Offshore Letter 2 2010 - Dillinger Hütte GTS

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Offshore Letter 2 2010 - Dillinger Hütte GTS

Dillinger Hütte - a plate producer with a long and proud tradition

Production at Dillingen started with cast

iron, the products being used to meet the

needs of fortresses constructed in the

surrounding area, and for military

equipment. The raw materials for production

were readily available nearby – wood and

water, as energy sources, and low-grade iron

ore located in easily recoverable form close

to the surface. Even then, the mill operated

in an economic environment that

necessitated continuous refinement of the

technologies used and the quality of the

goods supplied to meet market requirements.

Following initial forged plate

products, the first rolled plate was produced

more than 200 years ago. In addition to sheet

iron for further processing to thin plate,

heavy plates for various purposes were

produced. This is now effectively Dillinger

Hütte’s “only” product.

The 3.6 m rolling stand in Dillingen 1913

The input at Dillingen for production of

plates for the most diverse applications is

impressive. The world’s first continuous

caster for steel slabs was installed here more

than fifty years ago, for example. Today,

slabs with thicknesses of up to 400 mm

can be cast, with special benefits for the

production of plate for the offshore

industry. Such heavy slabs can be used

to achieve high plate weights, with

significant economic advantages for the

fabrication yards, thanks to the resultant

reductions in welding costs. In addition,

the high deformations of the material

during the rolling process result in

excellent mechanical properties at half

thickness. Dillingen was also one of the

leading pioneers in production of

thermomechanically rolled plates. Material

produced using this highly

sophisticated process possesses welding

properties significantly superior to those of

conventionally rolled and normalized plates.

Dillinger Hütte was also the first heavyplate

producer to combine thermomechanical

rolling and accelerated

cooling by water in the rolling

process. This innovation modifies

the internal structure of the plate and

improves mechanical properties

even further. Develop-ment and

production of this plate is always

conducted in close cooperation with

the customer. Indeed, Dillinger

Hütte’s 325-year evolution from a

simple iron-maker to a producer of

highly sophisticated plates would

probably not have been possible

without such intensive collaboration

with customers.

A look back over Dillinger Hütte’s 325-year

history is highly instructive. This

retrospective of the AG der Dillinger Hüttenwerke

is an inspiration both to the

company itself and to its customers. It

The AG der Dillinger Hüttenwerke (Dillinger Hütte)

celebrates its 325th anniversary this year. What does this

mean for the steel user?

Since 1685, Fe - the chemical element iron - has been the

basis of virtually all products supplied by Dillinger Hütte.

The production and use of scarcely any other material have

been so greatly influenced by technological developments

across such a long period as those of iron. What began as

simple cast iron, with high carbon and impurity contents,

has matured into a product which, thanks to the latest

technologies, now meets the highest standards for

mechanical and welding properties.

demonstrates that the company is always

following its vision to develop perspectives

and technologies needed to achieve products

which enable customers to select innovative

and competitive materials in order to

optimize the performance and competitiveness

of their own projects and products.

And also in future you can trust in Dillinger

products to achieve better and more

economical solutions.

Andreas Thieme

(Marketing Manager)

CONTENT

Issue 2/2010

The 5.2 m rolling stand in Dillingen today

Dillinger Hütte - a plate producer

with a long and proud tradition 1

More than just plate! 2

Portrait of Vanessa Di Rosa 4


Since 1804, when the company’s first heavyplate

rolling-mill was commissioned, the

development of high-quality plate in

numerous grades for a large range of

specialized sectors - with ever greater

dimensions and weights - continues today.

Almost from the very start of plate

production, fabrication of this product has

also played an important role, however.

It is only natural that not every customer has

always been (or is) able to process and shape

the plates supplied by Dillinger Hütte,

particularly in the case of dimensions in the

upper range, and especially when these are

combined with elevated requirements for

mechanical properties. In such situations –

when Dillingen’s plate customers’ in-house

manufacturing capabilities approach or reach

their limits, either in terms of plate size (e.g.

thickness, weight) or of production capacity

- Dillinger Hütte GTS can assist by supplying

not just the heavy plate material, but also ready

fabricated structural plates and parts.

The Heavy Fabrication Division exists for

this purpose. The origins of this specialized

sector at Dillinger Hütte can be traced back

to the 19 th century; the decision to invest in

greater forming capabilities –a 10,000 t

steam-hydraulic press to supplement the

5,000 t and 8,000 t presses already in place,

The Heavy Fabrication Division’s possession

of the latest generation of NC flame-cutting

machines and equipment means that plates

from the Dillingen supply range can be

Figure 2: Cut-to shape ring segment for

a hydro power plant, steel grade: S355J0+N,

thickness 305 mm

profiled with a right-angled edge and/or with

edges prepared for welding (see Figure 2).

In addition, they can also be supplied with

enhanced cut-surface quality and waviness

tolerances compared to standard requirements,

as is necessary, for example, in

the case of large cut racks for jack-up rigs

(see Figure 3). Plates cut to shape and/or with

oxycut beveled welding edges are used

mainly in mechanical and structural

engineering. For special tasks, the Heavy

More than just plate!

for example, and further expansion of

welding facilities–was taken in the late 1800s

(see Figure 1).

Figure 1:

Dillinger

history -

year 1904:

press shop

with 10,000 t

steam

hydraulic

press

At that time, the Heavy Fabrication

Division’s range of products and services

focused on the needs of naval shipbuilding,

heavy engineering and power-plant

construction. In the 20 th century,

development of the Heavy Fabrication Division

was influenced, on the one hand, by

the rapid development of Dillinger Hütte’s

plate rolling-mill toward thicker, wider and

heavier high-quality plates and driven, on the

other hand, by plate customers’ requirements

and their market activities, particularly in the

fast-growing energy sector and in the oil and

gas industry, including its downstream

processing facilities.

Plate cutting and trimming shop - cut-to shape and weld-edge beveled plates

Figure 3: Cut racks for an offshore jack-up

rig structure, steel grade S690Q, thickness up

to 210 mm

Fabrication Division can also make use of

the facilities of the plate rolling-mill,

featuring a plasma-cutting machine for plate

thicknesses up to 100 mm and a water-jet

cutting machine for thicknesses up to

150 mm.

Supply of edge-trimmed plates achieved by

machining, for either rectangular, trapezoidal

or annular plate shapes, is one of the Heavy

Fabrication Division’s specialties. All plate

edges, up to thicknesses of 120 mm, widths

of 5,000 mm and lengths of 25,000 mm, can

be machined to the very highest standards

(see Figure 4). This extremely efficient plate-

Today, the Heavy Fabrication Division is a

fully integrated business unit within Dillinger

Hütte GTS, featuring its own sales

organization, engineering team and

fabrication facilities, and maintaining close

ties with the various plate divisions at

Dillinger Hütte GTS and with the company’s

diverse interdisciplinary teams. These links

generate great benefits for new and ongoing

product developments, and therefore for

users of heavy plate, since innovations in

steelmaking and plate production, on the one

hand, and experience in the processing of

these products - especially in forming and

welding methods - on the other, interact and

complement each other ideally.

In addition to its foundry, the Heavy

Fabrication Division also operates three

facilities for plate working - a plate cutting

and trimming shop, a plate roll-bending and

welding shop, and a press shop - enabling

the division to supply a broad selection of

parts and services for a whole series of

industries. The Heavy Fabrication Division’s

range of plate-working machines - many of

them the most powerful of their type in the

world - and its state-of-the-art technology

permit performance of many highly

specialized fabrication operations on

Dillinger Hütte GTS plate.

processing technology is of particular benefit

to fabricators of structural tubulars, such as

are used, for example, in the construction of

offshore piles, for the penstocks of hydro-

Figure 4: Plate edge-milling machine with

trapezohedral and annular-shaped plates

during processing

electric power plants, and for storage tanks

(including rolled-to-radius plates, see

Figure 5). The excellent cut-face quality -

with no undesirable hardening - and high

level of accuracy achieved assure special

advantages for subsequent welding,

particularly where high-performance welding

equipment is to be used (see Table 1 and

Figure 6). This latest-generation milling

machine can also perform special operations,


including de-cladding and tapering, on all

welding edges.

To assure optimized solutions throughout the

supply chain, plates with ready-prepared

welding edges (individually marked and weldedge

coated) can be delivered “pile-wise” and

Figure 6: Weld-edged prepared plates

“just-in-time” for special projects, even in

cases in which the welding-edge section is

not specified when the order for the plate

is placed. This flexibility is possible only

thanks to close cooperation between the

customer and the DH-GTS team, including

Figure 5: Weld-edged prepared plates, rolled detailed tracking and analysis of projects

to radius, ready for shippment

and delivery schedules.

Roll bending and welding shop - cylindrical shell courses

Figure 7: 4-roll-bending-machine during the

cold bending of a shell course welded out of two

plates, steel grade: 20MnMoNi4-5

thickness: 146 mm, diameter: 7300 mm

Figure 9: Cut-back hemispherical head, steel

grade: SA387-22-2 (N+ACC+T),

thickness: 190 mm

The pressing shop operates a number of

hydraulic presses exerting press forces of up

to 4,000 t. Single-piece vessel heads featuring

no welds – simply hot formed by means of

deep-drawing using a ring/mould and die –

can therefore be supplied in a wide range of

geometries, including spherical (up to

Shell courses are produced by means of hot

or cold forming, depending on shell size,

material and/or code requirements. They are

generally supplied fully welded, but are also

optionally available in only tack-welded or

braced form. The Heavy Fabrication Division

also possesses a smaller four-roll

bending machine for shaping of standard

plates and another four-roll bending

machine, which remains unique in the

world, for bending of upper-range plate

sizes and/or materials featuring higher

mechanical strength properties (see

Figure 7). The shell course products are

typically used as structural elements, either

as complete parts or in welded assemblies

(see the example shown in Figure 8).

The pressing shop: single-piece vessel heads and multi-segment shell sections

3,700 mm in diameter, see the example in

Figure 9), torispherical, elliptical and flat

(diameter: up to 4,700 mm).

Where the customer’s requirements exceed

the potentials for production of single-piece

components, the Heavy Fabrication Division

can also supply multi-segment shell

sections (produced using either hot or cold

Figure 10: Conical transition piece and multi

segment sections

Table 1: Tolerances: “macroscopic” on the

beveled plate, “microscopic” on the machined

weld edge

Figure 8: Shell course for an offshore-rig

made of two half sections (tack-welded and

braced), steel grade: S460Q, thickness: 210

mm (cold rolled!)

Figure 11:

“Bell mouth”

for the cable

capture -

offshore

application

forming, see the example in Figure 10).

The available range also includes tailormade

sections, including transition pieces,

tapered segments and inlets for shaft linings,

since there are then no dimensional

restrictions (see example in Figure 11).

Available services include trial assembly for

shop inspection and supply of the finishwelded

component.


Additional processing services, inspection and documentation

• Heat treatment (normalizing, water quenching, tempering or stress-relieving – see Figure 12)

• Inspection by destructive and/or non-destructive testing (within the Dillinger Inspection Dptmt)

• Machining and/or weld-edge preparation (e.g. by vertical-lathe with 6m-diameter, cutting by

hand or by thermal-cutting-robot – see Figure 13)

• Welding (SMAW, SAW, TIG)

The documentation includes an inspection certificate in

Figure 12: conformity to EN 10204. Special fabrication and inspection

Heat procedures, such as quality plans and/or shop drawings, can

treatment also be provided on request, however. The Heavy Fabrication

of heads Division is certificated in conformity to the following

or shell standards: EN 9001, EN 14001, OHSAS 18001, ASMS S,

courses ASMS U, ASME U2. Auditing for accreditation as an

ASME III NPT-stamp holder and MO is currently taking

place.

Downstream fabrication and services

Dillinger Hütte’s Heavy Fabrication Division is the right address if you need tailor-made prefabricated structural plates, individual parts,

or complete packages providing all-in solutions. The Heavy Fabrication Division is a business unit fully integrated into the Dillinger Hütte

GTS organization and located on the same site as the plate-making facilities.

Dillinger Hütte traditionally supports its heavy-plate customers’ outsourcing strategies. Irrespective of the processes involved – cutting,

dishing, bending, forming, welding or machining – Dillinger Hütte, with its world-leading plate-processing technologies, is committed to

top quality and reliable on-time delivery.

Get the benefits of the Dillinger Hütte Heavy Fabrication Division’s professional expertise and comprehensive service, under our guiding

principle of

“More than just plate!”

Patrick A. REGNERY

(Heavy Fabrication Division)

The Heavy Fabrication Division’s delivery program is intended only to provide an impression of the various formats and dimensions

which can be supplied. Please contact us if you require formats, weights, fabrication operations, etc., not expressly included in the

program.

Stavanger, August 24 - 27, 2010

Hall C Stand 342, German pavilion

Vanessa Di Rosa

I studied mechanical engineering at the Saarbrücken

University of Applied Sciences, and

started an internship in a department of the

Heavy Fabrication Division, Foundry

Section, at Dillinger Hütte in late 2006,

subsequently writing my degree thesis on

topics associated with the experience I

gained there. A year later I joined the Health

and Safety department, moving in March

2008 to Marketing, where my activities focus

mainly on the Offshore, Structural Tubulars

and Linepipe sectors, and also on

Earthmoving & Mining Equipment and the

Visit us at the ONS fair

Marketing Department Offshore, Structural Tubulars, Linepipe

Born: 1980 in Saarlouis

Education: Graduate mechanical engineer

Hobbies: Sport, travel, arts

Dillinger Hütte Steel Service Centers. In

addition to the promotion of Dillinger Hütte

products, my responsibilities also

include answering technical and

commercial enquiries, with expert

assistance from DH’s internal specialists

where appropriate. Prompt and

comprehensive support for customers and

close cooperation with colleagues are

vitally important factors in my work:

‘Coming together is a beginning, staying

together is progress, and working together

is success’ is a quotation, from Henry Ford,

that I agree with wholeheartedly.

Figure 13: Weld-edge preparation

of one-piece heads, shell courses

or multi-segment section by robot

Impressum

Editor: Andreas Thieme

Co-Editor: Vanessa Di Rosa

DILLINGER HÜTTE GTS

P.O. Box 1580

66748 Dillingen/ Saar, Germany

Phone: +49 68 3 47 21 46

Fax: +49 68 3 47 99 21 46

E-Mail: marketing-offshore@dillinger.biz

http:\\www.dillinger.de

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