AD 2000-Merkblatt

ICS 23.020.30 July 2019 edition

Materials for AD 2000-Merkblatt

pressure vessels Steel flanges
W9

The AD 2000-Merkblätter are prepared by the seven associations listed below who together form the “Arbeitsgemeinschaft Druck-
behälter” (AD). The structure and the application of the AD 2000 Code and the procedural guidelines are covered by AD 2000-Merk-
blatt G 1.
The AD 2000-Merkblätter contain safety requirements to be met under normal operating conditions. If above-normal loadings are to be
expected during the operation of the pressure vessel, this shall be taken into account by meeting special requirements.
If there are any divergences from the requirements of this AD 2000-Merkblatt, it shall be possible to prove that the standard of safety of
this Code has been maintained by other means, e.g. by materials testing, tests, stress analysis, operating experience.
FDBR e. V. Fachverband Anlagenbau, Düsseldorf
Deutsche Gesetzliche Unfallversicherung (DGUV), Berlin
Verband der Chemischen Industrie e. V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e. V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
und Apparate, Frankfurt/Main
Stahlinstitut VDEh, Düsseldorf
VGB PowerTech e. V., Essen
Verband der TÜV e. V. (VdTÜV), Berlin
The above associations continuously update the AD 2000-Merkblätter in line with technical progress.

Contents
Page
0 Foreword.................................................................................................... 2
1 Scope......................................................................................................... 2
2 Suitable materials ...................................................................................... 2
3 Requirements for materials and for manufacture ....................................... 4
4 Testing ....................................................................................................... 4
5 Marking ...................................................................................................... 7
6 Certification of quality................................................................................. 8
7 Design values ............................................................................................ 9
Annex: Specimen ............................................................................................. 11

supersedes June 2017 edition; | = amendments to previous edition

AD 2000-Merkblätter are protected by copyright. The rights of use, particularly of any translation, reproduction, extract of figures, transmission by
photomechanical means and storage in data retrieval systems, even of extracts, are reserved to the author. Beuth Verlag has taken all reasonable
measures to ensure the accuracy of this translation but regrets that no responsibility can be accepted for any error, omission or inaccuracy. In cases of
doubt or dispute, the latest edition of the German text only is valid.
 AD 2000-Merkblatt
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0 Foreword
The AD 2000 Code can be applied to satisfy the essential safety requirements of the Pressure Equipment Directive,
principally for the conformity assessment in accordance with modules “G” and “B (type) + F”.
The AD 2000 Code is structured along the lines of a self-contained concept. If other technical rules are used in
accordance with the state of the art to solve related problems, it is assumed that the overall concept has been taken into
account.
The AD 2000 Code can be used as appropriate for other modules of the Pressure Equipment Directive or for different
sectors of the law. Responsibility for testing is as specified in the provisions of the relevant sector of the law.

1 Scope
1.1 This AD 2000-Merkblatt covers:
 forged and seamless rolled flanges,
 flanges formed by bending from sections, bar steel or strip stock and flash-butt welded flanges,
 flanges cut from plates/sheets,
 flanges manufactured by machining from rolled or forged sectional steel and bar steel,
 cast flanges made of cast steel.
They are made of ferritic, austenitic and austenitic-ferritic steels for the construction of pressure vessels which are
operated at working temperatures and ambient temperatures down to −10 °C and up to the upper temperature limits
specified in Clause 2 and the relevant AD 2000-Merkblätter for the starting materials. For working temperatures below
−10 °C, AD 2000-Merkblatt W 10 also applies.
1.2 This AD 2000-Merkblatt does not cover integrally cast flanges. For flanges produced by the pressure equipment
manufacturer, Clauses 2, 3, 4 and 7 apply.

2 Suitable materials
2.1 For forged or seamless rolled flanges:
2.1.1 General purpose structural steels S235JRG2 (1.0038), S235J2G3 (1.0116) and S355J2G3 (1.0570) in accordance
with DIN EN 10250-2 up to a design temperature1) ≤ 300 °C where the product of the maximum inside diameter di, in mm,
of the pressure vessel or the attachment and the maximum allowable pressure PS, in bar, is di ⋅ PS ≤ 20000 mm ⋅ bar.
Flanges with flange-plate thickness ≥ 30 mm shall be delivered in the normalized condition. Flanges with flange-plate
thickness < 30 mm can be supplied in the as-forged condition.
2.1.2 Weldable fine-grained structural steels according to Table 1 to DIN EN 10222-4, DIN 17102, DIN 17103 and
DIN EN 10273 in conjunction with the appropriate VdTÜV-Werkstoffblätter (Material Specification Sheets).
2.1.3 The weldable high-temperature steels according to Table 1 to DIN EN 10222-2, C22.8 according to VdTÜV-
Werkstoffblatt 350/3 as well as steel grade C21 according to VdTÜV-Werkstoffblatt 399/3 within the application limits
given. VdTÜV-Werkstoffblätter 184, 511/3 and 110 shall also be consulted for steel grades 14MoV6-3, X10CrMoVNb9-1
and X20CrMoV11-1.
2.1.4 Steels with high impact strength at low temperature according to Table 1 to DIN EN 10222-3 up to 50 °C. AD 2000-
Merkblatt W 10, Clause 6 applies for short-term service at higher temperatures.
2.1.5 Steel grades specified in AD 2000-Merkblatt W 2.
2.2 For flanges formed by bending from sections, bar steel or strip stock, and flash-butt welded flanges:
Steel grades specified in AD 2000-Merkblätter W 1, W 2 and W 13 as well as C22.8 according to VdTÜV-Werkstoff-
blatt 350/3.
2.3 For flanges cut from plates and manufactured by machining:
Steel grades specified in AD 2000-Merkblätter W 1 and W 2 in conjunction with Clause 6.9.
2.4 For flanges manufactured by machining from rolled and forged sectional steel and bar steel:
Steel grades specified in AD 2000-Merkblätter W 2 and W 13 in conjunction with Clause 6.9.
2.5 For cast flanges:
Cast steel specified in AD 2000-Merkblatt W 5.
2.6 For flanges regardless of the method of manufacture:
Other materials assessed as suitable by the relevant third party. The minimum requirements for other materials in the
W series of the AD 2000-Merkblätter shall be taken into account for these materials.

1) See AD 2000-Merkblatt B 0, Clause 5.

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Table 1 — Assignment of the steel grades in Clauses 2.1.2 to 2.1.4 to the relevant standards

Material No. Steel name

(according to
DIN EN 10027-2) DIN 17102 DIN 17103 DIN EN 10222-2 DIN EN 10222-3 DIN EN 10222-4 DIN EN 10273
1.0345 – – P235GH – – P235GH
1.0352 – – P245GH+N – – –
1.0425 – – P265GH – – P265GH
1.0426 – – P280GH+N – – –
1.0436 – – P305GH – – –
1.0460 – – P250GH – – P250GH
1.0473 – – – – – P355GH
1.0477 – – – – P285NH –
1.0478 – – – – P285QH –
1.0481 – – P295GH – – P295GH
1.0487 – – – – – P275NH
1.0488 TStE 285 TStE 285 – – – –
1.0565 – – – – P355NH P355NH
1.0566 TStE 355 – – – P355NL1 –
1.0571 – – – – P355QH1 –
1.1104 EStE 285 – – – – –
1.1106 EStE 355 – – – P355NL2 –
1.4903 – – X10CrMoVNb9-1 – – –
1.4922 – – X20CrMoV11-1 – – –
1.5415 – – 16Mo3 – – 16Mo3
1.5637 – – – 12Ni14 – –
1.5662 – – – X8Ni9 – –
1.5680 – – – X12Ni5 – –
1.6217 – – – 13MnNi6-3 – –
1.7335 – – 13CrMo4-5 – – 13CrMo4-5
1.7380 – – – – 10CrMo9-10
1.7383 – – 11CrMo9-10 – – –
1.7715 – – 14MoV6-3 – – –
1.8864 – – – – P460QL2 –
1.8868 – – – – P355QL1 –
1.8869 – – – – P355QL2 –
1.8871 – – – – P460QH P460QH
1.8872 – – – – P460QL1 –
1.8912 TStE 420 TStE 420 – – – –
1.8913 EStE 420 – – – – –
1.8915 TStE 460 – – – – –
1.8917 TStE 500 TStE 500 – – – –
1.8918 EStE 460 – – – – –
1.8919 EStE 500 – – – – –
1.8932 – – – – P420NH –
1.8935 – – – – – P460NH
1.8936 – – – – P420QH –
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3 Requirements for materials and for manufacture

3.1 For the chemical composition, delivery condition, mechanical and technical characteristics as a function of
dimensional limits, surface finish and dimensional accuracy of the product forms specified in Clauses 2.1 to 2.6, the
stipulations in the relevant AD 2000-Merkblätter, standards or VdTÜV-Werkstoffblätter are applicable. Surface defects
may only be repaired by welding with the approval of the customer and the relevant third party, which has been appointed
to carry out the acceptance test.
Deviating from Table 1 of DIN EN 10222-4, when steel flanges of grade P460Q are delivered in a normalized condition
(see option 5, footnote f in Table 4 and footnote a in Table 6 of the standard), the requirements of VdTÜV-Werkstoff-
blatt 357/3 for the mechanical characteristics at room and elevated temperature as well as for the minimum values of
impact energy apply.
3.2 Neck weld flanges and weld collars shall not be cut in the form of circles from plate. If they are manufactured from
plate, strips shall be cut in the rolling direction and bent in such a manner that one surface of the plate faces inwards
towards the axis of the flange (see also AD 2000-Merkblatt B 8).

4 Testing
4.1 Inspection and dimensional checks
The flanges shall be inspected in the as-supplied state and their dimensions checked.

4.2 Destructive material tests

4.2.1 Forged or seamless rolled flanges made of steels specified in Clause 2.1.1 (see also Table 5)
The flanges are tested in batches. A test batch includes flanges produced from one cast with the same kind of hot-forming
and heat treatment. A test batch may also include flanges produced from one cast which have differing dimensions and
have been heat treated separately but in the same way, provided that the uniform quality of the heat treatment is
demonstrated by means of hardness tests on 10 % of the flanges, but on three flanges at least. The hardness test
measures are also applicable to flanges that have not been treated.
For each test batch, with unit weights ≤ 300 kg, one tensile test specimen and three notched-bar impact test specimens
shall be tested at test temperatures in accordance with DIN EN 10250-2. The mean value obtained from three specimens
shall be regarded as the result of the impact test and no single value shall be less than 70 % of the required value. The
impact energy for the transverse/tangential direction using V-notched specimens shall be ≥ 27 J. In the case of unit
weights > 300 kg, the flanges are tested in accordance with Clause 4.2.2. Hammer-forged flanges with unit weights
> 300 kg are tested individually.
Specimens are cut transversely or tangentially to the material fibre. With flange-plate thicknesses > 30 mm, the specimens
shall be cut at a distance of at least 25 % beneath the front and side face.
To obtain the specimens, either the flanges themselves shall be utilized in the appropriate numbers or all the flanges that
are intended for testing shall have the necessary additional margin of material for the test piece. When flanges are
produced by drop-forging, the waste core of material which results from the piercing can be used to obtain the specimens
provided that the thickness of the core is not less than 75 % of the flange-plate thickness.
If flanges originating from one cast are rolled or forged at different times, for each cast a test piece – or where appropriate
several test pieces – of a size comparable with that of the flanges can be produced and subjected, stage by stage, to the
individual heat treatments for the flanges. This presupposes that the forming for the flanges and the test pieces is
comparable.

4.2.2 Forged or seamless rolled flanges made of steels specified in Clauses 2.1.2 to 2.1.4 in the normalized
state (see also Table 5)
The flanges are tested in batches as shown in Table 2. A test batch includes flanges produced from one cast with the
same kind of hot-forming and heat treatment. A test batch may also include flanges produced from one cast which have
differing dimensions and have been heat treated separately but in the same way, provided that the uniform quality of the
heat treatment is demonstrated by means of hardness tests on 10 % of the flanges, but on three flanges at least. The
hardness test measures are also applicable to normalized flanges.

Table 2 — Test batches

Number of flanges
Unit weight in kg
per test batch1)
≤ 15 ≤ 150
> 15 to ≤ 150 ≤ 100
> 150 to ≤ 300 ≤ 50
> 300 ≤ 25
1) The test specimens do not count as part of the test batch.
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In each test batch, for two flanges a tensile test specimen and three notched-bar impact test specimens shall be tested.
However, for each cast, hot-forming process and heat-treatment process, a maximum of four sets of specimens are
tested.
In the case of unit weights up to 1000 kg and quantities up to 10 flanges inclusive and in the case of unit weights up to
15 kg and quantities up to 30 flanges inclusive, it is sufficient for one flange to be tested using one tensile test specimen
and three notched-bar impact test specimens.
Hammer-forged flanges with unit weights > 300 kg are tested individually.
Specimens are cut transversely or tangentially to the material fibre. With flange-plate thicknesses > 30 mm, the specimens
shall be cut at a distance of at least 25 % beneath the front and side face. The stipulations in Clause 4.2.1 regarding the
removal of specimens and the provision of test pieces shall apply.
The mean value obtained from three specimens shall be regarded as the result of the impact test and no single value shall
be less than 70 % of the required values.

4.2.3 Forged or seamless rolled flanges made of steels specified in Clauses 2.1.2 to 2.1.4 in the hardened-and-
tempered state (see also Table 5)
The flanges are tested in batches. A test batch includes flanges produced from one cast with the same kind of hot-forming
and heat treatment. A test batch may also include flanges produced from one cast which have differing dimensions and
have been heat treated separately but in the same way, provided that the uniform quality of the heat treatment is
confirmed by the hardness tests.
All flanges shall be subjected to hardness tests. Where flanges are produced on a quantity basis (at least 50 flanges of the
same size from one cast), the hardness tests are performed on only 10 % of the test batch, but on 20 flanges at least. In
each test batch, for the flange with the lowest hardness and for the flange with the highest hardness, a tensile test
specimen and three notched-bar impact test specimens shall be tested.
In the case of unit weights up to 1000 kg and quantities up to 10 flanges inclusive and in the case of unit weights up to
15 kg and quantities up to 30 flanges inclusive, it is sufficient for one tensile test specimen to be tested for the flange with
the lowest hardness and for three notched-bar impact test specimens to be tested for the flange with the highest hardness.
Hammer-forged flanges with unit weights > 300 kg are tested individually.
Specimens are cut transversely or tangentially to the direction of the material fibre. With flange-plate thicknesses > 30 mm,
the specimens shall be cut at a distance of at least 25 % beneath the front and side face. The stipulations in Clause 4.2.1
regarding the removal of specimens and the provision of test pieces are applicable.
The mean value obtained from three specimens shall be regarded as the result of the impact test and no single value shall
be less than 70 % of the required values.
4.2.4 Forged or seamless rolled flanges made of steels specified in Clause 2.1.5 shall be tested in the same way as
forgings according to AD 2000-Merkblatt W 2.
4.2.5 Flanges specified in Clause 2.2 shall be tested as indicated in Table 3. The testing of specimens welded
separately is permissible if this is stipulated during process control (same geometrical dimensions).
4.2.6 In the case of flanges specified in 2.3, the plates shall be tested in accordance with AD 2000-Merkblatt W 1, W 2 or
W 10.
4.2.7 In the case of flanges specified in Clause 2.4, the starting material shall have been tested in keeping with the
intended application in accordance with AD 2000-Merkblatt W 2, W 10 or W 13.
4.2.8 Flanges specified in Clause 2.5 shall be tested in accordance with AD 2000-Merkblatt W 5.
4.2.9 Flanges made of other steels specified in Clause 2.6 shall be tested in accordance with the suitability assessment
procedures.

4.3 Non-destructive tests

4.3.1 Forged or seamless rolled flanges made of steels specified in Clause 2.1
Flanges with unit weights > 300 kg shall be inspected ultrasonically by the manufacturer in accordance with
DIN EN 10228-3 or DIN EN 10228-4. Ultrasonic inspection for internal defects shall be carried out with 100 % scanning
coverage. Defect sizing is performed applying the −6 dB drop technique; sensitivity adjustment is carried out using the
AVG method.
The following quality classes shall be applied when testing in accordance with DIN EN 10228-3:
Flange-plate thickness s ≤ 50 mm quality class 4
Flange-plate thickness 50 mm < s ≤ 100 mm quality class 3
Flange-plate thickness s > 100 mm quality class 2
For steel flanges in accordance with Clause 2.1.5, quality class 3 of DIN EN 10228-4 shall be applied. The flange-plate
thickness s is assumed to be the forging thickness given in that standard. In the case of austenitic steel flanges, the
ultrasonic test can be replaced by radiographic testing.
Flanges with unit weights > 300 kg in the hardened-and-tempered state shall additionally be surface-tested by the
manufacturer with reference to AD 2000-Merkblatt HP 5/3.
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Table 3 — Scope of testing and test certificates according to DIN EN 10204 for flanges specified in Clause 2.2

Scope of testing2),3) Test certificate according to DIN EN 10204

Finished product
Test
groups1) Tensile test4) Impact Starting Heat Mechanical/
(ReH, Rm, A) test5) material treatment6) NDT technological
tests

1 (1)7) – – 2.2/3.1 2.2 2.2 –

1 1
1 (2)8) per heat treatment per heat treatment 2.2 2.2 3.1 3.2
batch batch
1 1
2 2.2 2.2 3.1 3.2
per 25 flanges per 25 flanges
3 1 1 2.2 2.2 3.1 3.2
for every 10 flanges for every 10 flanges
4 from a cast from a cast 2.2 2.2 3.1 3.2

1 1
5.1 for every 25 flanges for every 10 flanges 2.2 2.2 3.1 3.2
from a cast from a cast
1 1
5.2 to 5.4 for every 10 flanges for every 10 flanges 2.2 2.2 3.1 3.2
from a cast from a cast
6 – – 3.1/3.2 2.2 2.2 –
1 1
7 for every 10 flanges for every 10 flanges 2.2 2.2 3.1 3.2
from a cast from a cast
1) Classification in accordance with Table 1a of AD 2000-Merkblatt HP 0 (test groups 1 (1) and 1 (2) in AD 2000-Merkblatt W 9, only).
2) The specimens shall be cut from the weld zone.
3) For hardened-and-tempered flanges, a hardness test shall be performed as directed in Clause 4.2.3. Annually, for two finished flanges, the basic
material and the weld zone are tested with reference to AD 2000-Merkblatt HP 5/2 whereby the cross-sectional area, geometry and scope of testing
shall be specified.
4) If stipulated for the primary material, a further tensile test shall be performed for each test batch at the maximum allowable temperature (TS).
5) For each impact test, three specimens are tested with the notch root sited in the middle of the weld seam.
6) Inspection document in accordance with the Annex to this AD 2000-Merkblatt.
7) With the exception of steel grades 16Mo3, P295GH, P355GH, P355N and P355NH.
8) Only steel grades 16Mo3, P295GH, P355GH, P355N and P355NH.

4.3.2 Flanges made of steels specified in Clause 2.2

4.3.2.1 The plates or strip stock shall be subjected to non-destructive testing by the manufacturer in accordance with
DIN EN 10160, quality class S2 or in accordance with DIN EN 10307, quality class S2. Special flanges such as bayonet
catches, quick-closing mechanisms and the like shall also be subjected to non-destructive testing in accordance with
DIN EN 10160, quality class E3 or DIN EN 10307, quality class E3.
4.3.2.2 Flanges made of steels in test groups 1 (1) and 6 in Table 3 are subjected by the manufacturer to ultrasonic
inspection with reference to AD 2000-Merkblatt HP 5/3, Appendix 1, test class A in the weld zone or to radiographic
inspection to the extent defined in Table 4. As a rule, flanges that are produced by continuous welding with the same
machine setting are grouped together to form a test batch.
4.3.2.3 In the case of flanges made of steels in test groups 1 (2), 2 to 5 and 7 in Table 3, each flange is subjected by the
manufacturer to ultrasonic inspection or radiographic inspection in the weld zone with reference to AD 2000-
Merkblatt HP 5/3, Appendix 1, test class A.
4.3.2.4 Flanges with unit weights > 300 kg shall be inspected ultrasonically or radiographically by the manufacturer.
4.3.2.5 Employing suitable methods in accordance with AD 2000-Merkblatt HP 5/3, Appendix 1, all welds shall be
surface-tested by the manufacturer. The following materials constitute exceptions: S235JR, P235GH, P250GH, P265GH,
P245GH+N.
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Table 4 — Scope of non-destructive testing for flash-butt welded flanges

Number of flanges Scope of

Minimum of:
per test batch non-destructive testing
≥ 1 to ≤ 20 100 %
> 20 to ≤ 50 50 % 20 flanges
> 50 to ≤ 200 25 % 25 flanges
> 200 to ≤ 1000 15 % 50 flanges
> 1000 10 % 150 flanges

4.3.3 Flanges specified in Clause 2.3

The plates shall be subjected to non-destructive testing by the manufacturer in accordance with DIN EN 10160,
requirements for quality class S2 or in accordance with DIN EN 10307, quality class S2.

4.3.4 Flanges specified in Clause 2.4

In the case of flanges with unit weights > 300 kg, the primary material shall have been subjected to non-destructive testing
in keeping with the intended application. The ultrasonic inspection shall be performed in accordance with DIN EN 10228-3
or DIN EN 10308 with 100 % scanning coverage. Defect sizing is performed applying the −6 dB drop technique; sensitivity
adjustment is carried out using the AVG method. The following quality classes shall be applied:
Thickness s ≤ 50 mm quality class 4
Thickness 50 mm < s ≤ 100 mm quality class 3
Thickness s > 100 mm quality class 2
Flanges with unit weights > 300 kg in the hardened-and-tempered state shall be surface-tested with reference to AD 2000-
Merkblatt HP 5/3, Appendix 1.

4.3.5 Flanges specified in Clause 2.5

Flanges with unit weights > 300 kg shall be tested by the manufacturer using the radiographic technique, if necessary in
conjunction with the ultrasonic technique, in accordance with the details in DIN EN 12680-2. Additionally, surface-testing is
required (using the magnetic-particle method wherever possible).

4.3.6 Flanges specified in Clause 2.6

The flanges shall be subjected to the tests in accordance with the suitability assessment procedures.

4.4 Testing for grade mixing

Flanges made of alloy steels shall be subjected to a suitable test by the manufacturer to ascertain that no grade mixing
has occurred.

4.5 Repetition of tests

If the results obtained from a test do not meet the requirements, the procedure to be adopted is as follows:
4.5.1 If it can be assumed that test results which are unsatisfactory are attributable to improper heat treatment, the heat
treatment of the flanges may be repeated, whereupon the entire test shall be repeated. More than one repetition of the
heat treatment process is only permissible following consultation with the relevant third party.
4.5.2 If unsatisfactory test results can be attributed to factors associated with the testing technique or to a defect of very
limited size in a specimen, the specimen in question may be left out of consideration when deciding whether the
requirements have been met and the test in question may be repeated.
4.5.3 For every specimen that fails to meet the minimum requirements, two further specimens shall be tested and both of
these shall satisfy the requirements.

5 Marking
The flanges shall be marked clearly and durably in accordance with the specifications given in the relevant DIN EN
standards. The marking shall comprise at least the following information:
 steel name or material number of the steel grade,
 manufacturer’s symbol,
 nominal bore and, if relevant, pipe outside diameter,
 nominal pressure.
 AD 2000-Merkblatt
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When delivered with an inspection certificate according to DIN EN 10204, the flanges shall additionally be marked with:
 cast number or symbol,
 test batch number with the product which provided the specimen being specially identified,
 test stamp of the relevant third party or works inspector,
 stamp for non-destructive testing if required.

6 Certification of quality
Certification of quality is by means of the inspection documents specified in DIN EN 10204.
6.1 For flanges made of steels specified in Clause 2.1.1 – with the exception of S355J2G3 – by means of a test report
according to DIN EN 10204.
In the case of flanges with DN ≤ 1000, the test report may be dispensed with if the requirements in Clause 6.8 are met.
For flanges made of material S355J2G3, an inspection certificate 3.1 according to DIN EN 10204 is required.
6.2 For flanges made from steels specified in Clauses 2.1.2 to 2.1.4 an inspection certificate 3.2 in accordance with
DIN EN 10204. However, an inspection certificate 3.1 is acceptable for steel grades P235GH, P245GH, P250GH,
P265GH and P280GH to DIN EN 10222-2, C22.8 to VdTÜV-Werkstoffblatt 350/3, P285NH to DIN EN 10222-4 and
P235GH, P250GH, P265GH and P275NH to DIN EN 10273. For steel grade C21, the specifications of VdTÜV-
Werkstoffblatt 399/3 apply.
6.3 For flanges made of steels specified in Clause 2.1.5, in accordance with AD 2000-Merkblatt W 2.
6.4 For flanges specified in Clause 2.2, Table 3 is applicable. Evidence shall be furnished in respect of the primary
material in accordance with AD 2000-Merkblätter W 1, W 2, W 10 or W 13. The testing of the starting materials by the
relevant third party may be dispensed with if the flange is to be tested by the relevant third party.
6.4.1 For flanges made of steels in test groups 1 (1) and 6 in Table 3, a test report according to DIN EN 10204 (see
specimen in Annex) shall be prepared by the manufacturer covering the results of the tests and also the nature of the heat
treatment and the heat-treated state.
In the case of flanges made of steels S235JR and S235J2 where the product di ⋅ PS ≤ 20000 mm ⋅ bar and DN ≤ 1000, the
test report and the inspection documents for the primary material may be dispensed with if the requirements in Clause 6.8
are met.
6.4.2 For flanges made of steels in test groups 1 (2), 2 to 5 and 7 in Table 3, an inspection document according to
DIN EN 10204 covering the results of the tests shall be prepared; the type of the document is determined by applying the
stipulations in AD 2000-Merkblätter W 1, W 2 or W 13 as appropriate. A test report according to DIN EN 10204 (see
specimen in Annex) shall be prepared by the manufacturer covering the nature of the heat treatment and the correctness
of the heat-treated state.
6.5 For flanges specified in Clauses 2.3 and 2.4, the necessary inspection documents for the primary material shall be
furnished in accordance with AD 2000-Merkblätter W 1, W 2, W 10 and W 13. During the course of production, it shall be
ensured by means of re-stamping that a clear correlation is established between starting material and finished product.
6.6 For flanges specified in Clause 2.5, in accordance with AD 2000-Merkblatt W 5.
6.7 For flanges specified in Clause 2.6, in accordance with the suitability assessment procedures.
6.8 If a test report in compliance with the order is dispensed with, the assumption is that the manufacturer has performed
the necessary tests, which constitute the basis for the issuing of a test report of compliance with the order, continuously
and that he keeps the results available for scrutiny by the relevant third party at any time.
This arrangement requires an agreement between the flange manufacturer and the relevant third party.
6.9 If flanges are produced from forged or cast flange blanks by mechanical processing or from plates or sectional steel
and bar steel by mechanical or thermal cutting with no changes in the material characteristics, the question of ensuring
correct processing, testing and restamping of the flanges shall be the subject of an agreement between manufacturer and
relevant third party.
6.10 Performance of the hardness tests and the test to ascertain that no grade mixing has occurred shall be certified.
 AD 2000-Merkblatt
AD 2000-Merkblatt W 9, 07.2019 edition Page 9

Table 5 — Scope of testing on flanges specified in Clauses 2.1.1 and 2.1.2

Flanges as Unit weight1) Test batches Scope of testing for each test batch2)
specified in in kg as defined in Hardness test Tensile test Impact test3)

≤ 300 4.2.1 1 1
2.1.1
> 300 4.2.2
none4)
2.1.2 2 2
4.2.2
(normalized)
2.1.2 –
(hardened and 4.2.3 100 %5) 26) 26)
tempered)
1) Hammer-forged flanges with unit weights in excess of 300 kg are tested individually.
2) For reduction of scope of testing, see Clause 4.2.2 and 4.2.3.
3) For each impact test, three specimens are tested.
4) In the case of flanges that have been subjected to heat treatments separately but in the same way, in order to make up a test batch the uniform quality
of the heat treatment can be demonstrated by means of hardness tests on 10 % of the flanges, but on three flanges at least.
5) For flanges manufactured on a quantity basis (at least 50 flanges of the same size made from the same cast), hardness tests on 10 %, but on
20 flanges at least.
6) These specimens shall be removed from those flanges for which, in the hardness tests, the Iowest and the highest hardness values were found.

7 Design values
7.1 For flanges made of steels specified in Clause 2.1.1, the room-temperature yield strength values specified in
DIN EN 10250-2 shall apply up to 50 °C; the values in Table 6 shall apply for design temperatures from 100 °C to 300 °C.
For flanges made of steels specified in Clause 2.1.2, the values set out in DIN EN 10222-4, DIN EN 10273, DIN 17102
and DIN 17103 apply. For flanges made of steels C22.8 and C21, the values specified in VdTÜV-Werkstoffblätter 350/3
and 399/3 apply.
The values specified in DIN EN 10222-2 apply to flanges made from steels in accordance with Clause 2.1.3. As a
deviation from this the values specified in VdTÜV-Werkstoffblatt 511/3 apply to flanges made from X10CrMoVNb9-1 steel.
Up to 50 °C, the values for yield strength given in DIN EN 10222-3 apply to flanges made from steel in accordance with
Clause 2.1.4. The values in Table 3a in AD 2000-Merkblatt W 10 apply to short-term service at higher temperatures.
7.2 For flanges made of steels specified in Clauses 2.2 to 2.5, the values stated in the relevant AD 2000-Merkblätter are
applicable.
7.3 For flanges made of steels specified in Clause 2.6, the values stipulated in suitability assessment procedures are
applicable.
7.4 The characteristic values quoted in the material specifications or suitability assessment procedures for 20 °C shall be
applicable for temperatures up to 50 °C and those quoted for 100 °C shall be applicable at up to 120 °C. In the remaining
temperature ranges, linear interpolation between the quoted values is necessary (e.g. for 80 °C, between 20 °C and
100 °C and for 180 °C, between 100 °C and 200 °C) but no rounding up is permissible. In the case of materials subject to
individual audits, the interpolation rule shall only apply where the interval between the already known values is sufficiently
small2).

2) This is generally understood to mean a temperature interval of 50 K in the elevated temperature yield strength range and an interval
of 10 K in the creep rupture strength range.
 AD 2000-Merkblatt
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Table 6 — Characteristic design values at higher temperatures for steels specified in DIN EN 10250-2

Characteristic value K
at design temperature
Nominal thickness
Steel grade °C
100 200 250 300
mm MPa

≤ 16 187 161 143 122

S235JRG2 > 16 to ≤ 40 180 155 136 117

S235J2G3 > 40 to ≤ 100 173 149 129 112

> 100 to ≤ 150 159 137 115 102

≤ 16 254 226 206 186

> 16 to ≤ 40 249 221 202 181

> 40 to ≤ 63 234 206 186 166

S355J2G3
> 63 to ≤ 80 224 196 176 156

> 80 to ≤ 100 214 186 166 146

> 100 to ≤ 150 194 166 146 126

 AD 2000-Merkblatt
AD 2000-Merkblatt W 9, 07.2019 edition Page 11

Annex to AD 2000-Merkblatt W 9

Specimen

Test report according to DIN EN 10204

Hot-formed, flash-butt welded steel flanges made from forged bars, strip stock or rolled bar steel, observing the
requirements in AD 2000-Merkblatt W 9.
Approval by relevant third party (technical Inspectorate) __________________________________________________________
of __________________________________________________________________________________________________________

Item Number Designation and dimensions Material Cast Specimen

 Heat treatment of the flanges following bending and welding not required in accordance with the expert opinion of the
relevant third party (technical Inspectorate) _________________________________________________________________
 Normalizing at _____°C, quenching in still air
 Hardening and tempering: austenitizing at _____°C, quenching in ____________________ , tempering at _____°C
 Solution treatment at _____°C, quenching in water at 20 °C
 We confirm that ultrasonic inspection of the plates used as starting material has been carried out in accordance with
AD 2000-Merkblatt B 8.

Testing of the flanges:

inspection and measurements: no deficiencies
 Surface inspection: no complaint
 Ultrasonic inspection: no complaint
 Radiographic inspection: no complaint

The components, as far as necessary, have been re-stamped and marked with the manufacturer’s symbol.

Remark:
This specimen does not claim to be complete, see for example DIN EN 10204 and DIN EN 10168.
 AD 2000-Merkblatt
Page 12 AD 2000-Merkblatt W 9, 07.2019 edition

Publisher: Source of supply:

Beuth Verlag GmbH

D-10772 Berlin
Tel. +49 30 / 26 01-22 60
Fax +49 30 / 26 01-12 60
E-Mail: [email protected] [email protected]
http://www.vdtuev.de www.beuth.de