DELIVERY PROGRAM

HEAVY FABRICATION
DIVISION
Cylindrical shell course, longitudinally welded, for power boiler designed to ASME I, Stamp S (Outside diameter 2045 mm x 195 mm x 4000 mm,
steel grade SA 516 grade 70)

All products manufactured by the System which has been estab- Vessels. The Heavy Fabrication
Heavy Fabrication Division of lished many years ago is duly cer- Division is also ASME-Stamp
Dillinger Hütte GTS are supplied tified to ISO 9001. Many specific holder for Section VIII-1
in the manner demanded by the approvals are available e.g to the (U-Stamp), Section VIII.2
relevant standards, technical Rules and Regulations of (Stamp-U2) and Section 1
delivery specifications and other AD-Merkblatt HP O/W O, TRD (S-Stamp).
agreements made with the cus- 100/200, Lloyd’s Register for
tomer. The Quality Assurance Class 1 Fusion Welded Pressure

edition 2004

1
A conical transition piece being made (Inner diameter 2700 mm / 1450 mm x 70 mm, height 1350 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
Fabrication facilities

38
Processed steel grades

43
Your contacts

3
 MODULAR SOLUTIONS FOR
HEAVY PLATE FABRICATION

The Hussein Mosque in Cairo (Erection of the dome made of spherical segments ID 12500 mm x 25 mm, Steel grade ST 52.3 to DIN 17100)

4
Anyone believing that the elegant booster domes - forging grade constructions, pressure vessels or
dome of the Hussein Mosque in ingots made of a special alloy heavy apparatus want to process
Cairo is a work of ancient Orien- from the Saarstahl AG - is rolled such plates completely on their
tal craftmanship would be out to 16 ton circular blanks in own. We know our plate material
wrong. The roof structure is, on the Dillinger plate mill and sub- best of all and we also have the
the contrary, a product of the sequently processed into dished necessary equipment available to
modern world: a 23 ton multi- heads. process these heavy and thick
segment hemisphere construction plates. This is why we offer to take
made of steel plates, manufac- Naturally our employees are not care of the difficult first stages of
tured in the Heavy Fabrication always involved in such spectacu- the processing and supply pre-
Division of Dillinger Hütte GTS. lar contracts. These examples do fabricated structural components
demonstrate however the exten- instead of just heavy plate.
It's a thin line between architec- sive capabilities of the Heavy
ture and art: the "Serpentine" Fabrication Division, the essen- The scope of products and ser-
(cf. page 38) sculpture created by tial aspect of which remains the vices of the Heavy Fabrication
the American artist Richard Ser- fabrication of heavy steel plates. Division is set out on the follow-
ra for the city of San Francisco ing pages; it includes modular
was also produced by the Heavy However, we ourselves are not heavy plate components, de-
Fabrication Division: Mr. Serra fabricators of finished equipment; signed for specific fields of appli-
has been using the steel produc- we prefer to view ourselves as cation in the required steel quali-
tion facilities in Dillingen for service-providers for processing ties. Our comprehensive range is
several years. companies involved in heavy en- the result of long years of experi-
gineering. Much of the material ence in cooperating with steel
And where technology is con- coming out of Dillinger Hütte plate fabricators. But, if you do
cerned, Dillinger Hütte GTS is GTS is unusual: sometimes it's have a special project or unique
reaching for the skies: When the the dimensions of the plates (in requirements such as the three
Ariane V takes off from the most cases the thickness or the examples cited above, we will
Kourou space centre in French- width), and other times it's the provide you, on an individual
Guyana, a part of Saar-made mechanical properties of the basis, with exactly the same
metallurgy also goes into orbit. plate. And often it's both. Not all service as offered to architects,
The starter material for the manufacturers of structural steel artists and space engineers.

Heavy Fabrication Division Dillinger Hütte GTS, Modular solutions for heavy plate fabrication [1/1], 2004

5
 FABRICATED PLATES

Shell plates equipped with machined weld-edge preparation

6
The bevelling of edges is part of form, is virtually absorbed by carried out by milling; for larger
the current preparation wherever the chips, the plate itself remains thickness, flame-cutting will
welding is required. This applies cold so that both hardening of apply. Depending on the cutting
mainly to the construction of the material and resulting cracks process, the edges are engineered
storage tanks, shaft linings, can be avoided. with single or double weld-
bridges, large pipes or tubular, preparation e.g. "I", "V", "X",
pressure vessels and nowadays The machining process is based "Y", "U" since all 4 edges can be
piles for offshore wind-mills. The on the "HF milling" method as individually equipped a specific
supply of edge-trimmed plates developed by LINSINGER, the weld-preparation.
achieved by a machining process Austrian manufacturer of this
is one of the specialities of equipment: it provides a smooth As the milling process is CNC
DILLINGER HÜTTE GTS. run and minimal vibrations driven, the machine can deal
despite the high performance with rectangular, trapezohedral
Manufacturing process necessary for the reduction to and annular-shaped plates.
chip form. The lay-out of the Special preparation like back-
While traditional methods of
machine is designed for a contin- cladding and tapering can also
shaping weld-edges use shearing,
uous service so the interruptions be achieved along the weld-edges.
flame cutting or planing, the
for exchanging the profile-milling
plate edge milling machine cuts
heads are minimised. The A high degree of accuracy and an
all the excess material into fine
machine comprises two milling excellent cut-face quality i.e. ex-
chips. The reduction to chip form
stations of 90 kW for processing tensively free of hardening effect
is done by hard metal plates
simultaneously the both longitu- characterise the weld-edges pre-
which are arranged at regular in-
dinal edges, one of the stations pared by a machining process,
tervals at the outer circumference
being turned at 90° to assume both being requirements for
of the profile-milling heads. The
the machining of the transverse performance welding.
machined edges are geometrical-
plate edges. Please refer also to the Technical
ly exact, smooth, even, and
Delivery Conditions on page 32.
burr-free; their quality surpasses
Scope of supply
by far the quality of sheared
Information required
or flame-cut plates. Since the The edge preparation of plates
thermal energy, which develops within the thickness range of Final plate sizes, rolling radius,
during the reduction to chip between 5 mm and 120 mm is weld-edge design.

Heavy Fabrication Division Dillinger Hütte GTS, Fabricated plates [1/3], 2004

7
Dimensional program

Shell plates Milling Flame-cutting

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
Yield point ≤ 1000 MPa

Cylindrical shell plates Halves 1) Thirds 1)

Thickness 15 – 230 mm 12 – 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
Yield point ≤ 850 MPa

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

Edge design

I V U

DV DU

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

Heavy Fabrication Division Dillinger Hütte GTS, Fabricated plates [2/3], 2004

8
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-I

1) measured from the plate top side

2) applicable to U and DU edges only

Dimensions

Width ± 1.0 mm

Length ± 1.0 mm

Difference between diagonals ≤ 2.0 mm

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 / 0.5 m
away from the end area ≤ 10 mm / 2 m

Straightness of the ends

s ≤ 20 mm ≤ 4 mm / 1000 mm
s ≤ 40 mm ≤ 3 mm / 1000 mm
s > 40 mm ≤ 2 mm / 1000 mm

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

template template

A A
Ri

Ri

A
shell plate 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], 2004

9
 CUT-TO-SHAPE PLATES

Profile for a flange ring (Outside diameter 4640 mm x 200 mm, steel grade 1CK45 to EN 10 083)

10
Cut-to-shape plates are intented Scope of supply wastage; unless otherwise agreed
mainly for use in structural and the scrap remains the property of
The blanks are supplied in the
mechanical engineering, e.g. as the supplier i.e. the shipping
steel grades within the plate De-
blanks for tool equipmemt or costs which apply to the resulting
livery Program of Dillinger Hütte
frames for hydraulic presses. net weight are therefore consider-
GTS preferably in pieces above
ably reduced. Please refer also to
3 tons in weight. They can also
Manufacturing process the Technical Delivery Condi-
be provided with flatness toler-
tions on page 32.
Cut-to-shape plates are profiled ances enhanced against those
true to dimensions on NC flame- specified in the standards e.g. EN
Information required
cutting machines with square 10029, ASTM A 6 / A 20. In ad-
edge, further weld-edge prepara- dition, when required by the steel Shape description supported
tion being manually flame-cut. grade, the profiles can also be with a full-dimensioned
The contour is constructed from supplied in the stress-relieved drawing.
straight and circular-shaped condition to suit subsequent pro-
lines, all other outlines are split cessing operations such as a ma-
up into polygonal courses with a chining. It is known that profile
high definition. cutting involves significant plate

Dimensional program

Width ≤ 5200 mm Thickness ≤ 350 mm

Length ≤ 18000 mm Weight ≤ 38 t

Standard tolerances

Dimensions ISO 9013-A

Edge design
Bevel ± 2° Land height ± 2 mm
Land position 1) ± 2 mm Cut face quality ISO 9013-I

1) measured from the plate top side

Heavy Fabrication Division Dillinger Hütte GTS, Cut-to-shape plates [1/1], 2004

11
 ONE-PIECE HEADS

Torispherical one-piece head, seamless (Outside diameter 4350 mm x 69.5 mm, steel grade 20MnNiMo4.5)

12
One-piece heads serve for exam- Manufacturing process Scope of supply
ple as end pieces for pressure
vessels and power boilers. The One-piece heads in Dillingen are Seamless heads can be supplied
widest range of shapes is avail- always hot formed by deep- spherical-shaped in outside
able: spherical, torispherical, drawing, the circular blanks be- diameters up to 3650 mm, tori-
elliptical, etc. The flat heads i.e. ing free of any weld seam. They spherical or elliptical-shaped up
flanged only within the proposed are dished by the means of to 4450 mm or flanged only up
dimensional range are mainly hydraulic presses up to 2500 tons to 4750 mm. The "Dimensional
used for the fabrication of ladles fitted with the proper tooling i.e. Program" table provides infor-
involved in metallurgical ring and die, the shape of which mation concerning the standard
processes. suits the inside contour of the shapes, diameters and wall
head. The edges are generally thicknesses to which the heads
worked by flame cutting; the can be manufactured:
machining of the weld-edge intermediate dimensions and
preparation can be also agreed other head shapes must be
upon for heads with wall thick- agreed upon. Please refer also to
nesses above 30 mm. the Technical Delivery Condi-
tions on page 32.

Heavy Fabrication Division Dillinger Hütte GTS, One-piece heads [1/7], 2004

13
Dimensional program
Wall thickness related to the external diameter for the different shapes

Outside diameter Thickness (mm)

(mm) 1)
Elliptical & Spherical 3) Flanged only 4)
torispherical 2)
from up to from up to from up to

1000 & 1050 6 90 12 90 - -

1100 & 1150 6 90 13 100 - -
1200 & 1250 6 100 14 120 - -
1300 & 1350 6 100 15 130 - -
1400 & 1450 6 110 16 140 - -
1500 & 1550 7 120 17 150 - -
1600 & 1650 7 120 18 170 - -
1700 & 1750 7 130 19 180 - -
1800 & 1850 7 130 20 200 - -
1900 & 1950 8 140 22 200 - -
2000 & 2050 8 140 24 200 - -
2100 & 2150 9 150 26 200 - -
2200 & 2250 9 150 28 200 - -
2300 & 2350 10 160 30 200 20 75
2400 & 2450 10 160 32 200 20 75
2500 & 2550 11 170 34 200 20 80
2600 & 2650 11 170 36 180 20 80
2700 & 2750 12 170 38 180 22 85
2800 & 2850 12 170 40 180 22 85
2900 & 2950 13 170 40 160 22 90
3000 & 3050 14 170 40 160 22 90
3100 & 3150 15 170 40 150 22 100
3200 & 3250 16 160 40 150 24 100
3300 & 3350 17 160 40 140 24 100
3400 & 3450 18 150 40 140 24 100
3500 & 3550 19 150 40 130 24 100
3600 & 3650 20 140 40 120 24 100
3700 & 3750 21 140 - - 24 100
3800 & 3850 22 120 - - 24 100
3900 & 3950 23 120 - - 24 100
4000 & 4050 24 110 - - 26 100
4100 & 4150 25 110 - - 26 100
4200 & 4250 26 110 - - 26 100
4300 & 4350 27 110 - - 28 100
4400 & 4450 28 110 - - 28 100
4500 & 4550 - - - - 30 100
4600 & 4650 - - - - 30 100
4700 & 4750 - - - - 30 100
The data on wall thicknesses apply for steel with 355 N/mm2 yield 1) Elliptical heads to NF E 81-103 (axis ratio 1.9:1) und ASME
strength. The flange height complies with the applicable standard or Code (axis ratio 2:1)
the customer's requirements but - due to the tool design - is normally 2) Torispherical heads to DIN 28 013 and SMS-482
restricted to 150 mm. Please inquire for other head shapes and inter- 3) Depending on the required design, the available diameters for
mediate dimensions. 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], 2004

14
Standard tolerances

Edge-preparation flame-cut machined

Bevel ± 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-I ISO 1302-N9

1) measured from the reference diameter Da or Di

2) applicable just to U and DU edges only

Diameter Boiler and pressure vessel steels Ni-steels (≥ 3.5 %)

s ≤ 20 mm
0.2 % + 0.4 % s ≤ 10 mm
0.0 % + 1.0 %

21 < s ≤ 60 mm
0.3 % + 0.3 % 11 < s ≤ 14 mm
0.0 % + 0.8 %

61 < s ≤ 80 mm
0.4 % + 0.2 % 15 < s ≤ 18 mm
0.1 % + 0.7 %

81 < s ≤ 100 mm
0.5 % + 0.1 % 19 < s ≤ 22 mm
0.3 % + 0.4 %

101 < s ≤ 120 mm
0.6 % + 0.0 % 23 < s ≤ 30 mm
0.3 % + 0.3 %

s > 120 mm
0.7 % + 0.0 % s > 30 mm
0.4 % + 0.2 %

Tolerances for other head shapes and for water-quenched and tem- Diameters are as a rule calculated from the actual measured circum-
pered steels are subject to special agreement. ference; please consider that Da ≈ Di + 2.4 s bzw. Di ≈ Da
2.4 s
The tolerance data regarding the diameter of hemispherical heads (Da = Outside diameter; Di = Inside diameter; s = Wall thickness)
are based on the connecting diameter which can be fitted by adjust-
ing the inner height.

Heavy Fabrication Division Dillinger Hütte GTS, One-piece heads [3/7], 2004

15
Information required

Torispherical heads

Shape
(applicable standard or dishing radius r1

s
and knuckle radius r2 )
Diameter Da or Di

r1
Minimum wall thickness after forming s

h2
h3
Straight flange h1 r2
Weld-edge preparation

h1
Di
Da

Elliptical heads

Shape
(applicable standard or axis ratio b : a)
s

Diameter Da or Di
Minimum wall thickness after forming s
b
Straight flange h1

h2
h3
a

Weld-edge preparation

h1
Di
Da

Flat heads, flanged only

Diameter Da or Di
Minimum wall thickness after forming s
s

Dishing radius or knuckle radius r1

Straight flange h1 or depth h3 (h1 + h2 )
Weld-edge preparation r2
h3

Di
h1

Da

Heavy Fabrication Division Dillinger Hütte GTS, One-piece heads [4/7], 2004

16
Information required

Hemispherical heads with straight flange

Dishing radius r1 or inside diameter Di

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

r1

h2
h3
h1
Di
Da

Hemispherical heads (r1 = h3)

Dishing radius r1 or inside diameter Di

s

Minimum wall thickness after forming s

Weld-edge preparation

h3
r1

Di
Da

Spherical heads
s

Dishing radius r1
Connecting inside diameter
Dh or "negative" height h1 or
r1

h3

depth h3
Minimum wall thickness after forming s
Weld-edge preparation
h1

Dh

Heavy Fabrication Division Dillinger Hütte GTS, One-piece heads [5/7], 2004

17
 HOT DISHING PROCESS OF A ONE-PIECE HEAD
TORI-SPHERICAL SHAPE
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], 2004

18
4. Lateral transfer lorry being positioned within the operating area of the hydraulic press fitted with the forming die

5. Circular blank being dished

6. Dished head being extracted out of the forming tools

Heavy Fabrication Division Dillinger Hütte GTS, One-piece heads [7/7], 2004

19
 MULTI-SEGMENT SHELL SECTIONS

Trial fit-up of a multi-segment dome for a blast-furnace cowper (Dishing radii from 3362 mm up to 6430 mm, length 17100 mm, height of the
largest spherical section 6430 mm, Steel grade 15Mo3)

20
When the required items exceed ameter cold-forming is applied. the fabrication of items outside
the dimensions of the one-piece The weld-edges of the shaped the manufacturing range of the
component, they can be produced segments are produced by flame cold spinning process which is
in multi-segment design, each cutting. mainly restricted to the shaping
pressing being supplied ready for of wall thicknesses up to around
assembly; the individual sizes of Scope of supply 33 mm. Please refer also to the
the segments can be also agreed Technical Delivery Conditions on
It includes mainly the fabrication
upon. page 32.
of torispherical heads to
DIN 28011 or NF E 81-102 and
Manufacturing process Trial fit-up
DIN 28013 or SMS-482 above
The pressings comprising a mul- 4450 mm in outside diameter and The pressings are produced to
ti-segment shell are individually spherical heads above 3650 mm in fabricate multi-segment heads
formed using tool equipment, the outside diameter; the multi-seg- or other large shell sections.
profile of which suits the contour ment design can be also extended When requested, the segments
of the part being made. The to „tailor-made“ shell sections are trial assembled for the shop
knuckle segments of torispherical suiting a specific shape i.e. transi- inspection by using key-plates
heads are basically hot-pressed; tion pieces, reversible conical seg- and pins; clamping cams can
as are the relative crown segments ments and inlets for shaft lining also be welded on which you
and any pressings designed with since no dimensional restriction can later put to advantage as
a dishing radius up to approxi- must be observed. The multi-seg- erection aids during the final
mately 3500 mm; above this di- ment design is an alternative to assembly.

Heavy Fabrication Division Dillinger Hütte GTS, Multi-segment shell sections [1/3], 2004

21
Standard tolerances

Edge design knuckle crown

Bevel ± 2° ± 2°
Land height ± 2 mm ± 2 mm
Land position 1) ± 2 mm ± 2 mm
Cut face quality ISO 9013-I ISO 9013-I

Shape

200 mm wide edge area 1) 2) ≤ 3 mm /1000 mm ≤ 2 mm /1000 mm

Away from edge area 1) 3) ≤ 6 mm /1000 mm ≤ 6 mm /2000 mm

Dimensions

Length / width 4) ± 2 mm ± 2 mm
Diagonal difference ≤ 3 mm ≤ 3 mm
Circumference5) 6) 7) ± 0.05 % Da ± 0.05 % Da
Out -of-roundness 6) ≤ 30 mm ≤ 30 mm
Inside height 6) 7) – 0 % + 0.5 % Da – 0 % + 0.5 % Da

1) related to the internal surface 4) given by arc measure since the root gap allowance is only taken
2) measured as a distance between a nominal shape template of into consideration when this has been specially agreed
1000 mm and the actual inner contour, the measuring position 5) calculated from measured circumference whereby the assembly
being along the segment edges gap allowances are not included
3) measured as a distance between a nominal shape template of 6) only with trial assembly
1000 mm respectively 2000 mm and the actual inner contour, the 7) Da = external diameter
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], 2004

22
Information required

Torispherical heads
Dk
Shape
(applicable standard or s
dishing radius r1 and
s

crown
knuckle radius r2 )

r1
Diameter Da or D i s
h3

Arrangement of segments r2 knuckle

h1

Diameter of crown D k
Di
Straight flange h1
Da
Minimum wall thickness(es)
after forming s

Spherical heads
Dk
Dishing radius r1 and s
inside diameter Di
s

Arrangement of segments crown

Diameter of crown Dk
Minimum wall thickness(es)
s
after forming s
r1 spherical
course

Di
Da

"Tailor-made" shell sections

Purpose for which they are used
Drawing including full measurements
Minimum wall thickness(es) after forming s

Heavy Fabrication Division Dillinger Hütte GTS, Multi-segment shell sections [3/3], 2004

23
 SPHERICAL SHELL PLATES

Fit-to-assembly segments comprising a spherical tank (Inside diameter 22500 mm x 95 mm, steel grade SA 537 class 2)

24
Spherical shell plates are tailor- very large tooling. The segments up to 125 mm, in width of up to
made segments or “petals” for spheres above 7000 mm in 4000 mm and in length of up to
manufactured ready-to-install diameter are normally manufac- 12000 mm within the final piece
spherical storage vessels where tured cold by progressive dishing. weight generally restricted at
the emphasis is placed on the Once the segments are shaped 25 tons. The scope of supply
high dimensionnal accuracy of properly, the weld-edges are sub- includes also “petals” fabricated
the individual segments. sequently prepared by flame cut- from material produced by
ting. thermo-mechanical controlled
Manufacturing process process or by water-quenching
Scope of supply process. Our extensive experience
Taking into account the material
based on the fabrication of more
properties, the plate thickness Unless otherwise required, the
than 250 spheres allows us to
and the required radius, either arrangement and the sizes of the
manufacture the segments ready
cold or hot forming can be used. segments are optimized by con-
for assembly without any shop
In both alternatives, the shaping sidering the available shop facili-
trial fit-up. Please refer also to
process is conducted in a “safe” ties, the transport conditions and
the Technical Delivery Condi-
way so that the steel mechanicals the field erection constraints.
tions on page 32.
remain preserved i.e. by using Depending on the material and
hydraulic presses with a force of the forming radius, the “petals”
up to 4000 tonnes equipped with can be fabricated in thickness of

Heavy Fabrication Division Dillinger Hütte GTS, Spherical shell plates [1/3], 2004

25
Dimensional program
Format of largest workable segment in relation to inside diameter and wall thickness

hot forming
cold forming

100

90

80

4 000 mm  12 000 mm1)

70
2 750 mm  6 000 mm1)

60
2 500 mm  4 000 mm1)

3 000 mm  10 000 mm1)

2 500 mm  2 500 mm1)

50
3 000 mm  8 000 mm1)

40

30
Wall thickness s (mm)

20

10

2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000

Inside diameter of sphere Di (mm)

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.

Heavy Fabrication Division Dillinger Hütte GTS, Spherical shell plates [2/3], 2004

26
Standard tolerances

Edge design Bevel ± 2°

Land height ± 2 mm
Land position 1 ) ± 2 mm
Cut face quality ISO 9013-I
Dimensions Length ± 2 mm
Width ± 2 mm
Diagonal difference ≤ 3 mm
Shape 200 mm wide edge area 1) 2) ≤ 2 mm / 1000 mm
away from edge area 1) ≤ 6 mm / 2000 mm

A A
Ri

Ri
template template

segment
segment A

The shape deviations are measured as distance A between a template with a chord 1) in relation to the internal surface
length of 1000 mm respectively 2000 mm fitted with the radius as given in the draw- 2) measuring position: along the plate edge
ing and the plate curvature: the checking is carried out as shown in the above sketch (Ri = Innenradius)
after the plates are laid down on a measuring bed set to the nominal radius.

Information required

Inside diameter Di
Arrangement of segments
Minimum wall thickness(es) after forming s
Fabrication code

Schematic description of lay-out

1
s1
2 crown
s2

ß1

3
s3 upper course

ß2 ß3

equatorial course
s4
4 Di a

ß4

s5
5 bottom

s6
6

Spherical shell plates are always outlined by longitudinal or latitudi- Unless otherwise agreed, allowance for assembly root-gap or for
nal arcs, either by "great circles" (with circle centre in sphere centre) welding shrinkage will not be taken into consideration.
or by "small circles" (with circle centre outside the sphere centre).
All dimensions are given by arc measure related to the inner surface.

Heavy Fabrication Division Dillinger Hütte GTS, Spherical shell plates [3/3], 2004

27
 CYLINDRICAL SHELL COURSES

Deep quenching of a cylindrical shell courses (ID 1750 mm x 116 mm x 4200 mm, steel SA 387 grade 11-2)

28
Cylindrical shell-courses are Optionally, the shell-courses able top rollers ( 880 mm,
basic items entering in a lot of are supplied just tack-welded – 1.200 mm and 1.500 mm )
applications such as components achieved from the outside – enable to cover a very wide
for pressure vessels or structural within the longitudinal joint or range of diameters.
sections. braced at both ends by using
strong-backs. This machine has been specially
Manufacturing process engineered for heavy section
As a rule, the plate edges of the plates made out of high strength
Shell-courses are produced by steels characterised by a yield
longitudinal joint are prepared
cold or hot forming, the choice point of 700 MPa. Such an
by a milling process performed
of the process being a function equipment is particularly advan-
from the outside what makes
of both the shell sizes and the tageous for steel grades where
a "narrow gap" weld-joint of
material properties. They are hot forming is always problem-
18° achievable. The circular
preferably supplied fully welded: atic e.g. for all steels intended
weld-edges of shell-courses are
welding is performed by using to be delivered either in the
usually produced by flame
either single-electrode, two-elec- water-quenched ( QT ) or in the
cutting; edge-machining of
trode or twin-arc submerged arc thermo-mechanically processed
shell-courses up to 2.650 mm
methods in accordance with the ( TM ) condition.
in length can be agreed.
provisions of the relevant inter-
national codes, for example AD, When required the forming can
Scope of supply
ASME (Stamps U, U2 and S are be also performed by using a hot
available), PD 5500, CODAP, The forming is achieved by process, conducted in the way
TRD. Depending on the materi- means of a 4-roller machine to keep extensively the surface
al and code requirements, the powered with 8.600 t force, finish free of the usual disconti-
formed parts can be given prop- designed to deal with 4.300 mm nuities resulting from this kind
er heat treatments, for instance (169,2") wide plate. Its perfor- of process.
normalising, tempering, water- mance includes the cold forming
quenching. of shell-course up to 240 mm Please consider also the
(9,4") in thickness at the full Technical Delivery Conditions
plate width; three interchange- on page 32

Heavy Fabrication Division Dillinger Hütte GTS, Cylindrical shell courses [1/3], 2004

29
 300
290
280
270
260 a (35 ksi)
th 240 MP
250 Yield streng
240
230
220 )
210 M Pa (53 ksi
ngth 360
200 Yield stre
190
180 (80 ksi)
re ng th 550 MPa
170 Yield st )

1.500 mm top roller

Performance chart of the roll-bending machine

160 a (100 ksi

ld st ren g th 700 MP
150 Yie
140

30
130
120
110
100

1.200 mm top roller

90
80
70
60
50
40
30
based on a cold forming process up to 4,300 mm (169,2'') in course length

880 mm top roller

20
10
0

Wall thickness [mm]

800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000

Heavy Fabrication Division Dillinger Hütte GTS, Cylindrical shell courses [2/3], 2004
Inside diameter [mm]

Delivery program of shell-courses upon enquiry

Standard tolerances

Edge-preparation Flame-cut Machined

Bevel ± 2.0˚ ± 1.0˚

Land position 1) ± 2.0 mm ± 1.0 mm
Land height ± 2.0 mm ± 1.0 mm
Radius 2) ± 1.0 mm
Cut face quality ISO 9013-I ISO 1302-N9

1) measured from the plate top side

2) applicable to U and DU edges only

Diameter 1) ± 0.3 % Da
Ovality 2) ≤ 1 % Da
Length ≤ 3 mm
Straightness ≤ 1 mm / 1000 mm

1) calculated from the measured circumference this tolerance must be agreed with shell courses to be
2) The ovality is defined by the difference between the smallest and – supplied in the tack-welded condition
the largest actual internal diameters (D max - D min); – subject to water quenching after forming process
3) enhanced tolerances might be agreed – formed within the ratio s /D ≤ 1 %

Information required

Diameter Di or Da
Length L
L
Minimum wall thickness after forming s s

Edge-design
Welding requirements and
fabrication code
Di Da

Heavy Fabrication Division Dillinger Hütte GTS, Cylindrical shell courses [3/3], 2004

31
 TECHNICAL DELIVERY CONDITIONS

Trial fit-up of cone and hemispherical heads in multi-segment design (3-segment cone: diameter 5300 mm / 3900 mm, thickness 75 mm, segment
height 4000 mm; 5-segment heads: forming radius 2100 mm, thickness 70 mm, steel quality SA 516 grade 70)

32
Plate fabrication be necessary to maintain the weld-edge preparation. The
shape during transport and stor- edges of cut-to-shape plates,
The applied processing opera-
age. In the case of packages i.e pressings and cylindrical shell
tions comply with the recom-
joint delivery of shell courses courses are as a rule worked by
mendations made by the steel
with adjacent pressings, the flame cutting, the cut-face being
maker having produced the
accuracy of the components to subsequently processed free of
plates. Furthermore, the fabrica-
each other shall be within the scale and slag accumulation by
tion operations meet the guide-
permissible misalignement grinding. All edge details i.e. “I”,
lines of SEW 88 - german direc-
allowed in the applicable code. “V”, “Y” - in single or in double
tives governing the processing of
design - described in the relevant
heavy steel plates. The require-
Surface condition standards such as API 650, DIN
ments contained in the relevant
8851, NF E 81-110 can be pro-
fabrication codes such as AD, The items are supplied with un-
duced in line with the cutting
ASME, BS, CODAP, IBR, treated surfaces in line with the
process. Any requirement for
STOOMWEZEN or TRD can processing method used; by
machining and tapering of weld-
also be agreed. Depending on agreement the surface quality
edge preparation must be addi-
the material steel grade and the can be evaluated against EN
tionally agreed.
applicable specifications, the 10163: Part 1 and 2. It can also
formed parts can be subsequent- be agreed that the surface of the
Identification
ly heat treated in accordance manufactured items must be
with the requirements of the descaled and primed: this Each item produced by Dillinger
client, e.g. normalizing, water- should be done in accordance Hütte GTS is originally marked
quenching, tempering or stress- with ISO 8501-1 (SIS 05-5900) in accordance with the applica-
relieving. As a rule the or equivalent standard. The ble plate standards; they are
mechanical properties of every surface preservation of shell- additionally identified by using a
pressings shaped by hot forming plates is generally carried out sequential piece number to
are verified by using test coupons prior to the processing opera- ensure the traceability of the
taken from material allowance tions (weld-edge preparation manufactured parts along the
after completion of the forming and shaping to radius). The fabrication operations back to
process and tested in the final plate weld-edges can be also the Inspection Test Certificates.
heat treatment condition. protected against corrosion by The markings are as a rule made
using a suitable coating, the on the top side of the plate i.e.
Dimensional and shape tolerances type of which is subject to on the concave side of the curved
agreement. The surface treat- shell sections. Unless otherwise
Each of the foregoing product-
ment may be subcontracted to agreed, heads and pressings are
information sheets includes spe-
an external company whose marked on the outside surface.
cific details regarding the stan-
quality system is controlled by The shipping marks are sten-
dard shop-fabrication tolerances;
Dillinger Hütte GTS. cilled in the manner required in
they will be applied unless other-
the purchase order. Additionally
wise agreed and are valid at the
Weld-edge preparation the items are equipped for tran-
time of the shop inspection. Sup-
sit with the brand name and the
porting structures, the type of Items supplied in the multi-seg-
emblem of Dillinger Hütte GTS.
which is to be agreed upon, may ment design are produced with

Heavy Fabrication Division Dillinger Hütte GTS, Technical delivery conditions [1/2], 2004

33
1/6 Sinusoidal segments ready to install a tunnel lining of an underground station, situated in a mining area (Clear diameter 6300 mm, wall thick-
ness 19 mm, steel grade ST 52.3 to DIN 17100)

34
Contract work Information required Enlarged scope of supply

In the case of free issued plates In order to be able to process The Heavy Fabrication Division
i.e. plates produced outside the your requirements, we need the of Dillinger Hütte GTS is well
works of Dillinger Hütte GTS, following details: equipped to deal with your or-
all processing conditions must be Material steel grade ders. The table on page 37 pro-
agreed in advance i.e. before re- Acceptance conditions (plate vides an overview of the most
lease of order; this concerns espe- material and fabricated item) important production facilities.
cially the hot forming parame- Testing condition (when devi- This gives you the opportunity to
ters, the machining and the mate- ating from the as-delivered check whether, in addition to our
rial allowances. condition) standard delivery program, we
Final heat treatment condition can also fulfill your particular
Fabrication code (mandatory wishes e.g. as demonstrated with
Packaging
for welded parts) the „tailor-made“ steel-sections
The items are usually provided shown on the page 34. Any de-
Weld-edge preparation
loose and unsecured i.e. shaped sign work, fabrication of finished
Dimensions
parts such as dished heads, press- equipment and erection on the
ings or curved shell sections are Please refer also to the tables field are basically outside the ser-
just laying on wooden timbers "Information required" individu- vices offered by Dillinger Hütte
fitting the outside curvature, usu- ally selected for each application. GTS. On request the indivual
ally with the inner side upwards. For the parts outside the standard components can be preassembled
Shell-plates are stacked into lift- delivery program, please support into heavy units, ready for subse-
ing units separated from each always your inquiry with a print quent processing operations by
other by means of wooden spac- showing the contour design of the the fabricator e.g. the cylindrical
ers. Other types of measures for part to be manufactured including shells courses can be fitted by
packaging, securing or lashing all measurements. welding to the adjacent heads or
e.g. the supply of any supporting other pressings. Large items of
structures being necessary to up to a total weight of 100 tons
Documentation
maintain the shape during trans- and 18000 mm in length can be
port (e.g. skids, pallets), the stow- Unless otherwise required, an handled. The manufacturing
ing into containers, the welding inspection test certificate to EN plants are installed in covered
of lifting lugs, the use of spacers 10204-3.1.B shall be provided for bays with a total surface area of
between shell-plates are always the base material and the manu- around 39000 m2 and have both a
subject to agreement. Packaging factured item as well. By agree- road and a rail link. The access
and lashing requirements in- ment, the documentation may to the company's own port facili-
structed just at the time of the also include fabrication and con- ties on the river Saar means that
call for shipping will have exten- trol procedures, quality plan and it is also possible to ship bulky
sive cost implications. shop drawings as well. components.

Explaination of symbols:
a = minor half-axis Di = iternal diameter L = length
 1,  2 = longitudinal centre angle Dk = crown diameter Ri = internal radius
b = major half-axis Dmin = minor diameter r1 = dishing radius
 1,  2 = latitudinal centre angle Dmax = major diameter r2 = knuckle radius
B = width h1 = straight flange s = wall thickness
Da = external diameter h2 = dishing height Da  Di + 2.4 s (only for heads)
Dh = connecting diameter h3 = depth or internal height (h1 + h2) Di  Da - 2.4 s (only for heads)

Heavy Fabrication Division Dillinger Hütte GTS, Technical delivery conditions [2/2], 2004

35
 FABRICATION FACILITIES

2500 ton hydraulic press

36
Machinery synopsis Thickness Width Length Clearance Diameter Weight
(mm) (mm) (mm) (mm) (mm) (t)
Forming cold hot
- dishing press ( 750 t ) 50 6
- multi-purpose press ( 2.250 t ) 110 170 4.900 1) 12
- multi-purpose press ( 2.500 t ) 125 200 5.400 1) 30
- flanging press ( 4.000 t ) 200 4.200 14
- 4-roll bending machine ( 1.500 t ) 25 4.000 2) 750 3)
10
2) 3)
- 4-roll bending machine ( 8.600 t ) 240 420 4.300 1.000 50
Machining
- Vertical lathe 2.000 4) 4.000 5) 10
- CNC vertical lathe 2.650 4) 6.100 5) 60
- CNC plate-edge milling machine 120 5.000 25.000 25
- weld-seam grinding machine of
longitudinal joints 5.000 6) 50
- milling machine for weld-edge
preparation of longitudinal joints
and back-gouging 170 10) 5.000 6) 50
Flame cutting
- CNC profile-cutting machine 8) 200 5.500 15.000 10
- CNC profile-cutting machine 8)
350 5.500 26.000 50
- equipment for edge-preparing of heads 200 4.800 30
Heat treating
- boogie hearth furnace 9) 4.300 10.000 3.600 4) 100
- walking beam furnace 9) 5.500 8.250 1.800 4) 16
- walking beam furnace 9)
6.000 12.500 2.300 4)
30
- 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 6) usable grinding length

2) usable length of the barrel 7) acetylene / oxygen gases
3) minimum diameter 8) natural / oxygen gases
4) clear height 9) normalising / tempering / stress-relieving
5) clear diameter 10) 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], 2004

37
 PROCESSED STEEL GRADES

The sculpture "Serpentine" by Richard Serra during the trial shop erection (Length: 33000 mm x 4000 mm x 45 mm, weighing over 100 tons)

38
For the manufacture of the com- collecting drums, and the tion of area up to 40 % can be
ponents described on the previ- DICREST steels for sour gas- agreed on.
ous pages, steel qualities of the charged boilers and pressure
relevant international standard vessels. A further speciality are Structural steel qualities to EN
for the intented application are our chrome molybdenum 10 025, EN 10 113 (Part 2) and
used. alloyed steels for the construc- EN 10 115 can also be supplied
tion of petrochemical reactors as longitudinally profiled plates,
Deliveries are made to the usual which meet the strictest de- i.e. with variable thickness over
german and international stan- mands of international specifi- the plate length - namely with a
dards and regulations. In addi- cations - for example with maximum thickness difference
tion we offer in many fields regard to the so-called step of up to 55 mm and at a slope
special works-standard grades coolings. Almost all steel quali- of up to 8 mm/m.
for severe application condi- ties can also be supplied with
tions. Examples of these are the improved qualities as regards For more detailed information
elevated temperature DIWA 373, thickness, for example to we refer you to the plate
a high-strength fine-grained ASTM-A 770 and EN 10164. Delivery Program of Dillinger
steel for high-pressure steam Here minimum values for reduc- Hütte GTS.

As a heavy plate producer the Dillinger Hütte GTS range of products includes:

general structural steels, weldable fine-grain abrasion-resistant structural

ship-building steels, structural steels, steels,
alloyed and unalloyed boiler high-strength quenched and alloyed and unalloyed
and pressure vessel steels, tempered fine-grain steels, hardening and heat-treatable
steels for pipe-line and special low-temperature steels,
penstock application, weldable structural steels, as special purpose steels.
low-temperature nickel-
alloyed steels (up to 9 % Ni),

Heavy Fabrication Division Dillinger Hütte GTS, Processed steel grades [1/1], 2004

39
Flat head, flanged only, seamless (Outside diameter 4100 mm x 95 mm, knuckle radius 100 mm, steel grade WStE355)

Spherical head, seamless (Inside diameter 2275 mm x 185 mm, steel grade StE355)

40
One-piece-heads (ASME 2:1) for IMO-5 gas containers, ready for shipment, secured on wooden paletts (Inside diameter 2410 mm x 17.7 mm, steel
quality SA 612)

Spherical heads, seamless (Inside diameter 3425 mm x 92 mm, steel quality SA 387 grade 11-1)

41
6-segment conical transition piece equipped with reversible flanges, being trial assembled (Inside diameter 4800 mm / 1650 mm x 98 mm,
height 3300 mm, steel quality SA 302 grade B, water-quenched)

Torispherical heads in multi-segment design, for bilobe gascontainers (Outside diameter 9500 mm x 25 mm, 5%Ni-steel 12Ni19)

42
 YOUR CONTACTS

Please feel free to submit your in-

dividual requirements as well as
any request regarding the present
Delivery Programm to the Sales
Department of the Heavy Fabrica-
tion Division or to the local repre-
sentatives of Dillinger Hütte GTS.

AG der Dillinger Hüttenwerke

Heavy Fabrication Division
P.O. Box 1580
D-66748 DILLINGEN/Saar
Telephone: +49- 6831 47 23 42
Telefax: +49- 6831 47 33 46
Telefax: +49- 6831 47 30 88
➝

ANTWERP
ROTTERDAM
BELGIUM E35
E451

E29 E44

Frankfurt
Rh

Main
ein

E44
E35
l
se E31
o

LUXEMBOURG MUNICH ➝
M

GERMANY
Luxemburg E451
S aa

E50
Dillingen
r

Metz Saarbrücken
➝
PARIS E35
Rhe
Mosel

in
S aa

E52
r

Stuttgart
Nancy
FRANCE
Strasbourg E35
E41
➝

BASEL, ZÜRICH

How to find us

43
AG der Dillinger Hüttenwerke

P.O. Box 1580

D-66748 Dillingen/Saar
Telephone: +49- 6831 47 - 0
Facsimile: +49- 6831 47 2212
Telex: 443 711-0 dhd

Liability: data provided on the

properties or suitability for use of
materials and/or products are
only to be regarded as descrip-
tions. Assurances regarding the
presence of certain properties or
the suitability for a particular
purpose must always be in the
form of written agreements.
Delivery Program Heavy Fabrication Division, 2004