en13445 part 6

EUROPEAN STANDARD

NORME EUROPÉENNE

EUROPÄISCHE NORM

FINAL DRAFTprEN 13445-6

March 2002

ICS 23.020.30

English version

Unfired pressure vessels - Part 6: Requirements for the designand fabrication of pressure vessels and pressure parts

constructed from spheroidal graphite cast iron

Récipients sous pression non soumis à la flamme - Partie6: Exigences pour la conception et la fabrication desrécipients sous pression et des parties sous pression

moulés en fonte à graphite sphéroïdal

Unbefeuerte Druckbehälter - Teil 6:Sicherheitseinrichtungen

This draft European Standard is submitted to CEN members for formal vote. It has been drawn up by the Technical Committee CEN/TC 54.

If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations whichstipulate the conditions for giving this European Standard the status of a national standard without any alteration.

This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other languagemade by translation under the responsibility of a CEN member into its own language and notified to the Management Centre has the samestatus as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.

Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice andshall not be referred to as a European Standard.

EUROPEAN COMMITTEE FOR STANDARDIZATIONC OM ITÉ EUR OP ÉEN DE NOR M ALIS AT IONEUROPÄISCHES KOMITEE FÜR NORMUNG

Management Centre: rue de Stassart, 36 B-1050 Brussels

© 2002 CEN All rights of exploitation in any form and by any means reservedworldwide for CEN national Members.

Ref. No. prEN 13445-6:2002 E

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Contents

Foreword....................................................................................................................... ...............................................4

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

2 Normative references .......................................................................................................... ..........................5

3 Terms, definitions, units and symbols ......................................................................................... ...............63.1 Terms and definitions....................................................................................................... .............................63.2 Units ....................................................................................................................... .........................................73.3 Symbols ..................................................................................................................... .....................................73.4 Inter-relation of thicknesses definitions................................................................................... ...................9

4 Service conditions ............................................................................................................ .............................94.1 Cyclic loading.............................................................................................................. ...................................94.2 Limitations on temperature and energy content ............................................................................... .......10

5 Requirements .................................................................................................................. .............................105.1 Materials................................................................................................................... .....................................105.2 Design ...................................................................................................................... .....................................115.2.1 Technical documentation................................................................................................... .........................115.2.2 Design methods ............................................................................................................ ...............................115.2.3 Design by the experimental method: hydraulic burst test ................................................................... ...135.2.4 Fillet radius ............................................................................................................. ......................................155.3 Founding.................................................................................................................... ...................................155.3.1 General................................................................................................................... .......................................155.3.2 Welding ................................................................................................................... ......................................16

6 Inspection and testing of castings............................................................................................ .................166.1 Production test of castings for acceptance ................................................................................. ............166.2 Production castings ......................................................................................................... ...........................166.2.1 General................................................................................................................... .......................................166.2.2 Frequency and number of materials acceptance tests........................................................................ ....176.2.3 Graphite structure........................................................................................................ ................................176.2.4 Documentation............................................................................................................. ................................17

7 Testing and final assessment.................................................................................................. ...................177.1 Testing ..................................................................................................................... .....................................177.1.1 General................................................................................................................... .......................................177.1.2 Testing requirements for CQ = 0,8..............................................................................................................177.1.3 Testing requirements for CQ = 0,9..............................................................................................................187.1.4 Surface imperfections ..................................................................................................... ............................197.1.5 Cracks and non-fused chaplets............................................................................................. .....................197.1.6 Ultrasonic testing and/or sectioning ...................................................................................... ...................197.1.7 Magnetic particle testing................................................................................................. ............................197.1.8 Penetrant testing......................................................................................................... .................................197.1.9 Radiographic testing ...................................................................................................... .............................207.1.10 Surface roughness ........................................................................................................ ..............................207.1.11 Minimum wall thickness................................................................................................... ...........................207.1.12 Wall thickness tolerances ................................................................................................ ...........................207.1.13 Other dimensions ......................................................................................................... ...............................207.1.14 Qualification of testing personnel....................................................................................... .......................207.2 Final assessment ............................................................................................................ .............................217.2.1 General................................................................................................................... .......................................217.2.2 Hydraulic test pressure ................................................................................................... ............................21

8 Pressure vessels constructed of a combination of parts in different materials ...................................21

9 Marking and documentation ..................................................................................................... ..................219.1 Marking of castings ......................................................................................................... ............................21

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9.2 Name plate for the complete pressure vessel ................................................................................. .........229.3 Documentation............................................................................................................... ..............................22

Annex A (normative) Requirements on tensile strength, proof stress, elongation and impactresistance values .............................................................................................................. ...........................23

A.1 Purpose..................................................................................................................... ....................................23A.2 Requirements ................................................................................................................ ...............................23A.2.1 Test pieces machined from separately cast samples......................................................................... .....23A.2.2 Test pieces machined from cast-on samples ................................................................................. ..........24A.2.3 Hardness.................................................................................................................. .....................................26A.3 Test methods................................................................................................................ ................................27A.3.1 Tensile test .............................................................................................................. .....................................27A.3.2 Impact test ............................................................................................................... .....................................27A.3.3 Hardness test ............................................................................................................. ..................................27

Annex B (informative) Ductility ..................................................................................................................... ...........28

Annex C (informative) Determination of the minimum local wall thickness and minimum required bursttest pressure .................................................................................................................. ..............................30

Annex ZA (informative) Clauses of this European Standard addressing essential requirements or otherprovisions of EU Directives. ................................................................................................... ....................31

Bibliography .....................................................................................................................................................32

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Foreword

This European Standard has been prepared by Technical Committee CEN /TC 54, "Unfired pressure vessels", theSecretariat of which is held by BSI.

This document is currently submitted to the Formal Vote.

This European Standard has been prepared under a mandate given to CEN by the European Commission and theEuropean Free Trade Association, and supports essential requirements of EU Directive 97/23/EC.

For relationship with EU Directive(s), see informative annex ZA, which is an integral part of this EuropeanStandard.

In this standard the Annex A is normative and the Annexes B and C are informative.

This European Standard consists of the following Parts:

Part 1: General

Part 2: Materials

Part 3: Design

Part 4: Fabrication

Part 5: Testing and Inspection

Part 6: Requirements for the design and fabrication of pressure vessels and pressure parts constructed fromspheroidal graphite cast iron

prCR 13445-7, Unfired pressure vessels - Part 7: Guidance on the use of conformity assessment procedures

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1 Scope

This European Standard specifies requirements for the design, materials, manufacturing and testing of pressurevessels and pressure vessel parts intended for use with a maximum allowable pressure, PS, equal or less 50 barand shell wall thicknesses not exceeding 60 mm, that are constructed of spheroidal graphite cast iron.

NOTE The grades of spheroidal graphite cast iron allowed are listed in Tables 5.1-1 and 5.1-2. Service conditions aregiven in clause 4.

2 Normative references

This European Standard incorporates, by dated or undated reference, provisions from other publications. Thesenormative references are cited at the appropriate places in the text and the publications are listed hereafter. Fordated references, subsequent amendments to or revisions of any of these publications apply to this Europeanstandard only when incorporated in it by amendment or revision. For undated references the latest edition of thepublication referred to applies (including amendments).

prEN 764-2, Pressure equipment — Part 2: Quantities, symbols and units

prEN 764-5, Pressure equipment — Part 5: Compliance and inspection documentation of materials

prEN 764-7 , Pressure Equipment — Part 7: Safety systems for unfired pressure equipment

EN 837-1, Pressure gauges — Part 1: Bourdon tube pressure gauges — Dimensions, metrology, requirements andtesting

EN 837-3, Pressure gauges — Part 3: Diaphragm and capsule pressure gauges — Dimensions, metrology,requirements and testing .

EN 1369, Founding — Magnetic particle inspection

EN 1370, Founding — Surface roughness inspection by visual tactile comparators

EN 1371-1, Founding — Liquid penetrant inspection — Part 1: Sand, gravity die and low pressure die castings

EN 1559-1, Founding — Technical conditions of delivery — Part 1: General

EN 1559-3, Founding —Technical conditions of delivery — Part 3: Additional requirements for iron castings

EN 1563, Founding — Spheroidal graphite cast irons

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EN 10204, Metallic products — Types of inspection documents

EN 12680-3, Founding — Ultrasonic inspection — Part 3: Spheroidal graphite cast iron castings

EN 12681, Founding — Radiographic inspection

EN 13068-1 Non-destructive testing – Radiographic testing - Part 1: Quantitative measurement of imagingproperties

EN 13068- 2 Non-destructive testing – Radiographic testing - Part 2: Check of long term stability of imaging devices

EN 13445-1, Unfired pressure vessels — Part 1 : General

EN 13445-2, Unfired pressure vessels — Part 2 : Materials

EN 13445-3, Unfired pressure vessels — Part 3 : Design

EN 13445-5, Unfired pressure vessels — Part 5 : Inspection and testing

EN 20945, Cast iron — Designation of microstructure of graphite (ISO 945:1975)

ISO 8062: Castings — System of dimensional tolerances and machining allowances

3 Terms, definitions, units and symbols

3.1 Terms and definitions

For the purposes of this European Standard, the following terms and definitions apply.

3.1.1critical zonehighly stressed area where a fracture is expected to occur in a burst test

NOTE 1 It can be caused, for example, by any of the following:

— sudden change in cross section;

— sharp edges;

— sharp radii;

— peak stresses;

— bending stresses;

— stresses due to other than membrane stress;

— changes in curvature.

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NOTE 2 A critical zone is analysed by any appropriate method, e.g. holographic, interferometric method, strain gaugemethods, burst test, fatigue testing, FEM analysis, etc.

NOTE 3 Additionally, thermal gradients and thermal stresses due to different operating wall temperatures are to beconsidered in defining critical zones.

3.1.2purchaserindividual or organisation that buys pressure equipment, including assemblies or parts, for its own use or on behalfof the user and/or operator

3.1.3manufacturerindividual or organisation responsible for the design, fabrication, testing, inspection, installation of pressureequipment and assemblies where relevant

NOTE 1 The manufacturer may subcontract one or more of the above mentioned tasks under its responsibility.

NOTE 2 In EU member states the manufacturer is responsible for compliance with the Pressure Equipment Directive97/23/EC. For those manufacturers outside of the EU their authorized representative inside the EU assumes this responsibility.

3.1.4casting manufacturersubcontractor that produces the castings used in the manufacture of pressure equipment.

3.1.5testing factorA reduction factor applied to the nominal design stress to take account of possible manufacturing deficiencies.

3.1.6temperature factorA reduction factor applied to the 0,2% proof stress to take account of temperature influence.

3.1.7wall thickness factora reduction factor applied to the nominal design stress to take account of reduced mechanical properties .

3.2 Units

For the purposes of this European Standard, the units given in EN 764-2 apply.

3.3 Symbols

Symbols used in this European Standard are listed in Table 3.3-1.

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Table 3.3-1 - Symbols

Symbol Quantity Unit

c corrosion allowance mm

e required thickness mm

ea analysis thickness (without corrosion allowance) mm

emin minimum thickness including corrosion allowance asspecified on drawing

mm

f nominal design stress MPa or N/mm²

Pd design pressure MPa, N/mm2

PS maximum allowable pressure bar, MPa, N/mm2

Rm minimum tensile strength N/mm2 , MPa

Rp0,2 minimum 0,2% - proof stress N/mm² , MPa

V internal volume l

TS Maximum / minimum allowable temperature °C

Ce wall thickness factor dimensionless

Ct temperature factor dimensionless

CQ testing factor dimensionless

eact actual thickness mm

Pb,act Actual burst test pressure MPa,N/mm²

n factor depending on shape of shell dimensionless

Pb bursting test pressure bar, MPa, N/mm2

Rm(3) average tensile strength of 3 test bars taken from thesame cast

N/mm² , MPa

� extra thickness due to casting process mm

� casting tolerance mm

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3.4 Inter-relation of thicknesses definitions

Key

e is the required thickness

ea is the analysis thickness

emin is the minimum thickness including corrosion allowance as indicated on drawings

eact is the actual thickness

c is the corrosion allowance

� is the extra thickness due to casting process

� is the casting tolerance

Figure 3.4-1 - Inter-relation of thicknesses definitions

4 Service conditions

4.1 Cyclic loading

Spheroidal graphite cast iron pressure vessels and vessel parts can be used for non-cyclic or cyclic operation. Ifthe service conditions require more than 200 000 full pressure cycles or equivalent number of cycles with smalleramplitude, then a fatigue analysis shall be performed (see NOTE).

For pressure cycles at a pressure •Pi less than the full pressure, the number of equivalent full cycles neq is given

by equation (4.1-1):

8,62

max

iieq �

�

�

�

��

�

� ��

.P

P n n (4.1-1)

NOTE An annex for fatigue assessment of pressure vessels and vessel parts made of spheroidal graphite cast iron isunder preparation by CEN/TC 54 and will be released as an amendment to this standard.

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4.2 Limitations on temperature and energy content

The minimum and maximum allowable temperature TS shall be in accordance with the limits given in Tables 5.1-1and 5.1-2. The maximum allowable temperature TS shall not exceed 300 °C.

The product PS · V for a single casting shall not exceed 1 000 MPa·l (10 000 bar·l).

5 Requirements

5.1 Materials

All spheroidal graphite cast iron materials subject to internal or external pressure shall comply with EN 1563. Onlythose grades listed in Table 5.1-1 shall be used for applications where the minimum allowable temperature ishigher or equal to – 10 C and those in Table 5.1-2 shall be used for applications where the minimum allowabletemperature is lower than – 10 C.

Material properties are specified in Annex A.

Design temperatures down to – 60 C can be used, provided that impact testing at the minimum allowabletemperature is carried out and the results meets the requirements for EN-GJS-350-22-LT or EN-GJS-350-22U-LTgiven in Annex A.

The applicable requirements for the delivery conditions are given in EN 1559-1 and EN 1559-3 shall also apply.

NOTE The materials EN-JS 1020, EN-JS 1024, EN-JS 1025, EN-JS 1049, EN-JS 1059 and EN-JS 1062 may be produced inthe as-cast or heat treated condition .For materials EN-JS 1010 , EN-JS 1014, EN-JS 1015 , EN-JS 1019 , EN-JS 1029 andEN-JS 1032 a ferritizing heat treatment shall be applied.

Table 5.1-1 — Allowable material grades for normal design temperature

Symbol Number Design temperature limits

°C

EN-GJS-350-22 EN-JS 1010 -10 TS 300

EN-GJS-350-22-RT EN-JS 1014 -10 TS 300

EN-GJS-350-22 U a EN-JS 1032 -10 TS 300

EN-GJS-350-22U-RT a EN-JS 1029 -10 TS 300

EN-GJS-400-18 EN-JS 1020 -10 TS 300

EN-GJS-400-18-RT EN-JS 1024 -10 TS 300

EN-GJS-400-18U a EN-JS 1062 -10 TS 300

EN-GJS-400-18U-RT a EN-JS 1059 -10 TS 300a Mechanical properties verified on test pieces from cast - on samples. These grades should be chosenin preference to the material grades with the separately cast samples when the unit mass of the castingis equal to or greater than 2 000 kg or when the relevant wall thickness varies between 30 mm and200 mm.

.

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Table 5.1-2 — Allowable material grades for low temperature (LT) design conditions

Symbol Number Design temperature limits

°C

EN-GJS-350-22-LT EN-JS 1015 -40 TS 300

EN-GJS-350-22U-LT a EN-JS 1019 -40 TS 300

EN-GJS-400-18-LT EN-JS 1025 -20 TS 300

EN-GJS-400-18U-LT a EN-JS 1049 -20 TS 300a Mechanical properties verified on test pieces from cast - on samples. These grades should be chosenin preference to the material grades with the separately cast samples when the unit mass of the castingis equal to or greater than 2 000 kg or when the relevant wall thickness varies between 30 mm and200 mm.

NOTE When materials specified in these tables are not available other suitable materials may be used when the technicaldocumentation defining the characteristics of the materials has been accepted in accordance with the requirements forEuropean approval for materials (EAM ) or particular material approval (PMA)

5.2 Design

5.2.1 Technical documentation

The manufacturer shall document those items listed in clause 5 of EN 13445-5:2002 prior to manufacturecommencing.

The manufacturer shall state which vessels are covered by the same design documentation.

5.2.2 Design methods

5.2.2.1 General

The loadings to be accounted for shall be in accordance with EN 13445-3:2002, clause 5.

Design methods shall be in accordance with EN 13445-3, design by formulae according to the relevant clauses, ordesign by analysis according to Annex C. If design by experimental method is used, it shall be in conformity with5.2.4 of this standard. However, nominal design stresses for materials used according to this part for pressure partsother than bolts shall be calculated in accordance with Table 5.2-1.

In general, the manufacturer shall define to the casting manufacturer which zones are critical related to the designand design loads. Other critical zones may be indicated by the casting manufacturer related to the casting processand should be taken into account by the manufacturer.

The manufacturer has the option to choose a testing factor CQ = 0,8 for visual inspection only, or to use CQ = 0,9with additional non destructive testing implied. This can result in smaller required wall thicknesses as is required forvisual inspection only. This option has to be determined from the start of the design.

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NOTE 1 For vessels for which Pd ·V � 600 MPa· l ( 6000 bar · l ) an experimental method as described in detail in 5.2.3hereafter may be solely applied instead.

NOTE 2 For vessels for which Pd ·V � 600 MPa· l the experimental method may be used in addition to detailed design.

NOTE 3 Testing factors 0,8 and 0,9 are comparable with joint efficiency factors 0,7 and 0,85 for welded constructions thatthey reduce the nominal design stress taking into account the amount of non destructive testing. Divided by the safety factor of 3for RP0.2T (see Table 5.2-1 below ) it gives overall lower design stress values as for steel with a comparable yield stress .

NOTE 4 An annex for fatigue assessment of pressure vessels and vessel parts made of spheroidal graphite cast iron isunder preparation by CEN TC 54 and will be released as an amendment to this standard

5.2.2.2 Design conditions

Table 5.2-1 — Design stress

Design conditions Testing conditions

3eQp0,2/ CCR

f T � (5.2-1)

33,1e/p0,2

testtest

CRf T

� (5.2-2)

where

0,2% proof stress at calculation temperature:

p0,2p0,2 RCR TT �/ (5.2-3)

and temperature reduction factor [2] :

1T �C for Tc 20°C (5.2-4)

)(, 2000101 �� cT TC for 20 < Tc 200°C (5.2-5)

82,0T �C for 200 < Tc 300°C (5.2-6)

Testing factors are as given by 7.1:

CQ = 0,8 see 7.1.2 (5.2-7)

CQ = 0,9 see 7.1.3 (5.2-8)

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Wall thickness reduction factor:

Ce = 1 for emin 60 mm (5.2-9)

Ce = 0,8 for 60 mm < emin 200 mm (5.2-10)

NOTE These requirements represent a safety factor at design conditions of 3,3 to 3,75 against 0,2% proof stress at designtemperature, taking into account lack of homogeneity, residual stresses and thickness effects on properties of spheroidalgraphite cast iron. The wall thickness reduction factor Ce = 0,8 is mainly to be applied to only visual inspected parts and otherthan shell thicknesses (i.e. thick cast flange designs) with cross-section thickness exceeding 60 mm (other than the main shell)due to lower 0,2% proof stress values for thick sections.

5.2.2.3 Testing conditions

The test pressure may exceed the value given in equation 7.2-2 either intentionally or occasionally. However, the

nominal design stress for testing conditions, ftest shall not exceed the 0,2 % proof stress test/p0,2 TR corrected with the

factor Ce at test temperature divided by the safety factor 1,33.

331,/ ep0,2

testtest

CRf T

�(5.2-11)

5.2.2.4 Reinforcement of openings in cylinders, flat ends, dished ends, cones, etc.

Reinforcement of openings in cylinders, flat ends, dished ends, cones, etc. shall be determined in accordance withEN 13445-3. When reinforcement is calculated with the area replacing method , the reinforcing length along thevessel wall considered shall be 2emin to calculate the additional reinforcing area .

5.2.2.5 Design for external pressure

Design for external pressure shall be carried out according to EN 13445-3:2002, clause 8, where :

eQp0,2/T CCRS �(5.2-12)

The minimum safety factor, which applies throughout this clause, is given by

k = 3,5 (5.2-13)

5.2.3 Design by the experimental method: hydraulic burst test

Where design by formulae to EN 13445-3 is not considered reliable due to complex shape, then a hydraulic bursttest to determine the analysis thickness ea and the minimum thickness emin shall be performed according thefollowing procedure. This burst test is also a part of the technical documentation.

A random sample from the production of the vessel or vessel part shall be taken for either the burst test or todetermine the maximum allowable working conditions. The procedure shall be as follows.

a) Verify that the part or vessel to be tested is cast according the specified drawing and any revision thereof. Thematerial used shall be the same type and grade as for the production part;

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b) Verify that the part or vessel is machined to the same dimensions as the production part;

c) Verify that the material properties meet the requirements of 5.1. For each casting for the burst test, 3 testpieces for tensile testing, and if applicable for impact testing, shall be poured and tested. The results and thecalculated average tensile strength shall be certified according to EN 10204, certificate type 3.1;

d) The wall thicknesses of the whole casting shall be measured (at least one measurement per 100 mm x 100mm) The results shall be written (permanent marker) on the casting at the location of the measurement or onthe drawing;

e) Verify that a calibrated pressure gauge is used; maximum tolerance shall conform to at least class 1 or betteraccording to EN 837-1 and EN 837-3;

f) The scale of the pressure gauge shall be approximately 4/3 of the anticipated burst pressure;

g) The hydraulic pressure shall be increased until the following minimum burst pressure is obtained:

� � �

�

�

�

��

�

�

�

n acteTQp0,2

nm(3)

b-

3

ceCCCR

eRPSP act

(5.2-14)

The part under investigation shall not show any sign of cracks, excessive local plastic deformation or leak onthe pressure bearing wall(s) when the minimum burst pressure Pb is reached;

h) The pressure shall be further raised until rupture occurs and this pressure recorded, together with the burst testdate, details of material, part number, material specification and measured wall thickness eact at the location ofburst to determine the analysis thickness ea and the minimum thickness emin according to equations 5.2-9 and5.2-10;

i) If rupture does not occur at a pressure higher than the minimum required Pb, or where the maximum pressurefor the pump (which shall also be higher than the required Pb) is reached, the burst test can be stopped. Theminimum measured values (see d) for each section of the vessel or vessel part shall be taken as eact, todetermine the analysis thickness ea and the minimum thickness emin according to equations 5.2-15 and 5.2-16.The reference area for the thickness measurement may also be determined on an identical part which is testedby using any of the following methods:

1) strain gauge measurement;

2) holographic interferometric method;

n

etQp

mact CCCRP

RPSee

/

,

)(

1

20

33��

�

�

��

�

�

�

actb,a (5.2-15)

cee a ��min (5.2-16)

where

Rp0,2 is in accordance with Annex A;

Pb,act is the actual reached value of burst pressure at the test;

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n = 1 for curved surfaces (cylinders, spheres) or cones with angles � 60°, stayed surfaces and stressedparts when it can be shown that the bending stress is less than 2/3 of the total stress;

n = 2 for all other surfaces except when it can be shown that the bending stress < 2/3 of the total stress;

j) Upon request a material sample will be taken from the weakest spot of the cast part and the chemical analysis,thickness measurement, microstructure and hardness determined;

k) A part is acceptable if all of the above requirements have been met;

l) If a part fails to meet any of those requirements, a second identical production part may undergo the same testprocedure. If this second part meets the test requirement, this part may be acceptable after investigation of thecause of failure of the first part. If this second identical part does not meet the test requirement, the design ofthe part is concluded not to meet the specification;

m) It is acceptable, during the burst test, for leaks and lack of tightness to occur between flanged, gasketted orbolted parts as long as the pressure Pb can be reached during test. It is acceptable for gasket(s) to breakduring the burst test or for the gasket characteristics to be modified without unduly changing flange loadproperties as long as they can be satisfactory designed according to the design rules of EN 13445-3 for theanticipated maximum allowable pressure PS;

n) It is acceptable, solely for the test, for bolting of a higher grade than that required by the design specification tobe used;

o) When flanged connections are designed according the requirements of EN 13445-3 with respect to minimumrequired thickness, minimum required bolt area and shape, it is acceptable, in order to reach burst testpressure, to install extra bolts in addition to the number specified for production;

p) The burst test or any hydraulic test shall not be performed by means of a clamped construction on a hydraulicpress that can counteract the shell bending stress resulting in no free movement of the wall under pressure.

5.2.4 Fillet radius

The largest possible fillet radius shall be used to walls under internal or external pressure in accordance with goodfoundry practice.

If it is not possible to avoid sudden changes in cross-section area, and the pressure bearing wall is subject to cyclicloading, a taper of maximum ratio 1:3 from the thin wall to the thick wall shall be included.

All radii applied to a vessel part, including external cast lugs, support feet, etc. shall be � than 1,5 times thethickness of the thinnest adjacent wall.

5.3 Founding

5.3.1 General

The castings shall be free from surface and internal defects that might impair their usability. No excessive residualstress shall be permitted to build up in the casting that could impair the fracture behaviour or the fatigue life of thecasting. This can be achieved by allowing the casting sufficiently long cooling periods in the mould followed bycooling in still air. The casting manufacturer shall document this cooling procedure (required cooling time) in aprocess or work instruction. If this procedure to avoid excessive residual stresses cannot be complied with, a stressrelieving heat treatment shall be carried out, based on agreement between the parties concerned.

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5.3.2 Welding

No production or repair welding shall be carried out on spheroidal graphite cast iron parts.

6 Inspection and testing of castings

6.1 Production test of castings for acceptance

Production tests shall be carried out on at least one casting and corresponding test piece taken from currentproduction.

For each casting for production tests, the casting manufacturer shall provide the following information:

a) chemical analysis of ladle samples, comprising the elements: C, Si, Mn, P, S and Mg;

b) where applicable, details of heat treatment;

c) applicable specification.

The dimensions of separately cast test pieces, dimensions of test specimens, mechanical testing procedures andapproval values/criteria shall be in accordance with the requirements of Annex A.

The following tests shall be performed:

a) tensile test (0,2 % proof stress, tensile strength and elongation at rupture at room temperature);

b) hardness test;

c) impact tests, when required according the material specification, see Annex A;

d) photomicrograph (x100), etched.

The following tests and examinations shall be carried out on each casting submitted for production tests:

a) Visual examination in the dressed and, where applicable, machined condition according to 7.1.4 and ultrasonicinspection and/or sectioning to 7.1.6 shall be carried out;

b) Hardness tests are to be carried out at various positions on the castings and the value of the hardness shall bewithin the limits according to Annex A;

c) If required, a hydraulic pressure test according to 7.2.2. shall be carried out;

d) A full dimensional examination.

6.2 Production castings

6.2.1 General

All material tests shall be performed according to Annex A.

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6.2.2 Frequency and number of materials acceptance tests

For each batch the amount of testing shall be, on each ladle treated for spheroidization:

— chemical analysis either by a spectrometrical or a chemical method shall be determined by the castingmanufacturer ;

— one tensile test;

— one hardness test;

— impact test, when required by material specification ( consisting of 3 test pieces ).

If the spheroidizing treatment is carried out in the mould, the same amount of testing for each 2 500 kg cast weightof identical parts produced during the same day shall be carried out.

The amount of impact testing can be reduced to 1 test on the ladle with the highest silicon content per day, for inseries production, using grades RT according to Table 5.1-1.

The test pieces, cast separately or cast – on shall be according to EN 1563. Test sample size is dependent on thewall thickness of the part (see EN 1563 for size determination).

NOTE Cast-on test pieces are representative of the castings to which they are attached and their size depends on therelevant wall thickness of the casting.

6.2.3 Graphite structure

Material shall be supplied with a graphite form V and VI in accordance with EN ISO 945. This verification ofnodularity shall preferably be carried out either by microscopic examination or by an ultrasonic method. Both handor computerised and/or automated methods are allowed.

When the ultrasonic method is used, the ultrasonic velocity shall be a minimum of 5 460 m/s using a calibratedmeasuring device. If the velocity is less than 5 460 m/s, the nodularity may still be verified and approved using themicroscopic method on the worst test specimen. If the spheroidisation is found acceptable, the material isapproved. When ultrasonic examination is used, the verification shall be carried out on the last cast metal of eachladle.

6.2.4 Documentation

Documentation shall be in accordance with EN 764-5.

7 Testing and final assessment

7.1 Testing

7.1.1 General

Testing of cast vessels and vessel parts, manufactured according to this part, shall be in accordance with Table7.1-1 and EN 13445-5, where applicable.

7.1.2 Testing requirements for CQ = 0,8

Testing shall be carried out in accordance with the requirements and adopting the acceptance criteria given inTable 7.1-1

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7.1.3 Testing requirements for CQ = 0,9

— At non critical zones: testing as for CQ = 0,8 as given in 7.1.2;

— At critical zones: all castings shall be subjected to a magnetic particle inspection of all critical zones asindicated on the drawing, without revealing any unacceptable imperfection.

The last casting representing a batch of castings made from the same heat or during the same day shall besubjected to a radiographic examination or equivalent (see footnote b in Table 7.1-1) of a zone indicated on thedrawing, without revealing any unacceptable defects.

For summary, see Table 7.1-1.

Table 7.1-1 — Summary of testing requirements for different testing factors

Testing factor

CQ = 0,8 CQ = 0,9

Location Non critical zone Critical zone

Surface defects

Requirement See 7.1.4

Cracks, laps, cold shut and non-fused chaplets are not permitted .

See 7.1.5

testing method Visual

testing frequency 100%

Defects close to the surface

requirement no requirement See 7.1.7

testing method - magnetic particle testing

testing frequency - 100%

Internal defects (micro and macro porosity)

requirement See 7.1.6

(EN 12680-3, severity level 3)

See 7.1.9

testing method Ultrasonic testing/sectioning Radiographic testing b

testing frequency Initial samples

Random sampling production series a

Initial samples

Last casting of each batch

a According to agreement between the parties concerned.

b Ultrasonic testing of castings may substitute radiographic testing following an agreement betweenthe parties concerned.

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7.1.4 Surface imperfections

Sand inclusions, slag inclusions and blowholes shall be limited as follows.

CQ = 0,8 and CQ =0,9 non critical zone:

A maximum of five defects in a square 100 mm x 100 mm facing inwards or outwards shall be accepted. None ofthese shall cover an area larger than 100 mm² and the total area of the defects shall not exceed 200 mm².

The maximum permissible depth of a defect is such that the minimum wall thickness is maintained. Grinding ofsuch surface imperfections is permitted down to the minimum wall thickness indicated on the drawing.

CQ = 0,9 critical zone

No defects are permitted within the critical zone. Grinding of surface imperfections is permitted down to theminimum dimensions as indicated on the drawing, provided no stress concentration occurs.

7.1.5 Cracks and non-fused chaplets

No cracks or non-fused chaplets are permitted.

To detect these defects, liquid penetrant inspections according to EN 1371-1 can be necessary.

7.1.6 Ultrasonic testing and/or sectioning

The ultrasonic shall be carried out according to EN 12680-3.

If ultrasonic testing is not feasible, sectioning shall be carried out to visually detect internal imperfections.

Defects shall not be permitted on the main pressure bearing part (casting section with minimum required wallthickness specified on the drawing). However, micro shrinkage (centreline porosity) is permitted provided that allmechanical properties in the material standard are fulfilled.

NOTE Micro shrinkage is defined as pores 0,2 mm to 0,5 mm in diameter.

On other parts of the casting imperfections which are centrally located and not covering an area of 300 mm² shallbe permitted, provided the minimum distance of the defect from the surface is a minimum of 1/3 of the wallthickness or at least 3 mm. Imperfections are not permitted around drilled holes, or where holes are to be drilled,within an area with a diameter of two times the diameter and concentric with the hole. Only micro shrinkage on thecentreline is accepted (defined as having pores between 0,2 mm and 0,5 mm) provided that the requiredmechanical characteristics of the material standard are fulfilled.

7.1.7 Magnetic particle testing

The testing shall be carried out in accordance with EN 1369. The maximum severity level shall be equal to or betterthan SM 3 in Table 2 of EN 1369:1996 and LM4/AM4 in Table 4 of EN 1369:1996.

7.1.8 Penetrant testing

The testing shall be carried out in accordance with EN 1371-1. The maximum severity level shall be equal to orbetter than SP 02/CP 02 in Table 2 of EN 1371-1:1997 and LP 2/AP 2 in Table 3 of EN 1371-1:1997.

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7.1.9 Radiographic testing

The testing shall be carried out in accordance with EN 12681 on a film size at least 100 mm x 240 mm.

The following is not permitted at any size:

— mottling, inserts, cracks, hot tears;

— porosity > Type A Grade 5;

— sand inclusions > Type B Grade 5;

— shrinkage > Type C Grade 5.

7.1.10 Surface roughness

Casting roughness or surface finish shall be approved by the customer on a sample casting. Production castingsshall have a surface roughness comparable to the approved sample.

The casting surface roughness shall, when required, be tested and specified according to EN 1370 using visualtactile comparators, or as specified by the manufacturer.

7.1.11 Minimum wall thickness

Castings shall be measured on specified locations in order to verify that the required minimum wall thickness hasbeen reached.

Results shall be recorded in an appendix to the material certificate.

The measurement shall be made by ultrasonic or any mechanical measuring devices with an accuracy inaccordance with indicated design tolerances.

7.1.12 Wall thickness tolerances

The casting manufacturer shall determine, test and inspect on a regular basis the wall thickness tolerance.

The wall thickness tolerance shall be given in accordance with ISO 8062.

The casting tolerance grade to be applied depends on the casting process. The casting manufacturer shall proveits capability to meet the agreed tolerances.

7.1.13 Other dimensions

The casting manufacturer shall inspect on a regular basis the other dimensions.

The casting tolerance grade to be applied depends on the casting process. The tolerances shall be in accordancewith ISO 8062 unless otherwise agreed.

7.1.14 Qualification of testing personnel

The personnel carrying out testing shall be qualified as indicated in EN 13445-5.

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7.2 Final assessment

7.2.1 General

Final assessment shall be carried out according to EN 13445-5:2002, clause 10, except for the standard hydraulictest pressure.

7.2.2 Hydraulic test pressure

All pressure bearing parts shall be hydraulically tested with a test pressure, corrected for temperature, greater orequal to;

Qt

dt CC

PP

�

431,(7.2-1)

8 Pressure vessels constructed of a combination of parts in different materials

When spheroidal graphite cast iron parts are used in conjunction with other metallic parts fabricated by welding,forging, etc. to form a pressure vessel, the components made according to different fabrication techniques shallsatisfy design, inspection, test requirements of the relevant clauses of EN13445-5

The assembled vessel shall satisfy the requirements for hydraulic testing at the pressure which is the highest testpressure of the individual components of the assembly. It shall be checked that at the hydraulic test pressure nocomponent exceeds the allowable stress specified for that component.

9 Marking and documentation

9.1 Marking of castings

Pressure vessel castings and cast vessel parts, irrespective of the testing factor, shall be marked at least with thefollowing information, preferably in cast characters with a minimum height of 6 mm:

— casting manufacturer logo or identification;

— type or designation;

— material grade according to EN 1563;

— cast date, mould or batch number;

— testing factor if CQ = 0,9;

Cast characters, either standing proud, raised or embedded shall not cause any adverse effect on the strength,static and dynamic stability or local stress concentration of the pressure vessel or vessel parts. The cast markingdescribed above may be replaced by a coded system agreed between the parties concerned, and may also behard stamped. Full traceability of the part to material and test certificates shall be guaranteed.

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9.2 Name plate for the complete pressure vessel

The marking of the vessel shall be made according to EN 13445-5:2002, clause 11.

9.3 Documentation

The written declaration of compliance with the standard, records and other relevant documents shall be inaccordance with EN 13445-5.

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Annex A (normative)

Requirements on tensile strength, proof stress, elongation and impactresistance values

A.1 Purpose

This annex gives for the allowable material grades of spheroidal graphite cast iron for pressure vessels and vesselsparts the corresponding tensile strength, proof stress, elongation and impact resistance values requirements. Thematerial designation and corresponding requirements are in conformity with EN 1563.

A.2 Requirements

A.2.1 Test pieces machined from separately cast samples

A.2.1.1 General

The mechanical properties shall be as specified in Tables A.2.1-1 and A.2.1-2, and, if applicable, in accordancewith the requirements given in A.2.1.2.

A.2.1.2 Impact resistance

The particular impact resistance values given in Table A.2.1-2 for room and low temperature applications, shall onlybe determined if required by the selected material grade.

Table A.2.1-1 � Mechanical properties measured on test pieces machined from separately cast samples

Material Tensile strength 0,2% Proof stress ElongationRM RP0,2 AN/mm2 N/mm2 %

Symbol Number min. min. min.EN-GJS-350-22-LT a EN-JS1015 350 220 22EN-GJS-350-22-RT EN-JS1014 350 220 22EN-GJS-350-22 EN-JS1010 350 220 22EN-GJS-400-18-LT a EN-JS1025 400 240 18EN-GJS-400-18-RT EN-JS1024 400 250 18EN-GJS-400-18 EN-JS1020 400 250 18a LT for low temperaturesB RT for room temperature

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Table A.2.1-2 � Minimum impact values measured on V-notched test pieces machined from separatelycast samples

Minimum impact resistance values (in J)

Material designationAt room

temperature

(23 + 5) oCAt (-20 + 2) oC At (-40 + 2) oC

Symbol Number Meanvaluefrom 3tests

Individualvalue

Meanvaluefrom 3tests

Individualvalue


Individualvalue

EN-GJS-350-22-LT a EN-JS1015 � � � � 12 9

EN-GJS-350-22-RT b EN-JS1014 17 14 � � � �

EN-GJS-400-18-LT a EN-JS1025 � � 12 9 � �

EN-GJS-400-18-RT b EN-JS1024 14 11 � � � �

a LT for low temperatures

b RT for room temperature

A.2.2 Test pieces machined from cast-on samples

A.2.2.1 General

The mechanical properties shall be as specified in Tables A.2.2-1 and A.2.2-2, and, if applicable, in accordancewith the requirements given in A.2.2.2.

A.2.2.2 Impact resistance

The particular impact resistance values given in Table A.2.2-2 for room and low temperature applications, shall onlybe determined if required by the selected material grade.

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Table A.2.2-1 � Mechanical properties measured on test pieces machined from cast-on samples

Relevant wallthickness

Tensilestrength

0,2% Proofstress

Elongation

t RM RP0,2 A

Material designation

mm N/mm2 N/mm2 %

Symbol Number min. min. min.

EN-GJS-350-22U-LT a EN-JS1015 t 30

30 � t 60

60 � t 200

350

330

320

220

210

200

22

18

15

EN-GJS-350-22U-RT b EN-JS1014 t 30

30 � t 60

60 � t 200

350

330

320

220

210

200

22

18

15

EN-GJS-350-22U EN-JS1010 t 30

30 � t 60

60 � t 200

350

330

320

220

210

200

22

18

15


30 � t 60

60 � t 200

400

390

327

240

230

220

18

15

12


30 � t 60

60 � t 200

400

390

370

250

250

240

18

15

12

EN-GJS-400-18U EN-JS1020 t 30

30 � t 60

60 � t 200

400

390

370

250

250

240

18

15

12



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Table A.2.2-2 � Minimum impact values measured on V-notched test pieces machined from cast-onsamples

Minimum impact resistance values (in J)Material designation Relevantwallthickness

t

At roomtemperature

(23 + 5) oCAt (-20 + 2) oC At (-40 + 2) oC

Symbol Number mm Meanvaluefrom 3tests

Indivi-dualvalue


Indivi-dualvalue


Indivi-dualvalue


60 � t 200

� � � � 12

10

9

7


60 � t 200

17

15

14

12

� � � �


60 � t 200

� � 12

10

9

7

� �


60 � t 200

14

12

11

9

� � � �



A.2.3 Hardness

The hardness test shall be carried out on a casting at locations agreed by the casting manufacturer and themanufacturer. If the locations have not been defined in an agreement the test shall be carried out at representativelocations chosen by the casting manufacturer.

The hardness to be expected is as given in Table A.2.3-1

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Table A.2.3 �1 Brinell hardness range (for information only)

Material designation Brinell hardness range

(for information only)

Symbol Number HB

EN-GJS-350-22-LT EN-JS1015 HB 160

EN-GJS-350-22-RT EN-JS1014 HB 160

EN-GJS-350-22 EN-JS1010 HB 160

EN-GJS-400-18-LT EN-JS1025 130 HB 175

EN-GJS-400-18-RT EN-JS1024 135 HB 180

EN-GJS-400-18 EN-JS1020 135 HB 180

A.3 Test methods

A.3.1 Tensile test

The tensile test shall be carried out in accordance with EN 1563. The preferred test piece diameter is 14 mm, but,for technical reasons , it is permitted to use a test piece of different diameter. In this case the original gauge lengthof the test piece shall conform to the formula :

DSL �� 556,5 00 (A.3.1-1)

Where

L0 is the original gauge length;

S0 is the original cross-sectional area of the test piece;

D is the diameter of the test piece along the gauge length.

A.3.2 Impact test

The impact test shall be carried out on three Charpy impact test pieces in accordance with EN 1563, using testequipment with available energy compatible with the properties of the spheroidal graphite cast iron being tested.

A.3.3 Hardness test

The hardness shall be determined as Brinell hardness in accordance with EN 1563. Other hardness tests may alsobe agreed.

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Annex B (informative)

Ductility

The use of a ductile material such as ferritic spheroidal graphite cast iron for applications involving tensile loadsrequires load-related evaluation of the strength and toughness characteristics in relationship to the operatingtemperature and the rate of loading with the aim of ensuring safety against brittle fracture under all operatingconditions.

Among others, the evaluation criteria for a design are based on the strength calculation and the establishment ofthe nominal stress. Not only dynamically loaded components should be ensured that brittle fracture does not leadto failure. Under conditions that promote brittle fracture it is possible that a fracture can be initiated a componentstress lower than the yield strength and then lead to fracture through unstable crack propagation. It is only with asufficient and known fracture toughness or ductility that a material can guarantee the “Leak before fracture”requirement of a component.

The notched bar impact test of spheroidal graphite cast iron is the usual method to determine safety against brittlefracture. Impact energy or notch toughness or notched bar impact energy respectively are mostly used as ameasure for determining the toughness or lack of brittleness. Because it is not possible to separate the individualmechanisms of the energy, such as plastic deformation, crack initiation and crack propagation, one uses theinstrumented notched bar impact test or the various methods of fracture mechanics. The latter are especiallysuitable for larger components.

With the fracture mechanics concept, crack size and component stress are quantitatively linked together with amaterial characteristic, which then is a measure to resistance to crack propagation. The objective is to determinethe critical crack size, or the stress that leads to an unstable crack path and to sudden failure of the component.

Linear-elastic fracture mechanics enable quantitative acquisition of the failure of crack-affected components as aresult of an unstable crack propagation with static loading or a stable crack propagation with cyclical loading. Thisdetermined fracture toughness KIC establishes the material resistance to unstable crack propagation leading tobrittle fracture. With ductile materials this concept is only applicable at low temperatures or the presence ofembrittlement effects, e.g. through microstructure or large wall thickness.

General yielding fracture mechanics are used if elongated plastic deformation occurs ahead of the crack tip i.e. anelasto-plastic material behaviour. Determination can firstly be by means of the CTOD concept (Crack Tip OpeningDisplacement), in which the damage mechanism is controlled by the critical deformation at the crack tip.

With the J-integral concept a line integral is defined around the crack tip. Analogous with the previous concept oneobtains a material characteristic that defines resistance to the initiation of cracks.

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In view of the foregoing comments it is understandable that, on its own, determination of the notch impact energy ina ferritic spheroidal graphite cast iron in no way represents a suitable measure for comparing its toughness orductility with that of steel. This is because it is not possible to make any statement regarding the plasticdeformability and cracking behaviour of the material.

Contrary to this, the ferritic spheroidal graphite cast irons which have a notched bar impact energy of 12 J to 20 J,have a crack initiation behaviour that corresponds with an unalloyed to a low alloy steel with a far higher notchimpact energy of around 50 J in the high position. The fracture toughness values of ferritic spheroidal graphite castiron results in elasto-plastic fracture behaviour even down to –60 oC, i.e. a tough fracture characteristic, so that theKIC values are on the same level as with an unalloyed and low alloyed steel.

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Annex C (informative)

Determination of the minimum local wall thickness and minimum requiredburst test pressure

Equations used

n

etQpbact

macta CCCRP

RPSee

/1

2,0

33��

��

�

� (C.1)

emin � ea + c (C.2)

tp0,2

p0,2

CR

R

t

120�

/

/ (C.3)

)(, 2000101 �� ct tC (C.4)

� �nactctQp0,2

nactm

bceCCCR

eRPSP

�

� 33

(C.5)

Table C.1

Design data Calculated data Measured dataPS = 0,8 MPa

Max. working pressure = designpressure

Pb = 6,86 MPa

Min. required burst test pressure

Pbact = 13 MPa

Actual burst pressure

emin = 7 mm

minimum thickness on drawing

ea = 3,7 mm

analysis thickness

eact = 8 mm

c = 1 mm n = 1 ( curved area)

tc = 120°C Ct = 0,9

Measured material data

CQ = 0,8 Rm(3) = 450 N/mm²

c = 1 mm Rp0,2 = 280 N/mm²

Annex A material data

Rm = 400 N/mm² minimum

Rp0,2 = 250 N/mm² minimum

Conclusion

Pbact = 13 MPa > Pb(required) Satisfactory.

eact = 8,0 mm > emin = 7,0 mm � ea +c = 3,7 + 1 = 4,7 mm; the foreseen wall thickness satisfies the designconditions.

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Annex ZA(informative)

Clauses of this European Standard addressing essential requirements orother provisions of EU Directives.

This European Standard has been prepared under a mandate given to CEN by the European Commission andsupports essential requirements of the Pressure Equipment Directive 97/23/EC.

Warning : Other requirements and other EU Directives may be applicable to the product(s) falling within the scopeof this standard.

The following clauses of this standard are likely to support requirements of the Pressure Equipment Directive97/23/EC.

Compliance with these clauses of this standard provides one means of conforming with the specific essentialrequirements of the Directive concerned and associated EFTA regulations.

Table ZA.1 — Correspondence between EN 13445-6 and Pressure Equipment Directive 97/23/EC

Relevant clausesof EN 13445-6

Essential requirements of

Directive 97/23/EC

Clauses in Annex I of

Directive 97/23/EC (PED)

4.1, 4.2, 5.2 Calculation method 2.2.3

5.2.3 Experimental design method. 2.2.4

5.3,6,7.1 Manufacturing procedures 3.1

9.1 Traceability 3.1.5

7.2 Final assessment 3.2

7.1 Testing 3.2.1

7.2.2 Proof test 3.2.2

9 Marking 3.3

5.1 , Annex A Materials for pressurized parts 4.1

5.2.3 ,Annex A Allowable stresses 7.1

5.1,Annex A Material characteristics 7.5

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Bibliography

[1] Gorsitzke, B . : Berechnung der Ermüdungslebensdauer wechselbeanspruchter Druckbehälter aus Gusseisenmit Kugelgrafit .

[2] Kikkert,J. Bepaling van de elasticiteitsgrens van verschillende nodulaire gietijzersoorten op verhoogdetemperatuur

[3] ISO/CD 1083, Spheroidal graphite cast iron (2001-01-18)

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