Manufacturing of Dish End PDF

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

Heavy Fabrication Division of
Dillinger Htte GTS are supplied
in the manner demanded by the
relevant standards, technical
delivery specifications and other
agreements made with the customer. The Quality Assurance
System which has been established many years ago is duly certified to ISO 9001. Many specific
approvals are available e.g to the
Rules and Regulations of
AD-Merkblatt HP O/W O, TRD
100/200, Lloyds Register for
Class 1 Fusion Welded Pressure
edition 2004
Vessels. The Heavy Fabrication

Division is also ASME-Stamp
holder for Section VIII-1
(U-Stamp), Section VIII.2
(Stamp-U2) and Section 1
(S-Stamp).
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)
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
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)
Anyone believing that the elegant

dome of the Hussein Mosque in
Cairo is a work of ancient Oriental craftmanship 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 Htte 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 Htte GTS is
reaching for the skies: When the
Ariane V takes off from the
Kourou space centre in FrenchGuyana, 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 however the extensive capabilities of the Heavy
Fabrication Division, the essential aspect of which remains the
fabrication of heavy steel plates.
However, we ourselves are not
fabricators of finished equipment;
we prefer to view ourselves as
service-providers for processing
companies involved in heavy engineering. Much of the material
coming out of Dillinger Htte
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
plate. And often it's both. Not all
manufacturers of structural steel
constructions, pressure vessels or

heavy apparatus want 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 and 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 plate.
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 in the required steel qualities. Our comprehensive range is
the result of long years of experience in cooperating with steel
plate fabricators. But, 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 Htte GTS, Modular solutions for heavy plate fabrication [1/1], 2004
FABRICATED PLATES
Shell plates equipped with machined weld-edge preparation
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 HTTE 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
the 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.
carried out by milling; for larger

thickness, flame-cutting will
apply. Depending on the cutting
process, the edges are engineered
with single or double weldpreparation e.g. "I", "V", "X",
"Y", "U" since all 4 edges can be
individually equipped a specific
weld-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.
Scope of supply
The edge preparation of plates
within the thickness range of
between 5 mm and 120 mm is
Information required
Final plate sizes, rolling radius,
weld-edge design.
Heavy Fabrication Division Dillinger Htte GTS, Fabricated plates [1/3], 2004
Dimensional program
Shell plates
Milling
Flame-cutting
Thickness
Width
Length
Plate weight
Yield point
5
120 mm
1.350 5.000 mm
4.000 25.000 mm
40 t
1000 MPa
10
230 mm
800 5.200 mm
2.000 18.000 mm
Cylindrical shell plates
Halves 1)
Thirds 1)
Thickness
Width
Length
Radius
Yield point
15
230 mm
800 4.300 mm
4.000 14.000 mm
4.000 mm
850 MPa
12
230 mm
800 4.300 mm
4.000 14.000 mm
6.000 mm
1) Workable plate sizes and other shell design are subject to agreement.
Edge design
DV
DU
Notes: details of weld-edge preparation e.g. root radius and slope angle must be agreed.
Standard tolerances
Edge preparation
Machined
Flame-cut
Bevel angle (, )
Land location (h) 1)
Land height (a)
Root radius (R) 2)
Slope angle () 2)
Cut face quality
0.5
0.5 mm
0.5 mm
0.5 mm
0.5
ISO 1302-N7/ N8
2.0
2.0 mm
2.0 mm
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
away from the end area
2 mm / 0.5 m
10 mm / 2 m
Straightness of the ends

s 20 mm
s 40 mm
s > 40 mm
4 mm / 1000 mm
3 mm / 1000 mm
2 mm / 1000 mm
s = wall thickness
Ri = internal radius
A = deviation from the theoritical curvature
Ri
template
Ri
template
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.
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

mainly for use in structural and
mechanical engineering, e.g. as
blanks for tool equipmemt or
frames for hydraulic presses.
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.
Scope of supply
The blanks are supplied in the
steel grades within the plate Delivery Program of Dillinger Htte
GTS preferably in pieces above
3 tons in weight. They can also
be provided with flatness tolerances enhanced against those
specified in the standards e.g. EN
10029, ASTM A 6 / A 20. In addition, when required by the steel
grade, the profiles can also be
supplied in the stress-relieved
condition to suit subsequent processing operations such as a machining. It is known that profile
cutting involves significant plate
wastage; unless otherwise agreed

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.
Shape description supported
with a full-dimensioned
drawing.
Dimensional program
Width
Length
5200 mm
18000 mm
Thickness
Weight
350 mm
38 t
Standard tolerances
Dimensions
ISO 9013-A
Edge design
Bevel
Land position 1)
2
2 mm
Land height
2 mm
Cut face quality ISO 9013-I
Heavy Fabrication Division Dillinger Htte 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 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.
Scope of supply
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 2500 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.
Seamless heads can be supplied

spherical-shaped in outside
diameters up to 3650 mm, torispherical or elliptical-shaped up
to 4450 mm or flanged only up
to 4750 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
Heavy Fabrication Division Dillinger Htte GTS, One-piece heads [1/7], 2004
13
Dimensional program
Wall thickness related to the external diameter for the different shapes
Outside diameter
(mm)
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000
3100
3200
3300
3400
3500
3600
3700
3800
3900
4000
4100
4200
4300
4400
4500
4600
4700
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
Thickness (mm)
1)
Elliptical &
torispherical 2)
from up to
1050
1150
1250
1350
1450
1550
1650
1750
1850
1950
2050
2150
2250
2350
2450
2550
2650
2750
2850
2950
3050
3150
3250
3350
3450
3550
3650
3750
3850
3950
4050
4150
4250
4350
4450
4550
4650
4750
6
6
6
6
6
7
7
7
7
8
8
9
9
10
10
11
11
12
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
-
90
90
100
100
110
120
120
130
130
140
140
150
150
160
160
170
170
170
170
170
170
170
160
160
150
150
140
140
120
120
110
110
110
110
110
-
Spherical 3)
Flanged only 4)
from
up to
from up to
90
100
120
130
140
150
170
180
200
200
200
200
200
200
200
200
180
180
180
160
160
150
150
140
140
130
120
-
20
20
20
20
22
22
22
22
22
24
24
24
24
24
24
24
24
26
26
26
28
28
30
30
30
12
13
14
15
16
17
18
19
20
22
24
26
28
30
32
34
36
38
40
40
40
40
40
40
40
40
40
-
The data on wall thicknesses apply for steel with 355 N/mm2 yield
strength. The flange height complies with the applicable standard or
the customer's requirements but - due to the tool design - is normally
restricted to 150 mm. Please inquire for other head shapes and intermediate dimensions.
75
75
80
80
85
85
90
90
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
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
14
Standard tolerances
Edge-preparation
flame-cut
machined
Bevel
Land position 1)
Land height
Milling radius 2)
Cut face quality
2.0
2.0 mm
2.0 mm
1.0
1.0 mm
1.0 mm
1.0 mm
ISO 1302-N9
ISO 9013-I
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 tempered steels are subject to special agreement.
Diameters are as a rule calculated from the actual measured circumference; please consider that Da Di + 2.4 s bzw. Di Da 2.4 s
The tolerance data regarding the diameter of hemispherical heads

are based on the connecting diameter which can be fitted by adjusting the inner height.
(Da = Outside diameter; Di = Inside diameter; s = Wall thickness)
15
Torispherical heads
h3
h2
r1
Shape
(applicable standard or dishing radius r1
and knuckle radius r2 )
Diameter Da or Di
Minimum wall thickness after forming s
Straight flange h1
Weld-edge preparation
h1
r2
Di
Da
Elliptical heads
Shape
(applicable standard or axis ratio b : a)
Diameter Da or Di
Straight flange h1
h3
h1
h2
Di
Da
Flat heads, flanged only
Diameter Da or Di
Dishing radius or knuckle radius r1
Straight flange h1 or depth h3 (h1 + h2 )
Da
16
h1
Di
h3
r2
Hemispherical heads with straight flange
h1
Di
Da
Hemispherical heads (r1 = h3)
r1
h3
Dishing radius r1 or inside diameter Di

Di
Da
Spherical heads
h1
r1
h3
Dishing radius r1
Connecting inside diameter
Dh or "negative" height h1 or
depth h3
Dh
17
h3
h2
r1
Dishing radius r1 or inside diameter Di

Straight flange h1 or depth h3 (h1 + h2 )
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
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
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

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.
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 3500 mm; above this di-
ameter 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
4450 mm in outside diameter and
spherical heads above 3650 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
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
33 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.
Heavy Fabrication Division Dillinger Htte GTS, Multi-segment shell sections [1/3], 2004
21
Standard tolerances
Edge design
knuckle
crown
Bevel
Land height
Land position 1)
Cut face quality
2
2 mm
2 mm
ISO 9013-I
2
2 mm
2 mm
ISO 9013-I
3 mm /1000 mm
6 mm /1000 mm
2 mm /1000 mm
6 mm /2000 mm
2 mm
3 mm
0.05 % Da
30 mm
0 % + 0.5 % Da
2 mm
3 mm
0.05 % Da
30 mm
0 % + 0.5 % Da
Shape
200 mm wide edge area 1) 2)
Away from edge area 1) 3)
Dimensions
Length / width 4)
Diagonal difference
Circumference5) 6) 7)
Out -of-roundness 6)
Inside height 6) 7)
1) related to the internal surface

2) measured as a distance between a nominal shape template of
1000 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
1000 mm respectively 2000 mm and the actual inner contour, the
measuring position being vertical to the plane defined by the
circumferential weld-edge
4) given by arc measure since the root gap allowance is only taken
into consideration when this has been specially agreed
5) calculated from measured circumference whereby the assembly
gap allowances are not included
6) only with trial assembly
7) Da = external diameter
22
Torispherical heads
Dk
r1
crown
h3
s
r2
h1
Shape
(applicable standard or
dishing radius r1 and
knuckle radius r2 )
Diameter Da or D i
Arrangement of segments
Diameter of crown D k
Straight flange h1
Minimum wall thickness(es)
after forming s
Di
Da
Spherical heads
Dk
s
s
Dishing radius r1 and

inside diameter Di
Diameter of crown Dk
Minimum wall thickness(es)
after forming s
knuckle
crown
r1
Di
Da
"Tailor-made" shell sections

Purpose for which they are used
Drawing including full measurements
Minimum wall thickness(es) after forming s
23
spherical
course
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 tailormade segments or petals

manufactured ready-to-install
spherical storage vessels where
the emphasis is placed on the
high dimensionnal accuracy of
the individual segments.
very large tooling. The segments

for spheres above 7000 mm in
diameter are normally manufactured cold by progressive dishing.
Once the segments are shaped
properly, the weld-edges are subsequently prepared by flame cutting.
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 i.e. by using
hydraulic presses with a force of
up to 4000 tonnes equipped with
Scope of supply
Unless otherwise required, the
arrangement and the sizes of the
segments are optimized by considering the available shop facilities, the transport conditions and
the field erection constraints.
Depending on the material and
the forming radius, the petals
can be fabricated in thickness of
up to 125 mm, in width of up to

4000 mm and in length of up to
12000 mm within the final piece
weight generally restricted at
25 tons. The scope of supply
includes also petals fabricated
from material produced by
thermo-mechanical controlled
process or by water-quenching
process. Our extensive experience
based on the fabrication of more
than 250 spheres allows us to
manufacture the segments ready
for assembly without any shop
trial fit-up. Please refer also to
Heavy Fabrication Division Dillinger Htte 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
4 000 mm 12 000 mm1)
80
Wall thickness s (mm)
3 000 mm 10 000 mm1)
30
3 000 mm 8 000 mm1)
40
2 500 mm 4 000 mm1)
50
2 500 mm 2 500 mm1)
60
2 750 mm 6 000 mm1)
70
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.
26
Standard tolerances
Bevel
Land height
Land position 1 )
Cut face quality
2
2 mm
2 mm
ISO 9013-I
Dimensions
Length
Width
Diagonal difference
2 mm
2 mm
3 mm
Shape
200 mm wide edge area 1) 2)

away from edge area 1)
2 mm / 1000 mm
6 mm / 2000 mm
Ri
Ri
Edge design
template
segment
template
segment
The shape deviations are measured as distance A between a template with a chord
length of 1000 mm respectively 2000 mm fitted with the radius as given in the drawing and the plate curvature: the checking is carried out as shown in the above sketch
after the plates are laid down on a measuring bed set to the nominal radius.
1) in relation to the internal surface

2) measuring position: along the plate edge
(Ri = Innenradius)
Inside diameter Di
Minimum wall thickness(es) after forming s
Fabrication code
Schematic description of lay-out
1
s1
2
crown
s2
1
3
s3
upper course
equatorial course
4
s4
Di
s5
5
6
bottom
s6
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.
Unless otherwise agreed, allowance for assembly root-gap or for

welding shrinkage will not be taken into consideration.
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

basic items entering in a lot of
applications such as components
for pressure vessels or structural
sections.
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.
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, waterquenching.
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
weld-edges of shell-courses are
usually produced by flame
cutting; edge-machining of
shell-courses up to 2.650 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 interchange-
able top rollers ( 880 mm,

1.200 mm and 1.500 mm )
enable to cover a very wide
range of diameters.
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
water-quenched ( 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
Heavy Fabrication Division Dillinger Htte GTS, Cylindrical shell courses [1/3], 2004
29
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
Wall thickness [mm]
30
1000
1.200 mm top roller
880 mm top roller
1200
1400
1.500 mm top roller

1600
1800
Delivery program of shell-courses upon enquiry
Inside diameter [mm]
800
2000
2200
2400
(80 ksi)
550 MPa
th
g
n
re
st
Yield
)
a (100 ksi
th 700 MP
g
n
re
st
ld
Yie
)
Pa (53 ksi
a (35 ksi)
th 240 MP
M
ngth 360
Yield stre
Yield streng
2600
2800
3000
3200
3400
3600
3800
4000
Performance chart of the roll-bending machine

based on a cold forming process up to 4,300 mm (169,2'') in course length
Standard tolerances
Edge-preparation
Flame-cut
Machined
Bevel
Land position 1)
Land height
Radius 2)
Cut face quality
2.0
2.0 mm
2.0 mm
1.0
1.0 mm
1.0 mm
1.0 mm
ISO 1302-N9
ISO 9013-I

2) applicable to U and DU edges only
Diameter 1)
Ovality 2)
Length
Straightness
0.3 % Da
1 % Da
3 mm
1 mm / 1000 mm
1) calculated from the measured circumference

2) The ovality is defined by the difference between the smallest and
the largest actual internal diameters (D max - D min);
3) enhanced tolerances might be agreed
this tolerance must be agreed with shell courses to be

supplied in the tack-welded condition
subject to water quenching after forming process
formed within the ratio s /D 1 %
Diameter Di or Da
Length L
L
Edge-design
Welding requirements and
fabrication code
Di
31
Da
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
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, BS, CODAP, IBR,
STOOMWEZEN or TRD can
also be agreed. Depending on
the material steel grade and the
applicable specifications, the
formed parts can be subsequently heat treated in accordance
with the requirements of the
client, e.g. normalizing, waterquenching, tempering or stressrelieving. As a rule the
mechanical properties of every
pressings shaped by hot forming
are verified by using test coupons
taken from material allowance
after completion of the forming
process and tested in the final
heat treatment condition.
Dimensional and shape tolerances
Each of the foregoing productinformation sheets includes specific details regarding the standard shop-fabrication tolerances;
they will be applied unless otherwise agreed and are valid at the
time of the shop inspection. Supporting structures, the type of
which is to be agreed upon, may
be necessary to maintain the

shape during transport and storage. In the case of packages i.e
joint delivery of shell courses
with adjacent pressings, the
accuracy of the components to
each other shall be within the
permissible misalignement
allowed 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: this
should be done in accordance
with ISO 8501-1 (SIS 05-5900)
or equivalent standard. The
surface preservation of shellplates 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 may be subcontracted to
an external company whose
quality system is controlled by
Dillinger Htte GTS.
Items supplied in the multi-segment design are produced with
weld-edge preparation. The

edges of cut-to-shape plates,
pressings and cylindrical shell
courses are as a rule worked by
flame cutting, the cut-face being
subsequently processed free of
scale and slag accumulation by
grinding. All edge details i.e. I,
V, Y - in single or in double
design - described in the relevant
standards such as API 650, DIN
8851, NF E 81-110 can be produced in line with the cutting
process. Any requirement for
machining and tapering of weldedge preparation must be additionally agreed.
Identification
Each item produced by Dillinger
Htte GTS is originally marked
in accordance with the applicable plate standards; they are
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.
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 Htte GTS.
Heavy Fabrication Division Dillinger Htte 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 thickness 19 mm, steel grade ST 52.3 to DIN 17100)
34
Contract work
Enlarged scope of supply
In the case of free issued plates

i.e. plates produced outside the
works of Dillinger Htte GTS,
all processing conditions must be
agreed in advance i.e. before release of order; this concerns especially the hot forming parameters, the machining and the material allowances.
In order to be able to process

your requirements, we need the
following details:
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)
Dimensions
Unless otherwise required, an

inspection test certificate to EN
10204-3.1.B shall be provided for
the base material and the manufactured item as well. By agreement, the documentation may
also include fabrication and control procedures, quality plan and
shop drawings as well.
The Heavy Fabrication Division

of Dillinger Htte GTS is well
equipped to deal with your orders. The table on page 37 provides an overview of the most
important production facilities.
This gives you the opportunity to
check whether, in addition to our
standard delivery program, we
can also fulfill your particular
wishes e.g. as demonstrated with
the tailor-made steel-sections
shown on the page 34. Any design work, fabrication of finished
equipment and erection on the
field are basically outside the services offered by Dillinger Htte
GTS. On request the indivual
components can be preassembled
into heavy units, ready for subsequent processing operations by
the fabricator e.g. the cylindrical
shells courses can be fitted by
welding to the adjacent heads or
other pressings. Large items of
up to a total weight of 100 tons
and 18000 mm in length can be
handled. The manufacturing
plants are installed in covered
bays with a total surface area of
around 39000 m2 and have both a
road and a rail link. The access
to the company's own port facilities on the river Saar means that
it is also possible to ship bulky
components.
Di = iternal diameter
Dk = crown diameter
Dmin = minor diameter
Dmax = major diameter
h1 = straight flange
h2 = dishing height
h3 = depth or internal height (h1 + h2)
L = length
Ri = internal radius
r1 = dishing radius
r2 = knuckle radius
s = wall thickness
Da Di + 2.4 s (only for heads)
Di Da - 2.4 s (only for heads)
Packaging
The items are usually provided
loose and unsecured i.e. 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 or lashing
e.g. the supply of any supporting
structures being necessary to
maintain the shape during transport (e.g. skids, pallets), the stowing into containers, the welding
of lifting lugs, the use of spacers
between shell-plates are always
subject to agreement. Packaging
and lashing requirements instructed just at the time of the
call for shipping will have extensive cost implications.
Explaination of symbols:
a = minor half-axis
1, 2 = longitudinal centre angle
b = major half-axis
1, 2 = latitudinal centre angle
B = width
Da = external diameter
Dh = connecting diameter
Please refer also to the tables

"Information required" individually selected for each application.
For the parts outside the standard
delivery program, please support
always your inquiry with a print
showing the contour design of the
part to be manufactured including
all measurements.
Documentation
Heavy Fabrication Division Dillinger Htte GTS, Technical delivery conditions [2/2], 2004
35
FABRICATION FACILITIES
2500 ton hydraulic press
36
Machinery synopsis
Thickness
(mm)
cold
Forming
- dishing press ( 750 t )
Width
(mm)
Length
(mm)
Clearance
(mm)
Diameter
(mm)
Weight
(t)
12
hot
50
- multi-purpose press ( 2.250 t )
110
170
4.900 1)
- multi-purpose press ( 2.500 t )
125
200
5.400 1)
- flanging press ( 4.000 t )
200
- 4-roll bending machine ( 1.500 t )

- 4-roll bending machine ( 8.600 t )
4.200
25
4.000 2)
240
2)
420
30
14
4.300
750
3)
10
1.000
3)
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
- weld-seam grinding machine of

longitudinal joints
- milling machine for weld-edge
preparation of longitudinal joints
and back-gouging
170 10)
25.000
25
5.000 6)
50
5.000 6)
50
Flame cutting
- CNC profile-cutting machine 8)
200
5.500
15.000
8)
350
5.500
26.000
- CNC profile-cutting machine
- equipment for edge-preparing of heads
10
50
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
12.500
4)
30
- walking beam furnace
9)
6.000
2.300
- 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)
2)
3)
4)
5)
diameter of the circular blank

usable length of the barrel
minimum diameter
clear height
clear diameter
6) usable grinding length

7) acetylene / oxygen gases
8) natural / oxygen gases
9) normalising / tempering / stress-relieving
10) depth of the U-groove preparation for narrow-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 Htte 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 components described on the previous pages, steel qualities of the
relevant international standard
for the intented application are
used.
Deliveries are made to the usual
german and international standards and regulations. In addition we offer in many fields
special works-standard grades
for severe application conditions. Examples of these are the
elevated temperature DIWA 373,
a high-strength fine-grained
steel for high-pressure steam
collecting drums, and the

DICREST steels for sour gascharged boilers and pressure
vessels. A further speciality are
our chrome molybdenum
alloyed steels for the construction of petrochemical reactors
which meet the strictest demands of international specifications - for example with
regard to the so-called step
coolings. Almost all steel qualities can also be supplied with
improved qualities as regards
thickness, for example to
ASTM-A 770 and EN 10164.
Here minimum values for reduc-
tion of area up to 40 % can be

agreed on.
Structural steel qualities to EN
10 025, EN 10 113 (Part 2) and
EN 10 115 can also be supplied
as longitudinally profiled plates,
i.e. with variable thickness over
the plate length - namely with a
maximum thickness difference
of up to 55 mm and at a slope
of up to 8 mm/m.
For more detailed information
we refer you to the plate
Delivery Program of Dillinger
Htte GTS.
As a heavy plate producer the Dillinger Htte GTS range of products includes:
general structural steels,
ship-building steels,
alloyed and unalloyed boiler
and pressure vessel steels,
steels for pipe-line and
penstock application,
weldable fine-grain
structural steels,
high-strength quenched and
tempered fine-grain steels,
special low-temperature
weldable structural steels,
low-temperature nickelalloyed steels (up to 9 % Ni),
abrasion-resistant structural
steels,
alloyed and unalloyed
hardening and heat-treatable
steels,
as special purpose steels.
Heavy Fabrication Division Dillinger Htte 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 individual requirements as well as

any request regarding the present
Delivery Programm to the Sales
Department of the Heavy Fabrication Division or to the local representatives of Dillinger Htte GTS.
ANTWERP
ROTTERDAM
BELGIUM
AG der Dillinger Httenwerke

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
E35
E451
E44
E29
Rh
Frankfurt
ein
Main
E44
LUXEMBOURG
M
o
E35
se
E31
MUNICH
GERMANY
Luxemburg
E451
S aa
r
Dillingen
E50
Saarbrcken
Metz
PARIS
E35
Rhe
in
S aa
Mosel
E52
Nancy
Stuttgart
FRANCE
Strasbourg
E35
How to find us
43
E41
BASEL, ZRICH
AG der Dillinger Httenwerke

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 descriptions. 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

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DELIVERY PROGRAM

All products manufactured by the

Vessels. The Heavy Fabrication

MODULAR SOLUTIONS FOR

Anyone believing that the elegant

booster domes - forging grade

constructions, pressure vessels or

Shell plates equipped with machined weld-edge preparation

The bevelling of edges is part of

form, is virtually absorbed by

carried out by milling; for larger

Cylindrical shell plates

1) measured from the plate top side

Difference between diagonals

Straightness of the ends

A = deviation from the theoritical curvature

Cut-to-shape plates are intented

wastage; unless otherwise agreed

1) measured from the plate top side

One-piece heads serve for example as end pieces for pressure

One-piece heads in Dillingen are

Seamless heads can be supplied

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

1) measured from the reference diameter Da or Di

Boiler and pressure vessel steels

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 %

The tolerance data regarding the diameter of hemispherical heads

(Da = Outside diameter; Di = Inside diameter; s = Wall thickness)

Flat heads, flanged only

Hemispherical heads (r1 = h3)

Dishing radius r1 or inside diameter Di

Dishing radius r1 or inside diameter Di

HOT DISHING PROCESS OF A ONE-PIECE HEAD

5. Circular blank being dished

6. Dished head being extracted out of the forming tools

MULTI-SEGMENT SHELL SECTIONS

When the required items exceed

ameter cold-forming is applied.

the fabrication of items outside

1) related to the internal surface

Dishing radius r1 and

"Tailor-made" shell sections

SPHERICAL SHELL PLATES

Spherical shell plates are tailormade segments or petals

very large tooling. The segments

up to 125 mm, in width of up to

4 000 mm 12 000 mm1)

Wall thickness s (mm)

3 000 mm 10 000 mm1)

3 000 mm 8 000 mm1)

2 500 mm 4 000 mm1)

2 500 mm 2 500 mm1)

2 750 mm 6 000 mm1)

Inside diameter of sphere Di (mm)