at Dillinger Hütte Heavy Fabrication Division Jean-Paul BERNARD Sales Divison-Manager jean-paul.bernard@dillinger.biz Rudolf J. Technical Division-Manager rudolf.cawelius@dillinger.biz 1 1 Introduction 2 Service Philosophy of the Dillinger Hütte s Heavy Fabrication 3 Components made at Dillinger Hütte s Heavy Fabrication 3.1 Pre-Fabrication Shop - Oxy-Cutting of Cut-to-Shape Sections - Edge-Milling of Plates - Roll-Bending of Plates for Storage-Tanks 3.2 Pressing Shop - Cold Formed Spherical Segments - One-Piece Heads (unwelded) - Multi-Segment Heads - Taylor-Made Pressings 3.3 Roll-Bending and Welding of heavy Section Shell Courses an Alternative to Forgings 4 Conclusion 2 1
DILLINGER HÜTTE s core activity: to provide Heavy Plates made out of sophisticated Carbon, Carbon-Manganese and low-alloyed Steel Grades in Formats up to: 41 mm in Thickness 5. mm in Width about 4 t in Weight DILLINGER HÜTTE s side Activity: Offering the Option for Processing of its Products: Plates in large Formats and Plates in High-Strength Steel Grades 3 2. Service-Philosophy: DILLINGER HÜTTE s HEAVY FABRICATION develops Solutions for the Application of thick and heavy Plates - produced by our Millin close Contact to our Customer! next step: Qualification as NPT Stamp-Holder and MO as per ASME III for Nuclear Services 4 2
2. Service-Philosophy: Supply more than a Plate, however never more than a Part! 1 To be a Partner and not a Competitor of the Plate Customers - no Design Engineering and no Design Calculation - no Assembly of finished Equipment and no Field-Activity. 2 Plates and prefabricated Sub-Assemblies from one Hand. 3 Enlarging the Plate Customer s Product Range in providing ready-for-assembly Packages of heavy Components that they cannot produce on their own. (Package of Formed heads and heavy Wall Shell Courses for Boiler and Pressure Vessel) 4 Providing Fabrication Services complementary to the Plates: proposed as an Option to the Steel Plates (e.g. Plates with machined Weld Bevels); the Approach of the Market is co-ordinated with the Plate Division of Dillinger Hütte GTS. 5 3. Components made at Dillinger Hütte s Heavy Fabrication 6 3
Main Products Fabricated at Dillinger Huette Heavy Fabrication Cut-to-shape plate Joint-welded shell-course Multi-segment sub-assembly One-piece elliptical head One-piece hemispherical head Weld-edge prepared plates 7 Fit for future Development of Production Facilities following the Capability of the Plate Mill 1 MPa Yield strength Plate width 45 MPa 36 mm 43 mm 45 mm 5 mm 42 mm Plate thickness 12 mm 4 t Plate weight 1966 Dishing 2 25 t - press Blanks < 4 mm Unit weight < 12 t 12 t 196 1965 197 1975 198 1985 199 1995 5 1981 Edge-preparing Milling machine 19 x 63 mm Unit weight < 25 t 1983 Roll-bending 3 5 t - machine 4 3 x 1 mm (cold) Unit weight < 3 t 1993 Dishing 2 5 t - press Blanks < 5 6 mm Unit weight < 25 t 2 Roll-bending 8 6 t - machine 4 3 x mm (cold) Unit weight < 8 t 4 Edge-preparing Milling machine 25 x 12 mm Unit weight < 4 t 8 4
3.1 Pre-Fabrication Shop Edge Milling Machine Roll Bending Machine Main Equipment 9 CNC Oxy-Cutting Machine Cut to Shape Plates Component of a Tool for Manufacturing of Tyres 12 mm in Thickness / 5. mm in Diameter 1 5
Machinery Edge-Milling of Plates Mobile milling station 2 milling Stations, each one fitted with one Profile Milling-Head Power: 18 kw 2 x 9 kw Principle: high-speed milling Length: 12 m Manufacturer: LINSINGER (A) Stationary Milling Station Spare Profile-Milling Heads 11 Edge-Milling of Plates Delivery programme U-Y combi-edge Thickness range: 12 mm Width: 1.36 mm to 5. mm Length: 4.3 mm to 25. mm Plate weight: 4 mt Output: 15. t / a Tapering: yes De-cladding: yes CNC process: yes Shape profiling: yes U-edge Double Y-edge 12 6
Roll-Bending of Storage-Tank Plates To supply Plates with machined Weld-Edge Bevels roll-bend to Radius -on request protected with a Shop-Primershipped ready for use at the Site. 13 Roll-Bending of Storage-Tank Plates Components for Flat Bottom Tanks 14 7
3.2 Pressing Shop 225t Press 25t Press 4t Press 15 Always more than a plate, never more than a part Petals for spherical tanks 16 8
Cold Dishing of a spherical Segment (Steel Grade SA537Cl2, 94mm thick) using large Forming Tools 17 One-Piece Heads (unwelded) Hot-Forming of Dished Heads ( Heat-Treatment of the Heads after Forming if required ) elliptical heads ID <= 45mm thickness up to m hemispherical ID <=37mm thickness up to mm flanged only ID<= 47mm thickness up to 1mm 18 9
Hot Forming of a Hemsipherical Head 19 Hemispherical Head at an intermediate Stage of Hot-Forming 2 1
Hemispherical Head while Water-Quenching 21 8 mm Thickness / 4.45 mm Diameter 22 11
Hemi-spherical head in one-piece design, un-welded: ID 3.52 mm x 7 mm 23 Hemispherical Head 19mm thick cut back for a forged Skirt-Ring Steel Grade SA 387-22-2 (N+AC+T) 24 12
End Dome of ARIANE V Space Rocket Side Booster 25 Hemispherical Heads made out of TMCP steel (X8 Type) hot formed Area for mechanical testing/ Procedure Qualification by DNV 26 13
Process control: check of mechanical properties Thermal Buffer Testing of Heads Rolling direction Test piece removed from material allowance at the skirt area 27 Testing of Heads Removal of Production Test Pieces Tested Area 28 14
Hemispherical Heads ID=3mm; smin=84mm Steel Grade SA 542 D 4a Testing of Heads Yield / Tensile Strength (MPa) 7 6 5 4 3 1 LT-HP 2,8 634 634 64 655 653 657 634 652 539 525 53 541 59 513 58 531 head head plate 1 plate 2 plate 3 plate 4 head 1 head 2 3 4 Rp,2 (MPA) Rm (MPA) 7 6 5 4 3 1 HP 21,2 61 599 61 68 612 618 62 617 476 468 488 482 475 486 464 486 plate plate plate plate head head head head 1 2 3 4 1 2 3 4 Rp,2 (MPA) Rm (MPA) 29 Hemispherical Heads ID=3mm; smin=84mm Steel Grade SA 542 D 4a Testing of Heads 3 15
Multi-Segment Dished Heads To improve the Fabrication of Dished Heads to larger Diameter and/or Wall Thickness. 31 Multi-Segment Hemispherical Heads IR=18mm, t=145mm Steel Grade SA542D4a (CrMoV) Weld Edge Preparation by Oxy-Cutting 32 16
Multi-Segment Hemispherical Heads IR=18mm, t=145mm Steel Grade SA542D4a (CrMoV) Segments with narrow-gap Weld-Edge Preparation 33 Some Hemispherical Heads and a Cone while Trial Assembling 34 17
Multi-Segment Petrochemical Heads made Reactors of Steel Grade SA 542 D 4a ID=466mm; smin=52mm Winkels-HP 2,8 Winkels-HP 21,1 Testing of Heads 8 8 7 7 6 6 5 5 4 4 Yield / Tensile Strength (MPa) 3 1 8 7 6 5 4 3 1 678 651 645 639 629 65 637 3 645 63 621 619 68 613 616 552 532 524 519 53 529 515 512 52 498 486 48 486 487 1 plate 1 petal 1 petal 2 petal 3 petal 4 petal 5 petal 6 plate 1 petal 1 petal 2 petal 3 petal 4 petal 5 petal 6 Rp,2 Rm Rp,2 Rm Winkels-HP 2,8 Winkels-HP 21,1 8 7 6 5 4 675 622 642 651 625 631 64 3 633 619 633 632 616 625 544 487 514 524 493 499 514 489 48 498 496 479 477 49 477 1 plate 2 petal 1 petal 2 petal 3 petal 4 petal 5 petal 6 plate 2 petal 1 petal 2 petal 3 petal 4 petal 5 petal 6 Rp,2 Rm Petals Rp,2 Rm 35 Testing of Heads Multi-Segment Heads made of Steel Grade SA 542 D 4a ID=466mm; smin=52mm Yield / Tensile Strength (MPa) 8 7 6 5 4 3 1 Winkels-HP 2,8 676 649 638 546 522 511 plate 1 crownplate 1 crownplate 2 8 7 6 5 4 3 1 Winkels-HP 21,1 629 622 616 487 487 483 plate 1 crownplate 1 crownplate 2 Rp,2 Rm Rp,2 Rm Crown Plates 36 18
Welding of a Multi-Segment Hemispherical Head 37 Taylor made Pressings Forming (hot or cold) of heavy Plate Segments following the Design of the Vessel Manufacturer 38 19
Some Types of Tori-Cones 39 Top of a Cowper made out of Segments Steel Grade 16Mo3 (SA 32 Gr B) 4 2
Machining shop Machinery: 6 t vertical lathe Manufacturer: SCHIESS FRORIEP High-efficient NC-driven equipment suitable for the workpiece format: - Diameter 6. mm - Height 2.65 mm - Weight 6 t Application: - Weld-edge preparation of dished heads and shell-courses - Roughening and finishing of forgings and castings as required by tools and machinery structures 41 Machining shop Machining of a circular Blank for Tube Sheet Mechanical Testing of Initial Plate considering ASME Requirements 42 21
Machining shop Hemispherical head equipped with a circular weld-edge preparation, machined out of the wall thickness for connection to a supporting skirt: alternative to built-up welding extending the service life of a cyclic-load operating pressure vessel 43 3.3 Roll-Bending and Welding Shop 44 22
Roll-Bending and Welding Shop Roll-Bending and Welding of Shell Courses Heavy Wall Shell Courses made out of Heavy Plates an Alternative to Forgings 45 Roll-Bending and Welding Shop 4,3m 4 Roller Roll-Bending Machine (2) Manufacturer: Haeusler 86 to Weight 3 inter-changeable Top Roller 88mm; 1mm; 15mm Diameter Acceptance Test in our Work-Shop Cold-Rolling of a Shell-Course ID=mm; 4,3m Length, 12mm Thick Actual Yield Strength 7MPa 46 23
Roll-Bending and Welding Shop 24mm thick Shell Plate for a Boiler Drum while Cold-Rolling Steel Grade SA516-7 ID = 3517mm L = 24mm Weight: 54to 47 Roll-Bending and Welding Shop Roll-Bending and Welding Shop Cold Rolling of a Shell Course ID=732mm Thickness=142mm Steel Type SA 533 Type B Class 2 (Q+T) made of 2 Shell Plates for a GTL Reactor 48 24
Cold Forming of a Welded Plate Steel Grade SA 516 Grade 7 Wall Thickness 115mm (evaluation and testing under supervision of LLoyd s Register as third party; LR is also the Authorised Inspection Authority of Dillinger Huette Heavy Fab as per ASME I, VIII-1 and VIII-2) 49 SA 516 Grade 7 - Welding of the Plate Material 5 25
Weld Seam 3 Tests for Cold Rolling: 3% strain: R f = 1917mm 5% strain: R f = 115mm 7% strain: R f = 821mm % Strain 5 t R = 1 R f R R f = main radius after forming R o = original mean radius (equal to infinity for a flat plate) t = normal thickness of plate = 115mm f direction of test specimen: tangential to the shell section direction 51 testing condition: - without PWHT - PWHT 61+/-1 C, 16 Min. - PWHT 61+/-1 C, 64 Min. ( = 4 cycles) Base Metal 52 26
Yield Strength 3% - 5% - 7% Cold Deformation 5% Cold Deformation Formed Section 3% Cold Deformation Formed Section 5 5 Yield Strength (MPa) 45 4 35 3 25 Yield Strength (MPa) 45 4 35 3 25 Inside/Top t/4 t/2 3/4t Outside/ Bottom Location Inside/Top t/4 t/2 3/4t Outside/ Bottom Location FS, without PWHT FS,PWHT 16min FS,PWHT 64min 7% Cold Deformation Formed Section 5 Yield Strength (MPa) 45 4 35 3 25 Inside/Top t/4 t/2 3/4t Outside/ Bottom 53 Tensile Strength 3% -5% -7% Cold Deformation Tensile Strength (MPa) 6 59 58 57 56 55 54 53 52 51 5 Cold Deformation Formed Section Cold Deformation Formed Section 3% Cold Deformation 5% Cold Deformation 6 59 58 57 56 55 54 53 52 51 5 Inside/Top t/4 t/2 3/4t Outside/ Inside/Top t/4 t/2 3/4t Outside/ Bottom Bottom Location Location FS, without PWHT FS,PWHT 16min FS,PWHT 64min Cold Deformation Formed Section 7% Cold Deformation 6 59 58 57 56 55 54 53 52 51 5 Inside/Top t/4 t/2 3/4t Outside/ Bottom Tensile Strength (MPa) Location Tensile Strength (MPa) 54 27
Elongation A5 3% -5% -7% Cold Deformation 3% Cold 3% deformation Cold Formed Deformation Section 5% Cold Cold Deformation Deformation Formed Section Elongation A5 (%) 39 37 35 33 31 29 27 25 Inside/Top t/4 t/2 3/4t Outside/ Bottom Location Location Elongation A5 (%) Elongation A5 (%) 39 37 35 33 31 29 27 25 39 37 35 33 31 29 27 25 Inside/Top t/4 t/2 3/4t Outside/ Bottom Location FS, without PWHT FS,PWHT 16min FS,PWHT 64min 7% Cold Deformation Formed Section 7% Cold Deformation 55 Inside/Top t/4 t/2 3/4t Outside/ Bottom 3% Cold Deformation, Formed Section 3% Cold Deformation, Formed Section, without PWHT Without PWHT 24 3% Cold Deformation, Formed Section 3% Cold Deformation, Formed Section, PWHT = 6 C/16' PWHT 6 C / 16 Minutes 24 22 Top 22 Top e/4 e/2 e/4 e/2 18 3e/4 18 3e/4 16 Bottom 16 Bottom 14 14 Av [J] 12 Av [J] 12 1 1 8 8 6 6 4 4 2 2-8 -7-6 -5-4 -3-2 -1 1 2 3 4-8 -7-6 -5-4 -3-2 -1 1 2 3 4 Temperatur [ C] Temperatur [ C] 3% Cold 3% Cold Deformation, Formed Section, PWHT Formed = 6 C/64' Section 24 22 18 PWHT 6 C / 64 Minutes Top e/4 e/2 3e/4 Bottom 16 Av [J] 14 12 1 8 6 4 2-8 -7-6 -5-4 -3-2 -1 1 2 3 4 Temperatur [ C] 56 28
5% Cold Deformation, Formed Section 5% Cold Deformation, Formed Section, without PWHT Without PWHT 24 22 Top 18 16 5% Cold Deformation, Formed Section 5% Cold Deformation, Formed Section, PWHT = 6 C/16' PWHT 6 C / 16 Minutes 24 22 18 16 Top e/4 e/2 3e/4 Bottom Av [J] 14 12 1 8 6 4 2-8 -7-6 -5-4 -3-2 -1 1 2 3 4 Temperatur [ C] Av [J] 14 12 1 8 6 4 2-8 -7-6 -5-4 -3-2 -1 1 2 3 4 Temperatur [ C] 5% Cold 5% Cold Deformation, Formed Section, PWHT Formed = 6 C/64' Section 24 22 PWHT 6 C / 64 Minutes Top 18 16 14 Av [J] 12 1 8 6 4 2-8 -7-6 -5-4 -3-2 -1 1 2 3 4 Temperatur [ C] 57 7% Cold Deformation, Formed Section, 7% Cold Deformation, Formed Section, without PWHT Without PWHT 24 22 Top e/4 e/2 18 3e/4 Bottom 16 24 22 18 16 7% Cold 7% Deformation, Formed Section, Formed PWHT = 6 C/16' Section, PWHT 6 C / 16 Minutes Top e/4 e/2 3e/4 Bottom 14 14 Av [J] 12 Av [J] 12 1 1 8 8 6 6 4 4 2 2-8 -7-6 -5-4 -3-2 -1 1 2 3 4-8 -7-6 -5-4 -3-2 -1 1 2 3 4 Temperatur [ C] Temperatur [ C] 7% Cold Deformation, Formed Section, 7% Cold Deformation, Formed Section, PWHT = 6 C/64' PWHT 6 C / 64 Minutes 24 22 18 16 Top e/4 e/2 3e/4 Bottom Av [J] 14 12 1 8 6 4 2-8 -7-6 -5-4 -3-2 -1 1 2 3 4 Temperatur [ C] 58 29
Weld Seam 59 Av average [J] 45 4 35 3 25 15 1 5 3% Cold Formed 5% Cold Formed WM,inside, without PWHT cycles WM,quater thickness inside, without PWHT cycles WM,half thickness, without PWHT cycles WM,quater thickness outside, without PWHT cycles WM,outside, without PWHT cycles -8-6 -4-2 2 Test Temperature [ C] Av average [J] WM,inside, without PWHT cycles WM,quater thickness inside, without PWHT cycles 45 WM,half thickness, without PWHT cycles 4 WM,quater thickness outside, without PWHT cycles 35 WM,outside, without PWHT cycles 3 25 15 1 5-8 -6-4 -2 2 Test Temperature [ C] Weld Metal Cold Formed Without PWHT Impact Test Av average [J] 45 4 35 3 25 15 1 5 WM,inside, without PWHT cycles WM,quater thickness inside, without PWHT cycles WM,half thickness, without PWHT cycles WM,quater thickness outside, without PWHT cycles WM,outside, without PWHT cycles -8-6 -4-2 2 Test Temperature [ C] 7% Cold Formed 6 3
Av average [J] 45 4 35 3 25 15 1 5 3% Cold Formed 5% Cold Formed WM,inside, 1 PWHT cycles WM,quater thickness inside, 1 PWHT cycles WM,half thickness, 1 PWHT cycles WM,quater thickness outside, 1 PWHT cycles WM,outside, 1 PWHT cycles -8-6 -4-2 2 Test Temperature [ C] Weld Metal Cold Formed PWHT 619 C, 16Minutes Impact Test Av average [J] Av average [J] WM,inside, 1 PWHT cycles WM,quater thickness inside, 1 PWHT cycles 45 WM,half thickness, 1 PWHT cycles 4 WM,quater thickness outside, 1 PWHT cycles 35 WM,outside, 1 PWHT cycles 3 25 15 1 5-8 -6-4 -2 2 45 4 35 3 25 15 1 5 Test Temperature [ C] WM,inside, without PWHT cycles WM,quater thickness inside, without PWHT cycles WM,half thickness, without PWHT cycles WM,quater thickness outside, without PWHT cycles WM,outside, without PWHT cycles -8-6 -4-2 2 Test Temperature [ C] 7% Cold Formed 61 Av average [J] 45 4 35 3 25 15 3% Cold Formed 5% Cold Formed HAZ,inside, without PWHT cycles HAZ,quater thickness inside, without PWHT cycles HAZ,half thickness, without PWHT cycles HAZ,quater thickness outside, without PWHT cycles HAZ,outside, without PWHT cycles Av average [J] 45 4 35 3 25 15 HAZ,inside, without PWHT cycles HAZ,quater thickness inside, without PWHT cycles HAZ,half thickness, without PWHT cycles HAZ,quater thickness outside, without PWHT cycles HAZ,outside, without PWHT cycles 1 1 5 5-8 -6-4 -2 2-8 -6-4 -2 2 Test Temperature [ C] Test Temperature [ C] HAZ Cold Formed Without PWHT Impact Test Av average [J] HAZ,inside, without PWHT cycles 45 HAZ,quater thickness inside, without PWHT cycles 4 HAZ,half thickness, without PWHT cycles HAZ,quater thickness outside, without PWHT cycles 35 HAZ,outside, without PWHT cycles 3 25 15 1 5-8 -6-4 -2 2 Test Temperature [ C] 7% Cold Formed 62 31
Av average [J] 45 4 35 3 25 15 1 5 HAZ,inside, 1 PWHT cycles HAZ,quater thickness inside, 1 PWHT cycles HAZ,half thickness, 1 PWHT cycles HAZ,quater thickness outside, 1 PWHT cycles HAZ,outside, 1 PWHT cycles 3% Cold Formed 5% Cold Formed -8-6 -4-2 2 Test Temperature [ C] HAZ Cold Formed PWHT 61 C, 16 Minutes Impact Test Av average [J] Av average [J] 45 4 35 3 25 15 1 5 1 5 HAZ,inside, 1 PWHT cycles HAZ,quater thickness inside, 1 PWHT cycles HAZ,half thickness, 1 PWHT cycles HAZ,quater thickness outside, 1 PWHT cycles HAZ,outside, 1 PWHT cycles -8-6 -4-2 2 HAZ,inside, 1 PWHT cycles Test Temperature [ C] 45 HAZ,quater thickness inside, 1 PWHT cycles HAZ,half thickness, 1 PWHT cycles 4 HAZ,quater thickness outside, 1 PWHT cycles 35 HAZ,outside, 1 PWHT cycles 3 25 15-8 -6-4 -2 2 Test Temperature [ C] 7% Cold Formed 63 Roll-Bending and Welding Shop SAW Narrow Gap Welding Equipment for 1 to 3 Electrodes 64 32
Heating for Water-Quenching of a Shell Course mm thick Design Code AD Steel Grade 12CrMo9-1 (SA 387-22-2) Q+T 65 Roll-Bending and Welding Shop Options for Water quenching of a Shell-Course (Shell Axis either vertical or horizontal) 66 33
Roll-Bending and Welding Shop Cylindrical Shell in Halve Section ID = 5.334 mm x 197mm x 2.6mm, cold-formed, SA516 Gr 7, unit weight ca. 39 t 67 Roll-Bending and Welding Shop Halve-Shell, warm rolled from ISR Temperature Steel Grade SA 542 D 4a ID= 559mm; smin=168mm; Width= 278mm; unit weight 25.865kg 68 34
4. Conclusion Advantages of with HEAVY FABRICATION efficient heavy Plate Manufacturer ( Quality Program, Dimensions, complementary Services ) compentent Partners in one Company at your Disposal for all Your Questions about Heavy Plates and their Processing prepared to follow the Expectations of our Customers Next step: qualification as NPT-Stamp Holder and MO following ASME III for Nuclear Services 69 Many Thanks for your Attention! 7 35