e.g.
ac) The sound beam shall not be impaired in its develop- a) sectorial and compound scanning with controlled phased
ment, i.e. all dimensions vertical to the main beam arrays,
path for sound paths up to twice the near field length
b) automated testing techniques, e.g. in connection with
(N) shall normally be greater than the transducer di-
ALOK (transit-time and amplitude locus-curves).
mension perpendicular to the scanning direction (DQ)
Decisive for greater sound path travel distances than
twice the near field length is the beam width DS-20dB at D 6 Adjustment of test system
the reflector location. In this case, the reference ob-
Note:
ject width is determined to the following formula:
Sections D 7 to D 9 contain requirements for the test system ad-
S
C  2  λ  max justment as regards the use of wave conversion and creeping
DQ wave techniques.
Exempted from this rule are reference blocks used for
testing the area with lateral wall influence on bars in D 6.1 Range adjustment
axial direction. In this case, the width of the reference (1) The time base range shall normally be calibrated on the
block shall be equal to the width of the test object. calibration block No. 1, the calibration block No. 2, the test
ad) The dimensions of the scanning surface of the test ob- object or on a similar reference block (e.g. to Figure D-2).
ject shall normally exceed 1.5 times the probe scan- The time base range shall be adjusted by locating known
ning surface. reflectors.
ae) The location of the reference reflectors in the refer-
ence block shall be selected such that their echoes do (2) Where probes have to be contoured, the range shall first
no interfere with each other and cannot be confused be calibrated with a non-contoured probe on a plane calibra-
with corner echoes. tion or reference block. Hereafter, the contoured probe shall
be positioned on a suitable shaped reference block to contain
b) to the reference reflector used: at least one reflector on a known time base range. By means
ba) The back walls shall normally be plane and vertical to of this reflector a zero-point correction shall be made.
the main beam as well as have dimensions exceeding (3) For longitudinal wave angle-beam probes a pre-adjust-
the beam width DS-20dB, but not less than the trans- ment of the time base range shall be carried out using a
ducer dimension. straight beam probe on the calibration blocks No. 1 or No. 2,
bb) Side-drilled holes shall normally be vertical to the main on the test object or on the reference block. Subsequently a
beam and parallel to the scanning surface. The correction of zero point shall be effected by means of the
lengths of the side-drilled holes shall normally be angle-beam probe to consider the delay path.
greater than the sound beam width DS-20dB, but not
less than the transducer dimension. The diameter
shall normally be 3 mm. D 6.2 Adjustment of the testing level when applying the DGS
bc) The bottom of flat bottom holes shall normally be verti- method
cal to the main beam when applying the single-probe D 6.2.1 Application of the DGS method
technique. Exempted from this rule are specifications
for the use of flat-bottom holes when applying the (1) The DGS method may only be used for probes where
wave conversion technique II and the creeping-wave probe-specific DGS diagrams are available.
technique.
(2) In the case of probes with adjusted contact surfaces, the
bd) The notches shall have a rectangular cross-section. DGS method shall basically not be used. When scanning with
The notch edges shall be vertical to the surface. The angle-beam probes which flat contact surfaces are adjusted
notches shall normally have a width  1.0 mm and, if
the use of the DGS method is permitted on test objects with d
not specified for the respective product form, have a
exceeding 100 mm where scanning is performed on a con-
depth of 1.0 mm. The acoustically effective length of
cave scanning surface of the test object, if the condition
the notches shall normally be 20 mm.
L < d is satisfied.
be) Where the echo amplitudes of side-drilled holes are to
be converted to echo amplitudes of DKSR, the formula (3) The following criteria apply to the use of the of the DGS
D-3 shall be considered. method:
a) The evaluable sound path begins, for single transducer
D 5 Optimization of the testing technique for ultrasonic probe, approximately at S = 0.7  N and for dual-element
testing of austenitic steels or nickel alloys probes as well as for focussing probes at the beginning of
the focal zone.
(1) To maintain a sufficient distance (at least 6 dB) of the b) In the case of a lateral wall influence the DGS method may
recording level to the noise level the test technique shall be only be used up to the sound path travel distance given in
optimised, e.g. by taking the following measures: Section D 2.3, equation D-7.
a) use of probes with low nominal frequency, c) In the case of angle-beam scanning the DGS method can
b) use of frequency-selective test instruments, only be applied for wall thicknesses exceeding 5  .
c) use of probes with composite transducers and test instru- d) Probe-specific DGS diagrams for disc shaped reflectors
ments suited for this purpose, shall be used to adjust the testing level.
d) use of longitudinal waves for angle-beam scanning, e) In the case of attenuated probes the DGS method may
e) electrodynamically excited surface waves and horizontally only be used if the ratio of the band width (f) to the nomi-
polarised transverse waves. nal frequency is less than 0.75.
 KTA 3211.1 Page 107

Wall thickness b) The reference reflector for angle-beam probes shall be

or ba) the circular arc R100 of the calibration block no. 1,
nominal wall Lateral view bb) the circular arc R25 of the calibration block no. 2
thickness of the of the reference block taking the known or determined probe-specific correction
test object values into account,
in mm
bc) a side-drilled hole or a flat bottom hole.
£1 (2) The diameter of a flat bottom hole (DFBB) corresponds to
the diameter of the disc shaped reflector (DKSR) provided that
DFBB > 1.5  .
1
s  10
(3) For the conversion of the echo amplitude of a side-drilled

sj
hole into the echo amplitude of a disc shaped reflector equa-
tion D-3 shall be used.

b
D 6.3 Adjustment of the testing level for the reference block

sj
method and DAC method
10 < s  15
1

D 6.3.1 Reference block method

£1 sj
b= (1) In the reference block method the indication from the test
2 object is directly compared to the reference reflector having
nearly the same sound path length. This may be done with
reference reflectors in the part or reference block.
5

(2) The testing level shall be adjusted by means of a reference

b
sj
15 < s  20 reflector located at the end of the time base range. Where ech-
5

oes of reflectors are detected in the test, further reference re-

b = sj 10 b flectors of the respective reference block may be used which
have the same or next greater sound path length. Where dif-
ferent types of reference reflectors are used (see Figure D-2)
the smaller echo height shall be used as reference level.
5 b b 5
sj

20 < s  40 D 6.3.2 DAC method

sj 10 b b (1) When applying the DAC method for simplifying the echo
b= amplitude description it is recommended to generate a DAC
2 curve by means of one or several equal reflectors located at
different depths in reference blocks (e.g. step wedge or to
Figure D-2) or by means of reference reflectors in the test
5 bbb 5

object located at different distances. Clause D 4.2 (2) b) ap-

sj

40 < s  80 plies with regard to the requirements for reference reflectors.

(2) The DAC curve shall be generated by at least three re-
sj 10 bbb sponses from the reference reflectors (e.g. side-drilled holes)
b=
3 in various probe distances (see Figure D-3). The echo with
the highest amplitude shall normally be adjusted for approxi-
mately 80 % of the screen height. The DAC curve constructed
5 bbbb 5

may be extrapolated by a maximum of 20 % beyond the time

base range limited by the reference reflectors. The gain set-
sj

s > 80 ting of the ultrasonic equipment shall be selected such that

the DAC curve is within the time base range between 20 %
sj 10 and 80 % of the screen height. If this is not possible for the
b= entire time base range, the DAC curve shall be staged as per
4 Figure D-4.
Pos.1 Pos.2 Pos.3 or Pos.1 Pos.2 Pos.3
Figure D-2: Reference blocks for adjusting the testing level
for angle beam scanning

D 6.2.2 Reference reflectors to be used

Bore hole diameter ³ 3mm
(1) The reference echo heigth shall be determined on refer-
ence reflectors meeting the following requirements:
a) The reference reflector for straight beam probes shall be
Pos.1
aa) the back wall of the test object provided the back wall
meets the requirements according to clause D 4.2 (2) ba), Pos.2
ab) the back wall of the reference block provided the back
wall meets the requirements according to clause D 4.2 Pos.3
(2) ba),
ac) the back wall of calibration block no. 1 with a thickness
of 25 mm or the back wall of calibration block no. 2 with Figure D-3: Generation of reference echo heights from side-
a thickness of 12.5 mm, drilled holes located at different probe distances
ad) a side-drilled hole or a flat bottom hole. for angle beam scanning
KTA 3211.1 Page 108

to be calculated in accordance with clause D 2.3 h) shall be

used as transfer correction.

Increased DAC curve (2) Where the V~ value thus determined is greater than
(e.g. by 12 dB) 6 dB, the test object shall be subdivided into testing sections
where the transfer correction of each section shall be consid-
ered separately. This subdivision shall be such that in each
section V~ is equal to or smaller than 6 dB.

GR G R + 12 dB D 6.4.4 Consideration of corrections

(1) Taking the aforementioned corrections into account, the
Figure D-4: Staged DAC curve resultant instrument sensitivity for adjustment of recording
level as per equation D-11 is obtained.
(2) Where sound attenuation in dependence of the sound
D 6.4 Corrections of testing level adjustment
path length is taken into account this shall be made with the
D 6.4.1 Transfer correction attenuation portion V contained in VT as per Figure D-8
when using the DGS method or as per Figure D-9 when using
(1) The transfer correction shall normally be determined on the DAC method.
at least 4 points of the test object in the intended direction of
testing. (3) If it is not necessary to consider the sound attenuation in
dependence of the sound path length, VT shall contain a
(2) The transfer correction shall normally be determined in constant sound attenuation portion V independent of the
accordance with Figure D-5 by means of transmission on the
sound path length.
calibration block and on the test object.
(4) Where an additional correction for considering greater
(3) To consider the transfer correction in angle-beam scan-
variations as per clause D 6.4.3 is required, this shall be done
ning VT of the V-transmission or W-transmission shall nor-
by means of V~ . Otherwise, the correction value V~ in
mally be used. Where ΔVT exceeds this value by more than
equation D-11 shall be omitted.
2 dB, the testing level adjusted to D 6.2 of D 6.3 shall be cor-
rected by the values obtained. In the case of ΔVT values equal
to or less than 2 dB these values shall generally be taken as 2 D 6.5 Setting of the ultrasonic instrument
dB when adjusting the testing level.
(1) Prior to adjusting the testing level it shall be ensured that
a) the amplifier suppression (“grass cutting”) is not used,
D 6.4.2 Determination of the sound attenuation
b) the amplifier is operated in the correct frequency range,
(1) The sound attenuation for straight-beam scanning shall c) the filter is set such that optimum resolution is obtained,
normally be determined as per Figure D-6 and for angle-beam
d) the test instrument impedance, where required, is adapted
scanning as per Figure D-7 at the same reference screen
such that a maximum echo height is obtained at constant
height level respectively in consideration of VS. resolution,
(2) The determination of the sound attenuation may be omit- e) the energy for the transmitter pulse is set as low as possi-
ted if it is considered by a constant allowance independent ble in due consideration of the gain control reserve.
from the sound path length (e.g. by transfer correction in ac-
(2) The pulse repetition frequency shall be adjusted such that
cordance with clause D 6.4.1).
a) the detection of all signals to be recorded is ensured,
b) the occurrence of so-called ghost echoes in case of long
D 6.4.3 Coupling and sound attenuation variations sound path lengths (especially in the case of materials with
(1) For the transfer correction the average value of the low sound attenuation) is avoided.
transmission values obtained from the test object shall be (3) Taking the corrections according to Section D 6.4 into
used if the range of variation does not exceed 6 dB. Where account the instrument gain shall be adjusted such that all
the range exceeds 6 dB, the average value from 20 transmis- echoes exceeding the recording level attain at least 20 % of the
sion values plus an allowance V~ = 1.7  standard deviation screen height at the end of the respective time base range.
 KTA 3211.1 Page 109

Calibration or reference block Test object

Scanning
over half
skip distance
or
or
Scanning
over full
skip distance

Reference height Reference height

0 1 2 3 4 5 6 7 8 9 10 0 1 2 3 4 5 6 7 8 9 10

S1 S2
G T1 = ... dB G T2 = ... dB

D V T = G T2 G T1 D V S Back-wall echo curve

Transfer correction during straight and of a DGS diagram
angle beam scanning [dB]
DVS

DVS = VS 2 VS 1
Divergence correction of back-wall echo curve
of a DGS diagram
V S 1 = Gain value for transmission echo on calibration
S1 S2
or reference block at reference level [dB]
V S 2 = Gain value for transmission echo
on test object at reference level [dB]
G T1 = Instrument gain for transmission echo
on calibration or reference block [dB]
G T2 = Instrument gain for transmission echo
on test object [dB]

Figure D-5: Determination of transfer correction during straight and angle beam scanning performed as V or W-transmission
KTA 3211.1 Page 110

DVk
Reference height
Transferred or
set-up DAC curve

Test object S1 DAC curve upon

S2
sound attenuation correction
s [ mm ]
G  GT1  VS GT1 ...dB
  T2 dB / mm V  2  S    2   1   dB
2  S2  S1 GT 2 ...dB

Figure D-6: Determination of sound attenuation for Figure D-9: Consideration of sound attenuation for the DAC
straight-beam scanning (example) method for the case 2 > 1 (example)

D 7 Creeping wave method

D 7.1 Description of method

V-transmission through W-transmission through (1) Longitudinal wave probes with usual angles of incidence
the test object the test object of 75 degrees to 80 degrees generate besides a sharp de-
clined transverse wave additionally to the longitudinal main
wave a longitudinal wave propagating in parallel to the scan-
ning surface (primary creeping wave).
Refe- Refe-
rence rence (2) By the propagation of the primary creeping wave along
height height the scanning surface transverse waves are permanently radi-
ated so that the intensity of the creeping wave rapidly de-
creases with the sound path length. For example the focal
S1 2S1 distance in the case of creeping wave dual-element probes
with transducer dimensions of D0  6 mm  13 mm will be
GT1  . . . dB G T2  . . . dB approximately 10 mm, by what a usable ultrasonic beam with
a length of approximately 20 mm exists.
GT 2  GT1  VS
 dB/mm
2  S1 (3) Where, for geometric reasons, the primary creeping
wave will dip into the volume, e.g. in the case of attachment
Figure D-7: Determination of sound attenuation for welds, it will propagate as normal longitudinal wave without
angle-beam scanning radiation. This leads to greater usable sound paths lengths of
30 mm to approximately 50 mm.

s2 D 7.2 Reference block

Test object ( k2 )
Vk [ dB ]

s1
(1) For the testing level adjustment of creeping wave probes
Reference block ( k 1 ) the following reference blocks shall be taken:
DVk

a) for testing attachment welds or build-up weldings the ref-

0 erence block as shown in Figure D-10, which shall contain
Reference echo flat bottom holes with a diameter of 3 mm distributed over
10 the maximum usable sound path length at equal distances
of approximately 5 mm to 10 mm.
DVkorr.
G

DV

20 b) for testing near-surface areas the reference block as

¥
shown in Figure D-11, which shall contain a 1 mm deep
V [ dB ]

DVk

30 notch with a length of 20 mm.

Value corrected 1.0
in consideration 0.8 (2) When testing with contoured probes, the curvatures of
40 of sound attenuation 0.6 the scanning surfaces of the reference block and the test
0.4 object shall match.
50

60 0.2 D 7.3 Testing level adjustment

50 100 200 300 500 1000 2000
(1) For testing attachment welds or build-up weldings a DAC
s [ mm ] curve shall be generated to meet the requirements of Section
D 6.3 by means of scanning the respective flat bottom holes in
V   2  S 2   2  S 1   1  dB  the reference block according to clause D 7.2 (1) a).
(2) For testing near-surface areas the reference echo height
Figure D-8: Consideration of sound attenuation in the DGS shall be the amplitude of the reference reflector according to
diagram for 2 > 1 (example) clause D 7.2 (1) b).
 KTA 3211.1 Page 111

Section A-A tions nearly parallel to the surface. The angle of incidence of
» 70 approximately 31 degrees is obtained, in the case of test
objects with parallel surfaces, by the accompanying trans-
°
» 45 verse wave of a 70-degree longitudinal wave angle-beam
probe (Figure D-14).
> 10

1.5
(2) Due to its near-surface linear propagation the secondary
Æ3

creeping wave is e.g. used to cover the root area of a welded

joint without being significantly influenced by the excess pene-
tration. In this case it shall be taken into account that
a) the intensity of the secondary creeping wave will rapidly
» 150 decrease with the sound path subject to the permanent ra-
diation of transverse waves,
b) the secondary creeping wave may be influenced by irregu-
larities (e.g. edges, grooves) in the root area.
» 45 (3) During scanning with the longitudinal wave angle-beam
probe on test objects having plane-parallel surfaces neighbour
» 35 echoes are generated which are called NE 1 and NE 2 (Fig-
ure D-15). For the detection of reflectors the echo NE 2 is used.
The echo NE 1 may be used for reflector depth estimation.
» 25
(4) When scanning thin test objects (wall thickness up to
approximately 20 mm depending on the material) with the
» 15
» 125

longitudinal wave probe (type 70 degree SEL) an analyzable

echo amplitude is generated which contains both the longitu-
» 100

»5 dinal wave portion (main echo-HE) and the converted trans-

» 75

A A verse wave portion (sequence of secondary echoes-NE)

» 50

(Figure D-16).
» 25

Note:
Echoes due to geometric discontinuities may be generated due to
the transverse wave generated simultaneously with the beam en-
Flat bottom holes Æ 3 mm try into the test object, since the transverse wave entering at a
very steep angle is highly sensitive to irregularities of the probe-
Figure D-10: Reference block for testing level adjustment remote surface (e.g. gauge marks, identification markings) and
when using the creeping wave technique (pri- reacts to deviations from shape. Therefore, it is especially im-
mary creeping wave) portant to
a) consider the probe position in relation to the centre of the
welded joint,
£1 b) know the sound velocities and the related angle of incidence of
the transverse wave,
c) know the various echo dynamics.
1

When exactly allocating the indication to the welded joint and con-
sj

sidering the fact that a reflector - contrary to the accompanying

transverse wave - has a great dynamic effect when being scanned
with 70 degree longitudinal waves, a distinction between such
Figure D-11: Reference block for testing level adjustment when spurious echoes and real defects is possible.
using the creeping wave technique (primary Scanning with secondary creeping waves in accordance with sub-
creeping wave) for testing near-surface areas para (2) and (3) is purposeful beginning with a wall thickness ex-
ceeding 15 mm. In the case of wall thicknesses 8 mm < s  20 mm
the examination shall be performed with longitudinal wave probes
(Type 70 degree SEL). The presence of the main echo HE and
D 7.4 Adaptation of probes the neighbour echo NE shows that the sound waves are reflected
at deep material discontinuities. Indications of root notches of little
(1) When testing on convex curved scanning surfaces of the depth are distinguished from deep defects due to the fact that
test object, the probes shall be selected in accordance with secondary echoes are not obtained (Figure D-16).
Figure D-12.
(2) When testing on concave scanning surfaces of the test D 8.2 Probe
object, specific probes with properly contoured contact surfac-
es shall be used. (1) In the case of plane-parallel surfaces of the test object
single transducer or dual-element angle-beam longitudinal
wave probes with beam angles of 70 degrees are used.
D 8 Wave conversion method  (secondary creeping wave)
(2) For the testing test objects with none plane-parallel sur-
D 8.1 Description of method faces probes with beam angles shall be used, where the angle
(1) Figure D-13 shows the principle of reflection with wave of incidence of the transverse wave on the opposite surface is
conversion in scanning with a longitudinal wave angle-beam approx. 31 degrees.
probe. When transverse waves in steel hit an opposite face at Note:
an angle less than 31 degrees, besides reflection of the The wall thickness to be tested, the nominal frequency and the
transverse wave a wave conversion occurs. A longitudinal transducer dimension as well as the amplitudes of the echo NE 2
wave (secondary creeping wave) is generated at an angle of obtained from the different deep notches shall be decisive with re-
incidence of approximately 31 degrees which contains por- gard to the selection of the probe.
KTA 3211.1 Page 112

40

Dimension (L) of scanning surface of the probe in direction of curvature, in mm

36
Use of specifically fabricated
probes with contoured scanning surfaces required
32

28
L= d
Use of probes with plane
24
scanning surfaces permitted provided the
required testing level is obtained
20

d
16 L=
3

12 d
L=
10

8
Adjustment of plane scanning
surfaces not required
4

0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Curvature diameter (d) of test object, in mm

= Range of application for creeping wave probes with plane scanning surface

Figure D-12: Ranges of application of creeping wave probes with and without contouring of scanning surfaces for testing on
convex test object scanning surfaces

A notch with rectangular cross-section provided on the refer-

ence block or test object shall be scanned (Figure D-15) in
which case the transverse wave portion of the longitudinal
wave angle-beam probe shall be included. The neighbour
s

echo NE2 shall be optimised by displacing the probe. On the

scanning surface the projected surface distance (p’) from the
point of incidence to the scanned notch shall be determined.
By means of the following equation
Figure D-13: Reflexion with wave conversion for longitudinal SNE2 = 1.5  s + p'
wave angle-beam probe
the value of the sound path length of the angle beam probe
shall be determined by approximation.
Note:
The neighbour echo NE 1 may be used for controlling the range
70° calibration. The sound path position of the echo NE1 is deter-
mined by approximation by means of the formula SNE1 = 2  s at a
31°
70° maximum value of the echo NE2.

31°
D 8.4 Testing level adjustment
(1) The testing level shall be adjusted on a reference block.
Directional characteristic Secondary creeping wave (2) To generate a reference echo notches as per clause
D 4.2 (2) bd) shall be used.
Figure D-14: Testing of internal near-surface area of welded
(3) By displacing the probe on the reference block the echo
joints by means of secondary creeping waves
NE 2 reflected from the notch shall be optimized and thus the
reference echo height be determined.
D 8.3 Range calibration
(4) In the case of testing as per clause D 8.1 (4) the testing
(1) The time base range shall be pre-adjusted in accordance level shall be adjusted on corresponding notches with rectan-
with D 6.1 (3). gular cross-section using longitudinal waves. The recording
(2) Hereafter, the zero-point correction for the longitudinal level is the reference echo amplitude of the direct longitudinal
wave angle-beam probe shall be effected. In this case the wave minus 6 dB. The indication of the edge on the reference
following procedure may be followed, unless performed on the block shall exceed the recording level by at least 10 dB. Oth-
100 mm circular arc profile (R100) of calibration block no.1: erwise, the recording level shall be reduced accordingly.
 KTA 3211.1 Page 113

D 8.5 Corrections during testing level adjustment b) zero-point correction with longitudinal wave angle-beam
probe on the 100 mm circular arc profile (R100) of calibra-
D 8.5.1 Transfer correction tion block no.1,
The difference of the acoustic properties between the similar c) determination of probe index point where required for the
reference block and the test object shall be determined and be longitudinal wave angle-beam probe.
considered during testing. This may be done by a global trans-
fer measurement. (2) Testing level adjustment according to the requirements
of Section D 8.4
a) positioning of probe index point of the longitudinal wave
D 8.5.2 Correction of sound attenuation caused by the weld
angle-beam probe above the notch of the respective refer-
metal ence block,
Different testing levels caused by the weld metal shall be b) determination of the distance p’ in case of optimised NE2
determined by suitable means and be taken into account. to reference echo (see Figure D-15),
c) consideration of respective allowances for testing level.
D 8.6 Performance of testing
(3) Displacement of the probe
(1) Range calibration according to the requirements of Sec- The longitudinal wave angle-beam probe shall be displaced
tion D 8.3 vertically to the weld so that the defined testing area is com-
a) pre-adjustment with straight-beam probe, pletely covered at the opposite surface.

NE 1

p´
Echo dynamic

NE 2

NE 1 NE 2

0 2 4 6 8 10

Figure D-15: Sound field geometry during transverse wave conversion

HE

HE

0 2 4 6 8 10

HE

NE

HE NE

0 2 4 6 8 10
HE: Main echo, NE: Neighbour echo

Figure D-16: Testing of components with nominal wall thicknesses 8 mm < s  20 mm by means of longitudinal waves
(70 degree SEL probe)
KTA 3211.1 Page 114

D 9 Wave conversion method II (LLT technique) D 9.2.3 Reference blocks

D 9.1 General (1) The reference block used for determining the scanning
(1) The LLT technique is used to detect reflectors vertical or zone dimension and location shall correspond to the test ob-
nearly vertical to the surface during volumetric testing of test ject as regards the geometry and acoustic properties. The
objects with parallel or concentrically curved surfaces and up reference reflectors are flat bottom holes with the same size
to a nominal wall thickness of 80 mm. as the disc shaped reflectors to be recorded. The reference
reflectors shall be provided on the front-face side in the centre
(2) The functional principle of the LLT technique is shown in of the scanning zone (depth location, distance YSa, YSb, Fig-
Figure D-17. The transmitting transducer generates a longitu- ure D-17) laid down by the given probe. To confirm proper
dinal wave with an angle of LW ranging between 7 and 45
subdivision of scanning zones, additional reference reflectors
degrees. This wave is reflected on the test object back-wall
shall be provided in the overlapping areas of the zone edges.
and hits the vertical reflector. Here, the greatest portion of the
wave energy is converted to form a transverse wave which is (2) The distance of the reference reflectors to the front faces
reflected at an angle TW and is received from the receiving shall be at least 20 mm.
transducer.
(3) The advantage of the LLT technique is the compact D 9.2.4 Establishment of LLT sensitivity diagrams
design of the LLT probes with the transmitting and receiving
transducer being arranged in one housing. (1) With the aid of sensitivity diagrams the testing level ad-
justment may be simplified.

D 9.2 Probes, scanning zones, reference blocks, LLT sensi- (2) The diagrams shall be established by means of meas-
tivity diagrams urements on flat bottom holes of the reference block in ac-
cordance with clause D 9.2.3 for the respective scanning
D 9.2.1 Use of probes zone. The echo heights (signal amplitudes) measured on the
flat bottom holes shall be entered over the depth location
(1) Due to their specific arrangement of transmitting and (YFBB, Figure D-18). The reference height of the front face
receiving transducers the probes are designed for testing of a (maximum of front-face echo) shall also be entered in the
certain depth zone (scanning zone) at the respective wall diagram. The distance between the reference height of the
thickness and curvature of the test object. The range of appli- front face and the peak of the sensitivity curve from the echo
cation shall be determined by means of probe-specific data heights of the flat bottom holes defines the value VLLT.
sheets. (3) To generate a depth scale the reflector depth location
shall be entered in a further diagram over the sound path
(2) LLT probes designed for the examination of flat test travel distance (see Figure D-19). To this end, at least three
objects may be used in testing of surfaces concentrically flat bottom holes provided at the front-face side of the refer-
curved in the direction of testing, where great radii of curvature ence block are necessary.
(R exceeding 1000 mm) exist.
D 9.3 Range adjustment
D 9.2.2 Probes and their scanning zones (1) The respective LLT probe shall be operated such that at
first only the receiving transducer is activated in the pulse-
D 9.2.2.1 Location and height of scanning zones
echo mode to generate transverse waves. Range adjustment
(1) LLT probes are sensitive only in a limited scanning zone shall be made at the 100 mm circular arc profile of the cali-
(depth zone). The location of the scanning zone is determined bration block No. 1. The range shall be adjusted such that the
by the beam angle LW , the angle of incidence TW and by the sound path travel distance to the centre of the scanning zone
is located in the middle of the time base range (SJust). The
arrangement of the transducers.
time base range shall be calculated and adjusted in accord-
(2) The scanning zone height is determined by the depth ance with formulae D-14 to D-17.
area (ZHa, ZHb, Figure D-17) where the sensitivity has de- Hereafter, the transmitting transducer shall also be connected
creased by half the value (-6 dB) compared to the maximum and the ultrasonic instrument shall change over to the dual-
value in the scanning zone centre (YSa, YSb, Figure D-17). element mode.
The height of the scanning zone depends on the wall thick- (2) To estimate the depth location of reflectors a depth scale
ness, the nominal frequency and the dimensions oft the determined in accordance with clause D 9.2.4 shall be used.
transmitting and receiving transducer.
D 9.4 Testing level adjustment
D 9.2.2.2 Subdivision of scanning zones
D 9.4.1 General
(1) The scanning zones shall cover the volume to be tested,
(1) The testing level shall be adjusted using the following
and the scanning zones shall overlap.
reference reflectors:
Note: a) end faces (front faces) or flat bottom holes vertical to the
The volume to be examined normally comprises the non-subsur- scanning surface of the test object or reference block
face area as of a depth of 10 mm distanced from the probe-
remote surface and probe-adjacent surface. or
b) flat-bottom holes which, depending on the testing task, are
(2) The subdivision of scanning zones may be estimated oblique to the scanning surface of the test object.
based on probe-specific data sheets. Where no probe-specific
The flat bottom holes shall be of the same size as the disk
data sheets are, the location and dimensions of the scanning
shaped reflectors to be recorded.
zones shall be determined by means of measurements with
the selected probes on reference blocks with flat bottom (2) During testing level adjustment the zone edge allowance
holes. and transfer correction shall be considered.
 KTA 3211.1 Page 115

D 9.4.2 Adjustment on end faces vertical to the scanning (2) In the case of austenitic steels and nickel alloys the dif-
surface of the test object (front faces) ference of the acoustic properties between the similar refer-
(1) For this type of adjustment probe-specific LLT sensitivity ence block and the test object shall be determined and be
diagrams shall be submitted in accordance with clause D 9.2.4. considered. This may also be done by assuming a global
transfer measurement.
(2) When setting the testing level the value VLLT shall be
taken from the probe-specific LLT sensitivity diagram (see
Figure D-18) for the centre of the scanning zone (Ys) and be D 9.6 Performance of testing
increased by 6 dB for the zone edge. The setting shall be
checked by means of flat bottom holes. (1) The testing using the LLT technique shall be performed
separately for each scanning zone.
D 9.4.3 Adjustment on flat-bottom holes
(2) The probe shall be coupled on the test object for each
Where no sensitivity diagrams are available or reference re- scanning zone at a distance a'LLT (see Figure D-18) to the
flectors oblique to the test object scanning surface are to be centre of the weld. The distances a'LLT shall be determined on
found, the testing level shall be adjusted on flat bottom holes the reference block.
in a reference block. For each scanning zone at least three flat
bottom holes shall be provided. (3) The probes shall be moved over each scanning zone
vertically to the direction of weld progress such that the vol-
D 9.5 Transfer correction ume to be tested is completely covered.
(1) In the case of ferritic steels the transfer correction may (4) The LLT probe coupling shall be monitored by observing
globally be assumed to be 2 dB. the noise.

a) one echo receiving point b) distanced echo receiving points

SS SS
ES
ES
TW TW
φ TW
YS a

φ TW

YS b
α TW α TW
Z Ha

α LW

Z Hb
φ LW
α LW
φ LW ∆ SE

s
LW LW LW LW

c 
TW = arc cos  TW  cos α LW 

 c LW 

2 s  tan  LW   SE
YSa, YSb =
tan  TW  tan  LW

ZHa, ZHb : depth zone

Figure D-17: Principle of LLT technique

KTA 3211.1 Page 116

a LLT
SS SS
ES
ES

YFBB
Front face,
end face

s
Flat-bottom holes
(at various depths)

0
Echo height, in dB

Maximum of front-face echo

(reference height of front face)
D V LLT
20
D V LLT Echo height difference between
reference height of front face
and peak of sensitivity curve
6 dB

40

Echo from
flat-bottom hole
60
YS
ZH
80
0 50 100 150

Reflector depth location YFBB in mm

Figure D-18: Example for a LLT sensitivity diagram

100
Reflector depth measure from scanning surface [mm]

90

80
a LW = 7° a LW = 20° a LW = 33° a LW = 45°
70

60

50

40

300

20

10

0
50 100 150 200 250
Sound path S Just [mm]

Figure D-19: Example for LLT reflector depth scales

 KTA 3211.1 Page 117

D 10 Performance of testing
D 10.1 Overlap Reflector
To ensure complete coverage during testing the distance
between two adjacent scanning tracks in the examination
volume shall be smaller than the beam width DB-6dB trans-
verse to the scanning direction.
Probe

D 10.2 Rate of probe movement

When selecting the rate of probe movement the pulse repeti-
tion frequency, the operator’s ability of detecting signals and
the test instrument’s capability of recording signals shall be Recording level

Echo amplitude
taken into account.
During manual scanning the rate of probe movement should
not exceed 150 mm/s.
Probe
D 10.3 Adjustment and check of the test system Recording length displacement

(1) Prior to testing, the testing level and range adjustments

shall be made after the warm-up periods given by the instru-
ment manufacturer. To this end, suitable calibration or refer- Recording level

Echo amplitude
ence blocks shall be used. The instrument setting shall be

6 dB
maintained during scanning and shall be controlled regularly
during and at the end of testing.
(2) Where deviations from the checks made before are Probe
found, all tests performed after the last check without devia-
Recording length displacement
tions shall be repeated with a corrected adjustment.

D 11 Description of indications Recording level

Echo amplitude

12 dB

D 11.1 Echo amplitude

The maximum echo amplitude of an indication referred to the
respective valid recording level is to be indicated in dB. Probe
Note: Recording length displacement
The reproduceability of the echo amplitude determination is
generally  3 dB.
Figure D-20: Determination of recording length

D 11.2 Extension of indications

D 11.2.1 General requirements D 11.2.4 Methods for the exact determination of indication
extension
Lengths of indications equal to or greater than 10 mm shall be
measured. Shorter indication lengths shall be recorded as „< 10“. The determination of the indication extension may be opti-
mized by one of the corrections described in clauses D 11.2.4.1
to D 11.2.4.4 or by examinations according to clause D 11.2.5.
D 11.2.2 Determination of the recording length at fixed re-
cording level
D 11.2.4.1 Correction for curved surfaces
The extension of reflector (see Figure D-20) shall be given by
the probe displacement range. This range is determined as For curved surfaces the length shall be determined mathemat-
the distance between locations where the echo amplitude is ically or graphically in the reflector depth determined.
lower the recording level by either 0 dB, 6 dB or 12 dB. Where
the noise level is reached, the recording length shall be indi- D 11.2.4.2 Selection of probe
cated to cover the point where the echo reaches the noise
level. Here, the distance of the recording level to the noise Scan positions and beam angle shall be selected such that the
level shall be recorded. scan path length shows the slightest deviation from 1.0  N
however is greater than 0.7  N. In such a case, a higher nom-
inal frequency than during the test may be used.
D 11.2.3 Determination of half-amplitude length
When measuring the half-amplitude length of indications, the D 11.2.4.3 Consideration of sound beam width
related probe displacements at echo amplitude decreases of
6 dB compared to the maximum echo amplitude shall be de- (1) The sound beam width DS-6dB shall be determined at the
termined. Here, for dual-element probes the acoustic separat- reflector location. If the measured indication length exceeds
ing line and for line focussing probes the line focus shall be this measured beam width the length of indication shall be the
vertical to the extension direction of the indication. corrected recording length calculated as per equation D-6.
KTA 3211.1 Page 118

(2) The beam width shall be determined by calculation or D 11.3 Indications due to geometric discontinuities
experimental analysis.
(1) Where indications from the root area of a weld are to be
(3) In the case of calculation equation D-4 shall be used if classified as indications due to geometric discontinuities, con-
probes are used, the contact surface of which has not been trol measurements shall be made to determine the cause of
adapted. In the case of angle beam scanning the horizontal indication.
included angle shall be inserted for 6. The included angle
(2) If it is to be proved that the indications recorded from
shall be taken from the data sheets on the probes used.
both weld sides arise on the two flanks of the excess penetra-
(4) Where the beam width has to be determined by experi- tion and are not caused by weld defects, the control meas-
mental analysis, measurements shall be made on a reference urement may be made by measuring the projected-surface
block to Section D 3.3. A reference reflector shall be provided distance on the test piece (see Figure D-21 a). The exact
into this reference block at the same depth location like for the projected-surface distances shall be determined on notches
reflector to be gauged. As reference reflector a flat bottom having rectangular cross-section with a depth and width of
hole of 3 mm diameter may be suited. The half-amplitude 1 mm each on a reference block (see Figure D-21 b). Where
length shall be determined on the reference reflector on the it is found out that the projected-surface distances of the re-
same sound path travel distance as for the reflector to be spective indications clearly overlaps [(2a - a’) equal to or
gauged. The value determined such shall correspond to the greater than 3 mm], the indications are considered to be
beam width at the respective depth of reflector. caused by geometric discontinuities. Where a smaller distance
than 3 mm is found, the indications shall no more be treated
separately.
D 11.2.4.4 Use of dual-element probes and focussing probes
(1) By means of dual-element probes or focussing probes
with suitable sound field the indication length shall be meas-
ured in the focal zone using the half-amplitude method.
(2) In this case several echo dynamics may be recorded
from the reflector on a grid pattern to increase the measuring
accuracy and to improve the reproduceability in the case of
focussing probes. The grid-line distances shall be smaller than
the diameter of the focussing beam of the probe.

D 11.2.5 Use of additional ultrasonic testing techniques for

the determination of indication extension
Where additional ultrasonic testing techniques are to be used
to determine the indication extension (length or depth), the
procedural requirements shall be laid down in a test instruc-
tion.
Note:
Examples for ultrasonic testing techniques for a more exact de-
termination of indication extension are:
a) Synthetic aperture focussing technique (SAFT),
b) Time-of-flight diffraction technique (TOFD),
c) Crack-tip signal detection technique, Figure D-21: Proof of indications caused by structural discon-
d) Echo tomography. tinuities from the root area of single-side welds
 KTA 3211.1 Page 119

Annex E
Performance of surface inspections by magnetic particle and penetrant methods

E 1 General requirements
Magnetic particle testing technique Characters
E 1.1 Surface condition
with permanent
(1) The surfaces to be inspected shall show a condition JD
Yoke magnetization magnet
suitable for testing.
with electromagnet JE
(2) They shall be free from scale, weld spatter or other dis-
turbing impurities. Magnetization by with coil LS
(3) Grooves and notches affecting the test result shall be current carrying- with other conduc-
conductors LK
removed. tors (cable)
Magnetization by self-induced current SS
E 1.2 Viewing conditions current flow induced current flow SI
(1) The viewing conditions of DIN EN ISO 3059 shall be
observed. In addition, the requirements as per (2) to (5) shall
be met. E 2.1.2 Contact areas in case of direct magnetisation
(2) The eyes of the operator shall have at least 5 minutes to (1) Where the test is performed by current flow technique,
adapt to the light conditions. consumable electrodes (e.g. lead fin alloys) shall be used, if
possible. It shall be ensured that in the contact areas over-
(3) For the purpose of better detectability of defects suffi-
heating of the material to be tested is avoided.
cient contrast shall be provided in magnetic particle testing by
the use of suitable media (e.g. fluorescent detection media or (2) Where overheating has occurred the overheated areas
application of a thin colour coat only slightly covering the un- shall be marked, ground over after the test and be examined
derground). Ultraviolet radiation of type UVA may additionally for surface cracks, preferably by magnetic particle testing
be used to improve the contrast in penetrant testing using using yoke magnetisation.
fluorescent penetrants.
(4) During the inspection the angle of viewing shall not devi- E 2.1.3 Direction of magnetisation
ate by more than 30 degrees from the surface normal. During
viewing the distance to the examination surface shall normally Each location on the surface shall be tested from two direc-
be approximately 300 mm. tions of magnetisation offset by approximately 90 degrees.

(5) For the inspection auxiliary means (e.g. magnifying

E 2.1.4 Magnetic field strength
glasses, contrast-improving spectacles, mirrors) are permitted.
(1) In the case of AC magnetisation the tangential field
E 1.3 Post-cleaning strength on the surface shall normally be at least 2 kA/m and
shall not exceed 6.5 kA/m.
Upon completion of inspection, the parts shall be properly Note:
cleaned to remove residues from the test fluid. a) The required magnetic flux density in the test object surface of
at least 1 Tesla will be obtained in low-alloy or low-carbon
steels with high relative permeability as early as at a tangen-
E 2 Magnetic particle testing
tial field strength of 2 kA/m.
E 2.1 Methods and performance of testing b) For other steels with lower permeability a higher field strength
may be required.
Magnetic particle testing shall be performed to DIN EN ISO c) Where magnetisation is too high, structural indications (spuri-
9934-1 to meet the following requirements. ous indications) may cover relevant indications.
(2) It shall be checked by measurements that these values
E 2.1.1 Methods are adhered to or test conditions shall be determined under
which these values may be obtained.
(1) Where magnetisation is achieved in partial areas by
current flow technique or yoke magnetisation, AC magnetisa-
tion shall normally be used. E 2.1.5 Magnetisation times

(2) The DC magnetisation method shall only be used upon The following guide values apply with respect to the applica-
agreement by the authorized inspector. tion of the magnetic particles and magnetisation:
a) Magnetisation and application: at least 3 seconds
(3) The residual magnetic field strength shall not exceed b) Subsequent magnetisation: at least 5 seconds
800 A/m unless a lower value is required for the fabrication.
Where the specified value is exceeded, the part shall be de-
magnetised and the value of the residual magnetic field E 2.2 Inspection medium
strength be recorded.
According to DIN EN ISO 9943-2 sample-tested media shall
(4) For the magnetic particle testing techniques the following be used. Verification of such sample testing shall be submitted
identifying characters shall be used: to the authorized inspector.
KTA 3211.1 Page 120

E 2.2.1 Wet particle inspection method (3) Only wet developers suspended in an aqueous solvent
shall be used. Dry developers may only be applied on the
(1) Magnetic particles with an average grain size smaller testing surface by electrostatic charging.
than or equal to 8 µm shall be used. Depending on applica-
tion, black, fluorescent or coloured powders may be used. (4) For the examination system at least sensitivity class
„highly sensitive“ to DIN EN ISO 3452-2 shall be adhered to.
Note:
The required average grain size ensures comparability with (5) The suitability of the testing system (penetrant, solvent
in-service inspections, cf. DIN 25435-2. remover and developer) shall be demonstrated by means of a
sample examination as to DIN EN ISO 3452-2. The results of
(2) Prior to bathing the surface care shall be taken to ensure the demonstration by sample testing shall be submitted to the
that the magnetic powder is distributed uniformly in the vehicle authorized inspector.
fluid and is kept in suspension. Prior to and during testing the
powder suspension shall be spot-checked by suitable pre- (6) Penetrants in test equipment and partly used open tanks
magnetised test units. (except for aerosol cans) shall be monitored by the user with
flux indicator 2 to DIN EN ISO 3452-3. In this test the maxi-
mum penetration and development times shall not exceed the
E 2.2.2 Dry particle method minimum times specified for the evaluation. The testing sensi-
(1) The dry particle method shall only be used for an inter- tivity obtained shall be recorded.
mediate test in warm condition.
E 3.2 Performance
(2) The device for applying the powder shall make possible
such a fine spraying that no accumulations of powder occurs. (1) Penetrant testing shall be performed to DIN EN ISO
It shall be ensured that the powders used do not agglomerate 3452-1 to meet the following requirements.
under the influence of the workpiece temperature.
(2) The penetration time shall normally be at least half an
hour.
E 2.3 Test instruments
(3) Immediately after drying of the developer a first inspec-
The test instruments shall meet the requirements of DIN EN tion shall normally be made. A further inspection shall normal-
ISO 9934-3. ly be made not earlier than half an hour after the first inspec-
tion has passed.

E 3 Penetrant testing (4) Further inspection times are required if during the second
inspection indications are detected which were not visible
E 3.1 Testing system during the first inspection.
Note:
(1) Colour contrast penetrants shall preferably be used.
Further inspection times may also be suitable if during the second
Fluorescent penetrants or fluorescent colour contrast pene- inspection significant changings or additional indications are de-
trants may also be used. tected.
(2) Solvents or water or both in combination may be used as (5) The evaluation shall be made in consideration of the
penetrant remover. results of all inspections.
 KTA 3211.1 Page 121

Annex F

Regulations and literature referred to in this Safety Standard

(The references exclusively refer to the version given in this annex. Quotations of regulations referred to
therein refer to the version available when the individual reference below was established or issued.)

AtG Act on the Peaceful Utilization of Atomic Energy and the Protection against its Hazards
(Atomic Energy Act) of December 23, 1959 (BGbl. I, p. 814) as Amended and Promul-
gated on July 15, 1985 (BGBl. I, p. 1565), last amended by article 2 (2) of the law dated
20th July 2017 (BGBl. I 2017, no. 52, p. 2808)
StrlSchV Ordinance on the Protection against Damage and Injuries Caused by Ionizing Radiation
(Radiation Protection Ordinance) dated 20th July 2001 (BGBl. I p. 1714; 2002 I p. 1459),
last amended in accordance with article 10 by article 6 of the law dated 27th January 2017
(BGBl. I p. 114, 1222)
SiAnf (2015-03) Safety Requirements for Nuclear Power Plants (SiAnf) as Promulgated on March 3rd
2015 (BAnz AT 30.03.2015 B2)
Interpretations (2015-03) Interpretations of the Safety Requirements for Nuclear Power Plants of November 22nd
2012, as Amended on March 3rd 2015 (BAnz. AT 30.03.2015 B3)
KTA 1401 (2017-11) General Requirements Regarding Quality Assurance
KTA 1408.1 (2017-11) Quality Assurance for Weld Filler Materials and Welding Consumables for Pressure and
Activity Retaining Systems in Nuclear Power Plants; Part 1: Qualification Testing
KTA 1408.2 (2017-11) Quality Assurance for Weld Filler Materials and Welding Consumables for Pressure and
Activity Retaining Systems in Nuclear Power Plants; Part 2: Manufacture
KTA 1408.3 (2017-11) Quality Assurance for Weld Filler Materials and Welding Consumables for Pressure and
Activity Retaining Systems in Nuclear Power Plants; Part 3: Processing
KTA 3211.2 (2013-11) Pressure and Activity Retaining Components of Systems Outside the Primary Circuit;
Part 2: Design and Analysis
KTA 3211.3 (2017-11) Pressure and Activity Retaining Components of Systems Outside the Primary Circuit;
Part 3: Manufacture
DIN EN ISO 148-1 (2017-05) Metallic materials - Charpy pendulum impact test - Part 1: Test method (ISO 148-1:2016);
German version EN ISO 148-1:2016
DIN EN ISO 643 (2013-05) Steels - Micrographic determination of the apparent grain size (ISO 643:2012); German
version EN ISO 643:2012
DIN EN ISO 898-1 (2013-05) Mechanical properties of fasteners made of carbon steel and alloy steel - Part 1: Bolts,
screws and studs with specified property classes - Coarse thread and fine pitch thread
(ISO 898-1:2013); German version EN ISO 898-1:2013
DIN EN ISO 898-2 (2012-08) Mechanical properties of fasteners made of carbon steel and alloy steel - Part 2: Nuts
with specified property classes - Coarse thread and fine pitch thread (ISO 898-2:2012);
German version EN ISO 898-2:2012
DIN EN ISO 1127 (1997-03) Stainless steel tubes - Dimensions, tolerances and conventional masses per unit length
(ISO 1127:1992); German version EN ISO 1127:1996
DIN EN 1369 (2013-01) Founding - Magnetic particle testing; German version EN 1369:2012
DIN EN 1370 (2012-03) Founding - Examination of surface condition; German version EN 1370:2011
DIN EN 1371-1 (2012-02) Founding - Liquid penetrant testing - Part 1: Sand, gravity die and low pressure die cast-
ings; German version EN 1371-1:2011
DIN EN 1559-2 (2014-12) Founding - Technical conditions of delivery - Part 2: Additional requirements for steel
castings; German version EN 1559-2:2014
DIN EN ISO 2400 (2013-01) Non-destructive testing - Ultrasonic testing - Specification for calibration block No. 1
(ISO 2400:2012); German version EN ISO 2400:2012
DIN EN ISO 2560 (2010-03) Welding consumables - Covered electrodes for manual metal arc welding of non-alloy
and fine grain steels - Classification (ISO 2560:2009); German version EN ISO
2560:2009
DIN EN ISO 3059 (2013-03) Non-destructive testing - Penetrant testing and magnetic particle testing - Viewing condi-
tions (ISO 3059:2012); German version EN ISO 3059:2012
DIN EN ISO 3452-1 (2014-09) Non-destructive testing - Penetrant testing - Part 1: General principles (ISO 3452-1:2013,
Corrected version 2014-05-01); German version EN ISO 3452-1:2013
KTA 3211.1 Page 122

DIN EN ISO 3452-2 (2014-03) Non-destructive testing - Penetrant testing - Part 2: Testing of penetrant materials
(ISO 3452-2:2013); German version EN ISO 3452-2:2013
DIN EN ISO 3452-3 (2014-03) Non-destructive testing - Penetrant testing - Part 3: Reference test blocks
(ISO 3452-3:2013); German version EN ISO 3452-3:2013
DIN EN ISO 3506-1 (2010-04) Mechanical properties of corrosion-resistant stainless steel fasteners - Part 1: Bolts,
screws and studs (ISO 3506-1:2009); German version EN ISO 3506-1:2009
DIN EN ISO 3506-2 (2010-04) Mechanical properties of corrosion-resistant stainless steel fasteners - Part 2: Nuts
(ISO 3506-2:2009); German version EN ISO 3506-2:2009
DIN EN ISO 3651-2 (1998-08) Determination of resistance to intergranular corrosion of stainless steels - Part 2: Ferritic,
austenitic and ferritic-austenitic (duplex) stainless steels - Corrosion test in media con-
taining sulfuric acid (ISO 3651-2:1998); German version EN ISO 3651-2:1998
DIN EN ISO 4136 (2013-02) Destructive tests on welds in metallic materials - Transverse tensile test
(ISO 4136:2012); German version EN ISO 4136:2012
DIN EN ISO 4287 (2010-07) Geometrical Product Specifications (GPS) - Surface texture: Profile method - Terms, def-
initions and surface texture parameters (ISO 4287:1997 + Cor 1:1998 + Cor 2:2005 +
Amd 1:2009); German version EN ISO 4287:1998 + AC:2008 + A1:2009
DIN EN ISO 5173 (2012-02) Destructive tests on welds in metallic materials - Bend tests (ISO 5173:2009 +
Amd 1:2011); German version EN ISO 5173:2010 + A1:2011
DIN EN ISO 5577 (2017-05) Non-destructive testing - Ultrasonic testing - Vocabulary (ISO 5577:2017); German ver-
sion EN ISO 5577:2017
DIN EN ISO 5579 (2014-04) Non-destructive testing - Radiographic testing of metallic materials using film and X- or
gamma rays - Basic rules (ISO 5579:2013); German version EN ISO 5579:2013
DIN EN ISO 6157-2 (2004-10) Fasteners - Surface discontinuities - Part 2: Nuts (ISO 6157-2:1995); German version
EN ISO 6157-2:2004
DIN EN ISO 6506-1 (2015-02) Metallic materials - Brinell hardness test - Part 1: Test method (ISO 6506-1:2014); Ger-
man version EN ISO 6506-1:2014
DIN EN ISO 6506-4 (2015-02) Metallic materials - Brinell hardness test - Part 4: Table of hardness values
(ISO 6506-4:2014); German version EN ISO 6506-4:2014
DIN EN ISO 6507-1 (2006-03) Metallic materials - Vickers hardness test - Part 1: Test method (ISO 6507-1:2005);
German version EN ISO 6507-1:2005
DIN EN ISO 6507-4 (2006-03) Metallic materials - Vickers hardness test - Part 4: Tables of hardness values
(ISO 6507-4:2005); German version EN ISO 6507-4:2005
DIN EN ISO 6892-1 (2017-02) Metallic materials - Tensile testing - Part 1: Method of test at room temperature
(ISO 6892-1:2016); German version EN ISO 6892-1:2016
DIN EN ISO 6892-2 (2011-05) Metallic materials - Tensile testing - Part 2: Method of test at elevated temperature
(ISO 6892-2:2011); German version EN ISO 6892-2:2011
DIN EN ISO 7963 (2010-12) Non-destructive testing - Ultrasonic testing - Specification for calibration block No. 2
(ISO 7963:2006); German version EN ISO 7963:2010
DIN EN ISO 8249 (2000-10) Welding - Determination of Ferrite Number (FN) in austenitic and duplex ferritic-
austenitic Cr-Ni stainless steel weld metals (ISO 8249:2000); German version EN ISO
8249:2000
DIN EN ISO 8492 (2014-03) Metallic materials - Tube - Flattening test (ISO 8492:2013); German version EN ISO
8492:2013
DIN EN ISO 8493 (2004-10) Metallic materials - Tube - Drift-expanding test (ISO 8493:1998); German version EN
ISO 8493:2004
DIN EN ISO 8495 (2014-03) Metallic materials - Tube - Ring-expanding test (ISO 8495:2013); German version EN
ISO 8495:2013
DIN EN ISO 8496 (2014-03) Metallic materials - Tube - Ring tensile test (ISO 8496:2013); German version EN ISO
8496:2013
DIN EN ISO 9606-1 (2013-12) Qualification testing of welders - Fusion welding - Part 1: Steels (ISO 9606-1:2012,
including Cor. 1:2012); German version EN ISO 9606-1:2013
DIN EN ISO 9712 (2012-12) Non-destructive testing - Qualification and certification of NDT personnel
(ISO 9712:2012); German version EN ISO 9712:2012
DIN EN ISO 9934-1 (2017-03) Non-destructive testing - Magnetic particle testing - Part 1: General principles
(ISO 9934-1:2016); German version EN ISO 9934-1:2016
DIN EN ISO 9934-2 (2015-12) Non-destructive testing - Magnetic particle testing - Part 2: Detection media
(ISO 9934-2:2015); German version EN ISO 9934-2:2015
 KTA 3211.1 Page 123

DIN EN ISO 9934-3 (2015-12) Non-destructive testing - Magnetic particle testing - Part 3: Equipment
(ISO 9934-3:2015); German version EN ISO 9934-3:2015
DIN EN 10028-2 (2009-09) Flat products made of steels for pressure purposes - Part 2: Non-alloy and alloy steels
with specified elevated temperature properties; German version EN 10028-2:2009
DIN EN 10028-3 (2009-09) Flat products made of steels for pressure purposes - Part 3: Weldable fine grain steels,
normalized; German version EN 10028-3:2009
DIN EN 10028-7 (2016-10) Flat products made of steels for pressure purposes - Part 7: Stainless steels;
German version EN 10028-7:2016
DIN EN 10160 (1999-09) Ultrasonic testing of steel flat product of thickness equal to or greater than 6 mm (reflec-
tion method); German version EN 10160:1999
DIN EN 10163-2 (2005-03) Delivery requirements for surface conditions of hot-rolled steel plates, wide flats and sec-
tions - Part 2: Plate and wide flats; German version EN 10163-2:2004
DIN EN 10164 (2005-03) Steel products with improved deformation properties perpendicular to the surface of the
product - Technical delivery conditions; German version EN 10164:2004
DIN EN 10204 (2005-01) Metallic products - Types of inspection documents; German version EN 10204:2004
DIN EN 10213 (2016-10) Steel castings for pressure purposes; German version EN 10213:2007+A1:2016
DIN EN 10216-2 (2014-03) Seamless steel tubes for pressure purposes - Technical delivery conditions -
Part 2: Non-alloy and alloy steel tubes with specified elevated temperature properties;
German version EN 10216-2:2013
DIN EN 10216-3 (2014-03) Seamless steel tubes for pressure purposes - Technical delivery conditions -
Part 3: Alloy fine grain steel tubes; German version EN 10216-3:2013
DIN EN 10216-5 (2014-03) Seamless steel tubes for pressure purposes - Technical delivery conditions - Part 5:
Stainless steel tubes; German version EN 10216-5:2013 (Corrigendum 2015-01)
DIN EN 10217-7 (2015-01) Welded steel tubes for pressure purposes - Technical delivery conditions -
Part 7: Stainless steel tubes; German version EN 10217-7:2014
DIN EN 10222-2 (2017-06) Steel forgings for pressure purposes - Part 2: Ferritic and martensitic steels with speci-
fied elevated temperatures properties; German version EN 10222-2:2017
DIN EN 10222-4 (2017-06) Steel forgings for pressure purposes - Part 4: Weldable fine grain steels with high proof
strength; German version EN 10222-4:2017
DIN EN 10222-5 (2017-06) Steel forgings for pressure purposes - Part 5: Martensitic, austenitic and austenitic-ferritic
stainless steels; German version EN 10222-5:2017
DIN EN 10228-1 (2016-10) Non-destructive testing of steel forgings - Part 1: Magnetic particle inspection;
German version EN 10228-1:2016
DIN EN 10228-2 (2016-10) Non-destructive testing of steel forgings - Part 2: Penetrant testing;
German version EN 10228-2:2016
DIN EN 10228-3 (2016-10) Non-destructive testing of steel forgings - Part 3: Ultrasonic testing of ferritic or mar-
tensitic steel forgings; German version EN 10228-3:2016
DIN EN 10228-4 (2016-10) Non-destructive testing of steel forgings - Part 4: Ultrasonic testing of austenitic and aus-
tenitic-ferritic stainless steel forgings; German version EN 10228-4:2016
DIN EN 10269 (2014-02) Steels and nickel alloys for fasteners with specified elevated and/or low temperature
properties; German version EN 10269:2013
DIN EN 10272 (2016-10) Stainless steel bars for pressure purposes; German version EN 10272:2016
DIN EN 10273 (2016-10) Hot rolled weldable steel bars for pressure purposes with specified elevated temperature
properties; German version EN 10273:2016
DIN EN 10307 (2002-03) Non-destructive testing - Ultrasonic testing of austenitic and austenitic-ferritic stainless
steels flat products of thickness equal to or greater than 6 mm (reflection method);
German version EN 10307:2001
DIN EN 10308 (2002-03) Non-destructive testing - Ultrasonic testing of steel bars; German version EN 10308:2001
DIN EN ISO 10484 (2004-10) Widening test on nuts (ISO 10484:1997); German version EN ISO 10484:2004
DIN EN ISO 10893-2 (2011-07) Non-destructive testing of steel tubes - Part 2: Automated eddy current testing of seam-
less and welded (except submerged arc-welded) steel tubes for the detection of imper-
fections (ISO 10893-2:2011); German version EN ISO 10893-2:2011
DIN EN ISO 10893-3 (2011-07) Non-destructive testing of steel tubes - Part 3: Automated full peripheral flux leakage
testing of seamless and welded (except submerged arc-welded) ferromagnetic steel
tubes for the detection of longitudinal and/or transverse imperfections
(ISO 10893-3:2011); German version EN ISO 10893-3:2011
KTA 3211.1 Page 124

DIN EN ISO 10893-4 (2011-07) Non-destructive testing of steel tubes - Part 4: Liquid penetrant inspection of seamless
and welded steel tubes for the detection of surface imperfections (ISO 10893-4:2011);
German version EN ISO 10893-4:2011
DIN EN ISO 10893-5 (2011-07) Non-destructive testing of steel tubes - Part 5: Magnetic particle inspection of seamless
and welded ferromagnetic steel tubes for the detection of surface imperfections (ISO
10893-5:2011); German version EN ISO 10893-5:2011
DIN EN ISO 10893-8 (2011-07) Non-destructive testing of steel tubes - Part 8: Automated ultrasonic testing of seamless
and welded steel tubes for the detection of laminar imperfections (ISO 10893-8:2011);
German version EN ISO 10893-8:2011
DIN EN ISO 10893-10 (2011-07) Non-destructive testing of steel tubes - Part 10: Automated full peripheral ultrasonic test-
ing of seamless and welded (except submerged arc-welded) steel tubes for the detection
of longitudinal and/or transverse imperfections (ISO 10893-10:2011); German version
EN ISO 10893-10:2011
DIN EN ISO 11699-1 (2012-01) Non-destructive testing - Industrial radiographic films - Part 1: Classification of film systems
for industrial radiography (ISO 11699-1:2008); German version EN ISO 11699-1:2011
DIN EN ISO 11970 (2007-09) Specification and approval of welding procedures for production welding of steel castings
(ISO 11970:2001); German version EN ISO 11970:2007
DIN EN 12668-1 (2010-05) Non-destructive testing - Characterization and verification of ultrasonic examination
equipment - Part 1: Instruments; German version EN 12668-1:2010
DIN EN 12668-2 (2010-06) Non-destructive testing - Characterization and verification of ultrasonic examination
equipment - Part 2: Probes; German version EN 12668-2:2010
DIN EN 12668-3 (2014-02) Non-destructive testing - Characterization and verification of ultrasonic examination
equipment - Part 3: Combined equipment; German version EN 12668-3:2013
DIN EN 12680-2 (2003-06) Founding - Ultrasonic examination - Part 2: Steel castings for highly stressed compo-
nents; German version EN 12680-2:2003
DIN EN 12681 (2003-06) Founding - Radiographic examination; German version EN 12681:2003
DIN EN 13018 (2016-06) Non-destructive testing - Visual testing - General principles;
German version EN 13018:2016
DIN EN ISO 13916 (1996-11) Welding - Guidance on the measurement of preheating temperature, interpass tempera-
ture and preheat maintenance temperature (ISO 13916:1996); German version EN ISO
13916:1996
DIN EN ISO 14174 (2012-05) Welding consumables - Fluxes for submerged arc welding and electroslag welding -
Classification (ISO 14174:2012); German version EN ISO 14174:2012
DIN EN ISO 14284 (2003-02) Steel and iron - Sampling and preparation of samples for the determination of chemical
composition (ISO 14284:1996); German version EN ISO 14284:2002
DIN EN ISO 19232-1 (2013-12) Non-destructive testing - Image quality of radiographs - Part 1: Determination of the im-
age quality value using wire-type image quality indicators (ISO 19232-1:2013);
German version EN ISO 19232-1:2013
DIN EN ISO 19232-3 (2014-02) Non-destructive testing - Image quality of radiographs - Part 3: Image quality classes
(ISO 19232-3:2013); German version EN ISO 19232-3:2013
DIN EN 26157-3 (1991-12) Fasteners; surface discontinuities; bolts, screws and studs subject to special require-
ments (ISO 6157-3:1988); german version EN 26157-3:1991
DIN 50104 (1983-11) Testing of hollow bodies by internal pressure; leak detection up to a certain pressure
value; general specifications
DIN 50125 (2016-12) Testing of metallic materials - Tensile test pieces
DIN 51220 (2003-08) Materials testing machines - Generals for requirements and for verification and calibra-
tion of materials testing machines
SEW 088 (1993-10) Weldable fine-grained structural steels; guidelines for processing, in particular for fusion
welding (incl. supplementary sheets 1 and 2)
AD 2000-Merk- (2014-11) Welding supervisors, welder
blatt HP 3
AD 2000-Merk- (2008-02) Austenitic and austenitic-ferritic steels
blatt W 2
AD 2000-Merk- (2009-03) Cast steel
blatt W 5
VdTÜV material (2001-06) High-temperature austenic rolled and forged steel, X 8 CrNiMoBNb 16 16 + wk,
sheet 113/2 material no. 1.4986 + wk
 KTA 3211.1 Page 125

VdTÜV material (2017-04) Weldable fine-grained steels with a minimum yield strength of 275 MPa; strips, plates,
sheet 352/1 wide flats, steel sections, steel bars
VdTÜV material (2017-04) Weldable fine-grained steels with a minimum yield strength of 275 MPa;
sheet 352/2 seamless hollow parts, seamless pipes, seamless headers
VdTÜV material (2017-04) Weldable fine grain steels with a minimum yield strength of 355 MPa; steel plate,
sheet 354/1 metal strips, wide flats, steel sections, steel bars
VdTÜV material (2016-03) Weldable fine grain steels with a minimum yield strength of 355 MPa;
sheet 354/2 seamless hollow parts, seamless pipes, seamless headers
VdTÜV material (2013-12) Weldable fine grain steels with a minimum yield strength of 355 MPa;
sheet 354/3 flanges; rings, hollow parts, forgings, steel bars
VdTÜV material (2010-09) Weldable martensitic rolled and forged steel, X3CrNiMo13-4;
sheet 395/3 material no. 1.4313; steel sections and steel bars, forged products
VdTÜV material (2011-06) Martensitic cast steel G-X4 CrNi 13 4 / G-X 3 CrNi 13 4, material no. 1.4317 /
sheet 452 material 1.6982; hollow castings, solid castings, cast valve bodies, pump casings, im-
pellers and diffusers, machine parts for hydraulic systems

Literature

[1] Handbuch für das Loseblattsammlung (Loose-leaf edition); Verlag Stahleisen, Düsseldorf
Eisenhüttenlaboratorium
[2] De Long, W. T. Welding Research Supplement 53 (1974), p. 273/286
[3] Richter, F. Physikalische Eigenschaften von Stählen und ihre Temperaturabhängigkeit,
(Physical Properties of Steels and Their Temperature Dependence)
Stahleisen-Sonderberichte Heft 10, 1983, Verlag Stahleisen, Düsseldorf.
[4] Petzow, G. Metallographisches, keramographisches, plastographisches Ätzen,
(Metallographic, ceramographic, plastographic etching)
Verlag Borntraeger; Nachdruck der 6. vollständig überarbeiteten Auflage
(19. Oktober 2006)
[5] Reference-Atlas for a comparative evaluation of ferrite percentage in the
fused zone of austenitic stainless steel welded joints; Internationales Institut
für Schweißtechnik: Istituto Italiano della Saldatura, Genova, 1972