Weiterverarbeitung 2008 e

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

the Heavy Fabrication Division
are supplied in the manner demanded by the relevant standards, technical delivery specifications and other agreements
made with the customers. The Integrated Management System is
certified to ISO 9001:2000, ISO
EN 14001:2005 and OHSAS

18001:1999.
The components can be supplied
in conformity with the relevant
fabrication codes and standards
such as PED 97/23/EC, EN
13445, PD 5500, etc.
Furthermore, a lot of specific accreditations are also available e.g.
edition 2008
AD-2000 Merkblatt W 0 / HP
0 / TRD 100 / 201 / 202
ASME Section VIII-1 (U
Stamp), Section VIII.2 (Stamp
U2) and Section 1 (Stamp S)
Manufacture License of Special
Equipment Peoples Republic
of China (Pressure vessels: A1,
A2, A3 and Boiler parts: A)
A conical transition piece being made (Inner diameter 2.700 mm / 1.450 mm x 70 mm, height 1.350 mm, steel grade SA 387 grade 11-1)
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
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)
Anyone believing that the elegant

dome of the Hussein Mosque in
Cairo is a work of ancient Oriental craftsmanship would be
wrong. The roof structure is, on
the contrary, a product of the
modern world: a 23 ton multisegment hemisphere construction
made of steel plates, manufactured in the Heavy Fabrication
Division of Dillinger 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 the extensive capabilities of the Heavy Fabrication
Division, the essential aspect of
which remains the processing of
heavy steel plates.
However, we ourselves are not
fabricators of finished equipment; we prefer to view ourselves
as service-providers to the manufacturers of equipment involved
in heavy engineering. Much of
the material coming out of
Dillinger 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 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
und thick plates. This is why we
offer to take care of the difficult
first stages of the processing and
supply prefabricated structural
components instead of just heavy
plates.
The scope of products and services of the Heavy Fabrication
Division is set out on the following pages; it includes modular
heavy plate components, designed for specific fields of application. Our comprehensive range
is the result of long years of experience in cooperating with steel
plate fabricators.
But don't take this as our final
word on the subject: if you do
have a special project or unique
requirements such as the three
examples cited above, we will
provide you, on an individual
basis, with exactly the same
service as offered to architects,
artists and space engineers.
Heavy Fabrication Division Dillinger Htte GTS, Modular solutions for heavy plate fabrication [1/1], 2008
FABRICATED PLATES
Fabricated plates equipped with machined weld-edges
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
material and resulting cracks can
be avoided.
ried out by milling; for larger

thickness, flame-cutting will apply. The 4 edges can be individually equipped with a specific
weld-edge preparation.
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.
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.
Scope of supply
A high degree of accuracy and an

excellent cut-face quality i.e. extensively free of hardening effect
characterise the weld-edges prepared by a machining process,
both being requirements for
performance welding.
Please refer also to the Technical
Delivery Conditions on page 32.
Information required
Final plate sizes, rolling radius,
weld-edge design.
The edge preparation of plates

within the thickness range of between 5 mm and 120 mm is car-
Heavy Fabrication Division Dillinger Htte GTS, Fabricated plates [1/3], 2008
Dimensional program
Shell plates
machined
flame-cut
Thickness
Width
Length
Plate weight
5
120 mm
1.350 5.000 mm
4.000 25.000 mm
40 t
10
230 mm
800 5.200 mm
2.000 18.000 mm
40 t
Shell-plates rolled to radius
Halves 1)
Thirds 1)
Thickness
Width
Length
Radius
15
230 mm
800 4.300 mm
4.000 14.000 mm
4.000 mm
15
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 9013-33
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
1) measured from the plate top side

2) applicable to U and DU edges only
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 / 500 mm
10 mm /2.000 mm
Straightness of the ends

s 20 mm
s 40 mm
s > 40 mm
4 mm / 1.000 mm
3 mm / 1.000 mm
2 mm / 1.000 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
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.
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 t in weight. They can also be
provided with enhanced waviness
tolerances against the standards
e.g. EN 10029, ASTM A 6 / A 20
and when required by the steel
grade also be supplied in the
stress-relieved condition to suit
subsequent processing operations
such as a machining. It is known
that profile cutting involves
mostly an important plate
wastage; unless otherwise agreed
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
5.200 mm
25.000 mm
Thickness
Weight
410 mm
60 t
Standard tolerances
Quality of cut faces and dimensional tolerances according to ISO 9013-331
Edge design
Bevel angle
Land position 1)
2
2 mm
Land height
2 mm
1) measured from the plate top side
Heavy Fabrication Division Dillinger Htte GTS, Cut-to-shape plates [1/1], 2008
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 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 2.500 tons
fitted with the proper tooling i.e.
ring and die, the shape of which
suits the inside contour of the
head. The edges are generally
worked by flame cutting; the
machining of the weld-edge
preparation can be also agreed
upon for heads with wall thicknesses above 30 mm.
Seamless heads can be supplied

spherical-shaped in outside
diameters up to 3.650 mm, torispherical or elliptical-shaped up
to 4.450 mm or flanged only up
to 4.750 mm. The "Dimensional
Program" table provides information concerning the standard
shapes, diameters and wall
thicknesses to which the heads
can be manufactured:
intermediate dimensions and
other head shapes must be
agreed upon. Please refer also to
the Technical Delivery Conditions on page 32.
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
(mm)
1.000
1.100
1.200
1.300
1.400
1.500
1.600
1.700
1.800
1.900
2.000
2.100
2.200
2.300
2.400
2.500
2.600
2.700
2.800
2.900
3.000
3.100
3.200
3.300
3.400
3.500
3.600
3.700
3.800
3.900
4.000
4.100
4.200
4.300
4.400
4.500
4.600
4.700
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
&
1.050
1.150
1.250
1.350
1.450
1.550
1.650
1.750
1.850
1.950
2.050
2.150
2.250
2.350
2.450
2.550
2.650
2.750
2.850
2.950
3.050
3.150
3.250
3.350
3.450
3.550
3.650
3.750
3.850
3.950
4.050
4.150
4.250
4.350
4.450
4.550
4.650
4.750
Thickness (mm)
1)
Elliptical &
torispherical 2)
from up to
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 angle
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 9013-33
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.
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

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
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
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.
The pressings comprising a multi-segment shell are individually
formed using tool equipment, the
profile of which suits the contour
of the part being made. The
knuckle segments of torispherical
heads are basically hot-pressed;
as are the relative crown segments
and any pressings designed with
a dishing radius up to approximately 3.500 mm; above this
diameter cold-forming is applied.

The weld-edges of the shaped
segments are produced by flame
cutting.
Scope of supply
It includes mainly the fabrication
of torispherical heads to
DIN 28011 or NF E 81-102 and
DIN 28013 or SMS-482 above
4.450 mm in outside diameter and
spherical heads above 3.650 mm in
outside diameter; the multi-segment design can be also extended
to tailor-made shell sections
suiting a specific shape i.e. transition pieces, reversible conical segments and inlets for shaft lining
since no dimensional restriction
must be observed. The multi-segment design is an alternative to
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.
Heavy Fabrication Division Dillinger Htte GTS, Multi-segment shell sections [1/3], 2008
21
Standard tolerances
Edge design
knuckle
crown
Bevel angle
Land height
Land position 1)
Cut-face quality
2
2 mm
2 mm
ISO 9013-33
2
2 mm
2 mm
ISO 9013-33
3 mm /1.000 mm
6 mm /1.000 mm
2 mm /1.000 mm
6 mm /2.000 mm
2 mm
3 mm
0.1% Da
30 mm
0.25% Da
2 mm
3 mm
0.1% Da
30 mm
0.25% Da
Shape 1)
200 mm wide edge area 2)
Away from edge area 3)
Dimensions
Arc length/arc width
Diagonal difference
Diameter 4) 5)
Out -of-roundness 5)
Inside height 5)
1) related to the internal surface

2) measured as a distance between a nominal shape template of
1.000 mm and the actual inner contour, the measuring position
being along the segment edges
3) measured as a distance between a nominal shape template of
1.000 mm respectively 2.000 mm and the actual inner contour, the
measuring position being vertical to the plane defined by the
circumferential weld-edge
4) calculated from measured circumference

5) only when trial assembled
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 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.
spheres above 7.000 mm in

diameter are normally manufactured cold by progressive
dishing. Once the segments are
shaped properly, the weldedges are subsequently engineered by flame cutting.
Scope of supply
Taking into account the material properties, the plate thickness and the required radius,
either cold or hot forming can
be used. In both alternatives,
the shaping process is conducted in a safe way so that the
steel mechanicals remain preserved. The segments for
Unless otherwise required, the

arrangement and the sizes of
the segments are optimised by
considering the available shop
facilities, the transport conditions and the field erection
constraints. Depending on the
material and on the forming
radius, the petals are fabricated in thickness of up to 110
mm in width, of up to 4.000
mm and in length of up to
12.000 mm: the final piece
weight is generally restricted
at 23 to. The scope of supply
includes also petals fabricated from material produced by
thermo-mechanical controlled
process (TMCP) or by waterquenching process (QT).
An extensive experience allows
manufacturing the segments
ready for assembly without any
shop trial fit-up.
Please refer also to the
Technical Delivery Conditions
on page 32.
Heavy Fabrication Division Dillinger Htte GTS, Spherical shell plates [1/3], 2008
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
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.
26
Standard tolerances
Bevel angle
Land height
Land position 1 )
Cut-face quality
2
2 mm
2 mm
ISO 9013-33
Dimensions
Arc length
Arc width
Diagonal difference
2 mm
2 mm
3 mm
Shape 1)
200 mm wide edge area 2)

away from edge area
2 mm / 1.000 mm
6 mm / 2.000 mm
Ri
Ri
Edge design
template
segment
template
segment
The shape deviation is measured as distance A between a template with a chord

length of 1.000 mm respectively 2.000 mm and the spherical segment laying down
on a measuring bed set to the nominal radius.
1) related to the internal surface

2) measuring position: along the plate edge
(Ri = inside radius)
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
Unless otherwise agreed, allowance for assembly root-gap or for

welding shrinkage will not be taken into consideration.
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.
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.
Shell-courses are produced by
cold or hot forming, the choice
of the process being a function
of both the shell sizes and the
material properties. They are
preferably supplied fully welded:
welding is performed by using
either single-electrode, two-electrode or twin-arc submerged arc
methods in accordance with the
provisions of the relevant international codes, for example AD,
ASME (Stamps U, U2 and S are
available), PD 5500, CODAP,
TRD. Depending on the
material and code requirements,
the formed parts can be given
proper heat treatments, for
instance normalising, tempering,
water-quenching.
Optionally, the shell-courses are
supplied just tack-welded -
achieved from the outside within the longitudinal joint or

braced at both ends by using
strong-backs.
As a rule, the plate edges of the
longitudinal joint are prepared
by a milling process performed
from the outside what makes a
narrow gap weld-joint of 18
achievable. The circular weldedges of shell-courses are usually produced by flame cutting;
edge-machining of shell-courses
up to 2.550 mm in length can be
agreed.
Scope of supply
The forming is achieved by
means of a 4-roller machine
powered with 8.600 t force,
designed to deal with 4.300 mm
(169,2") wide plate. Its performance includes the cold forming
of shell-course up to 240 mm
(9,4") in thickness at the full
plate width; three interchangeable top rollers (880 mm, 1.200
mm and 1.500 mm) enable to
cover a very wide range of
diameters.
This machine has been specially

engineered for heavy section
plates made out of high strength
steels characterised by a yield
point of 700 MPa. Such an
equipment is particularly advantageous for steel grades where
hot forming is always problematic e.g. for all steels intended to
be delivered either in the waterquenched ( QT ) or in the
thermo-mechanically processed
( TM ) condition.
When required the forming can
be also performed by using a hot
process, conducted in the way to
keep extensively the surface finish free of the usual discontinuities resulting from this kind of
process.
Please consider also the
Technical Delivery Conditions
on page 32
Heavy Fabrication Division Dillinger Htte GTS, Cylindrical shell courses [1/3], 2008
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
1.000
1.200
1.200 mm top roller
880 mm top roller
1.400
1.500 mm top roller

1.600
1.800
Delivery program of shell-courses upon enquiry
Inside diameter [mm]
800
2.000
2.200
2.400
(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
M
ngth 360
Yield stre
a (35 ksi)
th 240 MP
Yield streng
2.600
2.800
3.000
3.200
3.400
3.600
3.800
4.000
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 angle
Land position 1)
Land height
Root 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 9013-33
1) measured from the reference diameter Da or Di

2) applicable to U and DU edges only
Diameter 1)
Out-of-roundness 2)
Length
Straightness
0.3 % D
1% D
3 mm
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).
Diameter Di or Da
Length L
Edge-design
Welding requirements and
fabrication code
Di
31
Da
TECHNICAL DELIVERY CONDITIONS
Weld-edge machining of a hemi-spherical dished head (ID 3.100 mm x 100 mm)
32
Plate processing
Basically the applied processing
operations comply with the recommendations made by the steel
maker having produced the plates.
Furthermore, the fabrication operations meet the guidelines of SEW
88 - German directives governing
the processing of heavy steel
plates. The requirements contained
in the relevant fabrication codes
such as AD, ASME, CODAP,
PED 97/23/EC, EN 13445, PD
5500, etc. can also be agreed.
Depending on the material steel
grade and the applicable specifications, the formed parts can be given proper heat treatment e.g. normalizing, water-quenching, tempering, stress-relieving. As a rule
the mechanical properties of every
pressing shaped by hot forming
are verified by using test coupons
removed from the forming allowance after completion of the
forming process and tested in the
final heat treatment condition.
Dimensional and shape accuracy
The Product Information Sheets
on the pages 6 to 31 include specific details regarding the standard
fabrication tolerances; they apply
unless otherwise agreed and are
valid at the time of the shop inspection. Supporting structures,
the type of which is to be agreed
upon, can be necessary to maintain
the shape during transport and
storage. In the case of packages
i.e. joint delivery of shell-courses
with pressings, the accuracy of the

components to each other shall be
within the permissible misalignment required in the applicable
code.
Surface condition
The items are supplied with untreated surfaces in line with the
processing method used; by agreement the surface quality can be
evaluated against EN 10163: Part
1 and 2. It can also be agreed that
the surface of the manufactured
items must be descaled and
primed in accordance with ISO
8501-1 (SIS 05-5900) or equivalent standard. The surface preservation of shell-plates is generally
carried out prior to the processing
operations (weld-edge preparation
and shaping to radius). The plate
weld-edges can be also protected
against corrosion by using a suitable coating, the type of which is
subject to agreement. The surface
treatment can also be subcontracted to an external company whose
quality system is controlled by
Dillinger Htte GTS.
Items supplied in the multi-segment design ready for assembly
are produced with weld-edge
preparation. Any requirement for
tapering must be additionally
agreed upon. The edges of cut-toshape plates, pressings and cylindrical shell-courses are as a rule
worked by flame cutting, the cut-
face being subsequently processed

free of scale and slag accumulation by grinding. Edge details described in the relevant standards
such as API 650, DIN 8851, NF E
81-110 (I, V, Y in single or
in double design) can be engineered: the cut-face quality is in
line with the cutting process. Any
machining of weld-edge preparation for heads and shell-courses
must be additionally agreed. Weldedge protection against corrosion
can also be provided on request.
Identification
Each item produced by Dillinger
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 traceability of the manufactured parts
along the fabrication operations
back to the Inspection Test Certificates of the initial material issued
by the plate mill. The markings
are as a rule made on the top side
of the plate i.e. on the concave
side of the curved shell-sections.
Unless otherwise agreed, heads
and pressings are marked on the
outside surface. The shipping
marks are stencilled in the manner
required in the purchase order.
Additionally the items are
equipped for transit with the brand
name and the emblem of Dillinger
Htte GTS.
Heavy Fabrication Division Dillinger Htte GTS, Technical delivery conditions [1/2], 2008
33
1/6 Sinusoidal segments ready to install a tunnel lining of an underground station, situated in a mining area (Clear diameter 6.300 mm, wall thickness 19 mm, steel grade ST 52-3 to DIN 17100)
34
along with the purchase order.
Contract work
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 for
fabrication; this concerns especially the hot forming parameters,
the machining and the material
allowances for forming.
Packaging
The items are usually provided
loose and unsecured: shaped parts
such as dished heads, pressings or
curved shell-sections are just laying on wooden timbers fitting the
outside curvature, usually with
the inner side upwards. Shell-plates
are stacked into lifting units separated from each other by means of
wooden spacers. Other types of
measures for packaging, securing
and lashing e.g. the supply of skids
or pallets, any supporting structures being necessary to maintain
the shape during transport, the
stowing into containers, the welding of lifting lugs, the use of spacers between each shell-plates are
always subject to agreement. Any
specific packaging and lashing requirements have to be agreed
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)
Dimensions
Please refer also to the tables "Information required" of the Product
Information Sheets on the pages 6
to 31. For the parts outside the
standard delivery program, please
support always your inquiry with a
sketch showing the contour design
of the part to be manufactured
including all measurements.
Documentation
Unless otherwise required, an inspection test certificate to EN
10204-3.1 is provided for the base
material and the manufactured
item as well. By agreement, the
documentation can be extended

and include for instance some fabrication and control procedures,
quality plan and shop drawings.
Enlarged scope of supply
The Heavy Fabrication Division is
well equipped to deal with your
orders. The table on page 37 provides an overview of the main machinery. Any design work, fabrication of finished equipment and
erection on the field are basically
outside the services offered by
Dillinger 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 installed 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 facilities on the river Saar is available.
Heavy Fabrication Division Dillinger Htte GTS, Technical delivery conditions [2/2], 2008
35
FABRICATION FACILITIES
2.500 ton hydraulic press
36
Main machinery
Thickness
(mm)
Width
(mm)
Length
(mm)
Clearance
(mm)
Diameter
(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-roll bending machine ( 1.500 t )
25
- 4-roll bending machine ( 8.600 t )
240
4.000
4.000 2)
350
4.300
2)
750
3)
1.000
3)
Machining
- NC vertical lathe
2.550 4)
- CNC plate-edge milling machine
120
- milling machine for weld-edge

preparation of longitudinal joints
and back-gouging
160 8)
5.000
6.100 5)
25.000
4.300
Flame cutting
- NC profile-cutting machine 6)
200
5.500
15.000
- NC profile-cutting machine
410
9.800
40.000
6)
- 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
6.000
12.500
2.300 4)
7)
- 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

maximum barrel length
minimum inside diameter
clear height
clear diameter
6) cutting medium: oxygen with acetylene or

with natural gas
7) normalising / tempering / stress-relieving
8) depth of the U-groove preparation for nar
row-gap welding
Note
All information related to the above equipment are just given for reference purposes: the actual manufacturing capability must be enquired.
Heavy Fabrication Division Dillinger 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 components described on the previous pages, the Heavy Fabrication 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 processing possibilities.
Dillinger Htte GTS as the European market leader for heavy
plates is indeed the right address
for highly demanding tasks. The
plate delivery program includes
a wide range of low alloyed
carbon steel grades to German
and international standards e.g.
- weldable fine-grain structural
steels,
- high-strength quenched and
tempered fine-grain steels,
- special low-temperature
weldable steels,
- low-temperature nickelalloyed steels (up to 5 % Ni),
- abrasion-resistant structural
steels,
- alloyed and unalloyed hardening and heat-treatable
steels,
- conventional CrMo steels
and vanadium enhanced
CrMo steels for general
structural applications,
ship-building industries,
pipe-lines, penstocks, boiler
and pressure vessels (hydrotreating petrochemical
reactors), etc.
Sometimes enquiries for particular grades are made on heavy
plates outside the scope of the
standard. Dillinger Htte GTS
provides the proper solution for
the most frequent required additional properties e.g.:

- Low carbon equivalents
- TTT properties to ASTM-A
770 and EN 10164
- High resistance to Hydrogen
Induced Cracking (HIC)
- Defined resistance to Sulfide
Stress Cracking (SSC)
- Insensivity to embrittlement
in CrMo-alloyed pressure
vessel steels as evidenced with
step-cooling tests, J and X
factors
- Longitudinally profiled
plates, i.e. with variable
thickness over the plate
length for structural steel
qualities to EN 10 025,
EN 10 113 (Part 2) and
EN 10 115.
Dillinger 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 steamboilers and pressure vessels
DICREST: fine-grained
steels for pressure vessels and
storage tanks with resistance
to sour gas
DIROS 500: high-strength
water-quenched and tempered pressure vessel steels
for low-weight designs
DILLINAL 460/630: highstrength fine-grained steels

for tanks used for the trans
port of liquefied gas
DIZINC: special structural
steels for galvanizing pots
with extended service-life
DI-MC: thermo-mechanically-rolled structural steels
with optimised processing
properties
DIWETEN: structural steels
with improved atmospheric
corrosion resistance
DICUT: steels with
optimised laser-cutting
properties
DIMARINE: thermomechanically-rolled ship

building steels with optimised processing properties
DIMO: steels for plastic
moulds
DIPRO: armoured steels for
civil safety applications
DISAFE: high-strength
thermo-mechanically-rolled
fine-grained structural steels
for safes
DICLADUR: roll-bonding
clad dual layer steels for use
under abrasive conditions
More details about the brandnamed steels are available in Material Data Sheets; they can be downloaded
at www.dillinger.de or www.heavyplate.com.
Heavy Fabrication Division Dillinger Htte GTS, Processed steel grades [1/1], 2008
39
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
Germany
Phone: +49 68 31 47 2342
Fax: +49 68 31 47 3346
E-mail: heavy-fabrication@dillinger.biz
GREAT
BRITAIN
NETHERLANDS
AMSTERDAM
ROTTERDAM
LONDON
HANNOVER
BERLIN
WESER
NORTH
SEA
ELBE
E 51
DSSELDORF
ANTWERPEN
BRSSEL
BELGIUM
E 40
KLN
E 35
RHEIN
E 411
GERMANY
FRANKFURT
MAIN
CZECH
REPUBLIC
E 15
FRANCE LUXEMBURG
E 05
E 50
PARIS
E 15
DILLINGEN
METZ
MOSEL
SEINE
E 55
SAARBRCKEN
STRASBOURG
E 21
DONAU
STUTTGART
MNCHEN AUSTRIA
E 09
BASEL
43
E 56
E 52
E 25
How to find us
E 35
Aktien-Gesellschaft der
Dillinger Httenwerke
Heavy Fabrication Division
P.O. Box 1580
Germany
Phone: +49 68 31 47 23 42
Fax: +49 68 31 47 33 46
Liability:
any information on fabrication
process, plate material and product suitability are provided
without guarantee; assurance
regarding specific properties
and fields of application requires
always a written agreement.
Delivery Program Heavy Fabrication Division, 2008

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DELIVERY PROGRAM

The products manufactured by

EN 14001:2005 and OHSAS

MODULAR SOLUTIONS FOR

Anyone believing that the elegant

from the Saarstahl AG, is rolled

to process such plates completely

Fabricated plates equipped with machined weld-edges

The bevelling of edges is part of

form, is virtually absorbed by

ried out by milling; for larger

The machining process is based

As the milling process is CNC

A high degree of accuracy and an

The edge preparation of plates

Shell-plates rolled to radius

Difference between diagonals

1) measured from the plate top side

Straightness of the ends

A = deviation from the theoritical curvature

Cut-to-shape plates are intended

the scrap remains the property of

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

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

HOT DISHING PROCESS OF

5. Circular blank being dished

6. Dished head being extracted out of the forming tools

MULTI-SEGMENT SHELL SECTIONS

When the required items exceed

diameter cold-forming is applied.

the fabrication of items outside

1) related to the internal surface

4) calculated from measured circumference

Dishing radius r1 and

"Tailor-made" shell sections

SPHERICAL SHELL PLATES

Spherical shell-plates are

spheres above 7.000 mm in

Unless otherwise required, the

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)

200 mm wide edge area 2)

The shape deviation is measured as distance A between a template with a chord

1) related to the internal surface

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

CYLINDRICAL SHELL COURSES

Cylindrical shell-courses are

achieved from the outside within the longitudinal joint or

This machine has been specially