DELIVERY PROGRAM HEAVY FABRICATION DIVISION · 1 Cylindrical shell-course, fitted with 2 longitudinal weld-joints, ID 7.032 mm x 142 mm x 2.440 mm in steel grade 20 MnMoNi 4-5 to

HEAVY FABRICATIONDIVISION

DELIVERY PROGRAM

ums_3016_dihd_bro_hfd.411 01.10.2008 9:42 Uhr Seite 1

1

Cylindrical shell-course, fitted with 2 longitudinal weld-joints, ID 7.032 mm x 142 mm x 2.440 mm in steel grade 20 MnMoNi 4-5 to VD TÜV

440-1/00 manufactured at the Heavy Fabrication Division of Dillinger Hütte GTS

The products manufactured bythe Heavy Fabrication Divisionare supplied in the manner de-manded by the relevant stan-dards, technical delivery specifi-cations and other agreementsmade with the customers. The In-tegrated Management System iscertified to ISO 9001:2000, ISO

EN 14001:2005 and OHSAS18001:1999.The components can be suppliedin conformity with the relevantfabrication codes and standardssuch as PED 97/23/EC, EN13445, PD 5500, etc.Furthermore, a lot of specific ac-creditations are also available e.g.

AD-2000 Merkblatt W 0 / HP 0 / TRD 100 / 201 / 202ASME Section VIII-1 (U Stamp), Section VIII.2 (Stamp U2) and Section 1 (Stamp S)Manufacture License of SpecialEquipment People’s Republic of China (Pressure vessels: A1, A2, A3 and Boiler parts: A)

edition 2008

inh_3016_dihd_bro_hfd.411 01.10.2008 9:39 Uhr Seite 1

2

A conical transition piece being made (Inner diameter 2.700 mm / 1.450 mm x 70 mm, height 1.350 mm, steel grade SA 387 grade 11-1)


4Modular solutions for heavy plate fabrication

6Fabricated plates

10Cut-to-shape plates

12One-piece heads

20Multi-segment shell-sections

24Spherical shell plates

28Cylindrical shell-courses

32Technical delivery conditions

36Main fabrication facilities

38Material steel grades

40Some applications

43Your contacts

CONTENTS

3


4

MODULAR SOLUTIONS FOR

HEAVY PLATE FABRICATION

The Hussein Mosque in Cairo (Erection of the dome made of spherical segments ID 12.500 mm x 25 mm, Steel grade ST 52-3 to DIN 17100)


5

Anyone believing that the elegantdome of the Hussein Mosque inCairo is a work of ancient Orien-tal craftsmanship would bewrong. The roof structure is, onthe contrary, a product of themodern world: a 23 ton multi-segment hemisphere constructionmade of steel plates, manufac-tured in the Heavy FabricationDivision of Dillinger Hütte GTS.

It's a thin line between architec-ture and art: the "Serpentine" (cf. page 38) sculpture created bythe American artist Richard Ser-ra for the city of San Franciscowas also produced by the HeavyFabrication Division:Mr. Serra has been using thesteel production facilities inDillingen for several years.

And where technology is con-cerned, Dillinger Hütte GTS isreaching for the skies: When theAriane V takes off from theKourou space centre in French-Guyana, a part of Saar-mademetallurgy also goes into orbit.The starter material for thebooster domes, forging grade ingots made of a special alloy

from the Saarstahl AG, is rolledout to 16 ton circular blanks inthe Dillinger plate mill and subsequently processed intodished heads.

Naturally our employees are notalways involved in such spectacu-lar contracts. These examples dodemonstrate the extensive capa-bilities of the Heavy FabricationDivision, the essential aspect ofwhich remains the processing ofheavy steel plates.

However, we ourselves are notfabricators of finished equip-ment; we prefer to view ourselvesas service-providers to the manu-facturers of equipment involvedin heavy engineering. Much ofthe material coming out ofDillinger Hütte GTS is unusual:sometimes it's the dimensions ofthe plates (in most cases thethickness or the width), and other times it's the mechanicalproperties of the plates. And of-ten it's both.

Not all manufacturers of struc-tural steel constructions, pressurevessels or heavy apparatus want

to process such plates completelyon their own. We know our platematerial best of all and we alsohave the necessary equipmentavailable to process these heavyund thick plates. This is why weoffer to take care of the difficultfirst stages of the processing andsupply prefabricated structuralcomponents instead of just heavyplates.

The scope of products and ser-vices of the Heavy FabricationDivision is set out on the follow-ing pages; it includes modularheavy plate components, de-signed for specific fields of appli-cation. Our comprehensive rangeis the result of long years of expe-rience in cooperating with steelplate fabricators.

But don't take this as our finalword on the subject: if you dohave a special project or uniquerequirements such as the threeexamples cited above, we willprovide you, on an individual basis, with exactly the same service as offered to architects,artists and space engineers.

Heavy Fabrication Division Dillinger Hütte GTS, Modular solutions for heavy plate fabrication [1/1], 2008


6

FABRICATED PLATES

Fabricated plates equipped with machined weld-edges


7

The bevelling of edges is part ofthe current preparation whereverwelding is required. This appliesmainly to the construction ofstorage tanks, shaft linings,bridges, large pipes or tubular,pressure vessels and nowadayspiles for offshore wind-mills. Thesupply of edge-trimmed platesachieved by a machining processis one of the specialities ofDILLINGER HÜTTE GTS.

Manufacturing process

While traditional methods ofshaping weld-edges use shearing,flame cutting or planing, theplate edge-milling machine cutsall the excess material into finechips. The reduction to chip formis done by hard metal plateswhich are arranged at regular in-tervals at the outer circumferenceof the profile-milling heads. Themachined edges are geometrical-ly exact, smooth, even, and burr-free; their quality surpassesby far the quality of sheared or flame-cut plates. Since thethermal energy, which developsduring the reduction to chip

form, is virtually absorbed by the chips, the plate itself remainscold so that both hardening ofmaterial and resulting cracks canbe avoided.

The machining process is basedon the "HF milling" method asdeveloped by LINSINGER, theAustrian manufacturer of thisequipment: it provides a smoothrun and minimal vibrations despite the high performancenecessary for the reduction tochip form. The lay-out of themachine is designed for a contin-uous service so the interruptionsfor exchanging the profile-millingheads are minimised. The machine comprises two millingstations of 90 kW for processingsimultaneously the both longitu-dinal edges, one of the stationsbeing turned at 90° to assume the machining of the transverseplate edges.

Scope of supply

The edge preparation of plateswithin the thickness range of be-tween 5 mm and 120 mm is car-

ried out by milling; for largerthickness, flame-cutting will ap-ply. The 4 edges can be individu-ally equipped with a specificweld-edge preparation.

As the milling process is CNCdriven, the machine can dealwith rectangular, trapezohedraland annular-shaped plates. Special preparation like back-cladding and tapering can alsobe achieved along the weld-edges.

A high degree of accuracy and anexcellent cut-face quality i.e. ex-tensively free of hardening effectcharacterise the weld-edges pre-pared by a machining process,both being requirements for performance welding.Please refer also to the TechnicalDelivery Conditions on page 32.

Information required

Final plate sizes, rolling radius,weld-edge design.

Heavy Fabrication Division Dillinger Hütte GTS, Fabricated plates [1/3], 2008


8


Dimensional program

Shell plates machined flame-cut

Thickness 5 – 120 mm 10 – 230 mmWidth 1.350 – 5.000 mm 800 – 5.200 mmLength 4.000 – 25.000 mm 2.000 – 18.000 mmPlate weight 40 t 40 t

Shell-plates rolled to radius Halves 1) Thirds 1)

Thickness 15 – 230 mm 15 – 230 mmWidth 800 – 4.300 mm 800 – 4.300 mmLength 4.000 – 14.000 mm 4.000 – 14.000 mmRadius ≤ 4.000 mm ≤ 6.000 mm

1) Workable plate sizes and other shell design are subject to agreement.

I U

DU

V

DV

Notes: details of weld-edge preparation e.g. root radius and slope angle must be agreed.

Edge design


template

shell plate

A

Ri

RiA

A

template

shell plate


9

Standard tolerances

Edge preparation machined flame-cut

Bevel angle (γ, α) ± 0.5° ± 2.0°Land location (h) 1) ± 0.5 mm ± 2.0 mmLand height (a) ± 0.5 mm ± 2.0 mmRoot radius (R) 2) ≤ 0.5 mmSlope angle (β) 2) ± 0.5°Cut-face quality ISO 1302-N7/N8 ISO 9013-33

1) measured from the plate top side

2) applicable to U and DU edges only

Dimensions machined flame-cut

Width ± 1.0 mm ISO 9013-331

Length ± 1.0 mm ISO 9013-331

Difference between diagonals ≤ 2.0 mm ISO 9013-331

Edge straightness ≤ 1,0 mm

The dimensional tolerances apply to weld-edge prepared plates measured in the flat condition;

the tolerances on thickness and flatness are those agreed for the plate, e.g. EN 10029, ASTM A 6 or A 20.

Shape

Curvatureat the plate ends ≤ 2 mm / 500 mmaway from the end area ≤ 10 mm /2.000 mm

Straightness of the endss ≤ 20 mm ≤ 4 mm / 1.000 mms ≤ 40 mm ≤ 3 mm / 1.000 mms > 40 mm ≤ 2 mm / 1.000 mm

s = wall thickness Ri = internal radius A = deviation from the theoritical curvature

The shape deviations are measured as distance A between a template board (with a chord length of 500 mm respectively 2.000 mm) fitted with the radius and

the plate curvature: the checking is carried out as shown in the adjacent sketch after the plates are laid down on a measuring bed set to the nominal radius.


10

CUT-TO-SHAPE PLATES

Cut racks for jack-up rigs processed by flame-cutting out of a 178.5 mm plate in steel DILLIMAX 690


11

Cut-to-shape plates are intendedmainly for use in structural andmechanical engineering, e.g. asblanks for tool equipment orframes for hydraulic presses.


Cut-to-shape plates are profiledtrue to dimensions on NC flame-cutting machines with squareedge, further weld-edge prepara-tion being manually flame-cut.The contour is constructed fromstraight and circular-shapedlines, all other outlines are splitup into polygonal courses with ahigh definition.

Scope of supply

The blanks are supplied in thesteel grades within the plate De-livery Program of Dillinger HütteGTS preferably in pieces above 3 t in weight. They can also beprovided with enhanced wavinesstolerances against the standardse.g. EN 10029, ASTM A 6 / A 20and when required by the steelgrade also be supplied in thestress-relieved condition to suitsubsequent processing operationssuch as a machining. It is knownthat profile cutting involvesmostly an important platewastage; unless otherwise agreed

the scrap remains the property ofthe supplier i.e. the shippingcosts which apply to the resultingnet weight are therefore consider-ably reduced. Please refer also tothe Technical Delivery Condi-tions on page 32.


Shape description supportedwith a full-dimensioned drawing

Heavy Fabrication Division Dillinger Hütte GTS, Cut-to-shape plates [1/1], 2008

Standard tolerances

Quality of cut faces and dimensional tolerances according to ISO 9013-331

Edge design

Bevel angle ± 2° Land height ± 2 mmLand position1) ± 2 mm

1) measured from the plate top side

Dimensional program

Width ≤ 5.200 mm Thickness ≤ 410 mmLength ≤ 25.000 mm Weight ≤ 60 t


12

Hemispherical one-piece head, seamless: ID 3.520 mm x 70 mm in steel SA 516 grade 70 ASME II-A

ONE-PIECE HEADS


13

Heavy Fabrication Division Dillinger Hütte GTS, One-piece heads [1/7], 2008

One-piece heads serve for exam-ple as end pieces for pressurevessels and power boilers. Thewidest range of shapes is avail-able: spherical, torispherical,elliptical, etc. The flat heads i.e.flanged only within the proposeddimensional range are mainlyused for the fabrication of ladlesinvolved in metallurgicalprocesses.


One-piece heads in Dillingen arealways hot formed by deep-drawing, the circular blanks be-ing free of any weld seam. Theyare dished by the means ofhydraulic presses up to 2.500 tonsfitted with the proper tooling i.e.ring and die, the shape of whichsuits the inside contour of thehead. The edges are generallyworked by flame cutting; themachining of the weld-edgepreparation can be also agreedupon for heads with wall thick-nesses above 30 mm.

Scope of supply

Seamless heads can be suppliedspherical-shaped in outsidediameters up to 3.650 mm, tori-spherical or elliptical-shaped upto 4.450 mm or flanged only upto 4.750 mm. The "DimensionalProgram" table provides infor-mation concerning the standardshapes, diameters and wallthicknesses to which the headscan be manufactured:intermediate dimensions andother head shapes must beagreed upon. Please refer also tothe Technical Delivery Condi-tions on page 32.


14

Dimensional programWall thickness related to the external diameter for the different shapes

Outside diameter Thickness (mm)(mm) Elliptical1) & Spherical 3) Flanged only 4)

torispherical 2)

from up to from up to from up to

1.000 & 1.050 6 90 12 90 - -1.100 & 1.150 6 90 13 100 - -1.200 & 1.250 6 100 14 120 - -1.300 & 1.350 6 100 15 130 - -1.400 & 1.450 6 110 16 140 - -1.500 & 1.550 7 120 17 150 - -1.600 & 1.650 7 120 18 170 - -1.700 & 1.750 7 130 19 180 - -1.800 & 1.850 7 130 20 200 - -1.900 & 1.950 8 140 22 200 - -2.000 & 2.050 8 140 24 200 - -2.100 & 2.150 9 150 26 200 - -2.200 & 2.250 9 150 28 200 - -2.300 & 2.350 10 160 30 200 20 752.400 & 2.450 10 160 32 200 20 752.500 & 2.550 11 170 34 200 20 802.600 & 2.650 11 170 36 180 20 802.700 & 2.750 12 170 38 180 22 852.800 & 2.850 12 170 40 180 22 852.900 & 2.950 13 170 40 160 22 903.000 & 3.050 14 170 40 160 22 903.100 & 3.150 15 170 40 150 22 1003.200 & 3.250 16 160 40 150 24 1003.300 & 3.350 17 160 40 140 24 1003.400 & 3.450 18 150 40 140 24 1003.500 & 3.550 19 150 40 130 24 1003.600 & 3.650 20 140 40 120 24 1003.700 & 3.750 21 140 - - 24 1003.800 & 3.850 22 120 - - 24 1003.900 & 3.950 23 120 - - 24 1004.000 & 4.050 24 110 - - 26 1004.100 & 4.150 25 110 - - 26 1004.200 & 4.250 26 110 - - 26 1004.300 & 4.350 27 110 - - 28 1004.400 & 4.450 28 110 - - 28 1004.500 & 4.550 - - - - 30 1004.600 & 4.650 - - - - 30 1004.700 & 4.750 - - - - 30 100

The data on wall thicknesses apply for steel with 355 N/mm2 yield

strength. The flange height complies with the applicable standard or

the customer's requirements but - due to the tool design - is normally

restricted to 150 mm. Please inquire for other head shapes and inter-

mediate dimensions.

1) Elliptical heads to NF E 81-103 (axis ratio 1.9:1) und ASME

Code (axis ratio 2:1)

2) Torispherical heads to DIN 28 013 and SMS-482

3) Depending on the required design, the available diameters for

spherical heads can be restricted or enlarged

4) Flat heads can be produced with a knuckle-radius between 50

and 150 mm



15


Standard tolerances

Edge-preparation flame-cut machined

Bevel angle ± 2.0° ± 1.0°Land position 1) ± 2.0 mm ± 1.0 mmLand height ± 2.0 mm ± 1.0 mmMilling radius 2) ± 1.0 mmCut face quality ISO 9013-33 ISO 1302-N9

1) measured from the reference diameter Da or Di

2) applicable just to U and DU edges only

Diameter, out-of-roundness and shape according to applicable fabrication codes e.g. ASME I, ASMEVIII-1, ASME VIII-2, PD 5500, BS 1113, CODAP or AD 2000.


16



Torispherical heads

Shape(applicable standard or dishing radius r1and knuckle radius r2)Diameter Da or Di

Minimum wall thickness after forming sStraight flange h1

Weld-edge preparation

Elliptical heads

Shape (applicable standard or axis ratio b : a)Diameter Da or Di

Minimum wall thickness after forming sStraight flange h1


Flat heads, flanged only

Diameter Da or Di

Minimum wall thickness after forming sDishing radius or knuckle radius r1

Straight flange h1 or depth h3 (h1+h2)Weld-edge preparation

s

Di

Da

h 2 h 3

h 1

r 1

r 2

Di

Dah 2 h 3

h 1

s

b

a

Di

Da

h 3

h 1

r 2

s


17



Hemispherical heads with straight flange

Dishing radius r1 or inside diameter Di

Minimum wall thickness after forming sStraight flange h1 or depth h3 (h1+h2)Weld-edge preparation

Hemispherical heads (r1 = h3)

Dishing radius r1 or inside diameter Di

Minimum wall thickness after forming sWeld-edge preparation

Spherical heads

Dishing radius r1

Connecting inside diameter Dh or "negative" height h1 or

depth h3

Minimum wall thickness after forming sWeld-edge preparation

Di

Da

h 2 h 3

h 1

s

r 1

Di

Da

h 3

s

r 1

Dh

h 3h 1

s

r 1


18


1. Circular blank being removed out of the furnace once heated at the proper temperature

2. Circular blank being transferred to the 2500 t - hydraulic press by means of the overhead crane

3. Circular blank being positioned onto the forming ring laying on the lateral transfer lorry

HOT DISHING PROCESS OF

ONE-PIECE HEADSOD 4.200 mm x 80 mm in steel SA 516 grade 70


19


6. Dished head being extracted out of the forming tools

HOT DISHING PROCESS OF

ONE-PIECE HEADSOD 4.200 mm x 80 mm in steel SA 516 grade 70

4. Lateral transfer lorry being positioned within the operating area of the hydraulic press fitted with the forming die

5. Circular blank being dished


20

Trial fit-up of a multi-segment dome for a blast-furnace hot-stove(Dishing radii from 3.362 mm up to 6.430 mm, length 17.100 mm, height of

the largest spherical section 6.430 mm, Steel grade 15Mo3)

MULTI-SEGMENT SHELL SECTIONS


21

Heavy Fabrication Division Dillinger Hütte GTS, Multi-segment shell sections [1/3], 2008

When the required items exceedthe dimensions of the one-piececomponent, they can be producedin multi-segment design, eachpressing being supplied ready forassembly; the individual sizes ofthe segments can be also agreedupon.


The pressings comprising a mul-ti-segment shell are individuallyformed using tool equipment, theprofile of which suits the contourof the part being made. Theknuckle segments of torisphericalheads are basically hot-pressed;as are the relative crown segmentsand any pressings designed witha dishing radius up to approxi-mately 3.500 mm; above this

diameter cold-forming is applied.The weld-edges of the shapedsegments are produced by flamecutting.

Scope of supply

It includes mainly the fabricationof torispherical heads to DIN 28011 or NF E 81-102 andDIN 28013 or SMS-482 above4.450 mm in outside diameter andspherical heads above 3.650 mm inoutside diameter; the multi-seg-ment design can be also extendedto „tailor-made“ shell sectionssuiting a specific shape i.e. transi-tion pieces, reversible conical seg-ments and inlets for shaft liningsince no dimensional restrictionmust be observed. The multi-seg-ment design is an alternative to

the fabrication of items outsidethe manufacturing range of thecold spinning process which ismainly restricted to the shapingof wall thicknesses up to around30 mm. Please refer also to theTechnical Delivery Conditions onpage 32.

Trial fit-up

The pressings are produced tofabricate multi-segment headsor other large shell sections.When requested, the segmentsare trial assembled for the shopinspection by using key-platesand pins; clamping cams canalso be welded on which youcan later put to advantage aserection aids during the finalassembly.


22


Standard tolerances

Edge design knuckle crown

Bevel angle ± 2° ± 2°Land height ± 2 mm ± 2 mmLand position 1) ± 2 mm ± 2 mmCut-face quality ISO 9013-33 ISO 9013-33

Shape 1)

200 mm wide edge area 2) ≤ 3 mm/1.000 mm ≤ 2 mm /1.000 mmAway from edge area 3) ≤ 6 mm/1.000 mm ≤ 6 mm /2.000 mm

Dimensions

Arc length/arc width ± 2 mm ± 2 mmDiagonal difference ≤ 3 mm ≤ 3mmDiameter 4) 5) ± 0.1% Da ± 0.1% DaOut-of-roundness 5) ≤ 30 mm ≤ 30 mmInside height 5) ± 0.25% Da ± 0.25% Da

1) related to the internal surface

2) measured as a distance between a nominal shape template of

1.000 mm and the actual inner contour, the measuring position

being along the segment edges

3) measured as a distance between a nominal shape template of

1.000 mm respectively 2.000 mm and the actual inner contour, the

measuring position being vertical to the plane defined by the

circumferential weld-edge

4) calculated from measured circumference

5) only when trial assembled


23


Torispherical heads

Shape (applicable standard or

dishing radius r1 and knuckle radius r2)Diameter Da or Di

Arrangement of segmentsDiameter of crown Dk

Straight flange h1

Minimum wall thickness(es) after forming s

Spherical heads

Dishing radius r1 and inside diameter Di

Arrangement of segmentsDiameter of crown Dk

Minimum wall thickness(es)after forming s

"Tailor-made" shell sectionsPurpose for which they are usedDrawing including full measurementsMinimum wall thickness(es) after forming s

crown

Di

Da

Dk

h 3

h 1

r2r 1

s

knuckle

s

s

s

r 1

Di

Da

Dk

s

s

crown

sphericalcourse



24

SPHERICAL SHELL PLATES

Fit-to-assembly segments comprising a spherical tank (Inside diameter 22.500 mm x 95 mm, steel grade SA 537 class 2)


25

Spherical shell-plates are tailor-made segments(„petals“) manufactured readyto install spherical storage vessels where the emphasis isplaced on the high dimensionalaccuracy of the individual segments.


Taking into account the mater-ial properties, the plate thick-ness and the required radius,either cold or hot forming canbe used. In both alternatives,the shaping process is conduc-ted in a „safe“ way so that thesteel mechanicals remain pre-served. The segments for

spheres above 7.000 mm in diameter are normally manu-factured cold by progressivedishing. Once the segments areshaped properly, the weld-edges are subsequently engi-neered by flame cutting.

Scope of supply

Unless otherwise required, thearrangement and the sizes ofthe segments are optimised byconsidering the available shopfacilities, the transport condi-tions and the field erectionconstraints. Depending on thematerial and on the formingradius, the “petals” are fabri-cated in thickness of up to 110

mm in width, of up to 4.000mm and in length of up to12.000 mm: the final pieceweight is generally restricted at 23 to. The scope of supplyincludes also “petals” fabricat-ed from material produced bythermo-mechanical controlledprocess (TMCP) or by water-quenching process (QT). An extensive experience allowsmanufacturing the segmentsready for assembly without anyshop trial fit-up.

Please refer also to the Technical Delivery Conditionson page 32.

Heavy Fabrication Division Dillinger Hütte GTS, Spherical shell plates [1/3], 2008


26


Dimensional program Format of largest workable segment in relation to inside diameter and wall thickness

hot forming

cold forming

Wal

l thi

ckne

ss s

(m

m)

2.000 4.000 6.000 8.000 10.000 12.000 14.000 16.000 18.000 20.000 22.000

10

20

30

40

50

60

70

80

90

100

Inside diameter of sphere Di (mm)

2.50

0 m

m �

2.5

00 m

m1)

2.50

0 m

m �

4.0

00 m

m1)

2.75

0 m

m �

6.0

00 m

m1)

3.00

0 m

m �

8.0

00 m

m1)

3.00

0 m

m �

10.

000

mm

1)

4.00

0 m

m �

12.

000

mm

1)

24.000

1) The dimensions (length and width) are given by arc measure. The data on wall thickness apply to steel with 355 N/mm2 yield strength.


27


Inside diameter Di

Arrangement of segmentsMinimum wall thickness(es) after forming sFabrication code

Spherical shell plates are always outlined by longitudinal or latitudi-

nal arcs, either by "great circles" (with circle centre in sphere centre)

or by "small circles" (with circle centre outside the sphere centre).

All dimensions are given by arc measure related to the inner surface.

Unless otherwise agreed, allowance for assembly root-gap or for

welding shrinkage will not be taken into consideration.

s4

ß1

aDi

s5

s6

s1

s2

s3

�6

�5

�4

�3

�2

�1

crown

upper course

equatorial course

bottom

Schematic description of lay-out

ß2 ß3

ß4


Standard tolerances

Edge design Bevel angle ± 2°Land height ± 2 mmLand position 1) ± 2 mmCut-face quality ISO 9013-33

Dimensions Arc length ± 2 mmArc width ± 2 mmDiagonal difference ≤ 3 mm

Shape1) 200 mm wide edge area 2) ≤ 2 mm/1.000 mmaway from edge area ≤ 6 mm/2.000 mm

segment

A

RiA

A

template

segment

Ri

template

The shape deviation is measured as distance A between a template with a chord

length of 1.000 mm respectively 2.000 mm and the spherical segment laying down

on a measuring bed set to the nominal radius.

1) related to the internal surface

2) measuring position: along the plate edge

(Ri = inside radius)


28

CYLINDRICAL SHELL COURSES

Cold forming process by means of the 4-roll bending machine (8.600 t force) of a cylindrical shell-course in steel grade 20 MnMoNi 4-5 to

VD TÜV 440-1/00 designed for a petrochemical reactor


29

Cylindrical shell-courses are basic items entering in a lot ofapplications such as componentsfor pressure vessels or structuralsections.


Shell-courses are produced bycold or hot forming, the choiceof the process being a functionof both the shell sizes and thematerial properties. They arepreferably supplied fully welded:welding is performed by usingeither single-electrode, two-elec-trode or twin-arc submerged arcmethods in accordance with theprovisions of the relevant inter-national codes, for example AD,ASME (Stamps U, U2 and S areavailable), PD 5500, CODAP,TRD. Depending on the material and code requirements,the formed parts can be givenproper heat treatments, for instance normalising, tempering,water-quenching.

Optionally, the shell-courses aresupplied just tack-welded -

achieved from the outside -within the longitudinal joint orbraced at both ends by usingstrong-backs.

As a rule, the plate edges of thelongitudinal joint are preparedby a milling process performedfrom the outside what makes a“narrow gap” weld-joint of 18°achievable. The circular weld-edges of shell-courses are usual-ly produced by flame cutting;edge-machining of shell-coursesup to 2.550 mm in length can beagreed.

Scope of supply

The forming is achieved bymeans of a 4-roller machinepowered with 8.600 t force, designed to deal with 4.300 mm(169,2") wide plate. Its perfor-mance includes the cold formingof shell-course up to 240 mm(9,4") in thickness at the fullplate width; three interchange-able top rollers (880 mm, 1.200mm and 1.500 mm) enable tocover a very wide range of diameters.

This machine has been speciallyengineered for heavy sectionplates made out of high strengthsteels characterised by a yieldpoint of 700 MPa. Such anequipment is particularly advan-tageous for steel grades wherehot forming is always problem-atic e.g. for all steels intended tobe delivered either in the water-quenched ( QT ) or in the thermo-mechanically processed ( TM ) condition.

When required the forming canbe also performed by using a hotprocess, conducted in the way tokeep extensively the surface fin-ish free of the usual discontinu-ities resulting from this kind ofprocess.

Please consider also the Technical Delivery Conditionson page 32

Heavy Fabrication Division Dillinger Hütte GTS, Cylindrical shell courses [1/3], 2008


30


Performance chart of the roll-bending machinebased on a cold forming process up to 4.300 mm (169,2'') in course length

300

290

280

270

260

250

240

230

220

210

200

190

180

170

160

150

140

130

120

110

100 90 80 70 60 50 40 30 20 10 0

800

1.00

01.

200

1.40

01.

600

1.80

02.

000

2.20

02.

400

2.60

02.

800

3.00

03.

200

3.40

03.

600

3.80

04.

000

Insi

de d

iam

eter

[mm

]

Wall thickness [mm]

Yie

ld s

tren

gth

550

MP

a (8

0 ks

i)

Del

iver

y pr

ogra

m o

f sh

ell-

cour

ses

upon

enq

uiry

1.500 mm top roller

1.200 mm top roller

880 mm top roller

Yie

ld s

tren

gth

240

MP

a (3

5 ks

i)

Yie

ld s

tren

gth

360

MP

a (5

3 ks

i)

Yie

ld s

tren

gth

700

MP

a (1

00 k

si)


31



Diameter Di or Da

Length L

Minimum wall thickness after forming s

Edge-design

Welding requirements and fabrication code

L

Di Da

s

Standard tolerances

Edge-preparation flame-cut machined

Bevel angle ± 2.0˚ ± 1.0˚Land position 1) ± 2.0 mm ± 1.0 mmLand height ± 2.0 mm ± 1.0 mmRoot radius 2) ± 1.0 mmCut-face-quality ISO 9013-33 ISO 1302-N9

1) measured from the reference diameter Da or Di

2) applicable to U and DU edges only

Diameter 1) ± 0.3 % DOut-of-roundness 2) ≤ 1 % DLength ≤ 3 mmStraightness ≤ 1 mm /1.000 mm

1) calculated from the measured circumference

2) The out of roundness is defined by 2(D max - D min)/

D max + D min).


32

TECHNICAL DELIVERY CONDITIONS

Weld-edge machining of a hemi-spherical dished head (ID 3.100 mm x 100 mm)


33

Heavy Fabrication Division Dillinger Hütte GTS, Technical delivery conditions [1/2], 2008

Plate processing

Basically the applied processingoperations comply with the recom-mendations made by the steelmaker having produced the plates.Furthermore, the fabrication oper-ations meet the guidelines of SEW88 - German directives governingthe processing of heavy steelplates. The requirements containedin the relevant fabrication codessuch as AD, ASME, CODAP,PED 97/23/EC, EN 13445, PD5500, etc. can also be agreed. Depending on the material steelgrade and the applicable specifica-tions, the formed parts can be giv-en proper heat treatment e.g. nor-malizing, water-quenching, tem-pering, stress-relieving. As a rulethe mechanical properties of everypressing shaped by hot formingare verified by using test couponsremoved from the forming al-lowance after completion of theforming process and tested in thefinal heat treatment condition.

Dimensional and shape accuracy

The Product Information Sheetson the pages 6 to 31 include spe-cific details regarding the standardfabrication tolerances; they applyunless otherwise agreed and arevalid at the time of the shop in-spection. Supporting structures,the type of which is to be agreedupon, can be necessary to maintainthe shape during transport andstorage. In the case of packagesi.e. joint delivery of shell-courses

with pressings, the accuracy of thecomponents to each other shall bewithin the permissible misalign-ment required in the applicablecode.

Surface condition

The items are supplied with un-treated surfaces in line with theprocessing method used; by agree-ment the surface quality can beevaluated against EN 10163: Part1 and 2. It can also be agreed thatthe surface of the manufactureditems must be descaled andprimed in accordance with ISO8501-1 (SIS 05-5900) or equiva-lent standard. The surface preser-vation of shell-plates is generallycarried out prior to the processingoperations (weld-edge preparationand shaping to radius). The plateweld-edges can be also protectedagainst corrosion by using a suit-able coating, the type of which issubject to agreement. The surfacetreatment can also be subcontract-ed to an external company whosequality system is controlled byDillinger Hütte GTS.


Items supplied in the multi-seg-ment design ready for assemblyare produced with weld-edgepreparation. Any requirement fortapering must be additionallyagreed upon. The edges of cut-to-shape plates, pressings and cylin-drical shell-courses are as a ruleworked by flame cutting, the cut-

face being subsequently processedfree of scale and slag accumula-tion by grinding. Edge details de-scribed in the relevant standardssuch as API 650, DIN 8851, NF E81-110 („I“, „V“, „Y“ in single orin double design) can be engi-neered: the cut-face quality is inline with the cutting process. Anymachining of weld-edge prepara-tion for heads and shell-coursesmust be additionally agreed. Weld-edge protection against corrosioncan also be provided on request.

Identification

Each item produced by DillingerHütte GTS is originally marked in accordance with the applicableplate standards; it is additionallyidentified by using a sequentialpiece number to ensure the trace-ability of the manufactured partsalong the fabrication operationsback to the Inspection Test Certifi-cates of the initial material issuedby the plate mill. The markingsare as a rule made on the top sideof the plate i.e. on the concaveside of the curved shell-sections.Unless otherwise agreed, headsand pressings are marked on theoutside surface. The shippingmarks are stencilled in the mannerrequired in the purchase order. Additionally the items areequipped for transit with the brandname and the emblem of DillingerHütte GTS.


34

1/6 Sinusoidal segments ready to install a tunnel lining of an underground station, situated in a mining area (Clear diameter 6.300 mm, wall thick-

ness 19 mm, steel grade ST 52-3 to DIN 17100)


35

Contract work

In the case of free issued plates i.e.plates produced outside the worksof Dillinger Hütte GTS, all pro-cessing conditions must be agreedin advance i.e. before release forfabrication; this concerns especial-ly the hot forming parameters,the machining and the materialallowances for forming.

Packaging

The items are usually providedloose and unsecured: shaped partssuch as dished heads, pressings orcurved shell-sections are just lay-ing on wooden timbers fitting theoutside curvature, usually withthe inner side upwards. Shell-platesare stacked into lifting units sepa-rated from each other by means ofwooden spacers. Other types ofmeasures for packaging, securingand lashing e.g. the supply of skidsor pallets, any supporting struc-tures being necessary to maintainthe shape during transport, thestowing into containers, the weld-ing of lifting lugs, the use of spac-ers between each shell-plates arealways subject to agreement. Anyspecific packaging and lashing re-quirements have to be agreed

along with the purchase order.


In order to be able to process yourrequirements, we need a range ofdetails listed as follows:

Material steel gradeAcceptance conditions (plate material and fabricated item)Testing condition (when deviating from the as-deliveredcondition)Final heat treatment conditionFabrication code (mandatory for welded parts)Weld-edge preparationDimensions

Please refer also to the tables "In-formation required" of the ProductInformation Sheets on the pages 6to 31. For the parts outside thestandard delivery program, pleasesupport always your inquiry with asketch showing the contour designof the part to be manufacturedincluding all measurements.

Documentation

Unless otherwise required, an in-spection test certificate to EN10204-3.1 is provided for the basematerial and the manufactureditem as well. By agreement, the

documentation can be extendedand include for instance some fab-rication and control procedures,quality plan and shop drawings.

Enlarged scope of supply

The Heavy Fabrication Division iswell equipped to deal with yourorders. The table on page 37 pro-vides an overview of the main ma-chinery. Any design work, fabrica-tion of finished equipment anderection on the field are basicallyoutside the services offered byDillinger Hütte GTS. On requestthe individual components can bepre-assembled into heavy units.Items of up to a total weight of 100to and 18.000 mm in length can behandled. The joint delivery ofcomponents with unfabricatedplates is subject to agreement.

Logistics

The manufacturing plants are in-stalled in covered bays with a totalsurface area of around 39.000 m2.All bays have both a road and arail link. Furthermore, an accessto the company's own port facili-ties on the river Saar is available.

Heavy Fabrication Division Dillinger Hütte GTS, Technical delivery conditions [2/2], 2008


36

FABRICATION FACILITIES

2.500 ton hydraulic press


37

Heavy Fabrication Division Dillinger Hütte GTS, Fabrication facilities [1/1], 2008

1) diameter of the circular blank

2) maximum barrel length

3) minimum inside diameter

4) clear height

5) clear diameter

6) cutting medium: oxygen with acetylene or

with natural gas

7) normalising / tempering / stress-relieving

8) depth of the U-groove preparation for nar

row-gap welding

Main machinery Thickness Width Length Clearance Diameter(mm) (mm) (mm) (mm) (mm)

Forming cold hot

- multi-purpose press ( 2.250 t ) 110 170 4.900 1)

- multi-purpose press ( 2.500 t ) 125 200 5.400 1)

- trimming-press ( 4.000 t ) 140 4.000

- 4-roll bending machine ( 1.500 t ) 25 4.000 2) 750 3)

- 4-roll bending machine ( 8.600 t ) 240 350 4.300 2) 1.000 3)

Machining

- NC vertical lathe 2.550 4) 6.100 5)

- CNC plate-edge milling machine 120 5.000 25.000

- milling machine for weld-edge preparation of longitudinal joints and back-gouging 160 8) 4.300

Flame cutting

- NC profile-cutting machine 6) 200 5.500 15.000

- NC profile-cutting machine 6) 410 9.800 40.000

- equipment for edge-preparing of heads 200 4.500

Heat treating

- boogie hearth furnace 7) 4.300 10.000 3.600 4)

- walking beam furnace 7) 5.500 8.250 1.800 4)

- walking beam furnace 7) 6.000 12.500 2.300 4)

- deep quenching water pools for accelerated cooling

Welding The welding facilities comprise semi-automatic and automatic equipment for submerged arc welding and inert gas welding ( SMAW, SAW and TIG )

Note

All information related to the above equipment are just given for reference purposes: the actual manufacturing capability must be enquired.


38

MATERIAL STEEL GRADES

The sculpture "Serpentine" by Richard Serra during the trial shop erection (Length: 33.000 mm x 4.000 mm x 45 mm, weighing over 100 tons)


39

Heavy Fabrication Division Dillinger Hütte GTS, Processed steel grades [1/1], 2008

For the manufacture of the com-ponents described on the previ-ous pages, the Heavy Fabrica-tion Division processes theheavy plates produced by theplate mills of Dillinger HütteGTS. The exact knowledge ofour materials makes it possiblefor us to exploit the absolutetechnical limits of their process-ing possibilities.

Dillinger Hütte GTS as the Eu-ropean market leader for heavyplates is indeed the right addressfor highly demanding tasks. Theplate delivery program includesa wide range of low alloyed carbon steel grades to Germanand international standards e.g. - weldable fine-grain structural

steels,- high-strength quenched and

tempered fine-grain steels,

- special low-temperature weldable steels,

- low-temperature nickel-alloyed steels (up to 5 % Ni),

- abrasion-resistant structural steels,

- alloyed and unalloyed hard-ening and heat-treatable steels,

- conventional CrMo steels and vanadium enhanced CrMo steels for general structural applications, ship-building industries, pipe-lines, penstocks, boiler and pressure vessels (hydro-treating petrochemical reactors), etc.

Sometimes enquiries for particu-lar grades are made on heavyplates outside the scope of thestandard. Dillinger Hütte GTSprovides the proper solution for

the most frequent required addi-tional properties e.g.:- Low carbon equivalents- TTT properties to ASTM-A

770 and EN 10164- High resistance to Hydrogen

Induced Cracking (HIC)- Defined resistance to Sulfide

Stress Cracking (SSC)- Insensivity to embrittlement

in CrMo-alloyed pressure vessel steels as evidenced withstep-cooling tests, J and X factors

- Longitudinally profiled plates, i.e. with variable thickness over the plate length for structural steel qualities to EN 10 025, EN 10 113 (Part 2) and EN 10 115.

DILLIDUR: water-hardened wear-resistant steelsDILLIMAX: high-strength water-quenched and tempered structural steels forwelded componentsDIWA: alloyed high-strengthfine-grained steels for steam-boilers and pressure vesselsDICREST: fine-grained steels for pressure vessels andstorage tanks with resistanceto sour gasDIROS 500: high-strength water-quenched and tem-pered pressure vessel steels for low-weight designs

DILLINAL 460/630: high-strength fine-grained steels for tanks used for the transport of liquefied gasDIZINC: special structural steels for galvanizing pots with extended service-lifeDI-MC: thermo-mechani-cally-rolled structural steels with optimised processing propertiesDIWETEN: structural steelswith improved atmospheric corrosion resistanceDICUT: steels with optimised laser-cutting properties

DIMARINE: thermo-mechanically-rolled shipbuilding steels with opti-mised processing propertiesDIMO: steels for plastic mouldsDIPRO: armoured steels for civil safety applicationsDISAFE: high-strength thermo-mechanically-rolled fine-grained structural steels for safesDICLADUR: roll-bonding clad dual layer steels for use under abrasive conditions

Dillinger Hütte GTS has also developed some brandnamed steels optimised versus a range of individual applications, e.g.:

More details about the brandnamed steels are available in Material Data Sheets; they can be downloaded at www.dillinger.de or www.heavyplate.com.


40

Flat head, flanged only, seamless (Outside diameter 4.100 mm x 95 mm, knuckle radius 100 mm, steel grade WStE355)

Spherical head, seamless (Inside diameter 2.275 mm x 185 mm, steel grade StE355)

SOME APPLICATIONS


41

Deep quenching of a cylindrical shell courses (ID 1.750 mm x 116 mm x 4.200 mm, steel SA 387 grade 11-2)

Elliptical one-piece head OD 4.450 mm x 80 mm in steel SA 516 grade 70 ASME II-A

SOME APPLICATIONS


42

Hot dished and water-quenched segments being trial-fitted on the shop floor into a toriconical course (ID1 5.200 MM / ID2 3.200 mm x

2.300 mm x 60 mm) in steel SA 387 12-2

Knuckle of a torispherical head in segments ID 15.200 mm x 28 mm in steel A 516 Grade 70 ASME II-A, being trial-fitted for shop inspection

SOME APPLICATIONS


43

YOUR CONTACTS

How to find us

Further information on delivery programme are provided by the customer service team available at the Heavy Fabrication Division that will support you actively in helping you to elaborate the right solution to your problem.

Whenever you need assistance, please contact:

Aktien-Gesellschaft der Dillinger HüttenwerkeHeavy Fabrication DivisionPostal address: P.O. Box 158066748 Dillingen/SaarGermanyLegal address:Werkstrasse 166763 Dillingen/SaarGermany

Phone: +49 68 31 47 2342Fax: +49 68 31 47 3346E-mail: [email protected]

HANNOVER BERLIN

STUTTGART

MÜNCHEN

FRANKFURT

LUXEMBURG DILLINGEN

SAARBRÜCKENMETZ

STRASBOURG

BASEL

PARIS

SEINE

RHEIN

MOSELDONAU

ELBE

WESER

MAIN

E 35

E 51

E 25

E 35

E 52

E 40

E 55

E 56

E 15

E 50

E 21

E 09

E 05

E 15

E 411

AMSTERDAM

BRÜSSEL

ANTWERPEN

ROTTERDAM

DÜSSELDORF

KÖLN

FRANCE

GERMANY

GREATBRITAIN

CZECHREPUBLIC

AUSTRIA

SEANORTH

LONDON

NETHER-LANDS

BELGIUM


Aktien-Gesellschaft der Dillinger HüttenwerkeHeavy Fabrication DivisionP.O. Box 158066748 Dillingen/SaarGermanyPhone: +49 68 31 47 23 42Fax: +49 68 31 47 33 46

Liability: any information on fabricationprocess, plate material and pro-duct suitability are providedwithout guarantee; assurance regarding specific properties and fields of application requires always a written agreement.


Del

iver

y P

rogr

am H

eavy

Fab

rica

tion

Div

isio

n,20

08

ums_3016_dihd_bro_hfd.411 01.10.2008 9:42 Uhr Seite 4

Documents

DELIVERY PROGRAM HEAVY FABRICATION DIVISION · 1 Cylindrical shell-course, fitted with 2 longitudinal weld-joints, ID 7.032 mm x 142 mm x 2.440 mm in steel grade 20 MnMoNi 4-5 to