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Safety Standardsof theNuclear Safety Standards Commission (KTA)

KTA 3201.1 (06/98)

Components of the Reactor Coolant Pressure Boundary

of Light Water Reactors

Part 1: Materials and Product Forms

(Komponenten des Primärkreises von Leichtwasserreaktoren;

Teil 1: Werkstoffe und Erzeugnisformen)

Previous versions of this safetystandard were issued 11/82 and 6/90

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 +49-5341/885-(0) 901 • Telefax +49-5341/885-905

anwender

Reaffirmed: 11/03

KTA SAFETY STANDARD

June 1998Components of the Reactor Coolant Pressure Boundary

of Light Water Reactors; Part 1: Materials and Product Forms KTA 3201.1

CONTENTS

Fundamentals ......................................................................... 4

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

2 General principles ........................................................... 52.1 Selection and certification of materials......................... 52.2 Welding consumables..................................................... 62.3 General requirements regarding quality assurance.... 62.4 Requirements to be met by the material

manufacturer.................................................................... 62.5 Design review and quality documentation.................. 72.6 In-process inspection ...................................................... 92.7 Test and certification of material quality ..................... 92.8 Repairs ............................................................................ 102.9 Material properties for strength calculations............. 10

3 General requirements for and testing of materials ... 133.1 Allowable materials ...................................................... 133.2 Requirements ................................................................. 133.3 Tests and examinations of materials and

product forms ................................................................ 153.4 Re-examinations ............................................................ 213.5 Identification marking of the product forms ............. 213.6 Documentation .............................................................. 21

4 Seamless hollow parts, forged or rolled ..................... 22

5 Seamless hollow parts for nozzles, forged, rolledor pressed ....................................................................... 25

6 Forged single-piece plates for tubesheets .................. 28

7 Sheets and plates ........................................................... 31

8 Products dished, pressed, bent for rolled fromsheets and plates............................................................ 35

9 Straight pipe sections .................................................... 38

10 Seamless, forged hollow bodies for primarycoolant pump casings ................................................... 41

11 Pressure-retaining forged valve bodies...................... 43

12 Forged flat plates ........................................................... 45

13 Hot dished or pressed products from forged plates. 47

14 Forged or rolled bars for hollow-bored nozzlesand pipes ........................................................................ 49

15 Forged or rolled and hollow-bored andhollow-forged bars ........................................................ 50

16 Seamless pipes for piping............................................. 50

17 Seamless elbows for pipe systems............................... 52

18 Steam generator tubes................................................... 55

19 Seamless extrusion-clad composite tubes .................. 58

20 Bars and rings for bolts, nuts and washers, as wellas bolts, nuts and washers(dimensions exceeding M 130)..................................... 61

21 Bars and rings for bolts, nuts and washer as wellas bolts, nuts and washers(dimensions equal to or smaller than M 130)............. 63

22 Sheets, plates, bar steel and forgings fromstainless austenitic steels .............................................. 64

23 Seamless pipes from stainless austenitic steels.......... 70

24 Seamless elbows from stainless austenitic steels....... 71

25 Pressure retaining parts from quenched andtempered cast steel ........................................................ 73

26 Valve bodies made from ferritic cast steel ................. 83

27 Valve bodies from austenitic cast steel ....................... 89

28 Bars and forgings from stainless martensitic steel .... 97

29 Product forms and components from ferritic steelsfabricated by shape-welding........................................ 98

30 Product forms from ferritic steels for integralconnections to the reactor coolant pressureboundary....................................................................... 101

31 Product forms from austenitic steels for integralconnections to the reactor coolant pressureboundary....................................................................... 101

Annex A Material characteristics ............................... 103

Annex AP Characteristic values of physicalproperties ...................................................... 134

Annex B Performance of manual ultrasonicexaminations ................................................ 138

Annex C Performance of surface crack detectionexaminations by magnetic particle andliquid penetrant methods ........................... 148

Annex D Procedure for determining the deltaferrite content ............................................... 150

Annex E Form sheets................................................... 152

Annex F Regulations referred to in this SafetyStandard........................................................ 159

Annex G Changes with respect to the edition6/90 and explanations (informative) ........ 162

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. 170a on September 11, 1998. Copies may be ordered through the Carl Hey-manns Verlag 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 3201.1

Comments by the editor:

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

shall indicates a mandatory requirement,

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

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

should indicates a recommendation or an example of good practice,

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

KTA 3201.1

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 3Atomic 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 NuclearPower Plants against Incidents pursuant to Sec. 28 para 3 ofthe Radiological Protection Ordinance (StrlSchV) - IncidentGuidelines”.

(2) Criterion 1.1, „Principles of Safety Precautions” of theSafety Criteria requires, among other things, a comprehensivequality assurance for fabrication, erection and operation andCriterion 2.1, „Quality Assurance” requires, among otherthings, the application, preparation and observation of designrules, material specifications, construction rules, testing andinspection as well as operating instructions and the documen-tation of quality assurance. Criterion 4.1 ”Reactor CoolantPressure Boundary” principally requires, among other things,the exclusion of dangerous leakage, rapidly extending cracksand brittle fractures with respect to the state-of-the-art. Safetystandard KTA 3201.1 is intended to specify detailed measureswhich shall be taken to meet these requirements within thescope of its application. For this purpose, a large number ofstandards from conventional engineering, in particular DINstandards, are also used; these are specified in each particularcase. For the components of the reactor coolant pressureboundary the requirements of the aforementioned safetycriteria are further concretised with the following safety stan-dards

KTA 3201.2 Design and Analysis

KTA 3201.3 Manufacture

KTA 3201.4 Inservice Inspection and Operational Monitoring

as well as with

KTA 3203 Monitoring Radiation Embrittlement of the Ma-terials of the Pressure Vessel of Light Water Reac-tors.

(3) The requirements specified under KTA 3201.1 address,in particular,

a) the organisations that are involved in manufacture,

b) the manufacture of materials as well as their chemicalcomposition, mechanical properties, physical characteris-tics, heat treatment and subsequent fabrication,

c) the certification and supervision procedures for attainingand meeting the required material quality, e.g. destructiveand non-destructive testing as well as in-process inspec-tion and manufacturing supervision,

d) the preparation of documents for the documentation oftest results.

(4) This safety standard does not specify any requirementsthat do not serve the primary purpose of a safe enclosure ofthe reactor coolant.

1 Scope

(1) This safety standard applies to the manufacture of thematerials and product forms of pressure retaining compo-nents of the reactor coolant pressure boundary of light waterreactors.

(2) This safety standard does not apply to pipes and valveswith nominal diameters equal to or smaller than DN 50.

(3) In the case of pressurised water reactors, the reactorcoolant pressure boundary comprises the following compo-nents without internals:

a) the reactor pressure vessel,

b) the primary side of the steam generators, the secondaryshell of the steam generators including the feedwater inletand main steam exit nozzles up to the pipe connectingwelds, but not the minor nozzles and nipples, shall also betreated in accordance with this safety standard,

c) the pressurizer,

d) reactor cooling pump casing,

e) the connecting pipes between the above components andthe valve casings of any type contained in the pipe system,

f) the pipes branching off from the above components andtheir connecting pipes including the valve bodies installedin the piping system up to and including the first shut-offvalve,

g) the pressure retaining walls of the control rod drives andthe in-core instrumentation,

h) the integral parts of the component support structures inaccordance with Fig. 8.5-1 of KTA 3201.2 and the weldedattachments.

(4) In the case of boiling water reactors, the reactor coolantpressure boundary comprises the following componentswithout internals:

a) the reactor pressure vessel,

b) the pipework belonging to the same pressure space as thereactor pressure vessel including the installed valve bodiesup to and including the first shut-off valve, pipeworkpenetrating the containment shell and belonging to thesame pressure space as the reactor pressure vessel up toand including the last shut-off valve located outside thecontainment shell,

c) the pressure retaining walls of the control rod drive andin-core instrumentation,

d) the integral parts of the component support structures inaccordance with Fig. 8.5-1 of KTA 3201.2 and the attach-ments.

2 General principles

Note:Authorized inspectors for the tests and inspections in accordancewith this safety standard are those authorized in accordance withSec. 20 Atomic Energy Act by the licensing or supervisory authority.

2.1 Selection and certification of materials

2.1.1 Selection of materials

(1) The materials shall be selected according to their in-tended application by taking into account the mechanical,thermal and chemical loadings and the damage possible dueto neutron irradiation.

KTA 3201.1

(2) The materials shall safely withstand the loadings frompressure tests, operation and all specified plant conditions.

Note :The materials, in as far as they are certified with regard to the in-tended application, shall basically be chosen by the manufacturer,however if necessary, after consultation with the material manu-facturer.

2.1.2 Material certification

(1) The certification of materials with regard to their charac-teristics with respect to the above mentioned loadings and tothe workability of the materials shall be carried out by theauthorized inspector. Any individual certification will beapplicable to all products delivered hereinafter by the samemanufacturer within the scope of the certification.

(2) If the material is to be welded then it shall be suited forwelding. The weldability shall be attested in the certifiedmaterial test report of the authorized inspector. Where specialconditions have to be observed during welding, these shall bespecified in the initial material certification.

(3) Materials with characteristics in accordance with thosespecified in Annex A shall be considered to be applicable bythe manufacturers cited in the VdTUEV Material SpecificationSheets because the materials have been completely tested andinspected and proved to be reliable in service.

(4) Special materials require an initial material test certifi-cate by the authorized inspector. This test shall specify thecharacteristics of these other materials with regard to therequirements under this safety standard. Within the frame-work of the acceptance test, the authorized inspector shallverify that a continuous material quality is ensured by theindividual manufacturer.

(5) The tests by the authorized inspector required for specialmaterials shall be specified with regard to type and extentsuch that they form, together with the supplied manufac-turer's documentation, a sufficient basis for the material certi-fication. The proof that the required material characteristicsare continuously attained should be supported by a mathe-matical and statistical evaluation of already available testresults. If the material is manufactured in more than oneplant, this shall be considered in the initial certification. Theinitial certification shall extend to the evaluation of the follow-ing points

a) steel-making process,

b) chemical composition (also with respect to neutron activa-tion),

c) segregation behaviour,

d) product form,

e) limitations in dimensions,

f) as-delivered condition,

g) mechanical properties,

h) resistance to corrosion,

i) workability,

j) weldability,

k) scope of applicability,

l) type and extent of tests and inspections,

m) test certification,

n) identification marking.

(6) If a material is to be used beyond the scope of its certi-fied applicability, a supplementary certified material test

report by the authorized inspector is required. This also ap-plies to a special material that is to be used in an individualapplication. In special cases, an individual material certifica-tion regarding the extended scope of applicability shall beissued. This individual material certification shall be limitedto the certified material manufacturer and to similar scopes ofapplication. This individual certification shall be specified inthe acceptance test certificate.

(7) If new kinds of manufacturing processes (e.g. steel-making, casting and forming processes) are applied that werenot considered in the initial material certification then theirequivalency with those procedures considered in the initialmaterial certification shall be demonstrated. This proof shallbe contained in the supplementary material certification bythe authorized inspector.

2.2 Welding consumables

KTA safety standards 1408.1 to 1408.3 apply to the weldingconsumables.

2.3 General requirements regarding quality assurance

General requirements regarding quality assurance are speci-fied in KTA safety standard 1401.

2.4 Requirements to be met by the material manufacturer

(1) The manufacturers shall have manufacturing equipmentat their disposal which allow a proper and state-of-the-artmanufacturing of materials and product forms.

Note:The term „materials“ in the fo llowing refers to both the materialsand their product forms.

(2) The manufacturers shall have testing equipment at theirdisposal which allow the testing of materials in accordancewith the corresponding DIN Standards or with other stan-dards that apply. The test equipment shall correspond to DIN51 220 and be inspected in accordance with DIN 51 220.Within the measuring range of the test equipment, the permit-ted measuring inaccuracy of the forces measuring equipmentshall not exceed 1 %. Upon request, the test reports to DIN51 220 shall be submitted to the authorized inspector.

(3) Where testing equipment of other facilities is employed,these requirements apply accordingly.

(4) The manufacturer shall have equipment at his disposal,either at his works or at other facilities, that allow carrying outthe non-destructive tests required in accordance with thissafety standard. Mechanical or automated equipment em-ployed in the non-destructive examination in accordance withthis safety standard shall be certified by the authorized in-spector.

(5) A list shall be available of the required operating in-structions for the manufacturing and testing equipment inaccordance with para (1) through (4).

(6) The quality surveillance department of the manufacturershall ensure, and document correspondingly, that the materi-als are properly manufactured and processed and that thecorresponding technical standards have been met.

(7) The manufacturer shall have at his disposal expert per-sonnel that is able to carry out the tests and examinationsproperly.

KTA 3201.1

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

(9) The personnel (operators) carrying out the non-destructive examinations shall be part of the staff of themanufacturer's works. They shall have sufficient basic techni-cal knowledge and shall be capable of performing the exami-nations in accordance with the requirements. This shall bedemonstrated by the test supervisory personnel to theauthorized inspector on the basis of testing experience, ofworks internal training, or on the basis of corresponding cer-tificates from external examinations.

(10) In the case of ultrasonic tests and surface crack examina-tions, any works external operator may only perform testactivities in addition to the operators of the manufacturer’sworks.

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

(12) The works` inspector shall be a staff member of themanufacturer's works. The name and stamp of the works`inspector shall be known to the authorized inspector.

(13) In as far as the manufacturing of the product forms re-quires welding, then the following requirements shall be met:

a) The manufacturer shall have own supervisory personneland welders that are certified in accordance with DIN EN287-1 in connection with AD-Merkblatt HP 3. Only certi-fied welders shall be employed for the welding activities.

b) The welding supervisor shall be a member of the staff ofthe manufacturer's works and be named to authorized in-spector. With regard to the technical qualifications of thewelding supervisor the requirements in accordance withKTA 3021.3 shall apply.

(14) Any deviation observed from quality requirements shallbe reported to the appropriate division. The procedure shallbe specified in writing.

(15) The manufacturer shall have a quality department that isorganisationally independent from the fabrication depart-ment.

(16) The organisational independence and the individualtasks of the works` inspector, the supervisory personnel forthe operators, the quality department and, if required, thewelding supervision shall be specified in writing.

(17) Before initiating any fabrication steps, the authorizedinspector shall verify and certify in writing that all require-ments have been met. This examination shall be repeated attime intervals of between about one and two years unless theauthorized inspector can verify by other means that the re-quirements are being continually met.

2.5 Design review and quality documentation

2.5.1 General requirements

(1) The required values for the manufacture of the productforms and the required certifications of the tests and exami-nations to be performed in the course of manufacture shall bespecified in the design review documents. By agreement withthe authorized inspector, it may not be necessary to preparedesign review documents in part or in total for particularproduct forms, provided the requirements in accordance withthis safety standard are met and this safety standard containssufficient acceptance requirements for the particular productform. Regarding the product forms in accordance with Secs.22 through 24 and 27, a design review shall be carried outonly with respect to the design review documents specified inthe corresponding sections.

(2) The design review documents and the certifications ofthe tests and examinations performed in the course of manu-facture shall be documented and be compiled to form thequality assurance documentation. The quality documentationshall be continuously established in parallel to manufacture.The materials testing and specimen-taking plans (WPP) shall,in accordance with Figure 2-1, be subsectioned into a designreview part and a document part. The results of the tests andexaminations shall be certified in accordance with the re-quirements under Table 2-1 either as stamping and signature(ST) in the materials testing and specimen-taking plan or inindividual test certificates which are uniquely correlated tothe WPP via the certification number.

2.5.2 Type and duration of document filing

(1) The filing of the quality assurance documentation, i.e.final filing (E) or interim filing (Z), is specified in Table 2-1 inaccordance with KTA 1404.

(2) General requirements regarding the type and extent ofdocumentation as well as the filing duration and location arespecified in KTA 1404.

2.5.3 Abbreviations

(1) Uniform abbreviations shall be used in the manufactur-ing documents.

(2) If possible, the abbreviations suggested in Table 2-1 shallbe used.

(3) Any other or additional abbreviations used shall beexplained in the particular document.

2.5.4 Design review

2.5.4.1 Design review documents

The design review documents shall be prepared in due timeprior to the planned start of manufacture of the product formand shall be submitted to the authorized inspector. It is al-lowed to submit partially or completely standardised designreview documents.

2.5.4.2 Type and content

2.5.4.2.1 General requirements

(1) Generally, the documents specified in Secs. 2.5.4.2.2through 2.5.4.2.6 shall be prepared for design review. Addi-tional documents, e.g. for fabrication welds on cast steel, shall

KTA 3201.1

be prepared in accordance with the requirements in the pro-duct-form related sections.

(2) The documents shall contain the required information inaccordance with the forms E-1 through E-4. It is suggestedthat these forms be also used as the basic format for thedocuments.

2.5.4.2.2 Cover sheet

A cover sheet for the design review documents shall exactlyspecify the product form to be subjected for design reviewand shall list the individual design review documents withtheir abbreviation and the number of pages they contain.Additionally, a revision table and a list of all KTA safety stan-dards applicable to the manufacture and, if applicable, anyspecifications, test and inspection as well as operating in-structions shall be included in the design documents.

2.5.4.2.3 Technical drawings

(1) The product forms shall be represented in technicaldrawings if their geometry so requires.

(2) The technical drawings shall contain the major dimen-sions including their tolerances.

2.5.4.2.4 Materials testing and specimen-taking plans

(1) The materials testing and specimen-taking plans shallcontain the following information:

a) any information regarding fabrication (e.g. heat treatment)that is important for specifying and correlating the testsand supervision measures,

b) the mechanical tests including number, orientation andposition of the specimen in the test coupons and the posi-tion of the test coupons in the product form. If the geome-try of the product form so requires, the position of the testspecimen and test coupons shall be shown in a locationplan as an appendix to the materials testing and specimen-taking plan. All test specimens shall be identified unambi-guously in the specimen-taking plan.

c) the non-destructive examinations,

d) the individual measures, work and inspection instructionsrequired for the individual test steps,

e) the departments involved in the tests with an indication oftheir activities (e.g. performing the test, participating inthe test),

f) specification of the documentation (type of certificationand type of filing, cf. Table 2-1).

(2) The materials testing and specimen-taking plans shallcontain all tests and examinations to be performed in accor-dance with this safety standard. In this connection and underconsideration of Table 2-1 they shall also specify

a) whether the test results shall be certified by individual testcertificates or by attestation stamp and signature,

b) which form of filing (E or Z) is required for the documen-tation and

c) for which tests an overall certification (E/S) is applicable.

2.5.4.2.5 Heat treatment plans

Heat treatment plans shall be prepared for all heat treatmentsof product forms and accompanying test specimens as well as

for the simulation heat treatment of base material coupons.These should contain at least the following information:

a) type of heat treatment (e.g. tempering, simulation stressrelief heat treatment),

b) wall thickness and shapes of the pieces in the conditionready for heat treatment (if necessary with technicaldrawing in accordance with Sec. 2.5.4.2.3),

c) type of the heat treatment equipment (e.g. continuousfurnace, hearth type furnace),

d) type and extent of temperature measurements, location ofthe thermocouples on the piece taking into considerationthe intended location of the piece in the furnace,

e) time-temperature chart (e.g. heat-up rate, holding time,cooling rate; if the heat treatment is part of the hot formingprocess, this shall be indicated),

f) type of cooling, cooling agent.

2.5.4.2.6 Test instructions for non-destructive testing

(1) The manufacturer shall establish test instructions for thenon-destructive tests, especially for ultrasonic and radio-graphic testing.

(2) These test instructions may be prepared in standardisedform and independent of the particular project providedsimilar test objects are involved. In the case of surface crackdetection tests the test instructions may be replaced by workinstructions of the manufacturer that are independent of theproject and the test object.

(3) The test instructions shall contain detailed informationregarding:

a) the correlation to the individual test objects,

b) the point of time of the test if this has any influence on theextent and the performance of the test in accordance withthe test and inspection sequence plan,

c) the technical test prerequisites, testing techniques andtesting equipment to be employed, type of sensitivity ad-justment in the case of ultrasonic testing,

d) as required, any additional information regarding theperformance of the test (e.g. sketch to scale),

e) the coordinate system and direction of enumeration fordescription of findings assignable to the test object,

f) as required, any additional information regarding thedocumentation and evaluation of findings (e.g. in the caseof testing related replacement measures).

Note:The test instructions regarding automatically and mechanicallyperformed non-destructive tests shall be based on the results o fthe certification o f the test facilities by the authorized inspector.The test instructions shall be submitted to the authorized in-spector for design review..

2.5.4.3 Performing the design review

(1) If so required for the product form, the authorized in-spector shall check whether or not the submitted design re-view documents are complete and whether or not they meetthe requirements under this safety standard regarding theirtechnical content and prescribed measures.

(2) In the case of a positive result of his design review, theauthorized inspector shall put his checknote and signature onthe documents, thereby certifying that the design review hasbeen completed.

KTA 3201.1

(3) Any change and additions that become necessary in thecourse of the design review shall be worked into the designreview documents and shall be marked by a note of theauthorized inspector.

2.5.4.4 Validity

(1) The design review documents basically remain validuntil the corresponding product form has been completed.However, a review of these documents is required

a) if manufacturing is not begun within 24 months after thedate of the checknote application,

b) if manufacturing is interrupted for more 24 months.

(2) Where essential aspects of the requirements and safetystandards on which the design review was based are changed,it shall be clarified with the authorized inspector whether thedesign review must be repeated or not.

2.5.4.5 Revision of the design review documents

(1) If, after completion of the design review certain revisionsof the documents become necessary, the correspondingdocuments shall be re-subjected to a design review.

(2) The changed documents shall be subsequently num-bered corresponding to their state of revision.

2.5.5 Quality documentation by the manufacturer

(1) The manufacturer shall designate the task of compilingthe required documents to a central department which shallbe named to the authorized inspector.

(2) The manufacturer shall ensure

a) that the documentation system specified in this safetystandard is observed at his works,

b) that the prepared documents meet the requirements of thissafety standard with regard to completeness of data andwith the required check notes,

c) that, in the course of the manufacturing process, the qual-ity documentation is continually checked for correct en-tries and completeness such that this documentation cor-rectly represents the test condition of the product at alltimes during manufacturing.

(3) If in the course of manufacture deviations from the re-quired values are noticed, the manufacturer shall preparenon-conformance reports and submit them for review by theauthorized inspector. In addition to a description of the de-viation, the non-conformance report shall contain a descrip-tion of the further measures to be taken (e.g. repairing ortolerating the division) together with the statement of thecorresponding reasons. The non-conformance report shallbecome part of the final file (E).

(4) The revised and design reviewed documents shall bedocumented such that the traceability to the original planningstage is ensured.

(5) Upon completion of the product form, the manufacturershall submit the original documentation to the authorizedinspector for final review.

2.6 In-process inspection

2.6.1 In process inspection by the manufacturer

(1) During manufacture of the products, from the steel-making process to the delivery, an in-process inspection onthe basis of the manufacturing and design review documentsshall be carried out by the manufacturer’s quality assurancedepartment that is organisationally independent from manu-facture.

(2) This accompanying in-process inspection shall extend toat least the following points:

a) checking of the fabrication prerequisites with regard to thefulfillment of technical and organisational requirements inaccordance with this safety standard,

b) checking of the fabrication and hold points includingcountersigning in the records and certifications during thesteel-making process including casting, treatment and inthe case of repairs,

c) supervision and performance of the tests in accordancewith the manufacturing and design review documents inthe case of:

ca) non-destructive tests,

cb) mechanical tests,

cc) dimensional checks,

cd) identification stamping,

ce) visual examination,

cf) material identification check,

cg) leak tests (of steel castings).

(3) The manufacturer shall prepare a documentation of thein-process inspection in accordance with the manufacturingand design review documents; this documentation shall beavailable at the time of final inspection.

2.6.2 Manufacturing supervision by the authorized inspector

(1) The authorized inspector shall randomly convince him-self of the proper in-process inspection by the manufacturer.The authorized inspector has the right to attend any of themanufacturing processes. However, this may not detrimen-tally influence the manufacturing process. All quality assur-ance documents regarding fabrication and testing shall bemade available to the authorized inspector.

(2) The authorized inspector shall perform the tests andchecks prescribed for him in the design reviewed documents.In individual cases, the authorized inspector has the right torequire test coupons for a product analysis by an independenttesting agency.

(3) The authorized inspector shall establish a report on hismanufacturing supervision activities that should also addressany deviations from required values, the evaluation of thesedeviations, corrective changes and repairs; this report shall bepart of the acceptance certificate of the authorized inspector.

2.7 Test and certification of material quality

(1) The tests and certification regarding the material qualityshall meet the requirements in accordance with the product-form related sections and with Annex A.

(2) The material quality shall be demonstrated by materialtest certificates in accordance with DIN EN 10 204. They shallcontain the results of the tests, the test prerequisites, the test

KTA 3201.1

conditions and the name of the operator. In addition, theyshall certify that the requirements under this safety standardhave been met.

(3) The materials shall be tested at the manufacturer’sworks. The materials shall be identified in accordance withthe requirements under Sec. 3.5. The entire wording of theidentification marking shall be contained in the inspectioncertificate in accordance with DIN EN 10 204.

(4) An inspection certificate 3.1.C in accordance with DINEN 10 204 shall be established by the authorized inspector forthe product, which shall contain all results of the tests in ac-cordance with the manufacturing documents and shall certifythat the quality assurance system was applied to the acceptedproduct.

2.8 Repairs

(1) Prior to taking any measures with respect to repairing aflaw it shall be evaluated in how far repairing the flaw orleaving it as it is has any advantages or disadvantages regard-ing the safety of the component.

(2) This also applies to repair and temporary welds on fin-ished parts.

(3) Any fabrication steps that are needed to achieve thespecified quality and that were not part of the initial fabrica-

tion steps in accordance with the design reviewed manufac-turing documents shall be considered repairs.

(4) In the case of welds, the requirements under KTA 3201.3shall be considered. The same applies to temporary welds onfinished parts.

(5) All repairs require the prior consent of the authorizedinspector. The cause for the repairs shall be determined,documented and reported to the authorized inspector.

(6) Prior to performing any repair, corresponding designreview documents as well as additional manufacturingdocuments shall be prepared and the authorized inspectorshall have accepted these documents. The requirements inaccordance with Secs. 2.5.1 and 2.5.2 also apply to repairs.

2.9 Material properties for strength calculations

(1) Where the material has been generally certified, all ma-terial parameters required for the strength calculation shall betaken from Annex A.

(2) In the case of other materials, these characteristics shallbe taken from the initial certified material test report estab-lished by the authorized inspector.

KTA 3201.1

Required conditions

(design review) (documentationactivities)

Actual conditions

cationDocu-ment

Certifi-

marking

Test per-formed

Note on Remarks

1)

cationsperfor-mance oftest

Certifi-men

TesttestingNo. per

acc. toNo.Test

mentsRequire-

lot

Testtemp.

Speci- Speci-menmen

dimen-

Speci-

°C

Working instruction

Drawing

Heat treatment plan

Inspector´s check note

KTA Safety standard

DIN standard (certificates, records)

Test instruction

Final file ( E )

Interim file ( Z ) Test certification

65 8742 3

Materials Testing and Specimen-Taking Plan (WPP)

1 9

Manufacturer Release of documentationReleaseReason for Rev.

141110 1312

WPP ... -M

specimen-taking plan

Test instruction

Materials testing and

only if required due to product form geometry

WPP ... -S

specimen-taking plan

Drawing1)

functions ofdocumentation

Control andorganisational

Cover sheet Materials testing and

Heat treatment plan

WPP ... -S

WPP ... -M

sionslocation by key file

Figure 2-1: Interdependence of design review documents and product forms

KTA 3201.1

Test/inspection certificates Performance/Attendance

Type of Documentation

1 Tests/inspections at the product manufacturer’s works

1.1 Check of qualification or approval of manufacturer S ST

1.2 Check of material certification(base material, welding consumables)

S ST

1.3 Chemical analysis (ladle analysis, product analysis) H E

1.4 Check of validity of procedures for the

a) production welding of cast iron H, S ST

b) pressure testing of steam generator tubes H, S ST

c) special processes (e.g. sandblasting, bending) H, S ST

1.5 Mechanical testing prior to final heat treatment H, S 3) Z

1.6 Non-destructive testing prior to final heat treatment H, S 1) E 1) Z

1.7 Dimensional check prior to final heat treatment H Z

1.8 Proof of heat treatment (furnace recordings, furnace allocationplans, temperature measuring points)

H, S Z

1.9 Heat treatment certificates H, S E

1.10 Sulphur prints H Z

1.11 Testing of mechanical properties in the heat treated condition or as-fabricated condition including simulated heat treatments, if any, toprove that the required material properties have been obtained, e.g.by means of

a) mechanical testing H, S E

b) toughness testing H, S E

c) hardness testing H, S E

d) metallographic testing (e.g. grain size, structure, ferrite diskpickling test)

H E

e) corrosion testing (test for resistance to intergranular corrosion) H ST

1.12 Non-destructive testing in the as-delivered condition or upon finalheat treatment prior to further processing

H, S E

1.13 Dimensional check in the as-delivered condition

a) with yes/no statement H, S ST

b) with recording of actual dimensions H, S E

1.14 Visual inspection H, S ST

1.15 Pressure test H, S E

1.16 Check of identification marking H, S E 2) ST

1.17 Material identification check H ST

1.18 Cleanliness check H ST

1.19 Check of correct packing H ST

1.20 Review of documents H, S ST

1.21 Release of documentation S E

1) Only if testing upon final heat treatment is limited due to geometry.2) Replica of stamping, if possible.3) If required for the specific product form.

E : Final file

Z : Interim file

ST : Stamping

S : Authorized inspector

H : Manufacturer

Table 2-1: Test/Inspections - Performance/Attendance /Documentation

KTA 3201.1

(1) Tests and inspections

AP : production control test

APM : production control test on accompanying heattreated test coupons

APS : production control test on simulated heat treatedtest coupon

CHP : welding material test

DIP : leak test

DOP : review of documents

DS : radiography

DRP : pressure testing

EK : receiving inspection

FE : liquid penetrant examination

MK : dimensional check

MP : magnetic particle examination

MTP : mechanical testing

RP : cleanliness check

SUE : welding supervision

US : ultrasonic examination

VP : welding procedure qualification

VWP : materials identification check

WBK : heat treatment check

WP : materials testing

WPM : materials testing on accompanying heat treatedproduction control test coupons

WPS : material test on simulation heat treated testcoupons

WSP : eddy-current examination

VIP : visual inspection

ZfP : non-destructive testing

(2) Documents

AB : Non-conformance report

AW : work instructions

CHPP : plan for material tests

DBL : cover sheet

DRPP : pressure test plan

DPP : radiographic examination plan

PA : test instruction

PFP : test and inspection sequence plan

RPL : cleaning plan

SP : welding procedure sheet

SPK : welding record

WBP : heat treatment plan

WBPK : heat treatment record

WPP : materials testing and specimen-taking plan

ZG : drawing

(3) Others

AN : person responsible for establishment of certifi-cates

E : final file

E/S : final file for overall certificate

QS : quality assurance

QST : quality department

SF : welding sequence

ST : stamping plus initials

Z : interim file

..-S : signifies simulated heat treatment condition

..-M : signifies accompanying heat treated conditions

..-R : signifies repair document

..-RM : signifies reserve material documents

..-L : signifies service lifetime

(4) Participants in tests and inspections

H : manufacturer

S : authorized inspector

Table 2-2: Abbreviations to be used

3 General requirements for and testing of materials

3.1 Allowable materials

Only such materials are allowed for application that meet therequirements under Sec. 2 and whose suitability in accordancewith this safety standard has been verified in a certification bythe authorized inspector. This certification shall relate to themanufacturer and the specific product forms.

3.2 Requirements

3.2.1 General Requirements

(1) The materials chosen for the individual case of applica-tion shall be able to withstand any loadings, e.g. mechanical,thermal and chemical loadings on which the design wasbased, including any loadings from the manufacturing pro-

cess. In addition to the general requirements usually applica-ble to pressure vessel manufacture, neutron irradiation shallbe considered for those components in the belt-line region.

Note:The belt-line region is the irrad iated section o f the reactor pres-sure vessel wall which d irectly encloses the rad ioactive part o f thereactor (length o f the fuelled part o f the fuel elements) as well asthe ad jacent sections which, on account o f the pred icted referencetemperature increase are to be considered when selecting the ma-terials to be monitored.

(2) The material property requirements apply to the finalstate of the component after final inspection and pressure test.When testing materials and product forms, the material char-acteristics shall be demonstrated on test coupons that aresufficiently large and are in heat treatment conditions thatmeet the requirements under Sec. 3.3.5.

KTA 3201.1

3.2.2 Manufacturing

(1) The materials shall be produced to the steel-makingprocess specified in Annex A or in the initial material certifi-cation of the authorized inspector such that the chemicalcomposition is in the allowed range. A proof of equivalency isrequired in the case of deviations.

(2) During manufacture, the degree of segregation shouldbe kept as low as possible.

3.2.3 Heat treatment

(1) The heat treatment of the materials shall be performed asspecified in the product-form related sections or in Annex Aor in the initial material certifications of the authorized inspec-tor. A proof of equivalency is required in the case of any de-viation from the specified heat treatments.

(2) Each heat treatment shall be documented in a tempera-ture-versus-time log. The uniformity of the heat treatmentacross the product form shall be demonstrated by suitableinstruments and be documented with automatic recordingequipment. All records shall be made available to the author-ized inspector for reviewing.

(3) If, in the course of fabrication, product forms ofquenched and tempered steels are subjected to further heattreatments after their final tempering, the temperature rangesspecified in the design review documents for tempering andstress relieving should not overlap. If this cannot be avoided,then the highest unit temperatures measured in these furtherheat treatments shall not exceed the lowest unit temperaturemeasured during final tempering.

3.2.4 Material properties

3.2.4.1 General requirements

(1) The requirements regarding the mechanical propertiesand their uniformity within a product form depend on thematerial and the shape of the product. The requirements arespecified in the product-form related sections and in Annex Aor in the initial material certifications of the authorized inspec-tor. In the case of product forms subjected to internal pres-sure, the material characteristics, especially the ductile behav-iour shall preferably be specified with regard to the fibrousstructure.

(2) In the course of the material certification, it shall bespecified if and to what extent further examinations are re-quired beyond the tests specified in the product-form relatedsections and in Annex A.

3.2.4.2 Requirements for ferritic materials

(1) This section specifies requirements for ferritic materialsfor the product forms named in the scopes of Secs. 4 through17, 29 and 30.

(2) In the case of ferritic quenched and tempered steels,special attention shall be paid to the safety against brittlefracture in due consideration of the operating and loadingconditions.

Note:For the sake o f simplicity, the fo llowing sections refer only to„ferritic steels“. However, this always includes the ferriticquenched and tempered steels.

(3) The ferritic steels used shall have a fine-grained struc-ture.

(4) In the case of product forms for belt-line components,the design and loading conditions with regard to neutronirradiation may require that the content of certain elementsdetermined in the product analysis, in particular copper andphosphor, is reduced with respect to the usual values. In thiscase the corresponding requirements shall already be stated inthe order.

(5) Rolled and forged product forms with the exception ofthose under Secs. 14 and 15 shall show a reduction of area onperpendicular test specimens of 45 % as the average value ofthree values obtained on individual test specimens with nosingle value below 35 % being allowed.

(6) The ferritic steels for components subject to internalpressure shall be such that the reference temperature RTNDTof the base metal, welding material and heat affected zone isat least 33 K below both the lowest operational load tempera-ture and the pressure test temperature. Here, the referencetemperature RTNDT is defined by the following steps:

a) Specification of a temperature that is equal to or higherthan the nil ductility transition temperature TNDT deter-mined by means of drop weight tests.

b) At a temperature not higher than TNDT + 33 K each testspecimen from the notched bar impact test (Charpy trans-verse test specimens) shall show an absorbed impact en-ergy of at least 68 J and a lateral expansion of at least 0.9mm. If these requirements are met, the reference tempera-ture RTNDT is equal to TNDT.

c) Where the above mentioned requirements are not met,additional notched bar impact tests (Charpy transversetest specimens) in sets of 3 test specimens shall be per-formed to determine the temperature TAV at which theabove mentioned requirements are met. In this case thereference temperature is RTNDT = TAV - 33 K.

Thus, the reference temperature RTNDT is the higher of thetwo temperatures TNDT and TAV - 33 K.

(7) The upper shelf energy on transverse test specimensshall be at least 100 J.

(8) The NDT temperature should be equal to or less than0 °C. In the case of product forms for belt-line components theloading conditions may require that the NDT temperature isnot higher than -12 °C. If the required NDT temperature isexceeded, it is the customer who by agreement with theauthorized inspector and in consideration of the safety analy-sis, shall decide on further steps to be taken.

(9) The absorbed impact energy on transverse test speci-mens shall be determined at a temperature that is 22 K abovethe required NDT temperature. The values of the absorbedimpact energy and the lateral expansion shall not be below68 J and 0.9 mm, respectively. If these values are not obtainedthat higher temperature shall be determined at which thestated requirements are met in a notched bar impact test.When using these product forms it shall then be consideredthat this higher temperature must be below the temperaturespossibly obtained under critical conditions (e.g. pressure testor incident). For the notched bar impact tests, a repetition ofthe test at the original temperature is allowed under the fol-lowing conditions:

a) The average values of absorbed impact energy and lateralexpansion shall not fall below the specified individualvalues.

b) Only one test specimen may show values that fall belowthe specified single values.

KTA 3201.1

c) The test specimen which failed by not obtaining the speci-fied single values shall not show values of the absorbedimpact energy and lateral expansion that are lower thanthe specified single value by 14 J and 0.13 mm, respec-tively.

(10) When repeating a test, the failed test specimen shall bereplaced by two additional test specimens. These two testspecimens shall be taken from a location as close as possiblefrom the specimen-taking location of the failed test specimen.Both of these test specimens shall obtain the specified indi-vidual value. Where the individually specified values are notobtained in the reexamination, than that higher temperatureshall be determined at which each value meets the specifiedrequirements. This shall be done on the basis of the availableimpact energy versus temperature curves which, if required,shall be supplemented by further tests.

(11) Details of the test are given in the sections for the indi-vidual product forms below.

(12) In the case of materials used for safety-relevant thick-walled components, those toughness characteristics which,according to the state-of- the-art, are required in brittle frac-ture analyses (e.g. the KIc value characterising the fracturetoughness) shall be determined additionally.

3.2.4.3 Requirements for austenitic materials

(1) This section specifies the requirements for austeniticmaterials for the product forms under the scopes of Secs. 22through 24 and 31.

(2) The average grain size shall correspond to a characteris-tic index equal to or greater than 4 in accordance withEURONORM 103-71. Deviations are allowed provided re-quirements regarding subsequent fabrication and materialcharacteristics are met and, especially, ultrasonic examina-tions are not obstructed in any way.

(3) Scale layers and tempering colours from hot forming orheat treatment shall be removed. The surface shall be free offerritic impurities.

(4) The parts which during subsequent fabrication are sub-jected to welding without consumables shall have a delta-ferrite content of between 2 and 10 % in the base metal of theweld fusion zone. The parts which during subsequent fabri-cation are subjected to welding with consumables shall have adelta-ferrite content of between 1 and 10 % in the base metalof the weld-fusion zone. In both cases, no ferritic latticestructure is allowed. Deviations are allowed, provided thecharacteristics of the welded joints meet the requirementsunder KTA 3201.3.

(5) The material shall be resistant to intergranular corrosionunder the specified processing conditions, especially afterwelding or after heat treatment.

3.2.4.4 Requirements for quenched and tempered steels forbars and rings for bolts, nuts and washers

(1) This section specifies the requirements for ferritic mate-rials for the products forms under the scopes of Secs. 20 and 21.

(2) At a temperature of +20 °C Charpy-V test specimensshall meet the following requirements:

Impact energy absorbed(J)

Lateralexpansion(mm)

averagevalue of 3test speci-mens

smallestvalue ofsingle testspecimen

smallestvalue ofsingle testspecimen

D ≤ 25 52 42

25 < D ≤ 100 52 42 0.65

D > 100 61 0.65

3.2.4.5 Material for specific loading conditions

If specified loading conditions exist (e.g. erosion, corrosion,thermal loading, wear) only materials meeting the specificindividual specific requirements shall be used. The corre-sponding requirements shall be specified for each individualcase by agreement with the authorized inspector.

3.2.5 Internal and surface flaws

The product forms shall be free of internal surface flaws to theextent specified in the following sections.

Note:The fo llowing paragraphs also specify the acceptance standardsfor indications detected by non-destructive examinations thatconsider type and subsequent fabrication of the product form,their application and load ing.

3.2.6 Surface condition

The surface condition shall meet the requirements with regardto non-destructive examinations including in-service inspec-tions. Details are specified under Sec. 3.3.8.

3.2.7 Subsequent fabrication

For the subsequent fabrication of the materials and productforms including tests and examinations the requirements ofKTA 3201.3 apply.

3.3 Tests and examinations of materials and product forms

3.3.1 Materials testing and specimen-taking plan

The tests specified in the product-form related sections shallbe compiled in a materials testing and specimen-taking planin accordance with Sec. 2.5.4.2.4. In the course of the designreview it shall be specified within this plan at which point oftime during fabrication the required tests is to be performed.

3.3.2 Identification of the orientation and location of testspecimens

(1) The orientation of the test specimens with regard to theproduct forms shall be identified as follows:

a) Identification with regard to the direction of fibres:

Longitudinaltest specimen (L): Major axis of specimen is parallel to the

principal forming direction (parallel tothe direction of fibres); the notch of im-pact test specimens shall be perpendicu-lar to the plane of length and width di-rection.

Bar steeldiameter D

(mm)

KTA 3201.1

Transversetest specimen (Q): Major axis of specimen is perpendicular

to the plane of length and width direc-tion; the notch of impact specimen testsshall be perpendicular to the plane oflength and width direction.

Perpendiculartest specimen (S): Major axis of specimen is perpendicular

to the plane of length and width direc-tion; the notch of impact specimen testsshall be parallel to the principal formingdirection.

b) Identification with regard to the major direction of theproduct form shape:

Axialtest specimen (A): Major axis of specimen is parallel to the

axis of rotational symmetry of the pro-duct form; the notch of impact tests shallbe perpendicular to the cylindrical sur-face.

Tangentialtest specimen (T): Major direction of specimen is in the

direction of the circumference; the notchof impact tests shall be perpendicular tothe cylindrical surface.

Radialtest specimen (R): Major axis of specimen is normal to the

cylindrical surface, the notch of impacttests shall be parallel to the principal di-rection in which the material is formed.

(2) The location of the test specimen with regard to its depthbeneath the surface depends on the orientation of the speci-men’s major axis and, with regard to the edge distance on thelocation of the specimen’s cross-section. Details are specifiedin the product-form related sections.

3.3.3 Size of test coupons

(1) A sufficient amount of material shall be provided forobtaining test specimens such that, in addition to the demon-stration of the mechanical properties, a sufficient amount ofmaterial remains for test specimens, for production weld test,for re-examination specimens and, if required, for materialirradiation tests. If further test specimens are required foradditional tests, the purchasing order shall specify the num-ber and dimensions of these additional specimens.

(2) In the case of castings, additional test coupon plates, ifrequired, shall be provided from the same melt from whichthe product form was cast.

(3) In addition, reserve material from product forms inten-ded for the pressure retaining wall of the reactor pressure ves-sel (ferritic steel forgings with an internal diameter equal to orgreater than 250 mm and plates) shall be kept in reserve at theuser’s facilities. Heat treatment condition: ferritic steels,quenched and tempered; austenitic steels, solution annealed,in both cases corresponding to the condition of the productform.

(4) This reserve material shall be dimensioned such that inthe case of forgings and plates enough material is available inthe specified specimen-taking depth and major test directionfor one tensile test each at room temperature (RT) and at de-

sign temperature for one set of test specimen for notch barimpact tests and, if required in the product-form related sec-tions, for two Pellini-P2 test specimen.

3.3.4 Identification marking of test specimens, testcoupons remaining and reserve materials

(1) For the acceptance test, the test coupons shall be legiblyand unambiguously marked with respect to the specimen-taking plan prior to taking them from the product form. Themarking of the test specimens shall make it possible to exactlydetermine their original location in the product form(dimensional drawing). The authorized inspector chargedwith the acceptance test shall apply his stamp to the markingin the course of the acceptance test.

(2) The remaining and reserve material shall be markedsimilarly.

3.3.5 Heat treatment conditions of the test specimens

3.3.5.1 Ferritic steels

(1) All test coupons shall be heat treated on and togetherwith the product form.

(2) The tests required in accordance with Sec. 3.3.7, with theexception of the chemical analysis and the hardness test, shallbe performed on test specimens from these test coupons. Sub-sequent to quenching and tempering the product form, thetest coupons shall be divided to provide those test coupons

a) which are to be subjected to a simulation heat treatmentandb) which will go through all further temperature-versus-time

sequences during the processing of the product form(accompanying test coupon).

Note:The purpose o f the simulating heat treatment is to pred ict thematerial properties in the final condition o f the product form.The purpose o f testing specimens from the accompanying testcoupon which undergoes all heat treatment together with theproduct form and is subjected to tests only after the final heattreatment o f the product form is to demonstrate the properprocessing.

(3) To be able to specify the required heat treatment as ex-actly as possible in advance, the individual fabrication stepsassociated with a specific heat treatment must be known.Since this is usually not the case, e.g. with respect to repairsduring fabrication, the simulation heat treatment shall bespecified with the greatest possible safety with regard to theexpected highest temperature, number and duration of theindividual heat treatments.

(4) In general, the test coupons for the simulation heattreatment shall be detached from the product form after thelast tempering. The simulated heat treatment then comprisesall temperature-versus-time sequences above 500 °C, espe-cially the stress relief heat treatment which the product formundergoes from the last tempering to the completion of thecomponent. In addition, two intermediate stress relief heattreatments and one final stress heat relief treatment shall beincluded.

(5) In the simulation heat treatment, the holding times of theintermediate stress-relief heat treatments may be summed up.They shall be increased by a supplemental value equal to halfof the sum of heat-up and cooling-down rates above 500 °C.

KTA 3201.1

(6) Prior to the two simulations final stress heat relief treat-ments the test coupon shall be cooled down to at least 500 °C.

Note:Information regarding possible d ifferences between simulationconditions is given in the product-form related sections or in An-nex A.

(7) If the time-at temperature sequence of the stress relieftreatments is not yet known after the last quenching and tem-pering, then the simulated heat treatment shall be specified byagreement with the authorized inspector.

(8) In general, the following simulated heat treatments shallbe applied:

Component Simulation heattreatment

Parts for the pressure vessel, steamgenerators and pressurizer (productform under Secs. 4, 5, 6,7,8,13, and 14)

30 h 550 °C

+ 12 h 600 °C

+ 6 h 600 °C

Primary coolant pump (productforms under Secs. 10 and 25)

9 h 600 °C

+ 3 h 600 °C

Primary coolant pipes and valves(product forms under Secs. 9, 11, 12,16, 17, and 26)

6 h 600 °C

(9) If the products are delivered for subsequent fabricationin a non-tempered condition and are tempered only in thecourse of final processing, the simulation heat treatment shallalso include the tempering process.

(10) Sec. 3.2.3 applies to the monitoring of temperaturesduring the simulation heat treatment. The test coupons sub-jected to simulation heat treatment shall be tested prior tocompletion of the component.

(11) The accompanying test coupons shall be tested by thesubsequent manufacturer; to this end, the material manufac-turer shall supply the test coupons.

3.3.5.2 Austenitic steels

Test coupons of products from austenitic steels shall be takenand tested in the heat treatment condition typical for thesesteels, in accordance with the applicable sections of Annex A.

3.3.6 Taking of trepanned plugs

If during the fabrication of thick-walled components cutoutsfrom penetrations are obtained that are sufficiently large forthe taking of trepanned plugs, these cutouts shall be storeduntil a decision is made on the taking of trepanned plugs andtheir use. The results of the material appraisal shall be consi-dered.

3.3.7 Tests and applicable test procedures

3.3.7.1 Chemical analysis

(1) The chemical composition shall be determined by thetest procedure developed by the Chemical Committee of theAssociation of German Steel Manufacturers (cf. [1]).

(2) Unless different requirements are specified in the pro-duct-form related sections, the chemical elements specified inAnnex A or in the corresponding initial material certificationof the authorized inspector during each chemical analysis.

(3) In the case of products fabricated from several melts, theladle analysis documented shall be the average chemicalcomposition calculated from the chemical compositions of theindividual melts.

(4) In the case of electroslag or vacuum molten steels themelt analysis shall be that of the remolten ingot.

3.3.7.2 Hardness test

(1) Where required in the product-form related sections,products from tempered steels shall be subjected to hardnesstests upon tempering and prior to subsequent fabrication todemonstrate the uniformity of the heat treatment. The lowestand the highest individual hardness value determined on thesame piece shall be documented in the quality certificate. Thedifference between these two values, after carrying out a re-calculation in accordance with DIN 50 150, shall lie within thespecified allowed range of tensile strength values for singleunits.

(2) The hardness tests shall be performed in accordancewith DIN 50 133 or DIN EN 10 003-1. Other hardness testprocedures may be applied subject to agreement by theauthorized inspector.

3.3.7.3 Mechanical properties

(1) Tensile testWhere required in the product-form related sections or An-nex A, the yield strength or 0.2 %-proof stress, the tensilestrength, the elongation at fracture and the reduction of areashall be determined. In the case of austenitic steels, the 1 %-proof stress shall additionally be determined.The tensile test shall be performed in accordance with DINEN 10 002-1 and DIN EN 10 002-5 with the test specimenshape being in accordance with DIN 50 125. The tensile testsat room temperature and at elevated temperatures shall, ifpossible, be performed on test specimens with a diameterequal to or greater than 10 mm.When determining the reduction of area in the thickness di-rection the test specimens shall have a diameter equal to orgreater than 10 mm and a ratio of measurement length todiameter equal to or greater than 2; the test shall be performedat room temperature. These test specimens may also be usedfor the determination of the tensile strength, yield strengthand elongation at fracture where their geometry makes itpossible.

(2) Notched bar impact testThe notched bar impact test shall be performed in accordancewith DIN EN 10 045-1 on Charpy-V-notch specimens. A singletest shall basically consist of testing a set of three test speci-mens. For determining the impact energy absorbed, theCharpy-V test specimens shall be tested at test temperaturesthat are in conformance with the requirements under theproduct-form related sections or Annex A. In the case of fer-ritic steels the lateral expansion in accordance with DIN50 115 and the portion of dull fracture surface (ductile fractureportion) shall be determined additionally.

(3) Impact energy versus temperature curvesWhere required in the product-form related sections or An-nex A, the impact energy versus temperature curves shall bedetermined. The test shall be performed on Charpy-V notchtest specimens for at least six temperature values. Three ofthese temperature values shall always be 33 °C, 0 °C and -12 °C.

KTA 3201.1

For products that are intended for belt-line components andmust therefore reach an NDT temperature of -12 °C, the uppertemperature of 33 °C shall be substituted by 21 °C. The othertemperatures shall be chosen such that both the upper shelfenergy, characterised by a dull fracture surface portion of10 %, and the lower shelf energy, characterised by a dullfracture surface portion of 10 %, are determined and that thecourse of the nil-ductility transition temperature curve isreliably demonstrated.

At each test temperature a set of three notched bar impact testspecimens shall be tested. In the case of notched bar impacttest specimens to the determine the impact energy versustemperature curves for ferritic steels, the lateral expansionand the portion of dull fracture surface shall be determinedadditionally.

The tests in accordance with para (2) may be performed.

(4) Nil-ductility transition temperature (NDT Temperature)

If the product-form related sections or Annex A require aPellini drop-weight test to be performed to demonstrate thatthe requirements regarding the NDT temperature are met,then this test shall be performed on two test specimens(yes/no test). If an exact determination of the NDT tempera-ture is required, this test shall be performed on at least threetest specimens. Eight test specimens shall be made available.

The Pellini drop-weight test shall be performed in accordancewith SEP 1325.

(5) Tests on pipes

The mechanical tests on pipes shall, if required, be performedin accordance with

a) DIN EN 10 234 - Drift expanding test,

b) DIN EN 10 233 - Ring flattening test,

c) DIN EN 10 236 - Ring expansion test,

d) DIN EN 10 237 - Ring tensile test,

e) DIN EN 10 235 - Flanging test.

3.3.7.4 Metallographic examinations

(1) At all locations where the grain size is to be determined,the metallographic structure shall be assessed at an adequateenlargement and documented by micrographs (generally200:1 enlargement).

(2) The grain size shall be determined in accordance withEURONORM 103-71.

(3) In the case of products from quenched and temperedsteels the grain size need only be determined if portions ofpolygonal ferrite occur. In this case, it is only required to de-termine the characteristic grain size of the ferrite.

3.3.7.5 Determining the delta-ferrite content

(1) If so required by the product-form related sections orAnnex A, the delta-ferrite content of products from austeniticsteel or austenitic steel castings as well as austenitic claddingsof extruded composite tubes shall be in accordance with oneof the following methods:

a) metallographic analysis of the as-delivered condition,

b) metallographic analysis of the specimen in which case thebead-on-plate weld test shall be performed on that com-ponent section for which the chemical composition hasbeen determined by product analysis,

c) mathematical estimation in accordance with the De Long[4] procedure from the chemical composition.

(2) The product-form related sections indicate which of thethree models under para (1) a) through c) shall be applied byagreement with the authorized inspector, e.g. the physicalmeasurement methods in accordance with DIN 32 514-1.

(3) If the mathematical estimation results in ferrite numbersbelow 3 or larger than 7, then the delta ferrite content shalladditionally be determined by a metallographic analysis ofthe bead-on-plate test specimen.

(4) Details for performing the methods under para (1) a)through c) are given in Annex D.

(5) In the case of bead-on-plate weld test a liquid penetrantinspection of the melt run shall be performed to detect hotcracks. Indications shall be documented in the quality certifi-cate.

(6) The method shall be documented in the quality certificate.

3.3.7.6 Test for corrosion resistance

In the case of austenitic stainless steels the resistance againstintergranular corrosion shall be demonstrated in accordancewith DIN 50 914.

3.3.7.7 Influence of neutron irradiation

(1) If, in the case of components from ferritic steels, the fluxof fast neutrons integrated over the component’s lifetimeexceeds a certain limit (cf. KTA 3203), test specimens for irra-diation tests shall basically be provided unless these tests canbe dispensed with on the basis of the operational and loadingconditions and the current experience.

Note:The purpose o f these tests is to give advance information on thecondition o f the materials in the corresponding pressure-retainingparts during operation..

(2) The test specimens for these tests shall be taken from theindividual components under examination.

3.3.7.8 Check for dimensional accuracy

(1) After completion of the products, the actual dimensionsshall be documented in an actual-dimension drawing or in anas-built-report. This document shall be available for the accep-tance test at the material manufacturer (final pre-deliverytest).

(2) Dimensional deviations are acceptable only within thelimits specified in the design-review documents.

3.3.7.9 Materials identification check

(1) In the case of batch by batch examination each alloy steelpart shall be subjected to a materials identification check ex-cept for parts which were subjected to a product analysis.

(2) Details regarding this check can be taken from the indi-vidual product-form related sections.

3.3.7.10 Visual inspection

During the acceptance test, all products shall be visually in-spected with regard to their external condition.

KTA 3201.1

3.3.8 Manual non-destructive examinationsNote:(1) The requirements for mechanised test procedures are speci-fied in the product-form-related sections or will be laid down inthe course of design review.(2) Where automated or mechanised non-destructive test meth-ods are used , test instructions shall be prepared on the basis o f anevaluation of the test systems which demonstrate the equivalencyof the test results with those obtained with the described manualmethods.(3) Deviations from the requirements o f this paragraph are per-mitted by agreement with the authorized inspector.


(1) The requirements under Sec. 3.3.8 apply unless deviatingrequirements are specified in the product-form related sections.

(2) Manual ultrasonic and surface crack examinations shallbe performed in accordance with Annex B and C, respec-tively, and the radiographic examination in accordance withDIN 54111-2. Automated or mechanised non-destructive testsshall only be performed if the test instructions have beensubjected to design review.

(3) The entire volume of the product form shall be subjectedto an ultrasonic examination at the material manufacturer’sworks after the last forming and heat treatment in the mostsimple geometric condition, where possible.

(4) If, for reasons of material technology (e.g. reduction ofthe tempering cross-section), a geometry exists after the lastheat treatment that does not permit the examination of theentire volume with the required incidence angles then, byagreement with the authorized inspector, additional exami-nations of these areas of limited examinability shall be per-formed at an earlier point of time during manufacturing whena more advantageous geometric condition exists. This shall beindicated in the test report.

(5) Where weld edges and nozzles are dressed, thesedressed areas shall be subjected to an ultrasonic examinationif the surface is in its final condition and prior to dressing thefusion faces. In this case, the conditions of testing prior towelding shall be considered. In the case of wall thicknesses orsections at the point of connection equal to or greater than30 mm a section width equal to the wall thickness plus 10 mmis considered the weld edge or nozzle area, in the case ofgreater wall thicknesses or sections at the point of connection,a section width equal to the wall thickness plus 20 mm adja-cent to the fusion face or nozzle hole.

(6) The entire accessible surface in its finished conditionshall be subjected to a surface crack examination. Surfaces tobe cladded shall be examined prior to cladding. The surfacesof tapped holes and of tube holes in tubesheets shall not beincluded in this examination. Bevel edges shall be examinedin accordance with KTA 3201.3.

Note:The examination for surface crack detection on parts made o f barsshall be performed on the finished part in its finally dressedcondition.

3.3.8.2 Procedural requirements

3.3.8.2.1 Ultrasonic examination

(1) Condition of examination surfaces

The surfaces to be examined shall be free from interferingdiscontinuities and impurities (e.g. notches, scale, weld spat-

ter, tool marks). Where an opposite face is used as reflectingsurface it shall meet the same requirements as the examina-tion surface.

The root mean square roughness index Ra to DIN 4762 shallnot exceed 20 µm on the examination surface.

(2) Evaluation of indications

Where the boundary conditions of the distance gain (DGS)method as per section B 4.2.1 cannot be satisfied or the DGSmethod cannot be applied due to the sound attenuation of thematerial, the reference echo method to section B 4.3 shall beapplied.

(3) Adjustment of the system

For reference reflectors the following applies:

a) Flat bottom and round bottom holes for sensitivity leveladjustment shall have a diameter of 4 mm.

b) Side-drilled holes for sensitivity level adjustment shallhave a diameter of 3 mm and a length of 30 mm unlessspecified otherwise in the product-form related section.

Where a lateral wall effect occurs, the reference reflectormethod with a flat bottom hole as reference reflector shallpreferably be used. This reference reflector may be on the testobject or on a reference block. The reference block diameterand length (for bars) or the wall thickness (for hollow parts)shall not deviate by more than 10 % from the respective testobject dimensions.

During the sensitivity level adjustment the highest soundattenuation values shall be considered for all search units andsound entry directions.

The evaluation of the reflector indication shall be made in dueconsideration of the actual sound attenuation values meas-ured adjacent to the indicated echoes.

(4) Sound beam directions

The total volume shall basically be examined in three direc-tions vertical to one another by means of straight-beam scan-ning unless specified otherwise in the product-form relatedsections.

Where straight-beam scanning is not possible for geometricreasons each impracticable straight-beam scanning directionshall be substituted by two opposite angle-beam scanningdirections on the respective surface.

(5) Recording limits

a) When applying the DGS method the limit values applywhich depend on the nominal wall thickness or bar diame-ter, width or side length and have been specified in theproduct-form related sections.

b) When applying the reference reflector method with thereference reflectors to Figure B-1 all indications shall be re-corded the echo amplitude of which is equal to or exceeds50 % of the echo amplitude of the reference reflector.

c) The following shall be recorded additionally:

ca) for product forms with nominal wall thicknesses orbar/rod diameters equal to or greater than 10 mm, alllocations where the amplitude of the back reflectionfalls down to the recording limit,

cb) all locations with a concentration of echo indicationslower than the recording limit, which cannot be re-solved into single echo indications for one search unitposition or in the case of search unit displacement, orwhich cannot be clearly correlated to the sound beamangles used,

KTA 3201.1

cc) locations where the signal-to-noise ratio is less than6 dB with respect to the recording limit.

(6) Acceptance limitsThe acceptance limits are laid down in the product-form re-lated sections. In addition, the following applies:a) Reflections from regions which will definitely not be re-

moved during finish-machining shall not be considered,but recorded only. All echo indications from the structureshall not be part of the evaluation but shall be recorded inthe test record.

b) Where during straight-beam scanning using the DGSmethod liable-to-record echo indications of reflections arefound in the area of lateral wall effect influence, these in-dications shall be verified by means of straight-beamscanning using the reference reflector method or by meansof purposive angle beam scanning.Where the area of lateral wall effect is omitted due to thecutting-to size of the test object, this condition shall pref-erably be re-examined. The results of the re-examinationshall be considered in the evaluation.

c) In regions with signal-to-noise ratios smaller than or equalto 6 dB, or if the back-wall echo falls down to the record-ing limit for which no explanation is found, examinations(e.g. sound attenuation measurements) shall be made byagreement with the authorized inspector which make adecision on the usability of the component possible.

d) Where the acceptance limits are exceeded or reflectorindications below the recording limit accumulate whichcannot be resolved into single echo indications for onesearch unit position or in the case of search unit displace-ment, or which cannot be clearly correlated to the soundbeam angles used, supplementary examinations (e.g. byscanning in different directions) shall be performed.Where these examinations (e.g. by loss of intensity of asignal compared to product areas free from indications)show planar discontinuities or systematic defects, these lo-cations shall not be accepted.

e) In the case of test objects with a wall thickness exceeding15 mm, the reference reflector method with a rectangularnotch of 1 mm depth as reference reflector may be used forsensitivity level adjustment for near-surface areas.

f) Where for the purpose of actual flow size determinationsophisticated ultrasonic examination methods are to beused, the procedural requirements shall be laid down byagreement with the authorized inspector.

Note:Ultrasonic examination techniques for a more exact flaw sizedetermination are:

a) manual time-of flight evaluation,

b) ALOK technique (distance-amplitude-location curves),

c) acoustic holography,

d) SAFT (Synthetic Aperture Focusing Technique),

e) sector and compound scanning with phased arrays,

f) combination of ALOK and phase array methods,

g) electrodynamically induced surface waves and tangentiallypolarised transverse waves.

(7) Checking of couplingWhere the coupling cannot be checked by other means duringmanual examinations (e.g. by observation of a back wallecho), the gain shall be increased such that the backgroundnoise becomes visible.

(8) Size of ReflectorsWhere laminar or planar indications are permitted at thelocation of indication and no other requirements apply, thereflector size is determined from that probe movement where,depending on the wall thickness,

a) for wall thicknesses smaller than or equal to 10 mm theecho amplitudes correspond to the registration limit

or

b) for wall thicknesses exceeding 10 mm up to and including40 mm the echo amplitudes have dropped 6 dB below therecording limit

or

c) for wall thicknesses exceeding 40 mm the echo amplitudeshave dropped up to 12 dB below the recording limit.

Where the background noise is reached, the reflector size isdetermined by the locations where the echo disappears in thebackground. If the reflector size is the determining factor forits acceptability, additional examinations shall be performed(cf. Sec. B 5.2.4) to increase the accuracy of the reflector sizemeasurement. Reflectors with dimensions smaller than 10 mmshall be considered to be local indications.

3.3.8.2.2 Surface crack examination

(1) The arithmetical mean roughness height rating Ra de-termined in accordance with DIN 4762 shall not exceed thefollowing values depending on the process of surface treat-ment:

Surface finish Ra in µm

unmachined surfaces 20

machined surface 10

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

(3) When subjecting large areas to a magnetic particle ex-amination, the yoke magnetization method shall preferably beused. Small parts shall be examined, if practicable by means ofthe auxiliary or coil technique.

3.3.8.2.3 Radiographic examination of castings

Requirements for performing radiographic examinations ofcastings are specified in DIN 54 111-2 as well as in Secs. 25.6and 27.6.

3.3.8.3 Examinations by the authorized inspector

In the case of manual ultrasonic examinations, the authorizedinspector shall perform these tests independently of the ma-terial manufacturer. In the case of radiographic examinationshe shall make random checks regarding the performance ofthe tests and evaluate the radiographs. In the case of surfacecrack examinations he shall be present when the materialmanufacturer performs the examination and shall evaluatethe results.

3.3.8.4 Comparison of the test results

After completion of each test step, the authorized inspectorshall check the test reports of the individual testing agencieswith respect to deviations inherent to the testing procedure. If

KTA 3201.1

the values are within the specified limits, this shall be certifiedby the authorized inspector on the test reports of the testingagencies.

3.3.8.5 Procedure in case of deviations

(1) Where essential deviations are found in the ultrasonicexamination test reports of the various testing agencies, addi-tional control checks shall be performed.

(2) Where the indication limits specified in the followingproduct-form related sections are exceeded, a decision as tothe further use of the examined product shall be made byagreement with all parties concerned.

3.3.8.6 Test reports


All test reports on non-destructive examinations shall becomepart of the Acceptance Test Certificate 3.1.C in accordancewith DIN EN 10 204. The test reports shall contain all datarequired for any possible reference examination.

3.3.8.6.2 Manual ultrasonic examinations

(1) The examinations performed by several parties shall bedocumented either

a) in a mutual test report by all parties:

In this case and, provided the same examination tech-niques are used and the same results are achieved, thematerial manufacturer shall prepare the test report whichis then countersigned by all parties. If different examina-tion techniques are used or different results are achieved,the test report of the material manufacturer may be sup-plemented accordingly instead of preparing an individualtest report.

or

b) in individual test reports by each party:

In this case the authorized inspector shall certify that thereis sufficient correspondence between the individually re-corded test reports.

(2) Test results of similar test objects which are correlated tosimilar test instructions may be documented in collective testreports.

3.3.8.6.3 Surface crack examination

(1) No test reports are required in the case of magnetic par-ticle or liquid penetrant examinations where no or only al-lowable indications are found. In this case, the performance ofthe examination shall be documented by the parties con-cerned in the test sequence and examination plan by stamp-ing. With this procedure the following shall become evident:a) the test object (if applicable, the test section),b) the test or procedural instruction on which the test is

based,c) the operator (e.g. personal stamp or stamp and signature

abbreviation),d) the date and time of the test.

(2) In the case of non-allowable indications, the materialmanufacturer shall prepare a test report which shall be coun-tersigned by the parties concerned.

3.3.8.6.4 Radiographic examination

The material manufacturer shall prepare the test report. Thetest results shall be countersigned. Deviating evaluations shallbe noted and marked by the authorized inspector in the re-spective column.

3.4 Re-examinations

(1) Test results that are based on incorrect taking or prepa-ration of the test specimens (test specimen sets), on incorrectperformance of the test or on a random narrow flaw locationin one test specimen are invalid. The examination shall berepeated.

(2) If the test results of a properly performed examinationdo not meet the requirements, the further procedure is asfollows:

a) Lot examination

aa) The piece from which the inadequate test specimen(test specimen set) were taken shall be excluded fromthe lot. It shall be replaced by two other pieces fromthe lot which shall both be subjected to the requiredexaminations.

ab) The examination is considered successful if the resultsof the re-examination meet the requirements.

ac) The lot shall be rejected if the results of both re-examinations do not meet the requirements. However,each individual piece of the lot may be subjected to arenewed test regarding the specific property found tobe inadequate.

b) Individual examination

ba) For each inadequate test specimen (test specimen set)the re-examination shall be carried out on two addi-tional test specimen (test specimen sets) taken fromthe same location.

bb) The test results of both re-examinations shall meet therequirements.

(3) If the cause for the inadequacy of an examination can beremoved by a corresponding heat treatment, the heat treat-ment may be carried out with the test unit to be subsequentlysubmitted for re-examination.

(4) The cause for the inadequacy of the first examinationshall be examined.

3.5 Identification marking of the product forms

(1) All product forms shall be marked clearly, durably, asnotch-free as possible and such that an unambiguous correla-tion to the test certificates is possible at all times.

(2) The identification marking shall contain the followinginformation:

a) identification of the material manufacturer,

b) material identification,

c) melt number,

d) test specimen number,

e) head and tail location,

f) location of the neutral axis,

g) certification stamp of the authorized inspector,

h) major direction of forming.Note:Further details on identification mark ing are contained in Sec.11.2.1 KTA 3201.3.

KTA 3201.1

3.6 Documentation

(1) Details regarding the required test certification arespecified in the product-form related sections.

(2) All test documents including acceptance test documentsand the heat treatment records shall be compiled and checkedfor completeness by the material manufacturer and shall bepresented to the authorized inspector for his preparation ofthe inspection certificate.

4 Seamless hollow parts, forged or rolled

4.1 Scope

(1) This section applies to the following forged or rolledproduct forms from quenched and tempered steel:

a) seamless cylindrical rings without discontinuities for shellsections as well as seamless, non-cylindrical hollow partsand

b) seamless cylindrical rings for flanges and end (head) rein-forcements.

(2) For seamless hollow parts for forged, rolled or pressednozzles Section 5 applies.

(3) The requirements for the materials for these productforms are specified in Sec. A 1.

4.2 Requirements

The requirements under Sec. 3.2.4.2 shall apply.

4.3 Tests and examinations

4.3.1 Specimen-taking locations


(1) Product forms with a tempering length exceeding3000 mm shall be tested at the head and tail ends. One of thesetwo ends shall be subjected to the major examination in ac-cordance with clause 4.3.2.2.1.

(2) Tests performed on the other end serve to demonstratepost-tempering uniformity of the material characteristics (cf.Clause 4.3.2.2.2) The extent of tests on this end is reduced withrespect to the tests on the other end.

(3) The end at which the extend of tests may be reducedshall be specified in the initial material appraisal.

(4) Products with a tempering length between 1500 mm and3000 mm may be tested on only one end provided, theauthorized inspector agrees and the material manufacturerhas demonstrated the post-tempering uniformity of the mate-rial characteristics unless specified otherwise in the initialmaterial appraisal.

(5) Products with a tempering length equal to or less than1500 mm need to be tested on only one end unless specifiedotherwise in the initial material appraisal. This also applies iftwo or more components are to be fabricated from thequenched and tempered product.

(6) If tests on transverse test specimens are specified in thefollowing sections, however, the fibre direction on the productcannot be unambiguously identified, it is permitted to usetangential test specimens in the tests instead of the transversetest specimens.

4.3.1.2 Special requirements for seamless hollow, cylindri-cal rings without discontinuities for shell sections

(1) In the case of product forms with a clear tempering di-ameter exceeding 2000 mm , the test coupons shall be takenfrom the end faces at three locations offset by 120 degrees toeach other.

(2) In the case of product forms with a clear tempering di-ameter equal to or less than 2000 mm, the test coupon shall betaken from the end faces at two locations offset by 180 degreesto each other. Where the test coupons are taken at the headand tail ends, they shall be taken from locations that are offsetby 90 degrees with respect to the specimen-taking locations atthe opposite end.

(3) The test specimen shall be taken from locations at adepth of at least one quarter of the quenched and temperedwall thickness but not deeper than 80 mm beneath the cylin-drical surface, and at least one half of the quenched and tem-pered wall thickness but not deeper than 160 mm beneath theend face surface leveled for heat treatment. Thermal bufferingmay be applied.

4.3.1.3 Special requirements for seamless cylindrical ringsfor flanges and head (end) plate reinforcements

(1) This section applies to product forms with a temperingdiameter exceeding 2000 mm and a quenched and temperedwall thickness exceeding 320 mm.

(2) Depending on the form of the product or the method ofproducing it from the initial material block, the test couponsshall be taken in accordance with Figure 4-1

- from the end faces of the ring (head or tail end),

- from the punched-out metal discs taken after the temper-ing process

or

- from beneath the inner or outer circumferential surfacenear the head or tail end.

(3) The test coupons for the major test in accordance withclause 4.3.2.2.1 and for the tests to demonstrate uniformity ofmaterial characteristics over the height of the product in ac-cordance with clause 4.3.2.2.2 shall be taken such that the topand bottom end of the initial material block are included.

(4) The specimen-taking locations shall be at least 80 mmunder the individual tempering surface. Thermal bufferingmay be employed.

(5) If the test for verifying the NDT temperature in accor-dance with clause 3.2.4.2 does not show the required values atthe above mentioned depths of the specimen-taking locations,then the verification of these values shall be carried out for adepth t under the cylindrical tempering surface and a depthof 2t under a tempering surface perpendicular to the former.The value t is equal to the tempering allowance for the pro-duct, however, at least 20 mm.

4.3.2 Extent of testing


4.3.2.1.1 Ladle analysis

(1) In the case of products manufactured from a single heat,the ladle analysis shall be performed. Heats of materials forbelt-line components shall additionally be analysed for cobaltand tantalum.

KTA 3201.1

(2) In the case of products manufactured from more thanone heat, the calculated average chemical composition shall bespecified.

fe

c

a b

d

80

80

contour for tempering

80

uniformity test

8080

thermal bufferingdelivery condition major test

if required

80

80

80

80

80

80

80

80

80

80

80

8080

80

80

80

80

80

80

(dimensions in mm)

Figure 4-1: Examples of specimen-taking locations in case ofproducts in accordance with clause 4.3.1.3

4.3.2.1.2 Product analysis

(1) On each product (piece) a product analysis shall be per-formed for one specimen-taking location each at both thehead and the tail end. If the product form is required to betested on only one end, then the product analysis is required,likewise, for only one end.

(2) Additional product analyses, e.g. on the shell surface ofthe product, may be specified during the initial material ap-praisal.

(3) The content of carbon, manganese, phosphorus andsulphur shall be determined for all remaining specimen-taking locations in accordance with Sec. 4.3.1.

4.3.2.2 Tests on specimens subjected to simulation heattreatment

4.3.2.2.1 Major test

(1) Tensile testTwo transverse test specimens from each specimen-takinglocation shall be subjected to a tensile test in accordance withclause 3.3.7.3 (1), one at room temperature and one at designtemperature. In addition, one perpendicular test specimenfrom one specimen-taking location shall be tested at roomtemperature.

(2) Test for reduction of area on perpendicular testspecimens

Three perpendicular test specimens shall be taken from onespecimen-taking location. Initially only one test specimenshall be tested. If the value of the reduction of area is largerthan the specified average, then the requirements shall beconsidered to have been met. If the value is smaller than thespecified average, the remaining two test specimens shall betested.

(3) Impact test

One set of transverse test specimens from each specimen-taking location shall be subjected to an impact test in accor-dance with clause 3.3.7.3 (2) at 0 °C, 33 °C and 80 °C. In thecase of product forms intended for belt-line components, thetest at 33 °C shall be replaced by a test at 21 °C.One set each of longitudinal and of perpendicular test speci-mens from one specimen-taking location shall be subjected toan impact test in accordance with clause 3.3.7.3 (2) at 0 °C.

(4) Impact-energy-versus-temperature curveAn impact-energy-versus-temperature curve in accordancewith clause 3.3.7.3 (3) shall be plotted using transverse testspecimens from one specimen-taking location.

(5) Nil-ductility transition temperatureThe NDT temperature shall be determined in accordance withclause 3.3.7.3 (4) on longitudinal or transverse test specimensfrom one specimen-taking location. At least eight test speci-men shall be kept ready for these tests.It shall be shown on two longitudinal or transverse testspecimens from each of the other specimen-taking locationsthat they meet the requirements regarding the NDT tempera-ture.If this cannot be shown then the NDT temperature shall bedetermined for each specimen-taking location.

(6) Fracture mechanics related testsUnder consideration of the product form and the materialemployed suitable fracture mechanics related characteristics

KTA 3201.1

shall be determined (e.g. the KIc value characteristic of thefracture toughness). The materials 22 NiMoCr 3 7 and20 MnMoNi 5 5 are exempted from this test because the lowerlimit curve of the expected values is well known for thesematerials.

(7) Metallographic examinationsThe secondary grain size shall be determined from longitudi-nal cross sections on one notch-bend test specimen from eachspecimen-taking location, in each case, the microstructureshall be evaluated and documented in accordance with clause3.3.7.4.

4.3.2.2.2 Test to demonstrate uniformity of materialcharacteristics

(1) Tensile test

Two transverse test specimens from each specimen-takinglocation shall be subjected to a tensile test in accordance withclause 3.3.7.3 (1), one at room temperature and one at designtemperature.


Three perpendicular test specimens shall be taken from onespecimen-taking location. Initially, only one test specimenshall be tested. If the value of the reduction of area is largerthan the specified average then the requirements shall beconsidered to have been fulfilled. If the value is smaller thanthe specified average, the remaining two test specimens shallbe tested.

(3) Impact test

One set of transverse test specimens from each specimen-taking location shall be subjected to an impact test in accor-dance with clause 3.3.7.3 (2) at 0 °C.

(4) Nil-ductility transition temperature

In the case of product forms intended for belt-line compo-nents, it shall be shown on two longitudinal or transverse testspecimens from one specimen-taking location that they meetthe requirements for the NDT temperature in accordance withclause 3.3.7.3 (4).

(5) Metallographic examinations

The secondary grain size shall be determined from longitudi-nal cross sections on one impact test specimen from eachspecimen-taking location, and the microstructure shall beevaluated and documented in accordance with clause 3.3.7.4.

4.3.2.3 Tests on production control test coupons

(1) General requirements

From each specimen-taking location, test coupons shall betaken for tests on production control test coupons. The testsshall be performed for each product, however, for only onespecimen-taking location. The remaining test coupons shall bestored in the as-removed condition.

No tests on production control test coupons are required forproducts from the steel 20 MnMoNi 5 5, provided, the impacttest on simulation heat treated transverse test specimensdemonstrates that the smallest value of the impact energyabsorbed at 0 °C is equal to or greater than 68 J. However,tests on productions control test coupons are always requiredfor products intended for the reactor pressure vessel.

(2) Tensile test

Two transverse test specimen shall be subjected to a tensiletest in accordance with clause 3.3.7.3 (1), one at room tem-perature and one at design temperature.

(3) Impact test

One set of transverse test specimens shall be subjected to animpact test in accordance with clause 3.3.7.3 (2) at 0 °C.

(4) Impact energy-versus-temperature curve

An impact-energy-versus-temperature curve in accordancewith clause 3.3.7.3 (3) shall be plotted using transverse testspecimens.

In the case of products from the steel 20 MnMoNi 5 5 notintended for belt-line components, it will suffice to performthe test at 33 °C and 80 °C.


It shall be demonstrated by two longitudinal or transverse testspecimens that the requirements for the NDT temperature inaccordance with clause 3.3.7.3 (4) are met. In the case of prod-ucts intended for belt-line components, the exact NDT tem-perature shall be determined. At least eight test specimensshall be prepared for this test.


(1) To prove the uniformity of quenching and tempering asufficient number of hardness tests shall be performed inaccordance with clause 3.3.7.2.

(2) In the case of products with a length equal to or greaterthan 3000 mm or a clear diameter equal to or greater than2000 mm, hardness tests shall be performed on both end facesand on the circumferential surface in a grid with a maximumgrid size of 1000 mm by 1000 mm.

4.4 Non-destructive examinations

The requirements under clause 3.3.8 and 5.4 shall apply to thenon-destructive examinations.

4.5 Visual inspection

The requirements under clause 3.3.7.10 shall apply to thevisual inspection.

4.6 Check for dimensional accuracy

The requirements under clause 3.3.7.8 apply to the dimen-sional accuracy check.

4.7 Proof of the quality

The results of the tests and examinations in accordance withclauses 4.3.2.1, 4.3.2.2.1 (7), 4.3.2.2.2 (5) and 4.3.2.4 shall becertified by Acceptance Test Certificates 3.1.B in accordancewith DIN EN 10 204, the results of all the other tests by Accep-tance Test Certificates 3.1.C in accordance withDIN EN 10 204.

KTA 3201.1

5 Seamless hollow parts for nozzles, forged, rolled orpressed

Note:This section does not apply to set-on nozzles on the secondaryshell o f the steam generator. Requirements for this case arespecified in KTA 3211.1.

5.1 Scope

The requirements regarding materials for these product formsare specified in Section A1.

5.2 Requirements

The requirements under clause 3.2.4.2 apply.



(1) A quenched and tempered product with a finishedlength equal to or smaller than 1500 mm shall be tested fromone end face, and with a finished length exceeding 1500 mmfrom both end faces. The number of nozzles fabricated fromthis product is not considered.

Note:Finished length means fabrication length minus length o f the testcoupon. The fabrication length is the length o f the product duringquenching and tempering.

(2) Examples for specimen-taking locations are shown inFigure 5-1.

(3) If the quenched and tempered product is used for thefabrication of nozzles with an inside diameter less than450 mm in the finished condition, only one test coupon needsto be taken from each end face to be tested. In the case thatboth end faces are to be tested, the specimen-taking locationsat opposite ends should be offset by 180 degrees to each other.

(4) If the quenched and tempered product is used for thefabrication of nozzles with an inside diameter < 450 mm in thefinished condition, two test coupons shall be taken from eachend face to be tested. The specimen-taking locations on thesame end face shall be offset by 180 degrees to each other. Inthe case that both end faces are to be tested, the specimen-taking locations at opposite ends should be offset by 90 de-grees to each other.

(5) In the case of combination of forged set-in nozzles, thetest specimens shall be taken at that cross section that is rele-vant to the tempering process. With regard to test specimenlocation, the requirements under this section apply.

(6) The specimen-taking locations shall be at a depth of atleast one quarter of the quenched and tempered wall thick-ness but not deeper than 80 mm beneath the cylindrical sur-face, and at least one half of the quenched and tempered wallthickness but not deeper than 160 mm beneath the end facesurface levelled for heat treatment. Thermal buffering may beapplied.

(7) If the taking of transverse test specimens is impossible orin the case of products for the fabrication of nozzles with aclear diameter of less than 450 mm, longitudinal test speci-mens may be used instead of the transverse test specimensspecified in the following sections.




For each melt a ladle analysis shall be performed.


(1) On each product (piece) a product analysis shall be per-formed for one specimen-taking location at one end face.

(2) Where a product analysis is required for both ends, thecontent of carbon, manganese, phosphorus, and sulphur shallbe determined for one specimen-taking location at the oppo-site end face.

5.3.2.2 Tests on test specimens subjected to simulationheat treatment

(1) Tensile testTwo transverse test specimens from each specimen-takinglocation shall be subjected to a tensile test in accordance withclause 3.3.7.3 (1), one at room temperature and one at designtemperature.In the case of tempered products for the fabrication of nozzleswith an inside diameter equal to or greater than 450 mm inthe finished condition, one perpendicular test specimen fromone specimen-taking location shall additionally be tested atroom temperature.


Three perpendicular test specimens shall be taken from onespecimen-taking location. Initially only one test specimenshall be tested. If the value of the reduction of area is largerthan the specified average then the requirements shall beconsidered to have bee fulfilled. If the value is smaller thanthe specified average, the remaining two test specimens shallbe tested.

(3) Impact testOne set of transverse test specimens from each specimen-taking location shall be subjected to an impact test in accor-dance with clause 3.3.7.3 (2) at 0 °C.Additionally, one set of transverse test specimens from onespecimen-taking location at each end face shall be subjected toan impact test at 33 °C and at 80 °C.In the case of tempered products for the fabrication of nozzleswith an inside diameter equal to or greater than 450 mm inthe finished condition, one set of longitudinal and of perpen-dicular test specimens from one specimen-taking locationshall be subjected to an impact test at 0 °C.

(4) Impact energy-versus-temperature curveAn impact-energy-versus-temperature curve in accordancewith clause 3.3.7.3 (3) shall be plotted using transverse testspecimens from one specimen-taking location. The tests de-scribed in para (3) may be performed.

(5) Nil-ductility transition temperatureIt shall be shown on two longitudinal or transverse testspecimens from one specimen-taking location that they meetthe requirements regarding the NDT temperature in accor-dance with clause 3.3.7.3 (4).

(6) Metallographic examinationsThe secondary grain size shall be determined from longitudi-nal cross sections on one impact test specimen from each

KTA 3201.1

specimen-taking location and the microstructure shall beevaluated and documented in accordance with clause 3.3.7.4.


In the case of quenched and tempered products with a lengthequal to or greater than 3000 mm, hardness measurementsshall be performed on both end faces in the middle of the wallthickness and on the circumferential surface along a generatorbeginning at the edge and at distances not exceeding1000 mm.

5.3.2.4 Tests on production control coupons


From each specimen-taking location test specimens shall betaken for tests on production control test coupons. The testsshall be performed for each product, however, for only onespecimen-taking location. The remaining test coupons shall bestored in the as-removed condition.

If the product is used for the fabrication of several nozzlesthat are used in different component groups and are sepa-rately subjected to stress relief heat treatment, one set of pro-duction control test coupons shall be prepared from the pro-duct for each component group.

No tests on accompanying test coupons are required forproducts from the steel 20 MnMoNi 5 5, provided the impacttest on simulation heat treated transverse test specimensdemonstrates that the smallest value of the impact energyabsorbed at 0 °C is not less than 68 J. However, tests on pro-duction control test coupons are always required for productsintended for the reactor pressure vessel.

(2) Tensile test

Two transverse test specimens shall be subjected to a tensiletest in accordance with clause 3.3.7.3 (1), one at room tem-perature and one at design temperature.

(3) Impact test

One set of transverse test specimens shall be subjected to animpact test in accordance with clause 3.3.7.3 (2) at 0 °C.


In the case of products for the fabrication of nozzles with aninside diameter equal to or greater than 450 mm in the fin-ished condition, an impact-energy-versus-temperature curvein accordance with clause 3.3.7.3 (3) shall be plotted usingtransverse test specimens.

In the case of products from the steel 20 MnMoNi 5 5, it issufficient to perform the test at 33 °C and 80 °C.


It shall be shown on two longitudinal or transverse testspecimens that they meet the requirements regarding theNDT temperature in accordance with clause 3.3.7.3 (4).



The following requirements shall apply to manual examina-tions and supplement the requirements under clause 3.3.8.

5.4.2 Ultrasonic examinations

5.4.2.1 Sound attenuation measurements

For wall thicknesses equal to or greater than 200 mm soundattenuation measurements shall be made on three generators

offset by 120 degrees at least at three measuring points with adistance of not more than one metre. Where during straight-beam scanning no essential local deviations (signal-to-noiseratio equal to or less than 6 dB), the number of measurementsmay be reduced for angle-beam scanning.

5.4.2.2 Sound-beam angles

(1) All products shall be examined by the straight-beammethod from one shell surface and from both end faces, andby the angle-beam method from one cylindrical surface inboth circumferential directions. Those regions which are notreached by the end-face straight-beam examination (e.g.cones) or where recordable conditions from the straight-beamexamination with side-wall effects have to be evaluated shallbe examined by the angle-beam method from one cylindricalsurface in both axial directions.

(2) If necessary to achieve the required measuring accuracy,the examination shall be performed from both cylindricalsurfaces.

5.4.2.3 Recording limits

(1) All echo amplitudes that are equal to or exceed the val-ues specified in Table 5-1 shall be recorded.

(2) In the case of the sound attenuation measurements, anysound attenuation shall be recorded that is over 4 dB/m whentesting at 2 MHz or over 10 dB/m when testing at 4 MHz.

5.4.2.4 Acceptance standards


(1) The distance between the finished surface and the reflec-tors that lead to a recordable echo shall not be less than thevalues specified in Table 5-2.

(2) All recordable reflexions from the angle-beam examina-tion that do not exceed the recording limits in the straight-beam examination shall be subjected to a detailed examinationregarding their orientation. Indications which extend in thedirection of depth are unacceptable.

5.4.2.4.2 Additional requirements

(1) Regions of weld edges and nozzles

Unacceptable indications are:

a) indications from laminar reflectors,

b) straight-beam examination echoes with an amplitude thatis 12 dB over the recording limit.

Indications that are recordable both in the straight-beam andthe angle-beam examination are acceptable only up to an echoamplitude of 6 dB above the recording limit for the angle-beam examination.

Depending on the nominal wall thickness, the maximumacceptable frequency of all recordable echoes shall not exceedthe values specified in Table 5-3.

The smallest distance between reflexions shall not be less than100 mm.

(2) Other volumetric areas

Local indications found in the straight-beam examination inradial direction are acceptable if their echo amplitudes are upto 18 dB above the recording limit in accordance with Table5-1. Depending on the maximum echo amplitude, indicationswith lengths in accordance with curve 1 of Figure 5-2 are

KTA 3201.1

acceptable provided the amplitudes of the correspondingangle-beam echoes for these locations are less than 6 dB abovethe recording limit. However, the maximum acceptable reflec-tor length is 120 mm.Local indications found in the straight-beam examination inaxial direction are acceptable if their echo amplitudes are upto 12 dB above the recording limit. Depending on the maxi-mum echo amplitude, indications with lengths in accordancewith curve 2 of Figure 5-2 are acceptable provided the ampli-tudes of the corresponding angle-beam echoes for these loca-tions are less than 6 dB above the recording limit. However,the maximum acceptable reflector length in circumferentialdirection is 60 mm. Indications which extend more than10 mm in the direction of depth are unacceptable.The frequency of indications shall locally not be higher than10 per square metre with respect to the surface area and nothigher than 5 per square metre with respect to the total sur-face area.

5.4.3 Surface crack examinations

(1) The frequency of acceptable indications shall locally notbe higher than 10 per square decimetre and, with respect to theentire surface area, not higher than 5 per square decimetre.

(2) Additionally, the requirements under Tables 5-4 and 5-5apply.


The requirements under clause 3.3.7.10 apply to the visualinspection.


The requirements under clause 3.3.7.8 apply to the check fordimensional accuracy.


The results of the tests in accordance with clauses 5.3.2.1,5.3.2.2 (6), and 5.3.2.3 shall be certified by Acceptance TestCertificate 3.1.B in accordance with DIN EN 10 204, the resultsof all other tests by Acceptance Test Certificate 3.1.C in accor-dance with DIN EN 10 204.

Nominal wallthickness s

Diameter of the respective circular diskreflector, mm

in final condition,mm

Straight-beamscanning

Angle-beamscanning

s ≤ 15 1.5 1

15 < s ≤ 30 1.5 1.5

30 < s ≤ 60 2 2

60 < s ≤ 120 3 3

120 < s ≤ 250 4 1) 2) 3

s > 250 6 1) 2) 31) These values only apply if observation of the back wall echo is

possible; otherwise the same value as for angle-beam scanningapplies.

2) Where welding edge zones are examined, the same value as forangle-beam scanning applies.

Table 5-1: Recording limits for the ultrasonic examination offorgings

≥

<

>

=

< ≥

≤

≤

=T

450 mmiD450 mm

tempering contour

D

test coupon

delivered contour

450 mm

450 mm

tempering thicknessDi

D

D

inside diameter

i

i

i

T/2

1500

1500

T/4

T/4

T/2

D

T

T/4

T/4

i

iD

T

1. finished length

0˚

180˚

2. finished length > 1500

1500

90˚

180˚

0˚0˚

270˚

0˚180˚

Figure 5-1: Examples for specimen-taking locations

KTA 3201.1

curve 2

allowable

12

6

curve 1

0

0

0.5

length

1.0

max.

max

.ech

ohe

ight

60 mmmax.

120 mm

[dB

]18

length of indication related to the

beyo

ndth

ere

cord

ing

limit

toTa

ble

5-1

nominal wall thickness in the final condition

Figure 5-2: Allowable lengths of indications and echo heightsfor ultrasonic examination

Nominal wall thickness s in finalcondition, mm

Minimum distance,mm

s ≤ 40 5

40 < s ≤ 80 10

s > 80 20

Table 5-2: Minimum distance of recordable locations fromthe finished surface

Nominal wall thickness s in finalcondition, mm

Frequency per meter

s ≤ 10 0

10 < s ≤ 120 2

120 < s ≤ 250 4

s > 250 6

Table 5-3: Allowable frequency of recordable indications inwelding edge and nozzle regions

Indications≤ 3 mm,individual

RoundIndications> 3 mm upto ≤ 6 mm

RoundIndications> 6 mm

Linearindications 1)

> 3 mm

Acceptable

not to beincluded inthe evalua-tion

Acceptable

to be in-cluded inthe fre-quency

Unacceptable Unacceptable

Where it isshown that theindications arecaused by non-metallic inclu-sions, indications≤ 6 mm are ac-ceptable andshall be includedin the frequency.

1) A liquid penetrant indication is considered to be linear (linearindication) if the length of the largest dimension is at least threetimes the smallest length in transverse direction.

Table 5-4: Evaluation basis for liquid penetrant examination

Indications≤ 1.5 mmindividual

Indications> 1.5 mm upto ≤ 6 mm,caused bynon-metallicinclusions

Indications> 6 mm

LinearIndications> 1.5 mm

Acceptable

not to beincluded inthe evalua-tion

Acceptable

to be in-cluded inthe fre-quency

Unacceptable Unacceptable

Table 5-5: Evaluation basis for magnetic particleexamination

KTA 3201.1

6 Forged single-piece plates for tubesheets

6.1 Scope

The requirements for the materials for this product form arespecified in Sec. A 1.

Note:During fabrication, when forging these product forms in the fin-ished condition, adequate measures shall be taken to avoid , as faras technically feasible , any positive segregation on surfaces in-tended for weld ing or cladding. Measures to be considered are,e .g., upset forging, forging from the head surface and avoid ingany machining in the segregated zones.

6.2 Requirements

The requirements under Sec. 3.2.4.2 apply.



(1) The specimen-taking locations shall be specified in thecourse of the initial material certification in due considerationof the forging procedure (direction of major deformationeither parallel or normal to the ingot axis).

(2) The plates for tubesheets shall be tested from one endface or on the circumference unless specified otherwise by theinitial material certification.

(3) The test coupons shall be taken from three locations setapart by 120 degrees to each other. The specimen-taking loca-tions shall be at least 80 mm away from any tempering sur-face. The specimen-taking locations are shown in Figure 6-1.

120°

120°

120°

tempering contour

80

80

80

coupon removal

delivery contour

Figure 6-1: Example for specimen-taking locations




For each tubesheet fabricated from a single melt the ladleanalysis shall be performed. In the case of tubesheets fabri-cated from more than one melt, the calculated average chemi-cal composition shall be specified.


(1) For each specimen-taking location a product analysisshall be performed. Where tests are required for only one endface, the product analysis shall additionally be performed onthe other end face for a location that lies opposite to onespecimen-taking location on the initial end face.

(2) If the head and tail end of the ingot are not covered bythis analysis, the chemical composition of these areas shalladditionally be determined.

6.3.2.2 Tests on test coupons subjected to simulation heattreatment

(1) Tensile test

Two transfer or one tangential test specimens from eachspecimen-taking location shall be subjected to a tensile test inaccordance with clause 3.3.7.3 (1), one at room temperatureand one at design temperature.

In addition, one perpendicular test specimen (axial testspecimen) from one specimen-taking location shall be testedat room temperature..


Three perpendicular test specimens shall be taken from onespecimen-taking location. Initially only one test specimenshall be tested. If the value of the reduction of area is largerthan the specified average then the requirements shall beconsidered to have been fulfilled. If the value is smaller thanthe specified average, the remaining two test specimens shallbe tested.

(3) Impact test

One set of transverse or tangential test specimens from eachspecimen-taking location shall be subjected to an impact testin accordance with clause 3.3.7.3 (2) at 0 °C, 33 °C and 80 °C.Additionally, one set each of longitudinal and perpendiculartest specimens from one specimen-taking location shall besubjected to an impact test in accordance with clause 3.3.7.3(2) at 0 °C.

(4) Impact energy-versus temperature curveAn impact-energy-versus-temperature curve in accordancewith clause 3.3.7.3 (3) shall be plotted using transverse ortangential test specimens from one specimen-taking location.The tests described in para (3) may be performed.

(5) Nil-ductility transition temperatureIt shall be shown on two longitudinal or transverse testspecimens that they meet the requirements regarding theNDT temperature in accordance with clause 3.3.7.3 (4).

(6) Metallographic examinationsThe secondary grain size shall be determined from longitudinalcross sections on one impact test specimen from each speci-men-taking location; in each case, the microstructure shall beevaluated and documented in accordance with clause 3.3.7.4.

dimensions in mm

KTA 3201.1

6.3.2.3 Tests on production control test coupons

(1) General requirementsFrom each specimen-taking location, test specimens shall betaken for tests on accompanying test coupons. The tests shallbe performed for each product, however, only for one speci-men-taking location. The remaining test coupons shall bestored in the as-removed condition.

(2) Tensile testTwo transverse or tangential test specimens shall be subjectedto a tensile test in accordance with clause 3.3.7.3 (1), one atroom temperature and one at design temperature.

(3) Impact testOne set of transverse or tangential test specimens shall besubjected to an impact test in accordance with clause3.3.7.3 (2) at 0 °C.

(4) Impact energy-versus-temperature curveAn impact-energy-versus-temperature curve in accordancewith clause 3.3.7.3 (3) shall be plotted using transverse ortangential test specimens.

In the case of products from the steel 20 MnMoNi 5 5, it issufficient to perform the test at 33 °C and 80 °C.

(5) Nil-ductility transition temperatureIt shall be shown on two longitudinal or transverse testspecimens that they meet the requirements regarding theNDT temperature in accordance with clause 3.3.7.3 (4).


(1) The requirements of clause 3.3.7.2 apply to the hardnesstests.

(2) In the case of quenched and tempered products, theuniformity of tempering shall be demonstrated by hardnesstests on both end faces in a grid with a maximum grid size of1000 mm by 1000 mm and on the circumferential surfacealong one generator beginning near the edge and continuingat distances of not more than 1000 mm.



The following requirements apply to manual examinationsand supplement the requirements in accordance with Sec. 3.3.8.

6.4.2 Ultrasonic examinations


At about 10 positions equally distributed over one end face,sound attenuation measurements shall be performed with thestraight-beam method.

6.4.2.2 Sonic probes

In order to achieve the required examination sensitivity in thenear-surface region, special probes may have to be employed.

6.4.2.3 Sound beam angles

Ultrasonic testing shall be performed on both end faces andfrom the shell surface by means of the straight and anglebeam techniques.

For the examination the incidence angles 1 to 15 shown inFigure 6-2 shall be used where the angles 8 to 11 shall also beused from the ring surface.

In the case of angle-beam scanning an incidence angle of70 degrees and in the case of angle beam scanning from theshell surface in circumferential direction however, an angle of35 degrees shall be used.


(1) All indications and echo amplitudes shall be recordedwhere the values are equal to or exceed the values specified inTable 6-2.

(2) In the case of sound attenuation measurements, all at-tenuations larger than 4 dB/m measured at 2 MHz shall berecorded.

(3) In the examinations from the end faces with the straight-beam method, all indications at a depth of not more than 0.6times the plate thickness shall be evaluated.

7

6

3

Primary side

Secondary side

View: primary side

70˚

35˚

35˚

View: secondary side

6

7

2

1511

10

12

13 149

4

2

1

8

70˚

5

Examined contourFinished contour

Figure 6-2: Sound entry directions 1 to 15 for the ultrasonicexamination of forged single-piece plates fortubesheets



The distance between the finished surface and the locationleading to a recordable condition shall not be less than 30 mm.


(1) Weld edges and fusion faces

The requirements under Sec. 5.4.2.4.1 (2) and 5.4.2.4.2 (1) shallapply.

(2) Other volumetric regionsa) Local reflections

In the straight-beam examination in axial direction (beamangles 1 and 2 of Figure 6-2) the following indications areacceptable with the following restrictions:aa) non-laminar indications with echo amplitudes up to

24 dB above the recording limit,ab) laminar indications with echo amplitudes below the

curves in Figure 6-3.

KTA 3201.1

The acceptance of these reflections is based on the condi-tion that in the case of angle-beam scanning from the endfaces (sound entry directions 8 to 15 in Figure 6-2) no echoamplitudes higher than 6 dB above the recording limit areobtained at the respective locations and in the case of an-gle-beam scanning from the shell surface (sound entry di-rection 3 in Figure 6-2) no recordable indications arefound.

In the case of straight-beam scanning from the shell sur-face (sound entry direction 3 in Figure 6-2) the acceptancelimit is 12 dB above the respective recording limit. If thereflections show a longitudinal extension, additional non-destructive examinations shall be performed. All record-able indications obtained by angle-beam scanning whichin the case of straight-beam scanning are not found with arecording limit corresponding to the respective angle-beam scanning method, shall be thoroughly examined fortheir orientation. Indications having an extension in excessof 10 mm in thickness direction are not permitted.

b) Planar indications

Planar indications in the examination zones II and III inaccordance with Table 6-2 occurring during the straight-beam examination from the end face (beam-angle 1 and 2of Figure 6-2) are acceptable up to 12 dB above the record-ing limit provided the sound attenuation in these zonesdoes not exceed 4 dB/m at 2 MHz. If individual indica-tions from regions with accumulated indications exceedthe recording limit by 12 dB, they are only acceptable if thedistance of these indications is greater than twice the di-ameter of the larger of two adjacent reflectors and if thereare not more than three planar indications in the entirevolume.

Note:Planar indications are an accumulation of reflectors where theecho amplitudes cannot be separated anymore on the screen.

c) Acceptable frequencies

The frequencies of the local and planar recordable echoesshall, when projected onto one end face of the tubesheet,not exceed the values specified in Table 6-1.

6.4.3 Surface crack examination

The requirements under Sec. 5.4.3 shall be applied to the sur-face crack examination.


The requirements under Sec. 3.3.7.10 apply to the visual in-spection.


The requirements under Sec. 3.3.7.8 apply to the check fordimensional accuracy.


The results of the tests in accordance with Secs. 6.3.2.1, 6.3.2.2(6) and 6.3.2.4 shall be certified by Acceptance Test Certifi-cates 3.1.B in accordance with DIN EN 10 204, the results of allthe other tests by Acceptance Test Certificates 3.1.C in accor-dance with DIN EN 10 204.

Examination zoneto Table 6-2

Number of recordableindications per m2

I 10

II 25

III 40

Table 6-1: Acceptable frequency of recordable indication

Primary side 0.25

0.1

Examinationzones

Secondary side Finishedcontour

0.1

0.1

0.15

0.25

0.4s

s

ss

s

s

s

s

Diameter of the respective circular diskreflector, mm

Examination zone Iand welded seam

region

Examinationzones II and III

Straight-beamscanning 3 6

Angle-beamscanning 3

Table 6-2: Division into examination zones and recordinglimits for the ultrasonic examination of forgedsingle-piece plates for tubesheets

Zone II Zone III

[ dB

]

Zone I

00

150100

24

12

Max

imum

ech

o am

plitu

de in

exc

ess

ofth

e re

cord

ing

limit

to T

able

6-2

50

Length of indication [ mm ]

6

18

Figure 6-3: Allowable indication lengths and echo amplitudesfor straight-beam examination in axial direction(Sound entry direction 1 and 2 in Figure 6-2) in thecase of forged single-piece plates for tubesheets

Sound entrydirection

KTA 3201.1

7 Sheets and plates

7.1 Scope

The requirements for the materials for this product form arespecified in Sec. A 1.

7.2 Requirements

(1) The requirements under Sec. 3.2.4.2 shall apply.

(2) The tensile strengths determined for different specimen-taking locations of the same plate on similarly positioned andoriented test specimens shall not differ from each other bymore than 80 N/mm2.



(1) The test coupons shall be taken from the middle of thehead and tail end of each plate or of each tempering unit.Plates with a length of less than 5 m and a quenched andtempered wall thickness equal to or less than 200 mm shall betested only at the end. In the case of a quenched and temperedwall thickness exceeding 320 mm, the test coupons on one endshall be taken from the top side of the plate and on the otherend from the bottom side. It is assumed that the direction ofmain deformation lies in the head-to-tail direction of the ingotand that it is possible to identify the head and tail ends of theplate.

(2) In the case of a quenched and tempered wall thicknessequal to or less than 320 mm, the specimen-taking locationshall be at a depth of at least one quarter of the quenched andtempered wall thickness beneath the rolled surface and atleast one half of the quenched and tempered wall thicknessbeneath the end face surfaces levelled for heat treatment. Inthe case of a quenched and tempered wall thickness exceeding320 mm, the specimen-taking locations shall be at a depth ofat least 80 mm beneath the quenched and tempered surface.

(3) If in the following tests at one-half the wall thickness(T/2) are required, then in the case of a quenched and tem-pered wall thickness equal to or less than 320 mm, the speci-men-taking locations shall be at a depth of one half of thequenched and tempered wall thickness beneath the platesurface and at least one half of the quenched and temperedwall thickness beneath the edges levelled for heat treatment ofthe other surface. In the case of a quenched and temperedwall thickness exceeding 320 mm, the test coupons shall betaken from a depth of one half of the quenched and temperedwall thickness under the plate surface and at least 80 mmbeneath the edges levelled for heat treatment of the othersurfaces.

(4) The specimen-taking locations are shown in Figure 7-1.



(1) Ladle analysis

For each melt one ladle analysis shall be performed.

(2) Product analysis

Each plate shall be subjected to a product analysis at eachspecimen-taking location.

≥≥

>

>

≥

>

T

If T > 320 mm, see also Sec. 7.3.1

320 mm

tempering contour

320 mmT

at least 80 mm if

at least 80 mm if

Tail

T/2

T/2

T/4

Test couponRolling andDelivery condition

if necessary, test coupondi

rect

ion

of ro

lling

T: Tempering thickness

for re-examination

Head

320 mm

T

at least 80 mm ifT

Figure 7-1: Example for specimen-taking location on plates

7.3.2.2 Mechanical properties and microstructure


If, during the fabrication of the plates, the direction of mainforming does not clearly lie in the head-to-tail direction of theingot, then in addition to the transverse test specimens calledfor in the following sections, the same number of longitudinaltest specimens from the same specimen-taking location shallbe tested.

7.3.2.2.2 Tests of plates prior to quenching and tempering

In the following cases, the plates shall be tested prior toquenching and tempering:

Case A: If the material manufacturer delivers them to amanufacturer for subsequent fabrication in a condi-tion prior to quenching and tempering, or

Case B: If, in the course of subsequent fabrication, they arecut prior to quenching and tempering and the headand tail end can no longer be correlated to the pieces.

(1) Case A: Tests when plates are delivered prior toquenching and tempering

The tests shall be performed on test coupons that are bothsimulation quenched and tempered and simulation heattreated.

a) Tensile testTwo transverse test specimens from each specimen-takinglocation shall be subjected to a tensile test in accordancewith Sec. 3.3.7.3 (1), one at room temperature and one atdesign temperature. In the case of a quenched and tem-pered wall thickness exceeding 200 mm, an additional test

KTA 3201.1

shall be performed at room temperature on a transversetest specimen taken from the middle of the tail end at adepth of T/2.

b) Test for reduction of area on perpendicular test specimens

Three perpendicular test specimens from each specimen-taking location shall be tested at room temperature todemonstrate the required reduction of area.

c) Impact test

The impact energy shall be tested in accordance with Sec.3.3.7.3 (2) on one set of transverse test specimens at 0 °C.In the case of a quenched and tempered wall thickness ex-ceeding 200 mm, an additional test shall be performed at80 °C on one set of transverse test specimens taken fromthe middle of the head end at a depth of T/2.

d) Metallographic examinations

For each specimen-taking location, one impact test speci-men from the impact test shall be examined on a longitu-dinal polished section with respect to secondary grain size;the microstructure shall be evaluated and documented inaccordance with Sec. 3.3.7.4.

(2) Case B: Tests when plates are cut prior to quenchingand tempering

The tests shall be performed on test specimens that are bothsimulation quenched and tempered and simulation heattreated.

a) Tensile test

Two transverse test specimens from each specimen-takinglocation shall be subjected to a tensile test in accordancewith Sec. 3.3.7.3 (1), one at room temperature and one atdesign temperature. In the case of a quenched and tem-pered wall thickness exceeding 200 mm, an additional testshall be performed at room temperature on a transversetest specimen taken from the middle of the tail end at adepth of T/2.



c) Impact test

On transverse test specimens from one specimen-takinglocation (tail end) the impact energy shall be tested in ac-cordance with Sec. 3.3.7.3(2) at 0 °C, 33 °C and 80 °C. Inthe case of a quenched and tempered wall thickness ex-ceeding 200 mm, an additional test shall be performed at80 °C on one set of transverse test specimen taken from themiddle of the head end at a depth of T/2.

d) Impact energy-versus-temperature curve

On transverse test specimens from one specimen-takinglocation (head end) the impact-energy-versus-temperaturecurve shall be determined in accordance with Sec. 3.3.7 (3).

e) Nil-ductility transition temperature

It shall be shown on two longitudinal or transverse testspecimens from one specimen-taking location (head end)that they meet the requirements regarding the NDT tem-perature in accordance with Sec. 3.3.7.3 (4).

f) Metallographic examinations

For each specimen-taking location, the longitudinal cross-section of one impact-test shall be examined on a longitu-

dinal polished section with respect to secondary grain size,the microstructure shall be evaluated and documented inaccordance with 3.3.7.4.

7.3.2.2.3 Testing of plates after quenching and temperingNote:Plates in accordance with Case B under Sec. 7.3.2.2.2 shall betested at one specimen-tak ing location independent o f the head ortail end correlation.

(1) Tests of simulation heat treated test coupons

a) Tensile test

Two transverse test specimens from each specimen-takinglocation shall be subjected to a tensile test in accordancewith Sec. 3.3.7.3(1), one at room temperature and one atdesign temperature. In the case of a quenched and tem-pered wall thickness exceeding 200 mm, an additional testshall be performed at room temperature on a transversetest specimen taken from the middle of the tail end at adepth T/2.



c) Impact test

On transverse test specimens from one specimen-takinglocation (tail end) the impact energy shall be tested in ac-cordance with Sec. 3.3.7.3 (2) at 0 °C, 33 °C and 80 °C. Inthe case of a quenched and tempered wall thickness> 200 mm, an additional test shall be performed at 80 °Con one set of transverse test specimen taken from themiddle of the head end at a depth of T/2.


On transverse test specimens from one specimen-takinglocation (head end) the impact-energy-versus-temperaturecurve shall be determined in accordance with Sec.3.3.7.3 (3).


It shall be shown on two longitudinal or transverse testspecimens from one specimen-taking location (head end)that they meet the requirements regarding the NDT tem-perature in accordance with Sec. 3.3.7.3 (4).

f) Metallographic examinations

For each specimen-taking location, the longitudinal cross-section of one impact test specimen shall be examined on alongitudinal polished section with respect to secondarygrain size; the microstructure shall be evaluated anddocumented in accordance with Sec. 3.3.7.4.

(2) Test on accompanying test couponsFrom each specimen-taking location, test specimens shall betaken for tests on accompanying test coupons. The tests shallbe performed for each product, however, for only one speci-men-taking location. The remaining test coupons shall bestored in the as-removed condition.If the product is used for the fabrication of multiple productsthat are used in different component groups and are sepa-rately subjected to stress relief heat treatment, one set of ac-companying test coupons shall be prepared from the productfor each component group.No tests on accompanying test coupons are required forproducts from the steel 20 MnMoNi 5 5 provided the impacttest on simulation heat transverse test specimens demon-

KTA 3201.1

strates that the smallest value of the impact energy absorbedat 0 °C is not less than 68 J. However, tests on accompanyingtest coupons are always required for products intended forthe reactor pressure vessel.

a) Tensile test

Two transverse test specimens shall be subjected to a ten-sile test in accordance with Sec. 3.3.7.3 (1), one at roomtemperature and one at design temperature.

Where both transverse and longitudinal test specimenshave to be tested, the test specimens from that orientationshall be tested for which poorer results were obtained onsimulation heat treated test specimens (cf. Sec. 7.3.2.2.1).

b) Impact test

On one set of transverse test specimens the impact energyshall be tested in accordance with Sec. 3.3.7.3(2) at 0 °C (cf.para (2) a) above).

c) Impact energy-versus-temperature curve

Unless specified otherwise by the initial material ap-praisal, the impact-energy-versus-temperature curve shallbe determined in accordance with Sec. 3.3.7.3 (3) on trans-verse test specimens from the head end of the plate (cf.para (2) a) above). In the case of products from the steel20 MnMoNi 5 5 not in close vicinity to the core, it is suffi-cient to perform the test at 33 °C and 80 °C.

d) Nil-ductility transition temperatureIt shall be shown on two longitudinal or transverse testspecimens from one specimen-taking location (head end)that they meet the requirements regarding the NDT tem-perature in accordance with Sec. 3.3.7.3 (4).


(1) The requirements under Sec. 3.3.7.2 apply to hardnesstests.

(2) The hardness of quenched and tempered plates with alength equal to or greater than 3000 mm shall be tested on theplate surface along two lines offset by 90 degrees from eachother, starting close to the plate edge and continuing in lengthintervals of not more than 1000 mm.



(1) The following requirements shall apply to manual ex-aminations and supplement the requirements of Sec. 3.3.8.

(2) Deviating herefrom, the size of the reflector in thestraight-beam examination shall be determined by means ofthe half-value method in accordance with Sec. B 5.2.3.

7.4.2 Ultrasonic examination

7.4.2.1 Extent and point of time of examination

The entire volume of the plane plates shall be examined bymeans of straight-beam scanning upon the final forming proc-ess and prior to subsequent fabrication. This examination canbe omitted if an equivalent examination is performed on thefinal geometry of the product form.


Sound attenuation measurements by means of the straight-beam method shall be performed on a grid of 2 m x 2 m, how-ever, at least on 4 locations of each plate.

In the case of differing surface qualities the number of meas-uring points shall be doubled at least (to be referred to eachsurface condition).

Where the range of the minimum values obtained under thesame beam entry condition exceeds 6 dB (referred to thesound path to be evaluated) the number of measuring pointsshall be doubled at least.


(1) All indications shall be recorded where the echo ampli-tude is equal to or exceeds the values shown in Table 7-1.

Region Platethickness,

mm

Diameter of the circulardisk reflector, mm

Entire volume all 6

s ≤ 40 2

s > 40 3

Table 7-1: Recording limits for straight-beam scanning

(2) In the sound attenuation measurements any sound at-tenuation shall be recorded that is larger than 4 dB/m in ex-aminations with 2 MHz or larger than 10 dB/m in examina-tions with 4 MHz.


(1) Region of weld edges, nozzles and fusion facesRecordable reflexions shall be examined with respect to asubsequent weld examination and be evaluated.Planar indications up to 100 mm2 and with maximum lengthsand frequencies in accordance with Table 7-2 are allowed. Thesmallest distance between indications shall not be less than100 mm.

(2) Other volumetric regionsPlanar indications with up to 1000 mm2 are allowed. Thefrequency of the recordable echoes shall not exceed the valuesspecified in Table 7-3 with respect to wall thickness (nominalwall thickness) of the plate as ordered.


The requirements under Sec. 5.4.3 shall apply to surface crackexaminations.


The requirements under Sec. 3.3.7.10 shall apply to the visualinspection.


(1) The requirements under Sec. 3.3.7.8 shall apply to thecheck for dimensional accuracy.

(2) The thickness shall be checked in a grid of 500 mm by500 mm.


The results of the tests in accordance with Secs. 7.3.2.1,7.3.2.2.2 (1) d, 7.3.2.2.2 (2) f, 7.3.2.2.3 (1) f and 7.3.2.3 shall be

Weld edges, nozzlesand fusion faces

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certified by Acceptance Test Certificate 3.1.B in accordancewith DIN EN 10 204, the results of all the other tests by Accep-tance Test Certificate 3.1.C in accordance with DIN EN 10 204.

Ordered wall thick-ness s (nominalthickness), mm

Allowable length,mm

Maximum allow-able frequency

per metre

s ≤ 10 0

10 < s ≤ 20 20 2

20 < s ≤ 40 25 2

40 < s ≤ 60 30 2

60 < s ≤ 120 40 2

120 < s ≤ 250 40 4

s > 250 40 6

Table 7-2: Allowable frequency and length of recordableindication in weld edge and nozzle regions

Ordered wall Maximum allowable frequency

thickness s (nominalthickness), mm

locally per m2 referred to entiresurface per m2

s ≤ 120 3 2

120 < s ≤ 250 5 3

s > 250 10 5

Table 7-3: Allowable frequency of recordable indications inother volumetric regions

8 Products dished, pressed, bent for rolled from sheets andplates

8.1 Scope

(1) This section applies to hot or cold dished, pressed, bentof rolled products from quenched and tempered alloy steel inthe following product forms:

a) pressed parts, dished parts,

b) bent or rolled half shells,

c) bent or rolled sections.


8.2 Requirements

(1) The requirements under Sec. 3.2.4.2 shall be applied.

(2) The tensile strengths determined for different specimen-taking locations of the same plate on similarly positioned andoriented test coupons shall not differ from each other by morethan 80 N/mm2.


8.3.1 Specimen-taking locations and treatment of testcoupons

8.3.1.1 Specimen-taking locations

(1) The test coupons shall be taken from the middle of thehead and tail end of each product and, in the case of aquenched and tempered wall thickness exceeding 320 mm, onone end from the top side of the plate and on the other endfrom the bottom side, unless specified otherwise by the initialmaterial appraisal or in the following sections. It is assumedthat the direction of main forming lies in the head-to-tail di-rection of the ingot and that the head and tail ends of theproduct can be identified.

(2) In the case of the product with a length of less than 5 mand a quenched and tempered wall thickness equal to or lessthan 200 mm, test specimens need to be removed only fromthe head end.

(3) The areas from which test coupons will be removed shallhave been subjected to similar loading conditions in theforming process as the corresponding areas of the product tobe tested. If, for reasons of fabrication, the taking of larger testcoupons becomes necessary prior to the forming process, thisis permitted provided it is carried out by agreement with theauthorized inspector.

(4) In the case of a quenched and tempered wall thicknessequal to or less than 320 mm, the specimen-taking locationsshall be at a depth of at least one quarter of the quenched andtempered wall thickness beneath the rolled surface and atleast one half of the quenched and tempered wall thicknessbeneath the end face surfaces of the edges levelled for heattreatment. In the case of a quenched and tempered wall thick-ness > 320 mm, the specimen-taking locations shall be at adepth of at least 80 mm beneath the quenched and temperedsurface.

(5) Where in the following tests are required at one-half thewall thickness (T/2) then, in the case of a quenched and tem-pered wall thickness equal to or less than 320 mm, the speci-men-taking location shall be at a depth of one half of thequenched and tempered wall thickness beneath the platesurface and at least one half of the quenched and temperedwall thickness beneath the edges levelled for heat treatment ofthe other surfaces. In the case of a quenched and temperedwall thickness > 320 mm, the coupons shall be taken from adepth of one half of the quenched and tempered wall thick-ness under this plate surface and at least 80 mm beneath theedges levelled for heat treatment of the other surfaces.

(6) If, in the course of fabrication, penetrations are to bemade additional test coupons shall be taken from the cut-outsand trepanned plugs. By agreement with the parties involved,these may be used for supplementary tests.

(7) If the test coupons are removed prior to the hot formingand cannot receive a hot forming similar to that of the pro-duct, then the respective cut-outs and trepanned plugs shallbe used for additional tests to an extent which shall be agreedupon with the authorized inspector.

(8) Examples for specimen-taking locations are shown inFigure 8-1.

8.3.1.2 Treatment of test coupons

The test coupons for tests subsequent to the forming processshould be removed only after having completed the formingand tempering process of the product. If test coupons are

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removed before forming , then prior to the final temperingprocess of the product, these test specimens shall be weldedonto the product by circumferential welds usually at theoriginal specimen-taking location. These test coupons shall besubjected to all heat treatments under consideration of heat-ing-up and cooling-down conditions, and as far as possible, toall forming processes which the product was subjected to inthe intermediate fabrication stage.

≥

≥

≥

of the vessel base

Specimen taking location in the case of fabrication

T: Tempering wall thickness

of only one base plate from only one rolled plate

of a number of base plates from one rolled plate

T

Test coupon

Skirt

test

cou

pon

Specimen taking location in the case of fabrication

T/4

skirt length or by welding the test coupon onto the skirt

Tail

The skirt test coupon shall be created from an additional

T/2

T/4

Tail

Hea

d

Hea

d

direction of rolling

direction of rolling

Figure 8-1: Example for specimen-taking locations


If, during fabrication of the plates, the direction of mainforming is not clearly in the head-to-tail direction of the ingot,then in addition to the transverse test specimens called for inthe following sections, the same number of longitudinal testspecimens from the same specimen-taking location shall betested.


(1) Ladle analysis



For each specimen-taking location a product analysis shall beperformed.

8.3.2.2 Mechanical properties and microstructure


Note:The extent o f tests for demonstrating the mechanical propertiesand assessing the microstructure depends on whether or not theproduct has to be quenched and tempered after the forming proc-ess. A post-forming tempering and quenching my only be omittedifa) the original plate was quenched and tempered,b) the temperature during forming does not exceed the maxi-

mum allowed temperature for stress relief treatment, andc) the degree of forming does not exceed a certain limit value.

(1) The exact conditions under which post-forming, temper-ing and quenching may be omitted are specified in Sec. A 1.

(2) If, during fabrication of the plates, the direction of mainforming is not clearly in the head-to-tail direction of the ingot,then the same number of longitudinal test specimens from thesame specimen-taking location shall be tested additionally.

8.3.2.2.2 Tests on products quenched and tempered afterforming

(1) Test prior to forming on original plates

The original plate shall be tested in accordance with Sec.7.3.2.2.2.

If the original plate is cut apart and the head and tail endcannot anymore be clearly correlated to the products, then theoriginal plate shall be tested in accordance with Sec. 7.3.2.2.2(2).

(2) Tests prior to forming on simulation quenched and tem-pered and stress relief heat treated test coupons

This section applies provided no tests in accordance with para(3) are performed.

a) Tensile test

Two transverse test specimens from each specimen-takinglocation shall be subjected to a tensile test in accordancewith Sec. 3.3.7.3 (1), one at room temperature and one atdesign temperature. In the case of a quenched and tem-pered wall thickness exceeding 200 mm, an additional testshall be performed at room temperature on a transversetest specimen taken from the middle of the tail end at adepth of T/2.

b) Test for reduction of area on perpendicular test specimen


c) Impact test

The impact energy shall be tested in accordance with Sec.3.3.7.3 (2) on one set of transverse test specimens at 0 °C.In the case of a quenched and tempered wall thickness ex-ceeding 200 mm, an additional test shall be performed at

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80 °C on one set of transverse test specimens taken fromthe middle of the head end at a depth of T/2.

d) Metallographic examinations

For each specimen-taking location, one impact test speci-men shall be examined on a longitudinal polished sectionwith respect to secondary grain size; the microstructureshall be evaluated and documented in accordance withSec. 3.3.7.4.

(3) Test upon forming and quenching and tempering onsimulation stress relieved test coupons.

a) Tensile testTwo transverse test specimens from each specimen-takinglocation shall be subjected to a tensile test in accordancewith Sec. 3.3.7.3 (1), one at room temperature and one atdesign temperature. In the case of a quenched and tem-pered wall thickness exceeding 200 mm, an additional testshall be performed at room temperature on a transversetest specimen taken from the middle of the tail end at adepth of T/2. In the case of components with a wall thick-ness exceeding 120 mm, one perpendicular test specimenfrom each specimen-taking location shall be subjected to atensile test in accordance with Sec. 3.3.7.3 (1) at room tem-perature.

b) Test for reduction of area on perpendicular test specimensThree perpendicular test specimens from each specimen-taking location shall be tested at room temperature todemonstrate the required reduction of area.

c) Impact testOn sets of transverse test specimens taken from onespecimen-taking location (tail end) the impact energy shallbe tested in accordance with Sec. 3.3.7 (2) at 0 °C, 33 °Cand 80 °C. The notch shall be perpendicular to the surfaceof the plate. In the case of a quenched and tempered wallthickness exceeding 200 mm, an additional test shall beperformed at 80 °C on one set of transverse test specimenstaken from the middle of the head end at a depth of T/2.

d) Impact energy-versus-temperature curveOn transverse test specimens from one specimen-takinglocation (head end) the impact-energy-versus-temperaturecurve shall be determined in accordance with Sec.3.3.7.3 (3).

e) Nil-ductility transition temperatureOn two longitudinal or transverse test specimens from onespecimen-taking location (head end) it shall be demon-strated in accordance with Sec. 3.3.7.3 (4) that the require-ments regarding NDT temperature are met.

f) Metallographic examinationsFor each specimen-taking location, the longitudinal cross-section of one impact test specimen shall be examinedwith respect to secondary grain size and the microstruc-ture shall be evaluated and documented in accordancewith Sec. 3.3.7.4.

(4) Test on accompanying test coupons

From each test specimen-taking location, test coupons shall betaken for tests on accompanying test specimens. However,these tests need to be performed only for one specimen-takinglocation for each product. The remaining test coupons shall bestored in the as-removed condition.

No tests on accompanying test coupons are required forproducts from the steel 20 MnMoNi 5 5 , provided the impact

test on simulation heat treated transverse test coupons dem-onstrates that the smallest value of the impact energy ab-sorbed at 0 °C is not less than 68 J. However, test on accom-panying test coupons are always required for products in-tended for the reactor pressure vessel.

a) Tensile test

Two transverse test specimens shall be subjected to a ten-sile test in accordance with Sec. 3.3.7.3 (1), one at roomtemperature and one at design temperature.

Where both transverse and longitudinal test specimenshave to be tested, the test specimens from the orientationshall be tested for which poorer results were obtained onsimulation heat treated test specimens.

b) Impact test

On one set of transverse test specimens the impact energyshall be tested in accordance with Sec. 3.3.7.3 (2) at 0 °C (cf.also para (4)a, second paragraph, above).

c) Impact energy-versus-temperature curve

Unless specified otherwise by the initial material ap-praisal, the impact-energy-versus-temperature curve shallbe determined in accordance with Sec. 3.3.7.3 (3) on trans-verse test specimen (cf. also para (4)a, second paragraph,above). In the case of products from the steel20 MnMoNi 5 5, it will suffice to perform the test at 33 °Cand 80 °C.

d) Nil-ductility transition temperature

On two longitudinal or transverse test specimens from onespecimen-taking location (head end) it shall be demon-strated in accordance with Sec. 3.3.7.3 (4) that the require-ments regarding the NDT temperature are met.

8.3.2.2.3 Tests of products not quenched and temperedafter forming

(1) Test prior to forming of the original plates

The original plate shall be tested in accordance with Sec.7.3.2.2.3

(2) Post-forming tests of simulation heat treated test couponsNote:These tests are anticipated by the tests o f the original p late inaccordance with Sec. 7.3.2.2.3 (1).

(3) Test on accompanying test coupons

From each specimen-taking location, test coupons shall betaken for tests on accompanying test specimens. However,these tests need to be performed only for one specimen-takinglocation for each product. No tests on accompanying testcoupons are required for products from the steel20 MnMoNi 5 5 provided the impact test on simulation heattreated transverse test coupons demonstrates that the smallestvalue of the impact energy absorbed at 0 °C is not less than68 J. However, tests on accompanying test coupons are alwaysrequired for products intended for the reactor pressure vessel.

a) Tensile test

Two transverse test specimens shall be subjected to a ten-sile test in accordance with Sec. 3.3.7.3 (1), one at roomtemperature and one at design temperature. In the case ofcomponents with a wall thickness exceeding 120 mm, oneperpendicular test specimen from each specimen-takinglocation shall be subjected to a tensile test in accordancewith Sec. 3.3.7.3 (1) at room temperature.

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c) Impact test

On one set of transverse test specimens the impact energyshall be tested in accordance with Sec. 3.3.7.3 (2) at 0 °C (cf.also Sec. 8.3.2.2.2 (4)a, second paragraph).


Unless specified otherwise by the initial material ap-praisal, the impact-energy-versus-temperature curve shallbe determined in accordance with Sec. 3.3.7.3 (3) on trans-verse test specimens (cf. also Sec. 8.3.2.2.2 (4)a, secondparagraph, above). In the case of products from the steel20 MnMoNi 5 5, it is sufficient to perform the test at 33 °Cand 80 °C.


On two longitudinal transverse test specimens it shall bedemonstrated in accordance with Sec. 3.3.7.3 (4) that therequirements regarding the NDT temperature are met.


(1) The requirements under Sec. 3.3.7.2 shall apply to hard-ness tests.

(2) The hardness of each piece shall be tested on one outersurface along two generators offset by 90 degrees to eachother, starting close to the edge and continuing in length in-tervals of not more than 1000 mm.


(1) The requirements of Sec. 7.4 shall apply.

(2) An ultrasonic examination may be omitted if it wasalready performed on the original plate.





(2) The wall thickness shall be checked in a grid of 500 mmby 500 mm.


The results of the tests in accordance with Sec. 8.3.2.1,8.3.2.2.2 (2) d, 8.3.2.2.2 (3) f and 8.3.2.3 shall be certified byAcceptance Test Certificate 3.1.B in accordance with DIN EN10 204, the results of all the other tests by Acceptance TestCertificates 3.1.C in accordance with DIN EN 10 204.

9 Straight pipe sections

9.1 Scope

(1) This section applies to forged, seamless, pressure retai-ning straight pipes with an internal diameter equal to or

greater than 300 mm and a quenched and tempered wallthickness between 15 and 200 mm with forged-on nozzles.

(2) The requirements regarding the materials for theseproduct forms are specified in Sec. A 1.

9.2 Requirements





(1) All of the following requirements apply under the as-sumption that the direction of main forming of the pipes is inthe head-to-tail direction of the ingot.

(2) In the case of deviations from para (1), the requirementsregarding specimen-taking shall be specified within the initialmaterial appraisal.

(3) Pipes with a quenched and tempered length exceeding3000 mm shall be tested on both ends. The specimen-takinglocations should be offset by 180 degrees to each other.

(4) Pipes with a quenched and tempered length less than3000 mm shall be tested on only one end, unless specifiedotherwise by the initial material appraisal.

(5) The specimen-taking locations shall be at a depth of atleast one quarter of the quenched and tempered wall thick-ness but not more than 80 mm beneath the outer pipe surfaceand at least one half of the quenched and tempered wallthickness but not more than 160 mm beneath the end faceedges levelled for heat treatment (cf. Figure 9-1).

>

>

32

22

2

3

1

1

1

3

2

1

if

offsetview

T /4

viewoffset

with Sec. 9.3.1.1specimen taking in acc.

specimen taking in acc.

80 mm or

T: Tempering wall thickness

with Sec. 9.3.1.2

T

TT

T

TT

/4

/4

/ 2

TT

T T

if 80 mm or T / 2

If T3 < T2 : an agreement with the authorized inspector is necessary.

Dimensions refer to the quenched and tempered condition.

Figure 9-1: Specimen-taking locations on a forged pipe withnozzle

KTA 3201.1

9.3.1.2 Additional requirements for nozzle regions(cf. Figure 9-1)

Note:This specimen-tak ing location is not required if the materialmanufacturer has demonstrated that the material characteristicsdetermined for the pipe section are also valid in the nozzle region.

From each pipe with forged-on nozzles one set of test couponsshall be taken - in addition to the specimen-taking locationsunder Sec. 9.3.1.1 - from the nozzle with the largest nominaldiameter. In the case of a quenched and tempered wall thick-ness equal to or less than 320 mm, the specimen-taking loca-tions shall be at a depth of at least one quarter of thequenched and tempered wall thickness beneath the nozzlesurface region levelled for heat treatment. In the case of aquenched and tempered wall thickness exceeding 320 mm,the specimen-taking locations shall be at a depth of at least 80mm beneath any quenched and tempered surface. It shouldalways be the aim to chose the depth of the specimen-takinglocation such that it is as close as possible to the remainingwall of the straight pipe section (cf. Figure 9-1). The specimen-taking location of the perpendicular test specimens should beas close as possible to the future weld seam bevel.



(1) Ladle analysisFor each melt a ladle analysis shall be performed.

(2) Product analysisFor each pipe a product analysis shall be performed.


Note:Pipes with forged-on nozzles may show differing d irections o fmain forming in the pipe section and in the nozzle. This must betaken into account in correlating the fibre-related orientation ofthe test specimens with regard to the product form geometry. Thiscorrelation may change in the case o f deviations in the fabricationprocedure.

(1) Tensile test

Two transverse test specimens from each specimen-takinglocation shall be subjected to a tensile test in accordance withSec. 3.3.7.3 (1), one at room temperature and one at a designtemperature. In addition, one perpendicular test specimenfrom the nozzle region shall be tested at room temperature.Longitudinal test specimens are permitted if transverse testspecimens cannot be taken from the nozzle region.


Three perpendicular test specimens shall be taken from onespecimen-taking location of each pipe and of the nozzle re-gion for a test at room temperature.

Initially, only one test specimen shall be tested. If the value ofthe reduction of area is larger than the specified average thenthe requirements shall be considered as being fulfilled. If thevalue is smaller that the specified average, the remaining twotest specimens shall be tested.

(3) Impact test

One set of transverse test specimens from each specimen-taking location shall be subjected to an impact test in accor-dance with Sec. 3.3.7.3 (2) at 0 °C. The notch shall be perpen-

dicular to the pipe surface. Additionally, one set of transversetest specimens from one specimen-taking location in the noz-zle region shall be tested at 33 °C and at 80 °C.


For each pipe, an impact-energy-versus-temperature curve inaccordance with Sec. 3.3.7.3 (3) shall be plotted using trans-verse test specimens from one specimen-taking location.


On two longitudinal or transverse test specimens from onespecimen-taking location at the end of each pipe it shall bedemonstrated in accordance with Sec. 3.3.7.3 (4) that the re-quirements regarding NDT temperature are met.


The secondary grain size shall be determined from longitudi-nal cross sections on one impact test specimen from onespecimen-taking location for each pipe and the microstructureshall be evaluated and documented in accordance with Sec.3.3.7.4. In addition, the secondary grain size shall be deter-mined from longitudinal cross sections on one impact testspecimen from one specimen-taking location in the nozzleregion; a micrograph shall be taken for an evaluation of themicrostructure in accordance with Sec. 3.3.7.4.

9.3.2.3 Test on accompanying test coupons


From each specimen-taking location, test coupons shall betaken for tests on accompanying test coupons. The tests shallbe performed for each product, however, only for one speci-men-taking location. The remaining test coupons shall bestored in the as-removed condition.No tests on accompanying test coupons are required forproducts from the steel 20 MnMoNi 5 5.The accompanying test coupons for products from other steelsmay be dispensed with by agreement with the authorizedinspector. Pre-requisite for dispensing with accompanyingtest coupons is, e.g., that the temperature-versus-time se-quence during subsequent fabrication largely correspond tothe simulation heat treatment.

(2) Tensile testOne transverse test specimen shall be subjected to an impacttest in accordance with Sec. 3.3.7.3 (1).

(3) Impact testOne set of transverse test specimens shall be subjected to animpact test in accordance with Sec. 3.3.7.3 (2) at 0 °C. Thenotch shall be perpendicular to the pipe surface.

(4) Impact energy-versus-temperature curveAn impact-energy-versus-temperature curve in accordancewith Sec. 3.3.7.3 (3) shall be plotted using transverse testspecimens.

(5) Nil-ductility transition temperatureOn two longitudinal or transverse test specimens it shall bedemonstrated in accordance with Sec. 3.3.7.3 (4), that therequirements regarding NDT temperature are met. These testsare not required for a quenched and tempered wall thicknessof less than 25 mm.

KTA 3201.1


(1) The requirements under Sec. 3.3.7.2 shall apply to thehardness test.

(2) In the case of quenched and tempered products with alength equal to or greater than 3000 mm, hardness measure-ments shall be performed on both end faces at mid-wall andon the circumferential surface along one generator startingnear the edge and continuing in length intervals of not morethan 1000 mm.



(1) The pipe sections for ultrasonic examinations shall beseparated into two test sections in accordance with Figure 9-3.Testing section 1 (pipe region) shall be tested in accordancewith Sec. 5.4 covering also the transition region between pipeand nozzle. Test section 2 shall be tested in accordance withthe following paragraphs.

(2) The following requirements apply to manual examina-tions and supplement the requirements under Sec. 3.3.8.



(1) Test section 2 according to Figure 9-3 shall be tested intwo steps. In the first step, the forged-on collar is tested beforethe final heat treatment (Figure 9-2). In the second step, thenozzle (Figure 9-3) shall be tested after the final heat treat-ment provided the nominal diameter is equal to or greaterthan 100 mm.

(2) For collar dimensions equal to or greater than 200 mm,sound attenuation measurements in radial direction shall beperformed for at least four locations distributed over the cir-cumference.


Test section according to Fig. 9-3 shall be tested using thefollowing scanning position:

(1) as-forged condition (Fig. 9-2)

a) straight-beam method

positions 1 to 3

b) angle-beam method

positions 4 through 7

In the case of scanning positions 4 and 5 it shall be ensuredthat the examination covers the entire volume in the finishedcondition down to the inner surface of the pipe. If necessary, asupplementary examination shall be performed from theinside surface of the pipe (scanning position 8 and 9 of Figure9-2). The scanning position 6 and 7 from the two end facesshould predominately be used to cover the penetration regionbetween nozzle and pipe.

(2) Quenched and tempered condition (Figure 9-3)

a) straight-beam method

positions 10 and 11

These positions may be replaced by an angle-beam exami-nation provided it has sufficient informative value.

b) Angle-beam method

positions 12 and 13

In the case of scanning positions 12 and 13 it shall be ensuredthat the examination covers the entire volume in the finishedcondition down to the inner surface of the nozzle. If neces-sary, a supplementary examination shall be performed fromthe inside surface of the nozzle (scanning positions 14 and 15of Figure 9-3).

If the required scanning positions cannot be used or if theirinformative value is restricted, adequate replacement meas-ures to be taken shall be agreed upon with the authorizedinspector.

8 9

7

13 2

6

54

Figure 9-2: Sound entry position for the collar region in theas-forged condition

Testing section 1 (pipe region)

11

Testing section 2 (nozzle including the transition

13

region between pipe and nozzle)

14 15

12

s

10

max. 100 mmmin. wall thickness s

Note:

Test section 2 is comprised of the nozzle and transition regionincluding the radius transition (to test section 1) with a width of atleast the wall thickness (s), however, not to exceed 100 mm.

Figure 9-3: Test sections for ultrasonic examination andscanning positions for the nozzle region in thequenched and tempered condition

KTA 3201.1


(1) The requirements under Sec. 5.4.2.3 apply.

(2) In the case of examinations in accordance with Sec.9.4.2.2 (2), the nominal wall thickness of the nozzle governsthe recording limit.




The requirements under Sec. 5.4.3 apply.





(2) In case of wall thickness measurement by ultrasonics,Sec. 16.3.3.3 shall be taken into account.


The results of the tests in accordance with Secs. 9.3.2.1,9.3.2.2 (6) and 9.3.2.4 shall be certified by Acceptance TestCertificates 3.1.B in accordance with DIN EN 10 204, the re-sults of all the other tests by Acceptance Test Certificates 3.1.Cin accordance with DIN EN 10 204.

10 Seamless, forged hollow bodies for primary coolantpump casings

10.1 Scope

The requirements for the materials of these product forms arespecified in Sec. A 1.

10.2 Requirements



The following requirements apply to

a) casings with strongly varying contour and wall thicknesson both ends of the individual casing (suction nozzles anddischarge flange) and

b) forging procedures where the axis of the forging coincideswith the axis of the ingot. If these axes do not coincide, thespecimen-taking locations shall be specified in the initialmaterial certification and such that, as far as feasible, boththe head and tail end of the ingot are included.



(1) Each quenched and tempered forging shall be tested onboth ends.

(2) The major test shall be performed on the end of thedischarge flange. The suction nozzle end shall additionally betested on two specimen-taking locations offset by 180 degreesto each other, this test serving both to demonstrate the mate-rial characteristics with regard to the pipe connection forcesand to demonstrate the material uniformity. In addition, Sec.3.3.6 shall be taken into account.

10.3.1.2 Number of specimen-taking locations

(1) In the case of products with an internal quenched andtempered diameter exceeding 2000 mm or an outer quenchedand tempered diameter exceeding 3000 mm, the test speci-mens shall be taken from the end faces at three locations offsetby 120 degrees from each other.

(2) In the case of products with an inner quenched andtempered diameter equal to or less than 2000 mm or an outerquenched and tempered diameter equal to or less than3000 mm, the test specimens shall be taken from the end facesat two locations offset by 180 degrees to each other.

(3) The specimen-taking locations on the suction nozzle endshall be offset with regard to the specimen-taking location onthe discharge flange end.

10.3.1.3 Specimen-taking depth

(1) On the discharge flange end, the specimen-taking loca-tions shall be at least 80 mm beneath each quenched andtempered surface.

(2) On the suction nozzle end, the specimen-taking locationsshall be at a depth of at least one quarter of the quenched andtempered wall thickness but not more than 80 mm beneaththe outer pipe surface and at least one half of the quenchedand tempered wall thickness but not more than 160 mm be-neath the end face edges levelled for heat treatment.

(3) Thermal buffering may be applied.




For each product fabricated from one melt a ladle analysisshall be performed. In the case of products fabricated frommore than one melt, the calculated average chemical compo-sition shall be specified.


(1) For each product (piece) a product analysis shall beperformed for one specimen-taking location each at the headand the tail end.

(2) Additional product analysis, e.g. of the shell surface ofthe products may be specified in the initial material certifica-tion.

(3) For each of the other specimen-taking locations in accor-dance with Sec. 10.3.1 the content of carbon, manganese,phosphorus, and sulphur shall be determined.

KTA 3201.1


10.3.2.2.1 Major test on the discharge flange end

(1) Tensile testOne transverse test specimen from each specimen-takinglocation shall be subjected to a tensile test in accordance withSec. 3.3.7.3 (1).In addition, one perpendicular test specimen from one speci-men-taking location shall be tested at room temperature.

(2) Test for reduction of area on perpendicular test speci-mens

Three perpendicular test specimen shall be taken from onespecimen-taking location.Initially, only one test specimen shall be tested. If the value ofthe reduction of area is larger than the specified average thenthe requirements shall be considered to have been fulfilled. Ifthe value is smaller than the specified average, the remainingtwo test specimens shall be tested.

(3) Impact testOne set of transverse test specimens from each specimen-taking location shall be subjected to an impact test in accor-dance with Sec. 3.3.7.3 (2) at 0 °C, 33 °C and 80 °C. In addition,one set each of longitudinal and perpendicular test specimensfrom one specimen-taking location shall be subjected to animpact test in accordance with Sec. 3.3.7.3 (2) at 0 °C.

(4) Impact energy-versus-temperature curveAn impact-energy-versus-temperature curve in accordancewith Sec. 3.3.7.3 (3) shall be plotted using transverse testspecimens from one specimen-taking location. Results fromtests in accordance with para (3) may be used.

(5) Nil-ductility transition temperatureOn two longitudinal or transverse test specimens from onespecimen-taking location it shall be demonstrated in accor-dance with Sec. 3.3.7.3 (4), that the requirements regarding theNDT temperature are met.

(6) Metallographic examinationsThe secondary grain size shall be determined from longitudi-nal cross sections on one impact test specimen from eachspecimen-taking location; in each case, the microstructureshall be evaluated and documented in accordance with Sec.3.3.7.4.

10.3.2.2.2 Tests on the suction nozzle end

(1) Tensile testOne transverse test specimen from each specimen-takinglocation shall be subjected to a tensile test in accordance withSec. 3.3.7.3 (1). In addition, one perpendicular test specimenfrom one specimen-taking location shall be tested at roomtemperature.

(2) Test for reduction of area on perpendicular test speci-mens

Three perpendicular test specimens shall be taken from onespecimen-taking location. The further procedure shall be inaccordance with Sec. 10.3.2.2.1 (2).

(3) Impact testOne set of transverse test specimens from each specimen-taking location shall be subjected to an impact test in accor-dance with Sec. 3.3.7.3 (2) at 33 °C.


The secondary grain size shall be determined from longitudi-nal cross sections on one impact test specimen from eachspecimen-taking location; in each case, the microstructureshall be evaluated and documented in accordance with Sec.3.3.7.4.


From each specimen-taking location, test coupons shall betaken for tests on accompanying test coupons. The tests shallbe performed for each product, however, only for one speci-men-taking location. The remaining test coupons shall bestored in the as-removed condition.

(1) Tensile test

Two transverse test specimens shall be subjected to a tensiletest in accordance with Sec. 3.3.7.3 (1), one at room tempera-ture and one at design temperature.

(2) Impact test

One set of transverse test specimens shall be subjected to animpact test in accordance with Sec. 3.3.7.3 (2) at 0 °C.


An impact-energy-versus-temperature curve in accordancewith Sec. 3.3.7.3 (3) shall be plotted using transverse testspecimens. In the case of products made from the steel20 MnMoNi 5 5, it will suffice to perform the test at 33 °C and80 °C.


It shall be demonstrated in accordance with Sec. 3.3.7.3 (4)that two longitudinal or transverse test specimens meet therequirements for the NDT temperature.

10.3.2.4 Sulphur prints on the product

Sulphur prints that serve as information for the weld claddingmanufacturer shall be taken at those locations specified byagreement with the authorized inspector.



(2) The hardness tests shall include the discharge flangesand both inlet nozzles and shall be performed on the outersurface along one surface line beginning near the edge andcontinuing in length intervals of not more than 1000 mm.


(1) The requirements under Sec. 3.3.8 and 5.4 shall apply.

(2) On account of the geometrical deviations with respect tothe product forms under Sec. 5, the additional requirementsunder para (3) apply.

(3) When preparing the test instructions, the followingpoints shall be taken into account:

a) A true-to-scale sketch shall be prepared of the test object inits test conditions, i.e. with scanning its sketch contourcreated by machining procedures. This sketch shall con-tain the positions for the straight-beam and angle-beamexaminations and shall identify the test surfaces.

KTA 3201.1

b) In the non-cylindrical sections four angle-beam examina-tions from four directions offset by 90 degrees to eachother and one straight-beam examination shall be per-formed. As far as geometrically possible, the orientation ofthe scanning directions for the angle-beam examinationsshall be specified with respect to the axes of the cylindricalregions.

c) The measuring points for the required sound attenuationmeasurements shall be specified. Deviating from Sec.5.4.2.1, the sound attenuation measurements shall be per-formed for one scanning position per square meter of theouter surface, however, for at least three locations of thetest object.




The requirements under Sec. 3.3.7.8 shall apply to the checkfor dimensional accuracy.


The results of the tests in accordance with Sec. 10.3.2.1,10.3.2.2.1 (6), 10.3.2.2.2 (4), 10.3.2.4, and 10.3.2.5 shall be certi-fied by Acceptance Test Certificates 3.1.B in accordance withDIN EN 10 204, the results of all the other tests by AcceptanceTest Certificates 3.1.C in accordance with DIN EN 10 204.

11 Pressure-retaining forged valve bodies

11.1 Scope

(1) This section applies to hammer-forged or drop-forgedvalve bodies made from quenched and tempered alloy steel.

(2) The requirements for the materials of these productforms are specified in Sec. A 1.

11.2 Requirements




(1) Generally, the following requirements apply. However,where special conditions exist, e.g., during manufacture, de-viating requirements may be specified in the initial materialcertification.

(2) The following requirements are specified with respect tolarger pieces (cf. Sec. 11.3.2). In consideration of the initialmaterial certification of the authorized inspector, the follow-ing requirements shall be analogously applied also to thoseproduct forms from which the test specimens for the requiredtests can neither be removed at all nor in the required number,e.g. as is generally the case for drop-forged pieces. These casesmay lead to a lot-oriented testing where the test coupons areremoved from one completely sectioned forging.


11.3.2.1 Location of the test coupons

(1) Valve bodies with a nominal diameter equal to or lessthan 450 mm

The test coupons shall be taken from one location on one endface of each quenched and tempered product form which, ifpracticable, shall include the head or tail end of the ingot.

In the case of product forms with a finished length exceeding1500 mm, test coupons shall additionally be removed from theopposite end face at a location offset by 180 degrees to dem-onstrate the material uniformity.

Note:Finished length means fabrication length minus length o f thetest coupon. The fabrication length is the length o f the productas it is quenched and tempered.

(2) Valve bodies with a nominal diameter exceeding450 mm

The test coupons shall be taken from two locations offset by180 degrees to each other on one end face of each quenchedand tempered product form which, if practicable, shall in-clude the head or tail end of the ingot.

In the case of product forms with a finished length exceeding1500 mm, test coupons shall additionally be removed from theopposite end face to demonstrate material uniformity.

11.3.2.2 Specimen-taking depth

The specimen-taking location shall be at a depth of at leastone quarter of the quenched and tempered wall thickness butnot more than 80 mm beneath the outer pipe surface and atleast one half of the quenched and tempered wall thicknessbut not more than 160 mm beneath the end face edges levelledfor heat treatment. Thermal buffering may be applied.

11.3.3 Extent of Testing



(2) Product analysisFor each product (piece) a product analysis shall be per-formed for one specimen-taking location at one end face. Forthe other end face, the content of carbon, manganese, phos-phorus, and sulphur shall be determined.


11.3.3.2.1 Tests (major test) on parts under sec. 11.3.2.1 (1)and (2) (major test)

(1) Tensile testOne transverse test specimen from each specimen-takinglocation shall be subjected to a tensile test in accordance withSec. 3.3.7.3 (1). In addition, one perpendicular test specimenfrom one specimen-taking location shall be tested at roomtemperature.

(2) Test for reduction of area on perpendicular test specimensThree perpendicular test specimen shall be taken from onespecimen-taking location. Initially, only one test specimenshall be tested. If the value of the reduction of area is largerthan the specified average then the requirements shall be

KTA 3201.1

considered to have been fulfilled. If the value is smaller thanthe specified average, the remaining two test specimen shallbe tested.

(3) Impact testOne set of transverse test specimens from each specimen-taking location of one end face shall be subjected to an impacttest in accordance with Sec. 3.3.7.3 (2) at 0 °C and 33 °C.

In the case of valve bodies with a nominal diameter exceeding450 mm, additionally one set of longitudinal and perpendicu-lar test specimen from one specimen-taking location shall besubjected to an impact test at 0 °C.


An impact-energy-versus-temperature curve in accordancewith Sec. 3.3.7.3 (3) shall be plotted using transverse testspecimens.


On two longitudinal or transverse test specimens from onespecimen-taking location it shall be demonstrated in accor-dance with Sec. 3.3.7.3 (4), that the requirements regarding theNDT temperature are met.


The secondary grain size shall be determined from a longitu-dinal cross section of one impact test specimen from onespecimen-taking location and the microstructure shall beevaluated and documented in accordance with Sec. 3.3.7.4.

11.3.3.2.2 Supplementary tests on parts under Sec. 11.3.2 (1)and (2) (uniformity test)

(1) Tensile test

Two transverse test specimens shall be subjected to a tensiletest, one at room temperature and one at design temperature.

(2) Impact test

One set of transverse test specimens shall be subjected to animpact test in accordance with Sec. 3.3.7.3 (2) at 0 °C and33 °C.

(3) Metallographic examinationsThe secondary grain size shall be determined from a longitu-dinal cross section of one notch-bend test specimen and themicrostructure shall be evaluated and documented in accor-dance with Sec. 3.3.7.4.


(1) The requirements in accordance with Sec. 3.3.7.2 applyto hardness tests.

(2) In the case of product forms with a length equal to orgreater than 2000 mm the hardness tests shall be performed atmid-wall on the head and tail end faces and on the outer sur-face along one surface line beginning near the edge and con-tinuing in length intervals of not more than 1000 mm.



The following requirements apply to the manual examina-tions and supplement the requirements under Sec. 3.3.8.



11.4.2.1.1 Hammer forgings

(1) The ultrasonic examination generally comprises theexamination prior to tempering in accordance with Sec.11.4.2.2.1 and an additional post-tempering examination inaccordance with Sec. 11.4.2.2.3. The examinations shall beperformed at an as simple as possible geometry.

(2) A pre-tempering ultrasonic examination may be omittedin those cases where a post-tempering ultrasonic examinationis performed with the scanning positions in accordance withSec. 11.4.2.2.1.

Note:With regard to the acceptance test at the material manufacturer'sworks when the product form is still in its raw or unfinishedcondition, it is necessary that the drawings or the data regardingthe nominal thickness in the finished condition are available to thematerial manufacturer so that the test criteria relating to the finaldimensions can be satisfied.

11.4.2.1.2 Drop forgings

In the case of drop forgings, the ultrasonic examination shallbe performed on the initial material prior to drop forging andin accordance with Sec. 11.4.2.2.2. In the case of nominal di-ameters exceeding 100 mm and if the geometry allows, anadditional post-tempering ultrasonic examination in accor-dance with Sec. 11.4.2.2.3 shall be performed with the productin a condition having an as simple as possible geometry andafter having undergone that heat treatment which is decisiveto obtain the required material characteristics.

11.4.2.1.3 Sound attenuation measurements

In the case of a wall thickness equal to or greater than200 mm, sound attenuation measurements shall be performedat one location per square meter of their outside surface, how-ever, at not less than three locations per product form.


11.4.2.2.1 Hammer forgings

If geometrically possible, the entire volume shall be examinedwith the straight-beam method from three scanning directionsperpendicular to each other. If this is impossible on account ofthe geometric shape of the product form, then for each miss-ing scanning direction two angle beam examinations fromopposite directions shall be performed. In this case, the beamangle of the angle-beam examination shall be parallel to themain beam of the missing straight-beam examination.

11.4.2.2.2 Initial material for drop forging

The entire volume shall be examined from the shell surface bythe angle-beam method.

11.4.2.2.3 Additional post-tempering examination

(1) The additional post-tempering examination in accor-dance with Sec. 11.4.2.1.1 or 11.4.2.1.2 shall consist of astraight-beam examination from all outer surfaces where theradius of curvature is larger than 30 mm.

(2) The cylindrical regions of hammer forgings shall besubjected to an angle-beam examination in both circumferen-tial directions instead of the straight-beam examination.

KTA 3201.1

11.4.2.3 Recording limits for forgings

(1) The requirements under Sec. 5.4.2.3 apply.

(2) The decisive factor for the recording limit is the nominalwall thickness in the final condition.

(3) In the case of initial material for drop forging, the record-ing limit shall correspond to the acceptability limit under Sec.11.4.2.4.2.


11.4.2.4.1 Forgings

(1) The distance between the final surface and locationsfrom which recordable echoes are obtained shall not be lessthan the values shown in Table 5-2.

(2) In the case of straight-beam examinations, local indica-tions with echo heights equal to or greater than 12 dB abovethe recording limit are permitted in all volumetric regions.Longitudinally extended indications with lengths below thevalues shown in Figure 5-2 are permitted if during angle-beam scanning at these locations no echo heights equal to orgreater than 6 dB above the recording limit are obtained.Here, the greatest permissible reflector length in circumferen-tial direction is limited to 60 mm. Reflections with a lengthexceeding 10 mm in thickness direction are not permitted.

(3) In the weld edge and fusion face areas the requirementsof Sec. 5.4.2.4.1 (2) respectively 5.4.2.4.2 (1) apply.

(4) For the other volumetric regions the frequency of indi-cations referred to the outer surface of the test specimen shallnot exceed 10 per square meter and with respect to the entiresurface area 5 per square meter.

11.4.2.4.2 Pre-forged material for drop forging

All indications are acceptable that, in the case of diameters oroverall lengths equal to or less than 60 mm, do not exceed thevalues from a reference disk reflector of 2 mm and, in the caseof larger dimensions, from a reference disk reflector of 3 mm.



11.5 Materials identification check

If the forgings are tested in lots (cf. Sec. 11.3.1) where nochemical analysis is performed on each piece, each piece shallbe subjected to a materials identification check.




The requirements under Sec. 3.3.7.10 apply to the visual in-spection.


The results of the tests in accordance with Sec. 11.3.3.1,11.3.3.2.1(6), 11.3.3.2.2(3) and 11.3.3.3 shall be certified byAcceptance Test Certificates 3.1.B in accordance with DIN EN

10 204, the results of all other tests by Acceptance Test Certifi-cates 3.1.C in accordance with DIN EN 10 204.

12 Forged flat plates

12.1 Scope

(1) This section applies to forged flat plates for closures,blind flanges and similar parts.

Note:Regarding forged singe-piece plates for tubesheets, cf. Sec. 6.


12.2 Requirements




(1) In the case of a quenched and tempered weight equal toor greater than 500 kg, each quenched and tempered pieceshall be tested at one specimen-taking location from the headend. In the case of lengths exceeding 3000 mm one test eachshall be performed on the head and the tail end.

(2) In the case of a quenched and tempered weight less than500 kg, lot-oriented testing shall be performed. The piecesshall be sorted into lots with a lot size of not more than 5 tons.For each dimension, melt and heat treatment lot, the hardestand the softest piece shall be tested.

(3) The specimen-taking locations shall be at a depth of atleast one quarter of the quenched and tempered wall thick-ness but not more than 80 mm beneath the plate surface andat least one half of the quenched and tempered wall thicknessbut not more than 160 mm beneath the end face edges levelledfor heat treatment.





(2) Product analysisFor each specimen-taking location a product analysis shall beperformed.


Where no welding or cladding work is performed on theproduct, the tests may be performed without prior simulationheat treatment.

(1) Tensile testTwo transverse test specimen from each specimen-takinglocation shall be subjected to a tensile test in accordance withSec. 3.3.7.3 (1), one at room temperature and one at designtemperature.

(2) Test for reduction of area on perpendicular test specimensThree perpendicular test specimens shall be taken from one

KTA 3201.1

specimen-taking location. Initially, only one test specimenshall be tested. If the value of the reduction of area is largerthan the specified average then the requirements shall beconsidered to have been fulfilled. If the value is smaller thanthe specified average, the remaining two test specimen shallbe tested.

(3) Impact testOne set of transverse test specimens from each specimen-taking location shall be subjected to an impact test in accor-dance with Sec. 3.3.7.3 (2) at 0 °C.

(4) Impact energy-versus-temperature curveAn impact-energy-versus-temperature curve in accordancewith Sec. 3.3.7.3 (3) shall be plotted using transverse testspecimens from one specimen-taking location for each pieceto be tested.

(5) Nil-ductility transition temperatureOn two longitudinal or transverse test specimens from onespecimen-taking location it shall be demonstrated in accor-dance with Sec. 3.3.7.3 (4), that the requirements regarding theNDT temperature are met.

(6) Metallographic examinationsThe secondary grain size shall be determined from a longitu-dinal cross section of one impact test specimen from eachspecimen-taking location and the microstructure shall beevaluated and documented in accordance with Sec. 3.3.7.4.

12.3.2.3 Tests on accompanying test coupons


From each specimen-taking location, test coupons shall betaken for tests on accompanying test coupons. However, thesetests need to be performed only for one specimen-taking loca-tion for each product. The remaining test coupons shall bestored in the as-removed condition.

The tests on accompanying test coupons may be dispensedwith if no connection welds will be performed on the piece.

No tests on accompanying test specimens are required forproducts made from the steel 20 MnMoNi 5 5, provided, theimpact test on simulation heat treated transverse test speci-mens demonstrates that the smallest value of the impact en-ergy absorbed at 0 °C is not less than 68 J.

(2) Tensile test

Two transverse test specimens shall be subjected to a tensiletest in accordance with Sec. 3.3.7.3 (1), one at room tempera-ture and one at design temperature.

(3) Impact test

The impact energy shall be tested in accordance with Sec.3.3.7.3 (2) on one set of transverse test specimens at 0 °C.


The impact-energy-versus-temperature curve shall be deter-mined in accordance with Sec. 3.3.7.3 (3) on transverse testspecimens.

In the case of products made from the steel 20 MnMoNi 5 5, itwill suffice to perform the test at 33 °C and 80 °C.


On two transverse test specimens it shall be demonstrated inaccordance with Sec. 3.3.7.3 (4) that the requirements regard-ing the NDT temperature are met.



(2) In the case of quenched and tempered pieces with alength exceeding 3000 mm the hardness tests shall be per-formed at mid-wall on the head and tail end faces and on theouter surface along one surface line beginning near the edgeand continuing in length intervals of not more than 1000 mm.



The following requirements shall be applied to the manualexaminations and supplement the requirements under Sec.3.3.8.



In the case of wall thicknesses equal to or greater than200 mm, sound attenuation measurements shall be performedon a grid of 2 m x 2 m, however, at least at 4 locations of eachtest object. If, during straight-beam scanning, no significantlocal deviations (range equal to or smaller than 6 dB) arefound, the number of measuring points for angle-beam scan-ning may be reduced.


(1) The plates shall be examined from one major surface bymeans of straight and angle-beam scanning (scanning direc-tions 1 to 5 in accordance with Fig. 12-1). To obtain the re-quired sensitivity, an examination from the opposite surfaceshall also be performed.

(2) In the case of machined covers and blind flanges straightbeam scanning shall be additionally performed from thecross-sectional surface in the case of nominal wall thicknessequal to or greater than 100 mm.

Tail

Head

Major surface

4

2

Cross-section

1

5 3

Figure 12-1: Sound entry directions 1 to 5 for the ultrasonicexamination of forged plates


(1) All indications with echo amplitudes equal to or greaterthan the values given in Table 5-1 shall be recorded.

(2) In the sound attenuation measurements sound attenua-tions over 4 dB/m when testing at 2 MHz or over 10 dB/mwhen testing at 4 MHz shall be recorded.

KTA 3201.1



The requirements under Sec. 5.4.2.4.1 apply.


(1) In the straight-beam examinations any local indicationswith an echo amplitude up to 18 dB above the recording limitspecified in Table 5-1 are acceptable. Depending on the maxi-mum echo amplitude, laminar longitudinal indications with alength dimension below the values of curve 1 in Figure 5-2 areacceptable provided the angle-beam examination of theselocations does not lead to an echo amplitude of 6 dB above therecording limit. The largest acceptable reflector length is lim-ited to 120 mm.

Reflections with a longitudinal extension over 10 mm inthickness direction are not permitted.

(2) The frequency of indications relative to a major surfacearea shall locally not be larger than one per square meter.

(3) In the case of straight-beam scanning from the cross-sectioned surface local indications which are up to 12 dBabove the recording limit are permitted. Extended indicationsshall be thoroughly examined for their orientation. Indicationswith a longitudinal extension above 10 mm in thickness di-rection are not permitted.




In the case of lot-oriented testing each piece made of alloyedsteels shall be subjected to a materials identification checkwith a spectroscope.






The results of the tests in accordance with Sec. 12.3.2.1,12.3.2.2 (6) and 12.3.2.4 shall be certified by Acceptance TestCertificates 3.1.B in accordance with DIN EN 10 204, the re-sults of all the other tests by Acceptance Test Certificates 3.1.Cin accordance with DIN EN 10 204.

13 Hot dished or pressed products from forged plates

13.1 Scope

This section applies to hot dished or pressed products fromforged plates, e.g. the spherical section of the reactor pressurevessel, steam generator or pressurizer.

The requirements for the materials of these product forms arespecified in Sec. A 1.

13.2 Requirements

The requirements under Sec. 3.2.4.2 shall be applied.



(1) The following requirements apply under the assumptionthat the direction of main deformation of the initial plate liesin the head-to-tail direction of the ingot and that it is possibleto identify the head and tail ends of the plate.

(2) If this assumption does not apply in part or as a whole,possibly deviating requirements regarding specimen-takinglocations and orientations of the test specimens shall be speci-fied in the initial material certification.


(1) The test coupons shall be taken from each product in themiddle of the head and the tail end unless specified otherwiseby the initial material certification (cf. Sec. 13.3.1).

(2) The areas from which test coupons shall be taken shouldhave been subjected to similar loading conditions in theforming process as the corresponding areas of the product tobe tested. If, for reasons of fabrication, the taking of larger testcoupons becomes necessary prior to dishing the plate, this isallowed provided this procedure is carried out by agreementwith the authorized inspector. These test coupons shall besubjected to the same forming procedures as the dished prod-uct and shall be welded onto the latter prior to quenching andtempering.

(3) The specimen-taking locations shall be at a depth of atleast one quarter of the quenched and tempered wall thick-ness but not more than 80 mm beneath the plate surface andat least one half of the quenched and tempered wall thicknessbut not more than 160 mm beneath the end face edges levelledfor heat treatment.




(1) Ladle analysis

In the case of products from a single melt a ladle analysis shallbe performed. In the case of products from more than onemelt the calculated average chemical composition shall bespecified.




(1) Tensile test

Two transverse test specimens from each specimen-takinglocation shall be subjected to a tensile test in accordance withSec. 3.3.7.3 (1), one at room temperature and one at designtemperature.

One perpendicular test specimen from one specimen-takinglocation shall be subjected to a tensile test at room tempera-ture in accordance with Sec. 3.3.7.3 (1).

KTA 3201.1

(2) Test for reduction of area on perpendiculartest specimens

Three perpendicular test specimens shall be taken from onespecimen-taking location for a test at room temperature.

Initially only one test specimen shall be tested. If the value ofthe reduction of area is larger than the specified average thenthe requirements shall be considered to have been fulfilled. Ifthe value is smaller than the specified average, the remainingtwo test specimens shall be tested.

(3) Impact test

One set of transverse test specimens from each specimen-taking location shall be subjected to an impact test in accor-dance with Sec. 3.3.7.3 (2) at 0 °C, 33 °C and 80 °C. The notchshould be perpendicular to the spherical surface.


An impact-energy-versus-temperature curve in accordancewith Sec. 3.3.7.3 (3) shall be plotted using transverse testspecimens from one specimen-taking location.

(5) Nil-ductility transition temperatureOn two transverse test specimens from one specimen-takinglocation it shall be demonstrated in accordance with Sec.3.3.7.3 (4) that the requirements regarding the NDT tempera-ture are met.

(6) Metallographic examinationsThe secondary grain size shall be determined from a longitu-dinal cross section of one impact test specimen from eachspecimen-taking location and the microstructure shall beevaluated and documented in accordance with Sec. 3.3.7.4.

13.3.3.3 Tests on accompanying test coupons

(1) General requirementsFrom each specimen-taking location, test coupons shall betaken for tests on accompanying test coupons. However, thesetests need to be performed only for one specimen-taking loca-tion for each product. The remaining test coupons shall bestored in the as-removed condition.No tests on accompanying test coupons are required forproducts made from the steel 20 MnMoNi 5 5, provided, theimpact test on simulation heat treated transverse test speci-mens demonstrates that the smallest value of the impact en-ergy absorbed at 0 °C is not less than 68 J. In the case of pro-ducts for the reactor pressure vessel the tests on accompany-ing test coupons shall not be waived.

(2) Tensile testTwo transverse test specimens shall be subjected to a tensiletest in accordance with Sec. 3.3.7.3 (1), one at room tempera-ture and one at design temperature.

(3) Impact testOn one set of transverse test specimens the impact energyshall be tested in accordance with Sec. 3.3.7.3 (2) at 0 °C.

(4) Impact energy-versus-temperature curveThe impact-energy-versus-temperature curve shall be deter-mined in accordance with Sec. 3.3.7.3 (3) on transverse testspecimens.In the case of products made from the steel 20 MnMoNi 5 5, itwill suffice to perform the test at 33 °C and 80 °C.

(5) Nil-ductility transition temperatureOn two transverse test specimens it shall be demonstrated inaccordance with Sec. 3.3.7.3 (4) that the requirements regard-ing the NDT temperature are met.



(2) The hardness test shall be performed on each piece onone outer surface along two generators offset by 90 degrees toeach other, beginning near the edge and continuing in lengthintervals of not more than 1000 mm.



The following requirements apply to the manual examina-tions and supplement the requirements under Sec. 3.3.8.



In the case of a wall thickness equal to or greater than 200 mmsound attenuation measurements shall be performed with thestraight-beam method in a grid of 2 m x 2 m, however, fromnot less than four locations per test object.


(1) From one major surface, one straight-beam examinationand four angle-beam examinations with scanning directionsoffset by 90 degrees to each other shall be performed.

(2) In the case of cylindrical product forms, the angle-beamexamination shall be performed in the axial and circumferen-tial directions and, in the case of spherical product forms, inthe meridional and longitudinal directions.

(3) If necessary to achieve the required scanning sensitivitylevel, the examination shall also be performed from the op-posite surface.





The requirements under Sec. 5.4.2.4.1 apply.


(1) Regions of weld edges and nozzles

The requirements under Sec. 5.4.2.4.2 (1) apply.

(2) Other volumetric regions

Local indications found in the straight-beam examination inthe thickness direction are allowable if their echo amplitudesare up to 18 dB above the registration limit in accordance withTable 5-1. Depending on the maximum echo amplitude, indi-cations with a longitudinal dimension in accordance withcurve 1 of Figure 5-2 are acceptable provided the amplitudesof the corresponding angle-beam echoes for these locations

KTA 3201.1

are 6 dB above the registration limit. However, the maximumacceptable reflector length is 120 mm.

With respect to the major surface area, the frequency of indi-cations shall locally be not higher than 10 per square meterand, with respect to the entire surface area, not higher than 5per square meter.








The results of the tests in accordance with Sec. 13.3.3.1,13.3.3.2 (6) and 13.3.3.4 shall be certified by Acceptance TestCertificates 3.1.B in accordance with DIN EN 10 204, the re-sults of all other tests by Acceptance Test Certificates 3.1.C inaccordance with DIN EN 10 204.

14 Forged or rolled bars for hollow-bored nozzles and pipes

14.1 Scope

(1) This section applies to forged or rolled bars fromquenched and tempered alloy steel with a maximum outerfinished diameter of about 220 mm or a comparable cross-section that are used for pressure-retaining components, e.g.for the fabrication of nozzles and pipes.


14.2 Requirements




(1) A quenched and tempered product with a finishedlength equal to or less than 1500 mm shall be tested from oneend face, and with a finished length exceeding 1500 mm fromboth end faces. The number of nozzles fabricated from thisproduct is not taken into account.

Note:Finished length means fabrication length minus length o f the testcoupon. The fabrication length is the length o f the product as it isquenched and tempered.

(2) In the case of step-forged bars, the test coupons shall betaken at that cross-section that governs the heat treatment.

(3) The specimen-taking locations shall be at a depth of atleast one quarter of the quenched and tempered diameter, oras close as possible to this depth, and at least one half of thequenched and tempered diameter beneath the end face edgeslevelled for heat treatment. Thermal buffering may be applied.

(4) If the taking of transverse test specimens is not practica-ble as required below, longitudinal test specimens may betested.



(1) Ladle analysis



On each product form (piece) a product analysis shall be per-formed for one specimen-taking location at one end face,specifically the head end. The contents of carbon, manganese,phosphorus, and sulphur shall be determined for one speci-men-taking location at the opposite end face.


(1) Tensile test

Two transverse test specimens from each specimen-takinglocation shall be subjected to a tensile test in accordance withSec. 3.3.7.3 (1), one at room temperature and one at designtemperature.

(2) Impact test

One set of transverse test specimens from each specimen-taking location shall be subjected to an impact test in accor-dance with Sec. 3.3.7.3 (2) at 0 °C and 33 °C.


In the case of bars in the finished condition with a diameterequal to or greater than 160 mm, an impact-energy-versus-temperature curve in accordance with Sec. 3.3.7.3 (3) shall beplotted using transverse test specimens from one specimen-taking location. Test results from para (2) may be utilised.


In the case of bars in the finished condition with a diameterequal to or greater than 160 mm, it shall be demonstrated ontwo longitudinal or transverse test specimens from onespecimen-taking location in accordance with Sec. 3.3.7.3 (4)that the requirements regarding the NDT temperature aremet.


The secondary grain size shall be determined from a longitu-dinal cross section of one impact test specimen from eachspecimen-taking location and the microstructure shall beevaluated and documented in accordance with Sec. 3.3.7.4.



From each specimen-taking location, test coupons shall betaken for tests on accompanying test coupons. However, thesetests need to be performed only for one specimen-taking loca-tion for each product. The remaining test coupons shall bestored in the as-removed condition.If more than one piece are fabricated from one bar which areintended for different components and are subjected to sepa-rate stress relief heat treatments then one set of accompanyingtest coupons shall be provided for each of these components.No tests on accompanying test coupons are required for

KTA 3201.1

products made from the steel 20 MnMoNi 5 5 provided theimpact toughness test on simulation heat treated transversetest specimens demonstrates that the smallest value of theimpact energy absorbed at 0 °C is not less than 68 J. In the caseof products for the reactor pressure vessel the tests on accom-panying test coupons may not be dispensed with.

(2) Tensile testTwo transverse test specimens shall be subjected to a tensiletest in accordance with Sec. 3.3.7.3 (1), one at room tempera-ture and one at design temperature.

(3) Impact testOn one set of transverse test specimens the impact energyshall be tested in accordance with Sec. 3.3.7.3 (2), one at 0 °Cand 33 °C.

(4) Nil-ductility transition temperatureOn two longitudinal or transverse test specimens it shall bedemonstrated in accordance with Sec. 3.3.7.3 (4) that the re-quirements regarding the NDT temperature are met.



(2) In the case of bars with a length equal to or greater than3000 mm the hardness test shall be performed on both endfaces and on the outer surface along one surface line begin-ning near the edge and continuing in length intervals of notmore than 1000 mm.

14.4 Non-destructive examinationsNote:The requirements specified for the non-destructive examinationsalso apply to the product forms under Sec. 20 and 21. Therefore,hexagonal and quadratic bars are also dealt with in this section.


The following requirements apply to the manual examina-tions and supplement the requirements under Sec. 3.3.8 how-ever the requirements under Sec. 3.3.8.2.1 (5) cb) and3.3.8.2.1 (6) d) through f) do not apply.



(1) In the case of a diameter or a width across flats or a sidewidth of more than 30 mm up to including 60 mm, onestraight-beam examination shall be performed in radial direc-tion.

(2) In the case of a diameter or a width across flats or a sidewidth of more than 60 mm, one straight-beam examinationshall be performed each in radial direction and axial direction.Where, during the straight-beam examinations in axial direc-tion no sufficient signal-to-noise ratio can be maintained overthe entire length of the bar, the bar shall be tested in the cut-to-length condition or by means of a 45 degrees angle-beamexamination in both axial directions.

(3) In the case of a diameter or a width across flats or a sidewidth exceeding 120 mm, in addition to (2) one angle-beamexamination shall be performed in both circumferential direc-tions.

(4) The incident angle for the angle-beam examination incircumferential direction shall be 35 degrees.


The recording limits shall be equal to the acceptance limitsunder Sec. 14.4.2.3.


Those indications are acceptable where the echo amplitude, inthe case of sound entry directions according to Sec. 14.4.2.1 atdiameters or width across flats equal to or smaller than60 mm, does not exceed that of a 2 mm circular disk reflectorand, in the case of larger dimensions not that of a 3 mm circu-lar disk reflector.








The results of the tests in accordance with Secs. 14.3.2.1,14.3.2.2 (5) and 14.3.2.4 shall be certified by Acceptance TestCertificate 3.1.B in accordance with DIN EN 10 204, the resultsof all the other tests by Acceptance Test Certificate 3.1.C inaccordance with DIN EN 10 204.

15 Forged or rolled and hollow-bored and hollow-forgedbars

(1) This section applies to forged or rolled bars fromquenched and tempered alloy steel that are hollow-bored orhollow-forged prior to tempering and are designated for pres-sure-retaining parts, e.g. for nozzles and pipes.

(2) The requirements under Sec. 5 apply accordingly inwhich case the word „nozzles“ shall be replaced by „nozzlesand pipes“.

(3) The non-destructive examination shall basically be per-formed in accordance with Sec. 5.4. However, if it is known atthe point of time of the examination that the bars will be usedfor pipes, then the requirements under Sec. 16.4 shall apply.

Note:The testing o f bars with full material cross-section shall be per-formed in accordance with Sec. 14.4.

(4) The requirements regarding materials for these productforms are specified in Sec. A 1.

16 Seamless pipes for piping

16.1 Scope

(1) This section applies to seamless, rolled, pressed orforged pipes with a quenched and tempered wall thicknessbetween 15 and 200 mm.

(2) The requirements regarding materials for these productforms are specified in Sec. A 1.

KTA 3201.1

16.2 Requirements




(1) The following requirements apply under the assumptionthat the direction of main forming of the pipe lies in the head-to-tail direction of the ingot. If, in the case of forged pipes, thisassumption does not apply, possibly supplementary require-ments regarding specimen-taking shall be specified in theinitial material certification.

(2) The mechanical material characteristics shall be demon-strated on simulation heat treated test coupons (cf. Sec.16.3.3.2). Notwithstanding this requirement it may be agreed,in the case of pipes from which seamless pipe elbows arefabricated, to perform the tests in the quenched and temperedcondition.


(1) Pipes with a quenched and tempered length exceeding3000 mm shall be tested both at the head and tail end. Thespecimen-taking location shall be offset by 180 degrees to eachother.

(2) Pipes with a quenched and tempered length equal to orless than 3000 mm shall be tested from only one end face inwhich case the specimen-taking location with respect to theingot shall be specified in the initial material certification.

(3) The specimen-taking locations shall be at a depth of atleast one quarter of the quenched and tempered wall thick-ness beneath the surface and at least one half of the quenchedand tempered wall thickness beneath the end face edges lev-elled for heat treatment.



(1) Ladle analysis



For each pipe a product analysis shall be performed.


(1) Tensile test

Two transverse test specimens from each specimen-takinglocation shall be subjected to a tensile test in accordance withSec. 3.3.7.3 (1), on at room temperature and one at designtemperature. If it is impracticable to take transverse testspecimens, the test may be performed on longitudinal testspecimens.


Three perpendicular test specimens shall be taken from onespecimen-taking location for a test at room temperature.Initially only one test specimen shall be tested. If the value ofthe reduction of area is larger than the specified average thenthe requirements shall be considered to have been fulfilled. Ifthe value is smaller than the specified average, the remainingtwo test specimens shall be tested.

(3) Impact test

One set of transverse test specimens from each specimen-taking location shall be subjected to an impact test in accor-dance with Sec. 3.3.7.3 (2) at 0 °C. The notch shall be perpen-dicular to the pipe surface.


For each pipe an impact-energy-versus-temperature curve inaccordance with Sec. 3.3.7.3 (3) shall be plotted using trans-verse test specimens from one specimen-taking location.


On two transverse test specimens for one specimen-takinglocation from each pipe, it shall be demonstrated in accor-dance with Sec. 3.3.7.3 (4) that the requirements regarding theNDT temperature are met. If this cannot be demonstrated,then the NDT temperature shall be determined for eachspecimen-taking location. This test is not required for aquenched and tempered wall thickness of less than 25 mm.


For each pipe, the secondary grain size shall be determinedfrom a longitudinal cross section of one impact test specimenfrom one specimen-taking location and the microstructureshall be evaluated and documented in accordance with Sec.3.3.7.4.

16.3.3.3 Measurement of the wall thickness

(1) In the case of pipes with a diameter equal to or smallerthan 100 mm an ultrasonic measurement of the wall thicknessis required only, if the excess wall thickness is less then 20 %of the design wall thickness. In this case, ultrasonic wallthickness measurement shall be specified as special require-ment in the order of the customer.

(2) The wall thickness shall be measured by straight-beamscanning from the outside surface. Measurements shall betaken along three surface lines offset by 120 degrees to eachother with the distance between measurement points beingequal to or smaller than 1 000 mm.

(3) The accuracy of the equipment shall ensure that devia-tions of 1 % of the wall thickness or, in the case of a wallthickness smaller than 20 mm, a deviation of 0.2 mm can beascertained.



(2) In the case of pipes with a length equal to or greater than4000 mm, the hardness test shall be performed in mid-wall oneach end face and on the outer surface along one surface line,beginning near the pipe ends and continuing in length inter-vals of not more than 1000 mm.



(1) Forged pipes and pipes with a nominal wall thicknessgreater than 30 mm shall be examined to comply with therequirements of section 5.4.

(2) It is at the discretion of the pipe manufacturer to performthe ultrasonic examination mechanically or manually.

(3) In the case of a manual ultrasonic examination, the fol-lowing requirements supplement the requirements under Sec.

KTA 3201.1

3.3.8, however, the requirements under Sec. 3.3.8.2.1 (5) cb)and 3.3.8.2.1 (6) d) do not apply.



(1) An angle-beam examination shall be performed from theoutside surface in both circumferential directions to detectlongitudinal flaws.

(2) In the case of pipes with an outside diameter equal to orgreater than 100 mm, two additional examinations shall beperformed from the outside surface, i.e., an angle-beam ex-amination in both axial directions to detect transverse flawsand a straight-beam examination to detect lamellar tearing.

(3) Where during mechanical examination unexamined pipeends are obtained, they shall be cut off or be examined bymanual methods.

(4) The examination shall be performed after the last form-ing and heat treatment process.

16.4.2.2 Performance of examination and evaluation

16.4.2.2.1 Examination for longitudinal flaws

The examination and evaluation shall be performed in accor-dance with SEP 1915.

16.4.2.2.2 Examination for transverse flaws


16.4.2.2.3 Examination for lamellar tearing


16.4.2.2.4 Recording limits

All indications with echo amplitudes equal to or greater thanthe smallest echo height of the reference reflectors as per sec-tions 16.4.2.2.1 to 16.4.2.2.3 shall be recorded.

16.4.2.2.5 Acceptance standards

(1) All pipes with echo heights reaching or exceeding therecording limit shall be rejected.

(2) Rejected pipes may be dressed to minimum wall thick-ness. The dressed areas shall be subjected again to an ultra-sonic examination. Indications on rejected product forms maybe examined by other non-destructive procedures (visualexamination, radiography) to detect the type and size of therespective defect. The manufacturer shall demonstrate harm-lessness of the defect to the authorized inspector. Defects notremoved shall be recorded and shall not impair periodic in-spections.

(3) Dressed areas shall not impair periodic inspections. Thedeviations from the required shape of the examination areasreferred to a reference area of 40 x 40 mm shall not exceed0.5 mm. Where smaller reference areas are selected, the re-lated deviation from shape shall be linearly converted withrespect to the side length of the selected reference area.


16.4.3.1 Extent, type and point of time

(1) The entire outside surface of all pipes in the deliverycondition shall be examined for surface flaws.

(2) The inner surface of all pipes with an inner diameterequal to or greater than 600 mm shall likewise be examinedcompletely. In the case of an inner diameter of more than50 mm and less than 600 mm, the inner surface shall be exam-ined at the pipe ends over a length equal to 1 times the innerdiameter of the pipe.







(2) The requirements under Sec. 16.3.3.3 apply to the wallthickness measurements.


The results of the tests in accordance with Secs. 16.3.3.1,16.3.3.2 (6) and 16.3.3.4 shall be certified by Acceptance TestCertificates 3.1.B in accordance with DIN EN 10 204 the re-sults of all the other tests by Acceptance Test Certificates 3.1.Cin accordance with DIN EN 10 204.

17 Seamless elbows for pipe systems

17.1 Scope

(1) This section applies to seamless pipe elbows (butt weld-ing elbows) with a quenched and tempered wall thickness of15 mm up to 200 mm. The pipe elbows are fabricated fromseamless rolled, pressed or forged pipes and quenched andtempered after forming.

(2) Pipe elbows are required to have cylindrical ends only ifthis is necessary with regard to the non-destructive examina-tions in accordance with Sec. 13 of KT 3201.3 (taking intoaccount possible requirements due to in-service inspections).In the case of pipe elbows with a large nominal diameter, e.g.primary coolant piping system, this is generally not required.

(3) This section does not apply to pipe elbows fabricated ininductive bending machines or on a bending plate. Thesetypes of pipe elbows are dealt with in Sec. 7 of KTA 3201.3.

(4) The requirements for the materials of this product formare specified in Sec. A 1.

17.2 Requirements


KTA 3201.1



The following requirements apply under the assumption thatthe direction of main forming of the initial pipe lies in thehead-to-tail direction of the ingot. If, in the case of forgedpipes, this assumption does not apply, possibly supplemen-tary requirements regarding specimen-taking shall be speci-fied in the initial material certification.

17.3.2 Tests of the initial pipes

(1) If the pipe manufacturer delivers the pipes in aquenched and tempered condition to the elbow manufacturer,then the initial pipes shall be completely tested at the plant ofthe pipe manufacturer and in accordance with Sec. 16.

(2) If the pipe manufacturer fabricates the pipe elbows him-self, only the determination of the chemical composition of theinitial pipes by a product analysis of each specimen-takinglocation in accordance with Sec. 16.3.3.1 is required.

17.3.3 Tests of the pipe elbows (after forming and tempering)


(1) The specimen-taking locations shall be at a depth of atleast one quarter of the quenched and tempered wall thick-ness beneath the surface of the pipe and at least one half of thequenched and tempered wall thickness beneath the pipe el-bow’s end face (edges levelled for heat treatment).

(2) If only one elbow blank is manufactured from an initialpipe or, if the chord measure determined for the extrados ofthe bend is greater than 3000 mm, then the tests of the pipeelbow shall be performed for specimen-taking locations onboth elbow ends at the extrados of the bend.

(3) If, prior to tempering, the initial pipe is cut into sectionsfor manufacturing individual elbow blanks or, if the chordmeasure of the pipe elbow is smaller than 3000 mm, then eachelbow blank shall be tested after tempering at one specimen-taking location on the extrados of the bend, with both ends ofthe initial pipe to be covered by the test.

Note:In case o f the „Hamburg“ pipe elbow, the specimen-tak ing loca-tions shall be d istributed over the entire circumference, unlessspecified otherwise in the initial material certification. Irrespectiveof this requirement, impact test specimens shall always be takenas transverse test specimens from the intrados of the bend.

17.3.3.2 Extent of testing

17.3.3.2.1 Chemical analysis

(1) Ladle analysis



For each initial pipe a product analysis shall be performed.

17.3.3.2.2 Tests on tests coupons subjected to simulationstress relief heat treatment

(1) Tensile test

Two transverse test specimens from each specimen-takinglocation shall be subjected to a tensile test in accordance withSec. 3.3.7.3 (1), one at room temperature and one at designtemperature. If it is impracticable to take transverse test

specimens, the test may be performed on longitudinal testspecimens.

(2) Test for reduction of area on perpendicular test specimens

Three perpendicular test specimens shall be taken from onespecimen-taking location for a test for reduction of area atroom temperature.

Initially only one test specimen shall be tested. If the value ofthe reduction of area is larger than the specified average, thenthe requirements shall be considered to have been fulfilled. Ifthe value is smaller than the specified average, the remainingtwo test specimens shall be tested.

(3) Impact test

One set of transverse test specimens from each specimen-taking location shall be subjected to an impact test in accor-dance with Sec. 3.3.7.3 (2) at 0 °C and, for one specimen-takinglocation additionally at 33 °C and 80 °C.


For one elbow blank from each initial pipe and impact-energy-versus-temperature curve in accordance with Sec.3.3.7.3 (3) shall be plotted using transverse test specimensfrom one specimen-taking location.


On two longitudinal or transverse test specimens from onespecimen-taking location of each elbow blank it shall be dem-onstrated in accordance with Sec. 3.3.7.3 (4), that the require-ments regarding the NDT temperature are met. If this cannotbe demonstrated, then the NDT temperature shall be deter-mined for each specimen-taking location. This test is not re-quired for a quenched and tempered wall thickness of lessthan 25 mm.


For each elbow blank, the secondary grain size shall be de-termined from a longitudinal cross section of one impact testspecimen from one specimen-taking location, the microstruc-ture shall be evaluated and documented in accordance withSec. 3.3.7.4.



(2) On each pipe elbow, the hardness test shall be per-formed on the extrados of the bend along one surface line,beginning near the pipe elbow ends and continuing in lengthintervals of not more than 1000 mm.



(1) Forged pipe elbows and product forms with a nominalwall thickness greater than 30 mm shall be examined in ac-cordance with the requirements under Sec. 5.4.

(2) The following requirements apply to manual examina-tions and supplement the requirements under Sec. 3.3.8, how-ever, the requirements under Sec. 3.3.8.2.1 (5) cb) and3.3.8.2.1 (6) d) do not apply.

KTA 3201.1



(1) An angle-beam examination shall be performed from theoutside surface in both circumferential directions to detectlongitudinal flaws.

(2) In the case of pipe elbows with an outside diameterequal to or greater than 1000 mm, two additional examina-tions shall be performed from the outside surface, i.e., anangle-beam examination in both axial direction to detecttransverse flaws and a straight-beam examination to detectlamellar tearing.

(3) The examination shall be performed upon the lastforming and heat treatment process.

17.4.2.2 Examination and evaluation

17.4.2.2.1 Examination for longitudinal flaws

The examination shall be performed in accordance with SEP1915. The rectangular grooves shall be machined into theinner and outer surface of the pipe elbow near its averageradius of curvature (cf. Figure 17-1). The sensitivity adjust-ment may also be performed on a pipe-shaped referenceblock, provided the transfer differences due to the bent cou-pling surfaces on the component is taken into account.

a

1:a, b:

Longitudinal reference reflector (outside surface)2:

d

A

B

Longitudinal reference reflector (inside surface)

2

b

Section A-B

1

a

Calibration direction

b

a

Figure 17-1: Location of reference reflectors with respect tothe pipe elbow geometry for longitudinal flawexamination

17.4.2.2.2 Examination for transverse flaws

The examination shall be performed in accordance with SEP1918. The rectangular grooves shall be machined into theouter surface of the pipe elbow at its inner and outer radius ofcurvature (cf. Figure 17-2). The sensitivity adjustment mayalso be performed on a pipe-shaped reference block, providedthe transfer differences due to the bent coupling surfaces onthe component is taken into account.

a

a

2

b

b

(extrados and outer surface)

(intrados and outer surface)

Outer curvature

Inner curvature

Section A-B1

Calibration direction

d

A

B

1:

2:

a

Transverse reference reflector

Transverse reference reflector

a, b:

Figure 17-2: Location of reference reflectors with respect topipe elbow geometry for transverse flawexamination

17.4.2.2.3 Examination for lamellar tearing

The examination shall be performed to comply with the re-quirements of SEP 1919. The rectangular groove shall be ma-chined into the inner surface of the reference block (pipe el-bow) at its mid-radius.


All indications with echo amplitudes equal to or greater thanthe smallest echo height of the reference reflectors as per sec-tions 17.4.2.2.1 to 17.4.2.2.3 shall be recorded.


(1) All product forms with echo heights reaching or exceed-ing the recording limit shall be rejected.

(2) Rejected product forms may be dressed to reach theminimum wall thickness. The dressed areas shall be subjected.Indications on rejected product forms may be examined byother non-destructive procedures (visual examination, radiog-raphy) to detect the type and size of the respective defect. Themanufacturer shall demonstrate the defect harmlessness to theauthorized inspector. Defects not removed shall be recordedand shall not impair periodic inspections.

(3) Dressed areas shall not impair periodic inspections. Thedeviation from the required shape of the examination areasreferred to a reference area of 40 mm x 40 mm shall not exceed0.5 mm. Where smaller reference areas are selected, the re-lated deviation from shape shall be linearly converted withrespect to the side length of the selected reference area.


17.4.3.1 Extent

(1) The entire outside surface of all pipe elbows shall beexamined for surface flaws.

(2) The inner surface of all pipe elbows shall likewise beexamined completely if technically feasible.

KTA 3201.1


The requirements under 5.4.3 apply.

17.5 Identification marking

In addition to the requirements under Sec. 3.5, the followingapplies:

a) If more than one pipe elbow are manufactured from oneinitial pipe the correct correlation of the elbow to this ini-tial pipe shall be ensured.

b) The pipe elbows shall be individually numbered.





(2) For each pipe elbow, the wall thickness shall be deter-mined over its entire chord length including the elbow endsand over its entire circumference, furthermore, depending onthe order specification, either the outside or the inside diame-ter shall be measured. In addition, the out-of-roundness shallbe determined.


The results of the tests in accordance with Secs. 17.3.3.2.1,17.3.3.2.2 (6) and 17.3.3.3 shall be certified by Acceptance TestCertificates 3.1.B in accordance with DIN EN 10 204, the re-sults of all the other tests by Acceptance Test Certificates 3.1.Cin accordance with DIN EN 10 204.

18 Steam generator tubes

18.1 Scope


(1) This section applies to seamless straight and U-tubesmade from one tube without circumferential welds with awall thickness less than 2 mm made of corrosion resistantchrome/nickel steels and nickel or iron/nickel alloys.

(2) The requirements for the materials of these productforms are specified in Sec. A 2 and A 9.

18.1.2 Allowable materials and fabrication procedures

(1) The required values for the mechanical material proper-ties may be achieved by applying different combinations ofheat treatment and cold forming processes.

(2) Special surface treatments (e.g. surface blasting) toachieve internal compressive stress are allowed. This is to becovered by the initial material certification.

18.1.3 Heat treatment

The last heat treatment shall be performed in correspondencewith the requirements under Sec. 3.2.3.

18.1.4 Corrective work

(1) Only machining procedures (e.g. grinding) shall be em-ployed in the repair of surface flaws. No lower value than theminimum wall thickness is allowed.

(2) After corrective work, the corresponding tests shall beperformed.

(3) The details on post-repair tests on blasted tubes shall beagreed with the authorized inspector.

18.2 Requirements

18.2.1 Resistance to intergranular corrosion

In the case of austenitic chrome/nickel steels including thealloy X 2 NiCrAlTi 32 20, a demonstration of the resistance tointergranular corrosion is required. This demonstration is notrequired for nickel alloys (e.g. NiCr 15 Fe).

18.2.2 Surface roughness

The arithmetical mean deviation of the profile Ra shall notexceed the following values:

a) straight tubes

Ra ≤ 1.6 µm, inside and outside,

b) U-bends

Ra ≤ 2.5 µm, inside and outside,

c) surface treated tubes

Ra ≤ 3.5 µm, outside.

18.2.3 Unallowed flaws

(1) Surface flaws with a depth > 0.1 mm are not allowed.

(2) Any other flaw, even with less depth, is not allowed if itseffect cannot be properly judged.

(3) Further details are specified under Sec. 18.4.

18.2.4 Surface condition

The requirements regarding the surface cleanliness shall beagreed upon with the authorized inspector.



18.3.1.1 Forming of lots

The tubes shall be divided into lots of 100 tubes, however aremainder of up to 50 tubes may be uniformly distributedover the individual lots. Quantities and remaining tubes be-tween 51 and 100 shall be considered an individual lot. Allremaining tubes of one lot shall originate from one melt andproceed completely through the straight-tube fabricationprocesses and acceptance tests.

18.3.1.2 Lot-correlation of tubes

Throughout the fabrication procedure an unambiguous corre-lation of the tubes to their respective lot shall be ensured.

18.3.1.3 Specimen-taking

The test coupons shall be taken from tube ends.

KTA 3201.1



(1) Ladle analysis



A product analysis shall be performed on one rolled rod baror on one tube for each melt.

18.3.2.2 Disk pickling test

The head end of each rolled rod bar shall be subjected to adisk pickling test; the results shall be evaluated to complywith the manufacturer’s requirements.


The following tests shall be performed on the tubes in a con-dition as specified under Sections A2 and A9.

(1) Tensile test

Two transverse test specimen from one tube in each lot shallbe subjected to a tensile test, one at room temperature and oneat design temperature.

(2) Drift test

On one end of each tube a drift test shall be performed with a60°-cone and up to a diameter expansion of 20 %.

Where the tubes cannot be unambiguously correlated withregard to their orientation in the tube fabrication run, bothends of the tube shall be subjected to a drift test.


For one tube in each lot, the secondary grain size shall bedetermined and the microstructure be evaluated.

18.3.2.5 Resistance to intergranular corrosion

On one test specimen of each melt, the resistance to inter-granular corrosion shall be demonstrated.



The ultrasonic examinations shall generally be performed onautomatic examination facilities.

18.4.2 Extent, type and point of time

(1) The tubes shall be subjected to an ultrasonic examinationover their entire length and in the condition specified underSec. 18.1.2 in which also the mechanical properties have to bedemonstrated.

(2) Other non-destructive examination procedures may beemployed provided they have the required examination sen-sitivity. The requirements regarding these examinations, es-pecially the required sensitivity, shall be specified in the initialmaterial certification.

Note:For example, a combination of ultrasonic and eddy-current ex-aminations may be employed . In this case, the eddy-current ex-amination will predominantly be used to determine transverseflaws and the ultrasonic examination predominantly to determinelongitudinal flaws.

(3) Unexamined ends shall be discarded.

18.4.3 Procedural requirements and performance of exami-nation

(1) Examination facility

The examination shall be performed by the tube manufacturerusing automatic examination facilities that are equipped withautomatic recording equipment. In addition, automatic sort-ing facilities may also be employed.

(2) Sound beam angles

One ultrasonic examination in the two circumferential direc-tions shall be performed to predominantly determine longi-tudinal flaws and one ultrasonic examination in the two axialdirections to predominantly determine transverse flaws.

(3) Examination density

The examination density is considered to be sufficient if thereference reflectors specified under para (4) are displayed inaccordance with the requirements of para (5) under normaloperating conditions.

(4) Reference reflectors

The reference reflectors shall consist of wedge-shaped notches(saw tooth) in accordance with Figure 18-1 which shall bemachined into the inside and outside surfaces of the referencereflector (reference tube) both in longitudinal and in trans-verse direction. Where other reference reflectors are used,their equivalence shall be proved.

The distance between the individual reference reflectors toeach other and their distances to the tube end shall be suchthat each reflector can be clearly and separately detected.

(5) Intervention limit

Prior to performing the examination, the intervention limit isdetermined by six through transmissions of the reference tubeunder normal operating conditions and with unchanged set-tings of the measurement facility. The reference tube shall beturned after three through transmissions.

Note:For the purpose o f this section, the intervention limit is consideredto be that echo amplitude that equals the minimum echo ampli-tude o f the reference reflector in multiple through transmissionsof the reference tube.

(6) Test-runs during examination

In the course of one shift and at random intervals, however, atleast after every hundredth tube, test-runs shall be performedwith the reference tube to check the settings of the facility.Each individual indication shall be above the interventionlimit. The reference tube shall be turned between two succes-sive test-runs. If this requirement is not met, an additionaltest-run shall be performed. This shall consist of six additionalthrough transmissions of the reference tube under normaloperating condition of the facility with the reference tubebeing turned after the third through transmission. If theevaluation of all seven through transmissions of the referencetube results is no more than one indication for each sound-beam angle (cf. para (2)) with an echo amplitude below theintervention limit, then the examination may be continuedwithout any intervention. If this condition is not met, a read-justment of the measurement facility is required. In this case, are-examination of all tubes tested since the last successful test-run is required.

KTA 3201.1

±

±

± 10%

10%

10%

A

A

60˚

t

= 2.0mm

min. 0.10mm

Section A-A

0.10t = s

Figure 18-1: Dimensions of reference reflectors („saw tooth“)

18.4.4 Acceptance standards

(1) Acceptance limits

Before the start of fabrication the acceptance limit is specifiedon the basis of an available flaw catalogue and by mutualagreement between tube manufacturer, customer andauthorized inspector. This flaw catalogue may be based eitheron the fabrication prior to the test of about 400 tubes with atypical production length or on the previous order unlessessential changes in fabrication or testing have occurred.

(2) Evaluation

Tubes with echo amplitudes equal to or exceeding the accep-tance limits shall be rejected. The evaluation shall be carriedout either on the basis of the recording strip or by an auto-matic sorting facility. In the latter case, the reliability of thesorting facility shall be randomly checked with regard to therecorded indications. In this case, the dimensional checks asper Sec. 18.6 shall also be performed. The acceptance limitshall be continuously reviewed by means of the flaw cata-logues of the running fabrication in accordance with para (3).

Where the acceptance limit is lowered in the course of therunning fabrication, the examination results of the tubes ex-amined so far shall be evaluated again (e.g. by means of re-cording charts).

(3) Flaw catalogue of the running fabrication

A flaw catalogue shall be established for the running fabrica-tion which covers about 1 % of the examined tubes. The re-flections shall be selected, examined and evaluated by mutualagreement with all parties involved and under considerationof the following criteria:

a) Half of all examined locations shall have echo amplitudesbelow the acceptance limit.

b) The echo amplitudes of the examined locations shall bedistributed over the entire registration range as uniformlyas possible.

c) The examination of reflections shall be uniformly distrib-uted over the entirety of fabrication lots.

d) The reflections shall be evaluated with regard to flaw typeand flaw depth and shall be shown as example in micro-graphs.

e) The relationship between echo amplitude on the one handand flaw type and flaw depth on the other shall be evalu-ated appropriately.

The same applies correspondingly to the establishment of apre-fabrication flaw catalogue in accordance with para (1).

18.4.5 Documentation

(1) All echo indications shall be documented over the entirelength of each tube in automatic recording facilities. It shall beensured that the examination results can be clearly correlatedto the individual tube delivered.

(2) The intervention and acceptance limits shall be appro-priately documented. The flaw catalogue of the running fabri-cation shall become part of the documentation.

18.5 Surface examination

(1) Visual inspection

All tubes shall be visually inspected for any inside or outsidesurface flaws. Straight tubes shall be inspected in the finishedcondition, U-bends before bending and in the finished condi-tion after bending.

(2) Surface roughness

The surface roughness Ra shall be determined for the insideand outside surfaces of end sections from one tube per lot.Straight tubes shall be examined in the finished condition, U-bends in the finished condition after bending. For each tubelot, the surface roughness shall additionally be determined inthe bending region of two test bends with the smallest bend-ing radius.




(2) The wall thickness of each tube shall be determined overthe entire length by automatic ultrasonic examination.

(3) The outer diameter shall be determined for each tube. Ifdone by automated ultrasonic examination, the outer diame-ter shall be determined over the entire length of the tube. Ifdone manually, the outer diameter shall be determined withlimit caliper gauges at both ends of the tube and at randompositions over its length.

(4) In addition, the wall thickness and outer diameter of0.5 % of evenly distributed tubes shall be measured at the tubeends with a micrometer and shall be documented.

(5) Straight tubes shall be checked in the finished condition.U-bends shall be checked before bending.

(6) The U-bends shall be checked for dimensional accuracyand out-of-roundness after bending. The extent and details ofthese checks shall be specified in the test and inspection se-quence plan.

18.6.2 Procedural requirements for the check of dimen-sional accuracy with automated ultrasonic facilities

(1) The checks for dimensional accuracy shall be performedwith testing facilities that have been approved for the in-tended dimensional range by the authorized inspector (bysubstitution, an individual certification).

(2) It shall be ensured that the examination is carried out forat least four locations offset by 90 degrees around the circum-ference and that the distance between measurement locationsin axial direction is not larger than one quarter of the outertube diameter.

KTA 3201.1

(3) The reference reflectors used for the wall thicknessmeasurements shall be tube pieces from materials with similartesting characteristics and with a wall thickness in the speci-fied tolerance range. They shall have an outer diameter in theallowable diameter range.

(4) The reference reflectors used for the outer diameterexamination shall be tube pieces from materials with similartesting characteristics and with the outer diameter in thespecified tolerance range.

(5) The acceptance limits are the indications resulting from asingle through transmission from the reference reflectors.

(6) At random intervals during the course of one work shift,however, at least after every hundredth tube, the settings ofthe facility shall be checked. To this end, the reference reflec-tors of the tested tube shall be indicated in one single controlrun under nominal operating conditions. If the indications arebelow the acceptance limit then these values define the newacceptance limit with regard to the evaluation of the recordedindications of the examinations carried out since the last suc-cessful control-run.

(7) All wall thickness measurements over the entire lengthof each tube shall be documented in automatic recordingfacilities. It shall be ensured that the documented results canbe clearly correlated to the individual tube delivered. Theacceptance limits shall be appropriately documented.

18.7 Hydrostatic test

(1) Each tube in its finished condition shall be subjected to ahydrostatic test at 1.3 times the design pressure. Only freshlyprepared de-mineralised water shall be used. The requiredmaximum pressure shall be kept up for at least 10 seconds.

(2) Where surface blasting is intended for the tubes, thehydrostatic test shall be performed prior to blasting.

18.8 Check for cleanliness

(1) Each tube in its finished condition shall be examined forobstructions and cleanliness by blowing a felt plug throughthem. The pressurised air or nitrogen used in this test shall befree of moisture and fat.

(2) The discolouration of the felt plug shall not be strongerthan a sample specimen to be agreed upon with the author-ized inspector.


All tubes shall be subjected to an accepted materials identifi-cation check.


(1) Care shall be taken not to damage the tubes in the courseof identification marking.

(2) All tubes shall be identification marked such that a corre-lation to the tube manufacturer, melt and fabrication lot ispossible. The identification mark may be codified.


The results of the tests in accordance with Secs. 18.3.2.1,18.3.2.2, 18.3.2.3 (3), 18.3.2.3 (4), 18.5 (2), 18.7, 18.8, and 18.9shall be certified by Acceptance Test Certificates 3.1.B in ac-

cordance with DIN EN 10 204, the results of all the other testsby Acceptance Test Certificates 3.1.C in accordance with DINEN 10 204.

19 Seamless extrusion-clad composite tubes

19.1 Scope

(1) This section applies to extrusion-clad composite tubes,e.g. for the control rod nozzles and core instrumentation noz-zles, with a wall thickness of the base metal tube between 10and 30 mm.


19.2 Requirements

(1) The absorbed impact energy on transverse test speci-mens of the base material shall be at least 68 J at 33 °C and thelateral expansion at least 0.9 mm.

Note:The basis for specifying the test temperature o f the notched barimpact test is the consideration that the pressure test temperaturewhich is lower than the operating temperature, however, undermost detrimental conditions shall be not lower than 0 °C, that thistemperature may be not more than 33 K below the temperature atwhich the requirements regarding absorbed impact energy andlateral expansion are met by each individual test specimen.

If the above requirements are not met at 33 °C, additionalnotched bar impact tests (on transverse test specimens) shallbe carried out on sets of three test specimens each to deter-mine the temperature TAV at which these requirements aremet. Hereby, the tests for determining the impact energyversus temperature curves on transverse test specimens shallbe utilised. The pressure test temperature TD shall then be notlower than TAV - 33 K. In the case of notched bar impact tests,the repetition of the test at original temperature is allowedunder the following conditions:

a) The average values of absorbed impact energy and lateralexpansion shall be not lower than the specified single val-ues.

b) Only one test specimen shall show values lower than thespecified single values.

c) The test specimen which failed by not obtaining the speci-fied values shall not show values of the absorbed impactenergy and the lateral expansion that are lower than thespecified single values by 14 J and 0.13 mm, respectively.

When repeating a test, the failed test specimen shall be re-placed by two additional test specimens. These two testspecimens shall be taken from a location as close as possible tothe specimen-taking location of the failed test specimen. Bothof these test specimens are required to obtain the individuallyspecified values. Where the specified single values are notobtained in the re-examination, then that higher temperatureshall be determined at which each individual value meets thespecified requirements. To this end, the available impact en-ergy-versus-temperature-curves shall be taken, which, if re-quired, shall be extended by further tests.

(2) The thickness of the cladding shall be 2.5 mm ± 0.4 mm.When removing liquid penetrate indications from the clad-ding surface, up to 30 % of the inside surface may be groundover. By this procedure, however, the cladding thickness maynot, at any location, be reduced to a value lower than 1.5 mm.

KTA 3201.1

(3) The surface of the cladding material shall be resistant tointergranular corrosion down to a depth of 1.5 mm under allconditions of planned fabrication procedures, especially afterwelding or after heat treatment.

(4) The cladding material on those parts which, in thecourse of further fabrication, will be subjected to weldingwithout weld filler metals, shall show a delta-ferrite content inthe weld zone of between 2 and 10 %. The cladding materialon those parts which, in the course of further fabrication, willbe subjected to welding with weld filler metals, shall show adelta-ferrite content in the weld zone of between 1 and 10 %.A continuous ferritic structure is not allowed in either case.Deviations from these requirements are allowed provided thecharacteristics of the welded joints meet the requirements ofKTA 3201.3.


19.3.1 Condition of test coupons

The tubes shall be tested in the delivery condition. However,if in the course of further fabrication, the tubes are subjectedto stress relief heat treatment, e.g. after welding, they shall betested in the condition of simulation stress relief heat treat-ment; the specifications in the material appendix of Annex Aregarding stress relief heat treatment shall be considered.


The number of specimen-taking locations is specified withrespect to each test under Sec. 19.3.3. The test coupons shall betaken from the ends of the tubes in their fabrication lengths.



Unless otherwise specified in the individual sections, the testsshall always be related to test lots. One test lot shall only con-sist of tubes from one base material melt and from one heattreatment lot and shall contain not more than 20 fabricationlengths. In the case of continuous tempering, 40 tubes fromone melt shall be considered to be one heat treatment lot.

(2) Chemical analysis

a) Ladle analysisA ladle analysis shall be performed for each melt of thebase material and of the cladding material.

b) Product analysisA product analysis shall be performed on the base mate-rial and on the cladding material for one fabrication lengthfrom each melt.

(3) Disk pickling test

The initial material of each fabrication length shall be sub-jected to a disk pickling test. Alternatively, an ultrasonic ex-amination of the initial material may be taken into account.

(4) Hardness testa) The requirements under Sec. 3.3.7.2 shall apply to the

hardness test.b) Prior to specimen-taking, an adequate hardness test shall

be performed on both end faces of each fabrication lengthof the base material.

(5) Tensile test

Two longitudinal test specimens (circular tensile test speci-mens) for each fabrication length shall be subjected to a tensiletest in accordance with Sec. 3.3.7.3 (1), one at room tempera-ture and one at design temperature.

(6) Impact test

One set of longitudinal transverse test specimens for eachfabrication length shall be subjected to an impact test in ac-cordance with Sec. 3.3.7.3 (2) at 33 °C.


For one fabrication length from each test lot an impact-energy-versus-temperature curve in accordance with Sec.3.3.7.3 (3) shall be plotted using longitudinal and transversetest specimens from one tube end. One of the test tempera-tures shall be 33 °C.

(8) Delta-ferrite content

The delta-ferrite content of the cladding material shall bedetermined in accordance with Sec. 3.3.7.5 either by a meltingtest or by calculation under consideration of the nitrogencontent from each chemical composition determined thepiece.

(9) Resistance to intergranular corrosion

The resistance to intergranular corrosion in the outer 1.5 mmof the cladding shall be demonstrated for each clad materialmelt and each heat treatment lot. With regard to the test forresistance to intergranular corrosion in accordance with Sec.3.3.7.6, the sensitisation conditions of the intended subsequentfabrication shall be specified and reported to the tube manu-facturer by the customer when placing the order. The testspecimens shall be prepared in consideration of Sec. 10.1b ofDIN 50 914.

(10) Ring flattening test

One test specimen each from both ends of every fabricationlength shall be subjected to a ring flattening test.

(11) Adhesion test of cladding

For each fabrication length one test specimen shall be sub-jected to a side-bend test.


For each fabrication length, the secondary grain size of thebase material shall be determined and the microstructure ofthe transition zone between base material and cladding shallbe evaluated and documented in accordance with Sec. 3.3.7.4.

On one test specimen in each test lot, the course of hardnessHV 0.5 shall be determined and graphically displayed for thetransition zone along one line of about 15° to the cladding.



(1) The ultrasonic examinations shall generally be per-formed by automatic examination facilities.

(2) Manual ultrasonic examinations are allowed providedthe authorized inspector agrees.

(3) The requirement of Sec. 19.4.3 for the manual perform-ance of the surface crack examination supplement the re-quirements under Sec. 3.3.8.

KTA 3201.1

19.4.2 Ultrasonic examination (automatic)


(1) The examination shall be performed from both the axialand circumferential directions by means of the angle-beammethod from the outer surface to predominantly detect longi-tudinal and transverse defects.

(2) In addition, an examination shall be performed for cladbond or lamellar tearing by means of the straight-beammethod.

19.4.2.2 Procedural requirements and performance ofexamination

(1) Surface condition

The surface of the test objects shall be in a condition adequatefor fulfilling the objective of the examination. This generally isthe tube fabrication condition.

(2) Examination density

The sonic probes shall be guided along helical or straightlines. To ensure a complete examination of the entire tubevolume, it is required to choose the sonic beam spread angle,forward travel rate, number of examination sonic pulse fre-quency and examination speed such that the following valuesare obtained:

a) track superposition ≥ 20% relative to the width of thecrystal or transducer,

b) sonic pulse density 1 pulse per mm for da ≤ 50 mm

c) sonic pulse density 2 pulse per mm for da > 50 mm

(3) Sensitivity adjustment

a) Examination for predominantly longitudinal and trans-verse flaws

The sensitivity shall be adjusted using a reference tubewith sharp-edged rectangular grooves in longitudinal andtransverse direction on the inner and outer side (groovedimensions: depth ≤ 1.0 mm; length = 20 mm; width≥ 1,0 mm).

The amplification shall be adjusted such that the referenceecho amplitude is ≥ 80 % of the cathode ray tube height(CRTH). During the examination the monitor thresholdshall be adjusted to 40 % CRTH (corresponding to 50 % ofthe reference echo amplitude).

If the effective sound beam width (i.e. dB drop relative tomaximum sonic pressure) is < 20 mm, longer referencegrooves may be used.

b) Examination for lack of clad bond and lamellar tearing

The sensitivity shall be adjusted using a reference tubewith a radial flat-bottom bore hole of 10 mm in diameterdown to a depth equal to the cladding thickness.

The amplification shall be adjusted such that the referenceecho amplitude is ≥ 80 % of the cathode ray tube height(CRTH).

During examination the monitor threshold shall be ad-justed to 40 % CRTH.


19.4.2.3.1 Predominantly longitudinal and transverse flaws

(1) Tubes showing flaws with echo amplitudes equal to orgreater than 50 % of the reference echo amplitude under Sec.19.4.2.2 (3) (monitor threshold) shall be rejected.

(2) Remedial work is allowed unless it leads to a lower thanminimum wall thickness.

19.4.2.3.2 Lack of clad bond and lamellar tearing

(1) In the case of tubes showing flaws with echo amplitudesequal to or greater than 50 % of the reference echo amplitudeunder Sec. 19.4.2.2 (3) (monitor threshold), these flaws shall beexamined for areal expansion with the half-value method.

(2) Lack of clad bond between base material and claddingup to 500 mm2 as well as lamellar tearing in the base metal upto 80 mm2 are allowed.

(3) A maximum of two allowable indications per runningtube meter are acceptable provided the distance between twoindications is at least equal to the length of the larger reflector.

19.4.2.3.3 Toe of welds

In the region within 20 mm of the toe of weld, no flaws withecho amplitudes equal to or greater than 50 % of the echoamplitude of the reference reflector under Sec. 19.4.2.2 (3)(monitor threshold) are allowed.



(1) The entire inside and outside surface in the finishedcondition shall be subjected to a surface crack examination.

(2) A raw surface that, in the course of fabrication, will notanymore be subjected to any mechanical processing shall beconsidered to be in the „finished condition“.


(1) No indication that might indicate the existence of cracksis allowed. Indications with an actual length of less than 1.5mm where the image has not essentially changed after half-anhour of developing time are acceptable.

(2) Indications with a length up to 6 mm are acceptableprovided it can be shown that they are caused by non-metallicinclusions.

(3) The frequency of acceptable indications may locally notbe larger than 10 per square decimetres. Regions with largerflaw expansions or frequencies shall be repaired or these re-gions, by agreement between tube manufacturer and author-ized inspector, shall be subjected to additional examinationsrequired to demonstrate the usability of the tube.

(4) Any tube that does not meet these requirements shall berejected.

(5) Remedial works is allowed unless it leads to a lowerthan minimum allowed wall thickness.





KTA 3201.1

(2) After separation into finished lengths, each tube shall besubjected to a check for dimensional accuracy including ameasurement of the cladding thickness. The values deter-mined shall be recorded in an as-built drawing or an as-builtrecord. The as-built records shall be available for the accep-tance test.

19.7 Hydrostatic test

Each tube (in fabrication lengths) shall be subjected to a hy-drostatic test at 1.3 times the design pressure. The requiredmaximum pressure shall be maintained for at least 30 sec-onds.


The results of the tests in accordance with Secs. 19.3.3 (2),19.3.3 (3), 19.3.3 (4), 19.3.3 (8), 19.3.3 (9), and 19.3.3 (12) shallbe certified by Acceptance Test Certificates 3.1.B in accordancewith DIN EN 10 204, the results of all the other tests by Accep-tance Test Certificates 3.1.C in accordance with DIN EN 10 204.

20 Bars and rings for bolts, nuts and washers, as well asbolts, nuts and washers (dimensions exceeding M 130)

20.1 Scope

(1) This section applies to rolled or hammer forged bars,forged stepped bars as well as individually forged rings fromquenched and tempered steel from which, by further machin-ing procedures, the bolts for the main cover flange of thereactor pressure vessel and other bolts with dimensions inexcess of M 130 as well as the corresponding nuts and wash-ers are produced.

(2) This section also deals with the tests and examinations ofthe finished bolts, nuts and washers.


20.2 Requirements


20.3 General fabrication requirements

(1) Bars intended for nuts and washers shall be hollowbored before tempering.

(2) Repair welding is not allowed.


20.4.1 Specimen-taking locations and specimen orientationNote:Examples for specimen-taking locations see Figure 20-1.

20.4.1.1 Bars

(1) In the case of bars, longitudinal test specimens shall betested. The specimen-taking locations shall be positioned suchthat the middle of the test coupon is at least one half of thequenched and tempered diameter beneath the end face edgeslevelled for heat treatment. The specimen axis shall lie at leastone sixth of the quenched and tempered diameter beneath thecylindrical outside surface. Where a larger difference existsbetween finished diameter and quenched and tempered di-

ameter, the region of the finished part shall be included in thetest.

(2) Where the bars are hollow bored prior to tempering, thespecimen-taking locations shall meet the same requirementsas specified for rings under Sec. 20.4.1.2.

(3) Non-stepped bars with a length up to and including4000 mm shall be tested at one end and with a length excee-ding 4000 mm at both ends.

≥≥≥

≥

≥

D

aD

aDD s

s

s/2 s/2

i

Individually forged rings

for washers

tempering contourtest coupon

delivery contour

for nuts

b

b/2

Non-steppedforged rodsStepped

/2L t

/2d/

2

D/2

D/6D/6

forged rods

D

tL

D/6

D

d/6

i

s/2

D/6

d

tL

d/6

L t

Figure 20-1: Examples for specimen-taking locations

KTA 3201.1

(4) Stepped bars with a length up to and including 4000 mmshall be tested at the largest cross-section, unless otherwisespecified in the initial material certification. Stepped bars witha length exceeding 4000 mm shall be tested at both ends andadditionally at the largest cross section.

20.4.1.2 Rings

In the case of forged rings for nuts and washers, tangentialtest specimens shall be tested. The specimen-taking locationsshall be positioned such that the middle of the test coupon isat least one half of the quenched and tempered diameter be-neath the end face edges levelled for heat treatment. Thespecimen axis shall lie at one half of the quenched and tem-pered wall thickness.

20.4.2 Extent of tests on bars and rings


(1) Ladle analysis



For each melt and heat treatment lot a product analysis shallbe performed with respect to the chemical elements specifiedin Sec. A 11 for the individual steels.



The mechanical properties shall be determined for the finalheat treatment condition, i.e. the quenched and temperedcondition or the quenched and tempered and stress relief heattreated condition.

(2) Hardness test

Each bar shall be subjected to a hardness test along one sur-face line and continuing in length intervals of about 1000 mm.The two bar ends shall be included in this test.

Each forged ring shall be subjected to a hardness test on oneend face. In the case of rings from which more than one fin-ished product is fabricated, both end faces shall be subjectedto a hardness test.

(3) Tensile test

In the case of non-stepped bars, one test specimen from eachspecimen-taking location shall be subjected to a tensile test atroom temperature. Additionally, for each dimension, eachmelt and heat treatment lot, one tensile test specimen from thesoftest bar end shall be subjected to a hot tensile test at designtemperature. In the case of stepped bars, one test specimenfrom each specimen-taking location shall be subjected to atensile test at room temperature. Additionally, for each di-mension, melt and heat treatment lot, one tensile test speci-men from the largest cross-section of the softest bar shall besubjected to a hot tensile test at design temperature.

In the case of forged rings for nuts, for each dimension, meltand heat treatment lot, however, from at least 25 pieces, twotensile test specimen each from the hardest and softest ringsshall be subjected to a tensile test, one each at room tempera-ture and at design temperature.

(4) Impact test

a) In the case of bars, for each specimen-taking location oneset of notch-bend test specimen shall be tested at +20 °C.

b) In the case of forged rings for nuts, for each dimension,melt and heat treatment lot, however, for at least every 25pieces, one set of notch-bend test specimens from thehardest and the softest rings shall be tested at +20 °C.

c) In the case of forged rings for washers, for each dimen-sion, melt and heat treatment lot, however, for at leastevery 100 pieces, one set of notch-bend test specimensfrom the hardest and the softest rings shall be tested at+20 °C.


(1) Prior to subsequent fabrication, each part shall be visu-ally inspected on all sides for surface flaws.

(2) The requirements under Sec. 3.3.7.10 shall apply to thevisual inspection.


Prior to subsequent fabrication, each part shall be subjected toa check for dimensional accuracy in accordance with Sec.3.3.7.8.


Prior to subsequent fabrication, all parts shall be subjected toan accepted materials identification procedure.

20.4.3 Extent of tests on bolts, nuts and washers in the fin-ished condition




Each part in its finished condition shall be subjected to a checkfor dimensional accuracy in accordance with Sec. 3.3.7.8.


Each part in its finished condition shall be subjected to anaccepted materials identification procedure. In those caseswhere the part is manufactured from a bar or ring that wasidentification checked in accordance with Sec. 20.4.2.5 and towhich the identification mark was subsequently transferredby the authorized inspector, no further identification check isrequired.



The following requirements apply to manual ultrasonic ex-aminations and supplement the requirements under Sec. 3.3.8,however, the requirements under Sec. 3.3.8.2.1 (5) cb) and3.3.8.2.1 (6) d) through f) do not apply.



(1) Bars shall be examined in accordance with the require-ments under Sec. 14.4.2.1. In addition, straight beam scanningshall be performed. The incidence angle for angled-beamscanning in circumferential direction shall be 35 degrees.

KTA 3201.1

(2) In the case of hollow forged rings, the requirementsunder Sec. 5.4 apply. The requirements of Secs. 5.4.2.3, 5.4.2.4and 5.4.3 shall not apply.


All indications with echo amplitudes equal or greater thanthose shown in Table 20-1 shall be recorded.

Diameter of the respectivereference disk reflector,

mm

Straight beamscanning

Angle-beamscanning

30 < d (s) ≤ 60 2 2

60 < d (s) ≤ 120 3 2

d (s) > 120 3 3

Table 20-1: Recording and acceptance limits for ultrasonicexamination


Indications whose echo amplitude reaches or exceeds therecording limit to Sec. 20.5.2.2 are not permitted.



The entire surface of each bolt, nut and washer shall be sub-jected to a surface crack examination in the finished conditionof the product.

20.5.3.2 Procedural requirements

The bolt shaft shall be subjected to a magnetic particle exami-nation.

The threaded region may be subjected to a liquid penetrantexamination.


(1) No indication that might indicate the existence of cracksor crack-type flaws is allowed.

(2) In the magnetic particle examination, any indicationwith a length of less than 3 mm is acceptable provided it canbe shown that its cause is a non-metallic inclusion.

(3) In the liquid penetrant examination, any indication withan actual length below 1.5 mm where the image has not es-sentially changed after one half hour of developing time isacceptable.

(4) The frequency of acceptable indications may locally notbe larger than 10 per square decimetres.


The identification marking shall contain the following infor-mation:



c) melt number of identification code,

d) test coupon number,

e) certification stamp of the authorized inspector.


The results of the tests in accordance with Secs. 20.4.2.1,20.4.2.2 (2), 20.4.2.5, and 20.4.3.3 shall be certified by Accep-tance Test Certificates 3.1.B in accordance with DIN EN10 204, the results of all other tests by Acceptance Test Certifi-cates 3.1.C in accordance with DIN EN 10 204.

21 Bars and rings for bolts, nuts and washer as well as bolts, nuts and washers (dimensions equal to or smaller thanM 130)

21.1 Scope

(1) This section applies to rolled or hammer forged barsfrom which stud screws or necked-down bolts with dimen-sions equal to or smaller than M 130 as well as the corre-sponding nuts and washers are produced by machining pro-cedures. This section does not apply to hot-pressed or cold-shaped parts. Only the threads of bolts may also be rolled.

(2) This section also deals with the tests and examinations ofthe finished bolts, nuts and washers as well as expansionsleeves.

(3) The requirements for the materials of these productforms are specified in Secs. A11 and A12.

21.2 Requirements


21.3 Fabrication requirements

Repair welding is not permitted.


21.4.1 Specimen-taking locations and specimen orientation

(1) The tests shall be performed on longitudinal test speci-mens.

(2) The specimen-taking locations shall be positioned suchthat the middle of the test coupon is at least one half of theheat treatment diameter beneath the end faces levelled forheat treatment. In the case of bars with a diameter equal to orsmaller than 40 mm, the test coupon axis shall lie in the longi-tudinal axis of the bars. In the case of bars for screws and boltswith a diameter exceeding 40 mm, the test coupons axis shalllie at least one sixth of the heat treatment diameter, or as closeto this position as possible, beneath the cylindrical outsidesurface. In the case of bars for nuts, washer and expansionsleeves the test coupon axis shall lie in the middle of the wallthickness of the finished product.

21.4.2 Extent of tests on bars


(1) Ladle analysis


Diameter, widthacross flats, sidelength d or wall

thickness s in the testcondition, mm

KTA 3201.1


For each melt and heat treatment lot a product analysis shallbe performed with respect to the chemical elements specifiedin Annex A for the individual steels.



(2) The hardness shall be determined at both ends of eachbar to verify the uniformity of heat treatment.



The mechanical properties shall be determined for the finalheat treatment condition, i.e., in the quenched and temperedcondition or in the quenched and tempered and stress reliefheat treated condition.

Equally dimensioned bars from the same melt and same heattreatment lot shall be grouped into test lots of not nor than 500kg. From each test lot the hardest and the softest bar shall betested.

Bars with a heat treatment length up to and including4000 mm shall be tested on one end only.

Bars with a heat treatment length exceeding 4000 mm shall betested on both ends.

(2) Tensile test

In the case of bars intended for screws, bolts, nuts and expan-sion sleeves, one tensile test specimen from each specimen-taking location shall be subjected to a tensile test at roomtemperature.

Additionally, one tensile test specimen from one end of thesoftest bar shall be subjected to a hot tensile test at designtemperature.

In the case of bars intended for washers, one tensile testspecimen from each specimen-taking location shall be sub-jected to a tensile test at room temperature.

(3) Impact test

For each specimen-taking location one set of notch-bend testspecimens shall be tested at +20 °C.

21.4.2.4 Non-destructive examinations

Each bar shall be examined in accordance with the require-ments of Secs. 20.5.1 and 20.5.2. Differing herefrom, straightbeam scanning shall be performed on the front ends in thecase of diameters and widths across flats or side lengthsgreater than 30 mm, and where the dimensions exceed 60 mmangle-beam scanning shall be performed in both circumferen-tial directions.




Prior to subsequent fabrication, each bar shall be subjected toa check for dimensional accuracy in accordance with Sec.3.3.7.8.


Prior to subsequent fabrication, each bar shall be subjected toan accepted materials identification check.

21.4.3 Extent of test for screws, bolts, nuts, washers, andexpansion sleeves in the finished condition

21.4.3.1 Non-destructive examinations

Each piece in its finished condition shall be subjected to asurface crack examination in accordance with Sec. 20.5.3.




Each screw, bolt, nut, washer, and expansion sleeve in itsfinished condition shall be subjected to a check for dimen-sional accuracy in accordance with Sec. 3.3.7.8.


(1) Each part in its finished condition shall be subjected toan accepted materials identification check.

(2) In those cases where the part is manufactured from a barthat was identification checked in accordance with Sec.21.4.2.7 and to which the identification mark was subse-quently transferred by the authorized inspector, no furthermaterials identification check is required.


The identification marking should contain the following in-formation:



c) melt number or identification code,

d) test lot number,


In the case of small parts where a complete identificationmarking cannot be applied due to lacking space, the identifi-cation of the material manufacturer, the material identifica-tion, the melt number, and the test lot number may be com-bined in a single identification code.


The results of the tests in accordance with Secs. 21.4.2.1,21.4.2.2, 21.4.2.7, and 21.4.3.4 shall be certified by AcceptanceTest Certificates 3.1.B in accordance with DIN EN 10 204, theresults of all the other tests by Acceptance Test Certificates3.1.C in accordance DIN EN 10 204.

22 Sheets, plates, bar steel and forgings from stainless aus-tenitic steels

22.1 Scope

(1) This section applies to stainless austenitic steels in thefollowing product forms:

a) sheets and plates, hot fabricated,

KTA 3201.1

b) bar steel, hot fabricated, or

c) forgings except for plates

for pressure-retaining components.


(3) For hot (operating temperature ≥ 200 °C) reactor watercontaining pipework and components in boiling water reactorplants only the steel grade X 6 CrNiNb 18 10 S, and only withthe additional requirements of Table A-3-1, footnote 4, shallbe used.

22.2 Requirements




22.3.1.1 Sheets and plates

(1) The test coupons shall be taken as transverse test cou-pons.

(2) DIN 17 440 applies regarding the depth of specimen-taking.

(3) The following requirements apply to plates on the as-sumption that the direction of main forming of the initial platelies in the head-to-tail direction of the ingot and that it is pos-sible to identify the head and tail ends of the plate.

(4) If this assumption does not apply in part or as a whole,possibly deviating requirements regarding specimen-taking aswell as test specimen direction and orientation shall be speci-fied in the initial material certification.

(5) The test coupons shall be taken from the middle of thehead and the tail of each rolled plate and about 25 mm be-neath the end face surfaces. In the case of rolled plates with alength ≤ 5000 mm and a thickness ≤ 20 mm the test couponsshall be taken only from one end face.

22.3.1.2 Bars

(1) In the case of bar diameters or bar widths equal to or lessthan 100 mm longitudinal test specimens and for bar diame-ters or bar widths exceeding 160 mm transverse test speci-mens shall be tested. In the range of dimensions greater than100 mm, but smaller than 160 mm transverse test specimensmay be taken instead of longitudinal test specimens.

(2) The distance of the specimen-taking location beneath theend face surfaces shall be 25 mm.

(3) In the case of rods or bars with a raw weight (i.e., theweight at the time of heat treatment) exceeding 500 kg and alength exceeding 2000 mm, the test coupons shall be takenfrom both ends of each bar.

(4) In the case of bars with a raw weight exceeding 500 kgand a length equal to or less than 2000 mm, the test couponsmay be taken from only one end of each bar.

(5) In the case of rods and bars with a raw weight equal toor smaller than 500 kg the test coupon shall be taken fromonly one end.

(6) Bars from the same melt and heat treatment and similardimensions shall be grouped together in lots of 500 kg each.

From each lot two sets of test specimens shall be tested.Overall, only four sets of test specimens need to be tested foreach melt.

22.3.1.3 Forgings (except for plates)

(1) The specimen-taking locations shall be specified in thespecimen-taking plan (cf. Sec. 2.5.4.2.4). The test coupon shall,as far as possible, be taken transverse to the major direction offorming.

(2) The test coupons (longitudinal and transverse test cou-pons) shall be taken from specimen-taking locations that lie25 mm beneath the end face surfaces.

(3) In the case of forgings with a raw weight exceeding5000 kg, each piece shall be tested at not less than threespecimen-taking locations.

(4) In the case of forgings with a raw weight exceeding500 kg and equal to or smaller than 5000 kg, each piece shallbe tested from two specimen-taking locations which shall beoffset by 180 degrees to each other. In the case of a diameter-to-length ratio equal to or greater than 1, the two specimen-taking locations shall be either at the head or the tail end face.In the case of a diameter-to-length ratio less than 1, one of thetwo specimen-taking locations shall be at the head and theother at the tail end face.

(5) Forgings from the same melt and with the same heattreatment and similar dimensions having a raw weight equalto or smaller than 500 kg shall be grouped into lots of 500 kgeach. Two sets of test specimens shall be tested from each lot.


22.3.2.1 Chemical analysis.


(2) Product analysisOne product analysis shall be performed:

a) for each rolled plate and plate at the head end,

b) for each bar with a raw weight exceeding 500 kg at thehead end,

c) for one piece in each lot in the case of bars and forgingswith a raw weight equal to or smaller than 500 kg,

d) for one forging at the head end in the case of forgings witha raw weight exceeding 500 kg , but equal to or smallerthan 5000 kg,

e) for each forging with a raw weight exceeding 5000 kg atthe head and the tail end.

The nitrogen content shall be determined if the delta-ferritecontent is determined analytically.


(1) Tensile testFor each specimen-taking location two test specimens shall besubjected to a tensile test, one at room temperature and one atdesign temperature.

(2) Impact testFor each specimen-taking location one set of impact testspecimens shall be subjected to an impact test at room tem-perature.

KTA 3201.1


The grain size and microstructure shall be determined for onespecimen-taking location from one piece of each lot in the caseof bars and forgings with a raw weight of equal to or smallerthan 500 kg and from each piece of the lot in the other cases.

22.3.2.4 Delta ferrite content

The delta ferrite content shall be determined in accordancewith Sec. 3.3.7.5 for those parts which, in the course of furtherfabrication, will be subjected to welding; the method usedmay be by bead welding the test specimen or by a mathemati-cal estimation under consideration of the nitrogen contentfrom each chemical composition determined on an individualpiece (cf. 22.3.2.1).


For each melt and heat treatment lot one test specimen shallbe tested for resistance to intergranular corrosion.



The following requirements apply to manual examinationsand supplement the requirements under Sec. 3.3.8. The re-quirements of Sec. 3.3.8.2.1 (5) cb) do not apply.


22.4.2.1 Adjustment of the system

Differing from Sec. 3.3.8.2.1 (3) the following applies:

The side-drilled holes for the sensitivity adjustment shall havea diameter of 4 mm and a length of 30 mm.


22.4.2.2.1 Forged or rolled steels

(1) For diameters exceeding 30 mm straight-beam scanningin axial direction shall be performed.

(2) For diameters and side lengths exceeding 60 mm,straight-beam scanning shall be performed in axial directionadditionally from the head end. Where during straight-beamscanning in axial direction, no sufficient signal-to-noise ratiocan be maintained over the entire length of the bar, the ex-aminations shall be performed on the cut-off bar or by meansof 45° angle-beam scanning in both axial directions.

(3) In the case of diameters exceeding 120 mm angle-beamscanning shall be performed additionally in both circumfer-ential directions.

(2) The incident angle for angle-beam scanning in circum-ferential direction shall be 35 degrees.

22.4.2.2.2 Drop forgings

(1) The initial material for drop-forgings may also be testedin the non-solution heat treated conditions unless restrictionsas to the examinability exist.

(2) Initial materials with diameters or side lengths exceeding30 mm shall be examined by means of the straight-beammethod from the cross-sectional surface.

(3) Drop forgings greater than DN 100 shall be examined bymeans of the straight-beam method from the external surfacesif their radius of curvature exceeds 30 mm.

22.4.2.2.3 Hammer forged valve bodies

The entire volume shall be examined from all external sur-faces with the straight-beam method. Additionally, the cylin-drical regions shall be examined once in the pre-machined orin the finished condition with the angle-beam method in bothcircumferential directions.

22.4.2.2.4 Seamless hollow parts

The examination shall be performed from one cylindricalsurface and both end faces by means of the straight-beammethod as well as from one cylindrical surface in both circum-ferential directions by means of the angle beam method.Where the prescribed straight-beam examinations are notpossible for geometric reasons, each impracticable straight-beam scanning direction shall be substituted by two oppositeangle-beam scanning directions on the respective plane.

22.4.2.2.5 Forged blocks and plates

The requirements of Sec. 3.3.8.2.1 (4) apply.

22.4.2.2.6 Plates

The requirements of Sec. 7.4 apply.

22.4.2.3 Examination technique and examinability

22.4.2.3.1 Examination technique

(1) For the straight-beam method frequencies between 2 and5 MHz and for the angle-beam method a frequency of 2 MHzshall be selected where during the examination of weld edgesand nozzle areas miniature transverse wave probes shall basi-cally be used. The examination shall be performed to detectlongitudinal defects (defect orientation parallel to the direc-tion of welding progress). Here, the incidence angle shall beselected such that the angle at the inner surface lies within theusable range of the corner effect (impinging angle possibly 35degrees to 55 degrees).

(2) The examination technique for examining the weld edgeand nozzle areas shall be determined on a similar referencereflector or if practicable (e.g. where excess lengths are avail-able) on the test object. When using a reference reflector itshall be representative for the test object with respect to ge-ometry, acoustic properties and surface condition.

(3) To obtain a sufficient signal-to-noise ratio of at least 6 dBor to be within the recording limits the examination techniquemay be optimised upon agreement with the authorized in-spector, e.g. by the following measures:

a) probes with a low nominal frequency,

b) use of frequency selective equipment,

c) use of twin probes,

d) use of highly attenuated probes,

e) use of longitudinal waves also for the angle beam method.

22.4.2.3.2 Determination of examinability

(1) The examinability shall be determined for each test ob-ject.

KTA 3201.1

(2) The examinability shall be determined jointly by theparties involved in the examination.

(3) The wave lengths used for determining the examinabi-lity shall not be greater than those used for the straight andangle beam examinations that follow.

(4) For plates the back wall echo shall be determined in allcentre ranges of a grid of 200 mm and at the border line bymeans of straight-beam scanning and at intended frequency.

(5) For all other product forms a grid of 200 mm shall beprovided on each test object in the area of parallel or concen-tric walls to determine the examinability. In all centre rangesof this grid and additionally on all border lines of forgings theback wall echoes shall be determined by straight-beam scan-ning in wall thickness direction. In areas of non parallel ornon-concentric walls reference reflectors shall be used (e.g.boreholes, edges or through-transmission) for this examina-tion.

(6) The number and density of examination points requiredto determine the examinability shall be in a reasonable rela-tionship to the size and geometry of the test object. Here, theabsolute number of measuring points may be limited to 50.

(7) Where the examination has to be performed by straight-beam scanning, the sound wave attenuation in areas with aback wall echo attenuation greater than 6 dB shall also bedetermined by means of angle-beam scanning, e.g. by V-scanning.

(8) Areas with a high sound wave attenuation (back wallecho variation greater than 12 dB) shall be identified and beenveloped by a narrow measuring point grid in which casethe absolute number of measuring points shall be increasedaccordingly. The maximum sound attenuation shall be re-corded for each required scanning direction.

(9) For the weld edges and nozzle areas the examinabilityshall be determined for the conditions of weld examination.This shall be done, like for the examination to follow, bymeans of angle-beam scanning. A circumferential groove asreference reflector shall be provided on the test object in thearea where the weld will be laid, however, at a sufficient dis-tance to the edge. The grooves shall not exceed a width of 1.5mm, the reflection area shall be perpendicular to the surface.The depth of the reference reflector shall be determined independence of the wall thickness of the finished part in ac-cordance with Table 22-1. Where the reflector cannot be pro-vided on the test object, a reference reflector in accordancewith Sec. 22.4.2.3.1 (2) with a circumferential groove (if practi-cable over the full circumference, but at least with a length of50 mm) shall be provided. On the test object with circumfer-ential groove the groove shall be scanned over the full circum-ference. By observation of the groove echo the area with thegreatest sound attenuation will be determined.

Where using a reference reflector, the test object areas withthe greatest sound attenuation shall be determined by observ-ing the edge reflection. By comparison of the edge reflexion atthe test object and the reference reflector the differences inamplification referred to the reference echo amplitude shall bedetermined in accordance with Sec. 22.4.2.7 (4) and be takeninto account.

Wall thickness s, mm 8 < s ≤ 20 20 < s ≤ 40 40 < s

Groove depth, mm 1.5 2 3

Table 22-1: Depth of reference reflector for the examinationof weld edges end nozzle areas

22.4.2.3.3 Unrestricted examinability

If it can be proved for the area under examination with thegreatest sound attenuation that

a) for plates the required recording limits to 7.4.2.3

b) for all the other product forms with respect to the straightand each angle beam scanning method the recording lim-its to Sec. 22.4.2.7

can be satisfied, the test object has unrestricted examinability.

22.4.2.3.4 Restricted examinability

(1) Where for one or more sound beam entry directions in asound attenuation region the recording limit according to Sec.22.4.2.7 or the required signal-to-noise ratio of 6 dB cannot bemaintained even with an optimised examination technique(see Sec. 22.4.2.3.1 (2)), these volumetric regions with re-stricted examinability and the corresponding degree of restric-tion shall be determined.

(2) If, in the course of subsequent mechanical processing,more favourable conditions with regard to ultrasonic exami-nations are created for these regions (e.g. reduction of the wallthickness, shorter sound paths, removal of the regions of re-stricted examinability), then the ultrasonic examination of theregions in question may be carried out for the missing beam-ing directions in this subsequent fabrication condition. Thisexamination may also be carried out by the subsequent manu-facturer, provided the producer of the forging and the subse-quent manufacturer agree. If the required testing sensitivity isachieved in the subsequent fabrication condition, these re-gions shall also be considered to be unrestrictedly examinable.

22.4.2.4 Sensitivity adjustment

(1) During the sensitivity adjustment the largest soundwave attenuation values shall be considered for all probes andbeaming directions.

(2) The evaluation of the echo indications shall be carriedout with respect to the sound wave attenuation determinedin the immediate vicinity of the echo indications.

(3) When examining the weld edge and nozzle areas thesensitivity shall be adjusted to the reference echo method. Inaddition to the requirements of Annex B the following applies.The sensitivity shall be adjusted on a rectangular groove witha width not to exceed 1.5 mm and the reflection area of whichis perpendicular to the surface. The groove depth shall befixed in dependence of the wall thickness of the finished partin accordance with Table 22-1. Where an equivalent referencereflector is used, the groove length shall be 50 mm with thegroove run-out not being taken into account. The run-outradius shall not exceed 50 mm. Where the sensitivity is ad-justed on the test object, the groove shall be provided on thecircumference with sufficient distance to the edge.

22.4.2.5 Size of reflectors

Deviating from Sec. 3.3.8.2.1(8) the reflector size is given bythe probe movement at which the echo height has dropped by6 dB under the maximum echo amplitude (half-value methodaccording to Sec. B 5.2.3).

22.4.2.6 Types of examination

(1) The test objects shall be subjected either to an overall ul-trasonic examination or to a selective ultrasonic examination.

KTA 3201.1

Whether an overall or selective ultrasonic examination is to beperformed shall be agreed between the forging manufacturerand the manufacturer and be recorded in the design reviewdocuments.

The type of examination shall be indicated in the test record as„overall US“ or „selective US“.

(2) In the overall ultrasonic examination a detailed knowl-edge of the components to be fabricated from the test object isnot required. In this examination the acceptance limit is equalto the recording limit.

(3) In the selective ultrasonic examination it is required toknow the shape and final dimensions of the components to befabricated from the test object. To be able to correctly applythe recording limits and evaluation criteria on the nominalwall thickness, shape and location of the walls of the finishedcomponent it is required that at the time of examinationdrawings of the components to be fabricated from the testobject are available. These drawings shall be submitted by thepurchaser of the test object.

Note:The nominal wall thickness is the wall thickness indicated in thedrawing of the finished component (used in the power plant).


(1) For all forgings the following shall be recorded:

a) all echo indications the amplitude of which is equal to orgreater than the values indicated in Tables 22-2 or 22-4,

b) locations on forgings with wall thicknesses, diameters orside lengths equal to or exceeding 100 mm where the backwall echo to be expected drops to a value near the record-ing limit.

(2) In an overall ultrasonic examination in accordance withSec. 22.4.2.6 (2) and in the examination of initial material fordrop forgings the recording limit of Table 22-2 shall be used.

(3) In the selective ultrasonic examination in accordancewith Sec. 22.4.2.6 (3) the recording limits of Table 22-4 apply.

To obtain a sufficient signal-to-noise ratio (6 dB from the re-cording limit) the recording limit may partially be raised by6 dB for the respective sound beam entry positions and volu-metric regions. These regions as well as the recording limitsobtained for the different beam entry directions shall be re-corded.

However, the evaluation criteria according to Sec. 22.4.2.8.3refer to the originally prescribed recording limit to Table 22-4.

Where the raised recording limit cannot be obtained in con-sideration of the extent of restrictions (number and type ofbeam entry directions, number and size of volumetric re-gions), substitute measures shall be agreed with the author-ized inspector.

(4) When examining the weld edge and nozzle areas allindications shall be recorded which are equal to or greaterthan the reference echo amplitude. The reference echo ampli-tude is the echo height of the reference reflector to Table 22-1reduced by 12 dB. In addition, regions shall be recordedwhere the signal-to-noise ratio is less than 6 dB.



All indications liable to record during angle-beam scanningwhich are not liable to record during straight-beam scanning

shall be thoroughly examined with respect to their orienta-tion. Indications with a size exceeding 10 mm in thicknessdirection are not permitted.

22.4.2.8.2 Forged or rolled bars and initial material for dropforgings

Echo indications up to the recording limits specified in Table22-1 are permitted.

22.4.2.8.3 All other product forms

(1) When referring the echo height to the dimension in thetest condition, echo indications up to the recording limitsspecified in Table 22-2 are permitted.

(2) When referring the echo height to the nominal wallthickness of the finished product, the following requirementsof para 3 to 7 apply.

(3) In the case of straight and angle-beam scanning echoindications exceeding the recording limits specified in Table22-4 by up to 12 dB are permitted.

(4) The allowable frequency of recorded reflections shall be,in the case of nominal wall thicknesses or diameters of:

a) s or d ≤ 60 mm 3 per m2 locally and2 per m2 overall,

b) s or d > 60 mm 5 per m2 locally and3 per m2 overall.

In the case of an examination with raised recording limit inaccordance with Sec. 22.4.2.7 (3) only half the number of re-corded reflexions is permitted.

(5) In the case of straight-beam scanning in wall thicknessdirection reflexions with a length smaller or equal to thenominal wall thickness are permitted.

(6) For the other scanning direction reflexions with a lengthsmaller than or equal to the nominal wall thickness, but atmaximum 50 mm, are permitted.

(7) The minimum distance of the recorded reflexions fromthe final surface shall not be less than the values specified inTable 5-2.

22.4.2.8.4 Regions of weld edges and nozzles

(1) Indications exceeding the recording limit by up to 6 dBare permitted if their number per meter of weld edge length ata minimum recording length of 10 mm is limited to 3 indica-tions, and at a maximum recording length of 20 mm to oneindication.

(2) Where these limits are exceeded or areas are presentwhere the groove or weld edge signal-to-noise ratio is lessthan 6 dB, further steps shall be agreed with the authorizedinspector.



All accessible surfaces on the finished product shall be sub-jected to a liquid penetrant examination.


(1) The requirements specified in Table 22-3 apply.

KTA 3201.1

(2) The frequency of acceptable indications shall, relative tothe entire surface, not exceed 10 per square decimetre and,locally, 5 per square decimetre.

22.5 Examination procedures to be applied

(1) With regard to the examination for resistance to inter-granular corrosion in accordance with DIN 50 914 the sensiti-sation conditions required of the intended fabrication proce-dures shall be specified for the material manufacturer uponplacing the order.

(2) The details regarding the determination of the deltaferrite content in accordance with Sec. 22.3.2.4 are specified inAnnex D.


All parts shall be subjected to a materials identification check.Those parts which were subjected to a product analysis inaccordance with Sec. 22.3.2.1 (2) may be exempted from thischeck.


In addition to the requirements under Sec. 3.5 the followingapplies:

In the case of a lot-oriented testing in accordance with Secs.22.3.1.2 and 22.3.1.3, each part shall be marked with the lotnumber.






The results of the tests in accordance with Secs. 22.3.2.1,22.3.2.3, 22.3.2.4, 22.3.2.5, and 22.6 shall be certified by Accep-tance Test Certificates 3.1.B in accordance with DIN EN10 204, the results of all the other tests by Acceptance TestCertificates 3.1.C in accordance with DIN EN 10 204.

Scanningdirections

Wall thick-ness in testconditions (mm)

Reference Echo MethodRecordable echo ampli-tudes referenced to a4 mm cylindrical borehole

DGSMethodCirculardiskreflector

all ≤ 60 50% (-6 dB) 3

> 60 100% 4

Table 22-2: Recording limits and acceptance standards forultrasonic examination on forgings with refer-ence to the dimensions in the test condition andinitial material for drop-forged parts

Indications≤ 3 mmindividual

Circularindications> 3 mm to≤ 6 mm

Circularindications> 6 mm

Linearindications 1)

> 3 mm

allowable,shall not beincluded intheevaluation

allowable,shall beincluded inthe fre-quency

notallowable

not allowable.If it is shown that theindications are due tocarbon nitride inclu-sions, indications upto ≤ 6 mm are allowedand shall be includedin the frequency.

1) A liquid penetrant indication is considered to be linear (linearindication) if the length of its longest dimension is at least threetimes larger than the length in transverse direction.

Table 22-3: Acceptance standards for liquid penetrantexamination

a) Recording limits for DGS method. Recordable echoheights referred to circular disk reflector (mm)

Scanningdirection

Nominal wall thickness of finished product(mm)

s ≤ 15 15 < s ≤ 30 30 < s ≤ 60 s > 60

Straight beamscanning

2 3 3 4

Angle-beamScanning

1) 2 3 4

b) Recording limits for distance gain size or reference echomethod. Recordable echo heights referred to the echoheights of cylindrical bore holes ∅ 4 mm

Scanningdirection

Nominal wall thickness of finished product(mm)

s ≤ 30 s > 30

all 50% = (- 6 dB) 100%

1) Where scanning is performed on the nominal wall thickness,the recording limit is the echo height of a rectangular groove atthe end of the second path to be evaluated with the followingdimensions:

Depth ≤ 1.0 mmWidth ≤ 1.5 mmLength > Sound beam width

When scanning with full skip distance reference echo heightsfrom the inner and outer groove can be used for the respectivesound path regions.Regions scanned in the pre-fabricated condition which have awall thickness s > 15 mm at the time of test, may be examinedwith a recording limit: circular disk reflector 2 mm.

Table 22-4: Recording length for ultrasonic testing onforgings with reference to the nominal wallthickness of the finished product

KTA 3201.1

23 Seamless pipes from stainless austenitic steels

23.1 Scope

(1) This section applies to seamless hot or cold fabricatedheat treated pipes from stainless austenitic steels with a wallthickness of up to 50 mm.


(3) For hot (operating temperature ≥ 200 °C) reactor watercontaining pipes in boiling water reactor plants only the steelgrade X 6 CrNiNb 18 10 S, and only with the additional re-quirements of Table A-3-1, footnote 4, shall be used.

23.2 Requirements




(1) The test coupon shall basically be taken from the end ofthe pipe.

(2) The minimum distance between pipe end and specimen-taking location shall be at least equal to the wall thickness butnot exceed 25 mm.

(3) Wherever possible, transverse test specimen shall betaken. In the case of tensile tests on outer diameters equal toor smaller than 200 mm, longitudinal test specimens shall betaken.

(4) The requirements in accordance with DIN 17 458 applywith respect to the specimen-taking depth.



(1) Ladle analysis



Pipes (fabrication lengths) of the same melt and similar di-mensions shall be grouped in lots with each lot containing notmore than 10 fabrication lengths. A product analysis shall beperformed on one fabrication lengths in each lot. The nitrogencontent shall be determined if the delta ferrite content is de-termined analytically.

23.3.2.2 Tensile test

For each fabrication length two test specimens shall be sub-jected to a tensile test, one at room temperature and one atdesign temperature.

23.3.2.3 Impact test

As far as it is possible to take 10 mm wide Charpy-V notchbend test specimens, one set of notch bend test specimensfrom each fabrication length shall be subjected to an impacttest at room temperature.

23.3.2.4 Mechanical tests

For each fabrication length the following mechanical testsshall be performed on one end of the pipe:

a) ring expanding test or drift expanding test on pipes withan outer diameter equal to or greater than 146 mm and awall thickness equal to or greater than 2 mm,

b) ring flattening test on pipes with an outer diameter greaterthan 146 mm and a wall thickness greater than 2 mm,

c) ring tensile test on pipes with an outer diameter greaterthan 146 mm and a wall thickness equal to or smaller than40 mm.


Metallographic examinations shall be performed to determineand document the secondary grain size and microstructure.Fabrication lengths of the same melt and similar dimensionsand heat treatment shall be grouped in lots. For each lot onemetallographic examination shall be performed.

23.3.2.6 Determination of the delta ferrite content

The delta ferrite content shall be determined in accordancewith Sec. 3.3.7.5 for those pipes which, in the course of furtherfabrication, will be subjected to welding; the method usedmay be by bead welding the test coupon or by a mathematicalestimation under consideration of the nitrogen content fromeach chemical composition determined on each individualpiece (cf. Sec. 23.3.2.1).


(1) Pipes (fabrication lengths) of the same melt and similardimensions shall be grouped in lots with each lot containingnot more than 10 fabrication lengths.

(2) From each lot one fabrication lengths shall be tested forresistance to intergranular corrosion.


(1) Forged pipes and pipes with a nominal wall thicknessexceeding 30 mm shall be examined in the same way asseamless hollow bodies in accordance with Sec. 22.4. All pipesshall be examined in accordance with the specifications underSec. 16.4, in which case the examinability of the weld edgeand nozzle areas shall be additionally checked in accordancewith Sec. 22.4.2.3.

(2) Deviating from the specifications under Sec. 16.4.3.2, inthe case of titanium stabilised austenitic materials, indicationlengths exceeding 6 mm may be accepted by agreement withthe authorized inspector provided they are caused by non-metallic inclusions.

(3) In the case of hot fabricated pipes with an outer diameterexceeding 100 mm the examination sensitivity shall be cor-rected as described in para (4).

(4) Through-transmission values shall be determined withthe angle-beam method on both pipe ends and at the midsec-tion of the pipe. The measurements shall be performed atlocations offset by 90 degrees to each other and alternately incircumferential and in axial direction. They shall be per-formed at the same nominal frequency as the examination forlongitudinal and transverse flaws. If, relative to the longest

KTA 3201.1

sound path to be evaluated, the determined values exceed thereference value determined in the vicinity of the referenceflaw by more than 3 dB then the difference between this valueand 3 dB shall be added to the value determined in the ex-amination for longitudinal and transverse flaws.

If, in the course of these examinations, it is ascertained thatsufficient uniformity is achieved with regard to the compara-tive sound wave attenuation measurements that are depend-ent on fabrication procedure, material and dimensions, thenthe extent of these measurements may be reduced subject toagreement by the authorized inspector.





(2) On each pipe the wall thickness shall be checked on bothends and, depending on the order specification, either theinside or outside diameter.

23.7 Leak tightness test

Each pipe shall be subjected to an adequate test for leak tight-ness.


Each pipe shall be subjected to an adequate materials identifi-cation check.

23.9 Examination procedures to be applied

The details regarding the determination of the delta ferritecontent in accordance with Sec. 23.3.2.6 are specified in An-nex D.



a) The pipe shall be individually numbered.

b) The fabrication procedure (hot or cold) shall be specified.


(1) The results of the tests in accordance with Secs. 23.3.2.1,23.3.2.5, 23.3.2.6, 23.3.2.7, and 23.8 shall be certified by Accep-tance Test Certificates 3.1.B in accordance with DIN EN10 204, the results of all the other tests by Acceptance TestCertificates 3.1.C in accordance with DIN EN 10 204.

(2) For each heat treatment lot the heat treatment conditionincluding temperature, holding time and cooling-down con-ditions shall be certified. The correlation of the pipes to theheat treatment lots shall be specified.

24 Seamless elbows from stainless austenitic steels

24.1 Scope

(1) This section applies to hot or cold fabricated seamlesspipe elbows with an outside diameter equal to or greater than80 mm and a wall thickness equal to or smaller than 50 mmfrom stainless austenitic steels and, in particular, pipe elbowsthat are solution annealed and quenched after heat treatment.The pipe elbows may be fabricated from seamless pipes aswell as hollow-hammered or hollow-bored forgings.

(2) Pipe elbows are required to have cylindrical ends only ifthis is necessary with regard to the non-destructive examina-tions in accordance with Sec. 13 KTA 3201.3 (taking into ac-count possible requirements from in-service inspections). Inthe case of pipe elbows with a large nominal diameter this isgenerally not required.

(3) This section does not apply to pipe elbows taken frompipe bends which e.g. are fabricated on inductive bendingmachines or on a bending plate or by cold bending. Thesetypes of pipe elbows are dealt in with Sec. 7 of KTA 3201.3.

(4) The requirements for the materials of this product formare specified in Sec. A 3.

(5) For hot (operating temperature ≥ 200 °C) reactor watercontaining pipes in boiling water reactor plants only the steelgrade X 6 CrNiNb 18 10 S, and only with the additional re-quirements of Table A-3-1, footnote 4, shall be used.

24.2 Requirements



24.3.1 General

The following requirements apply under the assumption thatthe direction of main forming of the initial pipe lies in thehead-to-tail direction of the ingot. If, in the case of forgedpipes, this assumption does not apply in part or as a whole,possibly deviating requirements regarding specimen-takingshall be specified in the initial material certification.

24.3.2 Tests of the initial pipes

(1) If the pipe manufacturer delivers the pipes in a com-pleted heat treatment condition, i.e. in the solution annealedand quenched condition, to the elbow manufacturer, then theinitial pipes shall be completely tested at the plant of the pipemanufacturer, that is in the case of seamless pipes specifiedunder 23.3 and in the case of forgings as specified under Sec.22.3.1.3.

(2) If the pipe manufacturer fabricates the pipe elbow him-self, only the determination of the chemical composition forthe initial pipes by the ladle analysis and a product analysisare required. In this case the following applies: for each melt aladle analysis shall be performed. In the case of the productanalysis, the initial product forms shall be grouped in lots ofnot more than 10 fabrication lengths. In each lot one fabrica-tion length shall be subjected to a product analysis.

KTA 3201.1

24.3.3 Tests of the pipe elbows


(1) The test coupons shall be taken from the elbow ends.

(2) The distance between elbow end and specimen-takinglocation shall be at least equal to the wall thickness but notexceed 25 mm.

(3) If practicable, transverse test coupons shall be taken. Inthe case of tensile tests on outer diameters equal to or smallerthan 200 mm, longitudinal test coupons shall be taken.

(4) In the case of elbows with a wall thickness equal to orgreater than 20 mm, the test coupons shall be taken from alocation close to the mid-wall of the pipe as possible.


24.3.3.2.1 Extent of testing on elbows fabricated from prod-uct forms tested as specified under 24.3.2 (1)

24.3.3.2.1.1 General requirements

Unless specified otherwise in the following section, the testsare performed in lots consisting of elbows from the same meltof similar dimensions and, in the same heat treatment condi-tion; the size of the lot shall not exceed 10 pieces.

24.3.3.2.1.2 Chemical analysis

(1) For each lot a product analysis shall be performed. Inthis case, the members of the lot do not have to be in the sameheat treatment condition.

(2) The nitrogen content shall be determined if the delta-ferrite content is determined analytically.

24.3.3.2.1.3 Tensile test

From each lot two test specimens shall be subjected to a ten-sile test, one at room temperature and one at design tempera-ture.

24.3.3.2.1.4 Impact test

In the case of a wall thickness greater than 10 mm, where it ispossible to remove 10 mm wide Charpy-V notch bend testspecimens, one set of notch bend test specimens from each lotshall be subjected to an impact test at room temperature. If itis impossible to remove transverse test specimens, longitudi-nal test specimens shall be used.

24.3.3.2.1.5 Mechanical test

If a test in accordance with Sec. 24.3.3.2.1.4 is not possiblebecause of a wall thickness equal to or smaller than 10 mm,the following mechanical tests shall be performed instead ofthe impact test; these tests shall be performed at one end onone piece from each lot:

a) ring expanding test or drift expanding test on elbows frompipes with an outer diameter equal to or smaller than 146mm and a wall thickness equal to or greater than 2 mmand equal to or smaller than 10 mm,

b) ring tensile test on elbows from pipes with an outer di-ameter greater than 146 mm and a wall thickness equal toor smaller than 10 mm.

24.3.3.2.1.6 Metallographic examination

One metallographic examination shall be performed for eachlot to determine the secondary grain size and microstructure.

24.3.3.2.1.7 Determination of the delta ferrite content

The delta ferrite content shall be determined in accordancewith Sec. 3.3.7.5 for those parts which, in the course of furtherfabrication, will be subjected to welding; the method usedmay be by bead welding the test specimen or by a mathemati-cal estimation under consideration of the nitrogen contentfrom each chemical composition determined on each individ-ual piece (cf. Sec. 24.3.3.2.1.2 (2)).

24.3.3.2.1.8 Resistance to intergranular corrosion

From each lot (lot size equal to or smaller than 50) one testspecimen shall be tested for resistance to intergranular corro-sion.

24.3.3.2.2 Extent of tests on elbows fabricated from productforms tested as specified under Sec. 24.3.2 (2)

(1) The specifications under Sec. 23.3.2 shall apply accord-ingly to the extent of tests on elbows from seamless pipeswithin the dimensional scope of that section; however, it shallbe observed that the extent of tests shall be related to individ-ual elbows instead of two fabrication lengths. Deviating fromSec. 23.3.2, the chemical composition shall be determined by aproduct analysis as specified under Sec. 24.3.3.2.1.2 and thecheck for resistance to intergranular corrosion as specifiedunder Sec. 24.3.3.2.1.8.

(2) Elbows fabricated from forgings shall be individuallytested. Beyond that, the specifications under Secs. 24.3.3.2.1.2through 24.3.3.2.1.8 apply.

24.3.3.3 Examination procedures to be applied

(1) The sensitisation conditions required for the check forresistance to intergranular corrosion in accordance with DIN50 914 shall be specified with regard to the intended fabrica-tion procedures and shall be specified for the material manu-facturer when placing the order.

(2) The details regarding the determination of the deltaferrite content in accordance with Sec. 24.3.3.2.1.7 are speci-fied in Annex D.


(1) Forged elbows with a nominal wall thickness exceeding30 mm shall be examined like seamless hollow bodies in ac-cordance with Sec. 22.4. All other elbows shall be examined inaccordance with the specifications under Sec. 17.4 in whichcase the examinability of the weld edge and nozzle regionsshall additionally be checked in accordance with Sec. 22.4.2.3.

(2) Deviating from the specifications under Sec. 17.4.3.2, inthe case of titanium stabilised austenitic materials, indicationlengths exceeding 6 mm may be accepted by agreement withthe authorized inspector provided they are caused by non-metallic inclusions.

(3) In the case of elbows with an outer diameter exceeding100 mm the examination sensitivity shall be corrected as de-scribed in para (4).

KTA 3201.1

(4) Through-transmission values shall be determined withthe angle-beam method on both elbow ends at 4 locationsoffset by 90 degrees to each other. The measurements shall beperformed both in circumferential and in axial direction andat the same nominal frequency as the examination for longi-tudinal and transverse flaws. If, related to the longest soundpath to be evaluated, the determined values exceed the refer-ence value determined in the vicinity of the reference flaw bymore than 3 dB then the difference of this value and 3 dB shallbe added to the value determined in the examination forlongitudinal and transverse flaws.



a) If several elbows are fabricated from one initial productform, the correlation shall be included in the marking.

b) The elbows shall be individually numbered.

c) The fabrication procedure (hot or cold) shall be specified.


Each elbows shall be subjected to an adequate materials iden-tification check.





(2) On each elbow, the wall thickness shall be determined toa sufficient extent over the entire chord length including theelbow ends and over its entire circumference, furthermore,depending on the order specification, either the outside or theinside diameter shall be measured. In addition, the out-of-roundness shall be determined.


(1) The results of the tests in accordance with Sec.24.3.3.2.1.2, 24.3.3.2.1.6, 24.3.3.2.1.7, 24.3.3.2.1.8, and 24.6 shallbe certified by Acceptance Test Certificates 3.1.B in accor-dance with DIN EN 10 204, the results of all the other tests byAcceptance Test Certificates 3.1.C in accordance with DIN EN10 204.

(2) For each heat treatment lot the heat treatment conditionincluding temperature, holding duration and cooling-downconditions shall be certified. The correlation of the pipes to theheat treatment lots shall be specified.

25 Pressure retaining parts from quenched and temperedcast steel

25.1 Scope

(1) This section applies to quenched and tempered ferriticcast steels, e.g. for primary coolant pump castings (except forvalve bodies).


25.2 Requirements

(1) Chaplets employed in the production of castings are notallowed in the finished condition of the product form.

(2) Feeders as well as large cast-integral reinforcements thatdetrimentally affect quenching and tempering of the castingshall be removed prior to heat treatment.

(3) The upper shelf energy of the base metal shall be at least100 J.

(4) The NDT temperature shall be equal to or smaller than0 °C. Where the required NDT temperature is exceeded, thecustomer, by agreement with the authorized inspector, shalldecide on the further steps to be taken in due consideration ofthe safety analysis.

(5) The absorbed impact energy shall be determined for atemperature that is 33 K over the required NDT temperature.The absorbed impact energy shall be not less than 68 J and thelateral expansion not be less than 0.9 mm. If these require-ments are not met for one test specimen, additional tests shallbe carried out to determine the temperature at which theserequirements are met in the notched bar impact test. Regard-ing the application of such a product, it shall be consideredthat these higher temperatures must be lower than the tem-peratures possible under critical conditions (e.g. pressure test,incidents). In the case of the notched bar impact test a repeti-tion of the test at the original temperature is allowed underthe following conditions:

a) The average values of absorbed impact energy and lateralexpansion shall not fall below the specified single values.

b) Only one test specimen may show values that are lowerthan the specified single values.

c) The test specimen which failed by not reaching the speci-fied single values shall not show values of the absorbedimpact energy and lateral expansion that are lower thanthe specified single values by more than 14 J and morethan 0.13 mm, respectively.

When repeating a test, the failed test specimen shall be re-placed by two additional test specimens. These two testspecimens shall be taken from a location as close as possible tothe specimen-taking location of the failed test specimen. Bothof these test specimens are required to reach the individuallyspecified values. Where the specified single values are notachieved in the re-examination, then that higher temperatureshall be determined at which each individual value meets thespecified requirements. This should be done on the basis ofthe available impact energy versus temperature curves which,as required, shall be extended by further tests.

25.3 General requirements regarding fabrication

(1) In addition to the manufacturing documents specifiedunder Sec. 2.5.4, test and inspection sequence plans for theproduction and constructional welds, welding plans as well aslists of the corresponding production weld test shall be sub-mitted to the authorized inspector for design review. In thecase of production and constructional welds (casting to cast-ing) a design review of the test and inspection sequence plansmay be dispensed with, provided the welding is performedand tested in accordance with Table 25-1. Together with theinstructions for the non-destructive examinations, a plan withthe co-ordinate system (reference grid points) shall be submit-ted.

KTA 3201.1

(2) Besides these design review documents, the gating andfeeding techniques describing the casting technology shall bedocumented by the module calculations and by drawingsdepicting the locations of the feeders and the feeder regions.Furthermore, the locations and dimensions of integrally casttest coupons shall be depicted and justified. These documentsshall serve as information only. They do not require a formalacceptance stamp by the authorized inspector.

(3) The description of the casting technology as well as thespecifications under Sec. 25.6 shall be considered in estab-lishing the instructions for non-destructive examinations. Inthe case of regions of limited examinability, the adequacy ofcomponent safety shall be demonstrated by sufficient re-placement measures.

25.4 Welding


(1) The production and constructional weldings shall becarried out in accordance with DIN 1690-1 in combinationwith DIN 17 245 and KTA 3201.3. However, deviating fromthese specifications, the production and constructional wel-dings (connection welds: casting-to-casting during manufac-ture) generally requires renewed quenching and tempering.This shall be taken into account in the choice of welding con-sumables. Minor fabrication welds, e.g. for the removal ofsurface flaws, shall be avoided as far as possible. If they can-not be avoided, a subsequent stress-relief heat treatment isrequired.

(2) The authorized inspector shall be informed about anymajor production and constructional welding (connectionwelds: casting-to-casting during manufacture) that requiresquenching and tempering. These weldings shall be docu-mented, the documents becoming part of the interim file.

(3) The consent of the authorized inspector is required onlyfor those production and constructional weldings that will notbe quenched and tempered. In this case, the welding locationshall be numbered and the number, size and location of theweld shall be documented (final file).

(4) The surface of the weld bead shall be subjected to a sur-face crack examination in accordance with Sec. 25.6.

(5) Any welds subjected to a stress-relief heat treatmentshall only be welded higher by two bead layers; these shall,subsequently be ground flush to base metal height.

25.4.2 Prerequisites for weldings

(1) The basic requirements under Sec. 6 of KTA 3201.3 shallbe taken into consideration as far as acceptable.

(2) Manufacturers planning production and constructionalweldings shall perform a procedure qualification in accor-dance with Sec. 25.4.3 and shall present the results to theauthorized inspector prior to the start of fabrication.

25.4.3 Procedure qualification

Procedure qualification in accordance with the followingspecification are required for production welding (full andpartial penetration welding) and for constructional welding.

25.4.3.1 Procedure qualification for production welding


(1) Production welding

In the case of production welding basically the same proce-dure qualification shall be performed as required under Sec.10 of KTA 3201.3 for connection welds.

The weldings of the procedure qualification shall correspondto the conditions of the component welding as far as possible.The general requirements under Sec. 10 of KTA 3201.3 shall beobserved unless no deviating requirements are specified below.

The test coupons shall be dimensioned such that the tests inaccordance with Table 25-2 can be performed.

The test coupons for production welding shall be subjected toa heat treatment similar to the one planned for the compo-nent, i.e., the quenched and tempered test coupons shall afterwelding, be requenched and tempered and subjected to asimulation stress relief heat treatment (cf. 25.4.1 (1). The tem-perature-over-time sequence for the simulation stress-relieftreatment shall be specified under consideration of Sec. 3.3.5.1and by agreement with the authorized inspector.

(2) Partial penetration welding

In the procedure qualification for partial penetration weldingon pressure-retaining castings with a wall thickness equal toor greater than 100 mm a planar steel casting plate of the samematerial with a wall thickness equal to or greater than 100 mmshall be used. In the case of pressure-retaining castings with awall thickness less than 100 mm, generally a planar steelcasting plate of the same material with a wall thickness equalto or greater than 50 mm may be used.

In preparation for welding, the plates shall be chipped downto about 40 % of the wall thickness corresponding to the ex-pected production welding.

(3) Full penetration welding

The procedure qualification for full penetration welding shallbe performed like in the case of a penetrated wall on the com-ponent (cf. Sec. 10.1 of KTA 3201.3); here, a procedure qualifi-cation on a wall thickness dp shall apply to any wall thicknessdB of the final component up to dB = 1.5 x dp.

A procedure qualification for full penetration welding appliesto any partial penetration welding under para (2) if the wallthickness is equal to or greater than 50 mm. Where the wallthickness of the procedure qualification for full penetrationwelding is less than 50 mm, then, for a larger wall thickness,procedure qualifications for partial penetration welding asunder para (2) are required.

25.4.3.1.2 Procedure qualifications for quenched and tem-pered and simulation stress relief heat treatedproduction welding


Basically, the requirements under KTA 3201.3 shall be appliedunless deviating requirements are specified below:

(2) Specimen-taking

Test specimens shall be taken in accordance with Figures 25-1and 25-2.

(3) Extent of testing

a) Mechanical properties

The extent of testing is specified in Table 25-2.

KTA 3201.1

Note:(1) In the case o f quenched and tempered weld ings, the notchlocation shall be specified in the initial material certification.(2) Until that time, the impact energy shall be additionallydetermined on the fusion line and 0.5 ± 0.3 mm next to the fu-sion line in the all-weld material at the specified temperatures(0°C and 33 °C).

b) Non-destructive examinations

The extent of non-destructive examinations as well as theprocedural details are specified under Sec. 25.6. All thethree of the following examinations shall be performed inthe final heat treatment condition described above -quenched and tempered and simulation stress-relief heattreated condition:

ba) surface crack examination,

bb) radiographic examination, and

bc) ultrasonic examination.

Irrespective of this, the surface prepared for the two typesof production weldings (partial and full penetrationwelding) shall be subjected to a surface crack examination.

c) Other tests

The extent of other tests is specified in Table 25-2.

(4) Evaluation of the test results

The results of the tests for the mechanical properties and theother test shall meet the requirements under Table 25-3. Theresults of the non-destructive examinations shall be within theacceptance standards of 25.6.4.

25.4.3.1.3 Procedure qualification for stress-relief heattreated fabrication welding


Basically, the requirements of KTA 3201.3 shall be appliedunless deviating requirements are specified below.

(2) Specimen-taking


(3) Extent of tests and evaluation of results

The specifications under Sec. 10.2 of KTA 3201.3 shall be ap-plied with regard to extent of tests and evaluation of results.

25.4.3.2 Procedure qualification for constructional welding

(1) The requirements under Sec. 25.4.3.1.2 apply accordinglyto constructional welding if the welding is quenched andtempered and simulation stress-relief heat treated, those un-der 10.3 of KTA 3201.3 if the welding is simply stress-reliefheat treated.

(2) The non-destructive examination shall be performed inaccordance with Sec. 13 of KTA 3201.3.

25.4.4 Production weld tests

25.4.4.1 Production weld tests of production welding


The general requirements under Sec. 12.1 of KTA 3201.3 shallbe applied to the production weld tests. The production weldtests for production weldings shall be performed in accor-dance with the following requirements. One production weldtest correlated to a particular component weld may include

other component welds within the same scope of the proce-dure qualification, provided these are welded generallywithin 12 months from completion of the production weld testcorrelated to a particular component weld.

The test coupons shall be dimensioned such that the testsrequired in accordance with Table 25-2 can be performed. Itshall be ensured that sufficient reserve material is available.Sec. 12.1.4 KTA 3201.3 applies to the storage of reserve mate-rial. The test coupons for the production weld tests of pro-duction weldings shall be heat treated as is required for thecomponent, i.e., the quenched and tempered test couponsshall be re-quenched and tempered (accompanying or simu-lation heat treatment) after welding and shall be simulationstress-relief heat treated or simply stress-relief heat treated (cf.Sec. 25.4.1 (1)). The temperature-time sequences for the simu-lation stress-relief heat treatment shall be specified in consid-eration of Sec. 3.3.5.1 and by agreement with the authorizedinspector, additionally, the requirements under Sec. 12 of KTA3201.3 shall be observed.

(2) Specimen-taking

The test specimens shall be taken in accordance with Figure25-1 and 25-2.

(3) Extent of testing

a) Mechanical properties

The extent of tests for a quenched and tempered andsimulation stress-relief treated production welding de-pends on the requirements under Sec. 25.4.3.1.2 (3) a) andTable 25-2, however, no KV-T curves are required in Table25-2. If the test coupon is attached to the correspondingcasting from the same melt to be mutually quenched andtempered, or, if a similar temperature-time sequence isadequately demonstrated, a test of the mechanical proper-ties of the base material is not required since these are ob-tained from the test on the casting itself.

Note:(1) In the case o f quenched and tempered weld ings, the notchlocation shall be specified in the initial material certification.(2) Until that time, the impact energy shall be additionallydetermined on the fusion line and 0.5 ± 0.3 mm next to the fu-sion line in the weld material at the specified temperatures (0°C and 33 °C).

Regarding the extent of tests for a stress-relief heat treatedproduction welding, the specifications under Sec. 12 ofKTA 3201.3 shall apply.

b) Non-destructive examinations

The extent of the non-destructive examinations as well asthe procedural details are specified under Sec. 25.6. All thethree of the following examinations shall be performed inthe final heat treatment condition described above -quenched and tempered and stress-relief heat treated orsimply simulation stress-relief heat treated condition:

ba) surface crack examination,

bb) radiographic examination, and

bc) ultrasonic examination.

c) Other testsThe extent of other tests is specified in Table 25-2.

(4) Evaluation of the test results

The results of the tests for the mechanical properties and theother tests shall meet the requirements under Table 25-3. Theresults of the non-destructive examinations shall meet theacceptance standards under Sec. 25.6.4.

KTA 3201.1

25.4.4.2 Production weld tests for constructional weldings

(1) The requirements under Sec. 25.4.3.1.2 apply accordinglyto constructional weldings if the welding is quenched andtempered and stress-relief heat treated and those under Sec.10.3 of KTA 3201.3 if the welding is simply stress-relief heattreated.

(2) The non-destructive examinations shall be performed inaccordance with Sec. 13 of KTA 3201.3.

25.5 Tests on the casting

25.5.1 Specimen-taking

(1) The test specimen shall be taken from cast-integral cou-pons that shall not be cooled (cast-integral coupons, surpluslengths, nozzle cut-outs).

(2) The number and distribution of the specimen-takinglocations shall be as follows:

Casting weight,kg

Number of specimen-taking locationsand distribution over the casting

≤ 6000 two specimen-taking locations asclose to the feeder as possible

> 6000 two specimen-taking locations asclose to the feeder as possible and onespecimen-taking location as far awayfrom the feeder as possible

(3) One test coupon shall be provided for each specimen-taking location. If cast-technology so demands, a test couponmay also be divided into several parts.

(4) The thickness of the cast-integral coupons shall corre-spond to the governing wall thickness of the casting (Sec. 25.3shall be observed).

(5) The test coupons shall be taken after the last quenchingand tempering, provided the non-destructive examinationsare not detrimentally affected. If on account of the non-destructive examinations the removal must occur at an earliertime, then the test coupons shall subsequently be welded ontothe casting to be mutually quenched and tempered.

(6) A removal by flame cutting is basically allowed, pro-vided a stress-relief heat treatment is planned after flamecutting and is performed in the course of further fabrication,e.g. after production or constructional welding. The heat af-fected zone from the flame cutting on the casting shall bemechanically removed.

(7) If no stress-relief heat treatment is planned after speci-men-taking, the test coupons shall be taken by mechanicalmeans.

(8) Regarding the size of the test coupons, Sec. 3.3.3 shall beobserved.

(9) The test specimens shall lie at least one quarter of thequenched and tempered wall thickness beneath the length-side surface and at least one half of the quenched and tem-pered wall thickness beneath the end face surface of the testcoupons.

(10) When taking test specimens from test coupons that weretaken by flame cutting, attention shall be paid to observing asufficient distance to the heat affected zone.



(1) Ladle analysis

For each melt a ladle analysis shall be performed for the fol-lowing elements: C, Si, Mn, P, S, Al, Cr, Cu, Mo, N, Ni and Vas well as for the elements specified in Annex A.


On each casting at the specimen-taking locations in accor-dance with Sec. 25.5.1, a product analysis for the elementsspecified under para (1) shall be performed.

25.5.2.2 Tests on simulation heat treated test coupons

25.5.2.2.1 Mechanical properties

(1) Tensile test

Two transverse test specimens from each specimen-takinglocation shall be subjected to a tensile test, one at room tem-perature and one at design temperature.

(2) Impact test

On one set of transverse test specimens from each specimen-taking location it shall be demonstrated at 0 °C that the impactenergy for the cast steel used does not fall below the mini-mum required impact energy.

In addition, it shall be shown for each specimen-taking loca-tion that the RTNDT concept is fulfilled at 33 °C. On one fur-ther set of impact test specimens from one specimen-takinglocation it shall be demonstrated that the requirements underSec. 25.2 for the upper shelf energy are met.


The impact-energy-versus-temperature curve shall be deter-mined in accordance with Sec. 3.3.7.3 (3) for one specimen-taking location.


On one specimen-taking location from each casting it shall bedemonstrated by drop weight tests in accordance with Sec.3.3.7.3 (4) that the required NDT temperature is not exceeded.

25.5.2.2.2 Metallographic examinations

The secondary grain size shall be determined from one notch-bend test specimen from each specimen-taking location; themicrostructure shall be evaluated and documented in accor-dance with Sec. 3.3.7.4.



In order to check the workmanship, test coupon material fromone of the specimen-taking locations in accordance with Sec.25.5.1 shall be provided for the following tests and shall beadded to the corresponding component. Test coupon materialfrom the other specimen-taking locations shall be kept in theas-removed condition.


(1) Tensile test

Two transverse test specimens shall be subjected to a tensiletest, one at room temperature and one at design temperature.

KTA 3201.1

(2) Impact test

On one transverse test specimen it shall be demonstrated at0 °C and 33 °C that the requirements under Sec. 25.2 are met.


It shall be demonstrated that the requirements regarding theNDT temperature are met.


(1) The requirements under Sec. 3.3.7.2 apply to hardness test.

(2) The hardness tests shall be performed on the outer sur-face along one surface line that shall include both nozzle re-gions and the flange, beginning near the edge and continuingin length intervals of not more than 1000 mm.



The following requirements supplement the requirementsunder Sec. 3.3.8.2.3 and 3.3.8.6.4.



(1) The interrelation between extent, type and point of timeof the non-destructive examinations and the course of fabri-cation as well as the attendance of the authorized inspector inthese examinations is shown in Table 25-1.

(2) In the case of deviations from this sequence, a test andinspection sequence plan shall be established by the materialmanufacturer and submitted to the authorized inspector fordesign review.

25.6.2.2 Extent and type

(1) The castings including possible constructional weldingsshall be fully subjected to a radiographic examination.

(2) A surface crack examination - if possible by the magneticparticle procedure - shall be performed on all surfaces includ-ing production and constructional weldings. All cavities ob-tained from grinding out flaws and all fusion faces preparedfor constructional welding shall, likewise, be examined. Inthese cases the liquid penetrate examination procedure shallpreferably be used.

(3) Ultrasonic examinations shall be performed on

a) attachment weldings,

b) locations of major fabrication weldings,

c) constructional weldings,

d) all production weldings that are simply stress-relief heattreated

and

e) all those locations where the radiographic examinationleads to less reliable results or where the design reviewhas identified structural or cast-technological peculiarities.

(4) All production weldings that are performed due to theresults of the radiographic or ultrasonic examinations shall besubjected again to a radiographic or ultrasonic examination.

25.6.2.3 Point of time

(1) The radiographic examinations shall be performed afterat least one quenching and tempering process has been car-ried out.

(2) The final ultrasonic examination shall be performed afterthe final tempering process. Where production weldings arerequired after final tempering, these locations shall be exam-ined after stress-relief heat treatment.

(3) The final surface crack examination shall be performedafter the last heat treatment with the surfaces in the conditionintended for delivery. In those cases where the componentmanufacturer carries out subsequent fabrication, these newlycreated surfaces shall be subjected to a renewed surface crackexamination.

25.6.3 Procedural requirements

25.6.3.1 Surface quality

(1) The surface quality shall be evaluated in accordancewith recommendation technique No. 359-01 du Bureau deNormalisation des Industries de la Fonderie.

(2) The castings should have a surface quality that is equalto or better than reference patterns 3 S 1 or 4 S 2.

(3) Castings subjected to a liquid penetrate examinationshall have a surface quality that is equal to or better than ref-erence pattern 3 S 2.

25.6.3.2 Radiographic examinations

(1) The procedural details of the radiographic examinationshall not be described and design reviewed prior to the be-ginning of fabrication but after the first true-to scale casting isavailable; the written radiographic procedure shall be set upon the basis of a reference point grid and shall be design re-viewed. However, production weldings may be radiographedregardless of these test instructions, simply under considera-tion of their geometry and location.

(2) The radiographs created in conjunction with the estab-lishment of the test instructions may be used for the accep-tance test of component provided they correspond to thedesign reviewed test instruction.

(3) Basically, the requirements of Examination Category B inaccordance with DIN 54 111-2 shall be met. If reasons aregiven for deviating from this requirement (e.g. for regionswith operating stresses equal to or smaller than 50 N/mm2), ,the requirements of Examination Category A in accordancewith DIN 54 111-2 shall be met.

(4) Deviating from DIN 54 111-2, no thickness compensa-tions for contrast reduction are allowed in the case of a vary-ing wall thicknesses.

(5) The completeness of the radiograph shall be demon-strated by a radiographic representation of the reference pointgrid.

(6) If the geometrical dimensions in part or as a whole donot permit a radiographic examination from an interior radia-tion source, then, instead of an exterior circumferential radi-ography, a double-wall radiography in the sense of the over-view radiographs in accordance with Fig. 6 of DIN 54 111-2 isallowed provided, this leads to more meaningful results andan increase in the radiographed volume. This specificationalso applies to volumetric regions with cast-specific geome-tries as shown in Figs. 7 through 11 of DIN 54 111-2.

KTA 3201.1

25.6.3.3 Ultrasonic examination

(1) The ultrasonic examination shall be performed in accor-dance with Examination Category I in accordance with SEP1922.

(2) In the case of major production weldings, the angle-beam examination shall be performed in two opposite direc-tions perpendicular to each other with two beam angles whichshould differ by at least 15 degrees.

(3) In the case of smaller production weldings that are sim-ply stress-relief heat treated, a deviation from this require-ments is allowed, provided this is technologically sensible. Awritten examination procedure is not required in this case.

(4) The description of the locations of indications that leadto recordable conditions shall be based on the reference pointgrid established for the radiographic examination.

25.6.3.4 Surface crack examination

The magnetic particle examination shall be performed in ac-cordance with SEP 1935 and the liquid penetrant examinationin accordance with SEP 1936.


25.6.4.1 Radiographic examination

(1) Only those flaws are acceptable that are in accordancewith quality level 2 under DIN 1690-2. The weld attachmentends shall correspond to quality level 1 under DIN 1690-2,however, only flaws A1, B1 and C1 in accordance with ASTM-E280 are allowed, also for a wall thickness greater than 115mm. A weld attachment end is considered to be a strip with awidth equal to the wall thickness - however, between at least40 mm and not more than 100 mm - next to the fusion face ofa constructional welding.

(2) In the case of the double-wall radiography, the accep-tance standard for the thinner of the two walls applies, unlessadditional radiographs allow the correlation of the indicationsto the corresponding single wall thickness.



In the case of recordable attenuations of the back wall echo,the material manufacturer, by agreement with the authorizedinspector shall perform the necessary examinations regardingthe further usability of the product.

25.6.4.2.2 Indications confirmed by radiographic examina-tion

Ultrasonic indications that are confirmed by radiographicexaminations shall be evaluated in accordance with Sec.26.6.4.1.

25.6.4.2.3 Indications not confirmed by radiographicexamination

Only flaws corresponding to quality level 2 under DIN 1690Part 2 are acceptable. The weld attachment ends shall be inaccordance with quality level 1 under DIN 1690-2. A weldattachment end is considered to be a strip with a width equalto the wall thickness - however, of at least 40 mm and notmore than 100 mm - next to the fusion face of a constructionalwelding.


25.6.4.3.1 Weld cavities in fabrication welding

(1) Only those indications are acceptable that do not detri-mentally affect the welding and that are not caused by theparticular surface or volumetric flaw that will be removed.

(2) By agreement with the authorized inspector the weldsupervisor shall make a decision regarding the possible effectson the weldability of the remaining flaws.

25.6.4.3.2 Fusion faces

The evaluation shall be performed in accordance with Sec. 13of KTA 3201.3.

25.6.4.3.3 Component surface including production welding

Only flaws corresponding to quality level 1 under DIN 1690-2are acceptable.

25.6.4.4 Production weldings

Production weldings shall be evaluated like the base materialas specified under Secs. 25.6.4.1 and 25.4.6.2. If, by agreementwith the authorized inspector, indications inside the fabrica-tion weld are clearly shown to be inclusions, these may beconsidered to be individual defects and may be left as theyare, provided their maximum length does not exceed onethird of the respective wall thickness.

25.6.4.5 Constructional welding

The evaluation shall be performed in accordance with Sec. 13of KTA 3201.3.

25.6.5 Test reports

(1) Test reports shall be prepared in accordance with Sec.3.3.8.6 of all required or performed tests and examinations.

(2) These shall contain all information and data required tobe able to reproduce the execution of the tests. The descriptionof the indications from the volumetric examinations shall beclear and unambiguous and shall allow a definite correlationto every location on the component.






(1) Each casting shall be subjected to an interior pressuretest to show that it is leak tight; this test is usually performedduring subsequent fabrication with the component in a corre-sponding condition.

(2) The internal pressure test shall be performed in accor-dance with DIN 50 104. The pressure medium, pressure leveland duration of pressure loading shall be specified in writingupon placing the order. However, the nominal pressure shallin no case lead to a loading exceeding 90 % of the 0.2 % proofstress of the casting steel type.

KTA 3201.1


The identification marking of the casting shall contain thefollowing information:



c) melt number,




The results of the tests in accordance with Secs. 25.5.2.1,25.5.2.2.2 and 25.5.2.4 shall be certified by Acceptance TestCertificates 3.1.B in accordance with DIN EN 10 204, the re-sults of all the other tests by Acceptance Test Certificate 3.1.Cin accordance with DIN EN 10 204.

Tensile test specimen

Drop weight test specimen

Impact test specimen

Bend test specimen

Specimen locationin the welded jointin the weld metal

Specimen location

0.4

dd

0.6

d

dd

0.4

0.6

d

dd

0.4

dd

d0

.60

.4d

0.6

sketch III

sketch IV sketch V

sketch II

M

O

sketch I

notch location 0.5 ± 0.3 mm

next to fusion line in base material

M: midsection

sketch VI sketch VII

O: near surface region

Figure 25-1: Specimen taking for procedure qualification ofpartial penetration welds

Specimen locationin the welded joint

Specimen locationin the weld metal


Bend test specimen



dd

dd

M

O

M

O

sketch IV sketch V

sketch VI

sketch I sketch II

sketch III



sketch VII


M: midsection

Figure 25-2: Specimen taking for procedure qualification offull penetration welds

KTA 3201.1

1)

5)

4)

3)

authorized inspector (S)

Final acceptance test:

Complete magnetic particle examination by H and S

Destructive tests

yes no

Compilation of documents

Magnetic particle examination of production welds by H

±constructional weldings

Preparation and liquid penetrant examination of the regions

intended for welding by the manufacturer (H)

Ultrasonic examination by manufactorer (H) and authorized

inspector (S) of:

± regions of reduced information in radiography

Complete magnetic particle examination by manufacturer (H)

Dokumentation of the production weld seams

Plane-grinding of weld seams

welds by the manufacturer (H) and after final heat treatment by

Ultrasonic examination of stress-relief heat treated production

Obtain agreement of authorized inspector (S) on weldings

Welding

Stress-relief heat treatment

then, by agreement with the authorized inspector,

deviations from the standard procedure as described in

yes

If, in exceptional cases during subsequent fabrication,

production welding becomes necessary for the removal

of casting flaws at a far-advanced stage of fabrication,

this flow chart are allowed.

5)

radiographed or ultrasonically tested weld seams

Note regarding further volumetric examinations:2)

1) The sequence of ultrasonic examination and

radiographic examination may be reversed.

and casting regions with allowable indications or

characteristics.

Applies only to the cast steel GS-18 NiMoCr 3 7.4)

findings do not have to be reexamined.

3) Heat treatment for obtaining mechanical material

yes no

welding

and information of the authorized inspector

no

Quenching and tempering

no

Obtaining the surface quality in acc. with Sec. 25.6

Destructive evaluation test

larger production weld seams

±welding ends

yes

yes

Constructional welding (casting to casting)

Preparation and liquid penetrant examination of fusion flanks by H

Magnetic particle examination of constructional weld seam by H

Welding process of constructional weld seam

constructional

Plane-grinding of weld seam

Soaking or stress relief heat treatment

Evaluation of the films by H and S

no

Radiographic examination of the constructional weld seams

Volumetric examination

Ultrasonic examination of constructional weld seam by H

Authorized inspector (S) shall be informed of the results

Casting process (possibly annealing for GS-18 NiMoCr 3 7)


Obtaining the surface quality in acc. with Sec. 25.6

Complete magnetic particle examination by the manufacturer (H)

Preparation and liquid penetrant examination of fusion faces

by the manufacturer (H)

Documentation of larger production welds in acc. with

DIN 17 245 for interim file and information of the authorized

inspector (S)

Welding

Soaking of GS-18 NiMoCr 3 7 or stress-relief heat treatment

of larger production welds

Plane-grinding of weld seams

Magnetic particle examination of production weld seams by H

unallowable

indications

yes no

1) 2)Volumetric examination

Complete radiographic examination by the manufacturer (H)


Ultrasonic examination by the manufacturer (H) of:

±welding ends

±regions of reduced information in radiography

±larger production weld seams

Authorized inspector (S) shall be informed of ultrasonicexamination results

unallowable

indications

unallowable

indications

unallowable

indications

unallowable

indications

Table 25-1: Fabrication flow chart for pressure-retaining components made of ferritic cast steel

KTA 3201.1

Type of specimen Testtemp.

Test in accor-dance with

Value to be determined Number ofTest specimen

°C partialpenetra-tion weld

fullpenetra-tion weld

a) Weld metalTensile test specimenDIN 50 125

RT350

DIN EN 10 002-1DIN EN 10 002-5

Rm, Rp0.2,A5, ZRm, Rp0.2, A5, Z

25-1/I

25-1/I

1

1

RT

350

DIN EN 10 002-1

DIN EN 10 002-5

Rm, Rp0.2, A5, Z

Rm, Rp0.2, A5, Z

25-2/I

25-2/I

OMOM

1111

Impact test specimen 1)

33

DIN EN 10 045-1 KV-T-curve 1), lateral ex-pansion, mat fracture surfaceKV, lateral expansion, matfracture surface

25-1/IV

25-1/IV

3 each

3 3.1.C

1)

33


25-2/IV

25-2/IV

OMOM

3 each3 each

33

Drop weight test +5 SEP 1325, P2 yes/no 25-1/VI 2

specimen +5 SEP 1325, P2 yes/no 25-2/VI M 2

b) Welded joint

Tensile test specimenDIN EN 895Tensile test specimenDIN 50 125Tensile test specimenDIN 50 125

RT

RT

350

DIN EN 10 002-1

DIN EN 10 002-1

DIN EN 10 002-5

Rm, fracture location 3)



25-1/II

25-1/II

25-1/II

1

1

1

Tensile test specimenDIN EN 895Tensile test specimenDIN 50 125Tensile test specimenDIN 50 125

RT

RT

350

DIN EN 10 002-1

DIN EN 10 002-1

DIN EN 10 002-5




25-2/II

25-2/II

25-2/II

OMOMOM

111111

Bend test specimen RT DIN EN 910 bending angle tofirst crack

25-1/III 1

RT DIN EN 910 bending angle tofirst crack

25-2/III OM

11

3.1.C


33

DIN EN 10 045-1 KV-T-curve 1), lateral ex-pansion, mat fracture surface

KV, lateral expansion, matfracture surface

25-1/V

25-2/V

3 each

3

1)

33



25-2/V

25-2/V

OM

OM

3 each3 each

33

Drop weight test +5 SEP 1325, P2 yes/no 25-1/VII 2

specimen +5 SEP 1325, P2 yes/no 25-2/VII OM

22

c) Base metal 2)

Tensile test specimenDIN 50 125

RT DIN EN 10 002-1 Rm, Rp0.2, A5, Z 1

RT DIN EN 10 002-1 Rm, Rp0.2, A5, Z OM

11 3.1.C

Impact test specimen 33 DIN EN 10 045-1 KV, lateral expansion,mat fracture surface

3

33 DIN EN 10 045-1 KV, lateral expansion,mat fracture surface

OM

33

Table 25-2: Pressure-retaining components from ferritic cast steelExtent of procedure qualification and production weld tests on production welds (Part 1)

Testspecimenlocation

Fig./Sketch

AcceptanceTest Certificatein accordance

withDIN EN 10 204

Testspecimen

layerFig. 25-2

KTA 3201.1

d) Other tests and examinations(1) Production of a photograph of an etched macrosection of the entire cross-section of the production weld.

Certification by Acceptance Test Certificate 3.1.B in accordance with DIN EN 10 204.(2) Analysis of the alloying elements of the weld metal, in the case of full penetration welds in the test layers O and M

for: C, Mn, Si, P, S, Cr, Mo, Ni, Al, V, N2, Cu.Certification by Acceptance Test Certificate 3.1.B in accordance with DIN EN 10 204.

(3) The hardness traverse HV 5 from the base metal to weld metal to base metal, in the case of full penetration welds inthe test layers O and M, as well as over the entire weld depth at the centre of the weld metal.Certification by Acceptance Test Certificate 3.1.C in accordance with DIN EN 10 204.

(4) Micrograph of a transverse microsection, generally at a 200:1 enlargement, one each of the test layers in accordancewith Figure 25-1 and 25-2.Certification by Acceptance Test Certificate 3.1.C in accordance with DIN EN 10 204.The following shall be covered by this microphotograph:- all-weld metal,- transition between all-weld metal and base metal- (uninfluenced) base metal.

Where a weld is tested and examined in more than one heat treatment condition (e.g., simulation heat treatment condi-tion, accompanying heat treatment condition), then the tests under d) shall be performed only in the simulation heattreatment condition.1) See Sec. 3.3.7.3 (3). In the case of weld production tests, no KV-T-curve is required.2) A test or examination of the base metal is only required if no corresponding values of the base metal in the test layers O and M are available.3) For information only, the following shall be determined additionally:

a) round test specimen in accordance with DIN 50 125: Rp0.2, Z and the course of strain over the examination length for every 5 mm.b) flat test specimen in accordance with DIN 50 125: course of strain over the examination length for every 5 mm.

Table 25-2: Pressure-retaining components from ferritic cast steelExtent of procedure qualification and production weld tests on production welds (Part 2)

Tests and examinations Requirements

a) Weld metal

Tensile Test (RT and 350 °C) Like the base metal or as specified in the acceptance test of weld consumables.

Notched-bar impact test KV (0 °C), KV (33 °C) and lateral expansion (33 °C)corresponding to the requirements of the base metal.

Drop weight test in accordancewith SEP 1325

Demonstration of NDT ≤ 0 °C

Chemical analysis Like the acceptance test of the weld consumable.b) Welded joint

Tensile Test (RT and 350 °C) Like the minimum tensile strength of the base metal, fracture location not specified.


Bend test in accordance withDIN EN 910

Bending angle 180° with a bending diameter 3a. Determination of the bendingstrain in accordance with DIN EN 910. Tear-ups are allowable, provided, theyare caused by pores and incomplete fusion. Cracks without identifiable causeare allowable up to a length of 1.6 mm.



Metallographic examination overthe cross-section

The structure of the all-weld metal and of the heat-affected zone of the basemetal shall show a perfect bead sequence and complete penetration of the joint(macrosection) as well as a perfect crystalline structure (microsection). Mate-rial discontinuities (microsection) are allowed, provided, they are definitelyindividual defects judged by their number and location. Not allowed are ac-cumulations of such defects in the form of connected fields.

Hardness traverse over amacro-section

The hardness 350 HV 5 should not be exceeded in the heat affected zones. Anyhardness peaks beyond this value occurring in small zones require additionalexaminations. In this case 350 HV 10 shall not be exceeded. Individual peakvalues beyond this specified hardness are allowed, provided, they are shownto be strictly localized.

c) Base metal

Tensile Test (RT) andnotched-bar impact test (33 °C)

Like the base metal, in so far as specified for the individual test layers.

Table 25-3: Pressure-retaining components from ferritic cast steelRequirements for procedure qualification and production weld tests on production welds

KTA 3201.1

26 Valve bodies made from ferritic cast steel

26.1 Scope

(1) This section applies to cast valve bodies made of ferriticcast steels.

(2) The requirements for the materials of these productforms are specified in Sec. A 4 and A 5.

26.2 Requirements

(1) Chaplets employed in producing castings are not al-lowed in the finished condition of the product form.

(2) Feeders as well as large, cast-integral reinforcements thatdetrimentally affect quenching and tempering of the castingshall be removed prior to heat treatment.

(3) The upper shelf energy of the base metal shall be equalto or greater than 100 J.

(4) The NDT temperature shall be equal to or less than 0 °C.In the case of a larger NDT temperature, the customer, byagreement with the authorized inspector, and taking thesafety analysis into account, shall decide on the further stepsto be taken.

(5) The absorbed impact energy shall be determined for atemperature that is 33 K higher than the required NDT tem-perature. The absorbed impact energy shall be equal to orgreater than 68 J and the lateral expansion equal to or greaterthan 0.9 mm. If these requirements are not met for one testspecimen, additional tests shall be carried out to determinethe temperature at which these requirements are met in thenotched bar impact test. Regarding the application of such aproduct, it shall be considered that these higher temperaturesmust be lower than the possible temperatures under criticalconditions (e.g. pressure test, incidents). In the case of notchedbar impact tests a repetition of the test at the original tempera-ture is allowed under the following conditions:

a) The average values of absorbed impact energy and lateralexpansion shall not fall below the individually specifiedvalues.

b) Only one test specimen may show values that fall belowthe individually specified values.

c) The test specimen which failed by not obtaining the speci-fied single values shall not show values of the absorbedimpact energy and lateral expansion that are lower thanthe specified single values by not more than 14 J and notmore than 0.13 mm, respectively.

When repeating a test, the failed test specimen shall be re-placed by two additional test specimens. These two testspecimens shall be taken from a location as close as possible tothe specimen-taking location of the failed test specimen. Bothof these test specimens are required to obtain the individuallyspecified values. Where the specified single values are notobtained in the re-examination, then that higher temperatureshall be determined at which each individual value meets thespecified requirements. This shall be done on the basis of theavailable impact energy versus temperature curves which, ifrequired, shall be extended by further tests.


(1) In addition to the manufacturing documents specifiedunder Sec. 2.5.4, test and inspection sequence plan for theproduction and construction welds and lists of the corre-

sponding production weld tests shall be submitted to theauthorized inspector for design review. In the case of produc-tion and constructional welds (casting-to-casting) a designreview of the test and inspection sequence plan is not re-quired, provided, the weldings are performed and tested inaccordance with Table 25-1. Together with the instructions forthe non-destructive examinations, a plan with the co-ordinatesystem (reference grid points) shall be submitted.

(2) Besides these design review documents, the gating andfeeding techniques describing the casting technology shall bedocumented by the module calculations and by drawingsdepicting the locations of the feeders and the feeder regions.Furthermore, the locations and dimensions of the cast-on testcoupons shall be depicted and justified. These documentsserve as information only. They do not require a formal accep-tance stamp by the authorized inspector.

(3) The description of the casting technology as well as thespecifications under Sec. 26.6 shall be considered in estab-lishing the instructions for non-destructive examinations. Inthe case of regions of limited examinability, the adequacy ofcomponent safety shall be demonstrated by sufficient re-placement measures. If the adequacy of component safetycannot be demonstrated, it may become necessary to performa destructive test on a prototype. The procedure of this de-structive test (e.g. arrangements of the cuts) shall be specifiedin the design review.

26.4 Weldings


(1) Production and construction weldings shall be carriedout in accordance with DIN 1690-1 in combination with DIN17 245 and KTA 3201.3. However, deviating from these speci-fications, the production and construction weldings (connec-tion welds: casting-to-casting during manufacture) generallyrequire a renewed quenching and tempering. This shall betaken into account in the selection of weld consumables. Mi-nor production welds, e.g. to remove surface flaws, shall beavoided as far as possible. If they cannot be avoided, a subse-quent stress-relief heat treatment is required.

(2) The authorized inspector shall be informed about anymajor production and construction welding (connectionwelds: casting-to-casting during manufacture) that requiresquenching and tempering. These weldings shall be docu-mented, the documents becoming part of the interim file.

(3) The consent of the authorized inspector is required forany construction welding that will not be quenched and tem-pered. In this case, the welding locations shall be numberedand the number, size and location of the weld shall be docu-mented (final file).

(4) The surface of the weld groove shall be subjected to asurface crack examination in accordance with Sec. 25.6.

(5) Any welds subjected only to a stress-relief heat treat-ment shall be welded higher by two bead layers which shallsubsequently be ground down to base metal height.

26.4.2 Prerequisites for welding

(1) The basic requirements under Sec. 6 of KTA 3201.3 shallbe taken into consideration as far as applicable.

(2) Manufacturers planning to perform production andconstruction weldings shall perform a procedure qualification

KTA 3201.1

in accordance with Sec. 26.4.3 and shall present the results tothe authorized inspector prior to the start of fabrication.


26.4.3.1 General

Procedure qualifications in accordance with the followingspecifications are required for production weldings (partialand full penetration welding) and for construction weldings.

26.4.3.2 Procedure qualification for fabrication welding


(1) Fabrication welding

In the case of production weldings, basically the same proce-dure qualification shall be performed as required underSec. 10 of KTA 3201.3 for connection welds.

The weldings of the procedure qualification shall largely cor-respond to the conditions of the component welding. Thegeneral requirements under Sec. 10 of KTA 3201.3 shall beobserved unless deviating requirements are specified below.

The test coupons shall be dimensioned such that the tests inaccordance with Table 26-1 can be performed.

The test coupons for production welding shall be subjected toa heat treatment similar to the one planned for the compo-nent, i.e., the quenched and tempered test coupons shall afterwelding, be requenched and tempered and - in both cases -subjected to a simulation stress-relief heat treatment or only asimulation stress relief heat treatment. In the case of unal-loyed steel castings only a simulation stress relief heat treat-ment is required (cf. Sec. 26.4.1 (1)). The temperature-over-time sequence for the simulation stress-relief treatment shallbe specified in due consideration of Sec. 3.3.5.1 and by agree-ment with the authorized inspector.

(2) Partial penetration welds

In the procedure qualification for partial penetration weldingson pressure-retaining castings with a wall thickness equal toor greater than 100 mm a planar steel casting plate of the samematerial with a wall thickness of at least 100 mm shall beused. In the case of pressure-retaining casting with a wallthickness less than 100 mm, generally, a planar steel castingplate of the same material with a wall thickness of at least50 mm may be used.

To prepare the plates for welding they shall be chipped downto about 40 % of the wall thickness corresponding to the ex-pected production welding.

(3) Full penetration weldings

The procedure qualification for full penetration weldings shallbe performed in the same manner as for the welding of wallpenetrations on the component (cf. Sec. 10.1 of KTA 3201.3);here, a procedure qualification on a wall thickness dp shallapply to any wall thickness dB of the final component up todB = 1.5 x dp.

A procedure qualification for full penetration weldings ap-plies to any partial penetration welding under para (2) if thewall thickness is equal to or greater than 50 mm. Where thewall thickness of the procedure qualification for full penetra-tion weldings is less than 50 mm, then, for a larger wall thick-ness, procedure qualifications for partial penetration weldingsas under para (2) are required.

26.4.3.2.2 Procedure qualifications for quenched and tem-pered and simulation stress-relief heat treatedproduction weldings

26.4.3.2.2.1 General requirements

Basically, the requirements under KTA 3201.3 shall be appliedunless deviating requirements are specified below.

26.4.3.2.2.2 Specimen-taking


26.4.3.2.2.3 Extent of testing

(1) Mechanical properties

The extent of testing is specified in Table 26-1. In the case of awall thickness equal to or less than 30 mm, only one test layeris required even for full penetration weldings.

Note:(1) In the case o f quenched and tempered weld ings, the notch lo-cation shall be specified in the initial material certification.(2) Until this time, the impact energy shall additionally be deter-mined on the fusion line and 0.5 ± 0.3 mm next to the fusion linein the weld material for the specified temperatures (0 °C and33 °C).

(2) Non-destructive examinations

The extent of the non-destructive examinations as well asprocedural details are specified under Sec. 25.6. All the threeof the following examinations shall be performed in the finalheat treatment condition named above - quenched and tem-pered and stress-relief heat treated condition:

a) surface crack examination,

b) radiographic examination and

c) ultrasonic examination.

In addition, the surfaces prepared for the two types of pro-duction weldings (partial and full penetration welds) shall besubjected to a surface crack examination.

(3) Other tests

The extent of other tests is specified in Table 26-1.

26.4.3.2.2.4 Evaluation of the test results

(1) The results of the tests for the mechanical properties andthe other tests shall meet the requirements under Table 26-2.

(2) The results of the non-destructive examinations shallmeet the acceptance standards under Sec. 26.6.4.

26.4.3.2.3 Procedure qualification for only stress-relief heattreated production welding

26.4.3.2.3.1 General

Basically, the requirements under Sec. 10 of KTA 3201.3 shallapply unless deviating requirements are specified below.

26.4.3.2.3.2 Specimen-taking

The test specimens shall be taken in accordance with Figures26-1 and 26-2.

KTA 3201.1

26.4.3.2.3.3 Extent of testing and evaluation of test results

The specification under Sec. 10.2 of KTA 3201.3 shall applywith regard to extent of testing and evaluation of results.

26.4.3.3 Procedure qualification for construction weldings

(1) The requirements under Sec. 26.4.3.2 apply accordinglyto construction weldings if the weld is normalised, quenchedand tempered stress-relief heat treated and those under Sec.10.2 of KTA 3201.3 apply if the welding is stress-relief heattreated only.



26.4.4.1 Production weld tests of fabrication welding


(1) The production weld tests for the production welds shallbe performed in accordance with the following requirements(see also Sec. 12 of KTA 3201.3). One production weld testcorrelated to a particular component weld may include othercomponent welds within the same scope of the procedurequalification provided, these are welded, generally, within 12months from completion of the production weld test corre-lated to a particular component weld.

(2) The test coupons shall be dimensioned such that the testsrequired in accordance with Table 26-1 can be performed.

(3) It shall be ensured that sufficient reserve material isavailable. Sec. 12.1.4 of KTA 3201.3 applies to the storage ofreserve material.

(4) The test coupons for the production weld tests of pro-duction welds shall be heat treated as is required for the com-ponent, i.e., the quenched and tempered test coupons shall bere-quenched and tempered (accompanying or simulation heattreatment) after welding and shall be simulation stress-reliefheat treated or simply stress-relief heat treated (cf. Sec.26.4.1 (1)). The temperature-time sequences for the simulationstress-relief heat treatment shall be specified under considera-tion of Sec. 3.3.5.1 and by agreement with the authorizedinspector additionally the requirements under Sec. 12 of KTA3201.3 shall be observed.

26.4.4.1.2 Specimen-taking


26.4.4.1.3 Extent of testing

(1) Mechanical properties

The extent of testing for quenched and tempered and simula-tion stress-relief treated production welds depends on therequirements under Sec. 26.4.3.2.2.3(1) and Table 26-1, how-ever, none of the KV-T curves under Table 26-1 are required.If the test coupon is attached to the corresponding castingfrom the same melt to be mutually normalised or quenchedand tempered, or, if a similar temperature-time sequence isadequately demonstrated, a test of the mechanical propertiesof the base material is not required since these are obtainedfrom testing the casting itself.

Note:(1) In the case o f quenched and tempered weldments, the notchlocation shall be specified in the initial material certification.

(2) Until that time, additionally the impact energy shall be de-termined on the fusion line and 0.5 ± 0.3 mm next to the fusionline in the weld material for the specified temperatures (0 °C and33 °C).

Regarding the extent of tests for stress-relief heat treated pro-duction welds, the specifications under Sec. 12 of KTA 3201.3shall apply.

(2) Non-destructive examinations

The extent of the non-destructive examinations as well asdetails for their performance are specified under Sec. 25.6. Allthe three of the following examinations shall be performed inthe final heat treatment condition named above - normalised,quenched and tempered and stress-relief heat treated or sim-ply stress-relief heat treated condition:

a) surface crack examination,

b) radiographic examination, and

c) ultrasonic examination.

(3) Other tests

The extent of testing is specified in Table 26-1.

26.4.4.1.4 Evaluation of the test results

(1) The results of the tests to obtain the mechanical proper-ties and the other tests shall meet the requirements underTable 26-2.

(2) The results of the non-destructive examinations shallmeet the acceptance standards under Sec. 25.6.4.

26.4.4.2 Production control tests for construction weldings

(1) The requirements under Sec. 26.4.3.2 apply accordinglyto construction weldings if the welding is normalised,quenched and tempered and stress-relief heat treated, andthose under Sec. 12.2 of KTA 3201.3 if the welding is simplystress-relief heat treated.


26.5 Tests on the casting


(1) The test specimens shall be taken from cast-integral testcoupons that may not be cooled (cast-integral coupons, sur-plus lengths, nozzle cut-outs). The test coupons shall be dis-tributed over different locations of the casting.

(2) The number of test coupons shall be as follows:

Casting weight,kg

Number of test couponsper casting

≤ 500 1

> 500 to ≤ 1000 2

> 1000 3

(3) The thickness of the cast-integral coupons shall corre-spond to the governing wall thickness of the casting.

(4) The test coupons shall be cut off after the last heat treat-ment, provided the non-destructive examinations are notdetrimentally affected. If on account of the non-destructiveexaminations the coupons are to be cut off at an earlier time,

KTA 3201.1

then the test coupon shall subsequently be welded again ontothe casting to be mutually heat treated.

(5) A removal by flame cutting is basically allowed pro-vided a stress-relief heat treatment is planned after flamecutting and is performed in the course of further fabrication,e.g. after production or construction welding on the casting.The heat affected zone obtained from flame cutting on thecasting shall be mechanically removed.

(6) If no stress-relief heat treatment is planned after couponcut-off, the test coupons shall be taken by mechanical means.

(7) In special cases the test specimens may also be removedfrom separately cast test coupons from the same melt. Thesespecial cases shall be agreed upon between all parties in-volved (material manufacturer, customer and authorizedinspector).

(8) Regarding the size of the test coupons, Sec. 3.3.3 shall beobserved.

(9) The test specimens shall lie at least one quarter of thequenched and tempered wall thickness beneath the length-side-surface and at least one half of the quenched and tem-pered wall thickness beneath the end face surface of the testcoupons. This applies accordingly to castings in a normalisedcondition.

(10) When taking test specimens from test coupons that weretaken by flame cutting, attention shall be paid to observing asufficient distance to the heat affected zone.



(1) Ladle analysis

For each melt a ladle analysis shall be performed for the fol-lowing elements::

C, Si, Mn, P, S, Al, Cr, Cu, Mo, N, Ni and V as well as theelements specified in Sec. A 4 and A5.


On each casting, a product analysis for the elements specifiedunder para (1) shall be performed at one specimen-takinglocations in the vicinity of the feeder.

26.5.2.2 Tests on simulation heat treated test couponsNote:Also see Sec. 3.3.5.1.


(1) Tensile test

Two test specimens from each test coupon shall be subjectedto a tensile test, one at room temperature and one at designtemperature.

(2) Impact test

On one set of transverse test specimens from each test couponit shall be demonstrated at 0 °C that the energy absorbed forthe cast steel used does not fall below the minimum requiredimpact energy.

In addition, it shall be shown for each test coupon that theRTNDT concept is fulfilled at 33° C. On one further set of im-pact test specimens from one test coupon it shall be demon-

strated that the requirements under Sec. 26.2 for the uppershelf energy are met.


The impact-energy-versus-temperature curve shall be deter-mined in accordance with Sec. 3.3.7.3(3) for one specimen-taking location.


On one test coupon from each casting it shall be demonstratedby drop weight tests that the required NDT temperature is notexceeded.

26.5.2.2.2 Metallographic examinations

The secondary grain size shall be determined from one notch-bend test specimen for each test coupon; the microstructureshall be evaluated and documented in accordance with Sec.3.3.7.4.



(2) The hardness tests shall be performed on the outer sur-face along one surface line that shall include both nozzle re-gions and the flange, beginning near the edge and continuingin length intervals of not more than 1000 mm.


The requirements under Sec. 25.6 shall apply.






(1) Each casting shall be subjected to pressure test to showthat it is leak tight; this test is usually performed during sub-sequent fabrication with the component in a correspondingcondition.

(2) The pressure test shall be performed in accordance withDIN 50 104. The pressure medium, pressure level and dura-tion of pressure loading shall be specified in writing uponplacing the order. In no case, however, shall the nominal pres-sure lead to a loading in excess of 90 % of the 0.2 % proofstress of the cast steel type.


The identification marking of the casting pieces shall containthe following information:



KTA 3201.1

c) melt number,




The results of the tests in accordance with Sec. 26.5.2.1,26.5.2.2.2 and 26.5.2.3 shall be certified by Acceptance TestCertificate 3.1.B in accordance with DIN EN 10 204, the results

of all the other tests by Acceptance Test Certificates 3.1.C inaccordance with DIN EN 10 204.




Bend test specimen

Specimen locationin the welded jointin the weld metal

Specimen location

0.4

dd

0.6

d

dd

0.4

0.6

d

dd

0.4

dd

d0

.60

.4d

0.6

sketch III

sketch IV sketch V

sketch II

M

O

sketch I



M: midsection

sketch VI sketch VII



Specimen locationin the welded joint

Specimen locationin the weld metal


Bend test specimen



dd

dd

M

O

M

O

sketch IV sketch V

sketch VI

sketch I sketch II

sketch III



sketch VII


M: midsection


KTA 3201.1





full pene-trationweld

a) Weld metalTensile test specimenDIN 50125

RT

350

DIN EN 10 002-1

DIN EN 10 002-5

Rm, Rp0.2,A5, Z

Rm, Rp0.2, A5, Z

26-1/I

26-1/I

1

1

RT

350

DIN EN 10 002-1

DIN EN 10 002-5

Rm, Rp0.2, A5, Z

Rm, Rp0.2, A5, Z

26-2/I

26-2/I

OMOM

1111


33

DIN EN 10 045-1 KV-T-curve 1), lateral ex-pansionKV, lateral expansion, matfracture surface

26-1/IV

26-1/IV

3 each

33.1.C

1)

33


26-2/IV

26-2/IV

OMOM

3 each3 each

33

Drop weight test +5 SEP 1325, P2 yes/no 26-1/VI 2

specimen +5 SEP 1325, P2 yes/no 26-2/VI M 2

b) Welded joint

Tensile test specimenDIN EN 895Tensile test specimenDIN 50125Tensile test specimenDIN 50125

RT

RT

350

DIN EN 10 002-1

DIN EN 10 002-1

DIN EN 10 002-5




26-1/II

26-1/II

26-1/II

1

1

1

Tensile test specimenDIN EN 895Tensile test specimenDIN 50125Tensile test specimenDIN 50125

RT

RT

350

DIN EN 10 002-1

DIN EN 10 002-1

DIN EN 10 002-5




26-2/II

26-2/II

26-2/II

OMOMOM

111111

Bend test specimen RT DIN EN 910 bending angle to first crack 26-1/III 1 3.1.C

RT DIN EN 910 bending angle to first crack 26-2/III OM

11


33



26-1/V

26-2/V

3 each

3

1)

33


26-2/V

26-2/V

OMOM

3 each3 each

33

Drop weight test +5 SEP 1325, P2 yes/no 26-1/VII 2

specimen +5 SEP 1325, P2 yes/no 26-2/VII OM

22

c) Base metal 2)

Tensile test specimenDIN 50125

RT DIN EN 10 002-1 Rm, Rp0.2, A5, Z 1

RT DIN EN 10 002-1 Rm, Rp0.2, A5, Z OM

11 3.1.C

Impact test specimen 33 DIN EN 10 045-1 KV, lateral expansion, matfracture surface

3

33 DIN EN 10 045-1 KV, lateral expansion, matfracture surface

OM

33

Table 26-1: Valve bodies made from ferritic cast steelExtent of procedure qualification and production weld tests on production welds (Part 1)


Fig./Sketch


withDIN EN 10 204

Testspecimen

layerFig. 26-2

KTA 3201.1

d) Other tests and examinations(1) Production of a photograph of an etched macrosection of the entire cross-section of the production weld.

Certification by Acceptance Test Certificate 3.1.C in accordance with DIN EN 10 204.(2) Analysis of the alloying elements of the weld metal, in the case of full penetration welds in the test layers O and M

for: C, Mn, Si, P, S, Cr, Mo, Ni, Al, V, N2, Cu.Certification by Acceptance Test Certificate 3.1.B in accordance with DIN EN 10 204.

(3) The hardness traverse HV 5 from the base metal to weld metal to base metal, in the case of full penetration welds inthe test layers O and M, as well as over the entire weld depth at the centre of the weld metal.Certification by Acceptance Test Certificate 3.1.C in accordance with DIN EN 10 204.

(4) Micrograph of a transverse microsection, generally at a 200:1 enlargement, one each of the test layers in accordancewith Figure 26-1 and 26-2.Certification by Acceptance Test Certificate 3.1.C in accordance with DIN EN 10 204.The following shall be covered by this microphotograph:- all-weld metal,- transition between all-weld metal and base metal- (uninfluenced) base metal.

Where a weld is tested and examined in more than one heat treatment condition (e.g., simulation heat treatment condi-tion, accompanying heat treatment condition), then the tests under d) shall be performed only in the simulation heattreatment condition.1) See Sec. 3.3.7.3 (3). In the case of weld production tests, no KV-T-curve is required.2) A test or examination of the base metal is only required if no corresponding values of the base metal in the test layers O and M are available.3) For information only, the following shall be determined additionally:

a) round test specimen in accordance with DIN 50 125: Rp0.2, Z and the course of strain over the examination length for every 5 mm.b) flat test specimen in accordance with DIN 50 125: course of strain over the examination length for every 5 mm.

Table 26-1: Valve bodies made from ferritic cast steelExtent of procedure qualification and production weld tests on production welds (Part 2)


a) Weld metalTensile Test (RT and 350 °C) Like the base metal or as specified in the acceptance test of weld consumables.




Chemical analysis Like the acceptance test of the weld consumable.b) Welded joint

Tensile Test (RT and 350 °C) Like the minimum tensile strength of the base metal, fracture location not specified.







The structure of the all-weld metal and of the heat-affected zone of the basemetal shall show a perfect bead sequence and complete penetration of the joint(macrosection) as well as a perfect crystalline structure (microsection). Mate-rial discontinuities (microsection) are allowed, provided, they are definitelyindividual defects judged by their number and location. Not allowed are ac-cumulations of such defects in the form of connected fields.

Hardness traverse over amacro-section

The hardness 350 HV 5 should not be exceeded in the heat affected zones. Anyhardness peaks beyond this value occurring in small zones require additionalexaminations. In this case 350 HV 10 shall not be exceeded. Individual peakvalues beyond this specified hardness are allowed, provided, they are shownto be strictly localized.

c) Base metalTensile Test (RT) andnotched-bar impact test (33 °C)

Like the base metal, in so far as specified for the individual test layers.

Table 26-2: Valve bodies made from ferritic cast steelRequirements for procedure qualification and production weld tests on production welds

KTA 3201.1

27 Valve bodies from austenitic cast steel

27.1 Scope

(1) This section applies to cast valve bodies from austeniticcast steels.


27.2 Requirements

(1) Chaplets employed in the production of castings are notallowed in the finished condition of the product form.

(2) Feeders as well as large, cast-integral reinforcements thatdetrimentally affect tempering of the casting shall be removedprior to heat treatment.

(3) The base material should have a delta ferrite content ofat least 2 % unless other requirements are specified in theAnnex A.

(4) Under the planned fabrication conditions, especiallyafter welding and heat treatment, the material shall be resis-tant to intergranular corrosion.


(1) In addition to the manufacturing documents specifiedunder Sec. 2.5.4, test and inspection sequence plans for pro-duction and construction welds, welding schedules as well aslists of the corresponding production weld tests shall besubmitted to the authorized inspector for design review. Inthe case of production and construction welds (casting-to-casting) a design review of the test and inspection sequenceplans is not required provided, the weldings are performedand tested in accordance with Table 27-1. Together with theinstructions for the non-destructive examinations, a plan withthe co-ordinate system (reference point grid) shall be submit-ted.

(2) Besides these design review documents, the gating andfeeding techniques describing the casting technology shall bedocumented by the module calculations and by drawingsdepicting the locations of the feeders and the feeder regions.Furthermore, locations and dimensions of cast-integral testcoupons shall be depicted and justified. These documentsserve as information only. They do not require a formal accep-tance stamp by the authorized inspector.

(3) The description of the casting technology as well as thespecifications under Sec. 27.6 shall be considered in establish-ing the instructions for non-destructive examinations. Whereregions of limited examinability are present, the adequacy ofcomponent safety shall be demonstrated by sufficient re-placement measures. If the adequacy of component safetycannot be demonstrated, it may become necessary to performa destructive test on a prototype. The procedure of this de-structive test (e.g. arrangements of the cuts) shall be specifiedin the design review.

27.4 Weldings


(1) The production and construction weldings shall be car-ried out in accordance with DIN 1690-1 in combination withDIN 17 245 and KTA 3201.3. Production welding shall gen-erally be solution annealed (fabrication flow sheet, cf. Table27-1). However, no solution annealing and quenching is re-quired after production and construction weldings (connec-

tion welds: casting-to-casting during manufacture) provided,it has been shown that the toughness requirements in accor-dance with KTA 3201.3 are met. A stress-relief heat treatmentshall be avoided.

(2) The authorized inspector shall be informed about anymajor production and construction welding (connectionwelds; casting to casting during manufacture) that requiressolution annealing. These weldings shall be documented, withthe documents becoming part of the interim file.

(3) The consent of the authorized inspector is required onlyfor those production and construction weldings that will notbe solution annealed. In this case, the welding locations shallbe numbered and the number, size and location of the weldedjoints shall be documented.

(4) All weldings shall be ground to base metal height.

27.4.2 Prerequisites for welding

(1) The basic requirements under Sec. 6 of KTA 3201.3 shallbe taken into consideration as far as applicable.

(2) Manufacturers planing production and constructionwelds shall perform a procedure qualification prior to thestart of fabrication in accordance with Sec. 27.4.3 and shallsubmit the results to the authorized inspector.


Procedure qualifications in accordance with the followingspecifications are required for production weldings (partialpenetration and full penetration welding) and for construc-tion welds.

27.4.3.1 Procedure qualifications for production weldings


(1) In the case of production welds basically the same pro-cedure qualification shall be performed as required under Sec.10 of KTA 3201.3 for connection welds. The weldings of theprocedure qualification shall largely correspond to the condi-tions of the component weldings including heat treatment.The general requirements under Sec. 10.1 of KTA 3201.3 shallbe observed unless deviating requirements are specified be-low. The test coupons shall be dimensioned such that the testsin accordance with Table 27-2 can be performed. The testcoupons shall be subjected to a heat treatment similar to theone planned for the component, i.e. solution annealing andquenching (cf. Sec. 27.4.1 (1)).

(2) In the procedure qualification for partial penetrationwelds on pressure-retaining castings with a wall thicknessequal to or greater than 100 mm a planar cast steel plate of thesame material and a wall thickness of at least 100 mm shall beused. In the case of pressure-retaining castings with a wallthickness smaller than 100 mm generally a planar cast steelplate of the same material and a wall thickness of at least50 mm may be used. When preparing the plates for welding,they shall be chipped down to about 40 % of the wall thick-ness corresponding to the expected production weld.

(3) The procedure qualification for full penetration weldsshall be performed in the same manner as for a wall penetra-tion on the component (cf. Sec. 10.1 of KTA 3201.3), here aprocedure qualification on the wall thickness dp shall apply toany wall thickness dB of the final component up todB = 1.5 x dp. A procedure qualification for full penetrationwelds applies to any partial penetration weld under para. (2)

KTA 3201.1

if the wall thickness is equal to or greater than 50 mm. If thethickness of the procedure qualification for full penetrationwelds is less than 50 mm, then for a larger wall thicknessprocedure qualifications are required for partial penetrationwelds as under para (2).




(1) The extent of testing regarding mechanical properties isspecified in Table 27-2. In the case of a wall thickness equal toor smaller than 30 mm only one test layer is required, even forfull penetration welds.

(2) The extent of the non-destructive examinations as wellas procedural details are specified under Sec. 27.6. Both of thefollowing examinations shall be performed in the final heattreatment condition specified under Sec. 27.4.1:

a) surface crack examination and

b) radiographic examination.

In addition, the surface prepared for welding the two types ofproduction weldings (partial and full penetration welds) shallbe subjected to a liquid penetrant examination.

(3) The extent of the other tests is specified in Table 27-2.


(1) The results of the tests for the mechanical properties andthe other tests shall meet the requirements under Table 27-3.

(2) The results of the non-destructive examinations shallmeet the acceptance standards under Sec. 13 of KTA 3201.3.

27.4.3.2 Procedure qualification for constructional welds

(1) The requirements under Sec. 27.4.3.1 apply accordinglyto constructional welds.



The general requirements under Sec. 12.1 of KTA 3201.3 shallapply to production weld tests.

27.4.4.1 Production weld tests of production welds


(1) The production weld tests for production shall be per-formed in accordance with the following requirements (seealso Sec. 12 of KTA 3201.3). One production weld test corre-lated to a particular component weld may include other com-ponent welds within the same scope of the procedure qualifi-cation provided these are welded generally within 12 monthsfrom completion of the production weld test correlated to aparticular component weld.

(2) The test coupon shall be dimensioned such that the testrequired in accordance with Table 27-2 can be performed.

(3) It shall be ensured that sufficient reserve material isavailable. Sec. 12.1.4 of KTA 3201.3 applies to the storage ofreserve material.

(4) The test coupons for the production weld tests of theproduction welds shall be heat treated as is required for thecomponent, i.e., solution annealed and quenched (cf. Sec.27.4.1 (1)).


The test specimen shall be taken in accordance with Figure27-1 and 27-2.


(1) The extent of tests regarding the mechanical propertiesdepends on the requirements under Sec. 27.4.3.1.3 (1) andTable 27-2. If the test coupon is attached to the correspondingcasting from the same melt to be mutually solution annealedand quenched, or, if a similar temperature-time sequence isadequately demonstrated, a test of the mechanical propertiesof the base material is not required since these are obtainedfrom testing the casting itself.

(2) The extent of the non-destructive examinations as wellas procedural details are specified under Sec. 27.6. Both of thefollowing examinations shall be performed in the final heattreatment condition - solution annealed and quenched

a) surface crack examination and

b) radiographic examination.

(3) The extent of the other tests is specified in Table 27-2.


(1) The results of the tests to obtain the mechanical proper-ties and the other tests shall meet the requirements underTable 27-3.

(2) The results of the non-destructive examinations shallmeet the acceptance standards under 27.6.3.

27.4.4.2 Production weld tests for construction welds

(1) The requirements under Sec. 27.4.4.1 shall apply accord-ingly.


27.5 Tests on castings


(1) The test specimen shall be taken from cast-integral testcoupons that may not be cooled (cast-integral coupons, sur-plus lengths, nozzle cutouts). The test coupons shall be dis-tributed over different locations of the casting.

(2) The number of test coupons shall be as follows:

Casting weightkg

Number of test coupons percasting

≤ 500 1

> 500 to ≤ 1000 2

> 1000 3

KTA 3201.1

(3) The thickness of the cast-integral coupons shall corre-spond to the governing wall thickness of the casting.

(4) The test coupons shall be cut-off after the last temperingprovided the non-destructive examinations are not detrimen-tally affected. If on account of the non-destructive examina-tions the coupons are to be cut off at an earlier time, then thetest coupons shall subsequently be welded again onto thecasting to be mutually solution annealed and quenched.

(5) In special cases the test specimens may also be takenfrom cast melt test coupons. These special cases shall beagreed upon between the parties involved (material manufac-turer, customer and authorized inspector).

(6) Regarding the size of the test coupons, Sec. 3.3.3 shall beobserved. If possible, the test specimens shall lie at least onequarter of the quenched and tempered wall thickness beneaththe surface of the test coupons. When taking test specimensfrom test coupons that were taken by flame cutting, attentionshall be paid to observing a sufficient distance to the heataffected zone.

(7) The tests in accordance with Secs. 27.5.2.2 and 27.5.2.4shall be performed on solution annealed and quenched testcoupons removed in accordance with Sec. 27.5.1.



(1) Ladle analysis

For each melt a ladle analysis shall be performed for the fol-lowing elements:

C, Si, Mn, P, S, Nb, Cr, Mo, Ni and Co as well as the elementsspecified in Sec. A 6.


On each casting, a product analysis for the elements specifiedunder para. (1) shall be performed at one specimen-takinglocation in the vicinity of the feeder.


(1) Tensile test

Two test specimens from each test coupon shall be subjectedto a tensile test, one at room temperature and one at designtemperature.

(2) Impact test

On one set of transverse test specimens from each test couponit shall be demonstrated at 20 °C that the impact energy forthe cast steel used does not fall below the minimum requiredimpact energy.


The resistance to intergranular corrosion shall be demon-strated on one test specimen from one casting for each meltand heat treatment lot. The test specimen shall be in a sensi-tised heat treatment condition (cf. 27.10).

27.5.2.4 Determination of the delta ferrite content

The delta ferrite content shall be determined for one test cou-pon for each casting after the final heat treatment.

Note:Also see Sec. 27.10.



The following requirements supplement the requirementsunder Sec. 3.3.8.2.3 through 3.3.8.6.4.

27.6.2 Extent of type and point of time


(1) The interrelation between extent, type and point of timeof the non-destructive examinations and the course of fabri-cation as well as the participation of the authorized inspectorin these examinations is shown in Table 27-1.

(2) In the case of deviations from the sequence, a test andinspection sequence plan shall be established by the materialmanufacturer and submitted to the authorized inspector fordesign review.

27.6.2.2 Extent and type

(1) The castings shall be fully radiographed.

(2) A surface crack examination by means of the liquidpenetrant method shall be performed on all surfaces. All hol-low portions arising from grinding out flaws shall be exam-ined, too.

(3) All production welding shall be subjected to a liquidpenetrant and a radiographic examination.

27.6.2.3 Point of time

(1) The radiographic examination shall be performed afterat least one solution annealing.

(2) All production welds shall be subjected to a radio-graphic examination after final solution annealing and, like-wise, any major solution annealed production welds in accor-dance with DIN 17 245.

(3) In those cases where the valve manufacturer carries outsubsequent fabrication, these newly created surfaces shall besubjected to a renewed surface crack examination.

27.6.3 Procedural requirements

27.6.3.1 Surface quality

(1) The surface quality shall be evaluated in accordancewith Recommendation Technique No. 359-01 du Bureau deNormalisation des Industries de la Fonderie.

(2) The castings should have a surface quality that is equalto or better than reference pattern 3 S2.


(1) The requirements under Sec. 25.6.3.2 shall apply to theradiographic examination.

(2) Where the allowed radiation energies lead to indicationscaused by microstructural effects (e.g. due to X-ray diffrac-tion), control radiographs shall be made with higher radiationenergies or different radiographic arrangements or by enlarg-ing the focus-to-object distance. The procedure as well as theevaluation of these additional measures shall be agreed uponwith the authorized inspector.

KTA 3201.1


The examination shall be performed in accordance with SEP1936.






27.6.4.3 Production welds

Production welds shall be evaluated like the base material asspecified under Sec. 26.4.1 (1). If, by agreement with theauthorized inspector, indications inside the production weldare clearly shown to be inclusions, these may be consideredindividual flaws and may be left as they are provided theirmaximum length does not exceed one third of the respectivewall thickness.






(1) Each casting shall be subjected to a pressure test to showthat it is leak tight; this test is usually performed during sub-sequent fabrication with the component in a correspondingcondition.

(2) The pressure test shall be performed in accordance withDIN 50 104. The pressure medium, pressure level and dura-tion of pressure loading shall be specified in writing uponplacing the order. In no case shall, however the nominal pres-sure lead to a loading in excess of 90 % of the 0.2 % proofstress of the cast steel type.

27.10 Examination procedures

(1) The delta ferrite content shall be determined metallo-graphically (cf. Annex D).

(2) For the examination regarding resistance to intergranu-lar corrosion in accordance with DIN 50 914 the sensitisationconditions required with regard to the intended fabricationprocedures shall be specified for the material manufacturerwhen placing the order.


The identification marking of the casting shall contain thefollowing information:



c) melt number,




The results of the tests in accordance with Secs. 27.5.2.1 and27.5.2.3 shall be certified by Acceptance Test Certificates 3.1.Bin accordance with DIN EN 10 204, the results of all the othertests by Acceptance Test Certificate 3.1.C in accordance withDIN EN 10 204.

KTA 3201.1

Specimen locationin the weld metalSpecimen location


Bend test specimen

in the welded joint


0.6

d

d

0.4

d0.6

dd

d

0.4

0.4

d

dd

0.6

sketch II

sketch III

sketch IV

M

O

sketch I



sketch V


M: midsection


Specimen locationin the weld metalSpecimen location


Bend test specimen

in the welded joint


dd

d

M

O

M

O

sketch IV sketch V

sketch I

sketch III

sketch II




M: midsection


KTA 3201.1

1)

2)

3)

1)

yes no

Complete surface crack examination by H and S

Destructive testing

Compilation of documents

Final acceptance test

indications

Evaluation of the films by the manufacturer (H) and

authorized expert (S)

unallowable

Complete radiographic examination

yes

Welding

Plane-grinding of welds

no

yes

Obtaining the surface quality in accordance with Sec. 27.6

no

intended for welding by the manufacturer (H)

Documentation of larger production welds in accordance with

Casting process

Preparation and surface crack examination of the regions

Solution annealing

DIN 17 245 for intermediate file and information of the

authorized inspector (S)

Complete surface crack examination by the manufacturer (H)

Surface crack examination of production welds by H

Solution annealing

Obtaining agreement of authorized inspector (S) to the welding

Welding

manufacturer (H) of locations intended for welding

Documentation of the production welds

Plane-grinding of welds

Surface crack examination of production welds by H


Radiographic examination of production welds

yes

Obtaining the surface quality in accordance with Sec. 27.6

no

Complete surface crack examination by the manufacturer (H)

Preparation and surface crack examination by the

Radiographic examination of larger production welds

indications

unallowable

indications

unallowable

indications

unallowable

then, by agreement with the authorized inspector,

deviations from the standard procedure as described in

If, in exceptional cases during subsequent fabrication,

production welding becomes necessary for the removal

of casting flaws at a far-advanced stage of fabrication,

this flow chart are allowed.

3)

radiographed casting regions with allowable

Note regarding further radiographic examinations:1)

indications do not have to be reexamined.

characteristics.

2) Heat treatment for obtaining mechanical material


Table 27-1: Fabrication flow chart for pressure-retaining components made of austenitic cast steel

KTA 3201.1


withDIN EN 10 204

Testspecimen

layerFig. 27-2





full pene-trationweld

a) Weld metal

Tensile test specimen RT DIN EN 10 002-1 Rm, A5, Z, Rp0.2, Rp1.0 27-1/I 1

DIN 50 125 350 DIN EN 10 002-5 Rm, A5, Z, Rp0.2, Rp1.0 27-1/I 1

RT DIN EN 10 002-1 Rm, A5, Z, Rp0.2, Rp1.0 27-2/I OM

11 3.1.C

350 DIN EN 10 002-5 Rm, A5, Z, Rp0.2, Rp1.0 27-2/I OM

11

Impact test specimen 20 DIN EN 10 045-1 KV 27-1/IV 3

27-2/IV OM

33

b)Welded joint

Tensile test specimen RT DIN EN 10 002-1 Rm, fracture location 27-1/II 1

DIN EN 895 27-2/II OM

11

Bend test specimen RT DIN EN 910 27-1/III 1

27-2/III OM

11

3.1.C

Impact test specimen 20 DIN EN 10 045-1 KV 27-1/V 3

27-2/V OM

33

RT DIN 50 914 1

O 1

c) Base metal 1)

Tensile test specimen RT DIN EN 10 002-1 Rm, Rp0.2, Rp1.0, A5, Z 1

DIN 50 125 OM

11 3.1.C

Impact test specimen 20 DIN EN 10 045-1 KV 3

OM

33

d) Other tests and examinations

(1) Production of a photograph of an etched macrosection of the entire cross-section of the production weld.

Certification by Acceptance Test Certificate 3.1.C in accordance with DIN EN 10 204.

(2) Analysis of the alloying elements of the weld metal, in the case of full penetration welds in the test layers O and Mfor: C, Mn, Si, P, S, Cr, Mo, Ni, Nb, Cu, Co.

Certification by Acceptance Test Certificate 3.1.B in accordance with DIN EN 10 204.

(3) Micrograph of a transverse microsection, generally at a 200:1 enlargement, one each of the test layers in accordancewith Figure 27-1 and 27-2.

Certification by Acceptance Test Certificate 3.1.C in accordance with DIN EN 10 204.

The following shall be covered by this microphotograph:

- all-weld metal,

- transition between all-weld metal and base metal

- (uninfluenced) base metal.

1) A test or examination of the base metal is only required if no corresponding values of the base metal in the test layers O and M are available.

Table 27-2: Valve bodies made from austenitic cast steelExtent of procedure qualification and production weld tests on production welds


Fig./Sketch

3.1.B

bending angle to firstcrack

Intergranularcorrosiontest specimen

KTA 3201.1


a) Weld metal

Tensile Test (RT and 350 °C) Like the base metal or as specified in the acceptance test.

Notched-bar impact test (20 °C) KV Unannealed or solution annealed: 70/60 JStress-relief heat treated: 55/40 J

Chemical analysis Like specified in the acceptance test of weld consumables.

b) Welded joint

Tensile Test (RT) Like the minimum tensile strength of the base material.

Notched-bar impact test (20 °C) KV Unannealed or solution annealed: 70/60 JStress-relief heat treated: 55/40 J




The structure of the all-weld metal and of the heat-affected zone of the basemetal shall show a perfect bead sequence and complete penetration of thejoint (macrosection) as well as a perfect crystalline structure (microsection).Material discontinuities (microsection) are allowed, provided, they are defi-nitely individual defects judged by their number and location. Not allowedare accumulations of such defects in the form of connected fields.

c) Base metal

Tensile Test (RT)Notched-bar impact test (20 °C)

Like specified in Annex A or in the initial material certification, in so far asspecified for the individual test layers.

Table 27-3: Valve bodies made from austenitic cast steelRequirements for procedure qualification and production weld tests on production welds

28 Bars and forgings from stainless martensitic steel

28.1 Scope

(1) This section applies to rods and forgings from stainlessmartensitic steels that are used, e.g., for the pressure tubes ofcontrol rod drives, sealing housing and sealing cover of theprimary coolant pump as well as for parts of solenoid valves.

(2) The requirements for the materials of this product formare specified under Sec. A 8.


28.2.1 Test lots and specimen-taking locations

28.2.1.1 Bars

(1) Bars with a quenched and tempered weight equal to orsmaller than 500 kg shall be tested in lots. Bars of the samemelt and heat treatment and of similar dimensions shall begrouped into lots of 500 kg each, however, into lots of nomore than 10 pieces. One bar from each lot shall be tested atone end.

(2) Bars with a quenched and tempered weight greater than500 kg shall be tested individually. Bars with a quenched andtempered length equal to or smaller than 2000 shall be testedat one end. Bars with a quenched and tempered length ex-ceeding 2000 mm shall be tested at both ends with the speci-men-taking locations offset by 180 degrees to each other.

(3) Where practicable the tests shall be performed withtransverse test specimens. Longitudinal test specimens areallowed in the case of bars with a quenched and tempereddiameter, thickness or width equal to or less than 140 mm.

28.2.1.2 Forgings

(1) Forgings with a quenched and tempered weight equal toor smaller than 500 kg shall be tested in lots. Forgings of thesame melt and heat treatment and of similar dimensions shallbe grouped into lots of 500 kg each, however, into lots of nomore than 10 pieces. One set of test specimens from each lotshall be tested.

(2) Forgings with a quenched and tempered weight of morethan 500 kg but not exceeding 5000 kg shall be tested indi-vidually. Two test coupons shall be taken from each forging atlocations offset by 180 degrees to each other. If the quenchedand tempered length, the two specimen-taking locations shallbe located either at the head or the tail end of the forging. Ifthe quenched and tempered diameter is smaller than thequenched and tempered length, one of the specimen-takinglocation shall be at the head end and the other at the tail endof the forging.

(3) Forgings with a quenched and tempered weight exceed-ing 5000 kg shall be tested individually. Three test couponsshall be taken from each forging. If the quenched and tem-pered diameter is equal to or larger than the quenched andtempered length (e.g. rings or discs), the three specimen-taking locations shall be located at one end of the forging andoffset by 120 degrees to each other. If the quenched and tem-pered diameter is smaller than the quenched and temperedlength (e.g. rod or hollow body), the three specimen locationsshall be distributed over both ends of the forgings.

(4) As far as possible, the test coupons shall be taken withan orientation perpendicular to the direction of major defor-mation.

KTA 3201.1

(5) The specimen-taking locations shall be specified in thematerials specimen-taking plan in accordance with Sec.2.5.4.2.4.

28.2.2 Specimen-taking location

The test coupons shall be taken from a location that is T/4,however, not more than 80 mm under the lengthwise surfaceand under the end face surfaces, where T is equal to thequenched and tempered diameter or quenched and temperedwall thickness.



(1) Ladle analysis



A product analysis shall be performed

a) for one piece from each lot in the case of product formswith a quenched and tempered weight equal to or smallerthan 500 kg,

b) for one specimen-taking location from each piece in thecase of product forms with a quenched and temperedweight of more than 500 kg but not exceeding 5000 kg,

c) for one specimen-taking location from each piece in thecase of product forms with a quenched and temperedweight exceeding 5000 kg.

28.2.3.2 Tests in the quenched and tempered condition


(1) Tensile test


(2) Impact test

One set of notch bar test specimens from each specimen-taking location shall be tested in accordance with Sec. 3.3.7.3.

28.2.3.2.2 Hardness test

The hardness shall be determined on each piece to verify thetempering uniformity.

28.2.3.2.3 Non-destructive examinations

The specifications under Sec. 14.4 shall apply to bars andthose under Sec. 11.4 to forgings.

28.2.3.3 Tests on accompanying test coupons for pressuretubes of control rod drives

(1) If the products are stress-relief heat treated andquenched and tempered during subsequent fabrication, ac-companying test coupons shall be kept available.

(2) Each heat treatment lot for stress-relief heat treatment ortempering during subsequent fabrication shall be accompa-nied by one set of accompanying test coupons for every testlot or test piece of the original product forms.

(3) Under consideration of the specimen orientation asspecified under Secs. 28.2.1.1 or 28.2.1.2, the following testsshall be performed:

a) one tensile test at room temperature,

b) one tensile test at design temperature,

c) one impact test at room temperature on one set of testspecimens.


In addition to the specification under Sec. 3.5 the followingapplies:

In the case of a lot-oriented testing in accordance with Secs.28.2.1.1 or 28.2.1.2, each part shall be marked with the lotnumber.


Each product shall be subjected to a materials identificationcheck. Where the products have been subjected to a productanalysis in accordance with Sec. 28.2.3.1 (2), this analysis shallbe considered a valid materials identification check.






The results of the tests in accordance with Secs. 28.2.3.1 and28.2.3.2.2 shall be certified by Acceptance Test Certificates3.1.B in accordance with DIN EN 10 204, the results of theother tests by Acceptance Test Certificates 3.1.C in accordancewith DIN EN 10 204.

29 Product forms and components from ferritic steelsfabricated by shape-welding

29.1 Scope

(1) This section applies to rotationally symmetric productforms or components from ferritic steels that are fabricated bya multiple layer deposition of molten-off electrode materialand are subsequently not subjected to a heat-treatment of ahigher temperature than is permitted for stress-relief heattreatment.

(2) All materials in accordance with Appendix A10 areacceptable as well as other materials that meet the require-ments under Sec. 2.1, 3.1 and 3.2.

(3) The requirements regarding materials are specified inSec. A 10 or in the initial material certification of the author-ized inspection.

Note:

(1) If the product forms or components fabricated by shape-welding orshape-melting are comprised of two or more parts that were similarlyfabricated and assembled and with similar fabrication parameters, thenthe testing procedure shall be specified in the procedure appraisal.

(2) In the case of weld connections in shape-welded components, it shallfurthermore be observed that the material characteristics of the weld ma-terial shall correspond to those of the base material.

KTA 3201.1

29.2 Requirements


29.3 Prerequisites for manufacturing

29.3.1 Requirements regarding personnel for performingshape-melting tasks

In the case of an automated process-controlled shape-weldingfacility, it shall be demonstrated to the authorized inspectorthat the supervisory and operating personnel has sufficientknowledge regarding the operation of the facility.

29.3.2 Principles for performing shape-welding and shapemelting tasks

(1) In the case of nonautomated facilities, the requirementsunder Sec. 2.4 (13) shall be observed by the supervisory andoperating personnel of these facilities.

(2) Basically, the requirements under Sec. 6 of KTA 3201.3shall be met.

(3) Unless specified otherwise and by agreement with theauthorized inspector, the procedure appraisal regardingmanufacture and material shall replace the procedure qualifi-cation in accordance with Sec. 6 of KTA 3201.3.

(4) In the case of automated fabrication, the fabricationprocedure shall be recorded, by other adequate means, in lieuof a welding record which shall be checked within the proce-dure appraisal. This record shall proof that the process condi-tions - at all times during fabrication of a piece - have stayedwithin the limits specified in the material related procedureappraisal.

(5) In the period of time between shape-welding or shape-melting and intermediate and final tempering, the tempera-ture of the component shall not fall below 150 °C.

29.3.3 Weld filler metals

(1) The requirements under KTA 1408.2 shall basically ap-ply to the inspection.

(2) In the case of a continuous flux production, the fluxvolume produced in up to one day may, by agreement withthe authorized inspector, be considered one major batch in theexamination in accordance with KTA 1408.3. The flux manu-facturer shall establish a certificate to this effect in accordancewith KTA 1408.2. The results of the delivery inspection mustshow an adequate uniformity. Any interruption of the fluxfabrication limits the size of the batch.

29.4 Tests and examinationsNote:The following are provisional requirements since the initial materialcertification has not yet been completed.

(1) In the case of automated facilities which control all fabri-cation parameters relevant to quality, the extent of tests maybe reduced provided the manufacturer has gained sufficientexperience and the authorized inspector agrees. Sufficientexperience exists if 50 sets of notch-bar test specimens havebeen tested and have met the requirements. The measure forthe reduction of the extent of testing shall depend on the fol-lowing conditions:a) type and extent of the quality control,b) evaluation of the cross section in accordance with Sec.

29.4.2.2.3 (7),

c) the results of the hardness test in accordance with Sec.29.4.2.2.2,

d) the results of the non-destructive examinations in accor-dance with Sec. 29.4.3.

(2) The extent of tests may be reduced by a maximum of50 %. However, all batch combinations shall be tested thathave not been included in the tests in accordance with Sec.29.4.1.

29.4.1 Welding material test

Every batch or major batch under consideration of Sec. 29.3.3shall be subjected to a welding material test in accordancewith Sec. 4 of KTA 1408.3.

29.4.2 Tests on the individual product

29.4.2.1 Specimen-taking

(1) Tangential or axial test coupons shall be taken from oneend face of each individual product and such that the axes ofthe test specimens lie no more than 10 mm beneath the sur-face. With regard to the metallographic examination, one testcoupon shall be taken such that it spans the entire wall thick-ness.

(2) If more than two welding material combinations areused on one individual product, an additional test couponspanning the entire wall thickness shall be taken. This testcoupon shall be large enough to allow the production of oneradial tensile test specimen spanning the entire wall thickness,one radial test specimen for a hot tensile test in accordancewith DIN 50 125, as well as one set of notchbar test specimensin any orientation with the test cross section in the particularregion of the welding material combination.

(3) By agreement with the authorized inspector, the testcoupons may be removed from trepanned plugs.


29.4.2.2.1 Chemical analysis

A product analysis shall be performed for both of the speci-men-taking locations on one end face near the outside and theinside surface.

29.4.2.2.2 Proof of uniformity

Hardness measurements shall be performed on the end facesand the outside surface with the product in the deliverycondition to demonstrate uniformity; the measurements shallbe performed in a grid of not more than 1000 mm x 1 000 mm.

29.4.2.2.3 Tests in the stress-relief heat treated condition


Deviating from Sec. 3.3.5, the test coupons shall be taken fromthe products in the delivery condition, unless specified oth-erwise in the initial material certification.

(2) Tensile test

Two tangential or axial test specimens from each specimen-taking location shall be subjected to a tensile test in accor-dance with Sec. 3.3.7.3 (1), one at room temperature and oneat design temperature.

In the case of products from more than two welding materialcombinations, additionally, one radial test specimen spanning

KTA 3201.1

the entire wall thickness shall be subjected to a tensile test atroom temperature. From that wall region with the location offracture of this radial test specimen, an additional radial testspecimen shall be subjected to a tensile test in accordance withDIN 50 125 at design temperature.

(3) Reduction of areaIf the values for reduction of area determined by means of thetensile tests and Sec. 29.4.2.2.3 (2) are equal to or larger thanthe average value specified under Sec. 29.2 (2), then the re-quirements are considered to have been met.If one of these values is smaller than the specified average,then two test specimens of similar type, location and orienta-tion from the same specimen-taking location shall be tested.

(4) Impact testOne set of tangential or axial test specimens from each speci-men-taking location shall be subjected to an impact test inaccordance with Sec. 3.3.7.3 (2) at 0 °C, 33 °C (products forbelt-line components at 21 °C) and 80 °C. The test at 33 °Cmay be replaced by one test at 20 °C if it can be shown alreadyat 20 °C that the smallest single value for the impact energy isnot less than 68 J and the smallest single value for the lateralexpansion is not less than 0.9 mm.

(5) Impact energy-versus-temperature curveIn the case of products intended for belt-line components, animpact-energy-versus-temperature curve shall be determinedin accordance with Sec. 3.3.7.3 (3) for the specimen-takinglocation close to the internal surface.

(6) Nil-ductility transition temperatureIt shall be shown on two test specimens from each specimen-taking location that the requirements regarding the NDTtemperature in accordance with Sec. 3.3.7.3 (4) are met.

In the case of products intended for belt-line components, theNDT temperature shall be determined for one specimen-taking location.

(7) Metallographic examinationsA macrosection shall be made for one end face over the entirewall thickness and for a width of at least 40 mm. The surfacenormal of the macrosection should be parallel to the directionof welding. The hardness traverse (HV 5) shall be determinedon this macrosection in two lines perpendicular to each other.Additionally, one microsection shall be made at a location thatshall depend on the evaluation of the macrosection.

Photomicrographs shall be taken of the microsection (gene-rally, at an enlargement of 200 :1) and of the microsection.

29.4.2.2.4 Test on accompanying test coupons


Test material for the accompanying test coupons shall betaken from the product in the stress-relief heat treated condi-tion from one specimen-taking location.

(2) Tensile test

Two tangential or axial test specimens shall be subjected to atensile test in accordance with Sec. 3.3.7.3 (1), one at roomtemperature and one at design temperature.

(3) Impact testOne set of test specimens shall be subjected to an impact testin accordance with Sec. 3.3.7.3 (2) at 33 °C (products for belt-line components at 21 °C).

The test at 33 °C may be replaced by one test at 20 °C if it canbe shown already at 20 °C that the smallest single value for

the impact energy is not less than 68 J and the smallest singlevalue for the lateral expansion is not less than 0.9 mm.


On two test specimens from each specimen-taking location itshall be shown in accordance with Sec. 3.3.7.3 (4) that therequirements regarding the NDT temperature are met.

29.4.3 Non-destructive examinations


The following requirements shall apply to manual examina-tions and supplement the requirements under Sec. 3.3.8.


29.4.3.2.1 Sound attenuation measurements

In the case of a wall thickness equal to or greater than200 mm, the sound attenuation shall be determined with thestraight-beam method for one location per square meter of theouter surface, however, for not less than 3 locations. Whereduring straight-beam scanning no significant local fluctua-tions are found (range equal to or smaller than 6 dB), then thenumber of measurements for angle-beam scanning may bereduced.

29.4.3.2.2 Sound beam angles

(1) The entire volume of continuously fabricated and as-sembled shape-welded or shape-melted product forms shallbe examined by the straight-beam method in three soundbeam entry directions perpendicular to each other. Two of thesound beam entry directions shall be perpendicular to thedirection of welding (examination for longitudinal flaws) andone parallel to the direction of welding (examination fortransverse flaws). If a straight-beam examination is not pos-sible due to the contour of the test object, each missingstraight-beam examination shall be replaced by two oppositeangle-beam examinations. In this case the sound beam entrydirections of the angle-beam examination shall be parallel tothe major beam entry direction of the missing straight-beamexamination.

(2) For product forms fabricated by an automated process-controlled shape-welding facility, the number of beam entrydirections may be reduced provided the authorized inspectoragrees.

(3) The ultrasonic examination in all beaming directionsmay be performed from one surface. However, if required toachieve the necessary testing sensitivity level, an examinationfrom both surfaces may become necessary.

(4) In the case of a nominal wall thickness exceeding100 mm in the final condition, an examination for flaws per-pendicular to the direction of major loading shall additionallybe performed (e.g. by a tandem-probe examination in accor-dance with Appendix C of KTA 3201.3) provided this direc-tion is not already sufficiently covered by the straight-beamand angle-beam examinations. Depending on the structure ofthe weld layers, this additional examination may be waivedprovided the authorized inspector agrees.

KTA 3201.1


(1) All indications with an echo amplitude equal to or ex-ceeding the values specified in Table 29-1 shall be recorded.

Nominal wall thickness ≤ 40 mm


Angle-beamscanning

Entire volume 3 2

Regions ofweld edges andnozzles

2 2

Nominal wall thickness > 40 mm


Angle-beamscanning

Tandemscanning 1)

Entire volume 3 3 6

Regions ofweld edges andnozzles

3 3 6

1) Where performed

Table 29-1: Recording limit set by the diameter of therespective circular disc reflector

(2) In the sound attenuation measurements, any attenuationexceeding 4 dB/m when testing with 2 MHz or exceeding10 dB/m when testing at 4 MHz shall be recorded.


The acceptance standards specified under Sec. 5.4.2.4 shallapply.


The requirements under Sec. 5.4.3 shall apply with regard tothe acceptance standards of surface crack examinations.






The results of the chemical analysis in accordance with Sec.29.4.1 and 29.4.2.2.1 and the tests in accordance with Secs.29.4.2.2.2 and 29.4.2.2.3 (7) shall be certified by AcceptanceTest Certificates 3.1.B in accordance with DIN EN 10 204, theresults of all the other tests by Acceptance Test Certificates3.1.C in accordance with DIN EN 10 204.

30 Product forms from ferritic steels for integral connec-tions to the reactor coolant pressure boundary

30.1 Scope

This section applies to the product forms from ferritic steelsfor integral connections to components of the primary coolant

system, e.g. for the component support structures and pipe-whip restraints.

30.2 Requirements

(1) With regard to the different product forms, this safetystandard applies to the

a) materials and

b) general and additional requirements

whereas safety standard KTA 3205.1 applies to the

c) taking and treatment of test coupons,

d) non-destructive examinations,

e) identification marking, and

f) quality certification.

(2) The requirements under Sec. 30.3 apply to the extent oftests required for demonstrating the chemical analysis and thematerial properties.

30.3 Extent of testing

30.3.1 Chemical analysis

(1) Ladle analysis

For each melt ladle analysis shall be performed.



30.3.2 Mechanical properties

(1) Tensile test



Three perpendicular test specimens from each specimen-taking location shall be tested to verify reduction of area.

(3) Impact test

One set of transverse test specimens shall be subjected to animpact test at 0 °C and 33 °C.


On two test specimens from each specimen-taking location itshall be shown in accordance with Sec. 3.3.7.3 (4) that therequirements regarding the NDT temperature are met.

31 Product forms from austenitic steels for integral con-nections to the reactor coolant pressure boundary

31.1 Scope

This section applies to the product forms from austenitic steelsfor integral connections to components of the primary coolantsystem, e.g. for the component support structures and pipe-whip restraints.

31.2 Requirements

(1) With regard to the different product forms, this safetystandard applies to the

a) materials and

b) general and additional requirements

KTA 3201.1

whereas safety standard KTA 3205.1 applies to the

c) taking and treatment of test coupons,

d) non-destructive examinations,

e) identification marking, and

f) quality certification.

(2) The requirements under Sec. 31.3 shall apply with re-spect to the extent of tests.

31.3 Extent of testing

31.3.1 Chemical analysis


31.3.2 Tensile test

One test specimen from each specimen-taking location shallbe subjected to a tensile test at room temperature.

31.3.3 Determination of the delta ferrite content

For parts which, in the course of subsequent fabrication, willbe subjected to welding, the delta ferrite content shall be de-termined by a mathematical estimation taking the nitrogencontent from each chemical composition determined on thepiece (cf. Sec. 22.3.2.1(2)) into account. If the resulting ferritenumbers are less than 3 or greater than 7 then a bead-on-platetest (cf. Annex D) shall be performed on that piece with themost unfavourable chemical composition with respect to thedelta-ferrite content.

31.3.4 Resistance to intergranular corrosion

For each melt and heat treatment lot one test specimen shallbe tested for resistance to intergranular corrosion.

31.3.5 Materials identification check

Each part shall be subjected to a materials identification check.

KTA 3201.1

Annex A

Material characteristics

A 1 Steel 20 MnMoNi 5 5

A 2 Austenitic steel X 2 NiCrAlTi 32 20

A 3 Stainless austenitic rolled and forged steels

X 6 CrNiTi 18 10 S

X 6 CrNiNb 18 10 S

X 6 CrNiMoTi 17 12 2 S

A 4 Cast steel GS-18 NiMoCr 3 7

A 5 Cast steel GS-C 25 S

A 6 Austenitic cast steel G-X 5 CrNiNb 18 9 S

A 7 Quenched and tempered fine-grained structural steel as base material and stainless austenitic steelas cladding material for seamless, extrusion-clad composite tubes

A 8 Martensitic steel X 5 CrNi 13 4

A 9 Nickel Alloy NiCr 15 Fe

A 10 Materials 8 MnMoNi 5 5 and 10 MnMoNi 5 5 (for shape-welding or shape-melting)

A 11 Quenched and tempered steels for bars and rings for bolts and nuts and extension sleeves

A 12 Quenched and tempered steels in accordance with DIN 17 240 for bars and rings for bolts, nuts,and extension sleeves; supplementary requirements to DIN 17 240

KTA 3201.1

A 1 Steel 20 MnMoNi 5 5

A 1.1 Scope

(1) This Section A1 specifies the details with regard tochemical composition, characteristic mechanical and physicalproperties of the steel 20 MnMoNi 5 5 as well as further fabri-cation for the product forms within the scopes of Secs. 4through 17 and 30:

a) Seamless hollow parts, forged or rolled(Section 4)

b) Seamless hollow parts for nozzles, forged, rolled orpressed(Section 5)

c) Forged single-piece plates for tubesheets(Section 6)

d) Sheets and plates(Section 7)

e) Products flanged, extruded, bent or rolled from sheets andplates(Section 8)

f) Straight pipe fittings(Section 9)

g) Seamless, forged hollow parts for primary coolant pumpcasings(Section 10)

h) Pressure-retaining forged valve bodies(Section 11)

i) Forged flat plates(Section 12)

j) Hot dished or pressed products from forged plates(Section 13)

k) Forged or rolled bars for hollow bored nozzles and pipes(Section 14)

l) Forged or rolled and hollow-bored and hollow-forged bars(Section 15)

m) Seamless pipes for pipe systems(Section 16)

n) Seamless pipe elbows for piping systems(Section 17)

o) Product forms from ferritic steels for integral connectionsto the reactor coolant pressure boundary(Section 30)

(2) Deviations from these requirements are allowed pro-vided they are specified in the initial material certification ofthe authorized inspector.

A 1.2 Manufacturing of the material

(1) The material 20 MnMoNi 5 5 is a fine-grained quenchedand tempered alloy steel and is characterised by its highstrength at elevated temperatures.

(2) The material shall be molten and degassed in the electricarc furnace or by the basic oxygen process. If other processesare used, a proof of equivalency is required.

A 1.3 Requirements

A 1.3.1 Chemical analysis

The required chemical composition for the material is speci-fied in Table A1-1 and shall be determined by the ladle andthe product analysis.

Note:Some of the differences in the chemical compositions between the ladleanalysis and the product analysis are smaller than may be expected onthe basis of metallurgical considerations. This is due to the fact that thelimit values of the chemical composition for the product analysis arebased on the melt covered in the initial material certification. These val-ues will, therefore, be reviewed when further information is available. Ifthe sulphur content according to the ladle analysis is slightly larger, thenthe sulphur content from the product analysis and the mechanical prop-erties shall be the determining factors.

A 1.3.2 Mechanical properties

A 1.3.2.1 General requirements

(1) The requirements regarding mechanical properties of thematerial apply to the final condition of the component afterheat treatment.

(2) The properties in accordance with Secs. 4 through 17shall be demonstrated in the acceptance test on simulationstress-relief heat treated and accompanying test coupons. Therequired values given below are valid for the specimen-takinglocations, test specimen depths and orientation as specifiedunder Secs. 4 through 17.

(3) In the case of product forms within the scopes of Secs. 4through 6 and 10 through 13 and a quenched and temperedwall thickness between 220 and 320 mm, up to 10 % lowervalues than the minimum specified Rp0.2 and Rm are allowedat mid-wall than specified for the specimen-taking locations,and up to 20 % lower values for a quenched and temperedwall thickness exceeding 320 mm provided the impact energyand lateral expansion determined at a test temperature of80 °C at mid-wall are greater than 68 J and 0.9 mm, respec-tively. However, testing at mid-wall shall only be consideredif the fabrication process in accordance with Sec. 3.3.6 leads,e.g. to cut-outs from penetrations that are sufficiently large forthe removal of trepanned plugs. The extent of tests shall beagreed upon with the authorized inspector.

Note:The material certification has shown that it is possible for the productforms under Secs. 7, 8, 9, 15, 16, and 17 with a quenched and temperedwall thickness up to 200 mm and for product forms under Secs. 4, 10,11, 12, 13, and 14 up to 220 mm and finally for product forms underSec. 5 up to and including 230 mm to maintain the required propertiesover the entire cross section.

A 1.3.2.2 Tensile test at room temperature

(1) The characteristic values for the mechanical propertiesdetermined by the tensile test at room temperature are speci-fied in Table A 1-2.

(2) The elastic ratio shall not exceed 0.80.

(3) In the case of the product forms under Sec. 9, 16 and 17with a quenched and tempered wall thickness equal to or lessthan 70 mm, a ratio up to 0.85 is permissible.

(4) In the case of product forms under Secs. 7 and 8 with aquenched and tempered wall thickness exceeding 30 mm andequal to but less than 70 mm, an elastic ratio up to 0,85 ispermitted provided water quenching and tempering is carriedout.

(5) The values of the tensile strength determined with testspecimens of similar depth and orientation from the differentspecimen-taking locations on one product may not differ bymore than 80 N/mm2 with respect to each other.

KTA 3201.1

A 1.3.2.3 Tensile test at elevated temperatures

The characteristic values for the mechanical properties de-termined by a tensile test at elevated temperatures are speci-fied in Table A 1-3.

A 1.3.2.4 Impact test

(1) The values of the impact energy are specified in TableA 1-4 and apply to the base metal and also under considera-tion of Secs. A1.4.1 and A1.5.1, to the heat affected zone of theweld seams in the component.

Note:Additional requirements for the impact energy in transverse test speci-men are specified in the product-form related sections.

(2) In the case of product forms under Sec. 7 and 8, the fol-lowing applies additionally:

If the absorbed impact energy measured at 0 °C for a speci-men-taking location depth of T/4 has an average value be-tween greater 41 J and equal to or less than 51 J or a single va-lue equal to or less than 41 J, an additional impact toughnesstest for a specimen-taking location depth of T/2 is requiredwith T being the quenched and tempered wall thickness.

A 1.3.2.5 Nil-ductility transition temperature

(1) The test specimen shape chosen for the Pellini drop-weight test shall be P2 in accordance with SEP 1325.

(2) The NDT temperature of belt-line components is speci-fied under Sec. 3.2.4.2.

A 1.3.3 Grain size

After quenching and tempering, the characteristic value of thesecondary grain size shall be equal to or greater than 5 inaccordance with EURONORM 103-71.

A 1.3.4 Physical characteristics

Typical values for the physical characteristics are specified inAnnex AP.

A 1.4 Heat treatment

A 1.4.1 Quenching and temperingNote:The temperature values specified are individual piece temperatures.

(1) The following applies to product forms under Secs. 7and 8.


quenching tempering

870 °C to 930 °C 630 °C to 690 °C

The following applies to the other product forms under Sec. A 1.1:


quenching tempering

870 °C to 940 °C 630 °C to 680 °C

(2) The material manufacture together with the componentmanufacturer shall specify the heat-up and cooling rates, thetemperatures as well as the times at temperature dependingon the component dimensions and chemical composition suchthat, under consideration of any subsequent heat treatment,the mechanical properties in accordance with Sec. A.1.3.2 are

obtained in the final condition of the finished component.

A 1.4.2 Heat treatment during and after processing

(1) The last stress-relief heat treatment shall be performed ata temperature between 580 °C and 620 °C with subsequentcooling-down in the furnace or in still air.

(2) Necessary intermediate annealing may be performed at550 °C.

Note:Observe footnote 2 under Table A 1-1.

(3) The temperature of the stress-relief heat treatmentshould be lower than the minimum annealing temperature ofthe products used in the component or of the componentfabricated from the products.

(4) When specifying the annealing temperature, the heat-uptimes and cooling-down periods and times at temperature,attention shall be paid to the possible changes in materialcharacteristics during annealing taking also claddings intoaccount (corrosion resistance, ductility).

A 1.5 Further fabrication

A 1.5.1 Welding

(1) Product forms in the certified range of dimensions arefusion weldable by the following procedures:

a) Connection welding and deposition welding

aa) metal-arc welding with basic coated electrodes,

ab) submerged-arc welding with basic flux,

ac) gas-tungsten-arc (TIG) welding with welding con-sumables

b) Clad weldings

ba) metal-arc welding with basic coated electrodes ormixed types,

bb) submerged-arc welding with basic coated electrodesor flux mixtures,

bc) submerged-arc welding with wire electrodes,

bd) plasma cladding,

be) gas-metal-arc cladding,

bf) TIG cladding.Note:At the time being, less experience is available for the processes underac), bc), bd), be) and bf) than for the other methods.

(2) The pre-heating, intermediate layer or working tempera-ture depends on the thickness of the welded piece and shall bebetween 150 °C and 250 °C, for clad weldings the tempera-ture shall be between 120 °C and 180 °C.

(3) The welding conditions apply to connection weldings inthe filler layer region for cooling-down times t8/5 between 7and 25 sec.

Note:The correlation between weld parameters and t8/5 is shown in SEW 088.

(4) The weld filler metals and consumables allowed forsubmerged arc welding shall basically be basic-coated elec-trodes with controlled content of hydrogen or a similar basicflux that must be dried in accordance with the requirementsof the manufacturer of the weld filler metal to obtain a suffi-ciently low hydrogen content of the welding material.

Note:In the case of low-alloyed ferritic weld activities, sufficiently low hydro-gen content means hydrogen values of equal to or smaller than 3 ppm inthe bead material or about 5 ml hydrogen per 100 g of welding material

KTA 3201.1

from coated electrodes (HD5 in accordance with DIN 8572-E) or about 7ml hydrogen per 100 g of welding material from a wire/flux combination(HD7 in accordance with DIN 8575-UP).

(5) The component shall be saddened for a period of two ormore hours at about 280 °C directly from the welding heat,unless a stress-relief heat treatment is performed directly fromthe welding heat.

(6) A hydrogen reduction heat treatment (soaking) subse-quent to weld cladding may be omitted for product formsunder Secs. 4 to 6 and 10 to 14, provided the wall thickness inthe cladding region is equal to or less than 100 mm, and forproduct forms under Secs. 9 and 15, provided the wall thick-ness in the cylindrical part without discontinuities is equal toor less than 70 mm. In such a case, the cladded piece shall beheld at the minimum pre-heating temperature for a longertime and shall only then be slowly cooled down provided astress-relief heat treatment in accordance with Sec. A 1.4.2 isnot immediately performed from the welding heat.

(7) A hydrogen reduction heat treatment (soaking) subse-quent to weld cladding is not required for product formsunder Secs. 16 and 17, provided the wall thickness in thecladding region is equal to or greater than 70 mm. In thesecases, the cladded piece shall be kept at the minimum pre-heating temperature for a longer time and shall only the beslowly cooled down provided a stress-relief heat treatment inaccordance with Sec. A 1.4.2 is not immediately performedfrom the welding heat.

(8) In the case of product forms under Sec. 7 and 8, theweld-clad components shall be cooled down slowly directlyfrom the welding heat. Prerequisite is, however, that no seg-regation zones have been cut and cladded. If segregationzones must be clad, a saddening corresponding to that of theconnection weld is required.

(9) Any deviation from the requirements above, e.g. theapplication of different welding processes, reduction of thepre-heating temperature for clad welding, non-basic flux instrip-electrode weld cladding, shorter duration of saddeningor reduction of the saddening temperature, shall be agreedupon between material manufacturer and authorized inspec-tor. Hereby, the wall thickness and the type of weld fillermetals, the component type and the experience gained up tonow shall be taken into consideration. It shall be shown thatno damaging effects, e.g. of the weld connection, result fromthese deviations.

(10) A stress-relief heat treatment in accordance with A 1.4.2is always required after welding irrespective of the weldingprocedure and wall thickness involved.

A 1.5.2 Flame cutting

(1) A pre-heating temperature between 150 °C and 300 °C isrequired before any flame cutting. It is recommended to per-form the pre-heating in a furnace in order to achieve a uni-form temperature distribution (thorough heating).

(2) If the pre-heating is carried out locally, the heated regionmust be large enough to ensure thorough heating. The pre-heating temperature shall be maintained during the entireflame cutting process.

A 1.5.3 Forming

A 1.5.3.1 Hot forming

In consideration of the manufacturer specifications, anyforming shall be performed

a) at temperatures between 750 °C and 1250°C, in the case ofproduct forms under Secs. 4 to 6, 9 to 15,

b) at temperatures between 700 °C and 1100 °C, in the case ofproduct forms under Secs. 7, 8, 16, 17, and if necessary,within larger temperature ranges. The heat-up and coolingrates as well as the times at temperature shall be specifiedin accordance with the requirements of the material manu-facturer. After hot forming, a quenching and temperingtreatment is required.

A 1.5.3.2 Cold forming

(1) The cold forming of product forms under Secs. 7, 8, 16and 17 shall not be performed at temperatures lower than20 °C. Deviations shall be agreed with the authorized inspec-tor.

(2) A cold forming with a cold forming degree of equal to orless than 5 % requires a subsequent stress-relief heat treat-ment. An agreement between material manufacturer andauthorized inspector is required if the stress-relief heat treat-ment is to be waived. A cold forming with a cold formingdegree exceeding 5 % requires a renewed quenching andtempering.

A 1.6 Material certification

Material manufacturers possessing a completed material cer-tification in accordance with Sec. 2.1 are listed in VdTUEVMaterial Specification Sheets 401/1 to 401/3 which specify themanufacturing procedures, the delivery conditions and rangeof dimensions.

KTA 3201.1

Content by mass, %

C 6) Si Mn P 1) S Cr Mo

min. 0.17 0.15 1.20 0.40

max. 0.23 0.30 1.50 0.012 0.008 0.20 0.55

min. 0.15 0.10 1.15 0.40

max. 0.25 0.35 1.55 0.012 2) 0.012 2) 0.20 0.55 2)

Content by mass, %

Ni Altotal Cu 1) V Sn Ntotal As

min. 0.50 0.010

max. 0.80 0.040 0.12 0.020 0.011 0.013 0.025

min. 0.45 0.010

max. 0.85 0.040 0.12 2) 0.020 0.011 2) 0.013 2) 0.025

1) In the case of parts for belt-line components, the maximum Cu content shall be limited to 10 % and a lower P content shall be strived for.

2) If these values are exceeded and the limits for the contents determined in the product analysis are claimed to be P ≤ 0.015 %,S ≤ 0.015 %, Mo ≤ 0.63 %, Cu ≤ 0.18 %, Sn ≤ 0.016 % and Ntotal ≤ 0.015 %, then the authorized inspector shall decide, until further notice,whether or not examinations of the heat affected zone and, possibly, of tangential cross sections are required. If further fabrication calls forintermediate tempering at 550 °C, the permissibility of this temperature shall be shown in these examinations. Extent and procedure oftesting shall be agreed with the authorized inspector.

3) See note under Sec. A 1.3.14) For use in the reactor pressure vessel, the content of tantalum and cobalt may not exceed 0.030 % in both the ladle and product analysis.5) If the limit values are exceeded in the ladle analysis, then the limit values of the product analysis shall be the determining limits.6) In the case of product forms under Sec. 16 and 17 with a wall thickness ≤ 30 mm, a carbon content in the range between 0.14 and 0.18 % is

permitted in the ladle analysis and between 0.12 and 0.20 % in the product analysis.

Table A 1-1: Chemical composition determined by ladle and product analysis for various product forms made from the steel20 MnMoNi 5 5

0.2 %-Proofstress

Tensilestrength

Elongation atfracture

Percentage reduction ofarea Z

Rp0.2

N/mm2

min.

Rm

N/mm2

A5

%

min.

singlevalue

%

min.

average of 3test specimens

%

min.

longitudinal,transverse

390 560 to 700 19 45

perpendicular 390 560 to 770 35 45

> 15 to ≤ 150 430 570 to 710 19 45

9 3), 15, > 150 to ≤ 200 390 560 to 700

16 2) and 17 2) perpendicular > 15 to ≤ 150 430 570 to 710 35 45

> 150 to ≤ 200 390 560 to 700

> 30 to ≤ 70 450 590 to 730 18 45

> 70 to ≤ 150 430 570 to 710 18 45

> 150 to ≤ 200 390 560 to 700 18 45

perpendicular > 30 to ≤ 70 35 45

1) The definitions under Sec. 3.3.2 apply.2) The range of dimensions apply to forged pipes. In the case of rolled and pressed pipes, the values specified refer to a range of the

quenched and tempered wall thickness between > 15 to ≤ 100 mm and > 100 mm to ≤ 200 mm, respectively.3) Independently of the quenched and tempered wall thickness of the nozzle region, the same requirements apply as for the pipe section.

Table A 1-2: Mechanical properties in the tensile test at room temperature for various product forms from the steel20 MnMoNi 5 5

Product formunder the fol-lowing Sections

Quenched andtempered wallthickness

mm

4 to 6 and10 to 14

7 und 8

Type of Proof

Type of Proof

ladle analysis 4) 5)

ladle analysis 4) 5)

productanalysis 3) 4) 5)

productanalysis 3) 4) 5)

Orientationof testspecimen 1)



KTA 3201.1

Product formunder thefollowingSections

Orientationof test speci-men 1)

Temperature°C

0.2 %-Proof stress Rp0.2

N/mm2

min.

Tensile strength Rm

N/mm2

min.

Elongation at fractureA5

%min.

quenched and tempered wall thickness ≤ 400 mm

5 100 370 520 16

200 360 505 16

300 350 505 15

350 343 505 14

375 330 505 14

400 5) 320 490 14

quenched and tempered wall thickness (mm)

≤ 320 > 320 to≤ 650 4)

≤ 650 4) ≤ 320 > 320 to≤ 650 4)

4, 6 and 100 370 370 520 17 16

10 to 14 200 360 350 505 16 16

300 350 330 505 16 15

350 343 314 505 16 14

375 330 300 505 16 14

400 5) 320 290 490 16 14


> 15 to≤ 150

> 150 to≤ 200

≥ 15 to≤ 150

> 150 to≤ 200

> 15 to≤ 200

9 6), 15, 16 7) 100 412 370 530 530 16

and 17 7) 200 392 360 513 510 16

300 371 350 513 510 16

350 363 343 513 510 16

375 358 330 505 505 16

400 5) (353) 2) (320) 2) (500) 2) (500) 2) 16


≥ 30 to≤ 70

> 70 to≤ 150

> 150 to≤ 200

≥ 30 to≤ 70

> 70 to≤ 150

> 150 to≤ 200

≥ 30 to≤ 200

7, 8 100 431 412 382 550 530 510 17

200 412 392 371 530 510 505 16

300 392 371 353 530 510 505 16

350 382 363 343 530 510 505 16

375 377 358 338 530 505 492 16

400 5) (371) 2) (353)

2) (333) 2) (530)

2) (500) 2) (480)

2) 161) The definitions under Sec. 3.3.2 apply.2) The values in parantheses still need to be ensured statistically.3) In case of the perpendicular test specimens, only the values specified for Rp0.2 and Rm apply.4) In the case of product forms under Sec. 6 and 10, the values apply only up to a quenched and tempered wall thickness ≤ 1000 mm.5) When employing the steel at temperatures > 375 °C, additional examinations are required to determine the creep rupture strength.6) Independently of the quenched and tempered wall thickness of the nozzle region, the same requirements apply as for the pipe section.7) The range of dimensions apply to forged pipes. In the case of rolled and pressed pipes, the values specified refer to a range of the

quenched and tempered wall thickness between > 15 to ≤ 100 mm and > 100 mm to ≤ 200 mm, respectively.

Table A 1-3: Mechanical properties in the tensile test at elevated temperatures for various product forms from the steel20 MnMoNi 5 5

Test specimen shape Test specimen orientation Absorbed impact energy KVJ

single value average of 3 test specimens

Charpy-V transverse 34 1) 41 1)

1) If, on account of the dimensions in the case of pipes, longitudinal instead of transverse test specimens have to be taken, then the individ-ual value of the absorbed impact energy shall not be less than 45 J and the average of three test specimens not less than 55 J.

Table A 1-4: Minimum values of the absorbed impact energy at 0 °C for various product forms from the steel 20 MnMoNi 5 5

longitudinal,transverse,perpendi-cular 3)




KTA 3201.1

A 2 Austenitic steel X 2 NiCrAlTi 32 20

A 2.1 Scope

(1) Section A 2 specifies the details with regard to chemicalcomposition, characteristic mechanical and physical proper-ties of the austenitic steel X 2 NiCrAlTi 32 20 as well as fur-ther fabrication for the product forms within the scopes ofSec. 18:

steam generator tubes (Section 18)

(2) Deviations from these requirements are permitted pro-vided they are certified in the initial material certification ofthe authorized inspector.


(1) The material shall be molten in the electric arc furnaceand, where required be treated by the argon-oxygen decar-burization (AOD) process or the electro-slag remelt process. Ifother processes are used, a proof of equivalency is required.

(2) The tubes shall be delivered in the solution annealedand low-strain-hardened condition.

A 2.3 Requirements


The required chemical composition for the material is speci-fied in Table A 2-1 and shall be determined by the ladle andthe product analysis.



The requirements regarding mechanical properties of thematerial apply to the condition of delivery.

A 2.3.2.2 Tensile test at room temperature and elevatedtemperatures

The characteristic values for the mechanical properties de-termined by the tensile test at room temperature and at ele-vated temperatures are specified in Table A 2-2.

A 2.3.2.3 Drift test

The tubes shall meet the requirements of the drift test in ac-cordance with Sec. 18.

A 2.3.3 Grain size

The characteristic value of the grain size shall be at least 7 inaccordance with EURONORM 103-71.



A 2.3.5 Resistance to intergranular corrosion

(1) The steel, in the sensitisation-annealed condition, shallbe resistant to intergranular corrosion under the testingconditions in accordance with DIN 50 914.

(2) The sensitisation annealing shall be performed as fol-lows: heating-up to 650 °C in less than 1.5 minutes, time attemperature 5 minutes at 650 °C, quenching in water.


The solution annealing shall be performed at temperaturesbetween 980 °C and 1050 °C and in a protective atmosphere(even during cooling down).


A 2.5.1 Butt welding of the tubes

Butt welding shall be performed with the tungsten-inert-gas(TIG) procedure with or without filler metals and withoutany preheating.

A 2.5.2 Bending

The pipes shall be cold bent. The bending radius shall be atleast 4.5 times the outer diameter of the pipe.

A 2.5.3 Heat treatment

(1) No heat treatment is neither allowed after bending norafter welding-in of the tubes.

(2) In the course of vessel annealing, the temperature maynot exceed 400 °C.


Material manufacturers possessing a material certification inaccordance with Sec. 2.1 are listed in VdTUEV MaterialSpecification Sheet 474 which specifies the manufacturingprocedures, the delivery conditions and range of dimensions.

Content by mass, %

C Si Mn P 1) S Altotal Co Cr Cu Ntotal1) Ni Ti 2) Fe

min. 0.3 0.4 0.15 20.0 32.0

max. 0.03 0.7 1.0 0.020 0.015 0.45 0.10 23.0 0.75 0.030 35.0 0.60 rest1) If one of the two values is slightly exceeded, the sum of the mass content of phosphorus and nitrogen shall be the determining factor.

The sum shall be smaller than 0.050 %.2) Stabilizing ratio: Ti ≥ 12 x C and Ti ≥ 8 x (C + N).

Table A 2-1: Chemical composition of the steel X 2 NiCrAlTi 32 20 determined by ladle and product analysis

KTA 3201.1

Temperature°C

0.2%-Proof stress Rp0.2

N/mm2Tensile strength Rm

N/mm2Elongation at fracture A5

%min.

RT 335 to 470 570 to 700 30

100 325 550 25

200 315 525 20

300 305 505 20

350 295 495 20

400 285 485 20

Table A 2-2: Mechanical properties in the tensile test at room temperature and elevated temperatures for various productforms made from the steel X 2 NiCrAlTi 32 20

A 3 Stainless austenitic rolled and forged steel

A 3.1 Scope

(1) Section A 3 specifies the details regarding chemicalcomposition, characteristic mechanical and physical pro-perties of the stainless austenitic rolled and forged steelsX 6 CrNiTi 18 10 S, X 6 CrNiNb 18 10 S and X 6 CrNiMoTi 17 12 2 Sas well as further fabrication for the product forms within thescopes of Secs. 22 through 24 and 31:a) sheets, plates, bar steel and forgings

(Section 22)b) seamless pipes

(Section 23)c) Seamless elbows

(Section 24)d) product forms for integral connections to the reactor cool-

ant pressure boundary(Section 31)

(2) Deviations from these requirements are permitted pro-vided they are specified in the initial material conditions ofthe authorized inspector.


The material shall be molten in the electric-arc furnace and,where required be treated by the argon-oxygen decarburiza-tion (AOD) or vacuum-oxygen decarburization (VOD) proc-ess or be remolten under vacuum or by the electro-slag remeltprocess. If other processes are used, a proof of equivalency isrequired.

A 3.3 Requirements


(1) The required chemical compositions for the material arespecified in Tables A 3-1 and A 3-2 and shall be determinedby the ladle and the product analysis.

(2) For those parts that are welded in the course of furtherfabrication, no credit shall be taken simultaneously from theeased restrictions regarding grain size and upper limit of theallowable content of niobium and sulphur.



(1) The requirements regarding mechanical properties ofthe material apply to the final heat treatment condition of thecomponent.

(2) The required values given below are valid for thespecimen-taking locations, test specimen depths and orienta-tions as specified under Secs. 22 through 24.

(3) The characteristic values of the mechanical propertiesgiven below apply to the range of dimensions as specifiedwith respect to the steel type and product form in TablesA 3-3 and A 3-4.


The characteristic values for the mechanical properties de-termined by the tensile test at room temperature are specifiedin Tables A 3-3 and A 3-4.


The characteristic values for the mechanical properties de-termined by the tensile test at elevated temperatures arespecified in Tables A 3-5 to A 3-7.


The values of the impact energy at room temperature arespecified in Table A 3-8.




The product forms shall be solution annealed at temperaturesbetween 1020 °C and 1100 °C and be quenched in water or asquickly as possible in air. Sec. A 3.5 applies to heat treatmentsafter further fabrication.


A 3.5.1 Welding

(1) These steels are weldable by the following procedures:a) metal-arc welding with coated electrodes,b) submerged-arc welding,c) tungsten-inert gas (TIG) are welding with or without

welding filler metal,d) plasma welding,

e) electron beam welding.

KTA 3201.1

(2) No preheating is required.

(3) The intermediate layer and working temperature shallnot exceed 200 °C.

(4) The product forms are usually not stress-relief heattreated after welding. If in special cases annealing is required,it shall be performed in such a way that, in the annealedcondition, the values of the absorbed impact energy specifiedunder Table A 3-8 are met and that the resistance againstintergranular corrosion is not detrimentally affected.


Flame cutting is permitted provided adequate working con-ditions exist, e.g. by utilising flux, protective gas or plasma.Border regions that are detrimentally affected by flame cut-ting shall be mechanically removed.

A 3.5.3 Hot forming

(1) The products should be hot formed in the temperaturerange between 750 °C and 1150 °C. After hot forming, theproducts shall be solution annealed in the lower temperaturerange specified under Sec. A 3.4 and shall be quenched inwater or as quickly as possible in air. In those cases where theproducts have been already been solution annealed before,the lower value of the solution annealing temperature rangespecified under Sec. A 3.4 shall be reduced to 980 °C forproducts from steels that are not alloyed with molybdenum,and to 1000 °C for products from steels that are alloyed with2.0 to 2.5 % molybdenum.

(2) The solution annealing after hot forming may be waivedprovided other measures are taken to ensure that the condi-tion of the finished product is similar to the solution annealedand quenched condition in accordance with Sec. A 3.4, that iswith respect to the usability of the product, e.g. the mechani-cal properties and corrosion resistance. Solution annealingmay be waived in the following cases provided the author-ized inspector has certified the procedure:

a) In the case of products which prior to hot forming are notin the delivery condition specified under Sec. A 3.4, solu-tion annealing may be waived provided all of the follow-ing conditions are met:aa) The products shall be entirely warmed up to the

specified hot forming temperature.ab) The initial hot forming temperature shall be greater

than 1020 °C.ac) The final hot forming temperature shall be greater

than 850 °C.ad) After hot forming the products shall be quenched in

accordance with Sec. A 3.4.

b) In the case of products which prior to hot forming are inthe delivery condition specified under Sec. A 3.4, solutionannealing after hot forming may be waived provided thefollowing two conditions are met:

ba) The final hot forming temperature shall be greaterthan 850 °C.

bb) After hot forming, the products shall be quenched inaccordance with Sec. A 3.4.

Note:Contrary to the procedure under a), the initial hot forming tempera-ture may be freely chosen for products which prior to hot forming arein the delivery condition in accordance with Sec. A 3.4.

c) In the case of products from steels not alloyed with mo-lybdenum which prior to hot forming are in the deliverycondition specified under Sec. A 3.4, the solution anneal-ing after hot forming may be replaced by a stabilisationannealing at a temperature of 900 °C ± 20 K provided thesubsequent cooling-down is carried out in air.

(3) Locally hot formed products shall be entirely solutionannealed and quenched. In the case of local hot-forming pro-cedures with reproducible results, the authorized inspectormay specify different requirements provided

a) the products, prior to hot forming, are in the deliverycondition as specified under Sec. A 3.4 or are additionallyin a stabilisation annealed condition,

b) the products, after hot forming, are quenched in accor-dance with Sec. A 3.4.

Hereby, the final hot forming temperature shall generally begreater than 850 °C.

A 3.5.4 Cold forming

(1) The steels are generally suited for cold forming. It shall,however, be considered that cold forming affects the materialproperties. Therefore, a heat treatment in accordance withSec. A 3.4 is required after cold forming.

(2) In the case of cold forming less than 5 % or of straighten-ing with a similar degree of forming, the subsequent heattreatment may be omitted provided the products, prior to hotforming, are either in the delivery condition as specified un-der A 3.4 or in a similar condition (cf. Sec. A 3.5.3 (2) and (3)),and no requirements to the contrary were specified.

(3) Cold forming of a degree greater than, but 5 % equal toor less than 10 % without subsequent heat treatment in accor-dance with Sec. A 3.4 are allowed provided the authorizedinspector has certified and the customer has agreed to theprocedure.

(4) In the case of cold bending of pipes greater than DN 50but equal to or less than DN 150 without deforming the ends,subsequent heat treatment may be omitted if it can be dem-onstrated to the authorized inspector during the procedurecertification that after bending the minimum values of elon-gation at fracture A5 and of elongation before reduction ofarea are not less than 15 % and about 5 %, respectively. Theminimum required values of the initial pipe apply to theother mechanical properties, i.e. 0.2 % proof stress, 1.0 %proof stress, tensile strength and absorbed impact energy.

(5) In the regions of cold bending, no hot tasks like hotstraightening or welding are allowed. When performing othertasks on these areas, attention shall be paid to their coldforming condition.

(6) The cold bending of pipes greater than DN 150 requiresthe consent of the authorized inspector for each individualcase.


Material manufacturer possessing a material certification inaccordance with Sec. 2.1 are listed in VdTUEV MaterialSpecification Sheet 451 which specifies the manufacturingprocedures, the delivery conditions and range of dimensions.

KTA 3201.1

Steel type Content by mass, %

C Si Mn P S 1) Co Cr Mo Nb 1) Ni Ti

min. 17.0 9.0 5x(%C)

max. 0.06 1.0 2.0 0.035 0.015 0.2 19.0 12.0 0.5 2)

min. 17.0 4) 10x(%C) 9.0

max. 0.04 4) 1.0 4) 2.0 0.035 4) 0.015 4) 0.2 19.0 0.65 3) 4) 12.0

min. 16.5 2.0 10.5 5x(%C)

max. 0.06 1.0 2.0 0.035 0.015 0.2 18.5 2.5 13.5 0.5 2)

1) See also Sec. A 3.3.12) For parts that are annealed after welding (cf. Sec. A 3.5): 8 x (% C) ≤ (% Ti) ≤ 0.7.3) For parts that are annealed after welding (cf. Sec. A 3.5): 13 x (%C) ≤ (% Nb) ≤ 0.65.4) When used for hot (operating temperature T ≥ 200 °C) reactor water containing pipes and components to this Safety Standard in BWR

plants the following requirements apply:

a) for the chemical composition, apart from the elements Mn, Co and Ni, the following limit values apply:C ≤ 0.03 %Si ≤ 0.5 %P ≤ 0.025 %S ≤ 0.010 %18.0 ≤ (% Cr) ≤ 19.013 x (% C) ≤ (% Nb) ≤ 0.65

b) The test certificate shall show the boron and nitrogen content.

Table A 3-1: Chemical composition determined by ladle analysis for stainless austenitic rolled and forged steel

Chemical element Allowable deviation 1) (content by mass), %

carbon + 0.01

phosphorus + 0.005

sulphur + 0.005

silicon + 0.05

manganese + 0.04

chrome ± 0.20

molybdenum ± 0.10

nickel ± 0.15

cobalt + 0.05

titanium ± 0.05

niobium ± 0.05

1) If more than one product analysis is performed for one melt and the results show deviations of the chemical composition determined bythe product analysis from the range limit of the composition determined by the ladle analysis, then a particular element may either beabove or below the limit values of Table A 3-1.

Table A 3-2: Allowable deviations of the chemical composition determined by the product analysis from the range limit of thecomposition determined by the ladle analysis for stainless austenitic rolled and forged steel

X 6 CrNiTi 18 10 S

X 6 CrNiNb 18 10 S 4)


KTA 3201.1

Product form 2) 0.2%-Proofstress

1%-Proofstress

Tensilestrength


Steel typeSheet steel 1) Bar steel Forgings and

platesRp0.2

N/mm2Rp1.0

N/mm2Rm

N/mm2%

min.

Governing dimensions min. min. Test specimenorientation

wall thicknessmm

diametermm

wall thicknessmm

longi-tudinal

transverseor tangential

≤ 75 200 235

≤ 400 ≤ 275 190 225 40

≤ 75

≤ 900 ≤ 600 40

≤ 75

≤ 400 ≤ 275 40

1) The values for sheets between > 50 and ≤ 75 mm still have to be verified.2) Solution annealed and quenched condition.

Table A 3-3: Mechanical properties in the tensile test at room temperature of stainless austenitic rolled and forged steelfor the product forms sheet, bar, forging and plate

Steel type Wallthickness

0.2%-Proofstress

1%-Proofstress

Tensilestrength

Elongation atfracture A5

mm Rp0.2N/mm2

Rp1.0N/mm2

RmN/mm2

%min.

min. min. Test specimenorientation

longi-tudi-nal

transverseor tangen-tial

hot formed, solution an-nealed and quenched 180 215 460 to 680 35

cold formed, solution an-nealed and quenched 1) 200 235 500 to 730 30

X 6 CrNiNb 18 10 S ≤ 50hot or cold formed, solutionannealed and quenched 205 240 510 to 740 30 30

hot formed, solution an-nealed and quenched 190 225 490 to 690 35

cold formed, solution an-nealed and quenched 1) 210 245 500 to 730 30

1) For calculation purposes, the material properties of the hot formed condition shall basically be used. The material properties of the coldformed condition may be used only if it is ensured that cold formed pipes are actually delivered. Pipes with a nominal diameter > 200 mmare generally only available in the hot formed condition. In the case of cold formed elbows the cold formed properties may be used only, ifthe initial pipes have also been cold formed.

Table A 3-4: Mechanical properties in the tensile test at room temperature of stainless austenitic rolled and forged steelfor the product forms pipe and pipe elbow

Steel type 1)


N/mm2

min.

1%-Proof stress Rp1.0

N/mm2

min.

at temperature (°C)

50 100 150 200 250 300 350 400 50 100 150 200 250 300 350 400

X 6 CrNiTi 18 10 S 180 166 157 147 137 126 120 115 212 198 185 175 165 157 151 146

X 6 CrNiNb 18 10 S 191 177 167 157 147 136 130 125 226 211 196 186 177 167 161 156

X 6 CrNiMoTi 17 12 2 S 202 185 177 167 157 145 140 135 234 218 206 196 186 175 169 1641) Solution annealed and quenched condition. Dimensional range in accordance with Table A 3-3.

Table A 3-5: Mechanical properties in the tensile test at elevated temperatures of stainless austenitic rolled and forged steelfor the product forms sheet, bar, forging and plate (0.2%- and 1%-Proof stress)

Fabrication process and heattreatment condition

X 6 CrNiTi 18 10 S

X 6 CrNiNb 18 10 S


35

500 to 730

510 to 740

500 to 730

205

210 245

240

≤ 50

≤ 50X 6 CrNiMoTi 17 12 2 S

X 6 CrNiTi 18 10 S

KTA 3201.1

Steel type 1) 0.2%-Proof stress Rp0.2

N/mm2

min.

1%-Proof stress Rp1.0

N/mm2

min.


50 100 150 200 250 300 350 400 50 100 150 200 250 300 350 400

HSQ 162 147 132 118 108 100 94 89 201 181 162 147 137 127 121 116

CSQ 3) 190 176 167 157 147 136 130 125 222 208 195 185 175 167 161 156

X 6 CrNiNb 18 10 S HSQ or CSQ 191 177 167 157 147 136 130 125 226 211 196 186 177 167 161 156

HSQ 182 166 152 137 127 118 113 108 217 199 181 167 157 145 139 135

CSQ 3) 202 185 177 167 157 145 140 135 234 218 206 196 186 175 169 164

1) Wall thickness ≤ 50 mm.2) HSQ: hot formed, solution annealed and quenched

CSQ: cold formed, solution annealed and quenched3) For calculation purposes, the material properties of the hot formed condition shall basically be used. The material properties of the cold

formed condition may be used only if it is ensured that cold formed pipes are actually delivered. Pipes with a nominal diameter > 200 mmare generally only available in the hot formed condition. In the case of cold formed elbows the cold formed properties may be used only, ifthe initial pipes have also been cold formed.

Table A 3-6: Mechanical properties in the tensile test at elevated temperatures of stainless austenitic rolled and forged steelfor the product forms pipe and pipe elbow (0.2 %- and 1%-Proof stress)

Steel type 1) Tensile strength Rm 2)

N/mm2

min.


200 250 300 350 400

X 6 CrNiTi 18 10 S 370 360 350 335 320

X 6 CrNiNb 18 10 S 370 360 350 335 320

X 6 CrNiMoTi 17 12 2 S 390 380 370 355 340

1) Solution annealed and quenched condition.2) The values specified still have to be verified.

Table A 3-7: Mechanical properties in the tensile test at elevated temperatures of stainless austenitic rolled and forged steelfor the product forms sheet, bar, forging and plate (tensile strength)

Absorbed impact energy KV (Charpy-V test specimen), J

Heat treatment condition Test specimen orientation Average value obtained on3 test specimens

min.

Smallest single value

min.

Solution annealed and longitudinal 100 90

quenched transverse or tangential 70 60

Annealed longitudinal 85 60

(cf. Sec. A 3.5) transverse or tangential 55 40

Table A 3-8: Absorbed impact energy of stainless austenitic rolled and forged steel for various product forms

Fabrication processand heat treatmentcondition 2)

X 6 CrNiTi 18 10 S


KTA 3201.1

A 4 Cast steel GS-18 NiMoCr 3 7

A 4.1 Scope

(1) Section A 4 specifies the details regarding chemicalcomposition, characteristic mechanical and physical proper-ties of the cast steel GS-18 NiMoCr 3 7 as well as further fabri-cation for the product forms within the scopes of Secs. 25 and26:

a) pump casings from ferritic quenched and tempered caststeel(Section 25)

b) valve bodies from ferritic quenched and tempered caststeel(Section 26)

(2) Deviations from these requirements are permitted pro-vided they are specified in the initial material certification ofthe authorized inspector.


(1) The cast steel GS-18 NiMoCr 3 7 is a quenched and tem-pered alloy steel and is characterised by high strength atelevated temperatures.

(2) The material shall be molten in the electric-arc furnace,the electric induction oven or by the argon-oxygen decarburi-zation (AOD) process. If other processes are used, a proof ofequivalency is required.

A 4.3 Requirements


The required chemical composition for the cast steelGS-18 NiMoCr 3 7 is specified in Table A 4-1 and shall bedetermined by the ladle and the product analysis.

Note:Some of the differences in the chemical compositions between the ladleanalysis and the product analysis are smaller than is to be expected onthe basis of metallurgical considerations. This is due to the fact that thelimit values of the chemical composition for the product analysis couldonly be based on the melt covered in the initial material certification.These values will, therefore, be reviewed when further information isavailable.



(1) The requirements regarding mechanical properties ofthe material apply to the final condition of the componentafter heat treatment.

(2) The properties in accordance with Secs. 25 and 26 shallbe demonstrated in the acceptance test on quenched andtempered and simulation stress-relief heat treated and onaccompanying test coupons. The required values given beloware valid for the specimen-taking locations, test specimendepths and orientations as specified under Secs. 25 and 26.

(3) In the case of a quenched and tempered wall thicknessequal to or less than 300 mm, the specified mechanical prop-erties can be maintained over the entire wall thickness. In thecase of a quenched and tempered wall thickness exceeding300 mm, 20 % lower values of the minimum specified Rp0.2 andRm are permitted for mid-wall than specified for the speci-men-taking locations provided the impact energy and lateralexpansion determined for 80 °C at mid-wall are equal to orgreater than 68 J and 0.9 mm, respectively. However, testing

at mid-wall shall only be considered if cast-integral couponsare available in accordance with the definition under Secs. 25and 26, i.e. in accordance with the determining wall thickness,with a thickness exceeding 300 mm.



(2) The values for the shall be documented for informativepurposes only. The elastic ratio shall not exceed 0.80.


The characteristic values for the mechanical properties de-termined by the tensile test at elevated temperatures arespecified in Table A 4-3.


The values of the minimum impact energy are specified inTable A 4-4 and apply to the base metal and, also, underconsideration of Sec. A 4.4.1 and A 4.5.1, to the heat affectedzone of welded joints on the component.


In the Pellini drop-weight test the test specimen shape shallbe P2 in accordance with SEP 1325.

A 4.3.3 Grain size

After quenching and tempering, the characteristic value of thesecondary grain size shall be at least 5 in accordance withEURONORM 103-71.



A 4.4 Heat treatmentNote:The temperature values specified are single piece temperatures.

A 4.4.1 Quenching and tempering

(1) The casting steel GS-18 NiMoCr 3 7 shall be subjected toa double water quenching and tempering.

Quenching and Tempering

quenching tempering

800 °C to 950 °C 650 °C to 700 °C

(2) The material manufacturer together with the componentmanufacturer shall specify the heating and cooling rates, thetemperatures as well as the holding duration times at tem-perature depending on component dimensions and chemicalcomposition such that, under consideration of all subsequentheat treatments, the mechanical properties in accordance withSec. A 4.3.2 are obtained in the final condition of the finishedcomponent.

KTA 3201.1

A 4.4.2 Heat treatment after welding

A 4.4.2.1 Quenched and tempered production andconstruction weldings

Production and construction weldings (connection welds:casting-casting) shall be performed after the first quenchingand tempering in accordance with Sec. A 4.4.1. After thewelding, a renewed quenching and tempering is required,except where Sec. A 4.4.2.2 applies.

A 4.4.2.2 Stress-relief heat treated production and construc-tion weldings

(1) Small production weldings that are carried out after thedouble quenching and tempering procedure shall subse-quently be stress-relief heat treated (cf. Sec. A 4.4.2.3).

(2) Weldings that can only be performed after the doublequenching and tempering of the castings shall be weldedhigher by two layers. They shall subsequently be stress-reliefheat treated in accordance with Sec. A 4.4.2.3.

(3) Connection weldings between castings and rolled orforged product forms may be performed after the doublequenching and tempering of the castings. After welding, theyshall be stress-relief heat treated in accordance with Sec.A 4.4.2.3.

(4) Connection weldings that are performed at the assemblysite shall be subjected to stress-relief heat treatment. The re-quirements under KTA 3201.3 shall apply.

(5) In those cases where in the post-welding phase noquenching and tempering but rather only a stress-relief heattreatment is performed, special attention shall be paid to thepossibility for performing non-destructive examinations asinservice inspections.

A 4.4.2.3 Stress-relief heat treatment

(1) The final stress-relief heat treatment shall be performedbetween 580 °C and 620 °C with a subsequent cooling downperiod spent in the oven or in still air.

(2) Any required intermediate annealing may be performedat 550 °C.

Note:Observe footnote 1 under Table A 4-1.

(3) When specifying the annealing temperature rates, theheating-up and cooling rates and times at temperature, con-sideration shall be given to changes in material characteristicsthat may possibly occur during annealing, with special atten-tion also to be paid to the cladding (corrosion resistance,ductility).


A 4.5.1 Welding

(1) Castings in the certified range of dimensions are fusion-weldable by the following procedures:

a) Production and construction weldings:


ab) submerged-arc welding with basic flux.

b) Clad weldings:


bb) submerged-arc welding with strip electrodes and ba-sic flux or flux mixtures.

(2) The pre-heating, intermediate layer or working tempera-ture depends on the thickness of the welded piece and shallbe between 150 °C and 250 °C, clad weldings shall be per-formed at a recommended maximum temperature of 180 °C.The welding conditions apply to connection weldings in thefiller layer region for cooling-down times t8/5 between 7 and25 s.


(3) The weld consumables and filler materials allowed forsubmerged arc welding shall basically be basic-coated barelectrodes with controlled content of hydrogen or a similarbasic flux that must be dried in accordance with the require-ments of the manufacturer of the weld filler material toachieve a sufficiently low hydrogen content of the weld ma-terial.

Note:In the case of low-alloyed ferritic weld-consumables sufficiently low hy-drogen content means hydrogen values equal to or less than 3 ppm inthe bead metal or about 5 ml hydrogen per 100 g of welding materialfrom coated electrodes (HD5 in accordance with DIN 8572-E) or about7 ml hydrogen per 100 g of welding material from a wire/flux combina-tion (HD7 in accordance with DIN 8575-UP).

(4) The component shall be saddened for two hours or moreat about 280 °C directly from the welding heat, unless astress-relief heat treatment is performed directly from thewelding heat.

(5) A hydrogen reduction heat treatment (soaking) subse-quent to weld cladding may be waived provided it is shown(e.g. by a sulphur print) that the cladded region is free ofsegregations. In this case, a slow cooling-down shall be per-formed directly from the welding heat, unless a stress-reliefheat treatment in accordance with Sec. A 4.4.2.3 is performeddirectly from the welding heat.

(6) Any deviation from the requirements above, e.g., theapplication of different welding procedures, non-basic flux instip-electrode clad welding, shorter duration of saddening orreduction of the saddening temperature, shall be agreed uponbetween the material manufacturer and authorized inspector.Here, the wall thickness and the component type and experi-ence gained up to now, shall be taken into consideration. Itshall be shown that no damaging effects, e.g. of the weldconnection, result from these deviations.

A 4.5.2 Flame cutting and gouging

(1) A pre-heating at between 150 °C and 300 °C is requiredbefore any flame cutting or gouging. It is recommended toperform the pre-heating in a furnace in order to achieve auniform temperature distribution (soaking).

(2) If the pre-heating is carried out locally, the heated regionmust be large enough to ensure thorough heating. The pre-heating temperature shall be maintained during the entireflame cutting and gouging process.


Material manufacturers possessing a completed materialcertification in accordance with Sec. 2.1 are listed in VdTUEVMaterial Specification Sheet 381 which specifies the manufac-turing procedures, the delivery conditions and range of di-mensions.

KTA 3201.1

Type of Proof Content by mass, %

C Si Mn P S Cr Mo Ni Altotal Cu V Sn Ntotal As

min. 0.17 0.30 0.70 0.30 0.40 0.60 0.020

max. 0.23 0.50 1.10 0.012 0.010 0.50 0.60 1.10 0.050 0.12 0.02 0.011 0.015 0.025

min. 0.16 0.25 0.70 0.30 0.40 0.60 0.020

max. 0.23 0.50 1.20 0.012 1) 0.012

1) 0.50 0.60 1) 1.10 0.050 0.12 1) 0.02 0.011

1) 0.015 1) 0.025

1) If these values are exceeded and the limits for the content determined in the product analysis are claimed as P ≤ 0.015 %, S ≤ 0.015 %,Mo ≤ 0.63 %, Cu ≤ 0.18 %, Sn ≤ 0.016 % and Ntotal ≤ 0.015 %, examinations of the heat affected zone and possibly tangential cross sectionsshall be performed until further notice. If further fabrication calls for intermediate tempering at 550 °C, the acceptability of this tempera-ture shall be shown in these tests or examinations. The extent and procedure of testing shall be agreed with the authorized inspector.

2) See Note under Sec. A 4.3.1.

Table A 4-1: Chemical composition determined by ladle and product analysis for various product forms made from thecast steel GS-18 NiMoCr 3 7

Determiningwall thickness

mm

0.2%-Proof stress

Rp0.2

N/mm2

min.

Tensile strength

Rm

N/mm2

Elongation at fracture

A5

%

min.

≤ 300 390 570 to 735 16

Table A 4-2: Mechanical properties in the tensile test at room temperature for various product forms made from thecast steel GS-18 NiMoCr 3 7

Temperature

°C

0.2%-Proof stress

Rp0.2

N/mm2

min.

Tensile strength

Rm

N/mm2

min.

Elongation at fracture

A5

%

min.

100 370 570 16

200 360 550 15

250 350 535 14

300 345 520 13

350 343 490 12

375 338 475 11

400 1) 333 455 11

1) If the materials are to be used at temperatures higher than 375 °C, supplementary examinations shall be performed to determine thecreep rupture strength.

Table A 4-3: Mechanical properties in the tensile test at elevated temperatures for various product forms made from thecast steel GS-18 NiMoCr 3 7

Absorbed impact energy KV

(Charpy-V test specimen)

J

Upper shelf 2) of theabsorbed impact energy KV

(Charpy-V test specimen)J

at 0 °Cmin.

at 33 °C 1)

min. min.

average value of 3 test specimens 41

single value 34 68 100

1) If agreed upon when placing the order, this requirement also applies to lower temperatures, however, not below 10 °C.2) The test is generally performed at 80 °C.

Table A 4-4: Absorbed impact energy for various product forms made from the cast steel GS-18 NiMoCr 3 7

Ladle analysis

Product analysis 2)

KTA 3201.1

A 5 Cast steel GS-C 25 SNote:The following specifications are temporary in nature since the supple-mentary certification with respect to the requirements going beyondthose for the cast steel GS-C 25 in accordance with DIN 17 245 has notyet been completed.

A 5.1 Scope

(1) Section A 5 specifies the details regarding chemicalcomposition, characteristic mechanical and physical proper-ties of the cast steel GS-C 25 S as well as further fabricationfrom castings with a wall thickness up to 100 mm within thescope of Sec. 26:

valve bodies from ferritic cast steel (Section 26)



(1) The cast steel GS-C 25 S is a quenched and temperedalloy steel with high strength at elevated temperatures.

(2) The cast steel GS-C 25 S shall be molten in the electricarc furnace, the electric induction furnace or by the argon-oxygen decarburization (AOD) process. If other processes areused, a proof of equivalency is required.

A 5.3 Requirements


The required chemical composition for the cast steelGS-C 25 S is specified in Table A 5-1 and shall be determinedby the ladle and the product analysis.

Note:Some of the differences in the chemical compositions between the ladleanalysis and the product analysis are smaller than may be expected onthe basis of metallurgical considerations. This is due to the fact that thelimit values of the chemical composition for the product analysis couldonly be based on the melt covered in the initial material certification.These values will, therefore, be reviewed when further information isavailable.




(2) The properties in accordance with Sec. 26 shall be dem-onstrated in the acceptance test on simulation stress-reliefheat treated test coupons. The required values given beloware valid for the specimen-taking locations, test specimendepths and orientations as specified under Sec. 26.

(3) In the case of a quenched and tempered wall thicknessexceeding 100 mm, 10 % lower values of the minimum speci-fied Rp0.2 and Rm are allowed for mid-wall than specified forthe specimen-taking locations provided the impact energyand lateral expansion determined for 80 °C at mid-wall areequal to or greater than 68 J and 0.9 mm, respectively. How-ever, testing at mid-wall shall only be considered if cast-integral test coupons are available in accordance with thedefinition under Sec. 26, i.e., with a thickness exceeding100 mm in accordance with the determining wall thickness.



(2) The values for the reduction of area shall be docu-mented for informative purposes only.




The values of the minimum impact energy are specified inTable A 5-4 and apply to the base metal and, under consid-eration of Sec. A 5.4.1 and A 5.5.1, also to the heat affectedzone of welded joints on the component.


In the Pellini drop-weight test the test specimen shape shallbe P2 in accordance with SEP 1325.

A 5.3.3 Grain size

After quenching and tempering the characteristic value of thesecondary grain size shall be at least 5 in accordance withEURONORM 103-71.




A 5.4.1 Quenching and tempering

The cast steel GS-C 25 S shall be subjected to a double waterquenching and tempering.


quenching tempering

900 °C to 940 °C 650 °C to 700 °C

(2) The material manufacturer together with the componentmanufacturer shall specify the heating and cooling rates, thetemperatures as well as the times at temperature dependingon component dimensions and chemical composition suchthat, under consideration of all subsequent heat treatments,the mechanical properties in accordance with Sec. A 5.3.2 areobtained in the final condition of the finished component.

KTA 3201.1

A 5.4.2 Heat treatment during and after further fabrication

A 5.4.2.1 Quenched and tempered production and con-struction weldings

Production and construction weldings (connection weldscasting-to-casting) shall be performed after the first quench-ing and tempering in accordance with Sec. A 5.4.1. After thewelding, a renewed quenching and tempering is required,except where Sec. A 5.4.2.2 applies.

A 5.4.2.2 Stress-relief heat treated production and construc-tion weldings

(1) Small production weldings carried out after the doublequenching and tempering procedure shall subsequently bestress-relief heat treated (cf. A 5.4.2.3).

(2) Connection weldings between castings and rolled orforged product forms may be performed after the doublequenching and tempering of the castings. After welding, theyshall be stress-relief heat treated in accordance with Sec.A 5.4.2.3.

(3) Connection weldings performed at the assembly siteshall be subjected to stress-relief heat treatment. The require-ments under KTA 3201.3 shall apply.

(4) Weldings that can only be performed after the doublequenching and tempering of the castings shall be weldedhigher by two layers. They shall subsequently be stress-reliefheat treated in accordance with Sec. A 5.4.2.3.

(5) In those cases where in the post-welding phase noquenching and tempering but rather a stress-relief heattreatment is performed, special attention shall be paid to thepossibility of performing non-destructive examinations asinservice inspections.

A 5.4.2.3 Stress-relief heat treatment

(1) The final stress-relief heat treatment shall be performedbetween 580 °C and 620 °C.

(2) When specifying the annealing temperature, the heatingand cooling rates and times at temperature, considerationshall be given to changes in material characteristics that mayoccur during annealing.


A 5.5.1 Welding

(1) Castings in the certified range of dimensions are fusion-weldable and production and construction weldings) by thefollowing procedure:

a) metal-arc welding with basic coated electrodes,

b) submerged-arc welding with basic flux.

(2) The pre-heating, intermediate layer or working tempera-ture depends on the thickness of the welded piece and shallbe between 150 °C and 250 °C; in the case of sufficient experi-ence, the preheating may be omitted.

(3) The weld consumables and filler materials allowed forsubmerged arc welding shall basically be basic-coated barelectrodes with controlled content of hydrogen or similarbasic flux that must be dried in accordance with the require-ments of the manufacturer of the weld filler material. Thecomponent shall be saddened for not less than 2 hours atabout 280 °C directly from the welding heat, unless a stress-relief heat treatment is performed directly from the welding-heat. A heat treatment for low hydrogen content is not re-quired provided the component was preheated prior towelding.

(4) Any deviation from the requirements above, e.g., appli-cation of different welding procedures, shall be agreed uponbetween material manufacturer and authorized inspector.Here, the wall thickness and the type of weld consumables,the component type and experience gained up to now shallall be taken into account. It shall be shown that no damagingeffects, e.g. of the weld connection, result from these devia-tions.


A pre-heating is not required if the castings are in a normal-ised condition.


Material manufacturers possessing a material certification inaccordance with Sec. 2.1 are listed in the respective VdTUEVMaterial Specification Sheet which specifies the manufactur-ing procedures, the delivery condition and range of dimen-sions.

Note:At present, the VdTUEV material specification sheet is in preparation.


C Si Mn P S Cr Altotal Cu V Ntotal

min. 0.18 0.30 0.020

max. 0.22 0.60 1.10 0.015 0.010 0.30 0.070 0.18 0.02 0.015

min. 0.18 0.30 0.50 0.020

max. 0.22 0.60 1.10 0.015 0.012 0.30 0.070 0.18 0.02 0.015


Table A 5-1: Chemical composition of the cast steel GS-C 25 S determined by ladle and product analysis

Ladle analysis

Product analysis 1)

KTA 3201.1


mm

0.2%-Proof stressRp0.2

N/mm2

min.

Tensile strengthRm

N/mm2

min.


%min.

≤ 100 245 440 to 590 22

Table A 5-2: Mechanical properties of the cast steel GS-C 25 S in the tensile test at room temperature

Temperature

°C

0.2%-Proof stress 1)

Rp0.2

N/mm2

min.

Tensile strength 1)

Rm

N/mm2

min.

Elongation at fracture 1)

A5

%min.

100 (205) (410) (21)

200 175 (400) (20)

250 (160) (400) (19)

300 145 (390) (18)

350 135 (375) (20)

400 (130) (355) (25)

1) The values in parantheses still need to be ensured statistically.

Table A 5-3: Mechanical properties of the cast steel GS-C 25 S in the tensile test at elevated temperatures

Absorbed impact energy KV(Charpy-V test specimens)

J

Upper shelf 2) of theabsorbed impact energy KV(Charpy-V test specimens)

at 0 °Cmin.

at 33 °C 1)

min.J

min.


single value 34 68 100

1) If agreed upon when placing the order, this requirement also applies to lower temperatures, however, not below 5 °C.2) The test is generally performed at 80 °C.

Table A 5-4: Absorbed impact energy of the cast steel GS-C 25 S

A 6 Austenitic cast steel G-X 5 CrNiNb 18 9 S

A 6.1 Scope

(1) Section A6 specifies the details regarding chemical com-position, characteristic mechanical and physical properties ofthe cast steel G-X 5 CrNiNb 18 9 S as well as further fabrica-tion for the product forms within the scopes of Sec. 27:

valve bodies from austenitic cast steel(Section 27)



The cast steel G-X 5 CrNiNb 18 9 S should be molten in theelectric-arc furnace, the electric induction furnace or by theargon-oxygen decarburization (AOD) process. If other proc-esses are used, a proof of equivalency is required.

A 6.3 Requirements


The required chemical composition for the cast steelG-X 5 CrNiNb 18 9 S is specified in Table A 6-1 and shall bedetermined by the ladle and the product analysis.




(2) The required values given below are valid for thespecimen-taking locations, test specimen depths and orienta-tions as specified under Sec. 27.

KTA 3201.1



(2) The requirements regarding tensile strength are achiev-able over the entire cross section for a regular wall thicknesswithin the scope of Sec. 27.




The values of the minimum impact energy are specified inTable A 6-4 and apply to the base metal and, also, underconsideration of Sec. A 6.4.1 and A 6.4.2, to the heat affectedzone of weldings in the component.




The casting steel G-X 5 CrNiNb 18 9 S, in the sensitisationannealed condition (650 °C, 30 minutes), shall be resistant tointergranular corrosion under the testing conditions in accor-dance with DIN 50 914.


A 6.4.1 Solution annealing

The cast steel G-X 5 CrNiNb 18 9 S shall be solution annealedbetween 1050 °C and 1100 °C and subsequently be quenchedin water.

A 6.4.2 Heat treatment during and after processing

(1) Production and construction weldings (connectionwelds: casting-to-casting) shall be performed on the castingafter solution annealing and quenching. After the welding, arenewed solution annealing and quenching shall be per-formed.

(2) Connection weldings between castings and rolled orforged product forms may be performed after the last solu-tion annealing of the castings; after welding, no renewed heattreatment is required.

(3) In the case of smaller production weldings, the renewedsolution annealing and quenching may be omitted (cf. Sec.27).

(4) The material does not required stress-relief heat treat-ment after weldings.


A 6.5.1 Welding

(1) The cast steel G-X 5 CrNiNb 18 9 S in the certified rangeof dimensions is fusion-weldable by the following proce-dures:


b) submerged-arc welding with basic flux,

c) inert gas welding with or without weld additives (TIG,MIG).

(2) The material may be welded without any preheating.

(3) The intermediate layer and working temperatures shallnot exceed 200 °C..


The material may be flame-cut and gouged without requiringany preheating.


Material manufacturers possessing a completed materialcertification in accordance with Sec. 2.1 are listed in the re-spective VdTUEV material specification sheet which specifiesthe manufacturing procedures, delivery conditions and rangeof dimensions.



C Si Mn P S Cr Ni Mo Nb Co

min. 18.0 9.0 8x(%C)

max. 0.06 1.50 1.50 0.020 0.010 20.0 11.0 0.50 0.65 0.2

min. 18.0 9.0 8x(%C)

max. 0.06 1.50 1.50 0.020 0.010 20.0 11.0 0.50 0.65 0.2


Table A 6-1: Chemical composition of the cast steel G-X 5 CrNiNb 18 9 S determined by ladle and product analysis

Ladle analysis

Product analysis 1)

KTA 3201.1


mm


N/mm2

min.

1%-Proof stressRp1.0

N/mm2

min.

Tensile strengthRm

N/mm2

min.


%min.

≤ 150 175 200 440 to 640 20

Table A 6-2: Mechanical properties of the cast steel G-X 5 CrNiNb 18 9 S in the tensile test at room temperature

Temperature

°C


N/mm2

min.

1%-Proof stress 1)

Rp1.0

N/mm2

min.

Tensile strengthRm

N/mm2

min.


%min.

100 150 175 400 20

200 130 155 360 21

250 125 150 345 21

300 120 145 330 22

350 115 140 325 22

400 110 130 300 25

1) Regarding the utilisation of the minimum 1.0%-proof stress in strength calculations, see KTA 3201.2.

Table A 6-3: Mechanical properties of the cast steel G-X 5 CrNiNb 18 9 S in the tensile test at elevated temperatures

Absorbed impact energy KV (Charpy-V test specimens)

Jmin.


single value 70

Table A 6-4: Absorbed impact energy of the cast steel G-X 5 CrNiNb 18 9 S at 20 °C

A 7 Quenched and tempered fine-grained structural steelas base material and stainless austenitic steel as clad-ding material for seamless, extrusion-clad compositetubes

A 7.1 Scope

(1) Section A 7 specifies the details with regard to chemicalcomposition, characteristic mechanical and physical proper-ties of the aluminium-killed fine-grained structural steel asbase material and stainless austenitic steel as cladding mate-rial as well as further fabrication for the product forms withinthe scopes of Sec. 19:

seamless, extrusion-clad composite pipes(Section 19).



(1) The base material is an aluminium-killed fine-grainedstructural steel. The wall thickness of the base material liesbetween 10 and 30 mm. The cladding material is a stainlessaustenitic steel.

(2) The steels shall be molten in the electric-arc furnace andmay be treated further by the argon-oxygen decarburization(AOD) or the vacuum-oxygen decarburization (VOD) proc-ess. If other processes are used, a proof of equivalency isrequired.

(3) The composite pipes shall be delivered in the quenchedand tempered and stress-relief heat treated condition.

A 7.3 Requirements


The required chemical compositions for the base material andcladding material are specified in Tables A 7-1 and A 7-2 andshall be determined by the ladle and the product analysis.



(1) The requirements regarding mechanical properties ofthe material apply to the final condition of the componentafter the final heat treatment.

(2) The properties shall be demonstrated in the acceptance

KTA 3201.1

test on simulation stress-relief heat treated test coupons (cf.Sec. A 7.4.3). The required values given below are valid forthe specimen-taking locations, test specimen depths and ori-entations as specified under Sec. 19.


The characteristic values for the mechanical properties de-termined by the tensile test at room temperature are specifiedin Table A 7-3.




The values of the minimum impact energy are specified inTable A 7-5.

A 7.3.2.5 Nil-ductility transition (NDT) temperature

No requirements.

A 7.3.2.6 Ring flattening test

(1) In the ring flattening test in accordance with DIN EN10233, the test specimens or pipes shall be flattened to such adegree that a defined distance H between the two pressureplates is achieved. This distance H in mm is defined by thefollowing equation:

( )H

ss

da

=+ ⋅

+

1 0 07

0 07

.

.,

with s being the wall thickness and da the outer diameter,both in mm.

(2) The ring flattening test may be continued until the pipebreaks or cracks in order to be able to evaluate the fracturecross section. However, the deciding factor is that flatteningcan be performed down to the specified distance of the platewithout any cracks appearing in the pipe.

A 7.3.2.7 Bond test of cladding

The side-bend test to DIN 50 121-3 shall be performed oncladded axial test specimens and with a bending mandrel ofdiameter D = 4 x a (a being the specimen thickness); a bend-ing angle of 180 degrees shall be obtained.

A 7.3.3 Grain size

In the delivery condition, the characteristic value of the ferritegrain size for the base material shall be equal or greater than 5in accordance with EURONORM 103-71.


No requirements.


(1) Under given conditions of fabrication, especially after

welding and after heat treatment, the surface of the claddingmaterial shall be resistant to intergranular corrosion down toa depth of 1.5 mm when tested in accordance with DIN 50914.

(2) The sensitisation shall be carried out in accordance withSec. A 7.4.3, unless other requirements are specified whenplacing the order.


A 7.4.1 Quenching and tempering, and stress-relief heattreatment (delivery condition)


quenching tempering

900 to 950 °C

quenching inwater

640 to 690 °C

tempering inair

565 to 595 °C

1) After straightening the pipes.

A 7.4.2 Stress-relief heat treatment after welding

If, on account of the design, a stress-relief heat treatment isrequired after welding, it shall be performed within the tem-perature range of 550 °C and 600 °C.

A 7.4.3 Simulation heat treatment

(1) Unless other values are specified by the purchaser, thetest coupons for the acceptance test shall be subjected to thefollowing simulation heat treatment:

a) heating-up to 590 °C ± 10 K

holding time 5 h,

b) cooling-down to 500 °C ± 10 K,

c) heating-up 590 °C ± 10 K

holding time 5 h,

d) cooling down.

(2) Above 300 °C, the heating and cooling rates shall beabout 50 K/h.


A 7.5.1 Welding

(1) The application of the following welding procedures areconsidered to be certified for the base material and the clad-ding material:

a) metal-arc welding,

b) inert gas welding with weld consumables.

(2) The pre-heating and working temperature shall be atleast 120 °C, the intermediate layer temperature no higherthan 200 °C.

(3) When welding the weld root within the cladding layer,no pre-heating is required.

Stress-reliefheat treatment 1)

KTA 3201.1


Flame cutting is not intended to be performed.

A 7.5.3 Forming

It is not intended that any forming be performed during fur-ther fabrication.


Material manufacturers possessing a completed materialcertification in accordance with Sec. 2.1 are listed in VdTUEVMaterial Specification Sheet 439 which specifies the manufac-turing procedures, the delivery conditions and range of di-mensions.

Type of Proof Content by mass, % 1)

C Si Mn P S Al

min. 0.15 0.20 1.25 0.010

max. 0.20 0.40 1.60 0.020 0.015 0.030

min. 0.13 0.18 1.20 0.005

max. 0.22 0.42 1.65 0.020 0.015 0.040

1) The elements N, Cr, Cu, Mo, Nb, Ni, Ti and V shall not be added as alloying elements. In the material quality certificate, the content ofthese elements shall be specified as determined in the ladle analysis.

Table A 7-1: Chemical composition of the base material determined by ladle and product analysis for seamless, extrusion cladcomposite pipes

Type of proof Content by mass, %

C Si Mn P S N 1) Cr Mo 1) Ni Nb

min. 17.0 9.0 13 x (%C)

max. 0.040 1.00 2.00 0.030 0.030 19.0 12.0 0.65

min. 16.8 8.85 13 x (%C)

max. 0.050 1.05 2.04 0.035 0.035 19.2 12.15 0.70

1) The elements N and Mo shall not be added as alloying elements. In the material quality certificate, the content of these elements shall bespecified as determined in the ladle analysis.

Table A 7-2: Chemical composition of the cladding material determined by ladle and product analysis for seamless, extrusionclad composite pipes


N/mm2

min.

Tensile strength Rm

N/mm2

Elongation at fracture A5

%min.

345 500 to 650 25

Table A 7-3: Mechanical properties of the base material in the tensile test of longitudinal test specimens at room temperaturefor seamless, extrusion clad composite pipes

Temperature T

100 °C 150 °C 200 °C 250 °C 300 °C 350 °C 400 °C


N/mm2

min.310 305 295 295 295 295 265

Tensile strength Rm

N/mm2

min. 470

Table A 7-4: Mechanical properties of the base material in the tensile test of longitudinal test specimens at elevated tempera-tures for seamless, extrusion clad composite pipes

Test specimen shape Test specimen orientation Absorbed impact energy KV(smallest single value)

Jmin.

Lateral expansion(smallest single value)

mmmin.

transverse 41 0.6

longitudinal 160 1.5

Table A 7-5: Absorbed impact energy and lateral expansion of the base material at 20°C for seamless, extrusion clad composite pipes

Ladle analysis

Charpy-V

Product analysis

Ladle analysis

Product analysis

KTA 3201.1

A 8 Martensitic steel X 5 CrNi 13 4

A 8.1 Scope

(1) Section A 8 specifies the details with regard to thechemical composition, characteristic mechanical and physicalproperties of the martensitic steel X 5 CrNi 13 4 as well asfurther fabrication for the product forms within the scopes ofSec. 28:

Bars and forgings(Section 28)

(2) The maximum allowed design temperature is 350 °Cand the maximum allowed continuous operating temperatureis 300 °C.



The material shall be molten in the electric-arc furnace andmay be treated further by the argon-oxygen decarburization(AOD), the vacuum-oxygen decarburization (VOD) or theelectro-slag remelt process. If other processes are used, aproof of equivalency is required.

A 8.3 Requirements


The chemical composition of the material is specified in TableA 8-1 and shall be determined by the ladle and the productanalysis.



(1) The requirements regarding material characteristicsapply to the quenched and tempered or quenched and tem-pered and stress-relief heat treated condition.

(2) The required values given below are valid for thespecimen-taking locations, test specimen depths and orienta-tions as specified under Sec. 28.

(3) The characteristic values of the mechanical propertiesgiven below are valid for the range of dimensions specified inTable A8-2.



(2) The elastic ratio should not exceed a value of 0.90.




The values of the minimum impact energy at room tempera-ture are specified in Table A 8-4.



A 8.4 Heat treatmentNote:The temperature values specified are single piece temperatures..


quenching tempering

950 °C to 1050 °C

holding time at least 1 hafter soaking of theproduct

cooling in air or oil

560 °C to 600 °C

holding time at least 8 hafter soaking of the prod-uct; in the case of multipleannealing, this applies tothe overall holding time

cooling in furnace or in air


A 8.5.1 Welding

(1) The application of the following welding procedures areconsidered as certified:


b) submerged arc welding with basic flux,

c) tungsten-inert-gas welding with or without weld additives,

d) plasma welding.

(2) A pre-heating to a temperature between 150 °C and 200°C is required. The intermediate layer temperature shall notexceed 350 °C.

(3) After welding, a heat treatment is required.

(4) The heat treatment may be performed as follows

a) tempering in accordance with Sec. A 8.4 or

b) stress-relief heat treatment in the temperature range be-tween 530 °C and 570 °C, however, not above the actuallyused tempering temperature. The heating time shall be atleast 4 hours. The cooling shall subsequently be per-formed in the furnace.

A 8.5.2 Forming

It is not intended that any forming be performed during fur-ther fabrication.


Material manufacturers possessing a material certification inaccordance with Sec. 2.1 are listed in VdTUEV MaterialSpecification Sheet 395/3 which specifies the manufacturingprocedures, the delivery condition and range of dimensions.

KTA 3201.1


C Si Mn P S N Co Cr Mo Ni

min. 0.020 12.6 0.30 3.50

max. 0.050 0.60 1.00 0.030 0.015 0.20 13.9 0.70 4.50

min. 0.015 12.5 0.25 3.45

max. 0.060 0.65 1.05 0.035 0.018 0.23 14.0 0.75 4.60

Table A 8-1: Chemical composition of the steel X 5 CrNi 13 4 determined by ladle and product analysis

Product form Dimension Test specimenorientation

0.2%-Proofstress

Tensilestrength


Reductionof area

Diameter

mm

Wall thickness

mm

Rp0.2

N/mm2

min.

Rm

N/mm2A5

%min.

Z%

min.

transverse 780 to 980 15

Bars longitudinal 780 to 980 17

> 160 to ≤ 400 transverse 780 to 980 15

Forgings ≤ 750 transverse/tangential 780 to 980 15

The ratio Rp0.2 / Rm shall not exceed 0.90.

Table A 8-2: Mechanical properties of the steel X 5 CrNi 13 4 in the tensile test at room temperature

Product form Dimension Test temperature 0.2%-Proof stress Tensile strength

Diametermm

Wall thicknessmm °C

Rp0.2

N/mm2

min.

Rm

N/mm2

min.

100 650 745

150 635 730

Bars ≤ 160 transverse and 200 620 715

longitudinal 250 605 700

300 590 685

350 575 670

100 600 695

Bars > 160 to ≤ 400 transverse 150 585 680

200 570 665

250 555 650

Forgings ≤ 750 300 540 635

350 525 620

Table A 8-3: Mechanical properties of the steel X 5 CrNi 13 4 in the tensile test at elevated temperatures

Product form Dimension Test specimenorientation

Absorbed impact energy KV(Charpy-V test specimen)

J

Diameter

mm

Wall thickness

mm

average value on3 test specimens

min.

single value

min.

transverse 70 50

Bars longitudinal 90 70

> 160 to ≤ 400 transverse 70 50

Forgings ≤ 750 transverse/ tangential 70 50

Table A 8-4: Absorbed impact energy of the steel X 5 CrNi 13 4 at room temperature

≤ 160

Ladle analysis

≤ 160

Product analysis

40

685

635

Test specimenorientation

transverse/tan-gential

KTA 3201.1

A 9 Nickel alloy NiCr 15 Fe

A 9.1 Scope

Section A9 specifies the details with regard to the chemicalcomposition, characteristic mechanical and physical proper-ties of the nickel alloy NiCr 15 Fe as well as further fabrica-tion for the product forms within the scopes of Sec. 18:

steam generator tubes (Section 18).


(1) The material shall be molten in the electric-arc furnaceand may be treated further in the argon-oxygen decarburiza-tion (AOD) converter or by the electro-slag remelt process. Ifother processes are used, a proof of equivalency is required.

(2) The tubes shall be delivered in a soft tempered condi-tion.

A 9.3 Requirements


The chemical composition of the nickel alloy NiCr 15 Fe isspecified in Table A 9-1 and shall be determined by the ladleand the product analysis.



The requirements regarding material characteristics apply tothe delivery condition.

A 9.3.2.2 Tensile test at room temperature and at elevatedtemperatures

The characteristic values for the mechanical properties de-termined by the tensile test at room temperature and elevatedtemperatures are specified in Table A 9-2.

A 9.3.2.3 Drift test

The tubes shall meet the requirements of the drift test in ac-cordance with Sec. 18.

A 9.3.3 Grain size

The characteristic value of the secondary grains size shall beequal to or greater than 6 in accordance with EURONORM103-71.




The soft annealing shall be performed at temperatures be-tween 980 °C and 1030 °C. Cooling after annealing may beperformed in protective gas or water. Sec. A 9.5.3 shall beconsidered when performing the heat treatments.


A 9.5.1 Welding in the tubes

The tubes-to-tubesheet welding shall be performed with thetungsten-inert-gas welding with or without weld filler metals.No preheating is required. Sec. A 9.5.3 shall be taken intoconsideration.

A 9.5.2 Bending

(1) Cold bending of the tubes is allowed.

(2) No further heat treatment is allowed after cold bendingif performed.

A 9.5.3 Special fabrication measures

(1) At temperatures above 400 °C the material is sensitive tosulphur. Therefore, the surface shall be carefully cleanedbefore welding and after each heat treatment (e.g., oil andgrease residues, finger prints, paints and other markings,atmospheric pollution).

(2) The furnace atmosphere should be free of sulphur andmay then be adjusted to a slightly reducing or neutral atmos-phere.

(3) If freedom from sulphur cannot be ensured, the anneal-ing shall be performed in a slightly oxidising atmosphere.Fluctuations between oxidising and reducing conditions shallbe avoided.


Material manufacturers possessing a material certification inaccordance with Sec. 2.1 are listed in VdTUEV MaterialSpecification Sheet 305 which specifies the manufacturingprocedures, the delivery conditions and range of dimensions.


C Si Mn P S Cr Ni Fe Cu Co

min. 14.0 72.0 6.0

max. 0.08 0.50 1.00 0.015 0.015 17.0 10.0 0.50 0.20

min. 13.85 71.55 5.9

max. 0.09 0.53 1.03 0.018 0.018 17.25 10.1 0.53 0.20

Table A 9-1: Chemical composition of the nickel alloy NiCr 15 Fe determined by ladle and product analysis

Ladle analysis

Product analysis

KTA 3201.1

Temperature

°C

0.2%-Proof stress 1) Rp0.2

N/mm2

min.

Tensile strength 1) Rm

N/mm2

min.

Elongation at fracture 1) A5

%min.

RT 275 to 430 540 to 780 30

100 (265) (535) (25)

200 (245) (530) (25)

300 (235) (525) (25)

350 230 525 25

1) The values in parantheses still need to be ensured statistically.

Table A 9-2: Mechanical properties of the nickel alloy NiCr 15 Fe in the tensile test at room temperature and elevated tempera-tures

A 10 Materials 8 MnMoNi 5 5 and 10 MnMoNi 5 5 (forshape-welding or shape-melting)

Note:The following are provisional requirements since the initial materialcertification has not yet been completed.

A 10.1 Scope

(1) Section A10 specifies the details with regard to thechemical composition, characteristic mechanical and physicalproperties of the materials 8 MnMoNi 5 5 and 10 MnMoNi 5 5as well as further fabrication for the product forms within thescope of Sec. 29:

product forms and components manufactured by shape-welding or shape melting (Section 29).



The materials 8 MnMoNi 5 5 and 10 MnMoNi 5 5 are fabri-cated by shape-welding or shape-melting (melting down ofelectrodes in multiple layers).

A 10.3 Requirements


The chemical compositions of the materials are specified inTable A 10-1 and shall be determined by the product analysis.



(1) The materials are isotropic. The mechanical propertiesare, therefore, independent of wall thickness or direction.

(2) The requirements regarding material characteristicsapply to the final condition of the component after stress-relief heat treatment.

(3) The mechanical properties shall be demonstrated in theacceptance test on simulation stress-relief heat treated and onaccompanying test coupons. The required values given beloware valid for the specimen-taking locations, test specimendepths and orientation as specified under Sec. 29.



(2) The values of the yield strength determined for the dif-ferent specimen-taking locations on one and the same prod-uct shall not differ by more than 50 N/mm2 from each other.




The values of the minimum impact energy are specified inTable A 10-4.

A 10.3.2.5 Nil-ductility transition temperature (NDT-Temperature)

(1) In the Pellini drop-weight test the test specimen shapeshall be P2 in accordance with SEP 1325.

(2) The NDT temperature may not be higher than 0 °C.Lower values of the NDT temperature may be agreed uponwhen placing the order, however, not lower than -12 °C.



A 10.4 Heat treatment (stress-relief heat treatment duringmaterial fabrication and further fabrication)

(1) The stress-relief heat treatment shall be performed attemperatures between 580 °C and 620 °C with the subsequentcooling-down carried out in the furnace or in still air.

(2) Intermediate annealing shall be performed at tempera-tures below 580 °C.

(3) Deviating from the requirements under Sec. 29.3.2 (5), itis not required to perform the stress-relief heat treatmentsand the possibly necessary annealing of the intermediatelayers directly from the welding heat.

KTA 3201.1

(4) When specifying the annealing temperature, the heatingand cooling periods and the holding times, attention shall bepaid to changes in material characteristics that may occurduring annealing, with special attention also to be paid tocladdings (resistance to intergranular corrosion, ductility).


A 10.5.1 Welding

(1) Product forms in the certified range of dimensions arefusion weldable by the following procedures:

a) Connection welding and weld surfacing


ab) submerged-arc welding with basic flux,

ac) tungsten-inert-gas (TIG) welding with weld fillermetals,

b) Clad weldings


bb) submerged-arc welding with strip electrodes and ba-sic flux or flux mixtures,

bc) submerged-arc welding with wire electrodes,

bd) plasma cladding,

be) gas-metal-arc cladding,

bf) TIG cladding.Note:At the time being, less experience is available for methods ac) and bc)to bf) than for the others.

(2) The pre-heating, intermediate layer of working tempera-ture depends on the thickness of the welded piece and shallbe between 120 °C and 250 °C, clad weldings shall be per-formed at thickness and procedure dependent temperaturesof between 120 °C and 180 °C. The welding conditions applyto connection weldings in the filler layer region for cooling-down times t8/5 between 7 and 25 s.


(3) The weld and filler materials allowed for submerged arcwelding shall basically be basic-coated rod electrodes withcontrolled content of hydrogen or a similar basic flux thatmust be dried in accordance with the requirements of themanufacturer of the weld filler material to achieve a suffi-ciently low hydrogen content of the weld material.

Note:In the case of low-alloyed ferritic weld additives, sufficiently low hydro-gen content means hydrogen values equal to or less than 3 ppm in thebead metal or about 5 ml hydrogen per 100 g of welding material fromcoated electrodes (HD5 in accordance with DIN 8572-E) or about 7 mlhydrogen per 100 g of welding material from a wire/flux combination(HD7 in accordance with DIN 8575-UP).

(4) Depending on the application of the weld, the weldingregion or the component shall be saddened for not less than 2hours at about 280 °C directly from the welding heat, unless astress-relief heat treatment is performed directly from thewelding heat.

(5) A hydrogen reduction heat treatment subsequent toweld cladding may be dispensed with. In this case and pro-vided a stress-relief heat treatment is not immediately per-formed from the welding heat, the pre-heating temperaturebetween 150 °C and 180 °C shall be held for a longer timeimmediately from the welding heat; only then, slow cooling-down shall be initiated.

(6) Any deviation from the above requirements, e.g., theapplication of different welding procedures, reduction of pre-heating temperature for clad welding, non-basic flux in strip-electrode weld cladding, shorter duration of saddening orreduction of the saddening temperature shall, be agreed uponbetween material manufacturer authorized inspector. Here,the wall thickness and the type of weld consumables, thecomponent type and experience gained up to now shall betaken into consideration. It shall be shown that no damagingeffects, e.g. of the weld connection, result from these devia-tions.

(7) A stress-relief heat treatment in accordance with Sec.A 10.4 is required after welding, no matter what weldingprocedure and wall thickness is involved.


(1) A pre-heating between 120 °C and 250 °C is requiredbefore any flame cutting. It is recommended to design thepre-heating facility such that a uniform temperature distribu-tion (soaking) is achieved.

(2) If the pre-heating is carried out locally, the heated regionmust be large enough to ensure soaking. The pre-heatingtemperature shall be maintained during the entire flame cut-ting process.

A 10.5.3 Forming

It is not intended that cold or hot forming be performed.


Material manufacturers possessing a material certification inaccordance with Sec. 2.1 are listed in the respective VdTUEVMaterial Specification Sheet which specifies the manufactur-ing procedures, the delivery condition and range of dimen-sions.


KTA 3201.1

Steel type Content by mass, %

C Si Mn P 1) S Cr Mo Ni Altotal Cu V As Sn N

min. 0.05 1.00 0.45 0.80

max. 0.10 0.30 1.50 0.012 0.010 0.10 0.60 1.10 0.040 0.10 0.015 0.025 0.011 0.020

min. 0.08 1.00 0.45 0.80 0.010

max. 0.13 0.30 1.50 0.012 0.010 0.10 0.60 1.10 0.040 0.10 0.015 0.025 0.011 0.020

1) In the case of belt-line components, the phosphorus content should be ≤ 0.010 %.2) When using the materials in the reactor pressure vessel, the contents of tantalum and cobalt shall each be ≤ 0.030 %.

Table A 10-1: Chemical composition of the materials 8 MnMoNi 5 5 and 10 MnMoNi 5 5 determined by the product analysis

Steel type 0.2%-Proof stressRp0.2

N/mm2

min.

Tensile strengthRm

N/mm2

min.


%min.

Reduction of areaZ%

min.

8 MnMoNi 5 5 480 570 to 700 20 65

10 MnMoNi 5 5 500 620 to 760 20 65

Table A 10-2: Mechanical properties of the materials 8 MnMoNi 5 5 and 10 MnMoNi 5 5 in the tensile test at room temperature

Steel type Temperature

°C

0.2%-Proof stress 1)

Rp0.2

N/mm2

min.

Tensile strength 1)

Rm

N/mm2

min.

Elongationat fracture 1)

A5

%min.

100 (450) (530) (20)

200 (430) (510) (19)

300 (410) (510) (18)

350 390 510 17

375

400 2) (380) (500) (21)

100 (490) (590) (18)

200 (480) (580) (18)

300 (460) (560) (18)

350 (440) (540) (18)

375

400 2) (420) (520) (18)

1) The values in parantheses still need to be ensured statistically.2) If the materials are to be used at temperatures higher than 375 °C, supplementary examinations shall be performed to determine the

creep rupture strength.

Table A 10-3: Mechanical properties of the materials 8 MnMoNi 5 5 and 10 MnMoNi 5 5 in the tensile test at elevated tempera-tures

Type of specimen Test temperature°C

Absorbed impact energy KVJ

Lateral expansionmm

single value

min.

Average value of3 test specimens

min. min.

0 100 120 1.6

20 120 150 1.8

Table A 10-4: Absorbed impact energy and lateral expansion of the materials 8 MnMoNi 5 5 and 10 MnMoNi 5 5 at 0 °C and 20 °C

Charpy-V

8 MnMoNi 5 5 2)

10 MnMoNi 5 5 2)

8 MnMoNi 5 5

10 MnMoNi 5 5

KTA 3201.1

A 11 Quenched and tempered steels for bars and rings forbolts and nuts and extension sleeves

A 11.1 Scope

(1) Section A 11 specifies the details regarding the chemicalcomposition, characteristic mechanical and physical proper-ties of the steels as well as further fabrication of the productforms within the scopes of Secs. 20 and 21:

a) bars and rings for bolts, nuts and washers as well as bolts,nuts and washers as well as bolts, nuts and washers(dimensions exceeding M 130),

(Section 20),

b) bars and rings for bolts, nuts and washers as well as ex-tension sleeves and washers (dimensions equal to or lessthan M 130)

(Section 21).

(2) These requirements apply to forged bars and rings aswell as to the bolts, nuts and washers and extension sleevesmachined from these product forms.

A 11.2 Manufacturing of the steels

(1) The steels are quenched and tempered steels character-ised by specified minimum values of high strength at elevatedtemperatures.

(2) The steels shall be molten in the electric-arc furnace orby the basic-oxygen process and the ladle then be metallurgi-cally treated or remolten under vacuum or by the electro-slagremelt process. If other processes are used, a proof of equiva-lency is required.

(3) The steels are delivered in the quenched and temperedcondition or in the annealed and stress-relief heat treatedcondition.

A 11.3 Requirements


(1) The chemical compositions specified in Table A 11-1apply to these steels and shall be determined by the ladleanalysis.

(2) The allowable deviations of the chemical compositionsdetermined in the product analysis from the limit values ofthe ladle analysis are specified in Table A 11-2.



The requirements regarding mechanical properties apply tothe delivery condition as specified under Sec. A 11.2 (3). Thespecified values apply to the specimen-taking locations, testspecimen depths and orientation as specified under Secs. 20and 21 for bar steel and rings.


The characteristic values for the mechanical properties de-termined by the tensile test at room temperature are specifiedin Table A 11-3.




The values of the minimum impact energy at room tempera-ture are specified in Table A 11-5.




The details regarding heat treatment are specified in TableA 11-6.


Only machining procedures are allowed for further fabrica-tion.

Note:It is intended that hot or cold forming be formed during further fabrica-tion (thread rolling is not considered to be a cold forming procedure).


Material manufacturers of the steels 20 NiCrMo 14 5 and26 NiCrMo 14 6 possessing a material certification in accor-dance with Sec. 2.1 are listed in VdTUEV Material Specifica-tion Sheets 337 and 390 which specify the manufacturingprocedures, the delivery conditions and range of dimensions.

Material Content by mass, %

C Si Mn P S Cr Mo Ni V Altotal

min. 0.18 0.15 0.30 1.20 0.25 3.40 0.020

max. 0.25 0.40 0.50 0.020 0.010 1.50 0.50 4.00 0.050

min. 0.25 0.15 0.20 1.20 0.35 3.30 0.020

max. 0.30 0.30 0.50 0.020 0.010 1.70 0.55 3.80 0.08 1) 0.050

min. 0.30 0.15 0.40 1.40 0.15 1.40 2)

max. 0.38 0.40 0.70 0.020 0.010 1.70 0.35 1.70 1) Values between > 0.08 and ≤ 0.12 % may be specified in the individual material certification.2) An aluminium content is not specified.

Table A 11-1: Chemical composition determined by ladle analysis of the quenched and tempered steels for bars and rings forbolts, nuts, washers and extension sleeves

20 NiCrMo 14 5

26 NiCrMo 14 6

34 CrNiMo 6 S

KTA 3201.1

Chemical elementAllowable deviation 1) of values determined by product analysis

Content by mass, %

C ± 0.02

Si ± 0.03

Mn ± 0.04

P + 0.005

S + 0.005

Al ± 0.005

Cr ± 0.05

Mo ± 0.04

Ni ± 0.05 2)

V + 0.021) If more than one product analysis is performed for one melt and the results show deviations of the chemical composition by the product

analysis from the range limit of the composition by the ladle analysis, then a particular element may show deviation in only one directionabove or below the limit values of Table A 11-1.

2) If the nickel content determined by the ladle analysis lies between 2.00 and 4.00 %, the deviation as determined by the product analysis isallowed to be ± 0.07 %.

Table A 11-2: Allowable deviations of the chemical composition by the product analysis from the range limit of the composi-tion by the ladle analysis

Steel type Diameter(bar steel)

mm



N/mm2

min.

Tensile strength

Rm

N/mm2

min.


A5

%min.

Reductionof area

Z

%min.

20 NiCrMo 14 5 (I) ≤ 130 longitudinal 940 1 040 to 1 240 14 55

20 NiCrMo 14 5 (II) ≤ 130 longitudinal 980 1 080 to 1 280 14 55

≤ 130 longitudinal 940 1 040 to 1 240 14 50

26 NiCrMo 14 6 > 130 to ≤ 380 longitudinal ortangential

885 1 030 to 1 230 14 45

≤ 130 longitudinal 830 930 to 1 130 16 45

34 CrNiMo 6 S > 130 to ≤ 380 longitudinal ortangential

735 835 to 980 16 45

Table A 11-3: Mechanical properties of the quenched and tempered steels for bars and rings for bolts, nuts, washers and ex-tension sleeves in the tensile test at room temperature

Steel type Diameter(bar steel)

mm


0.2%-Proof stress

Rp0.2

N/mm2

min.

Tensile strength

Rm

N/mm2

min.


A5

%min.

Reductionof area

Z

%min.


300 350 300 350 300 350 300 350

20 NiCrMo 14 5 (I) ≤ 130 longitudinal 785 735 860 840 14 14 55 55

20 NiCrMo 14 5 (II) ≤ 130 longitudinal 830 785 900 880 14 14 55 55

26 NiCrMo 14 6 ≤ 380 longitudinal ortangential 1) 790 785 860 820 14 14 45 45

34 CrNiMo 6 S ≤ 380 longitudinal ortangential 1) 630 560 760 735 16 16 45 45

1) In the case of diameters ≤ 130 mm the values apply only to the longitudinal test specimen orientation.

Table A 11-4: Mechanical properties of the quenched and tempered steels for bars and rings for bolts, nuts, washers and ex-tension sleeves in the tensile test at elevated temperatures

KTA 3201.1

Steel type Diameter (bar steel)mm

Test specimen orientation Absorbed impact energy KVJ

Lateral expansionmm

average value of3 test specimens

single value single value

min. min. min.

20 NiCrMo 14 5 (I) ≤ 130 longitudinal 76 61 0.65

20 NiCrMo 14 5 (II) ≤ 130 longitudinal 76 61 0.65

26 NiCrMo 14 6 ≤ 380longitudinal or

tangential 1) 72 61 0.65

34 CrNiMo 6 S ≤ 380longitudinal or

tangential 1) 76 61 0.65

1) In the case of diameters ≤ 130 mm the values apply only to the longitudinal test specimen orientation.

Table A 11-5: Absorbed impact energy of the quenched and tempered steels for bars and rings for bolts, nuts, washers andextension sleeves on Charpy-V test specimens at 20 °C

Steel type Temperature range Quenching medium Temperature rangefor austenitizing

°Cfor tempering 1)

°Cfor stress-relief heat treatment

°C20 NiCrMo 14 5 (I) 520 to 600

20 NiCrMo 14 5 (II) 500 to 580

26 NiCrMo 14 6 840 to 870 water or oil 530 to 580 450 to 500

34 CrNiMo 6 S 820 to 870 water or oil 550 to 640 450 to 5001) The heating and cooling rates, the temperature as well as the holding times shall be specified by the material manufacturer depending on

the dimensions and chemical compositions such that the mechanical properties specified under Sec. A 11.3.2 are met.

Table A 11-6: Specifications for the heat treatment of the quenched and tempered steels for bars and rings for bolts, nuts,washers and extension sleeves

A 12 Quenched and tempered steels in accordance withDIN 17 240 for bars and rings for bolts, nuts, and ex-tension sleeves; supplementary requirements toDIN 17 240

A 12.1 Scope

(1) Section A12 supplements DIN 17 240 with respect to thesteel types specified in Table A 12-1 in as far as they are usedfor bolts, nut washers and extension sleeves in accordancewith Sec. 21.

(2) The requirements apply to rolled or forged bar steel andto the bolts and nuts fabricated from these product forms.

A 12.2 Limits of dimensions

The steel types specified in Table A 12-1 shall be applied onlyup to the dimensions specified in this table.

A 12.3 Impact test

The required values to be obtained for the absorbed impactenergy and the lateral expansion in the impact test on(longitudinal) Charpy-V-notch specimens at 20 °C are speci-fied in Table A 12-1.

A 12.4 Tensile test at elevated temperatures

The required values to be obtained for the tensile strength inthe tensile test at 300 °C and 350 °C are specified in TableA 12-1.


The material certification required in accordance with Sec. 2.1is considered to be successfully performed for the steel typesin accordance with DIN 17 240 as specified in Table A 12-1due to the proved experience with these materials underconsideration of the additional requirements specified inTable A 12-1 and of the scope specified under Sec. A 12.1.

Steel type in ac-cordance withDIN 17 240

Limits of allowabledimensions

Absorbed impact energyKV

J

Lateral expansion

mm

Tensile strengthRm

N/mm2

at room temperature(longitudinal Charpy-V test specimens)

min.

diameter average value single value single value at temperaturemm min. min. min. 300 °C 350 °C

Ck 35 ≤ 60 55 44 0.65 400 390

≤ 100 118 94 0.95 460 440

> 100 to ≤ 130 102 82 0.85 460 440

21 CrMoV 5 7 ≤ 100 63 52 0.65 590 560

Table A 12-1: Limit values for the dimensions and supplementary requirements for steels in accordance with DIN 17 240for bolts, nut washers and extension sleeves

840 to 900 water or oil 430 to 470

24 CrMo 5

KTA 3201.1

Annex AP

Characteristic values of physical properties

AP 1 General

AP 2 Characteristic values

AP 1 General

This Annex contains characteristic values for

a) the density,

b) the dynamic modulus of elasticity,

c) the average linear thermal expansion coefficient,

d) the average specific thermal capacity and

e) the thermal conductivity

of the steel types specified under Sec. A 1 through A 12.

AP 2 Characteristic values

AP 2.1 General

The characteristic values of physical properties specified inthe following tables represent data collated on the basis ofmeasurements on individual melts and of data from litera-ture [5].

AP 2.2 Determination of the characteristic values

At this time, there are no standard procedures for the deter-mination of the characteristic values for the physical proper-ties as mentioned herein.

AP 2.3 Deviation of the characteristic values

(1) Any changes in the chemical composition and the heattreatment will cause certain deviations in the physical prop-erties. E.g., a possible grain orientation has a particularlystrong influence on the modulus of elasticity.

(2) Differences in the measurement procedures used canlead to additional deviations.

(3) The data available at this time do not suffice to allow astatistical evaluation of their reliability.

(4) The data regarding the scatter band width (footnotes 1through 5) of the characteristic values specified under TablesAP-1 to AP-10 are taken from literature [5]. They indicate theaverage scatter band width of the corresponding measure-ment values.

Temperature T, °C

20 100 200 300 350 400

Density 1), 106 g/m3 7.86

Dynamic modulus of elasticity 2), 103 N/mm2 211 206 199 192 184

Average linear thermal expansion coefficient 3)

between 20 °C and T, 10-6 K-1 12.7 13.2 13.6 14.0

Thermal conductivity 5), Wm-1 K-1 44 44 43 41 39

Average specific thermal capacity 4) between 20 °Cand T, Jg-1 K-1 0.46 0.49 0.51 0.52 0.53

1) Average scatter band width of the measured values ± 0.05 ⋅ 106 g/m3.2) Average scatter band width of the measured values ± 5 ⋅ 103 N/mm2.3) Average scatter band width of the measured values ± 0.8 ⋅ 10-6 K-1.4) Average scatter band width of the measured values ± 0.01 Jg-1 K-1.5) Average scatter band width of the measured values ± 3.5 Wm-1 K-1.

Table AP-1: Characteristic values of physical properties for various product forms for the steel 20 MnMoNi 5 5

KTA 3201.1

Temperature T, °C

20 100 200 300 350 400

Density 1), 106 g/m3 7.94



between 20 °C and T, 10-6 K-1 15.4 16.0 16.5 16.8

Thermal conductivity 5), Wm-1 K-1 11.8 13.0 14.5 16.1 17.6

Average specific thermal capacity 4) between 20 °Cand T, Jg-1 K-1 0.48 0.50 0.52 0.53


Table AP-2: Characteristic values of physical properties for the steel X 2 NiCrAlTi 32 20

Steel type Density 1)

106 g/m3

at 20 °C

Dynamic modulus ofelasticity 2)

103 N/m2

at temperature T°C

Average linearthermal expansion

coefficient 3)

10-6 K-1

between 20 °C andtemperature T

°C

Thermal conductivity 5)

Wm-1 K-1

at temperature T°C

Average specificthermal capacity 4)

Jg-1 K-1


°C

20 100 200 300 350 400 100 200 300 350 400 20 100 200 300 350 400 100 200 300 350 400

X 6 CrNiTi 18 10 S 16.0 17.0 17.0 18.0

X 6 CrNiNb 18 10 S 7.93 200 194 186 179 172 16.0 17.0 17.0 18.0 15.0 16.0 17.0 19.0 20.0 0.47 0.49 0.50 0.51 0.52

X 6 CrNiMoTi 17 2 S 16.5 17.5 18.5 18.5

1) Average scatter band width of the measured values ± 0.05 ⋅ 106 g/m3.2) Average scatter band width of the measured values ± 5 ⋅ 103 N/mm2.3) Average scatter band width of the measured values ± 0.8 ⋅ 10-6 K-1.4) Average scatter band width of the measured values ± 0.01 Jg-1 K-1.5) Average scatter band width of the measured values ± 1.5 Wm-1 K-1

Table AP-3: Characteristic values of physical properties for stainless austenitic rolled and forged steels

Temperature T, °C

20 100 200 300 350 400

Density 1), 106 g/m3 7.86



between 20 °C and T, 10-6 K-1 12.6 13.9 14.8 14.9


Thermal conductivity 5), Wm-1 K-1 38 37 34 32 1) Average scatter band width of the measured values ± 0.05 ⋅ 106 g/m3.2) Average scatter band width of the measured values ± 5 ⋅ 103 N/mm2.3) Average scatter band width of the measured values ± 0.8 ⋅ 10-6 K-1.4) Average scatter band width of the measured values ± 0.01 Jg-1 K-1.5) Average scatter band width of the measured values ± 3.5 Wm-1 K-1.

Table AP-4: Characteristic values of physical properties for various product forms of the cast steel GS-18 NiMoCr 3 7

KTA 3201.1

Temperature T, °C

20 100 200 300 350 400

Density 1), 106 g/m3 7.83



between 20 °C and T, 10-6 K-1 12.2 12.9 13.4 13.9




Table AP-5: Characteristic values of physical properties for the cast steel GS-C 25 S

Temperature T, °C

20 100 200 300 350 400

Density 1), 106 g/m3 7.93



between 20 °C and T, 10-6 K-1 16.0 17.0 17.0 18.0




Table AP-6: Characteristic values of physical properties for the cast steel G-X 5 CrNiNb 18 9 S

Temperature T, °C

20 100 200 300 350 400

Density 1), 106 g/m3 7.58



between 20 °C and T, 10-6 K-1 10.5 11.0 12.0 12.5

Thermal conductivity 5), Wm-1 K-1 25

Average specific thermal capacity 4) between 20 °Cand T, Jg-1 K-1 0.46


Table AP-7: Characteristic values of physical properties for the steel X 5 CrNi 13 4

KTA 3201.1

Temperature T, °C

20 100 200 300 350 400

Density 1), 106 g/m3 8.4



between 20 °C and T, 10-6 K-1 12.7 13.2 13.6 14.0

Thermal conductivity 5), Wm-1 K-1 14.2 15.4 16.8 18.3 19.1

Average specific thermal capacity 4) between 20 °Cand T, Jg-1 K-1 0.46 0.48 0.50 0.51


Table AP-8: Characteristic values of physical properties for the nickel alloy NiCr 15 Fe

Temperature T, °C

20 100 200 300 350 400

Density 1), 106 g/m3 7.86



between 20 °C and T, 10-6 K-1 12.1 12.4 13.1 13.7




Table AP-9: Characteristic values of physical properties for the steels 8 MnMoNi 5 5 and 10 MnMoNi 5 5

Steel type Density 1)

106 g/m3

at 20 °C

Dynamic modulus ofelasticity 2)

103 N/m2

at temperature T °C

Average linearthermal expansion

coefficient 3)

10-6 K-1


°C

Thermal conductivity 5)

Wm-1 K-1

at temperature T°C

Average specificthermal capacity 4)

Jg-1 K-1


°C

20 100 200 300 350 400 100 200 300 350 400 20 100 200 300 350 400 100 200 300 350 400

20 NiCrMo 14 5 11.2 11.6 12.1 12.2 29 30 31 31 31

26 NiCrMo 14 6 7.84 205 200 191 182 11.2 11.6 12.1 12.2 29 30 31 31 31 0.46 0.49 0.51 0.52 0.53

34 CrNiMo 6 S 12.5 13.2 13.7 14.2 34 36 37 37 36

1) Average scatter band width of the measured values ± 0.05 ⋅ 106 g/m3.2) Average scatter band width of the measured values ± 5 ⋅ 103 N/mm2.3) Average scatter band width of the measured values ± 0.8 ⋅ 10-6 K-1.4) Average scatter band width of the measured values ± 0.01 Jg-1 K-1.5) Average scatter band width of the measured values ± 3.5 Wm-1 K-1

Table AP-10: Characteristic values of physical properties for the quenched and tempered steels for bars and rings for bolts,nuts, washers and extension sleeves

KTA 3201.1

Annex B

Performance of manual ultrasonic examinations

(The wording of this Annex is identical in both safety standards KTA 3201.1 and 3201.3)

B 1 General requirements

(1) This Annex covers the performance of manual non-destructive examinations.

(2) In this Annex, stipulations have been laid down for thecalibration of ultrasonic equipment for the pulse-echo methodwith reflectors or through-transmission and for the descrip-tion of indications.

B 2 Definitions, symbols, formulae

B 2.1 Definitions

The definitions of DIN 54 119 apply.

B 2.2 Symbols

In this Annex the following symbols are used:

Symbol Variable or designation Unit

A Scan path related to near field length inthe general DGS diagram

a, a’ Projected surface distance mm

AVG Distance / gain / size C Sound beam width, referred to dB echo

amplitude decreasemm

D0 Transducer dimension mm

Deff Effective transducer dimension mm

Dk Diameter of round bottom hole mm

DKSR Diameter of circular disk reflector mm

Dz Diameter of cylindrical bore mm

DS Beam diameter, referred to db echoamplitude decrease

mm

d Curvature diameter of test object mm

dref Curvature diameter of opposite face mm

∆f Band width (difference between upperand lower base frequency) referred to3 dB amplitude decrease

MHz

fN Nominal frequency MHz

G Reflector diameter referred to effectivetransducer diameter

GK Instrument gain when setting the refer-ence reflector for screen height level

dB

GT Instrument gain when setting thetransmission indication for screenheight level

dB

GT Arithmetical average of GT values dB

GR Instrument gain setting for recordinglimit

dB

Symbol Variable or designation Unit

γ6 Beam spread angle for 6 dB limit degree

H Echo amplitude referred to screenheight

HE Main echo

K1 Calibration block to DIN 54 120 No. 2 Calibration block to DIN EN 27 963 KSR Dimension of circular disk reflector mm

κ Sound attenuation coefficient(deviating from DIN 54 119; sound at-tenuation referred to sound path)

dB/mm

L Search unit dimension in direction ofcurvature

mm

λ Ultrasonic wave length mm

N Near field length NE1; NE2 Spurious echoes from wave mode con-

version

n Number of individually measuredvalues

p Projected surface distance for doubletraverse

mm

Ra Average roughness to DIN 4768 µm

RL Recording length mm

RLK Corrected recording length mm

S Sound path (distance between trans-ducer and reflector)

mm

S1 Sound path in reference block mm

S2 Sound path in component mm

SE Transmitter - receiver SEL Transmitter-receiver longitudinal

waves

s Wall thickness mm

sj Thickness of calibration block mm

V Gain in the general DGS diagram dB

∆V Sensitivity correction dB

∆Vκ Sound attenuation correction referredto a certain sound path

dB

∆Vkoppl Coupling correction dB

∆VS Beam spread correction of back reflec-tion curve

dB

∆V~ Corrected gain for considering transfervariations

dB

∆VT Transfer correction dB

KTA 3201.1

B 2.3 Formulae

The variables to be calculated shall be determined by meansof the following formulae:

a) The beam width C referred to a 20 dB echo amplitudedecrease:

CS

D= ⋅ ⋅2

0λ (B-1)

b) Conversion of side-drilled hole echo amplitudes to circulardisk reflector echo amplitudes:

D D SKSR Z= ⋅ ⋅ ⋅2

πλ , (B-2)

where S > 0.7 ⋅ N and DZ > 1.5 ⋅ λ.

c) Conversion of round bottom hole echo amplitudes tocircular disk reflector echo amplitude:

D DKSR k= ⋅λπ

, (B-3)

where S > 0.7 ⋅ N and Dk > 1.5 ⋅ λ.

d) The beam diameter DS referred to a 6 dB echo amplitudedecrease:DS = 2 ⋅ S ⋅ tan γ6, (B-4)

e) Average value of instrument gain setting GT :

valuesindividual of number valuesindividual of sum

n

GG T

T == ∑ , (B-5)

f) Corrected recording length RLK:

R R DD

RLK L SS

L= − ⋅ −

1 (B-6)

g) Sound path without lateral wall influence

Ss Deff=⋅

⋅2 λ(B-7)

h) Corrected gain ∆V∼:

( )∆V

Gn

G

n

T T~ .=− ⋅

−

∑∑1 7

1

1

2 2

(B-8)

or

( )∆V

G G

nT T~ .=

−

−∑1 7

1

2

(B-9)

i) Sensitivity correction ∆V:

∆VSS

= ⋅30 2

1lg (B-10)

B 3 General requirements

B 3.1 Performance of examination

(1) For the calibration and examination the same couplantshall be used. Only such couplants shall be used which do notdamage the object (e.g. corrosion). Upon examination, allcouplant residues shall be removed from the test object.

(2) Test object, reference block and search units shall ap-proximately have the same temperature.

(3) When setting the sensitivity level and during the exami-nation only the gain control, but no other control element (e.g.for frequency range, pulse energy, resolution, thresholdvalue) shall be adjusted. A threshold value may only be usedin exceptional justified cases.

(4) Prior to the examination, the sensitivity level and rangeadjustments shall be made after the warm-up periods givenby the instrument manufacturer. Both adjustments shall bechecked at suitable intervals. Where in this check clear devia-tions from the check made before are found, all examinationsperformed after that check shall be repeated with a correctedadjustment.

(5) The nominal frequency shall be within a range of 1 to6 MHz. The selection of the nominal frequencies and trans-ducer dimensions to be used in the examination shall be basedboth on the required sensitivity level (recording limit) for thevolume areas to be examined and the geometry of the part(sound path). In general, a frequency of 4 MHz shall be usedfor wall thicknesses ≤ 40 mm, and a frequency of 2 MHz forwall thicknesses > 40 mm.

(6) In the case of curved examination surfaces the searchunit probe shall be located with the probe index on the centreof the surface. At no point shall the probe shoes have a dis-tance greater than 0.5 to the examination surface. Where thedistance is greater, the probe shall be ground. This is the caseif L2 exceeds 2 x d.

(7) The use of auxiliary means for determining the echoamplitude (e.g. scales) is permitted if it is ensured that anevaluation as per B 4 is performed.

B 3.2 Test equipment

(1) The test equipment and accessories used including therequired auxiliary means shall show sufficient accuracy andstability for the intended use.

(2) The combination of equipment, cables and search unitsof various manufacturers is permitted if it is ensured (e.g. bymeasurements on reference reflectors) that the exactness ofresults is not affected.

B 3.3 Test object

(1) The test surfaces shall be free from discontinuities andimpurities (e.g. notches, scale, weld spatter, tool marks).

(2) Where an opposite face is used as reflecting surface itshall meet the same requirements as the test surface.

(3) The test surfaces` waviness shall be so little that theprobe shoe surface has sufficient contact. This is generally thecase if the distance between probe shoe surface and test sur-face does not exceed 0.5 mm at any point.

B 3.4 Reference blocks and reference reflectors

(1) When using differing materials for search units and testobject the difference in sound velocity shall be into account forrange adjustment and for the angular deviation in case ofangle beam scanning.

(2) When calibration blocks K1 or No. 2 are not used forcalibration the following applies:

a) to the calibration block used:

aa) The sound beam shall not be impaired in its develop-ment, i.e. all dimensions vertical to the main beampath for sound paths up to 2 x N shall be greater thanthe transducer dimension and for greater sound pathsexceed the beam width C.

ab) The dimensions of the coupling surface shall exceed1.5 times the effective probe shoe dimension.

KTA 3201.1

ac) The location of the reference reflectors in the referenceblock shall be selected such that the reference echoesdo no interfere with each other and cannot be con-fused with corner echoes.

ad) Claddings on the reference block shall be provided iftheir acoustic properties on the test object need not betaken into account.

b) to the calibration reflector used:

ba) the back walls shall be plane and vertical to the mainbeam as well as have dimensions exceeding the beamwidth C, but not less than the transducer dimension.

bb) Side-drilled holes shall be vertical to the main beamand parallel to the coupling surface. The lengths of theside-drilled holes shall be greater than the soundbeam width C, but not less than the transducer di-mension. The diameter shall generally be 3 mm.

bc) The bottom of flat bottom holes shall be vertical to themain beam when applying the single-probe technique.

bd) Round bottom holes shall be oriented such that the di-rections of hole axis and main beam deviate from eachother as little as possible.

be) Rectangular notches shall be vertical (transverse) tothe main beam and the notch edges be vertical to thesurface. The notches shall have a rectangular cross-section, a width ≤ 10 mm and, if not specified for therespective product form, have a depth of 1.0 mm. Thelength of rectangular notches shall exceed the beamwidth C, but not be less than the transducer dimen-sion.

bf) Where the echo amplitudes of side-drilled and roundbottom holes are to be converted to echo amplitudesof circular disk reflectors, the formulas (B-2) and (B-3)shall be considered additionally.

B 4 Calibration of test systems

B 4.1 Range adjustment

(1) The range shall be calibrated on the test object, the cali-bration blocks K1 and No. 2 or on similar calibration blocks.

(2) For longitudinal wave search units a calibration block(e.g. to Figure B-1) shall be used.

Two methods may be used

a) range calibration using a straight beam search unit on thetest object or on the calibration block and subsequentpulse zero-point correction with an angle beam search unit(delay path),

b) calibration on two far-distant holes.

In each case an advance calibration should be made on cali-bration block K1 or No. 2 with a straight beam search unit.

Note:This procedure is required due to the transverse wave portion occurringunder another beam angle.

>

≤

≥

≤

≤

≤

<

≤

≤<

<

< ≤

≥

≥

≥

≥

≥

j

j

j

j

jj

j

j

j

j

j

s

s

5

b

15b = 20Hole diameter = 3mm s 10

s

c

c

1

1

1

s

2b =

c

c

sb

Hole diameter = 3mm 1510

10s

s

1

c

5

80s

s

10

340

sb =Hole diameter = 3mm 80

4

10

55

b

bb

b

Hole diameter = 3mm b =s

b b

s

Hole diameter = 3mm

s

b10s

b =

bb

b

b

55

5b

b s

c

5

40202

bb

s

Figure B-1: Calibration blocks for sensitivity levelcalibration for angle beam scanning

KTA 3201.1

B 4.2 Application of the DGS method

B 4.2.1 Criteria for the application of the DGS method

The following criteria apply:

a) Echoes shall not be influenced by the original pulse.

b) The sound path to be evaluated begins, for transceiverprobes, at S = 0.7 x N and for dual crystal search units atthe beginning of the focal area.

c) In the case of a lateral wall effect the DGS method mayonly be used up to the beam path given in Section B 2.3,formula (B-7).

d) In the case of angle-beam scanning the DGS method canonly be applied for wall thicknesses exceeding 5 x λ

e) Where probe-specific DGS diagrams are not available, aspecific diagram for the respective probe may be derivedfrom the general diagram (Figure B-2) where data on thenear field length are available.

f) In the case of highly attenuated search units the DGSmethod may only be used if the ratio of the band width(∆f) to the nominal frequency is less than 0.75.

g) For longitudinal wave dual angle beam search units theDGS method shall not be used.

h) In the case of curved examination surfaces the conditionsof Table B-1 shall be satisfied for transceiver probes whenapplying the DGS method. Where the search units(probes) have to be adapted in accordance with SectionB 3.1 (7), the DGS method is applicable only if, in additionto the requirements of Table B-1, side-drilled, flat bottomor round bottom holes in the test object or in a referenceblock (deviations from diameter a thickness 10% at maxi-mum) are used as reference reflectors.

B 4.2.2 Reference reflectors to be used

(1) To generate a reference echo the following reflectorsshall be used unless back wall echoes can be generated fromthe test object:

a) calibration block K1 with a thickness of 25 mm and cali-bration block No. 2 with a thickness of 12.5 mm,

b) calibration block K1 with a 100 mm arc of circle or calibra-tion block No. 2 with a 25 mm arc of circle if the probe-specific correction factors (difference between the echoindications of the arc of a circle and plane back wall) areknown or have been determined,

c) Side-drilled, flat bottom or round bottom holes.

(2) For the conversion of the echo amplitude of a side-drilled or round bottom bore into the echo amplitude of acircular disk reflector formulas (B-2) and (B-3) shall be used.

B 4.3 Adjustment of the sensitivity level by the referenceecho or DAC method

(1) In the reference echo method the indication from the testobject is directly compared to the reference reflector havingnearly the same sound path. This may be done with referencereflectors in the part or reference block.

(2) For comparison the reference reflector with the same ornext-longer sound path shall be used. In exceptional cases(e.g. for reflectors close to the opposite face) the referencereflector may be distanced from the opposite at a maximum of20 % of the wall thickness, but not to exceed 20 mm.

∞

G=0.05

0.8

G=0.10

G=0.08

20

30

0

10

G=0.8

G=0.6

G=

G=1.0

G=0.2

G=0.15G=0.4

G=0.3

40

65 108410.5 32 80 10020

50

60

30 40 50

KSR

effG =

DD

A

V [ d

B ]

A =NS

Figure B-2: Standard DGS Diagram

≥

Pos.1 Pos.2Pos.3 or

Pos.1

Pos.2

Pos.3

Pos.3

3mmHole diameter

Pos.1 Pos.2

Figure B-3: Generation of indications from side-drilledholes located at different positions

RR

Increased referenceline ( e.g. by 12 dB )

+ 12 dBG G

Figure B-4: Staged reference line

(3) For simplifying the echo amplitude description it is rec-ommended to generate a DAC curve by means of one or sev-eral equal reflectors located at different depths in referenceblocks (e.g. step wedge or to Figure B-1) or by means of refer-ence reflectors in the test object located at different distances.Clause B 3.4.3 applies with regard to the requirements forreference reflectors.

KTA 3201.1

(4) The DAC curve shall be generated upon range calibra-tion by at least three responses from the reference reflectors(e.g. side-drilled holes) in various positions (see Figure B-3).The echo with the highest amplitude shall be adjusted forapproximately 80 % of the screen height. The curve obtainedmay be extrapolated by a maximum of 20 % beyond the rangelimited by the reflector indications. The gain setting of theequipment shall be selected such that the DAC curve is withinthe calibration range between 20 % and 100 % of the screenheight. If this is not possible for the entire calibration range,the gain shall be set as per Figure B-4.

B 4.4 Corrections of sensitivity level adjustment

B 4.4.1 Transfer correction

(1) The transfer correction shall be determined on at least 4points of the test object in the intended direction of examina-tion.

(2) The transfer correction shall be determined in accor-dance with Figure B-5 by means of scanning on the calibra-tion beam and on the test object.

(3) To consider the general transfer correction in angle-beamscanning ∆VT with Vee or W path shall be used.

κκ1

1 2

21

2

2211

S

2S

40%

Calibration block ( )

S

S

2S

2S

S

40%

2S

Test object ( )

G dBT1 = . . . G dBT2 = . . .

∆ ∆ ∆ ∆V G G V V VT T T S koppl= − − = +2 1 κ

( )∆V S Sκ κ κ= ⋅ ⋅ − ⋅2 2 2 1 1

∆V V VS S S= −2 1

Figure B-5: Determination of transfer correction forstraight-beam scanning or for angle-beamscanning with Vee or W path

B 4.4.2 Sound attenuation correction

(1) The sound attenuation for straight-beam scanning shallbe determined as per Figure B-6 and for angle-beam scanningas per Figure B-7 in consideration of ∆VS.

(2) The determination of the sound attenuation may beomitted if it is considered by an allowance independent fromthe sound path (e.g. by a general transfer correction).

2

1

2

1

H

S STest object

H

S

( ) ( )κ =− −

⋅ −==

G G V

S SdB mm

G dBG dB

T T S T

T

2 1

2 1

1

22/

. . .. . .

Figure B-6: Determination of sound attenuation forstraight-beam scanning

2

1 2

1

S

2S

W-pathV-path

40%

2S

S

40%

G dBT1 = . . . G dBT2 = . . .

( ) ( )κ =− −

⋅ −G G V

S SdB mmT T S2 1

2 12/

Figure B-7: Determination of sound attenuation for angle-beam scanning

B 4.4.3 Coupling and sound attenuation variations

(1) For the transfer correction the average value of thescanning values obtained form the test object shall be used ifthe range of variation does not exceed 6 dB. Where the rangeexceeds 6 dB, the average value from 20 scanning values plusan allowance ∆V~ = 1.7 x standard deviations to be calculatedin accordance with Section B 2.3 (h) shall be used.

(2) Where the ∆V~ value thus determined is greater than6 dB, the test object shall be subdivided into sections wherethe transfer correction of each section shall be consideredseparately. This subdivision shall be such that in each section∆V~ is equal to or smaller than 6 dB.

B 4.4.4 Consideration of corrections

(1) Taking the aforementioned sensitivity level correctioninto account, the following recording limit is obtained for theequipment sensitivity

GR = GK + ∆VT + ∆V∼, (B-11)

KTA 3201.1

where

∆VT = ∆Vkoppl + ∆Vκ (B-12)

(2) Where sound attenuation in dependence of the soundpath is taken into account this shall be made with the at-tenuation portion ∆Vκ contained in ∆VT as per Figure B-8when using the DGS method or as per Figure B-9 when usingthe DAC method.

(3) If it is not necessary to consider the sound attenuation independence of the sound path, ∆VT shall contain a constantsound attenuation portion ∆Vκ independent of the soundpath.

(4) Where an additional correction for considering greatervariations as per clause B 4.4.3 is required, this shall be doneby means of ∆V~ . Otherwise, the correction value in theabove equation shall be omitted.

∆∆

∆

∆∞

κ

κ κ

κκ

0.4

1.0

0.8

Reference echo

1

2

0

10

50 500300

20

60

100

50

30

40

1000

0.2

200

0.6

2000

consideration

of sound

attanuation

Calibration block ( )

Circular disk

reflector with

Vkorr

.V

VTest object ( )

Vjust

G

s

V[dB

]V

[dB

]

s

s [ mm ]

( ) [ ]∆V S S dBjustκ κ κ= ⋅ ⋅ − ⋅2 2 1

Figure B-8: Consideration of sound attenuation in the DGSdiagram for κ2 > κ1

∆κ

V

Reference line upon

Transfered or

set-up reference line

sound attenuation correction

( ) [ ]∆V S dBκ κ κ= ⋅ ⋅ −2 2 1

Figure B-9: Consideration of sound attenuation for the DACmethod for the case κ2 > κ1

B 4.5 Setting of instrument gain

Taking the coupling and attenuation losses into account theinstrument gain shall be adjusted such that the recording limitfor the respective calibration range attains at least 20% of thescreen height.

B 5 Description of indications

B 5.1 Echo amplitude

The maximum echo amplitude of a reflector referred to therespective valid recording limit is to be indicated in dB.

Note:The reproduceability of the echo amplitude determination is generally± 3 dB.

B 5.2 Extension of reflectors

B 5.2.1 General requirements

Recording lengths equal to or greater than 10 mm shall bemeasured. The measured lengths shall be given as integralmultiple rounded up or down to 5 mm (e.g. 10, 15, 20 etc.).Shorter recording lengths shall be recorded as „< 10“.

B 5.2.2 Determination of the recording length

The extension of reflector (see Figure B-10) shall be given bythe search unit displacement range. This range is determinedas the distance between locations where the echo amplitude islower by either 0 dB, 6 dB or 12 dB. Where the noise level limitis reached, the recording length shall be documented as thedistance between the points where the signal disappears inthe noise level.

B 5.2.3 Determination of half-amplitude and quarter-amplitude length

When measuring the half-amplitude or quarter-amplitudelength of reflectors the search unit displacements at echoamplitude decreases of 6 dB or 12 dB compared to the maxi-mum echo amplitude shall be determined. Here, for dualsearch units the acoustic separating line and for line focussingsearch units the line focus shall be vertical to the reflectordirection of extension.

B 5.2.4 Methods for the exact determination of reflectorextension

(1) The determination of the reflector extension may beoptimized by one of the following additional corrections orexaminations if this measurement alone is decisive for theassessment of the acceptability of an indication.

(2) The reflector shall be measured from the scan position orangle of incidence at which the scan path shows the slightestdeviation from 1.0 x near field length however is greater than0.7 x near field length. In such a case, another frequency thanthat for generating the maximum echo amplitude may beused.

(3) The beam diameter shall be determined at the reflectorlocation. If the measured length exceeds this measured beamdiameter the recording length shall be the corrected recordinglength calculated as per formula (B-6).

(4) The beam diameter shall be determined by calculation orexperimental analysis. It may be calculated according to for-mula (B-4) if non-adapted search units are used.

(5) In the case of angle beam scanning the horizontal in-cluded angle shall be inserted for γ6. The included angle shallbe taken from the data sheets on the search units used.

(6) Where the included angle has to be determined by ex-perimental analysis, measurements shall be made on a refer-ence block to correspond to the test object.

KTA 3201.1

(7) To this end, reference reflectors shall be bored into thisreference block at the same depth location like for the indica-tion to be corrected. As reference reflector a cylindrical hole orflat bottom hole of 3 mm diameter or a round bottom holewith a diameter exceeding 1.5 x λ may be suited.

(8) The half-amplitude length shall be determined on thereference reflector on the same sound path as for the reflectorto be corrected. The value determined such shall correspondto the beam diameter at the respective depth of indication.

(9) By means of suitable dual search units or focused beamsearch units the reflector shall be measured in the focal areaand be evaluated as follows:

a) Where the difference between the quarter-amplitude andhalf-amplitude length is ≤ 1.5 times the beam diameter, thehalf-amplitude length shall be the recording length.

b) Where the difference between the quarter-amplitude andhalf-amplitude length exceeds 1.5 times the beam diame-ter, the quarter-amplitude length minus the beam diame-ter shall be the recording length.

c) Where the half-amplitude length is smaller than the beamdiameter, the beam diameter or the focal width at thedepth location shall be the recording length.

(10) In a measurement of lengths with focused beam searchunits several echo volumes shall be recorded to increase themeasuring accuracy and to improve the reproduceability on agrid pattern. The grid-line distances should be smaller thanthe diameter of the focusing beam. A typical set-up of measur-ing equipment to record echo volumes is shown in FigureB-11.

12 d

BRecording length

Recording limit

6 dB

displacement

displacementRecording length

Search unit

Search unit

Recording limit

Echo

am

plitu

deEc

ho a

mpl

itude

Reflector

Search unit

Echo

am

plitu

de

Recording length

Recording limit

Search unitdisplacement

Figure B-10: Determination of recording length

Search unit guiding mechanism ( schematic )

Noise

Signal Signal

Rotary potentiometer withfriction-wheel drive

grid lines of grid pattern

Monitor( Puls amplitude )

Displacement

Echo

am

plitu

de

Reflector

Distance of adjacent

Ultrasonic instrument

Search unit

Figure B-11: Set-up of measuring equipment when using focused-beam search units for measuring reflector extensions

KTA 3201.1

Classification as to geometry Type of scanning Range of application

Straight-beam, radial d > 5 ⋅ N

angle-beam, axial and in cir-cumferential direction

d > 2.5 ⋅ NEvaluation up to p/2

Straight-beam, radial d > 5 ⋅ N

Straight-beam, axial and in cir-cumferential direction

d > 2.5 ⋅ N for evaluation up to p/2;dref > 10 ⋅ N for evaluation beyond p/2

Straight-beam, in thickness di-rection

d > 10 ⋅ N

angle-beam, tangentially d > 5 ⋅ N for evaluation up to p/2;dref > 20 ⋅ N for evaluation beyond p/2

Table B-1: Range of application of DGS method for transceiver probe techniques

B 5.2.5 Determination of depth extensionNote:Stipulations in course of preparation.

B 5.3 Structural discontinuities

(1) Where indications from the root area of a weld are to beclassified as geometric discontinuities, control measurementsshall be made to determine the cause of indication.

(2) If it is to be proved that the echoes reflected from the twoweld sides arise on the two flanks of the excess penetrationand are not caused by weld defects, the control measurementshall be made by measuring the projected-surface distance onthe test piece. The exact projected-surface distances shall bedetermined on rectangular notches with a depth and width of1 mm each on a reference block (see Figure B-12). Where it isfound out that the projected-surface distances of the respec-tive indications clearly overlaps [(2a - a’) equal to or greaterthan 2 mm], the echo amplitudes are considered to be causedby geometric discontinuities. Where a smaller distance than2 mm is found, the reflectors shall no more be treated sepa-rately.

obenDatei: K013

KTA :

Format:058

Gez.:Bild: B-12

65/70

25.12.95hn/3201.331.01.97Stand:

′

≥′ 3 mm2a -

a

a

a

1

1

a

a

ss

Figure B-12: Proof of indications cause by structural discon-tinuities from the root area of single-side welds

B 6 Creeping wave method

B 6.1 Description of method

(1) Longitudinal wave probes with usual angles of incidenceof 75 to 80 degrees generate additionally to the longitudinalmain wave a longitudinal wave propagating in parallel to theexamination surface (primary creeping waves).

(2) By the propagation of the creeping wave along the ex-amination face transverse waves are permanently radiated sothat the intensity of the creeping wave rapidly decreases withthe sound path. In the case of creeping wave twin probes withtransducer dimensions of e.g. D0 ≈ 6 x 13 mm2 the focal dis-tance will be approximately 10 mm.

(3) Where, for geometric reasons, the creeping wave will dipinto the volume, e.g. in the case of attachment welds, it willpropagate as normal longitudinal wave without radiation.This leads to greater usable sound paths of 30 mm to ap-proximately 50 mm.

B 6.2 Reference blocks

(1) For the calibration of creeping wave probes the referenceblocks as shown in Figure B-13 shall be taken.

(2) When examining with adapted probes, the curvatures ofthe examination faces of the reference block and the test objectshall match, if possible.

B 6.3 Adjustment of sensitivity

For the examination area a DAC curve shall be generated tomeet the requirements of section B 4.3 by means of scanningthe respective reference reflectors in the reference blocks inaccordance with section B 6.2.

B 6.4 Adaptation of probes

(1) When examining on convex curved examination faceswith d equal to or greater than L2/2 , the adaptation of theprobes may be waived.

(2) In the case of examination faces with L2/3 ≤ d < L2/2 anadaptation by shaped refracting prisms (wedges) or by shap-ing of the probe shoe is permitted.

Curved-surface full material (e.g. bars)

Concentric, uniaxial curved surface(e.g. pipes)

Concentric, biaxial curved surface (e.g.dished heads, tube-sheets)

KTA 3201.1

(3) In the case of examination faces with d < L2/3 speciallydesigned probes shall be used.

Section A-A

∅3

≈ 15

1.5

≈ 45°

≈ 25

≈5

≈ 45

≈ 35

≈125

≈50

≈25

≈100

≈75

≈ 70

>10

≈ 150

of the flat bottom hole indications

Flat bottom holes

The recording limit corresponds to the echo height

∅ 3 mm

AA

Figure B-13: Reference block and recording limit for thecalibration of creeping wave probes

B 7 Wave mode conversion method

B 7.1 Description of method

(1) When transverse waves hit an opposite face at an angleof approximately 31 degrees, a longitudinal wave (secondarycreeping wave) is generated which is nearly parallel to thesurface (Figure B-14). The angle of incidence of 31 degrees isobtained, in the case of plane-parallel test objects, by the ac-companying transverse wave of a 70-degree longitudinalprobe.

(2) Due to its scattered propagation the secondary creepingwave is e.g. used to examine the root area of a welded jointwithout being influenced by the excess penetration (FigureB-15). In this case it shall be taken into account that the in-tensity of the secondary creeping wave will rapidly decreasewith the sound path subject to the permanent radiation oftransverse waves.

(3) During scanning with the longitudinal wave probe onplane-parallel test objects a sequence of echoes is generatedthe individual echoes of which are called NE 1 and

NE 2 (Figure B-16). For the detection of reflectors the echoNE 2 is used. The echo NE 1 may be used for reflector depthestimation.

(4) When scanning thin test objects (8 mm < s ≤ 20 mm) withthe longitudinal wave probe (Type 70 degree SEL) an echoheight is generated which contains both the longitudinal waveportion (main echo-HE) and the converted transverse waveportion (sequence of secondary echoes-NE) (Figure B-17).

Note:Spurious echoes may be generated due to the transverse wave generatedsimultaneously with the beam entry into the test object, since the trans-verse wave entering at a very steep angle is highly sensitive to irregu-larities of the probe-remote surface, such as gauge marks, identificationmarkings, etc. and reacts to deviations from shape. Therefore, it is espe-cially important to

- consider the probe position in relation to the centre of the welded joint,

- know the sound velocities and the related angle of incidence of thetransverse wave,

- know the various echo dynamics.

When exactly allocating the indication to the welded joint and consider-ing the fact that a reflector has a great dynamic effect when beingscanned with longitudinal waves - contrary to the accompanying trans-verse wave of approx. 31 degrees- a distinction between such spuriousechoes and real defects is possible.

Scanning with secondary creeping waves in accordance with subpara (2)and (3) is purposeful beginning with a wall thickness > 15 mm. In thecase of wall thicknesses 8 mm < s ≤ 20 mm the examination shall be per-formed with longitudinal wave probes (Type 70 degree SEL). The pres-ence of the main echo HE and the secondary echo NE shows that thesound waves are reflected at deep material discontinuities. Indications ofroot notches of little depth are distinguished from deep defects due to thefact that secondary echoes are not obtained (Figure B-17).

B 7.2 Probe

In the case of plane-parallel surfaces 70 degree longitudinalwave probes are used as single transducer or transceiver de-sign which besides the longitudinal wave below 70 degreestransmit an accompanying transverse wave of approx. 31degrees to generate a secondary creeping wave on the internalsurface.

Note:

For the selection of the probe its dependency on the echo height from thegroove depth related to the echo NE 2 and to the wall thickness to be ex-amined must be known.

B 7.3 Range calibration

(1) The range shall be calibrated for longitudinal waves.

(2) A precalibration for sound velocity adjustment (velocityrange) shall be made by means of straight beam scanning onthe test object or on a similar reference block.

(3) A correction of the precalibration (zero point displace-ment) by taking the transverse wave portions in the soundpath into account shall be made on the test object or referenceblock by the scanning of a rectangular groove according to thewave conversion method. Here, the secondary echo NE 2 isoptimized. „a“ is determined on the coupling surface. With„a“ and in consideration of the above formula the zero pointdisplacement can be made (SEL probe). A marking on thescreen is purposeful. At one edge the calibration can bechecked by means of secondary echoes NE 1 and NE 2 (FigureB-16).S = 1.5 ⋅ s + a (B-13)

KTA 3201.1

B 7.4 Adjustment of sensitivity levels

(1) The sensitivity shall be adjusted on a similar referenceblock with regard to material and geometry.

(2) To generate a reference echo rectangular grooves as persection B 3.4 (2) be) shall be used.

(3) When examining with the secondary creeping wave thesecondary echo NE 2 reflected from the groove is optimizedand thus the sensitivity level is obtained.

(4) In the case of examination as per section B 7.1(4) thesensitivity shall be adjusted on corresponding rectangulargrooves with longitudinal waves. The recording limit is thereference echo height of the direct longitudinal wave minus6 dB. The indication of the edge on the reference block shallexceed the recording limit by at least 10 dB. Otherwise, therecording limit shall be reduced accordingly.

B 7.5 Corrections during sensitivity level adjustment

B 7.5.1 Transfer correction

The transfer correction shall be made with two transversewave angle probes of the same kind (angle of incidencegreater than 35 degrees) with V-transmission through the basemetal of the component and the reference block. In this case,the frequency of the longitudinal wave probe shall be used.

B 7.5.2 Correction of sound attenuation caused by thewelded joint

Different sensitivity levels caused by the filler metal shall bedetermined by suitable means and be taken into account.

B 7.6 Performance of examination

The examination is usually performed by displacing the probeon a small area parallel to the welded joint. Here, the probeposition is optimized by moving the probe vertically to thewelded joint. This has to be done on several tracks so that thetotal area to be examined is completely covered.

s

Figure B-14: Reflexion with wave mode conversion for longi-tudinal wave angle probe

70°

Directional characteristics

70°

≈31°

≈31°

Figure B-15: Examination of internal near-surface area of welded joints by means of secondary creeping waves

2 4 6

NE2NE1

0

NE2

NE1

a

8 10a

Figure B-16: Sound field geometry during transverse wave conversion

KTA 3201.1

64 1082

NE

HE

0

HE

NE

0

HE

HE

2 8 104 6

HE: Main echo, NE: Secondary echo

Figure B-17: Examination of components with wall thicknesses 8 mm < s ≤ 20 mm by means of longitudinal waves (70 degreeSEL probe)

Annex C

Performance of surface crack detection examinations by magnetic particle and liquid penetrant methods

(The wording of this Annex is identical in both safety standards KTA 3201.1 and 3201.3.)

C 1 General requirements

C 1.1 Surface condition

(1) The surfaces to be examined shall show a conditionsuitable for the examination.

(2) They shall be free from scale, weld spatter or other dis-turbing impurities.

(3) Grooves and notches affecting the test result shall beremoved.

C 1.2 Visibility conditions

C 1.2.1 Fluorescent tests fluids

(1) When using fluorescent test fluids the inspection shall bemade under ultraviolet light with a wave length maximum of365 nm ± 10 nm.

(2) The ultraviolet light incident on the examination surfaceshall have an intensity of at least 10 W/m2.

(3) The ultraviolet lamps shall have attained their full lumi-nous intensity prior to using it.

(4) The eyes of the operator shall have at least 5 minutes toadapt to the light conditions.

(5) The examination shall be performed in a darkened roomwithout disturbing incidence of light.

C 1.2.2 Non-fluorescent agents

(1) For the evaluation, the examination surfaces shall beilluminated by daylight or artificial light with an illuminanceof at least 500 lux.

(2) During examination, disturbing reflections and incidentlight shall be avoided.

KTA 3201.1

C 1.2.3 Auxiliary means for evaluation

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

C 1.3 Post-cleaning

Upon completion of examination, the parts shall be properlycleaned to remove residues from the test fluid.

C 2 Magnetic particle examination

C 2.1 Magnetisation

C 2.1.1 Methods

(1) The possibilities of magnetisation are given in DIN54 130.

(2) Where magnetisation is achieved in partial areas byinherent direct magnetisation or yoke magnetisation, ACmagnetisation shall be used.

(3) The DC magnetisation method shall only be used uponagreement by the authorized inspector.

(4) The residual magnetic field strength shall principally notexceed 103 A/m (12,5 Oe) unless a lower value is required forthe examination. Where the specified value is exceeded, thepart shall be demagnetised and the value of the residual mag-netic field strength be recorded.

C 2.1.2 Contact areas in case of direct magnetisation

(1) Where the examination is performed by inherent mag-netic flux, consumable electrodes (e.g. lead fin alloys) shall beused, if possible. It shall be ensured that in the contact areasoverheating of the material to be examined is avoided.

(2) Where overheating has occurred the overheated areasshall be marked, ground over after the examination and beexamined for surface cracks, preferably by a magnetic particlemethod using yoke magnetisation.

C 2.1.3 Direction of magnetisation

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

C 2.1.4 Magnetic field strengthNote:

a) The magnetic flux in the test object surface governs the quality of theexamination. The required minimum flux density is 1 T.

b) Due to the difficulties in measuring the magnetic field strength inthe part, the tangential field strength is used as auxiliary variable.

c) Tangential field strength is the tangential component of the mag-netic field strength on the test object surface. In low-carbon steelsthe required flux density is obtained at a field strength of 2 k/A.

d) Possibilities of checking whether the magnetisation of the test objectsuffices are given in the guideline of the Deutsche Gesellschaft fürZerstörungsfreie Prüfverfahren e.V. (DGZfP), Berlin, DGZfP-EM-3, Instruction sheet for the checking of examination parametersduring magnetic particle examination.

(1) The tangential field strength on the surface shall be atleast 2×103 A/m (approx. 25 Oe) and shall not exceed6,5×103 A/m (approx. 80 Oe).

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

C 2.1.5 Magnetisation times

(1) The following guide values apply with respect to theapplication of the magnetic particles and magnetisation:

a) Magnetisation and application: at least 3 seconds

b) Subsequent magnetisation: at least 5 seconds

(2) The evaluation shall be made during subsequent mag-netisation.

C 2.2 Inspection medium

C 2.2.1 Wet particle inspection method

(1) Only such particles shall be used as vehicle which do notcause corrosive damage on the test object even after pro-longed application. The examination surface shall be wettableby the vehicle fluid. For example, water is permitted withrespective anti-corrosion and low-surface tension additives.

(2) Only fine-grained iron oxide shall be used as magneticparticles. Depending on application, black, fluorescent orcoloured powders may be used.

(3) Prior to bathing the surface care shall be taken to ensurethat the magnetic powder is distributed uniformly in the ve-hicle fluid and is kept in suspension. Prior to and during theexamination the powder suspension shall be spot-checked bysuitable test units. When using the Berthold test unit the cross-recessions shall be oriented at an angle of approximately 45°to the direction of magnetisation and be wetted during thecheck. The concentration of the magnetic powder will sufficeif the cross-recession can be clearly and completely identified.

C 2.2.2 Dry particle method

(1) The dry particle method is subject to agreement by theauthorized inspector except for the intermediate check inwarm condition. Care must be exercised to ensure that thepower used is sufficiently dry.

(2) The device for applying the powder shall make possiblesuch a fine spraying that no accumulations of powder occurs.It shall be ensured that the powders used do not agglomerateunder the influence of the workpiece temperature.

C 2.2.3 Contrast

(1) Sufficient contrast shall be provided to improve thedetectability of defects by using suitable means (e.g. fluores-cent inspection medium or application of a thin colour coatingjust covering the surface).

(2) Sufficient contrast is obtained if black magnetic powderis used on metallic bright surfaces.

C 3 Liquid penetrant inspection

C 3.1 Inspection system

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

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

(3) Only wet developers suspended in an aqueous solventshall be used. Dry developers may only be applied on theexamination surface by electrostatic charging.

KTA 3201.1

(4) The suitability of the inspection system (penetrant, sol-vent remover and developer) shall be demonstrated to theauthorized inspector by means of a sample examination as perDIN 54 152-2.

(5) In the case of multiple use or storage of the penetrants inopen containers, the effectiveness of the examination systemshall be verified on reference block B to DIN 54 152-3 prior tobeginning the examination. In this test the maximum penetra-tion and development times shall not exceed the minimumtimes specified for the evaluation. The examination sensitivityobtained shall be recorded.

C 3.2 Performance

(1) Liquid penetrant inspections shall be performed to DIN54 152-1 to meet the following requirements.

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

(3) As soon as possible after drying of the developer a firstevaluation shall be made. A further evaluation shall not bemade before half an hour after the first evaluation has passed.

(4) Further evaluation times are required if during the sec-ond evaluation crack-like indications are detected which werenot visible during the first evaluation.

Note:Further evaluation times are required if during the second evaluationcrack-like indications are detected which were not visible during the firstevaluation.

(5) The evaluation shall be made in consideration of theresults of all evaluations.

Annex D

Procedure for determining the delta ferrite content

D 1 Scope

This appendix specifies details for the procedures required forthe determination of the products' delta ferrite content underSec. 3.3.7.5 (1).

D 2 Metallographic determination on castings in theas-delivered condition

(1) A test specimen shall be taken from the product at thespecified specimen-taking location, be ground and polished inthe usual way and etched in accordance with Murakami [2].The etched surface shall have an area of at least 10 mm by10 mm.

(2) The evaluation shall be performed at a magnification of100:1.

(3) A representative location of the etched surface shall bedocumented as photograph at a magnification of 100:1.

(4) With regard to the quantitative evaluation it is recom-mended to compare the micrograph with a correspondingdelta ferrite reference sheet and classify it accordingly. Alter-natively, the procedure of a quantitative microstructureanalysis may be employed.

(5) The test report shall state:

a) the shape, size and direction of the test specimen as wellas the specimen-taking location,

b) the heat treatment condition,

c) the delta ferrite content in %.

A micrograph shall be contained in the test report.

D 3 Metallographic analysis of the bead-on-plate testspecimen

(1) A test specimen of the following size shall be taken fromthe product form at the specified specimen-taking location:

length 200 mm, thickness ≥ 25 mm, width ≥ 40 mm.

(2) A melt run with a length of at least 180 mm shall bedeposited on the test specimen with a TIG burner withoutweld filler metals, using the following weld parameters(guidance values):

voltage about 20 V,

current about 160 A,

feed rate about 20 cm/min.

(3) In the case of product forms that do not allow taking oftest specimens with a size as specified under (1) and wherethe weld parameters as specified under (2) cannot be applied,the specimen shape and heat input shall be adjusted as closelyas possible to the welding to be performed later on the prod-uct.

(4) A specimen section shall be removed from the middle ofthe melt run perpendicular to the surface and to the weld runaxis; one side of this cross-section shall be ground and pol-ished in the usual way and etched in accordance with Mu-rakami [2].

(5) The evaluation shall be performed at a magnification of1000:1.

(6) A representative location of the surface-deposited weldzone on the etched surface shall be documented as photo-graph at a magnification of 1000:1.

KTA 3201.1

(7) With regard to the quantitative evaluation it is recom-mended to compare the micrograph with a correspondingdelta ferrite reference sheet [3] and classify it accordingly.Alternatively, the procedure of a quantitative microstructureanalysis may be employed.

(8) The test report shall state:

a) the shape, size and direction of the test specimen as wellas the specimen-taking location,

b) the actual values of the welding parameters,

c) the delta ferrite content in %.

A micrograph with a specification of its location shall be con-tained in the test report.

D 4 Metallographic determination for weld material(during the procedure qualification and productionweld test for weldings on castings)

From the weld materials an overview photograph of the entirecross section of the weld seam or of the cladding shall bemade as well as micrographs at a magnification of 1000:1 ofthose areas (at least three) that are representative for theevaluation of the delta ferrite content. The locations of theseareas shall be marked in the overview photography.

D 5 Mathematical estimation according to De LongNote:Figure D-1 in accordance with De Long [4] is used for the mathematicalestimation of the delta ferrite content of the base metal molten duringwelding of austenitic steels and casting steels as well as of austeniticweld material. In this graph the delta ferrite content is shown in relationto the chemical composition, however, not in terms of its volumetric ratiobut rather, on the basis of a special calibration (cf. DIN 32 514-1), interms of the characteristic "ferrite number (FN)". In the range of smallferrite numbers up to FN 7, the ferrite number is identical to the deltaferrite content in %.

(1) The nickel equivalent NiE shall be calculated from thechemical composition of the base metal according to theequation

NiE = % Ni + 30 ⋅ (%C + % N) + 0.5 ⋅ % Mn (D-1)

and the chrome equivalent CrE according to the equation

CrE = % Cr + % Mo + 1.5% Si + 0.5 ⋅ % Nb (D-2)

(2) The calculated values of the nickel equivalent andchrome equivalent are the coordinates of a point in FigureD-1. The corresponding ferrite number is read from the graph.As required, the values can be interpolated between thestraight lines of constant ferrite numbers.

(3) The documentation of the mathematical estimation shallcontain the following::

a) the chemical composition of the base metal,

b) the value of the nickel equivalent,

c) the value of the chrome equivalent,

d) the delta ferrite content in terms of the ferrite number.

0

1012

2

86

4

1618

14

Martensite

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E

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Figure D-1: Relationship between chemical composition andferrite numbers of molten base metal or weldmaterial (according to W.T. De Long [4])

KTA 3201.1

Annex E

Form sheets

Form sheets E 1 a to c Cover sheets

Form sheet E 2 Materials testing and specimen-taking plan

Form sheet E 3 Heat treatment plan

Form sheet E 4 Appendix

KTA 3201.1

Hersteller:manufacturer:

Auftrags-Nr.:contract no.

Bestell-Nr.:order no.

Anlage/Projekt:power plant / project: Deckblatt

cover sheet

Seite:page:

Komponente component:

Gegenstand item:

KKS/AKZ NPP identification system:

Typ, Antrieb, DN type, drive, DN:

Identnummer identification no.:

Komp.-Spezifikation component specification:

Klasse classification:

Prüfgruppe PG testing group:

Einzelteilgruppe EG parts group:

Inhaltsverzeichnis für Vorprüfunterlagentable of contents of design review documents

Revisionstabelle der Unterlagen der Rubrik 2table of revisions of documents class 2

Vorprüfunterlagen Nr.design review document no.

Seite: von - bispage: from - to

Rev. 01/aSeite Nr. page no.

Rev. 02/bSeite Nr. page no.

Rev. 03/cSeite Nr. page no

Rev. 04/dSeite Nr. page no.

Deckblatt DBLcover sheet

Zeichnung ZGtechnical drawing

Werkstoffliste WLmaterials list

Schweißstellenliste STLweld seam location list

Prüffolgeplan PFPtest and inspection sequence plan

Schweißplan SPwelding plan

Wärmebehandlungsplan WBPheat treatment plan

Werkstoffprüf- und Proben-entnahmeplan WPPmaterial test and specimen-taking plan

Auslegungsberechnungdesign calculation

Spannungsanalysestress analysis


Rev.revision

Datum:date

Erstellt von:prepared by

Geprüft QST:checked by quality dept.

Grund der Revisionreason for revision

Freigaberelease certification

00

01

02

03

04

Form sheet E 1a: Cover sheet

1

2

4

3

Prüfvermerk des Sachver-ständigen gemäß § 20 AtGcertification mark of autho-rized inspector to § 20 AtG

KTA 3201.1





cover sheet

DBL-Nr.:DBL no.

Seite:page:

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Rev.revision

Datum:date





00

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Form sheet E 1b: Cover sheet

5


KTA 3201.1






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KTA 3201.1

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Form sheet E 4: Appendix

KTA 3201.1

Annex F

Regulations referred to in this Safety Standard

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

KTA 1401 (06/96) General Requirements Regarding Quality Assurance

KTA 1404 (06/89) Documentation during the construction and operation of nuclear power plants

KTA 1408.1 (06/85) Quality Assurance for Weld Filler Materials and Weld Additives for Pressure and ActivityRetaining System in Nuclear Power Plants;Part 1: Suitability Testing

KTA 1408.2 (06/85) Quality Assurance for Weld Filler Materials and Weld Additives for Pressure and ActivityRetaining System in Nuclear Power Plants;Part 2: Manufacturing

KTA 1408.3 (06/85) Quality Assurance for Weld Filler Materials and Weld Additives for Pressure and ActivityRetaining System in Nuclear Power Plants;Part 3: Processing

KTA 3201.2 (06/96) Components of the Reactor Coolant Pressure Boundary of Light Water Reactors;Part 2: Design and analysis

KTA 3201.3 (06/98) Components of the Reactor Coolant Pressure Boundary of Light Water Reactors;Part 3: Manufacture

KTA 3201.4 (06/90) Components of the Reactor Coolant Pressure Boundary of Light Water Reactors;Part 4: Inservice Inspection and Operational Monitoring

KTA 3203 (03/84) Monitoring Radiation Embrittlement of the Materials of the Pressure Vessel of Light WaterReactors

KTA 3205.1 (06/91) Component-support structures with non-integral connections;Part 1: Component support structures with non-integral connections for components of the

reactor coolant pressure boundary

DIN EN 287-1 (04/92) Approval testing of welders for fusion welding; Part 1: Steels; German version EN 287-1:1992

DIN EN 895 (08/95) Destructive tests on welds in metallic materials. Transverse tensile test;German version EN 895:1995

DIN EN 910 (05/96) Destructive tests on welds in metallic materials; Bend tests; German version EN 910:1996

DIN 1690-1 (05/85) Technical delivery conditions for castings made from metallic Materials; general conditions

DIN 1690-2 (06/85) Technical delivery conditions for castings made from metallic material: steel castings; classifi-cation into severity levels on the basis of nondestructive testing

DIN 4762 (01/89) Surface roughness; terminology; surface and its parameters; identical with ISO 4287-1:1984

DIN 8572-1 (03/81) Determination of diffusible hydrogen in weld metal; manual arc welding

DIN 8572-2 (03/81) Determination of diffusible hydrogen in weld metal; submerged arc welding

DIN EN 10 002-1 (04/91) Tensile testing of metallic materials Part 1: Method of test at ambient temperature; includingamendment AC 1:1990; German version EN 10002-1:1990 and AC1:1990

DIN EN 10 002-5 (02/92) Tensile testing of metallic materials; Part 5; Method of test at elevated temperatures; Germanversion EN 10002-5:1991

DIN EN 10 003-1 (01/95) Metallic materials Brinell hardness test; Part 1: Test method; German version EN 10003-1:1994

DIN EN 10 045-1 (04/91) Charpy impact test on metallic materials; Part 1: Test method;German version EN 10 045-1:1990

DIN EN 10 204 (08/95) Metallic products.Types of inspection documents (including amendment AC1:1995); Germanversion EN 10204:1991 + A1:1995

DIN EN 10 233 (01/94) Metallic materials; Tube; Flattening test; German version EN 10 233:1993

DIN EN 10 234 (01/94) Metallic materials; Tube; Drift expanding test; German version EN 10 234:1993

DIN EN 10 235 (01/94) Metallic materials; Tube; Flanging test; German version EN 10 235:1993

KTA 3201.1

DIN EN 10 236 (01/94) Metallic materials; Tube; Ring expanding test; German version EN 10 236:1993

DIN EN 10 237 (01/94) Metallic materials; Tube; Ring tensile test; German version EN 10 237:1993

DIN 17 240 (07/76) Heat resisting and highly heat resisting materials for bolts and nuts; quality specifications

DIN 17 245 (12/87) Ferritic steel castings with elevated temperature properties; technical delivery conditions

DIN 17 440 (09/96) Stainless steels; technical delivery conditions for plate and sheet, hot rolled strip, rolled bars forpressure vessels, drawn wire and forgings

DIN 17 445 (11/84) Stainless steel castings; technical delivery conditions

DIN 17 458 (07/85) Seamless circular austenitic steel tubes subject to special requirements; technical delivery con-ditions

DIN EN 27 963 (06/92) Specification for calibration block No. 2 for ultrasonic examination of welds (ISO 7963:1985);German version EN 27963:1992

DIN 32 514-1 (06/90) Determination of the ferrite number in austenitic weld metal; measurement method

DIN 50 104 (11/83) Testing of hollow bodies by internal pressure; leak detection up to a certain pressure value;general specifications

DIN 50 115 (04/91) Notched bar impact testing of metallic materials; special test piece types and evaluation meth-ods

DIN 50 121-3 (01/78) Testing of metallic materials; Technological bending test on welded joint and weld claddings;Fusion welded claddings

DIN 50 125 (04/91) Test pieces for the tensile testing of metallic materials

DIN 50 133 (02/85) Testing of metallic materials; Vickers hardness test HV 0.2 to HV 100

DIN 50 150 (12/76) Testing of steel and cast steel; conversion table for Vickers hardness, Brinell hardness, Rockwellhardness and tensile strength

DIN 50 914 (06/84) Testing the resistance of stainless steels to intercrystalline corrosion; copper sulfate/sulfate/sul-fur acid method; Strauß test

DIN 51 220 (01/96) Materials testing machines. General requirements for materials testing machines and for theirtesting and calibration

DIN 54 111-2 (06/82) Nondestructive testing; testing of metallic materials by X-rays or gamma rays; radiographictechniques for castings

DIN 54 119 (08/81) Nondestructive testing; ultrasonic inspection; terms

DIN 54 120 (07/73) Nondestructive testing; calibration block 1 and its use for the adjustment and control of ultra-sonic echo equipment

DIN 54 130 (04/74) Nondestructive testing, magnetic leakage flux testing, general

DIN 54 152-1 (07/89) Nondestructive testing, penetrant inspection; procedure

DIN 54 152-2 (07/89) Nondestructive testing; penetrant inspection; verification of penetrant inspection materials

DIN 54 152-3 (07/89) Nondestructive testing; penetrant inspection; reference blocks for determination of the sensi-tivity of penetrant systems

EURONORM 103-71 (11/71) Microscopic determination of the ferritic or austenitic grain size of steels

AD HP 3 (04/96) Welding systems - Welders

SEP 1325 (12/82) Drop-weight test to W.S. Pellini

SEP 1915 (09/94) Ultrasonic testing of steel pipes for longitudinal flaws

SEP 1918 (01/92) Ultrasonic testing of steel pipes for transverse flaws

SEP 1919 (06/77) Ultrasonic testing of heat-resisting steel pipes for lamellar tearing

SEP 1922 (07/85) Ultrasonic testing of ferritic steel castings

SEP 1935 (06/82) Surface crack detection examination of steel castings; magnetic particle method

SEP 1936 (06/82) Surface crack detection examination of steel castings; liquid penetrant method

SEW 088 (10/93) Weldable fine-grained structural steels; guidelines for processing, in particular for fusionwelding (incl. supplementary sheets 1 and 2)

VdTUEVMaterial Sheet 305 (03/84) Nickel-chromium-iron alloy; NiCr 15 Fe; material no. 2.4816

KTA 3201.1

VdTUEVMaterial Sheet 337 (06/87) High temperature steels 20 NiCrMo 14 5 I and 20 NiCrMo 14 5 II, material no. 1.6772

VdTUEVMaterial Sheet 381 (09/85) High temperature quenched and tempered cast steel GS-18 NiMoCr 3 7

VdTUEVMaterial Sheet 390 (09/89) High-strength steel 26 NiCrMo 14 6 for screws, bolts and nuts; material no. 1.6958

VdTUEVMaterial Sheet 395/3 (03/95) Weldable, rolled and forged martensic steel X 5 CrNi 13 4, material no. 1.4313

VdTUEVMaterial Sheet 401/1 (05/83) High-temperature quenched and tempered steel 20 MnMoNi 5 5, material no. 1.6310; Product

form: sheets and plates (pages 9, 10, 13, and 14 replaced by new version 03/84; pages 5 and 16replaced by new version 09/84)


form: seamless extruded pipes (pages 11 and 12 replaced by new version 05/84)


form: forgings and bar steel, forged or forged and rolled (pages 13 and 14 replaced by new ver-sion 03/84)

VdTUEVMaterial Sheet 439 (09/84) Quenched and tempered fine-grained structural steel, clad plated with Nb stabilized austenitic

steel

VdTUEVMaterial Sheet 451 (09/82) Austenitic forged steel X 6 CrNiTi 18 10 S (1.4541 S), X 6 CrNiNb 18 10 S (1.4550 S),

X 6 CrNiMoTi 17 12 2 S (1.4571 S)

VdTUEVMaterial Sheet 474 (12/84) Austentic rolled and forged steel X 2 NiCrAlTi 32 20 with strain hardening; material no. 1.4558

Recommendation (09/86) Caracterisation d’etats de surface des pieces moulees; utilisation des échantillons types deTechnique Nr. 359-01 110 x 160 mmdu Bureau de Nor-malisation desIndustries de laFonderie

ASTM E 280 „Reference Radiographs for Heavy Walled (4 1/2 to 12 in) Steel Castings“ 91.

Literature

[1] Handbuch für das Loseblattsammlung; Verlag Stahleisen, DüsseldorfEisenhüttenlaboratorium

[2] Petzow, G. Metallkundliche technische Reihe; Metallographisches Ätzen, 6. Auflage; Berlin, Stuttgart,Borntraeger, 1994

[3] Reference-Atlas for a comparative evaluation of ferrite percentage in the fused zone of austeni-tic stainless steel welded joints; Internationales Institut für Schweißtechnik: Istituto Italianodella Saldatura, Genova, 1972

[4] De Long, W. T. Welding Research Supplement 53 (1974), S. 273/286

[5] Richter, F. Physikalische Eigenschaften von Stählen und ihre Temperaturabhängigkeit,Stahleisen-Sonderberichte Heft 10, 1983, Verlag Stahleisen, Düsseldorf.

KTA 3201.1

Annex G (informative)

Changes with respect to the edition 6/90 and explanations

(1) Section 2.4, clause 2 was changed to comply with DIN51 220 (1/96) by adhering to the requirements.

(2) The procedural requirements for ultrasonic testing inclause 3.3.8.2.1 were supplemented by requirements for cali-bration and sound beam entry directions.

(3) Requirements for sound attenuation measurementsregarding angle-beam scanning were added to clauses 5.4.2.1,6.4.2.1, 12.4.2.1, and 29.4.3.2.1.

(4) The scope of section 21 was extended to cover extensionsleeves. The restriction regarding dimensions ≥ M 27 in thetitle was contradictory to the text and was deleted.

(5) For high-temperature (operating temperature ≥ 200 °C)reactor water containing pipework and components of boilingwater reactors to be manufactured anew the steel grade X 6CrNiNb 18 10 S shall only be used with a restricted chemicalcomposition compared to the standard composition. Respec-tive requirements have been incorporated in sections 22.1,23.1 and 24.1 as well as in Section A 3, Table A 3-1.

Particularly, the following changes were made:

a) for the steel grades contained in Table A 3-1 the allowablesulphur content was decreased to a maximum of 0.015%(improvement of the degree of purity, adaptation to DIN17 400, edition 9/96),

b) for the steel grade X 6 CrNiNb 18 10 S the minimum Nbcontent was increased to 10 x (% C) (improvement of theresistance to intergranular stress corrosion cracking(IGSCC), adaptation to DIN 17 440, edition 9/96),

c) for the modified steel grade to Table A 3-1, footnote 4:

- the allowable carbon content was reduced to a maxi-mum of 0.03% (improvement of the resistance toIGSCC),

- the allowable contents of phosphorus and sulphur werereduced to a maximum of 0.025% and 0.010%, respec-tively (improvement of the degree of purity, reductionof susceptibility, if any, to IGSCC),

- the allowable silicon content was reduced to a maxi-mum of 0.5 % (obtained during the steel making processwhen a phosphorus content below 0.025% is obtained),

- the chronicum content is restricted to18.0 ≤ (% Cr) ≤ 19.0

(decrease of susceptibility to sensitization),

- no limit value, were given for boron and nitrogen; how-ever, the contents determined by means of the ladleanalysis shall be indicated in the material test certificateso that significant changes, if any, and their effects canbe found out immediately.

The restriction of the steel grades used for the manufacture ofnew high-temperature (operating temperature ≥ 200°C) reac-tor water containing pipework and components of boiling

water reactors had become necessary when it was realizedafter examinations on boiling water reactor pipework thatstabilized stainless austenitic steels, under certain conditions,can also be susceptible to IGSCC.

The examination results obtained up to now justify the as-sumption that at fluid temperatures below 200°C within theplanned service life of boiling water reactors no susceptibilityto IGSCC is to be expected for the modified steel gradeX 6 CrNiNb 18 10 S under the conditions prevailing in suchreactors. Upon completion of the examinations still beingperformed the fixed limit temperature value will have to bechecked anew.

The phosphorus and sulphur contents of the modified steelgrade X 6 CrNiNb 18 10 S has been limited since at the currentstate of knowledge it cannot be excluded that phosphorus andsulphur segregation may possibly increase the susceptibilityto IGSCC only synergistically.

(6) The delta ferrite content of product forms made of aus-tenitic steels after welding may be determined either by calcu-lation in accordance with Annex D, Section D 5 or by a bead-on-plate test. Where the latter is performed than the bead-on-plate test specimen shall also be examined for hot cracking bymeans of liquid penetrant testing. The respective requirementhas been incorporated with the same wording in clauses22.3.2.4, 23.3.2.6 and 24.3.3.2.1.7.

(7) The requirements for ultrasonic testing of product formsmade of austenitic steels in sections 22, 23 and 24 have beenextended to comply with the current state of knowledge. Forweld edges and nozzle areas test conditions and acceptancecriteria have been laid down which are compatible with therequirements valid for welded joints to KTA 3201.3. In thisconnection, the depth of the reference reflector used in theultrasonic testing of weld edges and nozzle areas was adaptedto the reference reflector depths used in the examination ofwelded joints to KTA 3201.3 (clauses 22.4.2.3.2 and 22.4.2.4) inwhich case a higher sensibility for defect detection is ensuredthan required by KTA 3201.3.

(8) In Table A 12.1 the range of allowable dimensions of thesteel grade 21 CrMoV 5 7 was restricted to ≤ 100 mm. Therequired individual impact energy value was increased from50 to 52 J for this type of steel to comply with the require-ments of KTA 3211.1.

(9) Annex B - Performance of manual ultrasonic examina-tions - was supplemented by sections B 6 „Creeping wavemethod“ and B 7 „Wave mode conversion method“.

(10) Annex D - Determination of the delta ferrite content -has been changed at several locations. In Section D 3 - (bead-on-plate test specimen) the quantitative micrograph evalua-tion has been admitted in addition to the structural examina-tions used up to now.