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

The products manufactured by EN 14001:2005 and OHSAS AD-2000 Merkblatt W 0 / HP

the Heavy Fabrication Division
are supplied in the manner de-
manded by the relevant stan-
dards, technical delivery specifi-
cations and other agreements
made with the customers. The In-
tegrated Management System is
certified to ISO 9001:2000, ISO
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 ac-
creditations are also available e.g.
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 Peoples Republic
of China (Pressure vessels: A1,
A2, A3 and Boiler parts: A)

edition 2008

1
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 Orien-
tal craftsmanship would be
wrong. The roof structure is, on
the contrary, a product of the
modern world: a 23 ton multi-
segment hemisphere construction
made of steel plates, manufac-
tured in the Heavy Fabrication
Division of Dillinger Htte GTS.
It's a thin line between architec-
ture and art: the "Serpentine"
(cf. page 38) sculpture created by
the American artist Richard Ser-
ra 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 con-
cerned, Dillinger Htte 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
Heavy Fabrication Division Dillinger Htte GTS, Modular solutions for heavy plate fabrication [1/1], 2008
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 spectacu-
lar contracts. These examples do
demonstrate the extensive capa-
bilities 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 equip-
ment; we prefer to view ourselves
as service-providers to the manu-
facturers of equipment 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 plates. And of-
ten it's both.
Not all manufacturers of struc-
tural 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 ser-
vices of the Heavy Fabrication
Division is set out on the follow-
ing pages; it includes modular
heavy plate components, de-
signed for specific fields of appli-
cation. Our comprehensive range
is the result of long years of expe-
rience 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.
 FABRICATED PLATES

Fabricated plates equipped with machined weld-edges

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 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 in-
tervals at the outer circumference
of the profile-milling heads. The
machined edges are geometrical-
ly 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
Heavy Fabrication Division Dillinger Htte GTS, Fabricated plates [1/3], 2008
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 contin-
uous 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 longitu-
dinal 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 be-
tween 5 mm and 120 mm is car-
7
ried out by milling; for larger
thickness, flame-cutting will ap-
ply. The 4 edges can be individu-
ally 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 back-
cladding and tapering can also
be achieved along the weld-edges.
A high degree of accuracy and an
excellent cut-face quality i.e. ex-
tensively free of hardening effect
characterise the weld-edges pre-
pared 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

DV DU

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

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

8
Standard tolerances

Edge preparation machined flame-cut

Bevel angle (, ) 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 () 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 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 Htte GTS, Fabricated plates [3/3], 2008

9
 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 flame-
cutting machines with square
edge, further weld-edge prepara-
tion 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
Width 5.200 mm
Length 25.000 mm
Standard tolerances
Quality of cut faces and dimensional tolerances according to ISO 9013-331
Edge design
Bevel angle
Land position 1)
1) measured from the plate top side
Heavy Fabrication Division Dillinger Htte GTS, Cut-to-shape plates [1/1], 2008
Scope of supply the scrap remains the property of
the supplier i.e. the shipping
The blanks are supplied in the
costs which apply to the resulting
steel grades within the plate De-
net weight are therefore consider-
livery Program of Dillinger Htte
ably reduced. Please refer also to
GTS preferably in pieces above
the Technical Delivery Condi-
3 t in weight. They can also be
tions on page 32.
provided with enhanced waviness
tolerances against the standards
Information required
e.g. EN 10029, ASTM A 6 / A 20
and when required by the steel Shape description supported
grade also be supplied in the with a full-dimensioned drawing
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
Thickness 410 mm
Weight 60 t
2 Land height 2 mm
2 mm
11
 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 exam- Manufacturing process
ple as end pieces for pressure
One-piece heads in Dillingen are
vessels and power boilers. The
always hot formed by deep-
widest range of shapes is avail-
drawing, the circular blanks be-
able: spherical, torispherical,
ing free of any weld seam. They
elliptical, etc. The flat heads i.e.
are dished by the means of
flanged only within the proposed
hydraulic presses up to 2.500 tons
dimensional range are mainly
fitted with the proper tooling i.e.
used for the fabrication of ladles
ring and die, the shape of which
involved in metallurgical
suits the inside contour of the
processes.
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 thick-
nesses above 30 mm.
Scope of supply
Seamless heads can be supplied
spherical-shaped in outside
diameters up to 3.650 mm, tori-
spherical or elliptical-shaped up
to 4.450 mm or flanged only up
to 4.750 mm. The "Dimensional
Program" table provides infor-
mation 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 Condi-
tions on page 32.

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

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

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/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 Htte GTS, One-piece heads [2/7], 2008

14
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 Htte GTS, One-piece heads [3/7], 2008

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 Htte GTS, One-piece heads [4/7], 2008

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 Htte GTS, One-piece heads [5/7], 2008

17
 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 Htte GTS, One-piece heads [6/7], 2008

18
 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

6. Dished head being extracted out of the forming tools

Heavy Fabrication Division Dillinger Htte 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 mul-
ti-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 approxi-
mately 3.500 mm; above this
Heavy Fabrication Division Dillinger Htte GTS, Multi-segment shell sections [1/3], 2008
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-seg-
ment design can be also extended
to tailor-made shell sections
suiting a specific shape i.e. transi-
tion pieces, reversible conical seg-
ments and inlets for shaft lining
since no dimensional restriction
must be observed. The multi-seg-
ment design is an alternative to
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 3 mm
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 4) calculated from measured circumference

2) measured as a distance between a nominal shape template of 5) only when trial assembled
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 Htte GTS, Multi-segment shell sections [2/3], 2008

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 Htte GTS, Multi-segment shell sections [3/3], 2008

23
 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 mater-
ial properties, the plate thick-
ness and the required radius,
either cold or hot forming can
be used. In both alternatives,
the shaping process is conduc-
ted in a safe way so that the
steel mechanicals remain pre-
served. The segments for
Heavy Fabrication Division Dillinger Htte GTS, Spherical shell plates [1/3], 2008
spheres above 7.000 mm in
diameter are normally manu-
factured cold by progressive
dishing. Once the segments are
shaped properly, the weld-
edges are subsequently engi-
neered 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 condi-
tions and the field erection
constraints. Depending on the
material and on the forming
radius, the petals are fabri-
cated in thickness of up to 110
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 fabricat-
ed from material produced by
thermo-mechanical controlled
process (TMCP) or by water-
quenching 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

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

2.000 4.000 6.000 8.000 10.000 12.000 14.000 16.000 18.000 20.000 22.000 24.000

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 Htte GTS, Spherical shell plates [2/3], 2008

26
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 3 mm
Shape 1) 200 mm wide edge area 2) 2 mm / 1.000 mm
away from edge area 6 mm / 2.000 mm

A A
Ri

Ri
template template

segment
segment A

The shape deviation is measured as distance A between a template with a chord 1) related to the internal surface
length of 1.000 mm respectively 2.000 mm and the spherical segment laying down 2) measuring position: along the plate edge
on a measuring bed set to the nominal radius. (Ri = inside 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

3
s3 upper course

2 3

equatorial course
s4
4 Di a

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 Htte GTS, Spherical shell plates [3/3], 2008

27
 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 TV 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-elec-
trode or twin-arc submerged arc
methods in accordance with the
provisions of the relevant inter-
national 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 -
Heavy Fabrication Division Dillinger Htte GTS, Cylindrical shell courses [1/3], 2008
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 weld-
edges of shell-courses are usual-
ly 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 perfor-
mance 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.
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 advan-
tageous for steel grades where
hot forming is always problem-
atic 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 fin-
ish free of the usual discontinu-
ities resulting from this kind of
process.
Please consider also the
Technical Delivery Conditions
on page 32
 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 n g th 550 MPa
170 Yield st )

1.500 mm top roller

Performance chart of the roll-bending machine

160 a (100 ksi

ld st re ng 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 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

Heavy Fabrication Division Dillinger Htte GTS, Cylindrical shell courses [2/3], 2008
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
L
Minimum wall thickness after forming s s

Edge-design
Welding requirements and
fabrication code
Di Da

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

31
 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 recom-
mendations made by the steel
maker having produced the plates.
Furthermore, the fabrication oper-
ations 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 specifica-
tions, the formed parts can be giv-
en proper heat treatment e.g. nor-
malizing, water-quenching, tem-
pering, 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 al-
lowance 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 spe-
cific details regarding the standard
fabrication tolerances; they apply
unless otherwise agreed and are
valid at the time of the shop in-
spection. 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
Heavy Fabrication Division Dillinger Htte GTS, Technical delivery conditions [1/2], 2008
with pressings, the accuracy of the
components to each other shall be
within the permissible misalign-
ment required in the applicable
code.
Surface condition
The items are supplied with un-
treated surfaces in line with the
processing method used; by agree-
ment 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 equiva-
lent standard. The surface preser-
vation 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 suit-
able coating, the type of which is
subject to agreement. The surface
treatment can also be subcontract-
ed to an external company whose
quality system is controlled by
Dillinger Htte GTS.
Weld-edge preparation
Items supplied in the multi-seg-
ment design ready for assembly
are produced with weld-edge
preparation. Any requirement for
tapering must be additionally
agreed upon. The edges of cut-to-
shape plates, pressings and cylin-
drical shell-courses are as a rule
worked by flame cutting, the cut-
33
face being subsequently processed
free of scale and slag accumula-
tion by grinding. Edge details de-
scribed 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 engi-
neered: the cut-face quality is in
line with the cutting process. Any
machining of weld-edge prepara-
tion for heads and shell-courses
must be additionally agreed. Weld-
edge protection against corrosion
can also be provided on request.
Identification
Each item produced by Dillinger
Htte GTS is originally marked
in accordance with the applicable
plate standards; it is additionally
identified by using a sequential
piece number to ensure the trace-
ability of the manufactured parts
along the fabrication operations
back to the Inspection Test Certifi-
cates 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
Htte 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 thick-
ness 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 Htte GTS, all pro-
cessing conditions must be agreed
in advance i.e. before release for
fabrication; this concerns especial-
ly 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 lay-
ing on wooden timbers fitting the
outside curvature, usually with
the inner side upwards. Shell-plates
are stacked into lifting units sepa-
rated 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 struc-
tures being necessary to maintain
the shape during transport, the
stowing into containers, the weld-
ing of lifting lugs, the use of spac-
ers between each shell-plates are
always subject to agreement. Any
specific packaging and lashing re-
quirements have to be agreed
Heavy Fabrication Division Dillinger Htte GTS, Technical delivery conditions [2/2], 2008
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 "In-
formation 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 in-
spection 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 fab-
rication 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 pro-
vides an overview of the main ma-
chinery. Any design work, fabrica-
tion of finished equipment and
erection on the field are basically
outside the services offered by
Dillinger Htte 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
The manufacturing plants are in-
stalled in covered bays with a total
surface area of around 39.000 m2.
All bays have both a road and a
rail link. Furthermore, an access
to the company's own port facili-
ties on the river Saar is available.
 FABRICATION FACILITIES

2.500 ton hydraulic press

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 120 5.000 25.000
- milling machine for weld-edge
preparation of longitudinal joints
and back-gouging 160 8) 4.300
Flame cutting
- NC profile-cutting machine 6) 200 5.500 15.000
- NC profile-cutting machine 6)
410 9.800 40.000
- equipment for edge-preparing of heads 200 4.500
Heat treating
- boogie hearth furnace 7) 4.300 10.000 3.600 4)
- walking beam furnace 7) 5.500 8.250 1.800 4)
- walking beam furnace 7)
6.000 12.500 2.300 4)
- deep quenching water pools for accelerated cooling
Welding The welding facilities comprise semi-automatic and automatic equipment
for submerged arc welding and inert gas welding ( SMAW, SAW and TIG )

1) diameter of the circular blank 6) cutting medium: oxygen with acetylene or

2) maximum barrel length with natural gas
3) minimum inside diameter 7) normalising / tempering / stress-relieving
4) clear height 8) depth of the U-groove preparation for nar
5) clear diameter 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 Htte 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 com-
ponents described on the previ-
ous pages, the Heavy Fabrica-
tion Division processes the
heavy plates produced by the
plate mills of Dillinger Htte
GTS. The exact knowledge of
our materials makes it possible
for us to exploit the absolute
technical limits of their process-
ing possibilities.
Dillinger Htte GTS as the Eu-
ropean 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,
Dillinger Htte GTS has also developed some brandnamed steels optimised versus a range of individual
applications, e.g.:
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 steam-
boilers 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 tem-
pered pressure vessel steels
for low-weight designs
More details about the brandnamed steels are available in Material Data Sheets; they can be downloaded
at www.dillinger.de or www.heavyplate.com.
Heavy Fabrication Division Dillinger Htte GTS, Processed steel grades [1/1], 2008
- special low-temperature
weldable steels,
- low-temperature nickel-
alloyed steels (up to 5 % Ni),
- abrasion-resistant structural
steels,
- alloyed and unalloyed hard-
ening and heat-treatable
steels,
- conventional CrMo steels
and vanadium enhanced
CrMo steels for general
structural applications,
ship-building industries,
pipe-lines, penstocks, boiler
and pressure vessels (hydro-
treating petrochemical
reactors), etc.
Sometimes enquiries for particu-
lar grades are made on heavy
plates outside the scope of the
standard. Dillinger Htte GTS
provides the proper solution for
DILLINAL 460/630: high-
strength 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-mechani-
cally-rolled structural steels
with optimised processing
properties
DIWETEN: structural steels
with improved atmospheric
corrosion resistance
DICUT: steels with
optimised laser-cutting
properties
39
the most frequent required addi-
tional properties e.g.:
- Low carbon equivalents
- TTT properties to ASTM-A
770 and EN 10164
- High resistance to Hydrogen
Induced Cracking (HIC)
- Defined resistance to Sulfide
Stress Cracking (SSC)
- Insensivity to embrittlement
in CrMo-alloyed pressure
vessel steels as evidenced 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.
DIMARINE: thermo-
mechanically-rolled ship
building steels with opti-
mised 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
 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
 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 Httenwerke
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

GREAT NETHER- HANNOVER BERLIN

AMSTERDAM LANDS
BRITAIN
LONDON ROTTERDAM
WESER
NORTH ELBE
SEA E 51
E 55

ANTWERPEN DSSELDORF
E 40
BRSSEL KLN
BELGIUM E 35
GERMANY
E 411 RHEIN FRANKFURT
MAIN
CZECH
E 15
REPUBLIC
FRANCE LUXEMBURG DILLINGEN
E 05
E 50
METZ E 35 E 56
PARIS MOSEL
SAARBRCKEN
STRASBOURG DONAU
SEINE STUTTGART
E 15 E 21 E 52
E 25
MNCHEN AUSTRIA
E 09

BASEL
How to find us

43
Aktien-Gesellschaft der
Dillinger Httenwerke
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 pro-
duct suitability are provided
without guarantee; assurance
regarding specific properties
and fields of application requires
always a written agreement.
Delivery Program Heavy Fabrication Division, 2008