UDC 669.141.25-4:61.74.002. Technical delivery conditions for castings DEUTSCHE NORM January 1991 of metallic materials Supplementary requirements for steel castings used for heavy-duty valves Technische Lieferbedingungen flr GuBstiicke aus metallischen Werkstotfen; hoher beanspruchte Armaturen ‘The symbole denotes items which shall the symbol 1 Scope and field of application ‘This standard specifies requirements for the pressure-con: taining components of heavy-duty valves (ct.subclause 2.2) ‘made from steel castings. Such requirements are intended to supplement those given in DIN 1690 Parts 1 and 2. Note. It is up to the purchaser to decide whether valves ‘must be designed for heavy-duty service. 2 Concepts In comparison with DIN 1690 Part 1,this standard specifies additional concepts (cf. subclauses 21,22 and 2.4 to 28) land defines one concept differently (ct. subclause 2.3). 24 Quality levels Table t specifies four quality levels to which castings maybe assigned, as a function of the required freedom from fefects.Castings complying with a certain qualitylevel shall ‘comply with the corresponding severity level as spec: ified in DIN 1680 Part 2, which deals with the internal and ‘external condition of castings, Quality tov Table 1 ‘Severity lovel asin DIN 1690 Part 2 Quality wo a Tevel External Internal MS 1 or ES 1 RV tor U1 + A 8 © MS 2 or ES 3 D MS 2 or ES 2 RV 2 or U2 RV 3 or U3, MS 3 or ES 4 AV 4 or U4 Factors relating to manufacture or service conditions, or @ particular casting design (e.g. thick-walled) may necessi- tate that different combinations of severity levels be select- ed (e.g. higher levels where surfaces are in contact with chemicals or aggressive media). 2.2 Heavy-duty valves For the purposes of this standard, heavy-duty valves are ‘those which, should they not function properly, present a hazard to persons or property. The body of such v Janzende Festlegungen fur Stahigu8 fur ‘denoting items which may, be agreed upon atthe time of ordering ‘understood to include all components subject to internal pressure, even where such loading does not act on all parts ‘of those components. 2.3 Production weld A production weld is a weld carried out by the casting or valve manufacturer during production, the object of which is to ensure the required quality of the casting 2.4 Acceptance batch ‘An acceptance batch is comprised ofall castings that were produced under specified conditions and that were sub- imtted for and subjected to testing. Where an acceptance batch is comprised of products originating trom different casts, test pieces trom each cast shall be tested. 2.5 Purpose-made castings Purpose-made castings are castings of unique design (e.not Intended for series production), For the purposes of this standard, a prototype is the first ‘casting produced under the conditions specified for series production, on which no production welds are made unt the results of non-destructive testing are established. 2.7 Pilot lot pilot lot is comprised of a representative number of cast: ings (5 to 10) which, after prototype approval. are produced under specified conditions. 2.8 Castings in series production Castings in series production are those produced under ‘specified conditions (as forthe pilot ot, it being possible to ‘carry out such production at any time. 3. Ordering 3.1 © The required quality level or severity level combina- tion (including scope of testing) of pressure-containing components made from steel castings shall be stated on the order. Continued on pages 2 to7 DIN 1690 Pan 10 Engl. Price group 7Page 2 DIN 1690 Part 10 Weld end made to at least severity le Transition piece (made from Figure 1. Vaive wit forged or rolled steel) ith transition pieces Made to at least ‘severity evel MS2~ AV2 Made to severity level MSt ~ RVI Figure 2, Valve without transition pieces where no specific qualitylevel orseveritylevel combination has been specitied, the requirements of quality evel D shall be complied with 3.2. The manufacturer shall immediately check all pattern ‘equipment supplied for its shape, dimensions, proper func- tion, and suitability for producing the required number of ‘castings. and inform the purchaser of any defects or defi ciencies found, 4 Requirements 41 General 4.14 © Where valves are to be supplied with transition pieces made from rolled or forged steel, the weld ends s comply with the severity level specified in figure 1, which corresponds to quality evel B. Where weld ends are of size DN 250 or greater, verification ‘of compliance with the requirements of quality level B shall, be provided. welds ends, such verifica: tion may be dispensed with provided the quality level ofthe valve body need not to be verified 4.42», _merevate artobe suppledinoutranston .ces made from rolled of forged steel, the weld ends shall Bemade to the severity level specfedin igure 2.and root ‘of compliance wit the relevant quality level shallbe provided 44.3 _Allother valve body parts (e.g.brackets,tlanges, ribs) land other cast valve Body components (e.g. obturators, levers) shall be produced to quality level D. 4.2. Valve production 4.2.1, Manufacturing process » ‘Other values may be agreed atthe time of ordering (eg. in compliance with DIN 3840)4.22 Production welds All production welds carried out shall pass a welding proce- dure qualiication test as specified in StahiEisen-Werk- stoffblatt (Iron and steel materials sheet) 110 or the equiva- lent. Where such a testis carried out it should be noted that,con- trary to the specifications made intine 3of tables 2.1and2.2 of that document, where welding is carried out using weld- Ing rod,an electrode or wire that is one size larger or smaller than the diameter specified, further testing must be carried out 4.2.24 8 Unless otherwise agreed, production welds shall be carried out using filer metals which have been test- ed for suitability in accordance with VaTUV-Merkblatt (VaTUV instruction sheet) 1153. 4.2.2.2 Where the results of the check forthe surface con. ition of the internal soundness of pressure-containing ‘components are unsatisfactory (ct. subclause 4.2.2), the Procedure described in the flowchart overleaf shali be Tollowed. Production welds shall be checked for their surface condi- tion and, where they are assigned to quality level A.B of C, {or their internal soundness.in the case ot holes in the valve DIN 1690 Part 10 Page 3 body that are closed by welding, the surtace condition of the weld shall be checked on both sides, along with radio- ‘araphic or ultrasonic inspection, The check for surtace condition and, where required, utra- ‘sonic inspection shall be carried out after final heat treat ‘ment, it being permitted to carry out radiographic inspec: tion beforehand, Where large zones have undergone extensive welding (ie-over 40% of the wal thickness, as definedin DIN17 246), the documentation shal be as specified for procedure 2 in figure 3 4.2.2.3 Where minor surface imperfections are detected after final heat treatment, and where such are to be reme- died, the manufacturer and purchaser may reach agree- ‘ment as to whether production welding is necessary, due Consideration being given to the required design wall thickness. Where castings made from GS-C 25, GS-C 25N. GS-20 Mn or GS-20 Mn SVstee! have undergone welding in zones smaller than those specified in subclause 4.2.22,it may be agreed to dispense with stress-relieving, provided the other requirements specified in DIN 17245 are com plied with,Page 4 DIN 1690 Part 10 Kiser ana terparngsnnesng or sou echig svt conan asi) Manutactro(M) to enecraurace andion?) ‘lpradacton melee) radoarepic mapedton®,3) eat veatment quenching a tempering sormatsing or toe Nonfat rested tt cneck toe conation?) (creck ot over sna of easng Mio pram tras teat on zones ‘domed nbeiaue 02235) Prosvcton wg without eins aa | to checxcutacecongtion ‘proaucton eige®) FB cneck ores souraness®) =) “Gompation of decumoriation Figure 3. Flowchert for the production and testing of steel castings {As specified in this standard ‘Those parts of the casting and production welds which have already successfully undergone testing need not be retested The purchaser shall be consulted with regard to produc- tion welds required at a late stage of manufacture, Ct. appendix B of DIN 17245 with regard to castings made from GS-C 25, GS-C 25N, GS-20 MnSV or GS-20 Mn5N steel Ultrasonic testing of large production-welded zones shall also be cartied out for castings made from GS-18 CrMo910 (1.7379), GS-17 CrMoVS11 (1.7708), q G-XBCMNi12 (14107) oF GX22CrMoV121 (1.4991) steel Provided the material prior to heat treatment. is stil resist- ant to intercrystaline corrosion (ct table § of DIN 17 445) Or such is achieved by reducing the carbon content. Of the items given in the numbered boxes in the flow- chart above, the following steps shall be documented, as, 2 function of the relevant procedure (steps 2,8 and 13, only where results are satisfactory): procedure 0: 1,2, and 14; Procedure 1: 6,7,8, 9, 10,12, 19 and 14; procedure 2:1, 10, 12,18 and 14.43. Mechanical properties ‘The requirements specified for the mechanical properties ‘on which the particular design is based shall apply for all pressure-containing parts of the valve ody. 44 Overall condition of casting 4.4.1 €8 The surface of austenitic and ferritc-austenitic steel castings shall be blasted using, unless otherwise agreed, mineral or austenitic abrasives, use of ferrtic, abrasives not being permitted may also be agreed that castings be pickled to have a ‘matt finish which permits production welds to be recog: nized in the condition as supplied. The pickling solution sed shall not contain hydrochloric aca. 44.2 Internal and external imperfections shall be reme- died, 44.3 The surface appearance of castings shall be assessed on the basis of comparison with the sample images aiven in Technische Empfeniung (Technical Recom: ‘mendation) 359-01, issued by the Bureau de Normalisation de l'industrie de la Fonderie (Standardization Otfice of the Foundry Industry) as follows: a) castings not subjected to non-destructive testing shall ‘comply with at least sample image 4 § 1 or 4 $ 2; b) castings subjected to radiographic, magnetic partice or ultrasonic inspection shall comply with at least sample image 3 $ 1 0r 4S 2; ©) castings subjected to liquid penetrant inspection shall ‘comply with at least sample image 3 S 2. 4.44 ©8 Unless otherwise agreed, the information given in table 4, footnotes 2 and 4, of DIN 1690 Part 2 does not apply o the castings covered here,norare chaplets orchills permissible, 4.45. The pressure-containing parts of the valve body shall be sound, 5 Testing ‘Samples shall be taken that are representative ofthe entire cross section of the pressure-containing part of the valve body. Where possible, samples shall be cast on 5.1 Scope of testing 5.4 All parts of castings belonging to quality evel A or B shall be checked for their surface condition and internal soundness by suitable means (cf. subciause 5.2). ‘Assuming the foundry is subject to quality contro! proce- dures, the scope of testing required for castings to comply with quality level C or O shall be as follows 541.4 Quality evel C castings All purpose-made castings, prototypes and pilot lots shall bbe checked for their surface condition and internal sound- rness.8) All castings in series production need only be checked for their surtace condition, Samples taken at random shall be checked fortheirinternal soundness, the following having been satisfied (see table 2 for number of test pieces) 8) Aset of one to three samples shall be taken trom the initial cast in the case of new designs, new pattern equipment, and whenever a change is made to produc tion or design, or different materials are used, ) The following particulars shall be documented for the samples taken as above: 1. the results of the check for dimensional accuracy, material quality, surface condition, internal sound: ess and, where requested, condition of cut fac DIN 1690 Part 10 Page § 2. description ofthe casting process and the feeding and gating system; 3. a description of production conditions (e.g. mould ing plant, coremaking process, moulding material, Ccoating/dressing, casting temperature, etc) Such documentation shall be kept on file by the casting manufacturer for seven years after the end of production, unless otherwise specified After the prototypes have been properly documented, @ pilot lot (ct. subclause 2,7) shall be checked non-destruc- tively for surface condition and internal soundness. Checking the pilot Jot is intended to reveal any casting zones that would be likely to pose problems during the casting process. ‘The conditions specified for production of the prototype shall be complied with for series production, ‘Should any changes be made during series production to the processes or materials used (e.g.to optimize the design fr to correct errors). the valve manufacturer shall be imme: diately notified of such 5142 Quality evel O castings Quality level D is regarded as the customary standard of ‘quality with which a competent valve castings works can be expected to comply The scope of testing shall be as follows. All prototypes shall be checked for their surtace condition ‘and internal soundness. ®) All castings in series production, where the mass of a unit is ‘greater than 50 kg, shall be checked for their surtace condi- tion, That of random samples from units weighing 50kg or less shall be checked, itso recommended by the valve cast- ing works, Subclause 5.11.1 shall be complied with in respect of random sampling, The number of samples to be checked for their internal ‘soundness shall be as specified in table 2 ‘5.1.2 All sides ofall castings shall be visually checked for ‘compliance with the relevant technical drawing and with the relevant sample image specified in subclause 4.43. It may be agreed to visually check random samples of cas tings in series production. 5.2 Test procedures 5.21 Check of internal soundness Where castings made from ferritic, pealtic or martensitic ‘materials have a wall thickness up to 60mm, the check of internal soundness shall preferably be made by radiographic inspection. 12 Use of ultrasonic testing for wall thicknesses up to ‘60mm may be agreed at the lime of ordering. © In the case of wall thicknesses over 60mm, the test ‘method used shall be agreed at the time of ordering, ‘© Where ultrasonic testing is used, the assessment c ‘ia specified in table 3 of DIN 1890 Part 2 shall be the sub- ject of agreement, ‘Austenitic castings shall undergo radiographic inspection. 5.214 ® The images with which castings checked by means of radiographic inspection are to comply shall be the subject of agreement. ‘Quality level A or B castings as specitied here shall comply with test class B as specified in DIN S411 Part 2, except for valve bodies with a nominal size of not more than DN 150, where the minimum source-to-object distance may be in 8) #8 instead of the check for internal soundness, it may be agreed to make cuts through the valve body at citfer- ent locations, their number and location also being the subject of agreement.Page 6 DIN 1690 Part 10 Table 2. Scope of testing for the check of internal soundness for quality level C or D valve In series production ),2) Line] Re: Its of check of pilot lot 3) Quality level © Quality level 0 1 | Pilot lot unsatisfactory, All zones in which imperfections Were detected, plus an internal Soundness check of all surtaces of samples numbering 10% of an ‘acceptance batch, or at least three, ‘All zones in which imperfections were detected, plus an internal ‘soundness check of such zones ‘complying with quality level D, on ‘samples numbering 10% of an ‘acceptance batch, or at least three, three. Internal soundness check of all sur- faces of samples numbering 10% of fan acceptance batch, of at least soundness check of zones impertections complying with ‘quality level D were detected, on ‘samples numbering 10% of an acceptance batch, or at least thr 3 | Pitot tot complies with a least one level higher than that requir Internal soundness check of all sur- *d. | faces of samples numbering 3% of fan acceptance batch, or at least 2) Where the results of the check of internal soundness ar 1) All casts comprising the acceptance batch should be represented for testing purposes. detective zone(s) of all castings making up the delivery shall be subjected to radiographic inspection. 3) All checks shall be carried out prior to any production welding. unsatisfactory for one or mare castings taken at random, the accordance with test class A The image quality ofthe radio- ‘graphs shall be assessed in accordance with DIN 84108 Part 2 Quality class C or D castings as specified here shall be per- mitted to comply with test clase A and a loss stringent image quality. Where the source-to-object distance is reduced (cf. subclause 8.12 of DIN 54111 Part 2), film ‘complying with film G2 or the equivalent shall be used, ‘The radiographs shall be marked with a code number indi Cating the particular order and with a serial number. To indi- cate the particular flm used, a grid shall be stamped on the valve body surface and included in the radiograph. ‘A photograph shall be taken, or a drawing made, of the points on the valve body subject to radiographic inspection, and submitted as part of the documentation, The results of radiographic inspection shall be included in a test report. 5.2.1.2 The test report shall include the particulars speo- ified in DIN 94111 Part 2 (radiographic inspection) or in Stahi-Eisen’Prifblatt (ron and steel test sheet) 1922 (utr: sonic testing), 5.2.2. Check of surtace condition Magnetic particle inspection shall be used to check the sur- {face condition of castings made trom magnetizable tech (98 It may be agreed to conduct penetrant inspection in addition Inthe case of non-magnetizable or not completely magnet lzable materials (e.g. compound steels), only penetrant inspection shall be carried out. Since the results of magnetic particle and penetrant Inspection do not correlate with each other, the method selected shall not be changed in the course of production or further processing. Where a change occurs (@..in cast- ing geometry) which necessitates that penetrant inspec- tion be used instead of magnetic particle inspection, and ‘where the maximum permissible indications specified in table 2 of DIN 1690 Part 2are exceeded, the actual extent of imperfections shall be determined by measurement and ‘compared with the maximum permissible values specified in table 1 of that standard. The results of the check of surtace condition shal be includ- ed ina test report in accordance with Stahi-Eisen-Prifblatt 1936 (magnetic particle inspection) or StanhEisen-Prifolatt 1936 (penetrant inspection), 5.3 Documentation The inspection certificate shall state the particular non: destructive test method used, and all relevant test reports shall be submitted, 6 Marking 6.1 All castings shall be marked with: a) the casting manufacturer's mark and, where required, that of the valve manufacturer; ) material designation or number in accordance with the relevant material standard; Castings supplied with a DIN 50049 inspection document shall also be marked with ) the cast number or symbols indicating the date or period of manufacture, and symbols indicating that the test reports and the results listed in them are related to a particular test unit or casting (ct. clause 6 of DIN 1690 Part 1); the mark ofthe inspector (who has either been selected in accordance with relevant regulations or commis- sioned by the purchaser), 6.2 ©@ In the case of small castings supplied with an inspection certificate and delivered in crates, it may be agreed to dispense with marking of the castings them selves with the cast number. ¢DIN 1600 Part 10 Page 7 ‘Standards and other documents referred to DIN. 1690 Part 1 Technical delivery conditions for castings of metallic materials: general information DIN 1690 Part 2 Technical delivery conditions for castings of metallic materiale; stee| castings; classification into severity, levels on the basis of non-destructive testing DIN 3840 Valve bodies: design for resistance to internal pressure DIN 17245 Heat resisting ferritic cast steel; technical delivery conditions DIN 17445 Stainless cast steel; technical delivery conditions DIN 50049 Inspection documents for the delivery of metallic materials DIN 54 109 Part 2 Non-destructive testing; image quality of radiographs; recommended practice for determining image Quality valves and image quality classes DIN 54111 Part 2 Non-destructive testing; testing of metallic materials by X-rays or gamma-rays; radiographic examination of castings made from ferrous materials Stahi-Eisen-Werkstoffblatt110*) _Verfahrensprifung fur FertigungsschweiBungen an Stahlgu® (Welding procedure qualifica tion testing of production welds made on stee! castings) Stah-€isen-Prifblatt 1922) Ultraschallprifung von GuBstlicken aus ferrtischem Stahi (Ultrasonic testing of castings made ‘rom ferritic steel) Stahl-Eisen-Prifblatt 1995*) Obertlichenri8pritung von GuBsticken aus Stahl: Magnetpulverpritung (Surtace crack testing of steel castings; magnetic particle inspection) Stahl-Eisen-Prifblatt 1996+) OberfléchenriBprifung von GuBstUcken aus Stahl; Eindringprifung (Surface crack testing of steel castings; penetrant testing) VaTUV-Merkbiatt 1153. Richtlinien 1Ur die Eignungspritung von Schwei8zusétzen (Guidelines for suitabity testing of welding filer metals) (obtainable from Verlag TUV Rheinland GmbH, O-KoIn) Technische Emptehlung 369-01, issued by the Bureau de Normalisation de Industrie de la Fonderie, obtainable from Editions Techniques des industries de la Fonderie, 12, Avenue Raphael, F-75016 Paris, Explanatory notes This standard has been prepared by Technical Committee 11 Stahigus of the Normenausschué Eisen und Stahl (Stee! and tron Standards Committee) In defining the term heavy-duty valves'the responsible technical committee had originally intended this to include only those valves used in plants subject to inspection. Subsequent discussion, however, revealed that it would be expedient to include valves which, should they malfunction, either present a health hazard to persons or result in expense to the user. International Patent Classification B22 D 1100-27120 GOIN *) Obtainable from Verlag Stahleisen mbH, Postfach 82:29, D-4000 Disseldort 1