Delivery program "Heavy Fabrication Division" - Dillinger Hütte GTS

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Delivery program "Heavy Fabrication Division" - Dillinger Hütte GTS

DELIVERY PROGRAM

HEAVY FABRICATION

DIVISION


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 by

the Heavy Fabrication Division

are supplied in the manner demanded

by the relevant standards,

technical delivery specifications

and other agreements

made with the customers. The Integrated

Management System is

certified to ISO 9001:2000, ISO

EN 14001:2005 and OHSAS

18001:1999.

The components can be supplied

in conformity with the relevant

fabrication codes and standards

such as PED 97/23/EC, EN

13445, PD 5500, etc.

Furthermore, a lot of specific accreditations

are also available e.g.

edition 2008

1

AD-2000 Merkblatt W 0 / HP

0 / TRD 100 / 201 / 202

ASME Section VIII-1 (U

Stamp), Section VIII.2 (Stamp

U2) and Section 1 (Stamp S)

Manufacture License of Special

Equipment People’s Republic

of China (Pressure vessels: A1,

A2, A3 and Boiler parts: A)


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)

2


CONTENTS

4

Modular solutions for heavy plate fabrication

6

Fabricated plates

10

Cut-to-shape plates

12

One-piece heads

20

Multi-segment shell-sections

24

Spherical shell plates

28

Cylindrical shell-courses

32

Technical delivery conditions

36

Main fabrication facilities

38

Material steel grades

40

Some applications

43

Your contacts

3


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)

4


Anyone believing that the elegant

dome of the Hussein Mosque in

Cairo is a work of ancient Oriental

craftsmanship would be

wrong. The roof structure is, on

the contrary, a product of the

modern world: a 23 ton multisegment

hemisphere construction

made of steel plates, manufactured

in the Heavy Fabrication

Division of Dillinger Hütte GTS.

It's a thin line between architecture

and art: the "Serpentine"

(cf. page 38) sculpture created by

the American artist Richard Serra

for the city of San Francisco

was also produced by the Heavy

Fabrication Division:

Mr. Serra has been using the

steel production facilities in

Dillingen for several years.

And where technology is concerned,

Dillinger Hütte GTS is

reaching for the skies: When the

Ariane V takes off from the

Kourou space centre in French-

Guyana, a part of Saar-made

metallurgy also goes into orbit.

The starter material for the

booster domes, forging grade

ingots made of a special alloy

from the Saarstahl AG, is rolled

out to 16 ton circular blanks in

the Dillinger plate mill and

subsequently processed into

dished heads.

Naturally our employees are not

always involved in such spectacular

contracts. These examples do

demonstrate the extensive capabilities

of the Heavy Fabrication

Division, the essential aspect of

which remains the processing of

heavy steel plates.

However, we ourselves are not

fabricators of finished equipment;

we prefer to view ourselves

as service-providers to the manufacturers

of equipment involved

in heavy engineering. Much of

the material coming out of

Dillinger Hütte GTS is unusual:

sometimes it's the dimensions of

the plates (in most cases the

thickness or the width), and

other times it's the mechanical

properties of the plates. And often

it's both.

Not all manufacturers of structural

steel constructions, pressure

vessels or heavy apparatus want

5

to process such plates completely

on their own. We know our plate

material best of all and we also

have the necessary equipment

available to process these heavy

und thick plates. This is why we

offer to take care of the difficult

first stages of the processing and

supply prefabricated structural

components instead of just heavy

plates.

The scope of products and services

of the Heavy Fabrication

Division is set out on the following

pages; it includes modular

heavy plate components, designed

for specific fields of application.

Our comprehensive range

is the result of long years of experience

in cooperating with steel

plate fabricators.

But don't take this as our final

word on the subject: if you do

have a special project or unique

requirements such as the three

examples cited above, we will

provide 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


Fabricated plates equipped with machined weld-edges

FABRICATED PLATES

6


The bevelling of edges is part of

the current preparation wherever

welding is required. This applies

mainly to the construction of

storage tanks, shaft linings,

bridges, large pipes or tubular,

pressure vessels and nowadays

piles for offshore wind-mills. The

supply of edge-trimmed plates

achieved by a machining process

is one of the specialities of

DILLINGER HÜTTE GTS.

Manufacturing process

While traditional methods of

shaping weld-edges use shearing,

flame cutting or planing, the

plate edge-milling machine cuts

all the excess material into fine

chips. The reduction to chip form

is done by hard metal plates

which are arranged at regular intervals

at the outer circumference

of the profile-milling heads. The

machined edges are geometrically

exact, smooth, even, and

burr-free; their quality surpasses

by far the quality of sheared

or flame-cut plates. Since the

thermal energy, which develops

during the reduction to chip

form, is virtually absorbed by

the chips, the plate itself remains

cold so that both hardening of

material and resulting cracks can

be avoided.

The machining process is based

on the "HF milling" method as

developed by LINSINGER, the

Austrian manufacturer of this

equipment: it provides a smooth

run and minimal vibrations

despite the high performance

necessary for the reduction to

chip form. The lay-out of the

machine is designed for a continuous

service so the interruptions

for exchanging the profile-milling

heads are minimised. The

machine comprises two milling

stations of 90 kW for processing

simultaneously the both longitudinal

edges, one of the stations

being turned at 90° to assume

the machining of the transverse

plate edges.

Scope of supply

The edge preparation of plates

within the thickness range of between

5 mm and 120 mm is car-

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

7

ried out by milling; for larger

thickness, flame-cutting will apply.

The 4 edges can be individually

equipped with a specific

weld-edge preparation.

As the milling process is CNC

driven, the machine can deal

with rectangular, trapezohedral

and annular-shaped plates.

Special preparation like backcladding

and tapering can also

be achieved along the weld-edges.

A high degree of accuracy and an

excellent cut-face quality i.e. extensively

free of hardening effect

characterise the weld-edges prepared

by a machining process,

both being requirements for

performance welding.

Please refer also to the Technical

Delivery Conditions on page 32.

Information required

Final plate sizes, rolling radius,

weld-edge design.


Dimensional program

Shell plates machined flame-cut

Thickness 5 – 120 mm 10 – 230 mm

Width 1.350 – 5.000 mm 800 – 5.200 mm

Length 4.000 – 25.000 mm 2.000 – 18.000 mm

Plate weight 40 t 40 t

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

Thickness 15 – 230 mm 15 – 230 mm

Width 800 – 4.300 mm 800 – 4.300 mm

Length 4.000 – 14.000 mm 4.000 – 14.000 mm

Radius ≤ 4.000 mm ≤ 6.000 mm

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

Edge design

I V

U

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

DV

Heavy Fabrication Division Dillinger Hütte GTS, Fabricated plates [2/3], 2008

8

DU


Standard tolerances

Edge preparation machined flame-cut

Bevel angle (γ, α) ± 0.5° ± 2.0°

Land location (h) 1) ± 0.5 mm ± 2.0 mm

Land height (a) ± 0.5 mm ± 2.0 mm

Root radius (R) 2) ≤ 0.5 mm

Slope 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

Curvature

at the plate ends ≤ 2 mm / 500 mm

away from the end area ≤ 10 mm /2.000 mm

Straightness of the ends

s ≤ 20 mm ≤ 4 mm / 1.000 mm

s ≤ 40 mm ≤ 3 mm / 1.000 mm

s > 40 mm ≤ 2 mm / 1.000 mm

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

A

R i

template

shell plate

A

R i

template

shell plate

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.

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

9

A


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

10


Cut-to-shape plates are intended

mainly for use in structural and

mechanical engineering, e.g. as

blanks for tool equipment or

frames for hydraulic presses.

Manufacturing process

Cut-to-shape plates are profiled

true to dimensions on NC flamecutting

machines with square

edge, further weld-edge preparation

being manually flame-cut.

The contour is constructed from

straight and circular-shaped

lines, all other outlines are split

up into polygonal courses with a

high definition.

Dimensional program

Standard tolerances

Scope of supply

The blanks are supplied in the

steel grades within the plate Delivery

Program of Dillinger Hütte

GTS preferably in pieces above

3 t in weight. They can also be

provided with enhanced waviness

tolerances against the standards

e.g. EN 10029, ASTM A 6 / A 20

and when required by the steel

grade also be supplied in the

stress-relieved condition to suit

subsequent processing operations

such as a machining. It is known

that profile cutting involves

mostly an important plate

wastage; unless otherwise agreed

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

11

the scrap remains the property of

the supplier i.e. the shipping

costs which apply to the resulting

net weight are therefore considerably

reduced. Please refer also to

the Technical Delivery Conditions

on page 32.

Information required

Edge design

Bevel angle ± 2° Land height ± 2 mm

Land position1) ±2mm

1) measured from the plate top side

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

Shape description supported

with a full-dimensioned drawing

Width ≤ 5.200 mm Thickness ≤ 410 mm

Length ≤ 25.000 mm Weight ≤ 60 t


ONE-PIECE HEADS

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

12


One-piece heads serve for example

as end pieces for pressure

vessels and power boilers. The

widest range of shapes is available:

spherical, torispherical,

elliptical, etc. The flat heads i.e.

flanged only within the proposed

dimensional range are mainly

used for the fabrication of ladles

involved in metallurgical

processes.

Manufacturing process

One-piece heads in Dillingen are

always hot formed by deepdrawing,

the circular blanks being

free of any weld seam. They

are dished by the means of

hydraulic presses up to 2.500 tons

fitted with the proper tooling i.e.

ring and die, the shape of which

suits the inside contour of the

head. The edges are generally

worked by flame cutting; the

machining of the weld-edge

preparation can be also agreed

upon for heads with wall thicknesses

above 30 mm.

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

13

Scope of supply

Seamless heads can be supplied

spherical-shaped in outside

diameters up to 3.650 mm, torispherical

or elliptical-shaped up

to 4.450 mm or flanged only up

to 4.750 mm. The "Dimensional

Program" table provides information

concerning the standard

shapes, diameters and wall

thicknesses to which the heads

can be manufactured:

intermediate dimensions and

other head shapes must be

agreed upon. Please refer also to

the Technical Delivery Conditions

on page 32.


Dimensional program

Wall thickness related to the external diameter for the different shapes

Outside diameter Thickness (mm)

(mm)

Elliptical 1) & 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 75

2.400 & 2.450 10 160 32 200 20 75

2.500 & 2.550 11 170 34 200 20 80

2.600 & 2.650 11 170 36 180 20 80

2.700 & 2.750 12 170 38 180 22 85

2.800 & 2.850 12 170 40 180 22 85

2.900 & 2.950 13 170 40 160 22 90

3.000 & 3.050 14 170 40 160 22 90

3.100 & 3.150 15 170 40 150 22 100

3.200 & 3.250 16 160 40 150 24 100

3.300 & 3.350 17 160 40 140 24 100

3.400 & 3.450 18 150 40 140 24 100

3.500 & 3.550 19 150 40 130 24 100

3.600 & 3.650 20 140 40 120 24 100

3.700 & 3.750 21 140 - - 24 100

3.800 & 3.850 22 120 - - 24 100

3.900 & 3.950 23 120 - - 24 100

4.000 & 4.050 24 110 - - 26 100

4.100 & 4.150 25 110 - - 26 100

4.200 & 4.250 26 110 - - 26 100

4.300 & 4.350 27 110 - - 28 100

4.400 & 4.450 28 110 - - 28 100

4.500 & 4.550 - - - - 30 100

4.600 & 4.650 - - - - 30 100

4.700 & 4.750 - - - - 30 100

The data on wall thicknesses apply for steel with 355 N/mm 2 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 intermediate

dimensions.

14

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

Heavy Fabrication Division Dillinger Hütte GTS, One-piece heads [2/7], 2008


Standard tolerances

Edge-preparation flame-cut machined

Bevel angle ± 2.0° ± 1.0°

Land position 1) ± 2.0 mm ± 1.0 mm

Land height ± 2.0 mm ± 1.0 mm

Milling radius 2) ± 1.0 mm

Cut 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, ASME

VIII-1, ASME VIII-2, PD 5500, BS 1113, CODAP or AD 2000.

Heavy Fabrication Division Dillinger Hütte GTS, One-piece heads [3/7], 2008

15


Information required

Torispherical heads

Shape

(applicable standard or dishing radius r 1

and knuckle radius r 2)

Diameter Da or Di

Minimum wall thickness after forming s

Straight flange h 1

Weld-edge preparation

Elliptical heads

Shape

(applicable standard or axis ratio b : a)

Diameter Da or Di

Minimum wall thickness after forming s

Straight flange h 1

Weld-edge preparation

Flat heads, flanged only

Diameter Da or Di

Minimum wall thickness after forming s

Dishing radius or knuckle radius r 1

Straight flange h 1 or depth h 3 (h 1+h 2)

Weld-edge preparation

Heavy Fabrication Division Dillinger Hütte GTS, One-piece heads [4/7], 2008

16

s

s

s

a

D i

D a

D i

D a

D i

D a

r 1

b

r 2

r 2

h 2

h 1

h 2

h 1

h 1

h 3

h 3

h 3


Information required

Hemispherical heads with straight flange

Dishing radius r 1 or inside diameter Di

Minimum wall thickness after forming s

Straight flange h 1 or depth h 3 (h 1+h 2)

Weld-edge preparation

Hemispherical heads (r 1 = h 3)

Dishing radius r 1 or inside diameter Di

Minimum wall thickness after forming s

Weld-edge preparation

Spherical heads

Dishing radius r 1

Connecting inside diameter

Dh or "negative" height h1 or

depth h3

Minimum wall thickness after forming s

Weld-edge preparation

Heavy Fabrication Division Dillinger Hütte GTS, One-piece heads [5/7], 2008

17

s

s

s

D h

D i

D a

D i

D a

r 1

r 1

r 1

h 3

h 1

h 2

h 1

h 3

h 3


HOT DISHING PROCESS OF

ONE-PIECE HEADS

OD 4.200 mm x 80 mm in steel SA 516 grade 70

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

Heavy Fabrication Division Dillinger Hütte GTS, One-piece heads [6/7], 2008

18


6. Dished head being extracted out of the forming tools

HOT DISHING PROCESS OF

ONE-PIECE HEADS

OD 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

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

19


MULTI-SEGMENT SHELL SECTIONS

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)

20


When the required items exceed

the dimensions of the one-piece

component, they can be produced

in multi-segment design, each

pressing being supplied ready for

assembly; the individual sizes of

the segments can be also agreed

upon.

Manufacturing process

The pressings comprising a multi-segment

shell are individually

formed using tool equipment, the

profile of which suits the contour

of the part being made. The

knuckle segments of torispherical

heads are basically hot-pressed;

as are the relative crown segments

and any pressings designed with

a dishing radius up to approximately

3.500 mm; above this

diameter cold-forming is applied.

The weld-edges of the shaped

segments are produced by flame

cutting.

Scope of supply

It includes mainly the fabrication

of torispherical heads to

DIN 28011 or NF E 81-102 and

DIN 28013 or SMS-482 above

4.450 mm in outside diameter and

spherical heads above 3.650 mm in

outside diameter; the multi-segment

design can be also extended

to „tailor-made“ shell sections

suiting a specific shape i.e. transition

pieces, reversible conical segments

and inlets for shaft lining

since no dimensional restriction

must be observed. The multi-segment

design is an alternative to

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

21

the fabrication of items outside

the manufacturing range of the

cold spinning process which is

mainly restricted to the shaping

of wall thicknesses up to around

30 mm. Please refer also to the

Technical Delivery Conditions on

page 32.

Trial fit-up

The pressings are produced to

fabricate multi-segment heads

or other large shell sections.

When requested, the segments

are trial assembled for the shop

inspection by using key-plates

and pins; clamping cams can

also be welded on which you

can later put to advantage as

erection aids during the final

assembly.


Standard tolerances

Edge design knuckle crown

Bevel angle ± 2° ± 2°

Land height ± 2 mm ± 2 mm

Land position 1) ± 2 mm ± 2 mm

Cut-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 mm

Away from edge area 3) ≤ 6 mm/1.000 mm ≤ 6 mm /2.000 mm

Dimensions

Arc length/arc width ± 2 mm ± 2 mm

Diagonal difference ≤ 3 mm ≤ 3mm

Diameter 4) 5) ± 0.1% Da ± 0.1% Da

Out-of-roundness 5) ≤ 30 mm ≤ 30 mm

Inside 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

Heavy Fabrication Division Dillinger Hütte GTS, Multi-segment shell sections [2/3], 2008

22

4) calculated from measured circumference

5) only when trial assembled


Information required

Torispherical heads

Shape

(applicable standard or

dishing radius r1 and

knuckle radius r2) Diameter Da or Di

Arrangement of segments

Diameter of crown Dk

Straight flange h1 Minimum wall thickness(es)

after forming s

Spherical heads

Dishing radius r1 and

inside diameter Di

Arrangement of segments

Diameter of crown Dk

Minimum wall thickness(es)

after forming s

h 3

h 1

"Tailor-made" shell sections

Purpose for which they are used

Drawing including full measurements

Minimum wall thickness(es) after forming s

s

s

s

23

s

D k

D i

D a

D k

s

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

D i

D a

s

r 1

r 1

r 2

crown

knuckle

crown

spherical

course


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)

24


Spherical shell-plates are

tailor-made segments

(„petals“) manufactured ready

to install spherical storage

vessels where the emphasis is

placed on the high dimensional

accuracy of the individual

segments.

Manufacturing process

Taking into account the material

properties, the plate thickness

and the required radius,

either cold or hot forming can

be used. In both alternatives,

the shaping process is conducted

in a „safe“ way so that the

steel mechanicals remain preserved.

The segments for

spheres above 7.000 mm in

diameter are normally manufactured

cold by progressive

dishing. Once the segments are

shaped properly, the weldedges

are subsequently engineered

by flame cutting.

Scope of supply

Unless otherwise required, the

arrangement and the sizes of

the segments are optimised by

considering the available shop

facilities, the transport conditions

and the field erection

constraints. Depending on the

material and on the forming

radius, the “petals” are fabricated

in thickness of up to 110

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

25

mm in width, of up to 4.000

mm and in length of up to

12.000 mm: the final piece

weight is generally restricted

at 23 to. The scope of supply

includes also “petals” fabricated

from material produced by

thermo-mechanical controlled

process (TMCP) or by waterquenching

process (QT).

An extensive experience allows

manufacturing the segments

ready for assembly without any

shop trial fit-up.

Please refer also to the

Technical Delivery Conditions

on page 32.


Dimensional program

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

Wall thickness s (mm)

100

90

80

70

60

50

40

30

20

10

hot forming

cold forming

2.500 mm � 2.500 mm 1)

2.500 mm � 4.000 mm 1)

2.750 mm � 6.000 mm 1)

2.000 4.000 6.000 8.000 10.000 12.000 14.000 16.000 18.000 20.000 22.000

Inside diameter of sphere Di (mm)

3.000 mm � 8.000 mm 1)

1) The dimensions (length and width) are given by arc measure. The data on wall thickness apply to steel with 355 N/mm 2 yield strength.

Heavy Fabrication Division Dillinger Hütte GTS, Spherical shell plates [2/3], 2008

26

3.000 mm � 10.000 mm 1)

4.000 mm � 12.000 mm 1)

24.000


Standard tolerances

Edge design Bevel angle ± 2°

Land height ± 2 mm

Land position 1) ± 2 mm

Cut-face quality ISO 9013-33

Dimensions Arc length ± 2 mm

Arc width ± 2 mm

Diagonal difference ≤ 3mm

Shape1) 200 mm wide edge area 2) ≤ 2 mm/1.000 mm

away from edge area ≤ 6 mm/2.000 mm

A

Information required

R i

Inside diameter Di

Arrangement of segments

Minimum wall thickness(es) after forming s

Fabrication code

Spherical shell plates are always outlined by longitudinal or latitudinal

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.

� 4

template

segment

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.

� 3

D i

� 5

� 2

ß 2

Schematic description of lay-out

� 6

� 1

ß 4

a

A

ß 1

s 6

s 1

27

ß3

s 2

s 5

s 3

s 4

crown

upper course

equatorial course

bottom

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

welding shrinkage will not be taken into consideration.

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

R i

template

segment

1) related to the internal surface

2) measuring position: along the plate edge

(Ri = inside radius)

A


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

28


Cylindrical shell-courses are

basic items entering in a lot of

applications such as components

for pressure vessels or structural

sections.

Manufacturing process

Shell-courses are produced by

cold or hot forming, the choice

of the process being a function

of both the shell sizes and the

material properties. They are

preferably supplied fully welded:

welding is performed by using

either single-electrode, two-electrode

or twin-arc submerged arc

methods in accordance with the

provisions of the relevant international

codes, for example AD,

ASME (Stamps U, U2 and S are

available), PD 5500, CODAP,

TRD. Depending on the

material and code requirements,

the formed parts can be given

proper heat treatments, for

instance normalising, tempering,

water-quenching.

Optionally, the shell-courses are

supplied just tack-welded -

achieved from the outside -

within the longitudinal joint or

braced at both ends by using

strong-backs.

As a rule, the plate edges of the

longitudinal joint are prepared

by a milling process performed

from the outside what makes a

“narrow gap” weld-joint of 18°

achievable. The circular weldedges

of shell-courses are usually

produced by flame cutting;

edge-machining of shell-courses

up to 2.550 mm in length can be

agreed.

Scope of supply

The forming is achieved by

means of a 4-roller machine

powered with 8.600 t force,

designed to deal with 4.300 mm

(169,2") wide plate. Its performance

includes the cold forming

of shell-course up to 240 mm

(9,4") in thickness at the full

plate width; three interchangeable

top rollers (880 mm, 1.200

mm and 1.500 mm) enable to

cover a very wide range of

diameters.

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

29

This machine has been specially

engineered for heavy section

plates made out of high strength

steels characterised by a yield

point of 700 MPa. Such an

equipment is particularly advantageous

for steel grades where

hot forming is always problematic

e.g. for all steels intended to

be delivered either in the waterquenched

( QT ) or in the

thermo-mechanically processed

( TM ) condition.

When required the forming can

be also performed by using a hot

process, conducted in the way to

keep extensively the surface finish

free of the usual discontinuities

resulting from this kind of

process.

Please consider also the

Technical Delivery Conditions

on page 32


Performance chart of the roll-bending machine

based 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 1.000 1.200 1.400 1.600 1.800 2.000 2.200 2.400 2.600 2.800 3.000 3.200 3.400 3.600 3.800 4.000

Yield strength 240 MPa (35 ksi)

Yield strength 360 MPa (53 ksi)

Yield strength 550 MPa (80 ksi)

Yield strength 700 MPa (100 ksi)

1.500 mm top roller

1.200 mm top roller

Heavy Fabrication Division Dillinger Hütte GTS, Cylindrical shell courses [2/3], 2008

30

880 mm top roller

Wall thickness [mm]

Inside diameter [mm]

Delivery program of shell-courses upon enquiry


Standard tolerances

Edge-preparation flame-cut machined

Bevel angle ± 2.0˚ ± 1.0˚

Land position 1) ± 2.0 mm ± 1.0 mm

Land height ± 2.0 mm ± 1.0 mm

Root radius 2) ± 1.0 mm

Cut-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 % D

Out-of-roundness 2) ≤ 1% D

Length ≤ 3 mm

Straightness ≤ 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).

Information required

Diameter Di or Da

Length L

Minimum wall thickness after forming s

Edge-design

Welding requirements and

fabrication code

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

31

L

D i

s

D a


TECHNICAL DELIVERY CONDITIONS

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

32


Plate processing

Basically the applied processing

operations comply with the recommendations

made by the steel

maker having produced the plates.

Furthermore, the fabrication operations

meet the guidelines of SEW

88 - German directives governing

the processing of heavy steel

plates. The requirements contained

in the relevant fabrication codes

such as AD, ASME, CODAP,

PED 97/23/EC, EN 13445, PD

5500, etc. can also be agreed.

Depending on the material steel

grade and the applicable specifications,

the formed parts can be given

proper heat treatment e.g. normalizing,

water-quenching, tempering,

stress-relieving. As a rule

the mechanical properties of every

pressing shaped by hot forming

are verified by using test coupons

removed from the forming allowance

after completion of the

forming process and tested in the

final heat treatment condition.

Dimensional and shape accuracy

The Product Information Sheets

on the pages 6 to 31 include specific

details regarding the standard

fabrication tolerances; they apply

unless otherwise agreed and are

valid at the time of the shop inspection.

Supporting structures,

the type of which is to be agreed

upon, can be necessary to maintain

the shape during transport and

storage. In the case of packages

i.e. joint delivery of shell-courses

with pressings, the accuracy of the

components to each other shall be

within the permissible misalignment

required in the applicable

code.

Surface condition

The items are supplied with untreated

surfaces in line with the

processing method used; by agreement

the surface quality can be

evaluated against EN 10163: Part

1 and 2. It can also be agreed that

the surface of the manufactured

items must be descaled and

primed in accordance with ISO

8501-1 (SIS 05-5900) or equivalent

standard. The surface preservation

of shell-plates is generally

carried out prior to the processing

operations (weld-edge preparation

and shaping to radius). The plate

weld-edges can be also protected

against corrosion by using a suitable

coating, the type of which is

subject to agreement. The surface

treatment can also be subcontracted

to an external company whose

quality system is controlled by

Dillinger Hütte GTS.

Weld-edge preparation

Items supplied in the multi-segment

design ready for assembly

are produced with weld-edge

preparation. Any requirement for

tapering must be additionally

agreed upon. The edges of cut-toshape

plates, pressings and cylindrical

shell-courses are as a rule

worked by flame cutting, the cut-

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

33

face being subsequently processed

free of scale and slag accumulation

by grinding. Edge details described

in the relevant standards

such as API 650, DIN 8851, NF E

81-110 („I“, „V“, „Y“ in single or

in double design) can be engineered:

the cut-face quality is in

line with the cutting process. Any

machining of weld-edge preparation

for heads and shell-courses

must be additionally agreed. Weldedge

protection against corrosion

can also be provided on request.

Identification

Each item produced by Dillinger

Hütte GTS is originally marked

in accordance with the applicable

plate standards; it is additionally

identified by using a sequential

piece number to ensure the traceability

of the manufactured parts

along the fabrication operations

back to the Inspection Test Certificates

of the initial material issued

by the plate mill. The markings

are as a rule made on the top side

of the plate i.e. on the concave

side of the curved shell-sections.

Unless otherwise agreed, heads

and pressings are marked on the

outside surface. The shipping

marks are stencilled in the manner

required in the purchase order.

Additionally the items are

equipped for transit with the brand

name and the emblem of Dillinger

Hütte GTS.


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 thickness

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

34


Contract work

In the case of free issued plates i.e.

plates produced outside the works

of Dillinger Hütte GTS, all processing

conditions must be agreed

in advance i.e. before release for

fabrication; this concerns especially

the hot forming parameters,

the machining and the material

allowances for forming.

Packaging

The items are usually provided

loose and unsecured: shaped parts

such as dished heads, pressings or

curved shell-sections are just laying

on wooden timbers fitting the

outside curvature, usually with

the inner side upwards. Shell-plates

are stacked into lifting units separated

from each other by means of

wooden spacers. Other types of

measures for packaging, securing

and lashing e.g. the supply of skids

or pallets, any supporting structures

being necessary to maintain

the shape during transport, the

stowing into containers, the welding

of lifting lugs, the use of spacers

between each shell-plates are

always subject to agreement. Any

specific packaging and lashing requirements

have to be agreed

along with the purchase order.

Information required

In order to be able to process your

requirements, we need a range of

details listed as follows:

Material steel grade

Acceptance conditions (plate

material and fabricated item)

Testing condition (when

deviating from the as-delivered

condition)

Final heat treatment condition

Fabrication code (mandatory

for welded parts)

Weld-edge preparation

Dimensions

Please refer also to the tables "Information

required" of the Product

Information Sheets on the pages 6

to 31. For the parts outside the

standard delivery program, please

support always your inquiry with a

sketch showing the contour design

of the part to be manufactured

including all measurements.

Documentation

Unless otherwise required, an inspection

test certificate to EN

10204-3.1 is provided for the base

material and the manufactured

item as well. By agreement, the

35

documentation can be extended

and include for instance some fabrication

and control procedures,

quality plan and shop drawings.

Enlarged scope of supply

The Heavy Fabrication Division is

well equipped to deal with your

orders. The table on page 37 provides

an overview of the main machinery.

Any design work, fabrication

of finished equipment and

erection on the field are basically

outside the services offered by

Dillinger Hütte GTS. On request

the individual components can be

pre-assembled into heavy units.

Items of up to a total weight of 100

to and 18.000 mm in length can be

handled. The joint delivery of

components with unfabricated

plates is subject to agreement.

Logistics

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

The manufacturing plants are installed

in covered bays with a total

surface area of around 39.000 m 2 .

All bays have both a road and a

rail link. Furthermore, an access

to the company's own port facilities

on the river Saar is available.


2.500 ton hydraulic press

FABRICATION FACILITIES

36


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

- milling machine for weld-edge

preparation of longitudinal joints

120 5.000 25.000

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 )

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

Note

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

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

37


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)

38


For the manufacture of the components

described on the previous

pages, the Heavy Fabrication

Division processes the

heavy plates produced by the

plate mills of Dillinger Hütte

GTS. The exact knowledge of

our materials makes it possible

for us to exploit the absolute

technical limits of their processing

possibilities.

Dillinger Hütte GTS as the European

market leader for heavy

plates is indeed the right address

for highly demanding tasks. The

plate delivery program includes

a wide range of low alloyed

carbon steel grades to German

and international standards e.g.

- weldable fine-grain structural

steels,

- high-strength quenched and

tempered fine-grain steels,

DILLIDUR: water-hard

ened wear-resistant steels

DILLIMAX: high-strength

water-quenched and

tempered structural steels for

welded components

DIWA: alloyed high-strength

fine-grained steels for steamboilers

and pressure vessels

DICREST: fine-grained

steels for pressure vessels and

storage tanks with resistance

to sour gas

DIROS 500: high-strength

water-quenched and tempered

pressure vessel steels

for low-weight designs

- special low-temperature

weldable steels,

- low-temperature nickelalloyed

steels (up to 5 % Ni),

- abrasion-resistant structural

steels,

- alloyed and unalloyed hardening

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 (hydrotreating

petrochemical

reactors), etc.

Sometimes enquiries for particular

grades are made on heavy

plates outside the scope of the

standard. Dillinger Hütte GTS

provides the proper solution for

DILLINAL 460/630: highstrength

fine-grained steels

for tanks used for the trans

port of liquefied gas

DIZINC: special structural

steels for galvanizing pots

with extended service-life

DI-MC: thermo-mechanically-rolled

structural steels

with optimised processing

properties

DIWETEN: structural steels

with improved atmospheric

corrosion resistance

DICUT: steels with

optimised laser-cutting

properties

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

39

the most frequent required additional

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 with

step-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.

Dillinger Hütte GTS has also developed some brandnamed steels optimised versus a range of individual

applications, e.g.:

DIMARINE: thermomechanically-rolled

ship

building steels with optimised

processing properties

DIMO: steels for plastic

moulds

DIPRO: armoured steels for

civil safety applications

DISAFE: high-strength

thermo-mechanically-rolled

fine-grained structural steels

for safes

DICLADUR: roll-bonding

clad dual layer steels for use

under abrasive conditions

More details about the brandnamed steels are available in Material Data Sheets; they can be downloaded

at www.dillinger.de or www.heavyplate.com.


SOME APPLICATIONS

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)

40


SOME APPLICATIONS

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

41


SOME APPLICATIONS

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

42


GREAT

BRITAIN

LONDON

E 05

How to find us

E 09

NORTH

SEA

PARIS

E 15

E 15

SEINE

YOUR CONTACTS

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 Hüttenwerke

Heavy Fabrication Division

Postal address:

P.O. Box 1580

66748 Dillingen/Saar

Germany

Legal address:

Werkstrasse 1

66763 Dillingen/Saar

Germany

Phone: +49 68 31 47 2342

Fax: +49 68 31 47 3346

E-mail: heavy-fabrication@dillinger.biz

AMSTERDAM

ROTTERDAM

ANTWERPEN

BRÜSSEL

FRANCE

BELGIUM

E 411

LUXEMBURG DILLINGEN

E 50

METZ

MOSEL

SAARBRÜCKEN

STRASBOURG

E 21

NETHER-

LANDS

43

KÖLN

DÜSSELDORF

E 25

E 35

RHEIN

BASEL

HANNOVER BERLIN

WESER

FRANKFURT

E 35

STUTTGART

MAIN

E 40

GERMANY

E 52

DONAU

E 56

E 51

MÜNCHEN

ELBE

E 55

CZECH

REPUBLIC

AUSTRIA


Aktien-Gesellschaft der

Dillinger Hüttenwerke

Heavy Fabrication Division

P.O. Box 1580

66748 Dillingen/Saar

Germany

Phone: +49 68 31 47 23 42

Fax: +49 68 31 47 33 46

Liability:

any information on fabrication

process, plate material and product

suitability are provided

without guarantee; assurance

regarding specific properties

and fields of application requires

always a written agreement.


Delivery Program Heavy Fabrication Division, 2008

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