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Safety Standardsof theNuclear Safety Standards Commission (KTA)

KTA 3205.1 (06/02)

Component Support Structures with Non-Integral Connections

Part 1: Component Support Structures with Non-Integral Connectionsfor Components of the Reactor Coolant Pressure Boundary ofLight Water Reactors

(Komponentenstützkonstruktionen mit nichtintegralen Anschlüssen;

Teil 1: Komponentenstützkonstruktionen mit nichtintegralen Anschlüs-sen für Primärkreiskomponenten in Leichtwasserreaktoren)

Previous versions of this Safety Standard were issued6/82 (Fed Gaz. No. 215a dated 19 November 1982 and6/91 (Fed. Gaz. No. 118a dated 30 June 1992)

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

Editor:

KTA-Geschaeftsstelle c/o Bundesamt fuer Strahlenschutz (BfS)Willy-Brandt-Strasse 5 • D-38226 Salzgitter • GermanyTelephone +49-1888/333-1621 • Telefax +49-1888/333-1625

anwender

Reaffirmed: 11/07

KTA 3205.1 page 2

KTA 3205.1 page 3

KTA SAFETY STANDARD

June 2002Component Support Structures with Non-Integral Connections;Part 1: Component Support Structures with Non-Integral Con-

nections for Components of the Reactor Coolant Pres-sure Boundary of Light Water Reactors

KTA 3205.1

CONTENTS

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

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

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

3 Loading levels (steel construction categories).........................................................................................6

4 Specifications ..........................................................................................................................................6

5 Documents to be submitted for design approval .....................................................................................6

6 Materials and product forms ....................................................................................................................66.1 Allowable materials..................................................................................................................................66.2 Materials testing and substantiation by test certificates ..........................................................................6

7 Design ...................................................................................................................................................107.1 General requirements............................................................................................................................107.2 Design of bar-type components (structural frames) ..............................................................................117.3 Dimensioning of plane load-bearing structures .....................................................................................17

8 Construction ..........................................................................................................................................198.1 General requirements............................................................................................................................198.2 Requirements ........................................................................................................................................19

9 Manufacture...........................................................................................................................................199.1 Requirements ........................................................................................................................................199.2 Welding supervision ..............................................................................................................................199.3 Welders .................................................................................................................................................199.4 Working principles for welding...............................................................................................................199.5 Weld filler metals and consumables......................................................................................................209.6 Welding procedure qualifications ..........................................................................................................209.7 Production control tests .........................................................................................................................219.8 Forming of components.........................................................................................................................219.9 Heat treatment.......................................................................................................................................219.10 Corrosion protection and cleanliness requirements ..............................................................................21

10 Final inspection......................................................................................................................................2210.1 General requirements............................................................................................................................2210.2 Extent and performance (at the works and on erection site) .................................................................2210.3 Verification of inspections and checks...................................................................................................23

11 Periodic inspections...............................................................................................................................23

(Continued next page)

PLEASE NOTE: Only the original German version of this safety standard represents the joint resolution of the50-member Nuclear Safety Standards Commission (Kerntechnischer Ausschuss, KTA). The German version wasmade public in Bundesanzeiger No. 189a on October 10, 2002. Copies may be ordered through the Carl HeymannsVerlag KG, Luxemburger Str. 449, D-50939 Koeln (Telefax +49-221-94373-603).All questions regarding this English translation should please be directed to:

KTA-Geschaeftsstelle c/o BfS, Willy-Brandt-Strasse 5, D-38226 Salzgitter, Germany

KTA 3205.1 page 4

CONTENTS(Continued)

12 Documentation...................................................................................................................................... 2312.1 General requirements ........................................................................................................................... 2312.2 Documents for final documentation ...................................................................................................... 2312.3 List of certificates .................................................................................................................................. 2312.4 Performance ......................................................................................................................................... 2312.5 Repair plans.......................................................................................................................................... 23

Annex A Materials test sheets (WPB)......................................................................................................... 27

Annex B Non-destructive examinations ...................................................................................................... 61

Annex C Verification of stability for austenitic steels at elevated temperatures .......................................... 71

Annex D Pipe-whip restraints ...................................................................................................................... 72

Annex E Design loadings............................................................................................................................ 76

Annex F Regulations referred to in this Safety Standard............................................................................ 83

Annex G Changes with respect to the edition 6/91 (informative) ................................................................ 88

Comments by the editor:

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

shall indicates a mandatory requirement,

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

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

should indicates a recommendation or an example of good practice,

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

KTA 3205.1 page 5

Fundamentals

(1) The safety standards of the Nuclear Safety StandardsCommission (KTA) have the task of specifying those safetyrelated requirements which shall be met with regard to pre-cautions to be taken in accordance with the state of scienceand technology against the damage arising from the con-struction and operation of the facility (Sec. 7 para. 2 subpara.3 Atomic Energy Act) in order to attain the protection goalsspecified in the Atomic Energy Act and the Radiological Pro-tection Ordinance (StrlSchV) and which are further detailed inthe "Safety Criteria for Nuclear Power Plants" and in the"Guidelines for the Assessment of the Design of PWR Nu-clear Power Plants against Incidents pursuant to Sec. 28 para3 of the Radiological Protection Ordinance (StrlSchV) - Inci-dent Guidelines".

(2) Criterion 1.1, “Principles of Safety Precautions”, of theSafety Criteria requires, among other things, a comprehensivequality assurance for fabrication and erection, and Criterion2.1 “Quality Assurance”, requires among other things, theestablishment and application of design and constructionrules and the documentation of quality assurance. KTA safetystandard 3205.1 is intended to specify detailed measureswhich shall be taken to meet these requirements within itsscope of application. For this purpose, a large number ofstandards from conventional engineering, in particular DINstandards, are also used.

(3) The safety-related function of component support struc-tures is the transfer of loads from the parts and componentssupported into the load-absorbing parts of the plant.

(4) This safety standard covers component support struc-tures with non-integral connections for components of thereactor coolant pressure boundary (scope in accordance withKTA safety standard series 3201). Component support struc-tures with non-integral connections for pressure and activity-retaining components in systems outside the primary circuitare covered by KTA safety standard 3205.2. Standard supportstructures which have been subjected to a qualification testare dealt with in KTA safety standard 3205.3. Componentsupport structures with integral connections for components ofthe reactor coolant pressure boundary are covered by KTAsafety standards 3201.1 to 3201.4. Component supportstructures with integral connections for systems outside theprimary circuit are especially dealt with in KTA 3211.3.

1 Scope

(1) This safety standard applies to non-integral componentsupports structures of steel construction category S1 for com-ponents of the reactor coolant pressure boundary with designtemperatures up to 350 °C in nuclear power plants with light-water reactors.

(2) The components to be supported of the reactor coolantpressure boundary cover:a) the reactor pressure vessel,b) the steam generator,c) the pressuriser,d) the reactor coolant pump,e) pipework attached to these components and valves in-

stalled on such pipework up to the first isolating valve.

(3) Parts connected to the component support structure,which are not intended to transfer loads, are not covered bythis safety standard. The stipulations apply to include theconnecting weld to the anchorage (anchor plate, dowel plate,through-anchors or other concrete-embedded load transferparts as well as platform supports).

(4) KTA safety standard 3205.3 lays down requirements forseries-production standard supports.

(5) Standard parts loaded or used in another way than de-scribed in the KTA 3205.3 annexes covering qualificationtesting, require the substantiation of loads in accordance withthe aforementioned safety standard and - if required - func-tional testing in accordance with KTA safety standard 3205.3.

(6) The delimitation of component support structures withnon-integral connections according to this safety standardagainst component support structures with integral connec-tions according to the KTA safety standards of the 3201 se-ries is shown in Figure 1-1. The component support structureis up to the connection to the structure (e.g. connecting weld,anchor plate, platform).

The distance l (run-out length) is calculated as follows:

l = 0.5 . sr ⋅ , (1-1)

where for shells (e.g. skirts, tubular nozzles) r is the meanradius and s the thickness of the shell-type support structure.

For other shapes r is one-half the maximum dimension of aflange, tee section, plate or round section or one-half themaximum leg width of an angle section and s the flange thick-ness of sections or plate thickness, s = r/2 for bar sections.

Component

: run-out length

non-

inte

gral

Building structure

Component support structure

connectiondetachable

Building structure

Component

limit of area

of componentof influence

inte

gral

non-

inte

gral

inte

gral

non-detachableconnection

Figure 1-1: Types of attachment of component supportstructure and area of influence of component

2 Definitions

(1) Final documentation

The final documentation comprises all documents to bemaintained during the lifetime of the plant or the plant partsfor which documents have to be established.

(2) Component support structures with non-integral connec-tions

Component support structures with non-integral connectionsare structures which are non-detachable from and outside thearea of influence (see Figure 1-1) of the connected compo-nent or which are detachable from the connected componentand are intended to transfer loads between the componentand the structure.

(3) Pipe-whip restraints

Pipe-whip restraints are structures to prevent broken pipingfrom whipping.

Note:Annex D to this safety standard contains the requirements forpipe-whip restraints.

KTA 3205.1 page 6

(4) Authorised inspectorAn authorised inspector is an expert person or organisation toact as inspector due to legal prescriptions (e.g. § 20 AtomicEnergy Act), guidelines, regulations, ordinances or acting onbehalf of the authority granting statutory approval or supervi-sory authority.

(5) Protective or special structuresProtective or special structures are pipe-whip restraints orother energy-absorbing elements.

3 Loading levels (steel construction categories)

(1) Component support structures are subject to differingrequirements in dependence of the safety-related importanceof the component to be supported as follows:a) Component support structures which support components

of the reactor coolant pressure boundary shall meet therequirements of this safety standard (steel constructioncategory S1). This does neither apply to pipe supports andpump supporting elements in piping with DN ≤ 100 nor toprotective and special structures which shall meet the re-quirements of KTA safety standard 3205.2 (steel con-struction category S2).

b) Component support structures which support componentsof outside systems, shall meet the requirements of KTAsafety standard 3205.2 (steel construction category S2).This does neither apply to steel platforms with supportingfunction, piping, valve and pump supports in the case ofDN < 100, nor to pressure vessel supports with a weightless than 50 kN and a product of pressure and litres ofless than 1000 [bar x l] which shall meet requirementsoutside the KTA safety standards (steel construction cate-gory S3).

c) Component support structures which support componentsoutside the reactor coolant pressure boundary and theoutside systems, shall meet requirements outside the KTAsafety standards (steel construction category S3).

d) Pipe-whip restraints for components of the reactor coolantpressure boundary and of outside systems shall meet therequirements laid down in Annex D to this safety stan-dard.

(2) Table 3-1 reflects this concept schematically.

(3) Table 3-2 contains the contains the protective goals andstability proofs for the various steel construction load cases.

4 Specifications

(1) The requirements to be met during fabrication and in-stallation shall be laid down in specifications.

(2) The specifications shall normally contain the following:a) a description of the component,b) spatial limitation, locations of installation,c) references to the design data sheet (ADB),d) design specifications,e) materials, material properties,f) drawings,g) fabrication and inspection prescriptions including specified

tolerances,h) independent in-process inspections at the manufacturer`s

works and during assembly, works and field inspections(test and inspection sequence plans),

i) functional testing,j) coat of paint, cleaning, packing and transport,k) applicable safety standards,l) Documentation.

(3) Information on further requirements may be included.Where individual requirements are specified in applicablesafety standards, reference shall be made to these standards.

5 Documents to be submitted for design approval

(1) The following documents shall be submitted to theauthorised inspector for design approval:a) design data sheet (ADB),b) design drawings with parts list,c) test and inspection sequence plan if not indicated in the

specification,d) welding procedure sheet including information on heat

treatments,e) calculations made (e.g. proof of stability),f) transfer of loads by connected parts to building structure,g) programs for special tests (e.g. pre-set loads),h) documents for welding procedures.

(2) Documents which are changed after design approvalshall be submitted anew to the authorised inspector.

6 Materials and product forms

6.1 Allowable materials

(1) The allowable materials for the various product formsare shown in Tables 6-1 to 6-5.

Other materials than those listed there are permitted if theiruse for the intended purpose has been accepted by theauthorised inspector.

(2) For parts which do not transfer loads and parts of minorimportance (e.g. concrete-embedded parts, distance plates,washers for bolted connections, minor parts, fillers, drainpipes) state-of-the-art-materials shall be used.

6.2 Materials testing and substantiation by test certificates

(1) The type and extent of materials testing as well as thesubstantiation by test certificates to DIN EN 10 204 are laiddown in the materials test sheets (WPB) in Annex A, to whichreference shall be made in the order.

(2) The manufacturer shall ensure that the tests and exami-nations laid down in the materials test sheets are performed.

(3) In the case of test and examinations made by themanufacturer he shall prove that he has qualified personneland the required facilities and at his disposal for the perform-ance of such test and examinations. The manufacturer mayalso employ facilities and personnel of other organisations asfar as they meet these requirements.

(4) Test reports shall be established on the non-destructivetests performed and be countersigned by the respective per-son charged with inspection duties. All test results obtainedshall be certified in the test certificates.

(5) Components (e.g. stored material) with already finisheddocumentation may be used unless objections are to bemade regarding non-conformance with safety requirements.

KTA 3205.1 page 7

KTA 3205.1 KTA 3205.2 Rules outside KTA 1)

KTA 3205.3Ser.No.

Type of steel structure

Components toKTA 3201

Components toKTA 3211

Othercomponents

1 Steel platforms with supporting function S1 S3 2)

2a DN > 100 S1 S2 5) S3 2), 5)

2b

Piping and valve supports, pumpsupports 3)

DN ≤ 100 S2 4), 5) S3 2), 5)

3a Pressure vessel supportsWeight � 50 kNor product of pressureand litre� 1000 [bar x l]

S1 S2 S3 2)

3b Weight < 50 kN andproduct of pressureand litre< 1000 [bar x l]

S1 S3 2)

4 Protective and special design equipment without ser. no. 5 S2 S3 2)

5 Pipe-whip restraints Requirements see Annex D

1) According to the rules of engineering practice.2) Supporting structures to be safeguarded against earthquakes shall additionally meet the requirements of KTA 3205.2; section 3.1,

clause 3.2 ( 2) and clause 8.8.3 (2).3) For pumps the DN of the nozzle shall control.4) Covered by the scope of this safety standard, substantiation shall, however, be made in accordance with KTA 3205.2.5) Irrespective of the category, periodic functional test shall be performed in the areas up to the next anchor.

Table 3-1: Loading levels (steel construction categories) for component support structures

Ser.No.

Structuralsteel load

cases

Comparison of Design criteria

DIN 18 801,DIN 15 018-1 and DIN 15 018-2

DIN 18 809

1 HHZHS1

HHZHS

HHZ

Fully suitable for intended use, cyclic load-ing possible, always re-usable.

2 HS2 HS Fulfilment of stability requirements andmaintenance of required functions, (e.g.bearing clearance).Limited deformation, generally re-usable

3 HS3 HS Gross plastic deformation permitted, re-usenot intended.

Notes:(1) The combined load cases to be verified shall be assigned to the structural steel load cases as per Table 7-1.(2) HS2/HS3: Generally requires only verification of primary stresses.

Table 3-2: Design criteria for component support structures and assignment to the structural steel load cases

KTA 3205.1 page 8

Ser. No. WPB Group of materials Allowable materials

1 1.1 Stainless steels to DIN EN 10 028-7 X5CrNi18-10 (1.4301)X6CrNiTi18-10 (1.4541)X6CrNiNb18-10 (1.4550)X6CrNiMoTi17-12-2 (1.4571)X5CrNiMo17-12-2 (1.4401)

2 1.2 High-temperature resisting quenched and temperedsteels acc. to supplementary sheet to WPB 1.2

20 MnMoNi 5 5 (1.6310)22 NiMoCr 3 7 (1.6751)

3 1.3 High-temperature resisting steels to DIN EN 10 028-2 P265GH (H II) (1.0425)16Mo3 (15 Mo 3) (1.5415)P295GH (17 Mn 4) (1.0481)P355GH (19 Mn 6) (1.0473)13CrMo4-5 (13 CrMo 4 4) (1.7335)

4 1.4 Structural carbon steels to DIN EN 10 025 S235JRG2 (RSt 37-2) (1.0038)S235J2G3 (St 37-3) (1.0116)S355J2G3 (St 52-3) (1.0570)

5 1.5 Quenched and tempered steels 1) to DIN EN 10 083-1 C35E (Ck 35) (1.1181)C45E (Ck 45) (1.1191)42CrMo4 (42 CrMo 4) (1.7225)34CrNiMo6 (34 CrNiMo 6) (1.6582)

6 1.6 Weldabel fine-grain steelsto DIN EN 10 028-3

P275NH (WStE 285) (1.0487)P355NH (WStE 355) (1.0565)

to DIN 17 102 WStE 255 (1.0462)

1) Shall not be welded.

Table 6-1: Allowable materials for plates and sheets (flat rolled products)

Ser.Nro

WPB Group of materials Allowable materials

1 2.1 Stainless steels to DIN 17 456; with special require-ments to DIN 17 457 or DIN 17 458

X5CrNi18-10 (1.4301)X6CrNiTi18-10 (1.4541)X6CrNiNb18-10 (1.4550)X6CrNiMoTi17-12-2 (1.4571)X5CrNiMo17-12-2 (1.4401)

2 2.2 Structural carbon steels to DIN EN 10 219-1 S235JRH (RSt 37-2) (1.0039)S355J2H (St 52-3) (1.0576)

3 2.3 High-temperature resisting steels to DIN 17 175 St 35.8 (1.0305)St 45.8 (1.0405)15 Mo 3 (1.5415)10 CrMo 9 10 (1.7380)13 CrMo 4 4 (1.7335)

4 2.4 Structural carbon steels

to DIN EN 10 210-1

S235JRH (RSt 37-2) (1.0039)S355J2H (St 52-3) (1.0576)S275J2H (St 44-3) (1.0138)

to DIN 17 121 St 37-3 (1.0116)5 2.5 High-temperature resisting quenched and tempered

steel acc. to supplementary sheet to WPB 2.520 MnMoNi 5 5 (1.6310)

6 2.6 High-temperature resisting fine-grain steel toDIN 17 178 or DIN 17 179

WStE 460 (1.8935)

7 2.7 High-temperature resisting quenched and temperedsteels acc. to supplementary sheet to WPB 2.7

15 NiCuMoNb 5 (1.6368)

Table 6-2: Allowable materials for welded and seamless tubes, hollow sections

KTA 3205.1 page 9

Ser.No.


1 3.1 Stainless steels to DIN EN 10 222-5 orDIN EN 10 272

X5CrNi18-10 (1.4301)X6CrNiTi18-10 (1.4541)X6CrNiNb18-10 (1.4550)X6CrNiMoTi17-12-2 (1.4571)X5CrNiMo17-12-2 (1.4401)

2 3.2 High-temperature resisting quenched and tempered steelacc. to supplementary sheet to WPB 3.2

20 MnMoNi 5 5 (1.6310)22 NiMoCr 3 7 (1.6751)

3 3.3 Structural carbon steels to DIN EN 10 250-2 or DIN EN10 025

S235JRG2 (RSt 37-2) (1.0038)S235J2G3 (St 37-3) (1.0116)S355J2G3 (St 52-3) (1.0570)

4 3.4 High-temperature resisting steels to DIN EN 10 222-2 orDIN EN 10 273

P250GH (C 22.8) (1.0460)16Mo3 (15 Mo 3) (1.5415)

5 3.5 Quenched and tempered steels 1)

to DIN EN 10 083-1 or SEW 550

C45E (Ck 45) (1.1191)42CrMo4 (1.7225)34CrNiMo6 (1.6582)

to DIN EN 10 269 21CrMoV5-7 (21 CrMoV 5 7) (1.7709)6 3.6 High-strength quenched and tempered steels acc. to

supplementary sheet to WPB 3.626 NiCrMo 14 6 (1.6958)20 NiCrMo 14 5 (1.6742)

1) Shall not be welded.

Table 6-3: Allowable materials for bars, forgings und steel sections

Ser.No.


1 4.1 Bolts to DIN EN ISO 898-1 Strength grades:4.6, 5.6, 5.8, 6.8, 8.8 and 10.91)

Nuts to DIN EN 20 898-2 Strength grades: 5, 6, 8 and 10

Washers for high-strength bolted joints toDIN EN 10 083-1 and DIN EN 10 083-2

C45C45E (Ck 45) or harder

2 4.2 Bolts and nuts ≤ M 39 toDIN EN ISO 3506-1 and DIN EN ISO 3506-2

Strength grades: 50, 70 or 80Steel grades: A2, A3, A4 and A5

3 4.3 Bolts and nuts, machined, thread rolled or cur, made ofstainless steels to DIN EN 10 222-5 or DIN EN 10 272

X6CrNiTi18-10 (1.4541)X6CrNiNb18-10 (1.4550)X6CrNiMoTi17-12-2 (1.4571)

4 4.4 Bolts and nuts, machined, thread rolled or cut, finally notheat treated,

Made of quenched and tempered steelsto DIN EN 10 083-1

C45E (Ck 45) (1.1191)42CrMo4 (42 CrMo 4) (1.7225)34CrNiMo6 (34 CrNiMo 6) (1.6582)

of steels with high strength at elevated temperaturesto DIN EN 10 269, DIN 267-13

C35E (Ck 35) (1.1181)25CrMo4 (1.7218)21CrMoV5-7 (21 CrMoV 5 7) (1.7709)40CrMoV4-6 (40 CrMoV 4 7) (1.7711)X19CrMoNbVN-11-1 (1.4913)

(X 19 CrMoVNbN 11 1)Acc. to Supplementary Sheet to WPB 4.4 20 NiCrMo 14 5 (1.6742)

26 NiCrMo 14 6 (1.6958)5 4.5 Bolts and nuts, hot formed, thread rolled or cut, finally heat

treated, of steels with high strength at elevated tempera-tures to DIN EN 10 269

C35E (Ck 35) (1.1181)21CrMoV5-7 (21 CrMoV 5 7) (1.7709)25CrMo4 (1.7218)40CrMoV4-6 (40 CrMoV 4 7) (1.7711)X19CrMoNbVN-11-1 (1.4913)

(X 19 CrMoVNbN 11 1)1) For high-strength bolted connections of strength-grade 10.9 only for design temperatures below 100 °C.

Table 6-4: Allowable materials for bolts, nuts, studs and washers subject to high-strength bolted joints

KTA 3205.1 page 10

Ser.No.


1 5.1 Ferritic cast steel acc. to suppl. sheet to WPB 5.1and to DIN EN 10 213-1 and DIN EN 10 213-2

GS-18 NiMoCr 3 7 (1.6756)GP240GH (GS-C 25) (1.0619)

2 5.2 Stainless cast steel to DIN EN 10 213-2 orDIN EN 10 213-4

GX5CrNiNb19-11 (G-X 5 CrNiNb 18 9) (1.4552)GX4CrNi13-4 (G-X 5 CrNi 13 4) (1.4317)

Table 6-5: Allowable materials for cast steel

7 Design

7.1 General requirements

7.1.1 Verification of strength

(1) The loading of components shall be substantiated byway of calculation or by experiments.

(2) Requirements as regards the type of verifications (e.g.design according to the respective structural steel designspecifications) shall be covered by the specifications. Specificsubstantiation my be made either by way of calculation orexperiments or as combination of calculations and experi-ments. To this end, the design methods described in Annex Bof KTA 3101.2 (e.g. finite element methods, elastic-plasticdesign method) or other procedures to be specified shall beused.

(3) Depending on the type of load-bearing structure theverification of strength shall be made to section 7.2 (bar-typeload-bearing structure) or section 7.3 (plane load-bearingstructure). In the case of specific design verifications the al-lowable stresses deviating from those laid down in clauses7.2.7 or 7.3.5 may be agreed with the authorised inspector inindividual cases.

(4) All design verifications required shall be performed com-pletely, be clearly arranged and make reviews possible. Thecalculations shall be consistent and contain clear referencesto the construction drawings. Therefore, no values shall gen-erally be taken from other calculations without indication ofsource or derivation.

(5) For designs, where plastic deformations are utilisedpurposefully, the design limits shall be agreed with theauthorised inspector. For pipe-whip restraints the require-ments of Annex D apply.

7.1.2 Indication of loadings

(1) All loadings acting alone or in combination with otherloadings shall be indicated.

(2) These loadings shall cover, where required:a) forces, moments, displacements and rotation from the

component to be supported due toaa) dead weight,ab) operational loadings,ac) settlement of buildings,ad) test loads,ae) assembly loads,af) external impacts (EVA),ag) internal impacts (EVI).

b) forces, moments, displacement and rotation of componentsupport structures due toba) dead weight,bb) external impacts (EVA),bc) internal impacts (EVI).

(3) The loadings include:a) permanent standard loads

dead weight of load-bearing structure and weight of sup-porting components with fluid and insulation (where in-stalled) – e.g. pipelines – unless covered by the compo-nent level loadings A to D to KTA 3201.2.

b) non-permanent standard loads- acting for a long period during operation, e.g. stockpiling

or assembly loads,- stockpiling, test or live loads not acting during opera-

tional periods or only for a short time during operation,c) component loads of level A to D

these are loads effected by the component to be sup-ported unless covered by the permanent standard loadsunder a) above,

d) special loadsthese loads cover external impacts such as earthquakesor internal impacts such as pipe rupture loads, jet thrustforces, pressure and temperature increase due to inci-dents.

(4) The design data sheet (ADB) shall contain the following:a) classification of the component support structures for the

seismic design to KTA 2201.1, structural steel class, load-bearing component,

b) plant part,c) room number and elevation,d) material group or material,e) system description, e.g. identification of piping to the

power plant identification system (KKS),f) loadings occurring (superposition, classification),g) temperature (ambient temperature, fluid temperature),h) functional requirements (e.g. degrees of freedom),j) test note.

7.1.3 Assumptions for component design

(1) The design temperature at the point of connection be-tween component and supporting structure shall be equal tothe component temperature during regular operation.

(2) The design of those component support structures tofulfil safety-related functions during incidents shall be basedon the component temperature at the point in time underconsideration in dependence of the load case.

(3) Where required, the time history of the loadings (e.g.temperature, pressure waves, jet thrust) shall be considered.

(4) Frictional effects shall only be verified in load cases Hand HZ. The following friction coefficients apply – withoutspecific verification – for ferritic steels:

a) µ = 0.45 steel on steel / unmachined;without sliding agent, with coating.

b) µ = 0.30 steel on steel / machined(e.g. brushed); free of coating.

3205.1 page 11

(5) A friction coefficient of µ = 0.15 – without specific verifi-cation - applies as regards the static equilibrium of a con-struction. Other friction coefficients are permitted, if verified.

(6) For friction-type bolted connections the following applies:

For either of the following frictional face preparation measures

a friction coefficient of µ = 0.5 may be used without exact verification:

a) 2 times flame descaling

b) shot blasting

c) steel shot peening.

(7) The design of component support structures

a) may comprise load portions of the loadings to be covered.

b) shall combine loads assumed to be applied simultane-ously in accordance with specification.

7.1.4 Loads and load cases

(1) A verification of strength shall be made for the following load cases:

a) H : principal loads,

b) HZ: principal and additional loads,

c) HS1: principal and special loads,

d) HS2: principal and special loads or

e) HS3: principal and special loads.

(2) The loads cases are derived from the combination of loads, e.g. for load case HZ from the combination of principal loads H and additional loads Z.

(3) Even if no principal loads occur, the additional loads Z shall be classified under load case HZ and special loads S under load cases HS1, HS2 or HS3.

7.1.5 Classification of loadings

In correspondence with the load case classification of compo-nents four levels of loads applied by the supported component are distinguished (A, B, C, D). The assignment of all loadings to load cases H, HZ, HS1, HS2 and HS3 is shown in Table 7-1.

7.1.6 Allowable stresses

(1) The determination of allowable stresses for the verifica-tion of the load cases H, HZ, HS1, HS2 and HS3 shall be based on he equivalent yield stresses Rv0.2 using the follow-ing design strength values:

ReHRT : minimum value of upper yield strength at room temperature

RmRT : minimum value of tensile strength at room tempera-ture

Rp0.2RT : minimum value of 0.2 proof stress at room tempera-ture

ReHT : minimum value of upper yield strength at tempera-ture T

RmT : minimum value of tensile strength at temperature T

Rp0.2T : minimum value of 0.2 proof stress at temperature T

(2) Table 7-2 determines the equivalent yield strength in dependence of the material for structural steel class S1.

(3) Table 7-3 (components) and Table 7-4 (welds) indicate the allowable stresses referred to the equivalent yield strength for the verification of strength of load cases H, HZ, HS1, HS2 and HS3. Tables 7-5 and 7-6 contain the allowable stresses for bolts as well as bearing parts and articulated connections.

(4) The minimum values shall principally be taken from the standards listed in Tables 6-1 to 6-5. For bearing material with already finished documentation the requirements of clause 5, section 6.2 apply. In individual cases, the mechani-cal property values may be taken from the inspection certifi-cates to DIN EN 10204 for the design.

(5) For component parts and welded joints made of S235 (St 37) and S355 (St 52) the reduction factors of Figure 7-1 shall be used.

Reduction only for values of T > 80 °C

ReHT = k ⋅ ReHRT or Rp0.2T = k ⋅ Rp0,2RT

Figure 7-1: Reductions factor k for determining the hot yield strength in dependence of the temperature

7.2 Design of bar-type components (structural frames)

7.2.1 General reqirements

(1) To substantiate the sufficient dimensioning of compo-nents the verifications covered by clauses 7.2.2 to 7.2.6 shall be made. Design verifications may be supplemented or be substituted by tests. The test program shall be agreed be-tween plant supplier, manufacturer and authorised inspector.

(2) The loadings shall be classified under load cases H, HZ, HS1, HS2 and HS3.

(3) In individual cases – and deviating from the specifica-tions hereafter – the design may be based on the applicable standards for structural steel parts (e.g. DIN 18 800-1) by agreement with the authorised inspector.

(4) For the purpose of verifying the load-carrying capacity an ultimate limit load analysis may be made instead of apply-ing clauses 7.2.2 and 7.2.3, i.e. at a given combination of loads the maximum load to be withstood by the structure shall be determined with which the safety-related function of the components are ensured.

(5) For the sake of simplification the ultimate limit load may be calculated by approximation in accordance with DIN 18 800-1. The safety factors for special load cases shall be fixed accordingly at the same level as those used for the allowable stress calculation.

(6) The verification of the load-carrying capacity (ultimate limit load analysis) to DIN 18 800-1 to DIN 18 800-4 shall always be made where the stress resultants increase super-proportionally compared to the loading.

For austenitic materials the 0.1 % proof stress, however not in excess of 360 N/mm

2 shall be used.

KTA 3205.1 page 12

7.2.2 General stress analysis

(1) A general stress analysis shall be performed for all com-ponents and connections for the various load cases (e.g.H = principal loads, HZ = principal and additional loads;HS1,/HS2/HS3 = principal and special loads). The stressescalculated shall be compared with the allowable stress values.

(2) The stresses for component parts including studs shallbe determined in accordance with section E 2 (see Annex E).

(3) The stresses for welded joints shall be determined inaccordance with section E 3. The equivalent stress σv toequation (E 3-5) shall only be used for S235 (St 37) and S355(St 52). Otherwise the equivalent stress shall be derived bymeans of equations (E 2-14 and E 2-15).

(4) The stresses for bolted joints shall be determined inaccordance with section E 4. The following shall be taken intoaccount:a) For the stress analysis regarding shear loading the section

under shear (shank cross-section or minor-diameter area)shall govern.

b) For the stress analysis regarding normal loading the ten-sile stress area shall govern for bolts with metric ISOthreads to DIN 13-1, otherwise the minor-diameter area.

c) For the stress analysis regarding allowable bearing stressthe bolt area shall govern.

d) The stress analysis for bolts not subjected to shear load-ing in the thread area is deemed to have been performedif the allowable stresses for both shear and normal loadingare adhered to separately. For bolts subject to shearloading in the thread area the equivalent stress σv shalladditionally be determined:

σv = 2 23σ τ+ ⋅ (7-1)

(5) For high-strength pre-tensioned friction-type bolted joints(GV) the analysis shall be made to section E 4.2. Where thedesign temperatures exceed 100 °C the load-carrying capac-ity shall additionally be verified in which case the stipulationsof KTA 3401.2, section 5.4 shall apply.

(6) The stresses for bearings and articulated joints shall bedetermined in accordance with the usual methods (e.g. con-tact stress, Hertzian stress).

7.2.3 Verification of stability

(1) Pressure-loaded components with a slenderness ratioexceeding 150 are not permitted.

(2) The verifications of stability (against buckling under axialload, overturning, shell or plate buckling) for ferritic steelsshall be made to DIN 18 800-2. In load cases HS2 and HS3 aminimum safety factor of 1.15 against the limit load shall beadhered to. In load case HS 1 the safety factor shall exceedthe safety factors of load cases HS2 and HS3 by 10%. Whereelevated temperatures occur the changed material propertyvalues for proof or yield stress shall be considered. Normallythe reduction of the elastic modulus is negligible.

(3) For austenitic steels the verification of stability may beperformed with acceptance certificate Z-30.3-6 of the Institutfür Bautechnik, Berlin. The buckling factors, equivalentstresses and buckling resistances listed in this certificateprimarily apply only to temperatures of up to 50 °C. In thecase of higher temperatures the procedure of Annex C maybe applied.

7.2.4 Verification of fatigue strength

The verification of fatigue strength can be omitted since pri-marily static loadings prevail.

7.2.5 Verification of static equilibrium

For the verification of stability to section E 5 the stabilisingloads shall be considered with a factor of 1.0 in the case ofspecial load cases. Destabilising loads shall be consideredwith a factor of 1.3 for load case HS1 and with a factor of 1.15for load cases HS2 and HS3.

7.2.6 Verification of strain limiting load

(1) An additional verification of the strain limiting load is onlyrequired if the function of the load-bearing component neces-sitates the limitation of strain.

(2) For the determination of strains, cross-sectional valueswithout deduction of area for holes may be used.

7.2.7 Allowable stresses

7.2.7.1 Components

The allowable stresses for components are shown in Table 7-3.

7.2.7.2 Welded joints

The allowable stresses for welded joints are shown in Table 7-4.

7.2.7.3 Bolted joints

(1) For ferritic bolt materials the following applies: RV0.2equals ReHT. For austenitic bolt materials the following ap-plies: RV0.2 equals Rp0.2T.

(2) As regards the allowable stresses for bolts of strengthgrades 4.6, 5.6 and 10.9 at temperatures less than or equal to80 °C the values of Table 7-5.1 shall be taken.For temperatures exceeding 80 °C the allowable stressesshall be reduced by the elastic ratio in accordance with DINEN ISO 898-1. For bolts of strength grade 4.6 the reductionfactor k for the steel S235 (St 37) to Figure 7-1 shall apply.

(3) The allowable stresses for other bolting materials arelisted in Tables 7-5.2 and 7.5-3.

(4) At pure tensile loading, the tensile force for load casesHS1/HS2/HS3 in the connected component shall not exceed0.9 times the value of the applied initial tension for friction-type connections in accordance with DIN 18 800-7 or VDI2230, Sheet 1.

KTA 3205.1 page 13

Load combinations(superposition of loadings)

1 2 3 4 5 6 7 8

Load cases

Ser.No.

Loadings

H HZ HS1 HS2/HS3 3)

1 Permanent and non-permanent standard loads X X X X X X X X

2 Constraint resulting from operating temperature ofsupporting structure

X

3 Constraint resulting from operating temperature ofsupported structure

X

4 Component loads A 5) X

5

Sta

ndar

d lo

ads

Component loads B 4) X

6 Component loads C 4) X

7 Component loads D X

8 Constraint resulting from incident temperture X

9 Pipe rupture loads X

10 Jet thrust forces X

11

Spe

cial

load

s 1)

External impact loads 2) X1) A detailled list of special loads referring to the respective steel structure shall be provided in the design data sheet.2) Design earthquake and bursting pressure wave, aircraft crash, explosion wave.3) The assignment to HS2 and HS3 shall be made in the design data sheet in dependence of the protective goal of the safety-related sup-

porting structure.4) Including loads from temperature constraint and edge displacements.5) The component loads A to D correspond to the loads assigned to loading levels A to D in accordance with KTA 3201.2.

Table 7-1: Load cases and classification of load cases

Ser.No.

Use Material Rv0.2 for structural steel class S1

1 Structural steelsS235 (St 37), S355 (St 52), St 35

ReHT

2Heat-resisting and fine-grain steelsP275NH, P355NH (W StE 355),P265GH (H ΙΙ), 16Mo3

ReHT

3 Ferritic steels,except for serial nos. 1 and 2 min { ReHT ; 2/3 RmT } 1)

4

Components andwelds

Stainless steels 1.5/1.1 Rp0.2T

5a Ferritic/martensitic min { ReHT ; 2/3 RmT } 1)

5bSteel casting 2)

Austenitic 1.5/1.1 Rp0.2T

6a Strength classes 4.6, 5.6, 8.8 and 10.9 Allowable stresses, see Table 7-5.1

6b Ferritic steels,except for serial no. 6a ReHT

6c

Bolts

Austentitic steels Rp0.2T

1) At a ratio ReHRT / RmRT �� v0,2 = min {ReHT ; 1.5/2.4 RmRT}. If there is no distinct yield stress, the values apply tothe 0.2 % proof stress.

2) The reduction of values for tensile loading and bending in accordance with Table 7-3 serial no. 2 shall be considered.

Table 7-2: Comparison of yield strength values Rv0,2 in dependence of the material

KTA 3205.1 page 14

Allowable stresses(referred to Rv0,2)Lfd.

Nr.Type of loading

H HZ HS1 HS2/HS3

1 Tension, tensile bending and bending pressure if verification of stability isnot required. 0.67 0.77 0.87 1.00

Ferritic and martensitic steel casting 0.50 0.58 0.65 0.752

Tensile bending and bend-ing pressure for steel cast-ing Austenitic steel casting 0.37 0.42 0.48 0.55

3 Pressure and bending pressure (verification of stability) 1) 0.60 0.67 0.73 0.80

4 Shear 0.37 0.43 0.50 0.57

5 Equivalent stress 0.77 0.80 0.90 1.00

6SL Pressed screws (DIN 7990), high-strength bolts

(DIN 6914) or countersunk head bolts(DIN 7969)Hole clearance 0.3 mm < ∆d ≤ 2 mm – without pre-tensioning 2)

1.17 1.33 1.50 1.73

7

SL High-strength bolts (DIN 6914)Hole clearance 0.3 mm < ∆d ≤ 2 mmUnplanned pre-tensioning: ≥ 0.5 ⋅ FV (FV toDIN 18 800-7 or VDI 2230)

1.57 1.73 2.00 2.33

8 SLP Body-fit bolts (DIN 7968)Hole clearance ∆d ≤ 0,3 mm - no pre-tensioning

1.33 1.50 1.73 2.00

9SLP High-strength body-fit bolt - hole clearance ∆d ≤ 0.3 mm

Unplanned pre-tensioning: ≥ 0.5 ⋅ FV (FV toDIN 18 800-7 or VDI 2230)

1.73 1.93 2.27 2.60

10

Bea

ring

pres

sure

(zul

σ1)

for t

hick

ness

of m

ater

ial ≥

3 m

mat

con

nect

ion

due

to b

GV,GVP

High-strength bolt - hole clearance 0.3 mm < ∆d ≤ 2 mmHigh-strength body-fit bolt - hole clearance ∆d ≤ 0.3 mmPre-tensioning: 1.0 � FV (FV to DIN 18 800-7 or VDI 2230) 3)

2.00 2.27 2.50 3.00

SL : bearing-type shear connection GV : friction-type connectionSLP : bearing-type shear connection in the case of body-fit bolts GVP : friction-type connection in the case of body-fit bolts

1) For austenitic materials the following applies:- load cases H and HZ to DIBt acceptance certificate Z-30.3-6- load case HS1 equal to 1.22 times H.- load cases HS2/HS3 equal to 1.33 times H.

2) For slots the following applies: in longitudinal direction 100 %, in transverse direection 70 % of the tabulated values appliy.3) For austenitic materials only by agreement with the authorised inspector.

Table 7-3: Allowable stresses (referred to equivalent yield stress Rv0,2 toTable 7-2) for components in dependence of thetype of loading and load case

7.2.7.4 Bearings and articulated connections

(1) For the load cases H and HZ the allowable stresses ofTable 7-6 shall be adhered to. For the load case HS 1.5 timesthe value of load case H applies.

(2) For bearings and articulated connections the allowableHertzian stress (σH) between rollers and plates made of non-hardened materials to DIN 15 070 shall be determined bymeans of the allowable Stribeck’s pressure loading (pzul) tothe following equation:

σH(T) = 1.3 .

)T(E1

)T(E1

)T(p7.0

21

zul

+

⋅(7-2)

where:

pzul(T) : allowable Stribeck’s pressure loading at temperatureT to DIN 15070, Table 2:

96R60.,0)T(p mT

zul +−= (RmT and pzul in N/mm2)

σH(T) : allowable Hertzian stress at temperature T

RmT : minimum tensile strength at temperature T

E1(T), : elastic moduli of the materials in contact at tempera-E2(T) ture T

For movable bearings with more than two rollersthese values shall be reduced by 15%.

KTA 3205.1 page 15

Allowable stresses 3)

(referred to RV0.2 of base material)Ser.No.

Type of weld Figure Quality of weld Type of loading

H HZ HS1 HS2/HS3

1 Butt weld All types Pressure and bending 0.67 0.77 0.87 1.00

2 Double-bevelgroove weld

Quality verified

Pressure and tensile bend-ing, equivalent stress

Pressure and tensile bend-ing for steel casting:

ferritic and martensiticaustenitic

0.67

0.500.37

0.77

0.580.42

0.87

0.650,48

1.00

0.750.55

3

Single-bevelgroove weldwith filletweld:

Backing runback-welded

4

Single-bevelgroove weldwith fillet weld

Full penetra-tion weldedat root

Quality notverified

Pressure and tensile bend-ing, equivalent stress



0.47

0.350.26

0.53

0.400.29

0.57

0.430.31

0.63

0.480.35

5Double-bevelbutt weld

Pressure and bending pres-sure

0.67 0.77 0.87 1.00

6

Single-veegroove withroot face withdouble filletweld

All qualitiesPressure and tensile bend-ing, equivalent stress



0.47

0.350.26

0.53

0.400.29

0.57

0.430.31

0.63

0.480.35

7 2)

8Fillet welds 4)

All qualities

9 2)

Pressure and bending pres-sure, tension and tensilebending, equivalent stress



0.47

0.350.26

0.53

0.400.29

0.57

0.430.31

0.63

0.480.35

10All weldsS235 (St 37)

All types of loading 5)0.57 0.63 0.73 0.83

11 All weldsS355 (St 52)

All qualities 0.47 0.53 0.60 0.70

12 All weldsother steels

Shear

0.37 1) 0.43 1) 0.47 1) 0.50 1)

1) If no higher values are proved by tests.2) Welds welded from both sides shall be preferred to single-side welds. The type of weld under serial nos. 7 and 9 shall only be used for

for filled welds at groove faces and connection of closed parts. Single-side welds are permitted for weld thicknessesa ≤ 5 mm.

3) Where the allowable stress is utilised with 70 % or more, the weld quality requirement is increased (evaluation group C instead of D),see also clause 9.4.4.

4) For S235 serial no.10 applies5) For pressure and bending pressure the higher values under serial nos. 1, 2 and 5 apply.

Table 7-4: Allowable stresses (referred to equivalent yield stress Rv0.2 to Table 7-2) for welds in dependence of type of weld,type of loading and load case

KTA 3205.1 page 16

Load caseH HZ HS1 HS2/HS3

Ser.No. Strength

gradeType of stress

N/mm2 N/mm2 N/mm2 N/mm2

1 Shear 112 126 146 1682

SLTension 110 125 143 165

34.6

Shear 140 160 182 2114

SLPTension 110 125 143 165

5 Shear 168 192 218 2526

SLTension 150 170 195 225

75.6

Shear 210 240 273 3158

SLPTension 150 170 195 255

9 Shear 168 189 22710

SLTension 252 287 344

118.8

Shear 196 224 26712

SLPTension 252 287 344

13 Shear 240 270 32414

SLTension 360 410 492

1510.9

Shear 280 320 38416

SLPTension 360 410 492

In bearing-type shear connections (SL) and bearing-type shear connections with body-fit bolts (SLP), under combined shearand tensile loading, all substantiations shall be made by separate calculations (shear, tension, bearing pressure) independ-ently of each other, in which case the allowable values for the individual types of loading can be fully utilised without proof ofequivalent stress.

Note:The allowable bearing pressure is obtained from the smaller Rv0.2 value of the bolts or base material, respectively acc. to Table 7-3.

Table 7-5.1: Allowable stresses for bolts of strength grades 4.6, 5.6, 8.8 and 10.9 at temperatures less than or equal to80 °C in dependence of the load cases

Load caseSer.No.

Type of stressH HZ HS1 HS2/HS3

1 Tension

2 Shear (transverse to bolt axis) 0.47 Rv0.2 0.52 Rv0.2 0.58 Rv0.2 0.64 Rv0.2

Table 7-5.2:Allowable stresses for bolts with ReHRT ≤ 450 N/mm2

Load caseSer.No.

Type of stressH HZ HS1/HS2/HS3

1 Tension 0.4 Rv0.2 0.45 Rv0.2 0.54 Rv0.2

2 Shear (transverse to bolt axis) 0.264 Rv0.2 0.3 Rv0.2 0.36 Rv0.2

Table 7-5.3: Allowable stresses for high-strength bolts with ReHRT > 450 N/mm2

MaterialS235 (St 37) / St 35.8 S355 (St 52)

Load caseH HZ H HZ

Ser.No.

Type of stress

N/mm2 N/mm2 N/mm2 N/mm2

1 Hertzian pressure 1) 650 800 850 10502 Bearing pressure for hinge pins 2) 210 240 320 360

1) For movable bearings with more than 2 rollers these values shall be reduced to 85 %. Such bearings should, however be avoided, wherepossible.

2) These values apply only to multiple-shear connections

Table 7-6: Allowable pressure stresses for bearing parts and hinged joints, in N/mm2

KTA 3205.1 page 17

7.3 Dimensioning of plane load-bearing structures

7.3.1 General requirements

(1) The requirements set forth hereafter apply to the deter-mination of stress resultants to the theory of elasticity.

(2) Where required, the strain limits of the supportingstructure shall also be verified.

(3) The verification shall be substantiated by way of calcula-tion. Where calculations are supplemented or substituted bytests, the plant supplier, manufacturer and authorised in-spector shall have agreed before on the test program.

(4) The loadings shall be assigned to load cases H, HZ,HS1, HS2 and HS3.

(5) The internal forces and moments shall be determined tothe theory of elasticity in due consideration of geometric im-perfections.

7.3.2 Equivalent stress intensity Sm

(1) For ferritic steels the equivalent stress intensity Sm shallbe determined as follows:

=4.2

R;5.1

RminS mRTeHTm (7-3)

(2) For austenitic steels the equivalent stress intensity Smshall be determined as follows:

=4.2

R;1.1

RminS mTT2.0pm (7-4)

At design temperatures equal to or less than 350 °C

7.2RS mRT

m = may be taken instead of4.2

RmT .

(3) For ferritic and austenitic steel castings subject to tensileloading and bending the equivalent stress intensity Sm shallbe determined as follows:

0.2R

ST2.0p

m = (7-5)

For other loadings equation (7-3) applies. For tensile loadingand bending equations (7-3) and (7-4) shall only be used byagreement with the authorised inspector.

(4) For welded joints the equivalent stress intensity Sm shallbe determined by means of equations (7-3) to (7-5) as forcomponents.

7.3.3 Classification of stresses

7.3.3.1 General requirements

(1) Stresses shall be classified in dependence of the causeof stress and its effect on the mechanical behaviour of thestructure into primary stresses, secondary stresses and peakstresses and be limited in different ways with regard to theirclassification.

(2) Where in special cases the classification into the afore-mentioned stress categories is unclear, the effect of plasticdeformation on the mechanical behaviour shall be determin-ing where an excess of the intended loading is assumed.

7.3.3.2 Primary stresses

(1) Primary stresses P are stresses which satisfy the laws ofequilibrium of external forces and moments (loads).

(2) Regarding the mechanical behaviour of a structure thebasic characteristic of this stress is that in case of (an inad-missibly high) increment of external loads the distortions upon

full plastification of the section considerably increase withoutbeing self-limiting.

(3) Regarding primary stresses distinction shall be madebetween membrane stresses (Pm, Pl) and bending stresses(Pb) with respect to their distribution across the wall.

(4) In the case of plane load-bearing structures membranestresses are defined as the average value of the stress com-ponent distributed over the thickness, and bending stressesare defined as the portion of the stresses distributed acrossthe thickness, that can be altered linearly.

(5) Regarding the distribution of membrane stresses acrossthe wall distinction is to be made between general primarymembrane stresses (Pm) and local primary membranestresses (Pl). Primary membrane stresses in shells are con-sidered to be local if the stress intensity does not exceed 1.1times the allowable general membrane stress in a regionremote from the discontinuity and with a length of 1.0 . r s⋅and two adjacent regions with maximum values of local pri-mary stress intensities shall not be closer than 2.5 . r s⋅from each other where r the smaller radius of curvature and sthe wall thickness. Where local primary membrane stressesdo not exceed 1.1 times the general primary membranestresses, even in the run-out length of adjacent discontinuitiesin consideration of a redistribution of stresses, the aboveminimum spacing requirements need not be met for the twoadjacent regions with maximum values of local primary stressintensity.

(6) While general primary membrane stresses are distrib-uted such that no redistribution of stresses due to plastifica-tion occurs into adjacent regions, plastification in the case oflocal primary membrane stresses will lead to a redistributionof stresses.

7.3.3.3 Secondary stresses

(1) Secondary stresses Q are stresses developed by con-straints due to geometric discontinuities and by the use ofmaterials of different elastic moduli under external loads andby constraints due to differential thermal expansions. Onlystresses that are distributed linearly across the cross-sectionare considered to be secondary stresses.

(2) With respect to the mechanical behaviour of the struc-ture the basic characteristics of secondary stresses are thatthey lead to plastic deformation when equalising different localdistortions in the case of excess of the yield strength. Secon-dary stresses are self-limiting.

7.3.3.4 Peak stresses

Peak stress F is that increment of stress which is additive tothe respective primary and secondary stresses. Peak stressesdo not cause any noticeable distortion and are only importantto fatigue in conjunction with primary and secondary stresses.

7.3.4 Superposition and evaluation of stresses


(1) As shown hereinafter, for each load case the stressesacting simultaneously in the same direction shall be addedseparately or for different stress categories be added jointly.

(2) From these summed-up stresses the stress intensity forthe primary stresses and the equivalent stress range each forthe sum of primary plus secondary stresses or the sum ofprimary stresses, secondary stresses and peak stresses shallbe derived.

KTA 3205.1 page 18

(3) The stress intensities and equivalent stress ranges shallbe limited in accordance with clause 7.3.5.

7.3.4.2 Stress intensities

(1) The equivalent stress ranges to be assigned to the vari-ous stress intensities shall be determined on the basis of thestress theory of von Mises or alternately on the theory of Tre-sca and be compared with the respective allowable values.

(2) Having chosen the three-dimensional set of co-ordinates, the algebraic sums of all stresses acting simulta-neously in the same direction shall be calculated each fora) the general primary membrane stresses,b) the local primary membrane stresses or,c) the sum of either the general primary membrane stresses

or the local primary membrane stresses and the bendingstresses.

Taking the algebraic sum of each of the three cases thestress intensities according to the shear stress theory of vonMises or alternately the theory of Tresca shall be derived.

7.3.4.3 Equivalent stress ranges

(1) To avoid failure due toa) progressive distortion (ratcheting),b) fatiguethe pertinent equivalent stress ranges shall be determinedfrom the various stress categories and be limited in differentways.

(2) In case (1) a) the required stress tensors shall be formedtaking the simultaneously acting stresses from primary andsecondary stress categories, and in case (1) b) taking the si-multaneously acting stresses from all stress categories.

(3) From the number of service loadings to be consideredtwo service loadings shall be selected by using one fixed co-ordinate system so that the stress intensity derived from thedifference of the pertinent stress tensors becomes a maxi-mum. This maximum value is the equivalent stress range.

(4) Where, upon application of the stress intensity to theshear stress method, the loading conditions to be consideredshow no change in the direction of principal stresses, it willsuffice to form the maximum value of the differences of anytwo principal stress differences. This maximum value then isthe equivalent stress range to the shear stress method. Theverification of the equivalent stress range for the sum of pri-mary and secondary stresses may be omitted if the stressintensity derived from (Pm + Pb + Q) or from (Pl + Pb + Q)does not exceed the 0.2% proof stress (Rp0.2T) or yieldstrength (ReHT) at either loading level H or HZ.

7.3.5 Allowable stress values

(1) Table 7-7 contains the limit values for stresses andequivalent stress intensities for each specific load case.

(2) The allowable stress values of load cases H to HS2 shallbe referred to the Sm value determined in accordance withclause 7.3.2 at the respective ruling temperature. For loadinglevel HS3 the hot tensile strength RmT shall be taken.

(3) For welds the allowable component stresses of Table 7-7apply if the design strength values of the filler metals areequal to or greater than those of the component. The types ofweld as per serial no. 7 and 9 in Table 7-4 shall not transferbending stresses Pb into plane load-bearing structures.

(4) Where allowable stress values exceeding Rp0.2T orReHT, they shall be considered fictitious stresses intended tolimit strains, if any.

Loadcases

Pm Pl, Pm + Pbor Pl + Pb

Pm + Pb + Qor Pl + Pb + Q

H 1.00 . Sm 1.20 . Sm 2.50 . Sm 1)

HZ 1.15 . Sm 1.38 . Sm 2.88 . Sm 1)

HS1 1.30 . Sm 1.56 . Sm -

HS2 1.50 . Sm 1.80 . Sm -

HS3 0.7 . RmT RmT -

1) in the case of verification by means of elastic or plastic fatigueanalysis in acc. with KTA 3201.2, cl. 7.8.2 these values may beexceeded.

Table 7-7: Allowable stress and equivalent stress values forplane load-bearing structures

7.3.6 Verification of stability

The stability of pressure-loaded plates and shells shall beverified with respect to geometry and load-carrying capabilityto DIN 18 800-3 or DIN 188 800-4, where applicable.

Alternatively, the verification of stability of pressure-loadedplates shall be made to DASt 012.

Table 7-8 shows the assignment of load cases.

Load cases Load case to DASt 012

H H

HZ HZ

HS1 S1)

HS2/HS3 S1) The safety factor for load case HS1 shall be increased by a

factor od 1.1 compared to load cases HS2/HS3.

Table 7-8: Assignment of load cases of this standard tothose of DASt 012

7.3.7 Fatigue analysis


In general, a fatigue analysis is not required within the rangeof application of this KTA standard. For components that arenot allowed to fail when subjected to cyclic loading a fatigueanalysis shall only be made for load cases H and HZ. To thisend, the equivalent stress range shall be determined from allstresses including peak stress (F) under clause 7.3.4.3.

7.3.7.2 Limitation of cumulative damage due to fatigue

As the equivalent stress rangesσv = 2 . σA = 2 . E20° . εA (7-6)

take different values, they shall be divided into adequate por-tions 2 . σAi and shall be accumulated as follows to the lineardamage rule:a) For each portion σAi = Sa the allowable number of cycles

n̂i shall be determined from the fatigue curves of Figures

7-2 and 7-3 and be compared with the specific, or in thecase of substantiation by way of calculation, the opera-tional number of load cycles ni.

KTA 3205.1 page 19

b) The sum of the quotients ni / n̂i forms the cumulative dam-age index (usage factor) D which shall be limited withindesign as follows:

0.1n̂n

n̂n

n̂nD

k

k

2

2

1

1 ≤⋅⋅⋅⋅++= (7-7)

8 Construction


(1) For the construction of structural steel components thefollowing shall be taken into account:a) function,b) loading,c) material,d) manufacture (testing and fabrication),e) maintenance.

(2) Where applicable, the following shall be considered:a) sufficient accessibility to the components,b) possibility of decontamination,c) inclusion of special loadings (e.g. earthquake) even in

horizontal direction,d) avoidance of designs critical to stability,e) thermal expansion (where required, expansion joints shall

be provided).

8.2 Requirements

(1) Parts that have to be disassembled for maintenance andinspection purposes shall be dismountable to minimise therisk of radiation exposure.

(2) Weld welded from both sides shall be preferred to sin-gle-side welds. The type of welds shown in Table 7-4, serialnos. 7 and 9 shall only be used in the case of side fillet weldsand for the connection of closed parts. Single-layer welds areonly permitted for weld thicknesses equal to or less than5 mm. The requirements of clause 10.2.4 shall be noted onthe drawing.

(3) The minimum dimension for load-bearing bolts shall beM-12 bolts. All bolted joints shall be secured which also in-cludes the design initial bolt pre-tensioning.

(4) Tensile loading in thickness direction for plates of ferriticsteel with a wall thickness s exceeding 20 mm are only per-mitted if the plates have been qualified to quality grade Z25 ofDIN EN 10 164 and have been checked for freedom of lami-nations at the welding ends.

(5) In the case of slots loaded transversely to their longitu-dinal axis sufficient distance from the plate edge shall beprovided.

(6) Hollow sections shall meet the requirements of DIN 18 808.

(7) Data on the initial tightening of pre-tensioned bolts (e.g.reduced shank bolts) shall be entered in the design drawings(e.g. minimum required and maximum allowable torque orturn-of-nut tightening as well as lubricants and tools).

(8) The wall thickness shall principally be equal to or greaterthan 4 mm. In justified cases, exceptions to this rule are possible.

(9) The building structure and anchoring location tolerancesshall be considered.

(10) Threaded bar connections shall be made with more thanone bolt.

(11) In the case of welded component support structures itshall be taken into account that the welds have to be accessi-ble for inspection (also for periodic inspections).

(12) To avoid spalling of concrete due to high thermal inputcare shall be taken to ensure sufficient edge distance whenwelding sections to anchoring elements; in exceptional casesthe heat input shall be minimised by an as little as possiblelayer thickness.

9 Manufacture

9.1 Requirements

(1) The manufacturer shall ensure the proper performanceof all necessary work with due consideration of the require-ments of KTA 1401 and this standard to be met.

(2) The manufacturer shall have facilities and personnel athis disposal so that the product forms can be fabricated,tested and transported properly. Facilities and personnel ofother agencies meeting these requirements may also beemployed.

(3) The manufacturer shall ensure that his products havethe required quality. The person or agencies engaged in qual-ity assurance shall be independent of the persons or agenciesresponsible for fabrication.

(4) The manufacturer shall employ responsible and expertsupervisory personnel for all production and inspection stepstaken under his influence.

(5) The manufacturer shall meet the requirements of DIN EN729-3. Within the course of fabrication the authorised inspector isentitled to convince himself at any time that the requirementshave been met.

9.2 Welding supervision

The welding supervisory personnel shall meet the require-ments of DIN EN 719.

9.3 Welders

(1) The welders shall have a valid welder’s qualificationrecord to DIN EN 287-1 for the welding work to be done.

(2) The operators of fully mechanised welding equipmentshall have proved that they possess sufficient knowledge tooperate the equipment. This proof shall be rendered by suit-able weld test specimens or by means of procedure qualifica-tion and welders approval tests.

(3) The manufacturer shall fill in a certificate (without spe-cific form) to show when and by which weld test specimens orprocedure or welders approval tests the operating personnelhas obtained the qualification.

9.4 Working principles for welding

9.4.1 Requirements for welding

Welding work shall not be started before the following re-quirements have been met:

a) All tests and inspections on the product forms and on thecomponent shall have been performed successfully includ-ing inspections, if any, of weld areas and weld fusion faces.

b) All documents required for welding (welding procedure sheet,drawings) shall have been subjected to a design review be-fore being laid out at the location of welding.

c) The work instructions of the manufacturer shall be avail-able at the workplace.

KTA 3205.1 page 20

9.4.2 Weld preparation by means of thermal gouging

The requirements of SEW 088, clause 4.3 shall have beenmet.

9.4.3 Performance of welding work


(1) For the welding procedures to be used the same type ofwelding equipment as that used during welding procedurequalification shall be employed. This equipment in connectionwith the pertinent power sources shall operate to the sameprinciple.

(2) The welding conditions to be laid down within proce-dure qualification shall be satisfied when welding compo-nents. In the case of deviations (e.g. change of weld build-up, deviations from the allowable heat input, changes ofheat input prior to and during welding or changes in post-weld heat treatment and range of weld parameters) thewelding supervisor, by agreement with the authorised in-spector, shall decide on the necessity and extent of a sup-plementary inspection. For this purpose, production controltests may be performed.

(3) During preheating the requirements of SEW 088, cl. 4.3shall be met for unalloyed and fine-grain steels, and the re-quirements of SEW 086 shall be met for unalloyed and al-loyed heat-resisting ferritic steels.

(4) To supervise the welding data the welding equipment formechanised welding shall be provided with measuring instru-ments for measuring amperage and voltage.

9.4.3.2 Temporary weld attachments

Temporary weld attachments shall be covered by the weldingprocedure sheet and be performed to SEW 088, section 7.2.

9.4.4 Weld quality

The quality of the welds with stresses equal to or greater than70% of the allowable values shall meet the requirements ofevaluation group C to DIN EN 25817, and those welds withstresses less than 70% of the allowable values the require-ments of evaluation group D to DIN EN 25817.

9.4.5 Welding record

(1) Welds on austenitic steels and high-strength fine-grainsteels shall be recorded.

(2) The welding record shall document that the conditions ofthe design-reviewed welding procedure sheet have beensatisfied. The welding record shall indicate in which cases andfor which purposes deviations from the welding proceduresheet had to be performed. In addition, unplanned interrup-tions of welding work as well as other irregularities shall bedocumented.

(3) The welding record shall be kept by the welding supervi-sor. In the case of weldments of long duration within onewelding sequence at least two entries per work shift shall bemade.

(4) The inspections prescribed in the test and inspectionsequence plan shall be shown on the welding record.

(5) Forms shall be used for the welding record (example:see Form 9-1) and be filled in to meet the welding proceduresheet requirements.

(6) The welding record shall become part of the manufacturer’sdocumentation upon completion of welding work.

9.4.6 Collective certificate

Instead of welding records to clause 9.4.5 collective certifi-cates to comprise the individual welding inspections to Form9-1 are permitted upon agreement with the authorised in-spector if the original welding records have been signed bythe inspector. These collective certificates shall become partof the documentation in lieu of the welding records.

9.5 Weld filler metals and consumables

The weld filler metals and consumables used shall bechecked for suitability to VdTÜV-Merkblatt 1153.

9.6 Welding procedure qualifications


(1) For the welding procedures employed valid procedure quali-fications to AD-Merkblatt HP 2/1 shall be available unless theextended qualification to DIN 18 800-7 applies. Is this not thecase, the qualifications shall be performed in the presence of theauthorised inspector.

(2) Here, the following shall be considered:a) the welding procedure employed,b) the range of welding parameters,c) the weld position,d) the weld filler metals and consumables,e) the materials to be welded (including the thickness of

components, applicable from 0.75 s to 1.5 s),f) the type of weld,g) the heat treatment condition required for the component.

(3) Repair welding, if any, on the component shall be sub-ject to an additional procedure qualification which may beperformed within the course of the component welding proce-dure qualification.

(4) Prior to performing the procedure qualification the fol-lowing documents shall be established by the manufacturerand be submitted for review by the authorised inspector:a) welding procedure sheet,b) heat treatment plan andc) materials testing and specimen-taking plan.

(5) The authorised inspector shall establish a report on thewelding procedure qualification test to contain the limits ofapplication and the conditions for the fabrication of the testspecimens. The test results shall be documented.

9.6.2 Scope


(1) The scope of a procedure qualification shall be con-firmed by the authorised inspector.

(2) The procedure qualification applicable by a manufac-turer’s works is also valid for welding work to be done outsidethe works, e.g. on erection sites.

9.6.2.2 Base metal

The welding procedure qualification covers the base metalsused in the qualification test. Where base metals of othercomposition are included, this shall be documented in the pro-cedure qualification report.

KTA 3205.1 page 21

9.6.2.3 Weld filler metals and consumables

(1) The procedure qualification applies to the weld fillermetals used (filler rod incl. type of coating, strip/wire elec-trodes, weld wires and rods) and consumables (shieldinggases, fluxes). Where filler metals are within the same rangeof application as to their qualification, a change of the brandname does not require the repetition of the procedure qualifi-cation.

(2) For shielding gases a changeover to another supplier ispermitted.

(3) For submerged-arc welding the electrode-flux combina-tion used during procedure qualification shall apply in whichcase an exchange of wire or strip electrodes with comparablechemical composition is permitted irrespective of the pro-ducer.

(4) An exchange of the type of flux used during procedurequalification is only permitted upon the authorised inspector’sagreement.

9.6.2.4 Deviations from welding procedure qualification

(1) The range of welding parameters laid down during pro-cedure qualification, i.e.a) dimensions of filler metals,b) weld position (position of welding head in the case of

mechanised welding),c) amperage,d) feed rate (mechanised welding),e) voltageshall not be changed.

(2) Dimensional deviations from the form of welded joint(e.g. angle of fusion faces, depth of groove in the case ofdouble-side welds) are permitted for component welding.

(3) Deviations from the range of weld parameters shall besubject to the authorised inspector’s agreement.

9.6.2.5 Heat treatment

The total duration of annealing applicable during procedurequalification referred to the sum of intermediate stress-relieving above 450 °C and to the sum of final stress-reliefheat treatments may be exceeded by up to 20% in the case ofcomponent annealing.

9.6.2.6 Period of validity

(1) The period of validity of a welding procedure qualificationshall be 24 months beginning with the date of confirmation bythe authorised inspector.

(2) The period of validity shall be extended by a further 24month-period if, within the first period of validity, a pertinentproduction control test has been performed.

(3) If production is interrupted for more than one year, theprocedure qualification test required for the new productionshall be performed.

9.7 Production control tests

(1) Production control tests are only required for steels witha yield stress of 0.2 proof stress equal to or greater than355 N/mm2.

(2) The performance and evaluation of production controltests shall be in accordance with AD-Merkblatt HP 5/2.

9.8 Forming of components


During forming the requirements of the applicable standardsand other documents shall be taken into account and theprocedure be agreed with the authorised inspector.

9.8.2 Certification

(1) The forming work performed shall be certified by themanufacturer indicating:a) the thermal treatment and forming facilities,b) the forming steps andc) the temperature control and supervision during the forming

process.

(2) For parts subject to normalising or quenching and tem-pering the data on the forming steps may be omitted.

9.9 Heat treatment


(1) Heat treatment plans shall be established for all heattreatments to be performed

(2) These plans shall contain, where required:a) the type of heat treatment, e.g. normalising, quenching

and tempering, tempering, stress relieving, solution an-nealing, stabilising, soaking,

b) heat treatment facility (furnace or local),c) time-at-temperature (heating, holding, cooling),d) cooling fluids,e) type and extent of temperature measurements,f) location of components of test specimens in the heat

treatment facility.

(3) Preheating and post-weld heat treatment are not consid-ered a heat treatment.

(4) The manufacturer shall check the functioning of the heattreatment facilities at regular intervals. These checks shall bedocumented and kept on file.

(5) The necessity and type of post-weld heat treatment shallbe laid down in the test and inspection sequence plan in de-pendence of the material and the component thickness.

9.9.2 Certification

(1) The manufacturer shall document the adherence to theheat treatment plan in accor-dance with cl. 9.9.1.

(2) Deviations from the heat treatment plan shall be re-corded. The acceptability of such deviations shall be agreedbetween manufacturer and authorised inspector.

9.10 Corrosion protection and cleanliness requirements

(1) The requirements of DIN EN ISO 1461, DIN EN ISO12944-1 to DIN EN ISO 12944-8, DIN 55 928-8 and DIN55 928-9 apply.

(2) The components and their surfaces shall be such as tomake decontamination possible.

(3) Corrosion-effecting contamination (e.g. chloride-containing or ferritic) on surfaces of stainless steels duringfabrication, transport, storage and assembly shall be avoided.

KTA 3205.1 page 22

10 Final inspection


(1) The extent of inspections and tests as well as the par-ticipation of the authorised inspector and the purchaser insuch tests and inspections shall be laid down in the test andinspection sequence plan in consideration of the requirementsof sections 6 and 9 as well as of the following sections 10.2and 10.3.

(2) When determining the location of test/inspection forpartial tests/inspections the loading level, especially in weldareas shall be considered.

10.2 Extent and performance (at the works and on erectionsite)

10.2.1 Receiving inspection

The following shall be checked during receiving inspections:a) stampings and identification markings,b) dimensions and check for transportation damage,c) material certificates of the product forms.

10.2.2 Inspections prior to beginning of fabrication

(1) Prior to further processing the following checks shall bemade on the product forms:a) check for transfer of identification marks in accordance

with material test sheets,b) check of the list containing the names of the persons enti-

tled to transfer identification marks,c) transfer of identification marks for further processing only

in the case of inspection certificate 3.1 to DIN EN 10 204.

(2) The validity of the manufacturer’s welding procedurequalifications to clause 9.6.1, sub-clause 1 shall be checked.

(3) The validity of the welder’s qualification records to DINEN 287-1 shall be checked.

(4) The annealing facilities and welding equipment to beemployed shall be controlled.

10.2.3 In-process inspections

(1) Production control tests, where provided, shall bechecked for validity.

(2) The storage and drying of weld filler metals and con-sumables shall be controlled.

(3) The sequence of testing at specified heat treatment inaccordance with the welding procedure sheet and heat treat-ment plans shall be adhered to as follows:a) check of preheating temperature (if preheating is per-

formed),b) control of welding process,c) check of root layer (if practicable) by visual inspection,d) check of heat treatment of welds (where heat treatment is

provided in the welding procedure sheet).

10.2.4 Extent of non-destructive testing

10.2.4.1 Tests under the manufacturer’s responsibility

The following tests shall be performed:a) The weld areas of plates and weld fusion faces shall be

non-destructively tested under the manufacturer’s respon-sibility.

b) The check for laminations in plates of ferritic steels subjectto tensile loading in thickness direction and the plate

thickness of which exceeds 20 mm, shall be performedunder the manufacturer’s responsibility. In this case therange and extent of testing shall also be determined underthe manufacturer’s responsibility.

10.2.4.2 Visual inspections

The weld shall be subject to visual inspection to DIN EN 970.The evaluation shall be made to DIN EN 25817 with theevaluation groups as mentioned in clause 9.4.4. The followingextent of inspection applies:

Manufacturer: 100 %.Authorised inspector: 25 %.

10.2.4.3 Examinations for surface crack detection

The following applies as regards surface crack detection onwelds:a) Welds with a quality to be verified (see Table 7-4) for the

steels S235JRG2 (RSt 37-2), S235J2G3 (St 37-3),S355J2G3 (St 52-3) and 16Mo3 (15 Mo3) to section 6.1:Manufacturer: 10 %.Authorised inspector: randomly.

b) Welds with a quality to be verified for heat-resisting heat-treatable steels:Manufacturer: 100 %.Authorised inspector: 25 %.

c) Welds with a quality to be verified for all other steels:Manufacturer: 25 %.Authorised inspector: 10 %.

10.2.4.4 Ultrasonic testing or radiography

(1) Butt welds with a wall thickness equal to or less than25 mm shall preferably be subjected to radiography, in thecase of ferritic butt welds with a wall thickness equal to orgreater than 15 mm radiography shall be substituted by ultra-sonic testing, at wall thicknesses greater than 25 mm andequal to or less than 40 mm the weld shall preferably be sub-jected to ultrasonic testing, or ultrasonic testing be replacedby radiography. For ferritic butt welds with a wall thicknessexceeding 40 mm ultrasonic testing shall be used.

(2) Ferritic attachment welds shall preferably be subjected toultrasonic testing. Where steels with Rp0.2RT > 355 N/mm2 areused, an additional ultrasonic test to detect underbead crackingshall be performed.

(3) Ultrasonic testing of welds need only be performed todetect imperfections oriented longitudinally to the direction ofwelding.

(4) The following applies as regards ultrasonic testing andradiography:a) Welds with a quality to be verified (see Table 7-4) for the

steels S235JRG2 (RSt 37-2), S235J2G3 (St 37-3),S355J2G3 (St 52-3) and 16Mo3 (15 Mo3) to section 6.1:Manufacturer: 10 %.Authorised inspector: randomly.

b) Welds with a quality to be verified for heat-resisting heat-treatable steels:Manufacturer: 100 %.Authorised inspector: 25 %.

c) Welds with a quality to be verified for all other steelsManufacturer: 25 %.Authorised inspector: 10 %.

KTA 3205.1 page 23

10.2.5 Performance of non-destructive testing

Non-destructive testing shall be performed in accordance withAnnex B. Supplementary stipulations of the material datasheets shall be considered.

10.2.6 Checking of finished component support structures

(1) During inspection the test and inspection sequenceplans shall be submitted to the authorised inspector. The testand inspection sequence plans as well as the lists of materi-als shall be signed and stamped by the authorised inspectorupon final inspection.

(2) The components shall be subjected to the followingchecks:a) correspondence with the design review documents (e.g.

dimensional check),b) stamping of individual parts,c) adherence to specified bolt pre-tensioning,d) coating where specified,e) completeness of documentation.

10.3 Verification of inspections and checks

(1) The performance of the tests and examinations shall bedocumented in the test and inspection sequence plan byrespective stampings. Deviations shall be recorded.

(2) Records shall be numbered such as to exclude confu-sions.

11 Periodic inspections

(1) Within periodic inspections, component support struc-tures that are to function flexibly shall visually be inspectedduring inspection of the pipework.

(2) Where spring hangers, shock absorbers and swaybraces are fabricated to this standard, they shall be subjectedto periodic inspection in accordance with KTA 3205.3, section11.

(3) When fixing the extent of inspection, footnote 5 of Table3-1 shall be considered.

12 Documentation


(1) The documentation shall permit the traceability of thetests and inspections performed beginning with the designand ending with the completion and installation of the compo-nent including deviations, if any.

(2) Changed documents shall be marked accordingly as tothe state of revision.

(3) The documents of the complete documentation shall beclearly arranged and provide a table of contents.

12.2 Documents for final documentation

The final documentation shall contain the latest version of alldocuments and test/inspection certificates specified undersection 6, 9 and 10 as follows:

a) List of materials including inspection certificates to DIN EN10 204The manufacturer and the authorised inspector shall con-firm in this list by a note that the required tests and in-spections have been performed to meet specifications.

b) Test and inspection sequence plansThe manufacturer and the authorised inspector shall con-firm by a note in the test and inspection sequence plan, ir-respective of whether a certificate is required or not, thatthe required tests and inspections have been performed tomeet specifications.

c) Welding procedure sheets and weld location plansd) Heat treatment plan and records (if required)

Where heat treatments had to be performed, the certifi-cates required under clause 9.2.2 shall be added to thedocumentation.

e) Welding records or collective certificatesAll entries shall be made in the welding records as re-quired under clause 9.4.5. For collective certificatesclause 9.4.6 applies.

f) Production control tests (if required)g) Deviations (repair documents, toleranced deviations)h) Design drawings and parts listsi) Design and analysisj) Design data sheetsk) Setting data for supporting hangers with clearancel) Instruction sheets for non-destructive tests (if required)

12.3 List of certificates

All certificates shall be comprised in a list of certificates.

12.4 Performance

(1) The documentation of the fabrication documents shall beestablished by a central agency of the manufacturer to ac-company the various production steps.

(2) All fabrication documents required for documentationshall have been submitted before the final inspection begins.

(3) The collection and arrangement of all these documentsshall be completed to the date of installation.

(4) All documents covering assembly work shall be availablebefore the commencement of hot trial run.

12.5 Repair plans

(1) Each individual repair plan and the related documentsshall be marked with the letter “R” in addition to the actual testand inspection plan designation.

(2) The documentation covering repair welding shall con-tain, in addition to the welding parameters, valid procedurequalification, preheating temperature a detailed description ofthe repair welding to make possible the assignment to thecomponent or component-related weld with governing dimen-sions.

KTA

3205.1 page 24

Fatigue curves for ferritic steelsFigure 7-2:

≤

=

=

1,5 3

5

86 9 2 43

3

4

7

8

5

4

10

65 8 97

6

1,5

4

2

10

5 63

8

1,5

3

2

10

10

9 3

10 2

74

9

51,57 8

10 22 542 9873

2

4

8

61,5

1,5

6 746

983

10

21,5 5

105

8

56

7

910

3

10 3

7

2

6

9

3

56

10 59

7

1,5

4

4

4

2

1,5

2

2

2

2

2

25

i

i

T

T

nAllowable number of load cycles

R N/mm

E

R

550

m

m

10

790 to 900

Tensile strength values between

Sa

Allo

wab

leha

lfth

eeq

uiva

lent

stre

ssra

nge

[N/m

m]

N/mm550 N/mm 790and

stress range is based on strains with anelastic modulus E

Where the calculated equivalent

E, the calculated

S nanda

equivalent stress range shall be

N/mm

relationship of

2.07

N/mm

may be subject to linear interpolation.

are shown in Table 7.8-2 of KTA 3201.2.

multiplied with the quotient E/E .

The exact and applicable values for

Note:

KTA

3205.1 page 25

=

5 6 987

10

7 8 432

3

89

1,5

2

6

10

21,5 4

3

7

5

4

6

4

5

10

78

2

10

10

6

3

1,5

1,5

10

2 3 9 21,54

1,5

2

2

5 1,5

9

543 7 21,52987 6410

7656

984

10

98 3

1056

33

7

4

2

1,5

9

5

4

3

10

8

6

4

9510

8

67

5

3

5

5 2E N/mm1.79 10

i

T

T

stress range is based on strains with anelastic modulus E

Where the calculated equivalent

E, the calculated

S nanda

equivalent stress range shall be

relationship ofare shown in Table 7.8-2 of KTA 3201.2.

multiplied with the quotient E/E .

The exact and applicable values for

Note:

inAllowable number of load cycles

Fatigue curves for austenitic steelsFigure 7-3:

2S

aA

llow

able

half

the

equi

vale

ntst

ress

rang

e[N

/mm

]

KTA 3205.1 page 26

Welding recordWR

Page: of:

Plant/project: Component: Component group:

KKS 1): PFP/WPP/Quality class 2):

/

Test no.:

Manufacturer’s order no.: ................... Order no.: Identification no. 3):

Welding schedule: Weld position no.:

Date: Time:

Welder no.:

Welding sequence:

Dimensions [mm]

Trade name

Heat no.

Wel

d fil

ler

met

als

Flux/lot no.

Position

Preheat/intermediate pass tem-perature [°C]

Weld filler metal no.

Amperage [A]

Voltage [V]

Welding speed[mm/min.] �

Weld nozzle no. �

Area (see sketch) �

Bead no. �

Oscilating width �

Act

ual w

eldi

ng d

ata

Weld pass �

Observations:

Manufacturer (H)

Authorised inspector (S)

Sup

ervi

sion

For machine welding only � - for manual welding �1) KKS = Power Plant Identificaton System 2) Delete, where inappropriate3) e.g. heat no. or test coupon no., does not apply in connection with PFP (specimen-taking plan) / WPP (materials testing plan)

Form 9-1: Example of a welding record

7

6

2

3

4

5

1

KTA 3205.1 page 27

Annex A

Materials test sheets (WPB)

Catalogue of materials test sheets

WPB Materials test sheets for flat product forms

1.1 Plates and sheets, wide flats of stainless steels1.2 Plates and sheets of quenched and tempered alloy steels with high strength at elevated temperatures

20 MnMoNi 5 5 and 22 NiMoCr 3 71.3 Plates and sheets of steels with high strength at elevated temperatures1.4 Plates and sheets, wide flats of structural carbon steel1.5 Plates and sheets of quenched and tempered alloy steels1.6 Plates and sheets, strips of fine-grained structural steels suited for welding

WPB Materials test sheets for welded or seamless tubes and hollow sections

2.1 Seamless and welded stainless steel tubes with general quality requirements and subject to special requirements2.2 Welded structural hollow sections made of structural carbon steel2.3 Seamless tubes made of steels with high strength at elevated temperatures2.4 Seamless tubes made of structural carbon steel2.5 Seamless tubes made of quenched and tempered alloy steel with high strength at elevated temperatures

20 MnMoNi 5 52.6 Seamless and welded fine grain steel tubes with high strength at elevated temperatures subject to special re-

quirements2.7 Seamless tubes made of quenched and tempered alloy steel with high strength at elevated temperatures

15 NiCuMoNb 5

WPB Materials test sheets for bars, forgings and steel sections

3.1 Forged or rolled bars and forgings made of stainless steels3.2 Forgings of quenched and tempered alloy steels with high strength at elevated temperatures 20 MnMoNi 5 5 and

22 NiMoCr 3 73.3 Forged and rolled bars, forgings and Steel sections of structural carbon steel3.4 Forged or rolled bars and forgings made of steels with high strength at elevated temperatures and suited for welding3.5 Bars and forgings of quenched and tempered alloy steels with and without threaded ends3.6 Bars and forgings of high-strength quenched and tempered alloy steels 26 NiCrMo 14 6 and 20 NiCrMo 14 5 with

and without threaded ends

WPB Materials test sheets for Bolts and nuts as well as for washers subject to high-strength bolted joints

4.1 Bolts and nuts acc. to strength grades as well as washers subject to high-strength bolted joints4.2 Bolts and nuts smaller than or equal to M 39 of stainless steels4.3 Bolts and nuts, machined, cut or rolled thread, finally not heat treated, of stainless steels4.4 Bolts and nuts, cut or rolled thread, finally not heat treated, made of steels with high strength at elevated tem-

peratures and quenched and tempered steels4.5 Bolts and nuts, hot formed, cut or rolled thread, finally heat treated, for use at room temperature and elevated

temperatures

WPB Materials test sheets for cast-steel

5.1 Ferritic cast-steel GS-18 NiMoCr 3 7 and GP240GH5.2 Stainless cast-steel GX5CrNiNb19-11 and GX4CrNi13-4

KTA 3205.1 page 28

Materials test sheet 1.1: Plates and sheets, wide flats of stainless steels to DIN EN 10 028-7

MATERIALS TEST SHEET WPB 1.1

Product form: Plates and sheets, wide flatsMaterials: X5CrNi18-10 (1.4301)

X6CrNiTi18-10 (1.4541)X6CrNiNb18-10 (1.4550)X6CrNiMoTi17-12-2 (1.4571)X5CrNiMo17-12-2 (1.4401)

Requirements: DIN EN 10 028-1 and DIN EN 10 028-7

Specimen taking and extent of testing: DIN EN 10 028-1

Tests and inspections Certificate toDIN EN 10 204

1. Chemical composition:Ladle analysis.

2.2

2. Attestation of heat treatment condition. 2.2

3. Tensile test at room temperature to DIN EN 10 002-1. 3.1.B

4. Visual inspection and dimensional check:Each component. Surface condition at least 1E to DIN EN 10 028-7.

3.1.B

5. Materials identification check:Each component by a suitable method.

3.1.B

Material identification: to DIN EN 10 028-1.

Materials test sheet 1.2: Plates and sheets of quenched and tempered alloy steels with high strength at elevated tempera-tures 20 MnMoNi 5 5 und 22 NiMoCr 3 7


Product form: Plates and sheets

Material: 20 MnMoNi 5 5 (1.6310)22 NiMoCr 3 7 (1.6751)

Requirements: Supplementary sheet to this materials test sheetSpecimen-taking: Supplementary sheet to this materials test sheet and DIN EN 10 164


1. Chemical composition:Ladle analysis with certification of steel-making process.

2.3

2. Attestation of heat treatment condition with certification of temperature and holding time. 2.33. Tensile test:3.1 Tensile test to DIN EN 10 002-1:

One tensile test specimen at room temperature from each location of specimen-taking. Value tobe determined: Rp0.2, Rm, A, Z.

3.1.C

3.2 Tensile test to DIN EN 10 164:Three tensile test specimens in thickness direction at room temperature per rolled plate with athickness > 20 mm, as far as the plates are subject to further processing by welding and tensileloading in thickness direction is to be expected due to the type of welded joint (see DASt 014).Requirements: Quality class Z25 to DIN EN 10 164; Specimen-taking: DIN EN 10 164See para. 8.2 (4) and 10.2.4.1 b) regarding ultrasonic testing.

3.1.C

3.3 Tensile test at elevated temperatures to DIN EN 10 002-5:One tensile test specimen at T = 350 °C at one location of specimen-taking, if the design tem-perature is higher than 250 °C. Value to be determined Rp0.2, Rm and A.

3.1.C

4. Notched bar impact test to DIN EN 10 045-1:One set of impact test specimens per tensile test as per no. 3.1 (one set = three Charpy-V-notchspecimens) at T = 0 °C as far as the plate thickness exceeds 10 mm.

3.1.C

5. Visual inspection and dimensional check:Each plate or sheet.

3.1.C

6. Materials identification check:Each plate or sheet by a suitable method.

3.1.B

Material identification: Steel grade, heat number, specimen number, manufacturer's mark, authorised inspector's mark, Z25(if verified).

KTA 3205.1 page 29

Supplementary sheet to materials test sheet WPB 1.2

This supplementary sheet specifies the details regarding plates and sheets of 20 MnMoNi 5 5 as well as tests and examina-tions of the products. The requirements for plates and sheets of 22 NiMoCr 3 7 shall be specified in the course of the designreview.

1 Materials data and requirements

1.1 Steel-making processThe steel is normally molten by the electric-arc or basic-oxygen process. If other processes are used, a proof of equivalency isrequired.

1.2 Chemical composition (content by mass in %)

Elements Ladle analysismin. max.

C 0.17 0.23 Si 0.15 0.30 Mn 1.20 1.50 P − 0.012 S − 0.008 Altot 0.01 0.04 Cu − 0.12 Cr − 0.20 Ni 0.50 0.80 Mo 0.40 0.55 V − 0.02 Sn − 0.011 Ntot − 0.013 As − 0.025

1.3 Mechanical properties of the material

The requirements regarding mechanical properties of the material apply to the final heat treatment condition of the component.The minimum values or ranges are given in this table.

Rp0.2 in MPaat

Rm in MPaat

A in %at

Z in %at

Absorbed impactenergy in J

at 0 °CProduct thickness

s in mm

Specimendirection

RT 350 °C RT 350 °C RT 350 °C RT Singlevalue

Averagevalue

s ≤ 70 450 382 590 to 730 530

70 < s ≤ 150 430 363 570 to 710 510

150 < s ≤ 200 343 18 16 45 34 41

200 < s ≤ 320 390 343 560 to 700 505

320 < s ≤ 600

trans

vers

e

315

1.4 Heat treatment

(1) The steel is used in the quenched and tempered condition.Austenitising: 870 °C to 930 °C with subsequent hardening in water.Tempering: 630 °C to 690 °C.Stress-relief heat treatment: 580 °C to 620 °C for the last heat treatment. Intermediate annealing may be performed at 550 °C.

(2) The material manufacturer together with the component manufacturer shall specify the heat-up and cooling rates, thetemperatures as well as the times at temperature depending on the component dimensions and chemical composition suchthat, under consideration of any subsequent heat treatment, the mechanical properties in accordance with Sec.1.3 are obtainedin the final condition of the finished component.

1.5 Processing

The temperature range for hot forming as well as the heat-up and cooling rates are to be selected to the base material manu-facturer`s specification. After hot forming, a quenching and tempering treatment to Sec. 1.4 is required.

KTA 3205.1 page 30

1.6 Flame cutting

(1) A pre-heating is required before any flame cutting. The pre-heating temperature shall be at least 150 °C.

(2) In justified individual cases, this temperature limit may be reduced by mutual agreement between steel maker, productmanufacturer, purchaser, and authorised inspector.

2 Specimen-taking

2.1 Heat treatment condition of the test specimens

The test coupons for verification of the mechanical and technological characteristics shall be taken from the plates or sheetsafter the last quenching and tempering.

2.2 Test unit and location of specimen-taking

(1) The test coupons for mechanical-technological testing shall be taken, as far as practicable, at least at 1/4 the heat treat-ment thickness under the surface and at least at 1/2 the heat treatment thickness under the face of the straightened edges.The specimens shall be taken from top mid thickness and toe mid thickness position of each rolled plate. At a rolle plate lengthsmaller than 5 m testing of specimen from top mid thickness position will suffice.

(2) In the case of quenched and tempered thicknesses exceeding 320 mm the specimen-taking locations shall be at least 80mm under each quenched and tempered surface thickness of the eadges straightened for heat treatment purposes.

2.3 Specimen direction

Mechanical-technological testing shall be performed on specimens taken transversely to the main direction of forming.

Transverse specimens:Longitudinal axis of specimen transverse to the main forming direction; for notched-bar impact specimens, the notch axis shallbe perpendicular to the plane of the transverse and longitudinal directions.

Materials test sheet 1.3: Plates and sheets of steels with high strength at elevated temperatures to DIN EN 10 028-2


Product form: Plates and sheetsMaterials: P265GH (HII) (1.0425)

16Mo3 (15 Mo 3) (1.5415)P295GH (17 Mn 4) (1.0481)P355GH (19 Mn 6) (1.0473)13CrMo4-5 (13 CrMo 4 4) (1.7335)

Requirements: DIN EN 10 028-1 and DIN EN 10 028-2Specimen taking and extent of testing: DIN EN 10 028-1 and DIN EN 10 164



2.2

2. Attestation of heat treatment condition. 2.23. Tensile test:3.1 Tensile test at room temperature to DIN EN 10 002-1. 3.1.B

3.2 Tensile test to DIN EN 10 164:Three tensile test specimens in thickness direction at room temperature per rolled plate with athickness > 20 mm, as far as the plates are subject to further processing by welding, and tensileloading in thickness direction is to be expected due to the type of welded joint (see DASt 014).

Requirements: Quality class Z25 to DIN EN 10 164Specimen-taking: DIN EN 10 164See para. 8.2 (4) and 10.2.4.1 b) regarding ultrasonic testing.

3.1.B

4. Notched bar impact test to DIN EN 10 045-1:One set of impact test specimens per tensile test as per no. 3.1 (one set = three Charpy-V-notchspecimens) as far as the plate thickness exceeds 10 mm.Test temperature to DIN EN 10 028-2.

3.1.B


3.1.B

6. Materials identification check for alloyed steels:Each plate or sheet by a suitable method.

3.1.B

Material identification: To DIN EN 10 028-1 and Z25 (if verfied)

KTA 3205.1 page 31

Materials test sheet 1.4: Plates and sheets, wide flats of structural carbon steel to DIN EN 10 025


Product form: Plates and sheets, wide flats (carbon steels)

Material: S235JRG2 1) (RSt 37-2) (1.0038)S235J2G3 (St 37-3) (1.0116)S355J2G3 (St 52-3) (1.0570)

Requirements: DIN EN 10 025

Specimen taking and extent of testing: DIN EN 10 025 and DIN EN 10 164


1. Chemical composition:Ladle analysis 2).

2.2


3. Tensile test:3.1 Tensile test to DIN EN 10 002-1:

One tensile test specimen at room temperature per melt, heat-treatment lot and thickness rangeeach.

3.1.B

3.2 Tensile test to DIN EN 10 164:Three tensile test specimens in thickness direction at room temperature per product form with athickness > 20 mm, as far as the plates are subject to further processing by welding and tensileloading in thickness direction is to be expected due to the type of welded joint (see DASt 014).

Requirements: Quality class Z25 to DIN EN 10 164Specimen-taking: DIN EN 10 164See para. 8.2 (4) and 10.2.4.1 b) regarding ultrasonic testing.

3.1.B

4. Notched bar impact test to DIN EN 10 045-1:One set of impact test specimens per tensile test as per no. 3.1 (one set = three Charpy-V-notchspecimens), if the wall thickness s exceeds 10 mm.Test temperature to DIN EN 10 025

3.1.B

5. Visual inspection and dimensional check: Each component. 3.1.B

Material identification: Steel grade, heat number, specimen number (the plate or strip number may also be taken as speci-men number), manufacturer’s mark, Z25 (if verified).

1) The material S235JRG2 shall not be used if loaded in thickness direction.2) The carbon equivalent CEV to DIN EN 10 025 shall be adhered to.

KTA 3205.1 page 32

Materials test sheet 1.5: Plates and sheets of quenched and tempered alloy steels to DIN EN 10 083-1


Product form: Plates and sheets

Material: C35E (Ck 35) (1.1181)C45E (Ck 45) (1.1191)42CrMo4 (42 CrMo 4) (1.7225)34CrNiMo6 (34 CrNiMo 6) (1.6582)

Requirements: DIN EN 10 083-1




2.2


3. Hardness test for verification of uniform heat treatment:On both ends of each component.

3.1.B

4. Tensile test at room temperature to DIN EN 10 002-1.One tensile test specimen at room temperature per melt, heat-treatment lot and thickness rangeeach.

3.1.B

5. Notched bar impact test to DIN EN 10 045-1:One set of impact test specimens per tensile test (one set = three Charpy-V-notch specimens)at room temperature, if required by DIN EN 10 083-1 and where the plate thickness s exceeds10 mm.

3.1.B


3.1.B

7. Materials identification check for alloyed steels:Each plate or sheet by a suitable method.

3.1.B

Material identification: Steel grade, heat number, specimen number, manufacturer’s mark

Materials test sheet 1.6: Plates and sheets, strips of fine-grained structural steels suited for welding to DIN EN 10 028-3 orDIN 17 102


Product form: Plates and sheets, stripsMaterial: to DIN EN 10 028-3: to DIN 17 102:

P275NH (WStE 285) (1.0487) WStE 255 (1.0462)P355NH (WStE 355) (1.0565)

Requirements: DIN EN 10 028-1 and DIN EN 10 028-3 or DIN 17 102Specimen taking and extent of testing: DIN EN 10 028-1 or DIN 17 102 and DIN EN 10 164



2.2

2. Attestation of heat treatment condition. 2.23. Tensile test:3.1 Tensile test at room temperature to DIN EN 10 002-1. 3.1.B3.2 Tensile test to DIN EN 10 164:

Three tensile test specimens in thickness direction at room temperature per rolled plate with athickness > 20 mm, as far as the plates are subject to further processing by welding and tensileloading in thickness direction is to be expected due to the type of welded joint (see DASt 014).Requirements: Quality class Z25 to DIN EN 10 164Specimen-taking: DIN EN 10 164See para. 8.2 (4) and 10.2.4.1 b) regarding ultrasonic testing.

3.1.B

4. Notched bar impact test to DIN EN 10 045-1:One set of impact test specimens per tensile test as per no. 3.1 (one set = three Charpy-V-notchspecimens) at T = 20 °C, if the wall thickness s exceeds 10 mm.

3.1.B

5. Visual inspection and dimensional check:Each component.

3.1.B

Material identification: to DIN EN 10 028-1 or DIN 17 102 and Z25 (if verified).

KTA 3205.1 page 33

Materials test sheet 2.1: Seamless and welded stainless steel tubes with general quality requirementsto DIN 17 456; subject to special requirements to DIN 17 457 or DIN 17 458


Product form: Seamless tubes, welded tubes

Material: X5CrNi18-10 (1.4301)X6CrNiTi18-10 (1.4541)X6CrNiNb18-10 (1.4550)X6CrNiMoTi17-12-2 (1.4571)X5CrNiMo17-12-2 (1.4401)

Requirements: DIN 17 456 or DIN 17 457 or DIN 17 458

Specimen taking and extent of testing: DIN 17 456 or DIN 17 457 or DIN 17 458



2.2



4. Visual inspection and dimensional check:Each tube. Surface condition at least c1 to DIN 17 456 or DIN 17 458 oder d3 to DIN 17 457.

3.1.B

5. Materials identification check:Each tube by a suitable method.

3.1.B

Material identification: To DIN 17 456 or DIN 17 457 or DIN 17 458

Materials test sheet 2.2: Welded hollow sections of structural carbon steel to DIN EN 10 219-1


Product form: Welded hollow sections

Material: S235JRH (RSt 37-2) (1.0039)S355J2H (St 52-3) (1.0576)

Requirements: DIN EN 10 219-1



1. Chemical composition:Ladle analysis 1).

2.2


3. Tensile test at room temperature to DIN EN 10 002-1 3.1.B

4. Notched bar impact test to DIN EN 10 045-1:One set of impact test specimens per tensile test (one set = three Charpy-V-notch specimens),if the wall thickness s exceeds 10 mm.Test temperature to DIN EN 10 219-1.

3.1.B

5. Visual inspection and dimensional check:Each tube.

3.1.B

Material identification: DIN EN 10 219-11) The carbon equivalent CEV to DIN EN 10 219-1 shall be adhered to.

KTA 3205.1 page 34

Materials test sheet 2.3: Seamless tubes made of steels with high strength at elevated temperatures to DIN 17 175


Product form: Seamless tubes made of steels with high strength at elevated temperatures

Material: St 35.8 (1.0305)St 45.8 (1.0405)15 Mo 3 (1.5415)10 CrMo 9 10 (1.7380)13 CrMo 4 4 (1.7335)

Requirements: DIN 17 175

Specimen taking and extent of testing: DIN 17 175



2.2



4. Notched bar impact test to DIN EN 10 045-1:One set of impact test specimens per tensile test (one set = three Charpy-V-notch specimens) 1)

at room temperature. Same requirements as for DVM specimens

3.1.B

5. Ring tests. 3.1.B


3.1.B

7. Materials identification check for alloyed steels:Each tube by a suitable method.

3.1.B

Material identification: To DIN 17 175.1) Alternatively, DVM specimens are allowable. Minimum wall thickness as per DIN 17 175.

Materials test sheet 2.4: Seamless tubes made of structural carbon steel to DIN EN 10 210-1 or to DIN 17 121


Product form: Seamless tubes made

Material: to DIN EN 10 210-1: to DIN 17 121:S235JRH (RSt 37-2) (1.0039) St 37-3 (1.0116)S355J2H (St 52-3) (1.0576)S275J2H (St 44-3) (1.0138)

Requirements: DIN EN 10 210-1 and DIN EN 10 210-2 or DIN 17 121

Specimen taking and extent of testing: DIN EN 10 210-1 or DIN 17 121



2.2



4. Notched bar impact test to DIN EN 10 045-1:One set of impact test specimens per tensile test (one set = three Charpy-V-notch specimens),if the wall thickness s exceeds 10 mm. Test temperature to DIN EN 10 210-1 or DIN 17 121,Same requirements as for ISO V-notch specimens.

3.1.B


3.1.B

Material identification: To DIN EN 10 210-1 or DIN 17 121.

KTA 3205.1 page 35

Materials test sheet 2.5: Seamless tubes made of quenched and tempered alloy steel with high strength at elevated tem-peratures 20 MnMoNi 5 5


Product form: Seamless tubes made

Material: 20 MnMoNi 5 5 (1.6310)

Requirements: Supplementary sheet to this materials test sheet

Specimen-taking: Supplementary sheet to this materials test sheet



2.3

2. Attestation of heat treatment condition with certification of temperature and holding time. 2.3

3. Tensile test:3.1 Tensile test to DIN EN 10 002-1:

One tensile test specimen at room temperature- per melt, dimension and heat-treatment lot each, if Da smaller than or equal to 600 mm, lot

size 20 tubes,- per manufacturing length, if Da exceeds 600 mm.

3.1.C

3.2 Tensile test at elevated temperatures to DIN EN 10 002-5:One tensile test specimen at T = 350 °C per melt, dimension and heat-treatment lot each, if thedesign temperature is higher than 250 °C. Value to be determined Rp0.2, Rm, A

3.1.C

4. Notched bar impact test to DIN EN 10 045-1:One set of impact test specimens per tensile test as per no. 3.1 (one set = three Charpy-V-notchspecimens) at T = 0 °C.

3.1.C

5. Ring tests:Type and extent as for grade III to DIN 17 175.

3.1.C

6. Visual inspection and dimensional check:Each tube. Surface condition to DIN 17 175.

3.1.C


3.1.B

Material identification: Steel grade, heat number, specimen number or tube number, manufacturer's mark, authorised in-spector's mark.


This supplementary sheet specifies the details for tubes of 20MnMoNi 5 5 as well as tests and examinations of the products.


1.1 Steel-making processThe steel is normally molten by the electric-arc or basic-oxygen process. If other processes are used, a proof of equivalence isrequired.1.2 Chemical composition (content by mass in %)

Ladle analysisElements min. max. C 0.17 0.23 Si 0.15 0.30 Mn 1.20 1.50 P − 0.012 S − 0.008 Altot 0.01 0.04 Cu − 0.12 Cr − 0.20 Ni 0.50 0.80 Mo 0.40 0.55 V − 0.02 Sn − 0.011 Ntot − 0.013 As − 0.025

KTA 3205.1 page 36


The requirements regarding mechanical properties of the material apply to the final heat treatment condition of the component.The minimum values or ranges are given by this table.

Product thicknesss

in mm

Specimendirection

Rp0.2 in MPa

at

Rm in MPa

at

A in %

at

Z in %

at


at 0 °C


Averagevalue

longitudinal 51 60 15 < s ≤ 100

transverse430 363

570 to710 513

34 41

longitudinal19 16 45

51 60100 < s ≤ 200

transverse390 343

560 to700 510

34 41

1.4 Heat treatment

(1) The steel is used in the quenched and tempered condition.Austenitising: 870 °C to 930 °C with subsequent hardening in water.Tempering: 630 °C to 690 °C.Stress-relief heat treatment: 580 °C to 620 °C for the last heat treatment.

Intermediate annealing may be performed at 550 °C.


1.5 Processing

The temperature range for hot forming as well as the heat-up and cooling rates are to be selected according to the base mate-rial manufacturer`s specification. After hot forming, a quenching and tempering treatment to Sec. 1.4 is required.

1.6 Flame cutting



2 Specimen-taking


The test coupons for verification of the mechanical and technological characteristics shall be taken from the tubes after the lastquenching and tempering.


The specimens for mechanical-technological testing shall be taken, as far as practicable, at least at 1/4 the heat treatmentthickness under the surface and at least at 1/2 the heat treatment thickness under the face of the straightened edges. Thespecimens shall be taken from one end of the tubes.


Mechanical-technological testing shall be performed on specimens taken transversely to the main direction of forming.


KTA 3205.1 page 37

Materials test sheet 2.6: Seamless and welded fine grain steel tubes with high strength at elevated temperatures subject tospecial requirements to DIN 17 178 or DIN 17 179


Product form: Seamless tubes Welded tubes

Material: WStE 460 (1.8935) WStE 460 (1.8935)

Requirements: DIN 17 179 and supplementary sheet to this materialstest sheet

DIN 17 178 1)

Specimen taking and extent of testing: DIN 17 179 and supplementarysheet to this materials test sheet

DIN 17 178



2.2



4. Notched bar impact test to DIN EN 10 045-1:One set of impact test specimens per tensile test (one set = three Charpy-V-notch specimens)at room temperature, if the wall thickness s exceeds 10 mm, same requirements as for ISO V-notch specimens.

3.1.B

5. Ring tests. 3.1.B

6. Visual inspection and dimensional check: Each tube. 3.1.B


3.1.B

Material identification: To DIN 17 178 or DIN 17 179.1) DIN 17 178 valid up to s = 40 mm (max.)


Material properties for product thicknesses exceeding 65 mm


Rp0.2 in MPa

at

Rm in MPa

at

A in %

at

Z in %

at

Absorbed impact en-ergy in J

at RT

Product thickness sin mm

Specimendirection


Averagevalue

longitudinal 19 36 5165 < s ≤ 80

transverse400

17 22 31

longitudinal490 to

690 19 36 5180 < s ≤ 100

transverse390

17 22 31

KTA 3205.1 page 38

Materials test sheet 2.7: Seamless tubes made of quenched and tempered alloy steel with high strength at elevated tem-peratures 15 NiCuMoNb 5


Product form: Seamless tubes madeMaterial: 15 NiCuMoNb 5 (1.6368)Requirements: Supplementary sheet to this materials test sheetSpecimen-taking: Supplementary sheet to this materials test sheet



2.3


One tensile test specimen at room temperature per melt, dimension and heat-treatment loteach.Number of lot: 100 tubes

3.1.C

3.2 Tensile test at elevated temperatures to DIN EN 10 002-5:One tensile test specimen at T = 350 °C for each melt, if the design temperature is higher than100 °C.

3.1.C

4. Notched bar impact test to DIN EN 10 045-1:One set of impact test specimens per tensile test as per no. 3.1 (one set = three Charpy-V-notchspecimens) at room temperature, if the wall thickness s exceeds 10 mm.

3.1.C

5. Ring tests:For each rolled length at one end. Type and extent same as for grade III to DIN 17 175.

3.1.C

6. Visual inspection and dimensional check:Each tube. Surface condition to DIN 17 175.

3.1.C


3.1.B

Material identification: Steel grade, heat number, Specimen number or tube number, manufacturer's mark, authorised in-spector's mark.


This supplementary sheet specifies the details for tubes made of 15 NiCuMoNb 5 as well as tests and examinations of theproducts.


1.1 Steel-making process

The steel is normally molten by the electric-arc or basic-oxygen process. If other processes are used, a proof of equivalency isrequired.


Ladle analysisElements

min. max. C 0.10 0.17 Si 0.25 0.50 Mn 0.80 1.20 P 0.030 S 0.025 Altot 0.050 Cu 0.50 0.80 Cr 0.30 Ni 1.00 1.30 Mo 0.25 0.50 Nb 0.015 0.045 N 0.020

KTA 3205.1 page 39



Product thickness sin mm

Specimendirection

Rp0.2 in MPaat

Rm in MPaat

A in %at

Z in %at


at RTRT 350 °C RT 350 °C RT 350 °C RT Single

valueAverage

value

longitudinal 19 36 51s ≤ 80

trans-verse/tan-

gential

440 373 610 to780

51017 25 35

1.4 Heat treatment

(1) The steel is used in the quenched and tempered condition.Austenitising: 880 °C to 980 °C with subsequent cooling-down in air,in water or in oil .Tempering: 580 °C to 680 °C.Stress-relief heat treatment: 530 °C to 620 °C for the last heat treatment.


1.5 Processing

The temperature range for hot forming as well as the heat-up and cooling rates are to be selected according to the base mate-rial manufacturer`s specification. After hot forming, a quenching and tempering treatment to Sec. 1.4 is required.

1.6 Flame cutting

Pre-heating is required before any flame cutting (see SEW 088).

2 Specimen-taking


(1) The test coupons for verification of the mechanical and technological characteristics shall be taken from the product afterthe last quenching and tempering. As far as practicable, the specimens shall be taken in transverse direction, otherwise inlongitudinal direction.

(2) In the case of longitudinal specimens the following requirements shall apply:

a) Tensile test at room temperature if the wall thickness issmaller than or equal to 30 mm Tube section or skelp specimen with both rolled surfaces or round tensile test speci-

men with specimen axis at 1/2 the wall thickness under the surfacegreater than 30 mm Tube skelp specimen with at least one as-rolled surface or round tensile test specimen

at 1/4 the wall thickness under the outer surface

b) Tensile test at elevated temperatures if the wall thickness issmaller than or equal to 30 mm Tube skelp or round tensile test specimen with specimen axis at 1/2 the wall thickness

under the surfacegreater than 30 mm Round tensile test specimen with specimen axis at 1/2 the wall thickness under the

surface

c) Notched bar impact test if the wall thickness isgreater than 10 mmbut smaller than 40 mm Specimens normally taken close to surfacegreater than or equal to 40 mm Specimens with specimen axis at 1/4 the wall thickness under the surface.

(3) In the case of transverse specimens, the specimen axis shall normally be at, or as close as possible to the location speci-fied for longitudinal specimens.

KTA 3205.1 page 40

Materials test sheet 3.1: Forged bars and forgings to DIN EN 10 222-5 and rolled bars to DIN EN 10 272 made of stainlesssteels


Product form: Bars, Forgings

Materials: X5CrNi18-10 (1.4301)X6CrNiTi18-10 (1.4541)X6CrNiNb18-10 (1.4550)X6CrNiMoTi17-12-2 (1.4571)X5CrNiMo17-12-2 (1.4401)

Requirements: DIN EN 10 222-1 and DIN EN 10 222-5 or DIN EN 10 272

Specimen taking and extent of testing: DIN EN 10 222-1 or DIN EN 10 272



2.2


3. Tensile test at room temperature to DIN EN 10 002-1:If practicable, transverse or longitudinal specimens, for bar steel with product thicknessessmaller than or equal to 160 mm, longitudinal specimens.

3.1.B

4. Visual inspection and dimensional check:Each component. Surface condition to DIN EN 10 222-1 or DIN EN 10 272.

3.1.B


3.1.B

6. Surface crack detection only on forgings:Each component subject to 100 % in acc. with Annex B.

3.1.B

Material identification: To DIN EN 10 222-1 or DIN EN 10 272.

KTA 3205.1 page 41

Materials test sheet 3.2: Forgings made of quenched and tempered alloy steels with high strength at elevated temperatures20 MnMoNi 5 5 and 22 NiMoCr 3 7


Product form: ForgingsMaterial: 20 MnMoNi 5 5 (1.6310)

22 NiMoCr 3 7 (1.6751)Requirements: Supplementary sheet to this materials test sheetSpecimen-taking: Supplementary sheet to this materials test sheet



2.3


One tensile test specimen at room temperature per location of specimen-taking. Value to be de-termined: Rp0.2, Rm, A, Z.

3.1.C

3.2 Tensile test at elevated temperatures to DIN EN 10 002-5:One tensile test specimen at T = 350 °C at one location of specimen-taking, if the design tem-perature is higher than 250 °C.Value to be determined Rp0.2, Rm, A.

3.1.C


3.1.C

5. Visual inspection and dimensional check:Each forging.

3.1.C

6. Materials identification check:Each forging by a suitable method.

3.1.B

7. Ultrasonic testing:For bar steel with product thicknesses greater than or equal to 30 mm and for forgings ≥ 300 kgeach component subject to 100 % in acc. with Annex B.

3.1.B

8. Surface crack detection:Each component subject to 100 % in acc. with Annex B.

3.1.B

Material identification: Steel grade, heat number, specimen number, manufacturer's mark, authorised inspector's mark.

Supplementary sheet to materials test sheet WPB 3.2This supplementary sheet specifies the details for forgings of 20 MnMoNi 5 5 as well as tests and examinations of the products.The requirements for forgings of 22 NiMoCr 3 7 shall be specified in the course of the design review.

1 Materials data and requirements1.1 Steel-making processThe steel is normally molten by the electric-arc or basic-oxygen process. If other processes are used, a proof of equivalence isrequired.1.2 Chemical composition (content by mass in %)

Ladle analysisElements min. max. C 0.17 0.23 Si 0.15 0.30 Mn 1.20 1.50 P 0.012 S 0.008 Altot 0.01 0.04 Cu 0.12 Cr 0.20 Ni 0.50 0.80 Mo 0.40 0.55 V 0.02 Sn 0.011 Ntot 0.013 As 0.025

KTA 3205.1 page 42


The requirements regarding mechanical properties of the material apply to the final heat treatment condition of the component.The minumum values or ranges are given by this table.

Rp0.2 in MPaat

Rm in MPaat

A in %at

Z in %at


at 0 °CProduct thickness s

in mmSpecimendirection


Averagevalue

s < 320 343

s � 320longitudi-nal/trans-

verse390

314560 to

700 504 19 14 45 34 41

1.4 Heat treatment

(1) The steel is used in the quenched and tempered condition.Austenitising: 870 °C to 940 °C with subsequent hardening in water.Tempering: 630 °C to 680 °C.Stress-relief heat treatment: 580 °C to 620 °C for the last heat treatment, intermediate annealing may be performed at appr.

550 °C


1.5 Flame cutting



2 Specimen-taking


The test coupons for verification of the mechanical and technological characteristics shall be taken from the product after thelast quenching and tempering.


(2) Where only one forging is fabricated from a forging ingot, the samples shall be taken at the top and toe end. Where forg-ings are cut after the rough forging process into components to be quenched and tempered separately, each component shallbe tested at one specimen-taking location, in which case the top and toe end or each rough forging shall be covered.

(2) For individually quenched and tempered forgings with a length exceeding 4 m in main forming direction or with a thicknessexceeding 500 mm, samples from both ends shall be tested.

(3) In the case of quenched and tempered wall thicknesses up to and incl. 320 mm, the specimen-taking location shall be atleast at 1/2 the quenched and tempered wall thickness under the face and side surfaces and at 1/4 the quenched and tem-pered wall thickness under the quenched and tempered surface of the edges straightened for heat treatment purposes.

(4) In the case of quenched and tempered wall thicknesses exceeding 320 mm, the specimen-taking location shall be at least80 mm below each quenched and tempered surface of the edges straightened for heat treatment purposes.


Mechanical-technological testing shall be performed on specimens taken transversely to the direction of main forming.


KTA 3205.1 page 43

Materials test sheet 3.3: Forged bars and forgings to DIN EN 10 250-2 as well as rolled bars and sections to DIN EN 10 025made of structural carbon steel


Product form: Bars, forgings and steel sectionsMaterials: S235JRG2 (RSt 37-2) (1.0038) 1)

S235J2G3 (St 37-3) (1.0116)S355J2G3 (St 52-3) (1.0570)

Requirements: DIN EN 10 250-1 and DIN EN 10 250-2 or DIN EN 10 025Specimen taking and extent of testing: DIN EN 10 250-1 or DIN EN 10 025 and DIN EN 10 164


1. Chemical composition:Ladle analysis. 2)

2.2

2. Attestation of heat treatment condition. 2.23. Tensile test:3.1 Tensile test to DIN EN 10 002-1:

One tensile test specimen at room temperature per melt, test unit and thickness range each.3.1.B

3.2 Tensile test to DIN EN 10 164 on steel sections with thicknesses exceeding 20 mm:Three tensile test specimens in thickness direction at room temperature per rolled length, as faras the sections are subject to further processing by welding and tensile loading in thicknessdirection is to be expected due to the type of welded joint (see DASt 014).Requirements: Quality class Z25 to DIN EN 10 164Specimen-taking: DIN EN 10 164Ultrasonic testing: Clause 8.2 , para. 4 and clause 10.2.4.1 b) apply accordingly.

3.1.B

4. Notched bar impact test to DIN EN 10 045-1:One set of impact test specimens per tensile test (one set = three Charpy-V-notch specimens),if the product thickness s or d is greater than or equal to 15 mm.Test temperature to DIN EN 10 250-2 or DIN EN 10 025

3.1.B


3.1.B

6. Ultrasonic testing:For bar steel with product thicknesses greater than or equal to 30 mm and forgings ≥ 300 kgEach component subject to 100 % in acc. with Annex B.

3.1.B

Material identification: To DIN EN 10 250-1 or DIN EN 10 025 and Z25 (if verified)1) The material S235JRG2 shall not be used if steel sections are loaded in thickness direction.2) The carbon equivalent CEV to DIN EN 10 025 shall be adhered to.

Materials test sheet 3.4: Forged bars and forgings to DIN EN 10 222-2 and rolled bars to DIN EN 10 273 made of steels withhigh strength at elevated temperatures and suited for welding


Product form: Bars and forgingsMaterials: P250GH (C 22.8) (1.0460)

16Mo3 (15 Mo 3) (1.5415)Requirements: DIN EN 10 222-1 and DIN EN 10 222-2 or DIN EN 10 273Specimen taking and extent of testing: DIN EN 10 222-1 or DIN EN 10 273



2.2

2. Attestation of heat treatment condition. 2.23 Tensile test at room temperature to DIN EN 10 002-1. 3.1.B4. Notched bar impact test to DIN EN 10 045-1:

One set of impact test specimens per tensile test (one set = three Charpy-V-notch specimens)at room temperature.

3.1.B


3.1.B

6. Materials identification check for alloyed steels:Each component by a suitable method.

3.1.B


3.1.B

Material identification: To DIN EN 10 222-1 or DIN EN 10 273

KTA 3205.1 page 44

Materials test sheet 3.5: Bars and forgings of quenched and tempered alloy steels with and without threaded endsto DIN EN 10 083-1 or SEW 550 or to DIN EN 10 269


Product form: Bars and forgings with and without threaded ends

Materials: to DIN EN 10 083-1 or SEW 550 1) : to DIN EN 10 269:C45E (Ck 45) (1.1191) 21CrMoV5-7 (21 CrMoV 5 7) (1.7709)42CrMo4 (42 CrMo 4) (1.7225)34CrNiMo6 (34 CrNiMo 6) (1.6582)

Requirements: DIN EN 10 083-1 or SEW 550 1) or DIN EN 10 269

Specimen taking and extent of testing: DIN EN 10 083-1 or SEW 550 or DIN EN 10 269



2.2


3. Hardness test for verification of uniform heat treatment:On both ends of each component.

3.1.B

4. Tensile test to DIN EN 10 002-1:One tensile test specimen at room temperature from the hardest and softest portion of eachmelt, dimensional range and heat treatment batch. The location of specimen-taking for precisionforgings shall be agreed.

3.1.B

5. Notched bar impact test to DIN EN 10 045-1:One set of impact test specimens per tensile test (one set = three Charpy-V-notch specimens) 1)

at room temperature.The location of specimen-taking for precision forgings shall be agreed.

3.1.B

6. Visual inspection and dimensional check:Each component.Additional requirements for parts with threaded endsThe visual inspection and dimensional check shall be performed in the final condition of eachpart.Each component shall be subjected to a surface crack examination in acc. with Annex B.

3.1.B

7. Materials identification check for alloyed steels:Each component by a suitable method.

3.1.B


3.1.B

Material identification: Steel grade, heat number, specimen number, manufacturer’s mark1) SEW 550 is to be applied to large forgings.

KTA 3205.1 page 45

Materials test sheet 3.6: Bars and forgings made of high-strength quenched and tempered steels26 NiCrMo 14 6 and 20 NiCrMo 14 5 with and without threaded ends


Product form: Bars and forgings with and without threaded endsMaterials: 26 NiCrMo 14 6 (1.6958)

20 NiCrMo 14 5 (1.6742)Requirements: Supplementary sheet to this materials test sheetSpecimen-taking: Supplementary sheet to this materials test sheet



2.3

2. Attestation of heat treatment condition with certification of temperature and holding time. 2.33. Hardness test for verification of uniform heat treatment:

On both ends of each component.3.1.B

4. Tensile test to DIN EN 10 002-1:One tensile test specimen at room temperature from the hardest and softest portion of eachmelt, dimensional range and heat treatment batch. The location of specimen-taking for precisionforgings shall be agreed.

3.1.C

5. Notched bar impact test to DIN EN 10 045-1:One set of impact test specimens per tensile test (one set = three Charpy-V-notch specimens).The location of specimen-taking for precision forgings shall be agreed.Test temperature to supplementary sheet.

3.1.C

6. Visual inspection and dimensional check:Each component.Additional requirements for parts with threaded ends:The visual inspection and dimensional check shall be performed in the final condition of the partEach component shall be subjected to a surface crack examination in acc. with Annex B.

3.1.C


3.1.B


3.1.B

Material identification: Steel grade, heat number, specimen number, manufacturer’s mark, authorised inspector’s mark.


This supplementary sheet specifies the details regarding bars and forgings of 20 NiCrMo 14 5 and 26 NiCrMo 14 6 as well astests and examinations of the products.

1 Material data and requirements

1.1 Steel-making processThe steel is normally molten by the electric-arc or by the basic-oxygen process. If other processes are used, a proof of equiva-lency is required.


Ladle analysis for materialsElements 20 NiCrMo 14 5 26 NiCrMo 14 6

min. max. min. max.C 0.18 0.25 0.25 0.30Si 0.15 0.40 − 0.30Mn 0.30 0.50 0.20 0.50P − 0.02 − 0.02S − 0.01 − 0.01Cr 1.20 1.50 1.20 1.70Ni 3.40 4.00 3.30 3.80Mo 0.25 0.50 0.35 0.55V − − − 0.12Al 0.02 0.05 0.02 0.05

KTA 3205.1 page 46



Rp0.2 in MPaat

Rm in MPaat

A in %at

Z in %at


at 20 °CProduct thickness s

in mmSpecimendirection


Averagevalue

Material

20 NiCrMo 14 5 I

s ≤ 130 1040 to 64 75

130 < s ≤ 200940 735

1240 − 14 − 5552 63

Material

20 NiCrMo 14 5 II

s ≤ 130 1080 to 64 75

130 < s ≤ 200980 785

1280 − 14 − 5552 63

Material

26 NiCrMo 14 6

long

itudi

nal

s ≤ 70 1040 to 55 75

70 < s ≤ 420940 765

1240 − 14 − 5036 52

1.4 Heat treatment

(1) The steels are used in the quenched and tempered condition.

a) Material 20 NiCrMo 14 5Austenitising: 830 °C to 900 °C with subsequent hardening in water/oil.Tempering: Grade I: 520 °C to 600 °C

Grade II: 500 °C to 580 °C.

b) Material 26 NiCrMo 14 6Austenitising: 840 °C to 870 °C with subsequent hardening in water/oil.Tempering: 530 °C to 620 °C.


2 Specimen-taking



2.2 Locations of specimen-taking

Diameter din mm

Location Specimen-taking direction Position

d ≤ 40 1/2 d

d > 40

Beginning or end of themanufacturing length longitudinal

1/6 d

KTA 3205.1 page 47

Materials test sheet 4.1: Bolts and nuts to strenght grades as well as for washers subject to high-strength bolted joints


Product form: Bolts and nuts,Washers for high-strength pretensioned joints

Strength class: Bolts: 4.6, 5.6, 5.8, 6.8, 8.8 and 10.9Nuts: 5, 6, 8 and 10Washers: Material C45 to DIN EN 10 083-2,

C45E (Ck 45) to DIN EN 10 083-1 or harder

Requirements: Bolts: DIN EN ISO 898-1Nuts: DIN EN 20 898-2Washers: DIN EN 10 083-1, DIN EN 10 083-2

Für high-strength bolted connections(10.9): Bolts additionally to DIN 6914Nuts additionally to DIN 6915Washers DIN 6916 to DIN 6918

Specimen taking and extent of testing: Bolts: DIN EN ISO 898-1Nuts: DIN EN 20 898-2Washers: DIN 6916 to 6918


1. Heat treatment:Certification of heat treatment condition.

2.2

2. Bolts:To DIN EN ISO 898-1.Tests shall be continuously performed under the manufacturer’s responsibility.Where testing with the type of specimen to DIN EN ISO 898-1 is not possible due to the part’s dimension,standard specimens to DIN EN 10 028-1 shall be taken from production bar sections which in the case ofquenched and tempered materials have been turned off to obtain the controlling heat treatment diameterof the bolts to be formed for quenching and tempering, and be tested. The properties relevant to thestrength grade in acc. with DIN EN ISO 898-1 shall also be verified for this case.

2.2 1)

3. Nuts:To DIN EN 20 898-2.Tests shall be continuously performed under the manufacturer’s responsibility.In lieu of the proof load test, a hardness measurement HV 30 may be performed in the case ofdimensions exceeding M 39. The values according to Table WPB 4.1-1 shall be adhered to.

2.2 1)

4. Bolts and nuts:Dimensional accuracy, identification marks and type.Tests shall be continuously performed under the manufacturer’s responsibility.

2.2 1)

5. Washers for high-strength bolted connections: dimensional accuracy,Certification of material used

2.2

Material identification:Bolts to DIN EN ISO 898-1, for high-strength bolted connections additionally to DIN 6914Nuts to DIN EN 20 898-2, for high-strength bolted connections additionally to DIN 6915Washers subject to high-strength bolted joints to DIN 6916 to DIN 6918

Strength grade5 6 8 10

Vickers hardness Vickers hardness Vickers hardness Vickers hardness

Thread diameter d inmm

min. max. min. max. min. max. min. max.

39 < d ≤ 48 128 302 142 302 207 353 272 353

d > 48 To be fixed within the course of the design approval procedure by agreementwith the authorised inspector

Table WPB 4.1-1: Hardness values

1) In lieu of the test report stamping will suffice if the manufacturer has been examined by the authorised inspector, however, not for bolts ofstrength classes 8.8 and 10.9 and nuts of strength classes 8 and 10.

KTA 3205.1 page 48

Materials test sheet 4.2: Bolts and nuts smaller than or equal to M 39 of stainless steelsto DIN EN ISO 3506-1 and DIN EN ISO 3506-2


Product form: Bolts and nuts smaller than or equal to M 39

Strength classes: 50 or 70 or 80, steel grades A2, A3, A4 and A5

Requirements: Bolts: DIN EN ISO 3506-1Nuts: DIN EN ISO 3506-2

Specimen taking and extent of testing: DIN EN ISO 3506-1 and DIN EN ISO 3506-2

Tests and inspections:Tests and inspections on finished bolts and nuts

Certificate toDIN EN 10 204

1. Tests and examinations to DIN EN ISO 3506-1 as well as to DIN EN ISO 3506-2,Extent of testing in acc. with Table WPB 4.2-1.

3.1.B

2. Visual inspection, dimensional check and materials identification check:Tests shall be continuously performed under the manufacturer’s responsibility.

2.2

Material identification: bolts to DIN EN ISO 3506-1, nuts to DIN EN ISO 3506-2

Number of pieces in test unit Number of pieces to be tested

≤ 800 1

801 up to 1300 2

> 1300 3

Table WPB 4.2-1: Number of parts to be tested in dependence of the number of parts per testunit in the case of mechanical-technological testing of bolts and nuts.

KTA 3205.1 page 49

Materials test sheet 4.3: Bolts and nuts, machined, cut or rolled thread, finally not heat treated,of stainless steels to DIN EN 10 222-5 or DIN EN 10 272


Product form: Bolts and nuts machined, cut or rolled thread, finally not heat treated

Materials: X6CrNiTi18-10 (1.4541)X6CrNiNb18-10 (1.4550)X6CrNiMoTi17-12-2 (1.4571)

Requirements: DIN EN 10 222-1 and DIN EN 10 222-5 or DIN EN 10 272

Specimen taking and extent of testing: DIN EN 10 222-1 or DIN EN 10 272


1. Tests on basic material:1.1 Chemical composition:

Ladle analysis.2.2

1.2 Attestation of heat treatment condition. 2.2

1.3 Tensile test at room temperature to DIN EN 10 002-1. 2.3

1.4 Materials identification check:Each component by a suitable method.

2.3

2. Tests on finished bolts and nuts:

2.1 Visual inspection and dimensional check:The bolts and nuts shall be checked for dimensional accuracy to meet product standard speci-fications. Table WPB 4.3-1 and Table WPB 4.3-2 apply regarding the extent of testing anddefect acceptance levels.

2.3

Material identification: Basic material to DIN EN 10 222-1 or DIN EN 10 272.Bolts and nuts: Short designations for assignment to initial material.

Main featuresThread limit dimensions (trueness to gauge size)Force-application areas for assemblyTransition under the bolt headThread root radius at the thread-to-shank transition

Secondary featuresLengths (bolt length, thread length)Deviations from shape and locationBearing surfacesHeights (head heights, nut heights)Diameters

Note: Further features as well as their classification can be defined in the purchase order.

Table WPB 4.3-1: Features to be inspected during the dimensional check of bolts and nuts as well astheir classification as main or secondary features

Extent of random checking Acceptance levels

Main features Secondary featuresMain features

Secondaryfeatures

Number of pieces inthe test unit

Bolts Nuts Bolts Nuts

up to 150 32 20 20 13 0 0151 up to 280 32 20 80 50 0 1281 up to 500 125 80 80 50 1 1501 up to 1 200 125 80 125 80 1 1

1201 up to 3 200 200 125 200 125 2 33201 up to 10 000 315 200 315 200 3 5

Table WPB 4.3-2: Extent of random checking and acceptance levels for the dimensional check and sur-face-crack detection of bolts and nuts

KTA 3205.1 page 50

Materials test sheet 4.4: Bolts and nuts, machined, cut or rolled thread, finally not heat treated, of steels with high strength atelevated temperatures to DIN EN 10 269, of quenched and tempered steels to DIN EN 10 083-1,DIN 267-13 and in acc. with supplementary sheet


Product form: Bolts and nuts machined, cut or rolled thread, finally not heat treated.

Materials: to DIN EN 10 269, DIN 267-13: to DIN EN 10 083-1: in acc. with suppl. sheet:C35E (Ck 35) (1.1181) C45E (Ck 45) (1.1191) 20 NiCrMo 14 5 (1.6742)25CrMo4 (1.7218) 42CrMo4 (42 CrMo 4) (1.7225) 26 NiCrMo 14 6 (1.6958)21CrMoV5-7 (21 CrMoV 5 7) (1.7709) 34CrNiMo6 (34 CrNiMo 6) (1.6582)40CrMoV4-6 (40 CrMoV 4 7) (1.7711)X19CrMoNbVN11-1 (1.4913)

(X 19 CrMoVNbN 11 1)

Requirements: DIN EN 10 269 and DIN 267-13 or DIN EN 10 083-1 or supplementary sheet to materials test sheet

Specimen taking and extent of testing: DIN EN 10 269 or DIN EN 10 083-1 or supplementary sheet


1. Tests on basic material:

1.1 Chemical composition:Ladle analysis.

2.2

1.2 Attestation of heat treatment condition. 2.2

1.3 Hardness test on one end of each bar upon final heat treatment. 3.1.B

1.4 Tensile test to DIN EN 10 002-1:One tensile test specimen at room temperature from the hardest and softest bar per melt, di-mension and heat-treatment lot each.

3.1.B 1)

1.5 Notched bar impact test to DIN EN 10 045-1:One set (one set = three Charpy-V-notch specimens) at room temperature or at test tempera-ture in acc. with supplementary sheet, of the hardest bar per melt, dimension and heat-treatment lot each.

3.1.B 1)

1.6 Materials identification check for alloyed steels:Each component by a suitable method.

3.1.B

2. Tests on finished bolts and nuts:

2.1 Visual inspection and dimensional check:The bolts and nuts shall be checked for dimensional accuracy to meet product standard speci-fications. Table WPB 4.4-1 and Table WPB 4.4-2 apply regarding the extent of testing anddefect acceptance levels.

3.1.B

2.2 Non-destructive examination:Non-destructive examinations based on DIN EN 26 157-3 for bolts and DIN EN 493 for nuts. Forthe extent of examination the requirements of Table WPB 4.4-2, secondary features, shall ap-ply.

3.1.B

Material identification:Basic material: to DIN EN 10 083-1, DIN EN 10 269.Bolts and nuts: Short designations for assignment to initial material.1) Nachweis 3.1.C für die Werkstoffe 20 NiCrMo 14 5 und 26 NiCrMo 14 6

Main featuresThread limit dimensions (trueness to gauge size)Force-application areas for assemblyTransition under the bolt headThread root radius at the thread-to-shank transition

Secondary featuresLengths (bolt length, thread length)Deviations from shape and locationBearing surfacesHeights (head heights, nut heights)Diameters


Table WPB 4.4-1: Features to be inspected during the dimensional check of bolts and nuts as well as theirclassification as main or secondary features

KTA 3205.1 page 51

MATERIALS TEST SHEET WPB 4.4 (continued)

Number of pieces inthe test unit


Main features Secondary features Main features Secondaryfeatures

Bolts Nuts Bolts Nuts

up to 150 32 20 20 13 0 0

151 up to 280 32 20 80 50 0 1

281 up to 500 125 80 80 50 1 1

501 up to 1 200 125 80 125 80 1 2

1201 up to 3 200 200 125 200 125 2 3

3201 up to 10 000 315 200 315 200 3 5



This supplementary sheet specifies the details regarding bars and forgings aus 20 NiCrMo 14 5 and 26 NiCrMo 14 6 as well astests and examinations of the products.


1.1 Steel-making process

The steel is normally molten by the electric-arc or by the basic-oxygen process. If other processes are used, a proof of equiva-lency is required.


Ladle analysis for materials

Elements 20 NiCrMo 14 5 26 NiCrMo 14 6

min. max. min. max.

C 0.18 0.25 0.25 0.30

Si 0.15 0.40 − 0.30

Mn 0.30 0.50 0.20 0.50

P − 0.02 − 0.02

S − 0.01 − 0.01

Cr 1.20 1.50 1.20 1.70

Ni 3.40 4.00 3.30 3.80

Mo 0.25 0.50 0.35 0.55

V − − − 0.12

Al 0.02 0.05 0.02 0.05

KTA 3205.1 page 52



Product thickness s in mm

Speci-men

direction

Rp0.2 in MPaat

Rm in MPaat

A in %at

Z in %at


at 20 °C


Averagevalue

Material20 NiCrMo 14 5 I

s ≤ 130 1040 to 64 75

130 < s ≤ 200940 735

1240 − 14 − 5552 63

Material20 NiCrMo 14 5 II l

s ≤ 130 1080 to 64 75

130 < s ≤ 200980 785

1280 − 14 − 5552 63

Material26 NiCrMo 14 6

s ≤ 70 1040 to 55 75

70 < s ≤ 420940 765

1240 − 14 − 5036 52

1.4 Heat treatment

(1) The steels are used in the quenched and tempered condition.

a) Material 20 NiCrMo 14 5Austenitising: 830 °C to 900 °C with subsequent hardening in water/oil.Tempering: Grade I: 520 °C to 600 °C

Grade II: 500 °C to 580 °C.

b) Material 26 NiCrMo 14 6Austenitising: 840 °C to 870 °C with subsequent hardening in water/oil.Tempering: 530 °C to 620 °C.


2 Specimen-taking



2.2 Locations of specimen-taking

Diameters din mm

Location Specimen-taking orientation Position

d ≤ 40 1/2 d

d > 40

Beginning or end ofmanufacturing length

longitudinal1/6 d

KTA 3205.1 page 53

Materials test sheet 4.5: Bolts and nuts, hot formed, cut or rolled thread, finally heat treated for use at room temperature orelevated temperatures to DIN EN 10 269


Product form: Bolts and nuts hot formed, cut or rolled thread, finally heat treated

Materials: C35E (Ck 35) (1.1181)21CrMoV5-7 (21 CrMoV 57) (1.7709)40CrMoV4-6 (40 CrMoV 47) (1.7711)X19CrMoNbVN11-1 (X 19 CrMoVNbN 11 1) (1.4913)

Requirements: DIN EN 10 269

Specimen taking and extent of testing: DIN EN 10 269 and DIN 267-13


1. Tests on basic material

1.1 Chemical composition:Ladle analysis.

2.2

1.2 Visual inspection and dimensional check:Each component.

2.3

1.3 Materials identification check for alloyed steels:Each component by a suitable method.

2.3

1.4 Check of material identification:Each component.

3.1.B

2. Tests on finished bolts and nuts2.1 Attestation of heat treatment condition:

Per heat treatment lot.3.1.B

2.2 Hardness test:On 10% of the parts, however on at least 15 pieces.

3.1.B

2.3 Mechanical testing per melt, dimension and heat-treatment lot each:Quantity delivered

of pieces (St)Number

of test specimensets

St ≤ 300300 < St ≤ 800800 < St ≤ 8000

124

In the case of delivered quantities exceeding 8.000, the number of test specimen sets shall beagreed with the authorised inspector.One set of test specimens for bolts:- One tensile test specimen at room temperature to DIN EN 10 002-1- In the case of > M 14 three Charpy-V notch test specimens at room temperature to

DIN EN 10 045-1- In the case of ≤ M 14 bolt head impact toughness testNuts:- Proof load test

3.1.B

2.4 Visual inspection, dimensional check:The bolts and nuts shall be checked for dimensional accuracy to meet product standard speci-fications. Table WPB 4.5-1 and Table WPB 4.5-2 apply regarding the extent of testing and de-fect acceptance levels.

3.1.B

2.5 Non-destructive examinations:Non-destructive examinations based on DIN EN 26 157-3 for bolts and DIN EN 493 for nuts.For the extent of examination the requirements of Table WPB 4.5-2, secondary features, shallapply.

3.1.B

Material identification:Basic material: Steel grade, manufacturer’s mark, heat number, authorised inspector’s mark.Bolts and nuts: Short designation for assignment to initial material

KTA 3205.1 page 54

MATERIALS TEST SHEET WPB 4.5 (Continued)

Main features

Thread limit dimensions (trueness to gauge size)Force-application areas for assemblyTransition under the bolt headThread root radius at the thread-to-shank transition

Secondary features

Lengths (bolt length, thread length)Deviations from shape and locationBearing surfacesHeights (head heights, nut heights)Diameters


Table WPB 4.5-1: Features to be inspected during the dimensional check of bolts and nuts as well astheir classification as main or secondary features


Main features Secondary featuresNumber of pieces

in the test unitBolts Nuts Bolts Nuts

Main features Secondaryfeatures

up to 150 32 20 20 13 0 0

151 up to 280 32 20 80 50 0 1

281 up to 500 125 80 80 50 1 1

501 up to 1 200 125 80 125 80 1 2

1201 up to 3 200 200 125 200 125 2 3

3201 up to10 000 315 200 315 200 3 5


KTA 3205.1 page 55

Materials test sheet 5.1: Ferritic cast-steel GS-18 NiMoCr 3 7 to supplementary sheet and GP240GHto DIN EN 10 213-2


Product form: Casting

Materials: to supplementary sheet: to DIN EN 10 213-2:GS-18 NiMoCr 3 7 (1.6756) GP240GH (GS-C 25) (1.0619)

Requirements: GS-18 NiMoCr 3 7 to supplementary sheet,GP240GH to DIN EN 10 213-1 and DIN EN 10 213-2 and supplementary sheet

Specimen-taking: Supplementary sheet to this materials test sheet

Note:The point of time of required tests and examinations given below shall be taken from the standard productionscheme for steel castings (Figure A-1).



2.2

2. Product analysis:One product analysis per heat shall be performed.

3.1.B

3. Attestation of heat treatment condition with certification of temperature and holding time incl.simulated annealing, if any, of the test pieces.

3.1.B

4. Tensile test to DIN EN 10 002-1:

4.1 One tensile test specimen at room temperature per location of specimen-taking. 3.1.B

4.2 Tensile test at elevated temperatures to DIN EN 10 002-5:One tensile test specimen at T = 350 °C at one location of specimen-taking, if the design tem-perature is higher than 250 °C. Value to be determined Rp0.2, Rm, A.

3.1.B


3.1.B


3.1.B

7. Materials identification check on the cast-steel grade GS-18 NiMoCr 3 7:Each component.

3.1.B

8. Non-destructive examinations:Note: For wall thicknesses smaller than 100 mm the type and extent of volumetric examination as well as thegrade shall be indicated by the purchaser.

8.1 Ultrasonic testing:In the case of wall thicknesses greater than or equal to 100 mm:Extent of testing:100 % (including production welds)Procedure and evaluation:DIN 1690-2

3.1.B

8.2 Surface crack detection:Extent of testing:100 % inner and outer surfaceProcedure and evaluation:DIN 1690-2

3.1.B

9. Check of identification marks:To be made by the manufacturer prior to delivering the parts

Material identification: Cast-steel grade, heat number, specimen number, manufacturer's mark, works`inspector`s mark

KTA 3205.1 page 56



1.1 Chemical composition (content by mass in %) for cast-steel grade GS-18 NiMoCr 3 7

Proof to made onElements melt product 1)

min. max. min. max. C 0.17 0.23 0.16 0.23 Si 0.30 0.50 0.25 0.50 Mn 0.70 1.10 0.70 1.20 P − 0.012 − 0.012 S − 0.01 − 0.012 Cr 0.30 0.50 0.30 0.50 Mo 0.40 0.60 0.40 0.60 Ni 0.60 1.10 0.60 1.10 Altot 0.02 0.05 0.02 0.05 Cu − 0.12 − 0.12 V − 0.02 − 0.02 Sn − 0.011 − 0.011 Ntot − 0.015 − 0.015 As − 0.025 − 0.025

1) The differences that the tabulated values indicate between chemical compositions per ladle and product analysis are sometimes smallerthan would be expected from the metallurgical relationship. The reason is that the limit values for chemical composition per the productanalysis are in this case based only on the heats covered by the appraisal. Thus the values will be reviewed once additional documentsbecome available.



MaterialRp0.2 in MPa

atRm in MPa

atA in %

atZ in %

atAbsorbed impact

energy in Jat 0 °C

Governingwall thickness

in mmRT 350 °C RT 350 °C RT 350 °C RT Single

valueAverage

value

GP240GH (GS-C 25) ≤ 100 245 135 440 to 590 (375) 1) 22 (20)1) -

GS-18 NiMoCr 3 7 ≤ 300 390 343 570 to 735 490 16 12 - 34 41

1) The values in parentheses must still be substantiated by statistics.

1.3 Internal and external finish / Preparation of the surfaces for non-destructive examination

(1) DIN 1690-2 applies regarding the requirements for internal and external finish with certification of the steel grades here-after in dependence of the materials as shown in the following table:

Material Grade to DIN 1690-2

GS-20 NiMoCr 3 7

GP240GH (GS-C 25)

MS2 1) - UV 2 1), 2)

MS3 - UV 3 2)

MS2 1) - UV 2 1), 2)

MS4 - UV 4 2)

1) Only for areas with machined surfaces.2) For wall thicknesses greater than or equal to 100 mm

(2) For the evaluation of surfaces prepared for the non-destructive examination DIN EN 1370, reference samples BNIF, shallapply:a) Limit acceptance level for sand-blasted surfaces at least 3 S1,b) Limit acceptance level for surfaces subjected to manual or swing-grinding at least 4 S2.

KTA 3205.1 page 57

1.4 Processing guidelines1.4.1 General requirementsThe casting technique shall be based on the principles of controlled solidification.For each type of casting the casting techniqueused shall be recorded and be part of the internal documentation.

1.4.2 Standard production scheme for steel castingsThe production and testing sequences shown in Figure A-1 shall be adhered to. In the case of deviations the manufacturershall establish a test and inspection sequence plan and submit it to the purchaser for review (design approval).

1.4.3 Heat treatment(1) GP240GH (GS-C 25) quenching and tempering to DIN EN 10 213-1 and DIN EN 10 213-2The cast steel GS-18 NiMoCr 3 7 shall be used in the double quenched and tempered condition.Austenitising: 800 °C to 950 °C with subsequent hardening in water.Tempering: 650 °C to 700 °C.Stress-relief heat treatment: 580 °C to 620 °C for the last heat treatment, intermediate annealing may be performed at ap-

prox. 550 °C.


1.4.4 Production weldsThe following applies in addition to DIN EN 1559-1:(1) The performance of production welds requires procedure qualifications to SEW 110. The following shall be submitted tothe authorised inspector for review:a) welding procedure sheet,b) heat-treatment plan,c) material testing and sampling plan.(2) The manufacturer shall establish a report on the procedure qualification to contain the limits of application and the condi-tions for fabricating test pieces. The test results shall be recorded.

(3) For weld filler metals and welding consumables the stipulations of Sec. 9.5 shall apply.(4) The use of a filling piece in production welds is subject to agreement by the purchaser.(5) Where inacceptable indications are found by surface crack detection or volumetric examinations, production welds shallbe made to the standard production scheme for cast steel products (Figure A-1)(6) A major production welds which is to be documented according to Figure A-1 is considered to be each location preparedfor production welding the depth of which exceeds 40% of the wall thickness or the following values:For steel grade DIN 1690-2 MS2 - UV2 25 mm

MS3 - UV3 40 mmMS4 - UV4 60 mm

2 Specimen-taking

2.1 Heat treatment condition of the test coupons(1) The integrally cast test coupons shall not be cut-in or cut-off before the last quenching and tempering treatment andstamping have been performed. Deviations from this requirement shall be subject to special agreements,(2) Test coupons of castings which are to be stress-relieved during further processing shall be subjected to a simulationstress-relief heat treatment prior to specimen-taking. In this case, any stress-relief heat treatment to be perforemd in the courseof further processing of the casting including repair annealing, if any, shall be taken into account.(3) Test coupons of castings where the number, temperature and time of stress-relief heat treatments cannot be predicted,shall be annealed in accordance with the following requirements.Heat rate: less than or equal to 100 °C/h as of 300 °CHolding temperature: 620 °C ± 20 KHolding time upon raching holding temperature: 15 h ± 1 hCooling conditions: furnace or still air up to 300 °C

2.2 Number and taking of test coupons and specimen location(1) The cast-integral test coupons shall be cast integrally with the casting to meet casting technique requirements or shall betaken from excess lengths. They shall be cast integrally in such number and with such a volume that the specified reservematerial for substitute specimens, where necessary, can be taken.(2) The test coupons for determining the mechanical properties shall be taken from the cast-integral test coupons as close aspossible to the casting.

KTA 3205.1 page 58

(3) The location of the cast-integral test coupons shall be recorded by photography or on a sketch to be added to the accep-tance test certificate. In the case of further cast-integral coupons of the same model with the same specimen location, a copy ofthe formerly submitted photography shall be added to the acceptance test certificate.

KTA 3205.1 page 59

3)

3)

3)

2)

1)

2)

6)

1)

4)

6)

6)

4)

6)

4)

5)

5) Where, in exceptional cases within the course of further processing, the componentmanufacturer has to perform production welding in an advanced state of processing,this shall be agreed with the purchaser.

Only applicable to cast steel grade GS-18 NiMoCr 3 7.

Note: Production welds that have already been examined and casting areaswith acceptable indications need not be examined anew.

For a dimension s < 100 mm the procedure for volumetric examination shall beagreed with the purchaser.

See supplementary sheet to materials test sheet 5.1, cl. 1.4.4, sub-clause 6.

Where procedure 2 is followed, the cast steel GS-18 NiMoCr 3 7 shall bedouble-quenched and tempered prior to production welding

production weld)

indications

Setting of the surface quality,

complete surface-crack detection

Inacceptable

Inacceptable

Welding

yes

Procedure 1

Production welds with complete heat treatment

(quenching and tempering)

Inacceptable

Ultrasonic examination (base material and

yes

no

yes

(quenching and tempering)

Production welds without subsequent heat treatment

Surface-crack detection of the production weld

Grinding the welds smooth

Procedure 2

yes no

yes

Welding

yes

yes

no

Volumetric examination

indications

indications

yes

Documentation, for the final file, of all largerproduction welds

no

Stress-relief annealing

Inacceptable

Inacceptable

indications

no

Compilation of the documentation

Inacceptable

Setting of the surface quality,

Ultrasonic examination of larger production welds

Inacceptable


indications

Surface-crack detection of the production weld


Inacceptable

Inacceptable

Mechanical and technological tests,

Ultrasonic examination

Casting

no

Quenching and temperingin a condition similar to finished contour

Complete surface-crack detection

Setting of the surface quality

yes

no

Acceptance:no

yes

Grinding the welds smooth

the places prepared for welding

Grooving out and liquid-penetrant examination of

Documentation of larger production welds

Soaking in the case of larger production welds

yes

Heat treatment to establish the mechanical and tech-

complete surface-crack detection

nological characteristics (quenching and tempering)


indications

indications

no

indications

indications

Grooving out and liquid-penetrant examination ofthe places prepared for welding

6)production weld)Ultrasonic examination (base material and

Figure A-1: Production scheme for steel castings

KTA 3205.1 page 60

Materials test sheet 5.2: Stainless cast steel GX5CrNiNb19-11 and GX4CrNi13-4to DIN EN 10 213-2 or DIN EN 10 213-4


Product form: Steel casting

Materials: GX5CrNiNb19-11 (G-X 5CrNiNb 18 9) (1.4552) to DIN EN 10 213-4GX4CrNi13-4 (G-X 5CrNi 13 4) (1.4317) to DIN EN 10 213-2

Requirements: DIN EN 10 213-1 and DIN EN 10 213-2 or DIN EN 10 213-4

Specimen-taking: DIN EN 10 213-1

Tests and inspections: Certificate toDIN EN 10 204


2.2


3. Tensile test to DIN EN 10 002-1:One tensile test specimen at room temperature from each location of specimen-taking.

3.1.B

4. Notched bar impact test to DIN EN 10 045-1:One set of impact test specimens per tensile test (one set = three Charpy-V-notch specimens)at room temperature.

3.1.B


3.1.B


3.1.B

7. Non-destructive examination to DIN 1690-2:Surface crack detection: 100 %The purchaser shall indicate the steel grades to be subjected to non-destructive examinationand the extent of volumetric examination. Where no steel grades have been agreed in the order,the following minimum requirements apply:a) DIN 1690-2 - ES3 (for sand-molding casting),b) DIN 1690-2 - ES1 (for precision castings or ceramic moulding casting).

3.1.B

Material identification: Cast-steel grade, heat number, specimen number, manufacturer’s mark, authorised inspector’smark.

KTA 3205.1 page 61

Annex B

Non-destructive examinations

ContentsPage

B 1 Scope........................................................................................................................................................................61

B 2 General specifications for non-destructive testing ....................................................................................................61B 2.1 Personnel ..................................................................................................................................................................61B 2.2 Equipment and test fluids..........................................................................................................................................61B 2.3 Point in time of NDT..................................................................................................................................................62

B 3 NDT procedural requirements...................................................................................................................................62B 3.1 Magnetic particle testing ...........................................................................................................................................62B 3.2 Liquid penetrant testing.............................................................................................................................................62B 3.3 Radiography..............................................................................................................................................................62B 3.4 Ultrasonic testing ......................................................................................................................................................62

B 4 Performance and evaluation of tests on ferritic product forms.................................................................................63B 4.1 Bars...........................................................................................................................................................................63B 4.2 Fasteners (bolts, nuts, studs)....................................................................................................................................64B 4.3 Forgings ....................................................................................................................................................................64

B 5 Performance and evaluation of tests on austenitic product forms (rolled or forged components) ............................64B 5.1 Surface crack detection ............................................................................................................................................64B 5.2 Ultrasonic testing ......................................................................................................................................................64

B 6 Performance and evaluation of tests on ferritic welds...............................................................................................65B 6.1 Ultrasonic testing of weld junction areas for plates...................................................................................................65B 6.2 Surface crack detection of weld fusion faces............................................................................................................65B 6.3 Surface crack detection of welds ..............................................................................................................................65B 6.4 Radiography of welds................................................................................................................................................65B 6.5 Ultrasonic testing of welds ........................................................................................................................................65

B 7 Performance and evaluation of tests on austenitic welds ........................................................................................66B 7.1 Surface crack detection ............................................................................................................................................66

B 7.2 Radiography..............................................................................................................................................................66

B 1 Scope

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

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

Note:The procedure, extent and point in time of NDT are laid down inmaterial test sheets (Annex A) and in-process test and inspectionsequence plans.

B 2 General specifications for non-destructive testing

B 2.1 Personnel

(1) The manufacturer shall notify the test supervisor to theauthorised inspector. Regarding the manufacturer’s organiza-tion, test supervisors shall be independent of the manufac-turing department. Test supervisors shall have the knowledgerequired for performing their tasks and shall have basicknowledge of production processes and shall know the appli-cation limits and possibilities of the test procedures. In addi-tion, test supervisors shall be capable or performing the testdescribed in the following clauses and shall be responsible forthe proper condition of the test equipment. They shall alsoensure that the test instructions to be established by themanufacturer are adhered to. Test supervisors shall havebeen qualified and certified with at least level 2 to DIN EN 473

for the test procedures to be applied in the respective productand industrial sectors.

(2) The test supervisors shall ensure that only qualifiedpersonnel is employed and shall supervise the test to beperformed by the manufacturer, evaluate the test results andsign the test report.

(3) NDT operators shall be able to perform the tests de-scribed in the following clauses. They shall have been quali-fied and certified according to DIN EN 473 for the test proce-dures to be applied in the respective product and industrialsectors. This knowledge shall be proved to the test supervisoreven if operators not in the employ of the manufacturer areemployed.

(4) Test supervisors and NDT operators shall have sufficientvisual capacity which is to be checked by an ophtalmologist,optician or another medical person in conjunction withDIN EN 473. The visual capacity shall be checked yearly.

B 2.2 Equipment and test fluids

(1) For the performance of non-destructive tests equipmentand fluids shall be used which are suited for the respectivepurposes. The measuring and test equipment to be used shallbe calibrated which shall be certified.

(2) The test systems shall conform to the state-of-the-art.

KTA 3205.1

B 2.3 Point in time of NDT

The product forms shall be tested by the manufacturer in theas-delivered condition and welds in the final-heat treatmentcondition, where possible.

B 3 NDT procedural requirements

B 3.1 Magnetic particle testing

B 3.1.1 General requirements

Magnetic particle testing shall preferably be performed bymeans of wet, fluorescent or AC excitation methods

B 3.1.2 Requirements for equipment and test fluids

(1) Where magnetization is effected by the magnetic fluxmethod, suitable measures shall be taken to ensure that arcstriking is avoided during the test as far as possible.

(2) To this end, the test may be carried out e.g. with con-sumable electrodes or with the aid of contact pads.

(3) The test fluid shall wet the test surface and shall notcause any corrosive damage. Additional rust preventingagents are permitted if they do not adversely effect the testresult.

(4) The test fluid shall make the detection of defects possi-ble; if required, a suitable contrast aid shall be used.

(5) The test fluid shall be randomly controlled on suitabletest units.

B 3.1.3 Surface condition

The test surfaces shall be cleaned and be free from disturbingimpurities. Unless particular requirements are specified in theclauses referring to materials and product forms, the arith-metical average of the profile (root mean square) Ra to DINEN ISO 4287 shall not exceed a value of 20 µm.

B 3.1.4 Performance

B 3.1.4.1 Direction of magnetization

All surfaces shall be tested using two different directions ofmagnetization which shall be offset by 90 degrees, wherepossible. It shall be ensured that the field directions are notoutside an angular range between 50 and 130 degrees.

B 3.1.4.2 Magnetic field strength

The tangential field strength shall be between 2 • 103 A/m and6.5 • 103 A/m. Compliance with these values shall be con-trolled by means of suitable measuring instruments, or testconditions shall be determined under which these values canbe obtained.

Note:Possibilities of verifying the sufficient magnetization of the testobject are given in the guideline of DGZfP - Deutsche Gesellschaftfür zerstörungsfreie Prüfverfahren e.V., Berlin, DGZfP-EM-3: "In-struction sheet for the control of parameters in magnetic particletesting".

B 3.1.4.3 Contact spots

Arc strikes shall be removed and be subjected to a liquidpenetrant test or a magnetic particle test using the yoke mag-netization technique.

B 3.1.4.4 Duration of magnetization

(1) The following times shall be adhered to:

Magnetization and wetting: at least 3 secondsRe-magnetization: at least 5 seconds

(2) The evaluation shall be made during re-magnetization.

B 3.2 Liquid penetrant testing

B 3.2.1 Requirements to be met by penetrants

(1) The suitability of the test system (liquid penetrant, inter-mediate cleaning agent and developer) shall be demonstratedto the authorised inspector by a model test to DIN EN ISO3452-2.

(2) Suitable measures shall be taken to ensure that theproperties of the test system as specified under (1) are main-tained.


The surface condition shall meet the requirements specifiedunder B 3.1.3.

B 3.2.3 Performance

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

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

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

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

Note:Further points in time of inspection may be necessary if during thesecond inspection essential changes or additional indications aredetected.

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

B 3.3 Radiography

Class A to DIN EN 1435 shall be adhered to unless test classB has been fixed in the test and inspection sequence plans.

B 3.4 Ultrasonic testing

B 3.4.1 Requirements for test frequencies and transducer(crystal) dimension

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


The test surfaces shall be free from rust, scale, weld spatter,and other impurities which may interfere with the probe-to-specimen contact and shall be in a condition suited for thetest purpose. Regarding the arithmetical average of the profile(root mean square) Ra to DIN EN ISO 4287 of the test surfaceand the opposite surface a value equal to or smaller than 20µm should be obtained.

KTA 3205.1 page 63

B 3.4.3 Performance

B 3.4.3.1 Test instructions

For the ultrasonic testing of components with complex ge-ometry impairing the performance of the test the details shallbe laid down in test instructions and be agreed with theauthorised inspector.

B 3.4.3.2 Setting of sensitivity (examination levels)

The sensitivity shall be set on the test object, on calibrationblock No. 1 to DIN EN 12 223 or on calibration block No. 2 toDIN EN 27 693 or on equivalent reference blocks of the samegeometry by using suitable reference reflectors. Referencereflectors may be back walls, grooves and boreholes. Thereference block dimensions should not differ by more than10 % from the test piece dimensions.

B 3.4.3.3 Adaptation of the probe to curved surfaces

The probe shall be centred in the probe index area. The dis-tance between the probe base and the test surface should notexceed 0.5 mm at any point. If required, the probe base shallbe adapted accordingly (see Figure B-1).

≤0.

5m

m

adapted convexlyProbe base must be

R

R

Concave couplingsurface

or adapted concavely

surfaceConvex coupling

Probe base not adapted

≤0.

5m

m

≤0.

5m

m

≤0.

5m

m

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

B 4 Performance and evaluation of tests on ferriticproduct forms

B 4.1 Bars

B 4.1.1 Surface crack detection

B 4.1.1.1 Performance

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

(2) Magnetic particle testing shall be performed in accor-dance with B 3.1.

(3) Liquid penetrant testing shall be performed in accor-dance with B 3.2.

B 4.1.1.2 Evaluation of magnetic particle test and liquidpenetrant test

(1) Indications with a maximum extension equal to orsmaller than 1.5 mm detected by magnetic particle testingand indications equal to or smaller than 3 mm detected byliquid penetrant testing shall not be included in the evaluation.Larger indications from which the presence of cracks can be

concluded are not permitted. Indications proved to be non-metallic inclusions as well as rounded indications up to anextension of 6 mm are permitted.

(2) The frequency of permissible indications may be locallylimited to a number of ten on an area of 100 mm • 100 mm. Inthe case of larger dimensions or frequency these areas shallbe repaired or agreement shall be reached with theauthorised inspector on the acceptability of the component.

B 4.1.2 Ultrasonic testing


Section B 3.4 applies to the performance of ultrasonic testing.

B 4.1.2.2 Scanning positions and conditions and evaluationfor round bars

(1) The scanning positions for round bars are shown inFigure B-2.

4 5

23 1

λ

λ

:

:

:

:

< a< a

Da =

effective transducer diameter

evaluable area

ultrasonic wave length

round bar diameter

2D

d

da

Figure B-2: Scanning positions for round bars

(2) Straight beam scanning shall be effected in positions 1,2 and 3. For round bars with a diameter d equal to or smallerthan 60 mm position 3 will suffice. For bar lengths l greaterthan 2a and diameters d greater than 60 mm angle beamscanning shall additionally be performed on three paths offsetby 120 degrees.

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

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

B 4.1.2.3 Scanning positions and conditions, evaluation forrectangular or polygonal bars

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

(2) Straight beam scanning shall be effected in positions 1,2 and 3, in the latter case, on three paths offset by 120 de-grees (hexagonal bar) or on two paths offset by 90 degrees(rectangular bar). For rectangular or polygonal bars with dequal to or smaller than 60 mm position 3 will suffice. For barlengths l greater than 2a and diameters d greater than 60 mmscanning shall additionally be performed on three paths offsetby 120 degrees (hexagonal bar) or on two paths offset by 90degrees (rectangular bar). For other polygonal bars scanningshall be effected accordingly.


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

KTA 3205.1

33

3

5

12

4

λ

λ

D

a

d

< a

a =

< a

dD

d

ultrasonic wave length

width across flats of square

d

or hexagonal bars

Hexagonal bar

Square bar

:

:

:

:

effective transducer diameter

evaluable area

2

Figure B-3: Scanning positions for rectangular or polygonalbars

B 4.2 Fasteners (bots, nuts, studs)


(1) Surface crack detection tests shall be performed in ac-cordance with B 3.1 or B 3.2

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

B 4.3 Forgings



(1) Magnetic particle testing shall be performed in the fin-ished surface condition in accordance with B 3.1.

(2) Liquid penetrant testing shall be performed in the fin-ished surface condition in accordance with B 3.2.

B 4.3.1.2 Evaluation

The evaluation shall be made in accordance with B 4.1.1.2.

B 4.3.2 Ultrasonic testing


Ultrasonic testing shall be performed in accordance with B3.4.

B 4.3.2.2 Extent and point in time of testing

The test shall be performed in a state of simple geometry(original condition). The full volume shall be tested.

B 4.3.2.3 Scanning positions and conditions, evaluation forplates and sheets

(1) The scanning positions are shown in Figure B-4.

1

2

s

2

Figure B-4: Scanning positions for plates and sheets


(3) The evaluation shall be made in accordance with Ta-ble B-6. When testing plates scanning position 1 (see Fig-ure B-4) shall be used to observe the back-wall echo.

(4) Considerable reductions of back-reflections (back-wallechoes) shall be recorded. A considerable back-reflectionreduction is obtained if the back-wall echo is reduced to attainrecording level, but at least by 12 dB. The cause of this re-duction shall be ascertained. The participating partners shallagree on the further use of the component.

B 4.3.3 Scanning positions and conditions for open-dieforgings

(1) Forgings shall be tested such that each volumetric areais tested from at least two scanning positions offset by ap-proximately 90 degrees. If this cannot be done by straightbeam scanning, angled beam scanning shall be used.

(2) Details for the performance of the tests shall be fixed foreach product form in test instructions to para. B 3.4.3.1.

(3) The evaluation shall be made to Table B-6 for scanningposition 2. In the case of open-die forgings the back-wallecho of the respective areas (parallel back wall) shall beevaluated. In this case it will suffice to scan each volumetricelement from one direction only. Considerable reductions ofback-reflection shall be recorded. A considerable back-reflection reduction is obtained if the back-wall echo is re-duced to attain recording level, but at least by 12 dB. Thecause of this reduction shall be ascertained. The participatingpartners shall agree on the further use of the component

B 5 Performance and evaluation of tests on austeniticproduct forms (rolled or forged components)

B 5.1 Surface crack detection

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

(2) The tests shall be performed in accordance with B 3.2.

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

B 5.2 Ultrasonic testing

B 5.2.1 Extent and point in time of testing

The test shall be performed in a state of simple geometry, inwhich case the full volume shall be tested.

KTA 3205.1 page 65

B 5.2.2 Scanning directions and frequencies

(1) The components shall be tested such that each volumet-ric area is tested by straight beam scanning from at least twoscanning directions, if practicable, offset by approximately 90degrees. The test frequencies may range from 0.5 to 4 MHz.

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

B 5.2.3 Evaluation

The evaluation shall be made in accordance with the specifi-cations of Section B 4. If this criteria cannot be complied with,separate specifications shall be agreed with the authorisedinspector.

B 6 Performance and evaluation of tests on ferritic welds

B 6.1 Ultrasonic testing of weld junction areas for plates

Ultrasonic testing of the weld junction areas shall be effectedin accordance with the manufacturer’s specifications. Testingin due consideration of the evaluation criteria for the finishedweld is recommended.

B 6.2 Surface crack detection of weld fusion faces

The examination to detect surface cracks on weld fusionfaces shall be performed to the manufacturer’s specifications.

B 6.3 Surface crack detection of welds

B 6.3.1 Performance

(1) Surface crack detection shall be performed in accor-dance with B 3.1 or B 3.2.

(2) As far as practicable, magnetic particle testing shall beperformed.

(3) The adjacent base metal areas shall be covered by thetest up to a width of 20 mm.

B 6.3.2 Evaluation

(1) Indications with a maximum extension equal to orsmaller than 1.5 mm detected by magnetic particle testingand indications equal to or smaller than 3 mm detected byliquid penetrant testing shall not be included in the evaluation.Larger indications from which the presence of cracks can beconcluded are not permitted. Indications proved to be non-metallic inclusions as well as rounded indications up to anextension of 6 mm are permitted.

(2) The frequency of permissible indications may locally beup to 3 per 100 mm weld length. In the case of larger dimen-sions or frequency these locations shall be repaired oragreement shall be reached with the authorised inspector onthe acceptability of the component.

B 6.4 Radiography of welds

B 6.4.1 Performance

Radiography shall be performed in accordance with B 3.3.

B 6.4.2 Evaluation

The evaluation of findings shall be made in accordance withDIN EN 25 817 using the evaluation categories of clause9.4.4.

B 6.5 Ultrasonic testing of welds

B 6.5.1 General requirements

(1) The volume to be tested shall include the weld metal andthe adjacent base metal on both sides over a width ofa) 10 mm on each side for wall thicknesses equal to or

smaller than 30 mm,b) 1/3 of the wall thickness on each side for wall thicknesses

greater than 30 mm and smaller than 60 mm,c) 20 mm on each side for wall thicknesses equal to or

greater than 60 mm.

(2) The volume to be tested shall be scanned from twodifferent directions.

B 6.5.2 Butt welds

(1) All butt welds shall be examined for presence of longitu-dinal defects.

(2) The scanning positions are shown in Figure B-5. Thetest shall be performed from scanning positions 1 and 2 overthe full skip distance. Where testing from this position is im-practicable, it may be performed from scanning positions 1and 3, and where this is impracticable, from position 1 - asshown in Figure B-5.


(4) The evaluation shall be made in accordance with TableB-8.

2

3

1

1 1

1

11 2

3

>s ≤ 4040

area not evaluable

or

(interference zone)

area not evaluable(interference zone)

additionally from a second angles

or

or

or

Figure B-5: Scanning positions for butt welds

(5) In the case of unacceptable indications, these indica-tions may be proved to be unobjectionable by means of sup-plementary tests (radiography or test bores).

(6) Where echos are classified as geometry-related indica-tions, this shall be proved by control measurements. For ge-ometry-related indications this is deemed to have beenproved if, upon scanning from the other side of the weld, thepresumed location of the reflection does not produce anyecho indication.

(7) Where, by measurement of the projection distances onthe test piece, it shall be proved that the echos emanatingfrom both sides of the weld are caused on the two faces of anunmachined weld root and not by weld defects, the exact

KTA 3205.1

projection distance shall be determined on reference reflec-tors. If the locations of the reflections are found to be distinctlyseparate from each other, the echo indications are consideredto be geometry-related. Where a distance of less than 2 mmis found, the reflections shall not be treated as separate re-flections.

(8) Where evaluable reflections are produced by radiogra-phy, they shall be included in the evaluation.

B 6.5.3 Double-bevel groove welds

B 6.5.3.1 Scanning positions for examining the weld volume

(1) In the case of wall thicknesses s equal to or greater than15 mm and equal to or smaller than 40 mm, scanning posi-tions 1 and 2 or 3 in acc. with Figure B-6 shall be used fortesting double-bevel groove welds (or, where it is impossible,the scanning positions 1, 4 and 5 or the scanning positions 1,6 and 7).

(2) In the case of wall thicknesses exceeding 40 mm inaddition to these scanning positions the scanning position 3or, where it is impossible, the scanning positions 1 and 2 withadditional beam angle shall be used.

B 6.5.3.2 Scanning positions for examining steels withRp0.2RT > 355 N/mm2 for underbead craking

Scanning positions 8 and 9 shall be used for surface beadcrack examinations (creep wave method) acc. to Figure B-6.

Note:The creep-wave method is described in KTA 3201.3, Annex B 6.

B 6.5.3.3 Performance and Evaluation


(2) The evaluation shall be made in accordance with Ta-ble B-11.

s

1

36

4

2

5

7

8 9

Figure B-6: Scanning positions for double-bevel groovewelds

B 7 Performance and evaluation of testson austenitic welds

B 7.1 Surface crack detection

Surface crack detection shall be performed and evaluated bymeans of the liquid penetrant method in accordance withB 6.3.

B 7.2 Radiography

Radiography shall be performed and evaluated in accordancewith B 6.4.

Diameter d in mm Scanning positions Beam angles, degrees Frequency in MHz30 < d ≤ 60 3 0 4

1 to 3 0 460 < d ≤ 1204 and 5 70 41 and 2 0 4

d > 120 3 0 2 to 44 and 5 70 2 to 4

Where the bar length exceeds 2a and the diameter is greater than 60 mm, ultrasonic testing shall be performed at scanning positions 4 and5 in the hatched area as shown in Figure B-2 with half the skip distance (single traverse technique).

Table B-1: Scanning conditions for round bars

KTA 3205.1 page 67

Scanning positions 1 and 2 3 4 and 5

Reference reflectorComponent backwallor plane backwall of

calibration block No. 1

Component backwallor plane backwall of

reference block



Backwall of circulararc of calibration block

No. 1 or No. 2

DimensionComponent length

l ≤ 2 ⋅ aComponent length

l > 2 ⋅ a

Component diameter

dD

≥2

λ

R 100 (No. 1)R 25 (No. 2)

Evaluation method DGS DGS DGS DGS

Recording limit 60 < d ≤ 120: CDR 4d > 120: CDR 6

60 < d ≤ 120: CDR 4d > 120: CDR 6

d ≤ 60: CDR 360 < d ≤ 120: CDR 4

d > 120: CDR 6CDR 3

Permissible excess of the echoamplitude over the recording limit,dB

6 6 6 6

Permissible half-amplitudelength 1)

locally locally ≤ d, maximum 50 locally

Allowable frequency of indica-tion per metre 5 5 d ≤ 60 : 3

d > 60 : 5 5

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

Table B-2: Evaluation of ultrasonic test on round bars

Width across flats d in mm Scanning positions Beam angles, degrees Frequency in MHz30 < d ≤ 60 3 0 4

1 and 2 0 4d > 60 3 0 2 to 4

4 and 5 70 2 to 4Where the bar length exceeds 2a and the width across flats d according to Figure B-3 is greater than 60 mm, ultrasonic testing shall be per-formed at scanning positions 4 and 5 in the hatched area as shown in Figure B-3 for rectangular bars on two paths offset by 90 degrees orfor polygonal bars on three paths offset by 60 degrees with half the skip distance (single traverse technique). For other polygonal bars testingshall be performed accordingly.

Table B-3: Scanning conditions for rectangular or polygonal bars

Scanning positions 1 and 2 3 4 and 5

Reference reflectorComponent backwallor plane backwall of



reference block



Backwall of circular arcof of calibration block

No. 1 or No. 2

DimensionComponent length

l ≤ 2 ⋅ aComponent length

l > 2 ⋅ a

cdD

≥⋅ ⋅2 λ

c : edge lengthd : dimension in scan-

ning direction

R 100 (No. 1)R 25 (No. 2)

Evaluation method DGS DGS DGS DGS

Recording limit60 < d ≤ 120: CDR 4

d > 120: CDR 660 < d ≤ 120: CDR 4

d > 120: CDR 6

d ≤ 60: CDR 360 < d ≤ 120: CDR 4

d > 120: CDR 6CDR3

Permissible excess of theecho amplitude over the re-cording limit, dB

6 6 6 6

Permissible half-amplitudelength 1)

locally locally ≤ d, maximum 50 locally

Allowable frequency of indica-tion per metre

5d ≤ 60 mm: 3d > 60 mm: 5 5

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

Table B-4: Evaluation of ultrasonic test on rectangular or polygonal bars

KTA 3205.1

Wall thickness s in mm Scanning positions Beam angles, degrees Frequency in MHzs ≤ 60 1 0 2

1 0 2s > 60

2 0 4

Table B-5: Scanning conditions for plates

Scanning positions 1 2

Reference reflector Component backwallComponent backwall or plane back-

wall of calibration block No. 1Evaluation method DGS DGS

Recording limits ≤ 60: CDR 3

60 < s ≤ 120: CDR 4s > 120: CDR 6

s ≤ 120: CDR 4s > 120: CDR 6

Permissible excess of the echo amplitudeover the recording limit, dB no limitation 6

Permissible half-amplitude length (area) 1000 mm2 1)

Wall thickness s, maximum 100 mm

Allowable frequency of indication per m2 locally: 10total: 5 2

An evaluation os only possible up to the distance a = s . D/2 . λWhere: s : Product thickness,

D : Effective transducer diameter,λ : Ultrasonic wave length.

1) Determination of size of imperfections to the half-value width measuring method byx means of intermediate echoes

Table B-6: Evaluation of ultrasonic test on plates

Wall thickness s in mm Scanning positions Beam angles, degrees Frequency in MHz

15 ≤ s ≤ 40 1 to 3 60 or 70 2 to 4s > 40 1 to 3 60 or 70 and 45 2 to 4

Table B-7: Scanning conditions for butt welds

Scanning positions 1 to 3Reference reflector Backwall of circular arc R 100 of calibration block no. 1 or backwall of circular arc R25 of cali-

bration block no. 2 or transverse bore with 3 mm diameter in reference blockEvaluation method DGS or reference echo or DAC methodRecording limit 15 ≤ s ≤ 40 : 50 % cylindrical bore or circular disk reflector CDR 2

s > 40 : 50 % cylindrical bore or circular disk reflector CDR 3Permissible excess of echoamplitude over the recor-ding limit, dB

≥ of weld) per meterindication(one local 12

or 6:15 s

Permissible frequency in accordance with Table B-9Permissible distances For every two indications the distance of which is smaller than twice the length of the larger in-

dication, the indication distance shall be covered by the evaluation. In this connection, particu-larly the orientation of the indications in relation to each other and in the weld, their reflectionbehaviour from different scanning directions and the wall thickness shall be taken into consid-eration.The following generally applies:Indications of the same depth (< ± 2.5 mm) and the same width (< ± 5 mm) located in the di-rection of welding shall have a distance from each other of at least the length of the longer in-dication. Otherwise, the indications are considered to be continuous. Where more than two in-dications follow each other closely, they shall be compared to each other in pairs and shall fulfilthe above criteria.Indications of the same width (< ± 5 mm) located in thickness direction shall have a distance atleast exceeding half the length of the longer indication, but not less than 10 mm.Indication of the same depth (< ± 2.5 mm) located side by side shall have a distance of at least10 mm in the direction of width.

Table B-8: Evaluation of ultrasonic tests on butt welds

KTA 3205.1 page 69

Maximum number of indications Nimax per m of weld

Nominal wall thickness s, mmLength of indication 1)

(Length category), mm10 < s ≤ 20 20 < s ≤ 40 40 < s ≤ 60 60 < s ≤ 120 120 < s ≤ 250 250 < s

Up to 10 17 19 21 23 25 27

Up to 15 12 14 16 18 20 22

Up to 20 8 10 12 14 16 18

Up to 25 6 2) 8 10 12 14 16

Up to 30 4 2) 6 2) 8 10 12 14

Up to 35 1 2) 4 2) 6 8 10 12

Up to 40 1 2) 4 6 8 10

Up to 45 2 4 6 8

Up to 50 1 3 5 7

Up to 55 2 4 6

Up to 60 1 3 5

Up to 65 2 4

Up to 70 1 3

Up to 75 2

Up to 80 1

The allowable number of indications per m of weld is obtained if the following condition is satisfied:N

NN

NN

NN

Ni

i

n

nmax max max max= + + ⋅ ⋅ ⋅ ≤∑ 1

1

2

21

N i : Number of indications of equal lengthN imax : Maximum allowable number of indications

1) When determining the indication lengths, the conditions of KTA 3201.3, 13.2.5.3.4 may be applied.2) Ultrasonic indications of reflectors with these lengths are only permitted if they are clearly identified as inclusion-type defects.

Table B-9: Reference values for the evaluation of ultrasonic tests

Scanning positions Beam angles, degrees Frequency in MHz

1 and 2 45 1), 70

3 0

4 to 7 45

8 and 9 ≥ 70 (creeping wave)

2 to 4

1) Additional beam angle for wall thicknesses exceeding 40 mm.

Table B-10: Scanning conditions for double-bevel groove welds

KTA 3205.1

Scanning positions 1, 2 and 4 to 9 3

Reference reflector

Backwall of circular arc R 1000 of calibration block no. 2 or backwallof circular arc R 25 of calibration block no. 2 or transverse bore with 3mm diameter in reference block as wall as flat-bottom bore with 3 mmdiameter for scanning positions 8 and 9

Component back-wall

Evaluation method DGS or reference echo or DAC method DGS

15 ≤ s ≤ 40 : 50 % cylindrical bore or circular disk reflector CDR 2 CDR 2

s > 40 : 50 % cylindrical bore or circular disk reflector CDR 3 CDR 3Recording limit

Scanning positions 8 and 9: CDR 3

≥ of weld) per meterindication(one local 12

or 6:15 sPermissible excess of echoamplitude over the recordinglimit, dB

Scanning positions 8 and 9: excess not permitted

Permissible frequency As per Table B-9

Permissible distances For every two indications the distance of which is smaller than twice the length of the largerindication, the indication distance shall be covered by the evaluation. In this connection,particularly the orientation of the indications in relation to each other and in the weld, theirreflection behaviour from different scanning directions and the wall thickness shall be takeninto consideration.The following generally applies:Indications of the same depth (< ± 2.5 mm) and the same width (< ± 5 mm) located in thedirection of welding shall have a distance from each other of at least the length of thelonger indication. Otherwise, the indications are considered to be continuous. Where morethan two indications follow each other closely, they shall be compared to each other in pairsand shall fulfil the above criteria.Indications of the same width (< ± 5 mm) located in thickness direction shall have a dis-tance at least exceeding half the length of the longer indication, but not less than 10 mm.Indication of the same depth (< ± 2.5 mm) located side by side shall have a distance of atleast 10 mm in the direction of width.

Table B-11: Evaluation of ultrasonic tests on double-bevel groove welds

KTA 3205.1 page 71

Annex C

Verification of stability for austenitic steels at elevated temperatures

(1) For austentic steels the verification of stability may beperformed with acceptance certificate Z.30.3-6 for stainlesssteels of the Institut für Bautechnik, Berlin. The bucklingfactors, equivalent stresses and buckling resitances listedin this certificate will at first apply only to temperatures upto 50 °C.

(2) On the assumption that the course of the dimension-less line showing the limit stresses is maintained at ele-vated temperatures, the verification may be made as fol-lows:

a) Calculation of

σ

σ=λ

VKiT

T2.0T (C-1)

with

λπ=σ 2

T2

VKiTE (bars) (C-2)

and with ET = tangent module at temperature T (seee. g. DIN EN 10 028-7 Table A.1), here λ is the ef-fectvive slenderness ratio of the bar: λ = sk/i (pure ge-ometry).

σVKiT for plates shall be determined in correspondencewith the acceptance certificate.

b) σ0,2T is found e.g. in z DIN EN 10 028-7 Table 13.

c) With this λT enter the σ VK , λ curve and determine

σVKiT .

d) The allowable pressure stress than is:

σ⋅σ=σ⋅σ

=σ T2.0TT2.0K

VKTdzulT V

(C-3)

(3) For austenitic steels with Rp0.2RT ≥ 225 N/mm2 theσT , λT -diagram given in Figure C-1 may be used for the calcu-lation which then applies to load case H.

(4) In the case of load case HZ σdzulT may be increased by thefactor 1.14 and in the case of load case HS1 by the factor 1.27.

(5) In load cases HS2 and HS3 specific safety factors shall beagreed with the authorised inspector.

λσ

=

=

=

σ

σ

σ

σ σ

λ

2T

T

1.0

1.0

(0 ; 0.585) Euler`s hyperbola

2.5

11

2.0

(1.6 ; 0.125)(2.0 ; 0.1)

0.2T

VKiT

0.0

0.5(0.55 ; 0.4)

(1.0 ; 0.2)

0.0

zulT

0.2T

T

Figure C-1: Dimensionsless limit stress line for austenitic ma-terials

KTA 3205.1 page 72

Annex D

Pipe-whip restraints

ContentsPage

D 1 General requirements................................................................................................................................. 72

D 2 Design principles ........................................................................................................................................ 72

D 3 Design loads............................................................................................................................................... 73D 3.1 General requirements................................................................................................................................. 73D 3.2 Boundary conditions for design .................................................................................................................. 73

D 4 Design models and calculation limits ......................................................................................................... 73D 4.1 Design models............................................................................................................................................ 73D 4.2 Design and calculation principles ............................................................................................................... 74D 4.3 Allowable stresses...................................................................................................................................... 74D 4.4 Verification of stability................................................................................................................................. 74D 4.5 Plastification of the structure due to dynamic loading ................................................................................ 74

D 5 Materials ..................................................................................................................................................... 74

D 6 Fabrication and assembly........................................................................................................................... 74

D 7 Tests and inspections................................................................................................................................. 74D 7.1 General requirements................................................................................................................................. 74D 7.2 In-process and acceptance inspection at the manufacturer’s works and on site ....................................... 74D 7.3 Tests and inspections to be performed within putting into operation and periodic inspections.................. 74

D 8 Documentation ........................................................................................................................................... 74

D 1 General requirements

(1) Where pipe rupture is possible, measures shall be takento prevent unacceptable damage consequences from beingcaused by pipe whipping or buckling. One measure will be theinstallation of pipe-whip restraints to limit pipe movements.

(2) Pipe movements shall not impair the function or integrityof safety-related components and systems needed to masterthe consequences of incidents.

(3) Pipe-whip restraints are required if none of the items a)to d) hereafter is satisfied:a) proof that at postulated pipe rupture only admissible pipe

movements can occur due to the energy stored in thepiping,

b) sufficient spatial separation is provided between the bro-ken pipe run and the safety-related components and sys-tems,

c) limitation of possible effects of pipe rupture by building orstructural parts (e.g. ceilings, walls, platforms, platformsupports),

d) exclusion of supercritical failure (see KTA 3211.3, section14) of pipe welds.

(4) Where pipe anchors or supports, snubbers or shocksuppressors take over the function of a pipe-whip restraint,the requirements of this annex shall apply in the load case“pipe rupture”.

D 2 Design principles

(1) The principal design feature of pipe-whip restraints is towithstand single short-term thrust loadings – caused by jetthrust reaction forces variable in time during pipe rupture –

and to limit deformation. The design measures shall be takensuch that the operation of the total plant is ensured, i.e.:a) the pipe is not inadmissibly restrained during regular op-

eration,b) no inadmissible thermal bridges are formed.

(2) The design shall lead to simple geometries of the pipe-whip restraints and sufficient accessibility to the piping forinspection purposes shall be provided.

(3) Pipe-whip restraints shall be designed for single incidentcontrol. To this end, the conditions under section D 4.5 permitplastic deformation of pipe-whip restraints. Therefore, damp-ing elements shall be provided between the piping and thepipe-whip restraint to absorb energy. All components of apipe-whip restraint designed to undergo plastic deformationshall be replaced after having been subjected to a specificdesign load.

(4) Adequate functioning of pipe-whip restraints shall beensured as follows:a) by a loose enclosure of the piping,b) by frictional connections (integral or non-integral connec-

tions).

(5) Principally strains occuring shall be verified.

(6) Where strain limitation of the pipe-whip restraint is re-quired, this shall be indicated in the design data sheet. Independence of the protective goal the pipe-whip restraint shallbe classified under load cases H21, HS 2 or HS3.

KTA 3205.1 page 73

D 3 Design loads

D 3.1 General requirements

The notations as to the forces occurring during pipe ruptureare shown hereafter by Figure D-1 with the example of acrack.

jet force

jet reaction force

force acting on pipe whip restraint

reaction force acting on pipe whip restraint

Figure D-1: Notation of forces caused by leaking fluid dueto cracking

D 3.2 Boundary conditions for design

(1) The arrangement and design of pipe-whip restraintsshall be subject to the effects of rupture occurring.

(2) The quantities governing the loading of pipe-whip re-straints are:a) jet reaction force,b) pipe stiffness,c) pipe mass (including fluid, insulation),d) pipe guidance,e) maximum unimpeded movement (free whip) of pipe until

limitation by pipe-whip restraint,f) stiffness of pipe-whip restraint,g) plastic deformability of piping and pipe-whip restraint.

(3) For the analysis of the pipe-whip restraint behaviour(load as function of time) due to pipe rupture the loading func-tion (qualitative course in Figure D-2) can be divided into twotime ranges.

(4) The pipe-whip restraint loading within time range 1 shallbe proven by a dynamic analysis or a suitable approximationmethod (“Biggs” method). The possibility of rebound due tothe elastic energy store in the pipe/pipe-whip restraint shall betaken into account.

(5) For the determination of the thrust loading the maximumpossible free movement s of the piping shall be used, if re-quired by adding the elastic deformation. In the case of looseenclosures s may be determined by means of Figure D-3.

D 4 Design models and calculation limits

D 4.1 Design models

(1) Spring/mass models are e.g. suited as design models(energy balance models).

(2) A verification by statical calculation of thrust-loadedpipe-whip restraints is possible on the basis of load factorsderived from the dynamic calculation of a similar structure.

The transfer of such load factors shall consider the influencescovered under Section D 3.

(3) Where the plastic behaviour of the load supportingstructure of pipe-whip restraints is considered, it shall bebased on a load deformation diagram which may be deter-mined by means of an assured calculation procedure or rep-resentative tests.

(4) The determination of the load deformation characteristiccurve used in the calculation shall consider the following:a) the upper stiffness and strength values shall be used to

calculate the transferred loadings and in the stress analy-sis,

b) for the deformation analysis the lower stiffness andstrength values shall be used.

Time range 1 Time range 2

Time range 1 : dynamic loadingTime range 2 : quasi-steady loading from

jet reaction force

t

FRm

FR

Figure D-2: Loading of pipe-whip restraint

a1 a2

s1 da

b

��

� � ��

��

Figure D-3: Maximum free whip s

KTA 3205.1 page 74

D 4.2 Design and calculation principles

(1) For pipe-whip restraints subject to elastic calculationsthe principles of section 7 of this KTA standard, DIN 18 800-1,DIN 18 800-7 and DIN 18 801 apply as regards the designand calculation.

(2) For load supporting structures subject to plastificationthe design principles of DIN 18 800-1 shall be considered.

D 4.3 Allowable stresses

D 4.3.1 Base metal of load supporting structure

The allowable stress values of the base metal of the load-supporting structure shall be taken from Table D-1.

D 4.3.2 Welded joints

The allowable stress values of the welded joints shall betaken from Table 7-4, load case HS3.

D 4.3.3 Bolted joints

The allowable stress values of bolts shall be taken from Table7-5, load case HS3.

D 4.4 Verification of stability

The stability (against column buckling, overturning, buckling)shall be verified by analysis to cl. 7.2.3, load case HS3.

D 4.5 Plastification of the structure due to dynamic loading

Plastification of the load-supporting structure and the energy-absorbing elements is permitted if it can be substantiated byway of calculation that in the case of tension members theelongation before reduction does not exceed 50%. In the caseof specific pressure-loaded damping elements, i.e. dampedpipes, higher values may be used upon agreement with theauthorised inspector.

D 5 Materials

(1) The materials listed in section 6 are permitted for use onpipe-whip restraints. The use of other materials shall be per-mitted upon agreement with the authorised inspector.

(2) For components strained in the plastic range only mate-rials shall be used for which sufficient deformability can beproved, e.g. elongation at fracture exceeding 20%, qualitygrade Z25 or Z35 to DIN EN 10 164.

D 6 Fabrication and assembly

The requirements of section 9 apply.

D 7 Tests and inspections

D 7.1 General requirements

The general requirements of section 10 apply.

D 7.2 In-process and acceptance inspection at the manu-facturer’s works and on site

The performance of inspections shall be based on the re-spective documents marked with the authorised inspector’snote. The tests and inspection on components made of mate-rials to section D 5, cl. 1 shall be performed in accordancewith Table D-2.

D 7.3 Tests and inspections to be performed within puttinginto operation and periodic inspections

(1) Within putting into operation and periodic inspections,tests and inspections shall be performed on pipe-whip re-straints of the piping concerned in accordance with Table D-3.

(2) The licensee/plant user shall establish records on allperiodic inspections performed.

D 8 Documentation

The requirements of section 12 apply.

Ser. No, Type of loading Allowable stress(referred to Rv0,2)

1 Tensile bending and bending pressure if no verification of stability is required 1.26

2 Tension 1.10

3 Pressure and bending pressure (proof of stability) 1) 0.90

4 Shear 0.73

5 Equivalent stress 1.26

6 SL without pre-tensioning 3) 1.90

7 SL unplanned pre-tensioning 2.56

8 SLP without pre-tensioning 2.20

9

Bearing pressure at

connection due to 2)

SLP unplanned pre-tensioning 2.73

10 GV pre-tensioning 4)

GVP 3.00

1) For austenitic materials 1.5 times the value of load case H to Table 7-3 applies.2) The assignment of bolts and hole clearance is made Table 7 of DIN 18 800-1.3) For slots in longitudinal direction 100 %, in transverse direction 70 % of the tabulated values apply.4) For austenites only by agreement with the authorised inspector.SL : bearing-type shear connection GV : friction-type connectionSLP : bearing-type shear connection in the case of body-fit bolts GVP : friction-type connection in the case of body-fit bolts

Table D-1: Allowable stresses (referred to Rv0,2) for pipe-whip restraint components

KTA 3205.1 page 75

Ser. no. Type of test/inspection Manufacturer’sworks

On site

1 Verification of manufacturer’s qualification for product forms, shop fab-rication, assembly in accordance with sections 9.1 and 9.6

S S

2 Verification of welder’s approval test to section 9.3 S S

3 Check of stamping of product forms for comparison with certificatesprior to fabrication

H, (S) 2) H 1), (S)

4 Check of weld filler metals and consumables including their storage H, (S) H, (S)

5 Check of weld preparation and adaptation H, (S) H, (S)

6 Checking of welding work for conformacne with welding schedule H, (S) H, (S)

7 Control of heat treatment H, (S) 3) H 1), (S) 3)

8 Visual inspection and dimensional check to design review documents H, (S) H, (S)

9 Check of control data sheets S S

10 Check for transportation damage H, S

11 Check of assembly and installation H, S

12 Check for completeness of documentation H, S H, S

13 Visual inspection of welds to DIN EN 25 817 evaluation group D H, S H 1), S 1)

14 Check for accessibility for periodic inspection on pipings H, S

15 Control of specified gaps between piping and pipe-whip restraint H, S

16 Control of anti-corrosive coating H

17 Surface crack detection in acc. with Annex B on welds with proof ofweld quality;Tack and attachment weld locations upon removal of temporary weldattachments for arc striking and contact points in acc. with Annex B

H (100 %)S (10 %)

H (100 %)S (10 %)

18 Ultrasonic testing or radiography in acc. with Annex B on full-penetration welds (proof of quality to Table 7-4)

H (100 %)S (10 %)

H (100 %)S (10 %)

1) Unless performed at the manufacturer’s works.2) In the case of premature inspection at the manufacturer’s works.3) To be determined during design review.

S : Authorised inspector H : Manufacturer

Table D-2: Tests and inspections for pipe-whip restraints

PerformanceSer. no. Type of test/inspection

Putting into opera-tion

Periodic inspec-tions

1 Checking of specified distances between piping and pipe-whip re-straint at hot condition 1)

H, S G, S

2 Control of bolted joint for firm tigthening G, S

3 Visual inspection G, S

1) Where exact knowledge on pipe movements has been obtained by measurement at representative locations since putting into operation,periodic inspections on pipe-whip restraints may be omitted even at hot condition.

G : Licensee/plant owner H : Manufacturer S : Authorised inspector

Table D-3: Tests and inspections within putting into operation and periodic inspections

KTA 3205.1 page 76

Annex E

Design loadings

ContentsPage

E 1 Scope ......................................................................................................................................................... 76

E 2 Determination of stresses for bar-type components (structural framework)............................................... 76E 2.1 Notations .................................................................................................................................................... 76E 2.2 Loading by longitudinal force N .................................................................................................................. 76E 2.3 Loading by a transverse force Qy or Qz..................................................................................................... 77E 2.4 Loading due to a bending moment My or Mz............................................................................................... 77E 2.5 Loading by a torsional moment MT ............................................................................................................. 77E 2.6 Simultaneous loading by a longitudinal force N and bending moments My and Mz................................... 77E 2.7 Biaxial stress conditions ............................................................................................................................. 77

E 3 Determination of stresses for welded joints................................................................................................ 78E 3.1 Arc-welded joints ........................................................................................................................................ 78E 3.2 Other welding procedures such as resistance flash butt welding, frictional welding .................................. 79

E 4 Determination of stresses for bolted joints ................................................................................................. 79E 4.1 Bearing-type shear connections (Bearing-type shear connections with/without fit bolts) ........................... 79E 4.2 Friction-type connections with high-strength bolts (friction-type connections and connections with fit bolts)80E 4.3 Connections subject to tension in direction of the bolt axis due to external loading................................... 80

E 5 Verification of state of equilibrium .............................................................................................................. 81E 5.1 Safety against lifting and attainment of critical limit compression βcr ........................................................ 81E 5.2 Limit slip capacity ....................................................................................................................................... 82E 5.3 Verification of strain .................................................................................................................................... 82

E 1 Scope

The following stipulations apply to the general stress analysis.

E 2 Determination of stresses for bar-type components(structural framework)

E 2.1 Notations

The notations in equations (E 2-1) to (E 2-15) and in FigureE 2-1 refer to:

Coordinates:x centroidal axisy, z main axis of cross-section

Stress resultants:N longitudinal force in x-directionQy, Qz transverse forcesMy, Mz bending moments

(moment vectors)MT (MX) torsional moments in x-directionS 1st order moment of area (statical moment) of full

cross-sections, referred to centroidal axis of fullcross-section

Sy, Sz statical momentsI 2nd order moment of area (moment of inertia) of full

cross-sectionIy, Iz moments of inertiaW section modulusWy, Wz section moduliWD, WZ ruling section modulus for edge compressive and

tensile stressA area of full cross-section

∆A sum of all deductable hole areas lying on that crackplane giving the smallest value of A-∆A

AQy, AQz transverse force area capable of withstanding theapproximated shear forces acting on it due totransverse force

t thickness of cross-section capable of withstandingthe transverse force

Stresses:σx normal stress due to N, My and Mz

σD compressive stressσZ tensile stressσx,m average value of normal stress σx in the cross-

section to be analysedσy, σz normal stresses due to local application of forceσy,m, σz,m average value of normal stress σy or σz in the

cross-section to be analysedτxy, τxz shear stress in cross-section (normal x to area) in

direction y or z due to Qy, Qz and MTτm average value of shear stress in the cross-section

to be analysedτQ shear stress due to transverse force

E 2.2 Loading by longitudinal force N

(1) For a component subject to a longitudinal (axial) forcethe verification shall be made with equations (E 2-1) and (E 2-2).

Pressure N < 0;AN

D =σ ≤ σzul (E 2-1)

Tension N > 0; AA

NZ ∆−

=σ ≤ σzul (E 2-2)

KTA 3205.1 page 77

(2) In the case of tension bars with asymetrical connectionby a bolt only, the verification shall be made for the weakerportion of the net section with half the force to be transmitted.

σ

σ

σ

ττ

τ

τ

z

y

T

z

y

x

X

yx

z

y

xz

zx

xy

x

y

z

N

M

(M )

Q

M

QM

Figure E 2-1: Coordinate system for internal forces and moments and loadings

E 2.3 Loading by a transverse force Qy or Qz

(1) For a component subject to a transverse force Qy or Qzthe shear stress shall generally be verified by means of equa-tion (E 2-3):

⋅⋅

=τ

⋅⋅

=τ

tSQ

andt

SQ

y

maxyzmaxQ

z

maxzymaxQ

z

y

I

I

zulτ≤ (E 2-3)

(2) The maximum shear load τmax may exceed the shearstress τzul by up to 10 % (equation (E 2-4)), if the averageshear stress τm of one portion of the cross-section does notexceed the allowable shear stress τzul (equation (E 2-5)).

⋅⋅

=τ

⋅⋅

=τ

tSQ

andt

SQ

y

maxyzmaxQ

z

maxzymaxQ

z

y

I

I

zul1,1 τ⋅≤ (E 2-4)

=τ

=τ

zz

yy

Q

zm,Q

Q

ym,Q

AQ

and

AQ

≤ τzul (E 2-5)

(3) Where shear stress portions due to transverse forces Qyand Qz as well as torsion occur simultaneously, equations(E 2-6) to (E 2-8) apply to the sum of shear stresses

max ( )TzQyQ τ+τ+τ ≤ τzul (E 2-6)

max ( )TzQyQ τ+τ+τ ≤ 1.1 ⋅ τzul (E 2-7)

τ+τ+τ

τ+τ+τ

TzQm,yQ

Tm,zQyQ≤ τzul (E 2-8)

E 2.4 Loading due to a bending moment My or Mz

For a component subject to a bending moment My or Mzthe verification shall be made to equations (E 2-9) and(E 2-10):

Bending pressure:

=σz,D

z

y,D

yD W

M;WM

max ≤ σzul (E 2-9)

Tensile bending:

=σz,Z

z

y,Z

yZ W

M;WM

max ≤ σzul (E 2-10)

E 2.5 Loading by a torsional moment MT

For a component subject to a torsional moment MT the re-sulting shear stresses τ shall be determined to the St. Venantmethod, and where required, warping stresses shall also bedetermined.

E 2.6 Simultaneous loading by a longitudinal force N andbending moments My and Mz

Where a component is subject to a longitudinal force N (σN)and bending moments My and Mz (σMy, σMz), the stress por-tions determined for the individual forces and moments inaccordance with sections E 2-1 and E 2-3 shall be combinedfor the governing edge or corner points. The verifications toequation (E 2-11), (E 2-12) or (E 2-13) shall be made.

Longitudinal force and uniaxial bending (N and My or N andMz):

σ+σ

σ+σ

zMN

yMN≤ σzul (E 2-11)

Longitudinal force and biaxial bending (N, My and Mz):

zMyMN σ+σ+σ ≤ σzul (E 2-12)

If each of the expressions is satisfied

σ+σ

σ+σ

zMN

yMN ≤ 0.8 ⋅ σzul

the maximum edge stress may be

zMyMN σ+σ+σ ≤ 1.1 ⋅ σzul (E 2-13)

E 2.7 Biaxial stress conditions

(1) Where biaxial stress conditions prevail, the equivalentstress shall be verified by means of equation (E 2-14) to sub-stantiate the combined action of individual stresses (e.g. σx,σy and τ).

KTA 3205.1 page 78

2y

2yxx

2v 3 τ⋅+σ+σ⋅σ−σ=σ (E 2-14)

(2) For sections subject to bending, which are exclusivelyloaded by transverse forces and uniaxial bending, the verifi-cation may be made to equation (E 2-15) instead of (E 2-14).

22v 3 τ⋅+σ=σ (E 2-15)

(3) As regards the verifications to equation (E 2-14) or(E 2-15), the average shear stress τm may be used instead of τ inaccordance with sections E 2.3 and E 2.5.

E 3 Determination of stresses for welded joints

E 3.1 Arc-welded joints

In the equations and figures (E 3-1) to (E 3-5) the followingnotations are used:Aw design throat area to DIN 18 800-1, item (821)F force to be transmitted (longitudinal force N, transverse

force Q)Ιw second order moment of area (moment of inertia) of

weld cross-sectionz1....4 distance of welds to centroidal axis of connecting sur-

faces (according to Figure E 3-1)a design throat thicknessΣa sum of the respective weld thicknesses for the con-

nected cross-sectional areasaF1....4 weld thickness for connection of flangesaSt weld thickness for connection of webse unwelded length in the case of intermittent welds� weld length

⊥σ normal stress transverse to direction ofweld

⊥τ shear stress transverse to direction ofweld

seeFigure E 3-2

IIσ normal stress in direction of weld

IIτ shear stress in direction of weldt thickness of components to be welded

E 3.1.1 Dimensions and values of cross-sections

(1) The dimensions and values of cross-sections for weldedjoints shall be determined to DIN 18 800-1, items (819 to824).

(2) The following limit values are recommended for filletwelds due to welding restrictions:

( )5.0t;2mina maxmin −≥

minmax t7.0a ⋅≤ (a and t , mm)

Centroidal axis ofconnecting surfaces

Centroidal axis oftotal cross-section

Figure E 3-1: Connection of section resistant to bending

σ

σ

τ

στ

1

4

3

3’

2’

290°

a

Figure E 3-2: Possible directions of stress application onfillet weld

E 3.1.2 Stresses in welds

(1) For a welded joint subject to either a longitudinal force Nor a transverse force Q the normal and shear stresses are asfollows:

)a(F

AF

wII

�⋅Σ==

ττσ

⊥

⊥(E 3-1)

(2) For a welded joint subject to a bending moment M thenormal stress will be:

zM

w⋅=σ⊥ I

(E 3-2)

In consideration of DIN 18 800-1, item (801) and when satis-fying σ zul in the flanges the bending moment M shall only beassigned to welds connecting the flanges.

(3) For a longitudinal weld of a section loaded by a trans-verse force Q the shear stress will be

KTA 3205.1 page 79

aSQ

II Σ⋅⋅=τ

I(E 3-3)

and for intermittent welds

�

�+⋅Σ⋅⋅=τ e

aSQ

II I. (E 3-4)

For junctions incorporating I sections the shear stress may becalculated by means of (E 3-1), if the component was de-signed accordingly.

(4) For a welded joint subject to a torsional moment MT theresulting shear stresses and, where required, the warpingstresses shall be considered.

(5) In the case of combined loadings in fillet welds or double-bevel butt joints to Table 7-4, serial nos. 5 to 9 when loadedby more than one of the stresses mentioned under 1 to 4, e.g.for the connection of a bending-resistant section, the equiva-lent stress σV may be determined by means of equation(E 3-5).

2II

22V τ+τ+σ=σ ⊥⊥ (E 3-5)

where the respective maximum stress value is to be enteredalong with the pertinent other stresses. Equation (E 3-5) doesnot consider the normal stress σII.

The equivalent stress need not be determined for fillet weldsand double-bevel butt joints of a bending-resistant connectionwith the forces and moments such as bending moment, trans-verse and longitudinal force, if it is proved that the flangewelds withstand the greatest normal force (see sub-clause 2)and the section joints withstand the greatest transverse forceas per equation (E 3-1).

E 3.2 Other welding procedures such as resistance flash buttwelding, frictional welding

Where the resistance flash butt welding or frictional weldingprocess is applied, an expert opinion and analysis reportissued by an accredited body (by agreement with the author-ised inspector) shall be submitted to prove the loading capa-bility of the welded joint.

E 4 Determination of stresses for bolted joints

E 4.1 Bearing-type shear connections(Bearing-type shear connections with/without fit bolts)

E 4.1.1 Type of loading

(1) In bearing-type shear connections bolts are loaded nor-mal to their axis. The calculation of forces to be transmitted isexclusively based on the shear loading in the bolt as well ason the bearing resistance between bolt and bearing surface ofthe component to be connected. High-strength bolts (strengthgrade 10.9) may be used without pre-tensioning or with anapplied initial tension equal to or greater than 0,5 ⋅ Fv (Fv toDIN 18 800-7 or VDI 2230), hereafter called „unplanned“ pre-tensioning.

(2) Due to the unplanned pre-tensioning of the bolts thedeformation behaviour due to bearing pressure can be im-proved by utilising the three-dimensional stress state underuseful load. This may be taken into account by increasing theallowable bearing pressure (see Table 7-3, serial nos. 7 and 9).

(3) Bearing-type shear connections may be used with aclearance ∆d less than or equal to 2 mm (bearing-type shearconnections) and ∆d 0.3 mm (bearing-type shear connections

with fit bolts). In the case of junctures and joints in frames thatmay be subject to lateral movement the clearance shall notexceed 1 mm.

(4) Countersunk head bolts may be used. In the case ofconnections with countersunk head bolts the clearance ∆dshall not exceed 1 mm.

E 4.1.2 Verifications

(1) The notations used in equations (E 4-1) to (E 4-3) arethe following:Aa cross-sectional area of bolt shankF internal forces transmitted (longitudinal force N, trans-

verse force Q)QSL zul allowable force of a bolt to be transmitted per shear

area normal to bolt axis in a bearing-type shearconnection

QSLP zul allowable force of a bolt to be transmitted per sheararea normal to bolt axis in a bearing-type shearconnection with fit bolts

d bolt shank diametern number of bolts in connectionm number of shear planes (single- or multiple-shear)Σ tmin smallest sum of plate thicknesses with bearing

pressures acting in the same directionσL bearing pressure between bolt and hole wall of the

component to be connectedτa bolt shear stress

(2) The equations hereafter apply to single-shear as well as tomultiple-shear symetrical connections. The bearing pressure σLand the shear stress τa shall be calculated irrespective of theactual stress ratio as follows:

minL tnd

FΣ⋅⋅

=σ (E 4-1)

The values σl, zul for the component and for the bolt are con-tained in Table 7-3. In the case of differing materials for thecomponent and the fastener the design shall be based on thesmaller value of the respective part.

aa Amn

F⋅⋅

=τ with Aa = 4d2⋅π (E 4-2)

4d

Q

Q2

zula

zulSLP

zulSL⋅π⋅τ=

(E 4-3)

The τa zul values are contained in Tables 7-5.1, 7-5.2 and 7-5.3.

(3) The verification for countersunk head bolts may be madeto this section if the design bearing stress between the com-ponent and the unthreaded shank (area ΙΙ to Figure E 4-1)does not exceed the allowable value. Otherwise the allowableforces shall be reduced to 80 %. In connections with counter-sunk head bolts greater strains than in other connections withcomparable dimensions are to be expected where the allow-able load is exceeded, especially in the case of a reduction ofarea ΙΙ the bolt countersunk head may tend to unscrew due tothe wedge effect caused by load transmission on area Ι.

(4) In the case of hinged pins the bending stress andequivalent stress shall be analysed additionally.

KTA 3205.1 page 80

External component

Area

Area

Countersunk head boltto DIN 7969

Figure E 4-1: Connection by countersunk head boltto DIN 7969

E 4.2 Friction-type connections with high-strength bolts (fric-tion-type connections and connections with fit bolts)

E 4.2.1 Performance

(1) In fricion-type connections the bolts shall be pre-tensioned (design initial tension) to DIN 18 800-7 or VDI 2230.This allows the transmission of forces normal to the bolt axisby friction in the specifically treated surfaces of the compo-nents to be connected (friction-type connections). In connec-tions with fit bolts the transmission of forces is obtained byshear and bearing pressure (friction-type connections with fitbolts).

(2) Friction-type connections may be used with a cleance ∆dless than or equal to 2 mm or 3 mm (friction-type connections)and with a clearance ∆d less than or equal to 0.3 mm (friction-type connections with fit bolts).

E 4.2.2 Verifications

(1) The notations in the equations (E 4-4) and (E 4-5) arethe following:

FV applied initial tension to DIN 18 800-7 or VDI 2230

QGV zul allowable force to be transmitted by a bolt per fric-tion surface normal to the bolt axis in a friction-typeconnection

QGVP zul allowable force to be transmitted by a bolt per fric-tion surface (shear plane) normal to the bolt axis ina friction-type connection with fit bolts

QSLP zul allowable force to be transmitted by a bolt pershear surface (plane) normal to the bolt axis in abearing-type shear connection with fit bolts [cf.equation (E 5-3)]

5.0=µ friction factor of contact surfaces subjected to oneof the following surface treatments:a) steel shot peeningb) 2 x flame descalingc) sand blasting

νG limit slip capacity

(2) In friction-type connections with high-strength bolts with aclearance ∆d less than or equal to 2 mm (friction-type connections)the following applies:

G

vzulGV

FQν⋅µ= (E 4-4)

with νG, H = 1.25 or νG, HZ = 1.10 or νG, HS = 1.05

At a clearance of 2.0 mm < ∆d ≤ 3.0 mm these values shall bereduced to attain 80 %.

(3) In friction-type connections with high-strength fit bolts,with a clearance ∆d less than or equal to 0.3 mm (friction-typeconnections with fit bolts) the following applies:

zulGVzulSLPzulGVP QQ21Q +⋅= (E 4-5)

(4) The bearing pressure σ I in the parts to be connectedshall be substantiated by way of calculation using equation(E 4-1) in which case the effects of frictional forces need notbe considered. The values for σ I, zul shall be taken from Table7-3 serial. no. 10. The shear stress τa need not be verified.

(5) For parts subject to tensile loading connected by friction-type connections or friction-type connections with fit bolts, itmay be assumed in the general stress analysis that 40 % of theallowable force to be transmitted QGV zul as per equation (E 4-4) ofthose high-strength bolts located in the considered cross-sectionfor which deduction of holes has been made, have been con-nected by friction prior to the deduction of area for holes (antici-pated reduction of force).

In addition, the cross-section shall be substantiated by calcu-lating with the total force.

(6) Where friction-type connections with fit bolts are sub-jected to internal forces and moments with alternating signs,the transmission of the force with the greater value shall besubstantiated by means of QGVP zul and the transmission ofthe force with the smaller value be substantiated by means ofQGV zul.

E 4.3 Connections subject to tension in direction of the boltaxis due to external loading

E 4.3.1 Connections with unplanned pre-tensioning

(1) The notations in equation (E 4-6)are the following:

Zzul allowable force to be transmitted by a bolt in directionof bolt axis

σz zul allowable bolt tensile stress

AS tensile stress aread2 nominal shank diameter

SeeDIN EN ISO 898-1

d3 nominal root diameter

The following applies:

Zzul = σz zul ⋅ sA (E 4-6)

with 2

32S 2

dd4

A

+⋅π=

The values of σz zul are given in Table 7-5.1.

(2) The use of high-strength bolts without applied initialtension (pre-tensioning) or with unplanned initial tensionwhere the bolt is tensile-loaded due to external loading is onlypermitted if the expected number of load cycles N of the non-permanent loads meets one of the following conditions:a) N ≤ 104

b) N ≤ 105; however stresses exceeding 40 % of the allowablevalues for load case H to Table 7-5.1 shall not exceed thenumber of load cycles 104

Here, the allowable tensile force Zzul to be transmitted may bedetermined by means of equation (E 4-6). The respectivevalues of σz zul can be found in Table 7-5.1.

KTA 3205.1 page 81

(3) In bearing-type shear connections and bearing-typeshear connections with fit bolts each value (Q, σ L, Z) shall besubstantiated independently of the other values in the case ofsimultaneous loading by shear and tension. Here, the allow-able values for load cases H and HZ for the individual types ofstresses to Tables 7-5.1, 7-5.2 and 7-5.3 and equation(E 4-3) may be fully utilised without verification of the equivalentstress For the load cases HS the equivalent stress σ V shall beverified as per clause 7.2.2, sub-clause 4, item d. As regardsthe allowable bearing pressure σ L the values of Table 7-3,serial no. 6 (bearing-type connections) or serial no. 8 (bear-ing-type connections with fit bolts) shall be considered in thecase of connections subject to unplanned pre-tensioning(≥ 0,5 ⋅ FV).

E 4.3.2 Design applied initial tension

(1) The tensile stress due to external loading shall be sub-stantiated by way of calculation and be assigned to the boltsonly, i.e. the actual reduction of the clamping load at the con-tact faces of the parts to be connected as well as the increasein pressure on the bearing surfaces of bolt head and nut willnot be considered. The design tensile force acting on an indi-vidual bolt or fit bolt Z shall not exceed Zzul as per equation(E 4-6).

(2) In friction-type connections and friction-type connectionswith fit bolts the allowable force QGV zul or QGVP zul to betransmitted shall be reduced as follows if the connection issubjected simultaneously to external loading in axial directionand normal to the bolt axis:

zulGVzul

zulzulZ,GV Q

ZZZ8.02.0Q ⋅

−⋅+= (E 4-7)

zulSLPzulZ,GVP Q5.0Q ⋅= + (E 4-8)

zulGVzul

zul QZ

ZZ8.02.0 ⋅

−⋅+

(3) As regards the allowable bearing pressure σL the valuesas per Table 7-3, serial no. 7 (bearing-type shear connec-tions) or serial no. 9 (bearing-type shear connections with fitbolts) shall be considered.

E 5 Verification of state of equilibrium

The verification of state of equilibrium for load-bearing steelstructures comprises the verification of safety against lifting,safety against overturning (limit compression) and limit slipcapacity.

E 5.1 Safety against lifting and attainment of critical limitcompression βcr

For the safety against overturning and the attainment of limitcompression the most unfavorable lading shall be determinedfrom the governing principal, additional and special loads inwhich case the individual portions shall be multiplied by theload intensification factor γcr as per Table E 5-1.

E 5.1.1 Lifting

(1) The safety against lifting of individual base joints shall beverified if it has not been definitely proved. It will suffice if thefollowing condition is satisfied:

zD ≥ (E 5-1)

The following notations apply:

ND normal component of the resultant force of compressiveload portions acting on the base joint derived from γcr timesthe loadings

NZ normal component of the resultant force of all lifting forceportions acting on the base derived from γcr times the load-ings

(2) Where anchors are provided as safety against lifting, theanchor tensile force ZA may be considered as follows:

ZzulAD 3.1 ≥⋅+ (E 5-2)

Here ZA zul is the allowable tensile force of the anchor at loadcase H; σz zul see Table 7-5.1

(3) It shall be proved that the anchor provides sufficientanchorage.

Lfd. Nr. Loadings γcr

1Favourably acting portions of all loadsapplied 1.0

2 Unfavourably acting portions of dead load 1.1

3Unfavourably acting portions of loads ex-cept for the loads to lines 2 and 5 1.3

4Unfavourably acting portions of loads in theas-built condition 1.5

5Unfavourably acting portions of resultantloads in the case of impacts 1.1

6 Displacements and torsional loads 1.0

Unplanned eccentricities and the deformations of the sys-tem under γcr times the loadings shall be considered, whererequired.

Table E 5-1: Load intensification factors γcr to determine thesafety against lifting and overturning

E 5.1.2 Attainment of critical compression βcr (Overturning)

The safety of structures against overturning shall be verified ifit has not been definitely proved before. It will suffice if thefollowing condition is satisfied under γcr times the loadings:

crcr

crcr A

Dβ≤=σ (E 5-3)

The following notations apply:

σcr compression under γcr -times the loadings, based on theassumption that the compressive stresses are evenly dis-tributed over a part of the surface area of the base jointand the state of equilibrium is maintained; it is permitted toassume that the part of the surface under compression isrectangular.

Dcr reaction force at base joint (see Figure E 5-1),

Ncr normal component of resultant force of all forces actingon the base joint under γcr times the loading,

Acr partial areas of total base joint surface area the centroidof which lies on the line of action of Dcr (assuming thatσ is constant),

βcr critical compression on base joint under γcr times theloading (βcr for concrete- see DIN 1054; βcr for steels: 1.5times the Hertzian compression for load case H); see Ta-ble 7-6 for allowable values.

KTA 3205.1 page 82

(lifting) (compressive)

1.3 1.3

1.3 1.3

Figure E 5-1: Determination of anchor tensile force

ZA = A

Ncree

3.1N ⋅

E 5.2 Limit slip capacity

(1) The limit slip capacity parallel to the base joint shall beverified as follows, unless specified otherwise in the stan-dards:

5.1 N ⋅≤⋅ (E 5-4)

(2) Where the frictional force is not considered in the calcu-lation, the simple verification hereafter applies:H ≤ D (E 5-5)

where:µN friction coefficients

steel on steel: µN = 0.10steel on concrete: µN = 0.30

N normal compressive force on the base joint due to externalloads

H force acting in parallel to the base joint due to externalloadsN and H apply for the same governing combination ofloads

D allowable force to be transmitted by oarlocks, ribs or simi-lar shearing protections, if any, in the sliding direction de-termined along with the allowable stresses for the respec-tive load case as per clause 7.2.7.

(3) In the case of impact loads the factor 1.0 shall be en-tered in equation (E 5-4) instead of 1.5.

E 5.3 Verification of strain

(1) The functionability of the structure may require the limi-tation of strains depending on the range of application. Fromcase to case, the allowable limit strain values are contained inthe standards; otherwise they shall be fixed with the pur-chaser prior to establishing the design and constructiondocuments.

(2) For the determination of limit strains the cross-sectionvalues may generally be used without deduction of area forholes.

(3) Further specifications as to the verification of strain limi-tation, e.g. consideration of bolt slip, are contained in thestandards, where applicable.

KTA 3205.1 page 83

Annex F

Regulations referred to in this Safety Standard

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

AtG Act on the Peaceful Utilization of Atomic Energy and the Protection against itsHazards (Atomic Energy Act) of December 23, 1959 (BGbl. I, p. 814) asAmended and Promulgated on July 15, 1985 (BGBl. I, p. 1565), last Amend-ment by the Act of April 22nd, 2002 (BGBl. I No. 26)

KTA 1401 (6/96) General Requirements Regarding Quality Assurance

KTA 2201.1 (6/90) Design of Nuclear Power Plants against Seismic Events;Part 1: Basic Principles

KTA 3201.2 (6/96) Components of the Reactor Coolant Pressure Boundary of Light WaterReactors; Part 2: Design and analysis

KTA 3201.3 (6/98) Components of the Reactor Coolant Pressure Boundary of Light WaterReactors; Part 3: Manufacture

KTA 3205.2 (6/90) Non-integral Component Supports;Part 2: Non-integral Component Supports for Pressure and Activity Re-taining Components in Systems outside the Primary Circuit

KTA 3205.3 (6/89) Non-integral Component Supports;Part 3: Series-produced Standard Supports

KTA 3211.3 (6/90) Pressure- and activity-retaining components of systems outside the pri-mary circuit; Part 3: Manufacture

KTA 3401.2 (6/85) Steel containment vessels; part 2: analysis and design

DIN 13-1 (11/99) ISO general purpose metric screw threads - Part 1: Nominal sizes forcoarse pitch threads; nominal diameter from 1 mm to 68 mm

DIN 267-13 (8/93) Fasteners; technical specifications; parts for bolted connections withand suppl. sheet specific mechanical properties for use at temperatures ranging from

- 200 °C to +700 °C

DIN EN 287-1 (8/97) Approval testing of welders - Fusion welding - Part 1: Steels (includesAmendment A1:1997); German version EN 287-1:1992 + A1:1997

DIN EN 473 (3/01) Non-destructive testing - Qualification and certification of NDT personnel -General principles; German version EN 473:2000

DIN EN 493 (7/92) Fasteners; surface discontinuities; nuts; German version EN 493:1992

DIN EN 571-1 (3/97) Non-destructive testing - Penetrant testing - Part 1: General principles;German version EN 571-1:1997

DIN EN 719 (8/94) Welding co-ordination; Tasks and responsibilities;German version EN 719:1994

DIN EN 729-3 (11/94) Quality requirements for welding - Fusion welding of metallic materials -Part 3: Standard quality requirements; German version EN 729-3:1994

DIN EN ISO 898-1 (11/99) Mechanical properties of fasteners made of carbon steel and alloy steel -Part 1: Bolts, screws and studs (ISO 898-1:1999);German version EN ISO 898-1:1999

DIN EN 970 (3/97) Non-destructive examination of fusion welds - Visual examination;German version EN 970:1997

DIN 1054 (11/76) Subsoil; Permissible Loading of Subsoil

DIN EN 1370 (2/97) Founding - Surface roughness inspection by visualtactile comparators;German version EN 1370:1996

DIN EN 1435 (10/97) Non-destructive examination of welds - Radiographic examination of weldedjoints; German version EN 1435:1997

DIN EN ISO 1461 (3/99) Hot dip galvanized coatings on fabricated iron and steel articles - Specifi-cations and test methods (ISO 1461:1999);German version EN ISO 1461:1999

KTA 3205.1 page 84

DIN EN 1559-1 (8/97) Founding - Technical conditions of delivery - Part 1: General;German version EN 1559-1:1997

DIN 1690-2 (6/85) Technical delivery conditions for castings made from metallic materials;steel castings; classification into severity levels on the basis of non-destructive testing

DIN EN ISO 3452-2 (6/00) Non-destructive testing - Penetrant testing - Part 2: Testing of penetrantmaterials (ISO 3452-2:2000); German version EN ISO 3452-2:2000

DIN EN ISO 3506-1 (3/98) Mechanical properties of corrosion-resistant stainless steel fasteners -Part 1: Bolts, screws and studs (ISO 3506-1:1997);German version EN ISO 3506-1:1997

DIN EN ISO 3506-2 (3/98) Mechanical properties of corrosion-resistant stainless steel fasteners -Part 2: Nuts (ISO 3506- 2:1997); German version EN ISO 3506-2:1997

DIN EN ISO 4287 (10/98) Geometrical Product Specifications (GPS) - Surface texture: Profile method -Terms, definitions and surface texture parameters (ISO 4287:1997);German version EN ISO 4287:1998

DIN 6914 (10/89) High-strength hexagon head bolts with large widths across flats for struc-tural steel bolting

DIN 6915 (12/99) Hexagon nuts with large widths across flats for high strength structuralbolting

DIN 6916 (10/89) Round washers for high-strength structural steel bolting

DIN 6917 (10/89) Square taper washers for high-strength structural bolting of steel I sections

DIN 6918 (4/90) Square taper washers for high-strength structual bolting of steel channelsections

DIN 7968 (12/99) Hexagon fit bolts with hexagon nut, for steel structures

DIN 7969 (12/99) Slotted countersunk head bolts with hexagon nut, for steel structures

DIN 7990 (12/99) Hexagon head bolts with hexagon nut for steel structures

DIN EN 10 002-1 (12/01) Metallic materials - Tensile testing - Part 1: Method of testing at ambienttemperature; German version EN 10002-1:2001

DIN EN 10 002-5 (2/92) Tensile testing of metallic materials; method of testing at elevated tem-perature; German version EN 10002-5:1991

DIN EN 10 025 (3/94) Hot rolled products of non-alloy structural steels; technical delivery condi-tions (includes amendment A1:1993); German Version EN 10025:1990

DIN EN 10 028-1 (7/00) Flat products made of steel for pressure purposes - Part 1: General re-quirements; German version EN 10028-1:2000

DIN EN 10 028-2 (4/93) Flat products made from steel for pressure purposes; part 2: non-alloyand alloy steels with specified elevated temperature properties; Germanversion EN 10028-2:1992

DIN EN 10 028-3 (4/93) Flat products made from steel for pressure purposes; part 3: weldable finegrain steels, normalized; German version EN 10028-3:1992

DIN EN 10 028-7 (6/00) Flat products made of steels for pressure purposes - Part 7: Stainlesssteels; German version EN 10028-7:2000

DIN EN 10 045-1 (4/91) Charpy impact test on metallic materials; test method; German versionEN 10045-1:1990

DIN EN 10 083-1 (10/96) Quenched and tempered steels - Part 1: Technical delivery conditions forspecial steels (includes Amendment A1:1996); German versionEN 110083- 1:1991 + A1:1996

DIN EN 10 083-2 (10/96) Quenched and tempered steels - Part 2: Technical delivery conditions forunalloyed quality steels (includes Amendment A1:1996); German versionEN 10083-2:1991 + A1:1996

DIN EN 10 164 (8/93) Steel products with improved deformation properties perpendicular to thesurface of the product; technical delivery conditions; German version ofEN 10164:1993

DIN EN 10 204 (8/95) Metallic products - Types of inspection documents (includes AmendmentA1:1995); German version EN 10204:1991 + A1:1995

DIN EN 10 210-1 (9/94) Hot finished structural hollow sections of non-alloy and fine grain struc-tural steels - Part 1: Technical delivery requirements; German version EN10210- 1:1994

KTA 3205.1 page 85

DIN EN 10 210-2 (11/97) Hot finished structural hollow sections of non-alloy and fine grain struc-tural steels - Part 2: Tolerances, dimensions and sectional properties;German version EN 10210-2:1997

DIN EN 10 213-1 (1/96) Technical delivery conditions for steel castings for pressure purposes -Part 1: General; German version EN 10213-1:1995

DIN EN 10 213-2 (1/96) Technical delivery conditions for steel castings for pressure purposes -Part 2: Steel grades for use at room temperature and elevated tempera-tures; German version EN 10213-2:1995

DIN EN 10 213-4 (1/96) Technical delivery conditions for steel castings for pressure purposes -Part 4: Austenitic and austenitic-ferritic steel grades;German version EN 10213-4:1995

DIN EN 10 219-1 (11/97) Cold formed welded structural hollow sections of non-alloy and fine grainsteels - Part 1: Technical delivery requirements;German version EN 10219- 1:1997

DIN EN 10 222-1 (9/98) Steel forgings for pressure purposes - Part 1: General requirements foropen die forgings; German version EN 10221-1:1998

DIN EN 10 222-2 (4/00) Steel forgings for pressure purposes - Part 2: Ferritic and martensiticsteels with specified elevated temperature properties (including corrigen-dum AC:2000); German version EN 10222- 2:1999 + AC:2000

DIN EN 10 222-5 (2/00) Steel forgings for pressure purposes - Part 5: Martensitic, austenitic andaustenitic-ferritic stainless steels; German version EN 10222-5:1999

DIN EN 10 250-1 (12/99) Open die steel forgings for general engineering purposes - Part 1: Gen-eral requirements; German version EN 10250-1:1999

DIN EN 10 250-2 (12/99) Open die steel forgings for general engineering purposes - Part 2: Non-alloy quality and special steels; German version EN 10250-2:1999

DIN EN 10 269 (11/99) Open die steel forgings for general engineering purposes - Part 2: Non-alloyquality and special steels; German version EN 10250-2:1999

DIN EN 10 272 (1/01) Stainless steel bars for pressure purposes; German version EN 10272:2000

DIN EN 10 273 (4/00) Hot rolled weldable steel bars for pressure purposes with specified ele-vated temperature properties; German version EN 10273:2000

DIN EN 12 223 (1/00) Non-destructive testing - Ultrasonic examination - Specification for cali-bration block No. 1; German version EN 12223:1999

DIN EN ISO 12 944-1 (7/98) Paints and varnishes - Corrosion protection of steel structures by protec-tive paint systems - Part 1: General introduction (ISO 12944-1:1998);German version EN ISO 12944-1:1998

DIN EN ISO 12 944-2 (7/98) Paints and varnishes - Corrosion protection of steel structures by protectivepaint systems - Part 2: Classification of environments (ISO 12944-2:1998);German version EN ISO 12944-2:1998

DIN EN ISO 12 944-3 (7/98) Paints and varnishes - Corrosion protection of steel structures by protec-tive paint systems - Part 3: Design considerations (ISO 12944-3:1998);German version EN ISO 12944-3:1998

DIN EN ISO 12 944-4 (7/98) Paints and varnishes - Corrosion protection of steel structures by protec-tive paint systems - Part 4: Types of surface and surface preparation(ISO 12944-4:1998); German version EN ISO 12944- 4:1998

DIN EN ISO 12 944-5 (7/98) Paints and varnishes - Corrosion protection of steel structures by protec-tive paint systems - Part 5: Protective paint systems (ISO 12944-5:1998);German version EN ISO 12944-5:1998

DIN EN ISO 12 944-6 (7/98) Paints and varnishes - Corrosion protection of steel structures by protec-tive paint systems - Part 6: Laboratory performance test (ISO 12944-6:1998); German version EN ISO 12944-6:1998

DIN EN ISO 12 944-7 (7/98) Paints and varnishes - Corrosion protection of steel structures by protec-tive paint systems - Part 7: Execution and supervision of paint work(ISO 12944-7:1998); German version EN ISO 12944- 7:1998

DIN EN ISO 12 944-8 (7/98) Paints and varnishes - Corrosion protection of steel structures by protectivepaint systems - Part 8: Development of specifications for new work andmaintenance (ISO 12944-8:1998); German version EN ISO 12944-8:1998

DIN 15 018-1 (11/84) Cranes; steel structures; verification and analyses

DIN 15 018-2 (11/84) Cranes; steel structures; principles of design and construction

DIN 15 070 (12/77) Cranes; basic calculation of crane rail wheels

KTA 3205.1 page 86

DIN 17 102 (10/83) Weldable normalized fine grain structural steels; technical delivery condi-tions for plate, strip, wide flats, sections and bars

DIN 17 121 (6/84) Seamless circular steel tubes for structural steelwork; technical deliveryconditions

DIN 17 175 (5/79) Seamless tubes of heat-resistant steels; technical conditions of delivery

DIN 17 178 (5/86) Welded circular fine grain steel tubes subject to special requirements -Technical delivery conditions

DIN 17 179 (5/86) Seamless circular fine grain steel tubes subject to special requirements;technical delivery conditions

DIN 17 456 (2/99) Seamless circular stainless steel tubes with general quality requirements -Technical delivery conditions; Amended by:DIN-Mitt., 1999, No. 6, p. A 486 * DIN-Mitt., 1999, No. 8, p. A 663

DIN 17 457 (7/85) Welded circular austenitic stainless steel tubes subject to special re-quirements; technical delivery conditions

DIN 17 458 (7/85) Seamless circular austenitic stainless steel tubes subject to special re-quirements; technical delivery conditions

DIN 18 800-1 (11/90) Structural steelwork; design and construction

DIN 18 800-1/A1 (2/96) Steel structures - Part 1: Design and construction; Amendment A1

DIN 18 800-2 (11/90) Structural steelwork; analysis of safety against buckling of linear membersand frames

DIN 18 800-2/A1 (2/96) Steel structures - Stability - Part 2: Buckling of bars and skeletal struc-tures; Amendment A1

DIN 18 800-3 (11/90) Structural steelwork; analysis of safety against buckling of plates

DIN 18 800-3/A1 (2/96) Steel structures - Stability - Part 3: Buckling of plates; Amendment A1

DIN 18 800-4 (11/90) Structural steelwork; analysis of safety against buckling of shells

DIN 18 800-7 (5/83) Steel structures; Fabrication, verification of suitability for welding

DIN 18 801 (9/83) Structural steel in building; design and construction

DIN 18 808 (10/84) Steel structures; structures made from hollow sections subjected to pre-dominantly static loading

DIN 18 809 (9/87) Steel road bridges and foot bridges; design and construction

DIN EN 20 898-2 (2/94) Mechanical properties of fasteners; part 2: nuts with specified proof load val-ues; coarse thread (ISO 898-2:1992); German version EN 20898- 2:1993

DIN EN 25 817 (9/92) Arc-welded joints in steel; guidance on quality levels for imperfections(ISO 5817:1992); German version EN 25817:1992

DIN EN 26 157-3 (12/91) Fasteners; surface discontinuities; bolts, screws and studs subject to spe-cial requirements (ISO 6157-3:1988); German version EN 26157-3:1991

DIN EN 27 963 (6/92) Welds in steel; calibration block No. 2 for ultrasonic examination of welds(ISO 7963:1985); German version EN 27963:1992

DIN 55 928-8 (7/94) Protection of steel structures from corrosion by organic and metallic coatings;part 8: protection of supporting thin-walled building components from corro-sion

DIN 55 928-9 (5/91) Corrosion protection of steel structures by the application of organic or metal-lic coatings; composition of binders and pigments for coating materials

DIN 58 220-3 (1/97) Visual acuity testing - Part 3: Test for use in expertise

DIN 58 220-5 (1/97) Visual acuity testing - Part 5: Vision screening test for general use

AD HP 2/1 (1/00) Procedure qualification testing for joining processes - Procedure qualifica-tion testing for welded joints

AD HP 5/2 (9/01) Manufacture and testing of joints; production testing of welds, testing ofbase metal after postweld heat treatment

DASt 012 (10/78) Proof of safety against bulging for plates

DASt 014 (1/81) Recommendations for the avoidance of terrace ruptures in welded struc-tures of structural steel

SEW 086 (4/87) Unalloyed and alloy creep-resistant ferritic steels; preheating in welding

KTA 3205.1 page 87

SEW 088 (10/93) Weldable fine-grained structural steels; guidelines for processing, in par-ticular for fusion welding (incl. supplementary sheets 1 and 2)

SEW 110 (7/86) Procedure test for production welding at cast steel

SEW 550 (8/76) Steels for larger forgings; quality regulations

DIBt Z - 30.3-6 (9/98) General building inspection certification; Issuance of certification for com-ponents and fasteners made from stainless steels, issued by the GermanInstitute for Building Construction, Berlin; valid until 30 September 2003

VdTÜV-Merkblatt 1153 (11/88) Guidelines for testing the suitability of welding fillers

VDI 2230 Blatt 1 (7/86) Systematic calculation of high duty bolted joints - Joints with one cylindri-cal bolt

KTA 3205.1 page 88

Annex G (informative)

Changes with respect to the edition 6/91

For the purpose of adapting this KTA safety standard to thestate-of-the-art especially Section 7 “Design“ and Annex A“Materials test sheets“ were updated

1 Section 7: Design

(1) In the former edition of KTA 3205.1 (6/91) Section 7 “De-sign“ was based on the structural steel standard DIN 18 800-1,Edition 3/81, which was withdrawn in the meantime. With thepublication of the new DIN 18 800-1, edition 11/90, the designmethods were principally changed. According to the new DIN18 800-1 the strength is now verified by means of a limit loadanalysis instead of the formerly usual determination andevaluation of allowable stresses (σzul concept).

(2) For KTA 3205.1 as published the following procedure wasselected for the Section „Design“: On the one hand the directapplication of existing European and national design rules(Eurocode 3, DIN 18 800-1, Edition 11/90) shall be made possi-ble. To this end, adequate opening clauses were introduced.Since, on the other hand, the abovementioned rules do notcompletely cover nuclear plant design requirements (verificationof stresses and stability in the case of incidents), the designmethod used up to now in DIN 18 800-1 (3/81) was incorpo-rated as new Annex E into KTA 3205.1. Therefore, no furtherreference to DIN 18 800-1 (3/81) is required in the future. Bymeans of Annex E future substantiations by way of calculationbased on the allowable stress calculation method (σzul concept)shall be made possible for verifications of strength formerlyapplied during the plant erection stage.

(3) When revising KTA 3205.1 the various procedures laiddown in the KTA 3205 safety standard series as regards thelimit stress analysis of bar-type load-bearing structures wereharmonised (KTA 3205.1: structural steel class S1, KTA3205.2: structural steel class S2). To this end, the allowablestresses based on the equivalent stress value Sm were sub-stituted by the allowable stresses based on the equivalentyield stress Rv0,2.

(4) The allowable shear stresses welds of S235 (St 37) wereextended to all type of loadings and thus adapted to the state-of-the-art.

(5) The former verification of strength for bolted joints wassubstituted by a rule making uniform procedure applicationpossible analogously to the verification for components andwelded joints. For the usual bolts (strength classes) the allow-able stresses were taken over from DIN 18 800-1 (3/81) andentered in Table 7-5.1 in dependence of the load case, andvalues for special load cases were added.For other bolts the allowable stresses were defined in Tables7-5.2 and 7-5.3 in dependence of the load case.

(6) In clause 7.2.7.4 the allowable pressure stresses formaterials within the scope of KTA 3205.1 were taken overfrom DIN 18 800-1 (3/81) as Table 7-6 (allowable pressurestresses for bearing parts and hinged joints).

(7) The verification of strength for plane load-bearing struc-tures was not changed. Contrary to bar-type load-bearingstructures (steel construction) plane load-bearing structuresas covered by this safety standard are support skirts usuallyconnected to the components. The modeling/calculation shallbe made for the total system consisting of the component andthe supporting structure. Within a calculation method it is notpurposeful to use different safety criteria so that the Smmethod applicable to the components as per KTA 3201.2shall also be used for the supporting structure.

2 Materials and materials test sheets

The materials test sheets and Tables 6-1 to 6-5 were gener-ally adapted to the current state of standardisation (especiallywith respect to the materials and materials testing standards).Where changed material designations (short designation) hadto be taken over due to the current material standards, theformer designations were bracketed. For ease of applicationthe respective material numbers were added.Since not all materials (e.g. 24 CrMo 5) from the withdrawnstandards were taken over, when establishing Europeanstandards (e.g. change-over from DIN 17 240 to DIN EN 10269), the stipulations of section 6.2, sub-clause 5 may alsobe applied accordingly to semi-finished parts.

3 Other sections and annexes

This saftey standard was completely checked with respect toreferences to rules and standards and adapted accordingly.At various locations, the editorial changes also cover moreprecise requirements due to feedback of experience madewith the application of this standard. Essential changes are:

(1) Section 9.1 was supplemented by a reference to KTA1401 thus defining more exactly the quality assurance meas-ures required for the performance of all work.

(2) In Annex D several items were defined more exactly andthe definition of allowable stresses converted from Sm to RV0,2in analogy to the procedure for bar-type load bearing struc-tures. The conversion was made for all type of loadings for allcomponents of pipe-whip restraints with a ratio of RV0,2/Sm of1.5 applicable to ductile materials. By doing so the intensifica-tion factors for short-time loading applied up to now havebeen maintained due to the more favourable effect of dynamicincrease in yield stress.