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Heads and cones

Shell plates, heads and cones from one source

voestalpine Grobblech GmbH


www.voestalpine.com/grobblech
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Shell plates, heads and cones from one source

Customer benefits of a package supplier


Advantages in manufacturing vessels based on the use of the same chemical composition of steel
grades for plates, heads and cones from one source and thus special advantages during welding

Technical advice and coordination from one quality department and R&D department

Savings of time and costs for the customer as a result of simultaneous completion and shipment
of shell plates, heads and cones

Lower administrative expense – one contact person for plates, heads and cones

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The market
Our strengths
voestalpine Grobblech is the world’s only pro- We supply shell plates, heads and cones for
ducer of carbon steel, low-alloyed steel and boiler and pressure vessel manufacture from
clad plates with integrated production of heads a single source.
and cones.

Heads and cones can be processed of carbon


steel, low-alloyed steel or clad plates.

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Typical fields of application

We deliver heads and cones to the Our heads and cones are used in:
following industries: coke drums
oil and gas industry reactors
refineries heat exchangers
chemical industry separators
petrochemical industry columns
transport industry compressors
power plants storage tanks
energy industry special tank wagons

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Single-piece heads

We supply single-piece heads made of carbon


steel and roll-bonded clad plates.

Heads are produced by hot pressing and can be


dished and flanged.

Dimensions

pressed flanged

Diameter max. 3,400 mm max. 3,400 mm

Thickness max. 160 mm max. 65 mm

Alternative dimensions on request.

Welded single-piece heads

We supply welded single-piece heads made of


carbon steel and roll-bonded clad plates.

Welding of plates before pressing enables


production of heads with enlarged diameter.

Heads are formed by using:


– Dishing press
– Flanging machine

Dimensions

pressed flanged

Diameter 3,400 - 3,700 mm 3,400 - 6,500 mm

Thickness max. 160 mm max. 65 mm

Alternative dimensions on request.

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Multi-piece heads and cones
(crowns and segments)
We supply multi-piece heads and cones made
of carbon steel and roll-bonded clad plates.

Crowns and segments are dished and pressed


(Dishing press/flanging machine)

Matching of all parts is proven by trial assembly.

Production program covers:


– Torispherical heads (ASME)
– Semi-elliptical heads (ASME)
– Hemispherical heads

Dimensions

Diameter max. 10,000 mm

Thickness max. 160 mm

Alternative dimensions on request.

Clad heads and cones

We supply clad heads and cones made of


roll-bonded clad plates.

Roll-bonded clad plates are produced in-house


by voestalpine Grobblech.

Single-piece, welded single-piece and


multi-piece clad heads and cones are available.

Dimensions

Diameter max. 10,000 mm

Thickness max. 120 mm

Alternative dimensions on request.

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Heads and shell plates for LPG tank wagons

LPG (Liquified Petroleum Gas) is transported in tank wagons built of


special vessel steels. In Europe we are the only manufacturer who
can deliver both shell plates and heads of special steel grade
P460 NL2 mod. (increased tensile strength) according to VdTÜV 531.

Dimensions for plates

Thickness 7 - 20 mm

Width 1,500 - 3,800 mm*

Length max. 18,000 mm

Weight per plate max. 11.7 mt

*alternative dimensions on request

Dimensions for heads

Thickness 7 - 20 mm

Diameter 1,500 - 3,500 mm*

*alternative dimensions on request

Yield Tensile

strength strength

Rp0,2 min. [MPa] Rm [MPa]

Steel grade Standard T=20°C T=20°C

P460 NL2 mod. VdTÜV 531 460 630 - 725

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Quality assurance

Product integrity for pressure vessels is of great importance.


Products, processes and business systems of voestalpine
Grobblech is certified by Lloyds Register of Quality Assurance to
ISO 9001. This certification covers all aspects of sales, service,
design, manufacture and testing.

voestalpine Grobblech is certified for heavy plates as well as


clad plates by the Verband der Technischen Überwachungs-
vereine (VdTÜV) (Union of Technical Inspection Groups)
and by the Technischer Überwachungsverein Industrie Service
GmbH (=TÜV-Süd) (former Technical Inspection Group
Bavaria):

AD-Merkblatt W0 / TRD 100


EG-Druckgeräterichtlinie Nr. PED97/23/EC
(PED = Pressure Equipment Directive)
Welding of heads and cones is possible
according to PD 5500, AD 2000, EN 13445,
ASME U and U2 Stamp.

Product support

Our Research & Development department is a


dedicated center of expertise. We continually
invest in the education of our staff and in the
latest research tools to assure first-class techni-
cal investigation.

We have an independent and fully accredited


testing facility on site.

Our R & D is continually developing new


materials for more complex applications and
contributes to the optimization of our pro-
duction processes. Additional work includes
simulations of material performance such as
weldability, deformation and edging behavior,
fatigue tests and fracture mechanics. These
tests provide a complete performance profile of
our steels under practical conditions.

We calculate the pressing tools for hot forming


of heads with the finite element method.

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Production of heads

« Hydraulic press with a


press force of 3,500 mt

« Walking beam furnace

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Dishing press »

Flanging machine »

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Further treatment

Heat treatment
Heat treatment is set according to material requirements.
Water quenching can be provided up to a diameter of 6,500 mm.

Normalized (N)
Normalized and tempered (N+T)
Quenched (Q)
Quenched and tempered (Q+T)

Edge preparation for welding


Edges are flame-cut in preparation for welding
according to customer specifications.

Shotblasting for carbon steel heads


Carbon steel heads can be shotblasted to a
roughness of SA 2.5.

Surface finish for clad heads


The surface of the base material is normally
„as rolled“ or shotblasted.

The surface of the clad material is normally ground with a grain


size of 60 - 240. Other grain sizes are available on request.

Another option is blasting with glass beads for ferritic-free surface.

The clad surface is protected for transport with a special easily


removeable and water-soluble glossy top paint.

Pre-assembly of multi-piece heads


All parts of multi-piece heads and cones are pre-assembled to
ensure a perfect match.

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Carbon steels for heads and cones

We offer a comprehensive range of steel grades for heads and cones:


Structural steels and fine-grain steels
Pressure vessel steels
voestalpine special grades

Structural steels

Steel group Standard Steel grade

S235 JR+AR, JR+N, J0+AR, J0+N, J2+AR, J2+N

S275 JR+AR, JR+N, J0+AR, J0+N, J2+AR, J2+N


Unalloyed structural steels EN 10025-2
S355 JR+AR, JR+N, J0+AR, J0+N, J2+AR, J2+N
K2+AR, K2+N
S275N, NL

S355N, NL
Fine-grain steels, normalizing rolled, normalized (furnace) EN 10025-3
S420N, NL

S460N, NL

(S)A 36

Structural steels ASTM/ASME (S)A 283 Grade C

(S)A 572 Grade 50 Type 1

Weather resistant structural steels ASTM/ASME (S)A 588 Grade A

Delivery in accordance with AD 2000 specifications, TRD rules (Technical Rules for steam boilers) and BN 91802 upon request.

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Pressure vessel steels

Steel group Standard Steel grade

P235, 265, 295, 355GH


Non alloyed
16Mo3, 20MnMoNi4-5
and alloyed EN 10028-2
13CrMo4-5, 10CrMo9-10
creep resistant steels
13CrMoV9-10

P275 NH, NL1, NL2


Fine grain steels
EN 10028-3 P355 NH, NL1, NL2
for pressure vessels
P460 NH, NL1, NL2

12Ni14

X12Ni5
Ni-alloyed steels EN 10028-4
X7Ni9

X8Ni9

(S)A 203 Grade D, E

(S)A 387 Grade11 Class2

(S)A 387 Grade12 Class2

(S)A 387 Grade22 Class2


Steels for pressure vessels ASTM / ASME
(S)A 516 Grade60, 65, 70

(S)A 537 Class1, 2

(S)A 553 Type 1

(S)A 738 Grade A, B

Delivery in accordance with PED (Pressure Equipment Directive of European Union), AD 2000 specifications and TRD rules (Technical Rules for steam boilers).

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Materials for clad heads and cones

Clad heads and cones are made of roll-bonded clad plates made by voestalpine Grobblech.

Base materials Claddings


We offer the same steel grades as for heads and We offer ferritic and austenitic stainless steels,
cones of carbon steels (see pages 13 and 14). nickel and nickel-based alloys, copper and
Alternative base materials on request. copper-nickel-alloys as well as titanium as
cladding materials.

Stainless steels and Special steels, non-ferrous metals


heat-resistant steels and alloys
Comparable grades

EN material
ASTM Type EN / DIN / SEW
number

B 409 UNS N08800 Alloy 800 1.4876 SEW 470


EN material
Comparable ASTM A240
Standard number
Grade / ASME SA240 type B 625 UNS N08904 Alloy 904 L 1.4539

B 709 UNS N08028 Alloy 28 1.4563 EN 10088

1.4000 X6Cr13 410S B 625 UNS N08926 Alloy 926 1.4529

B 463 UNS N08020 Alloy 20 2.4660 DIN 17744


1.4301 X5CrNi18-10 304

B 424 UNS N08825 Alloy 825 2.4858 DIN 17744

1.4306 X2CrNi19-11 304L


B 443 UNS N06625 Alloy 625 2.4856 DIN 17744

1.4541 X6CrNiTi18-10 321 B 575 UNS N06022 Alloy C 22 2.4602 DIN 17744

B 575 UNS N06455 Alloy C 4 2.4610 DIN 17744


1.4550 X6CrNiNb18-10 347

B 575 UNS N10276 Alloy C 276 2.4819 DIN 17744

1.4401 X5CrNiMo17-12- 2 316


B 575 UNS N06059 Alloy 59 2.4605 DIN 17744

EN B 333 UNS N10665 Alloy B 2 2.4617 DIN 17744


1.4404 X2CrNiMo17-12-2 316L
10088

B 168 UNS N06600 Alloy 600 2.4816 DIN 17742

1.4571 X6CrNiMoTi17-12-2 316Ti


B 127 UNS N04400 Alloy 400 2.4360 DIN 17743

1.4432 X2CrNiMo18-14-3 316L Mod Mo>2.5 B 162 UNS N02200 Alloy 200 2.4066

DIN 17740

B 162 UNS N02201 Alloy 201 2.4068


1.4435 X3CrNiMo17-13-3 316L Mod Mo>2.5

– – 2.0070 DIN 1787

1.4429 X2CrNiMoN17-13-3 316LN Mod Mo>2.5


B 152 UNS C12200 – CW 024 A

1.4438 X2CrNiMo18-15-4 317L B 171 UNS C70600 Alloy CuNi 90/10 CW 352 H EN 1652

B 171 UNS C71500 Alloy CuNi 70/30 CW 354 H


1.4439 X2CrNiMoN17-13-5 317LMN

B 265 Grade 1 Titanium Grade 1 3.7025

DIN 17850
SEW 470 1.4828 X 15 CrNiSi 20 12 –
B 265 Grade 2 Titanium Grade 2 3.7035

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Forming processes

The prematerial is rounds cut of heavy plates or roll-bonded clad plates made in-house.

35,000 kN Press Dishing press

Flanging machine

Heads and cones Heads

single-piece heads: single-piece heads:


diameter: max. 3,700 mm* diameter: max. 6,500 mm*
thickness: max. 160 mm thickness: max. 65 mm

multi-piece heads:
diameter: max. 10,000 mm
thickness: max. 160 mm

multi-piece cones:
diameter: max. 10,000 mm
thickness: max. 160 mm

*from 3,400 - 3,700 mm *from 3,400 - 6,500 mm


with weld seam with weld seam

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Shapes of single-piece heads and cones

max. diameter / max. thickness [mm]

pressed flanged

Semi-elliptical heads (ASME) 3,700 / 160 6,500 / 65

Korbbogenböden (DIN 28013)

Torispherical heads (ASME) 3,200 / 160 6,500 / 65

Klöpperböden (DIN 28011)

Hemispherical heads 3,000 / 160

Halbkugelböden

Standard-type dished heads 6,500 / 65

Normalgewölbte Böden

Flat heads 3,600 / 80 6,500 / 40

Flachböden

Dished discs / spherical segments 4,000 / 160 6,500 / 65

Gewölbte Scheiben/Kugelsegmente

Cones

Kegel with weld seam

thickness and diameter depend on height

Special pressed parts

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Shapes of multi-piece heads and cones

max. diameter / max. thickness [mm]

pressed

Torispherical heads (ASME) 10,000 / 160

Klöpperböden (DIN 28011)

Semi-elliptical heads (ASME) 10,000 / 160

Korbbogenböden (DIN 28013)

Hemispherical heads 10,000 / 160

Halbkugelböden

Cones 10,000 / 160

Kegel

If no tools are available for single-piece heads, we offer


dished and pressed crowns and segments:

Pressed with oversize for subsequent edge preparation.


Pressed with edge preparation and trial assembly.
Trial assembly is carried out using mounting clamps in
matching material. The segments are marked in such a
way that trouble-free re-assembly is possible at the
customer. Marking the remaining mounting clamps
makes this job easier.
Shrinkage during welding is taken into consideration
in the design.
Recommendations for welding of clad heads can be
found in the brochure ”Roll-bonded clad plates”.

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Dimensions

Single-piece heads and cones

Hot- or cold-pressed:
s = 6 - 160 mm
Ø 1,000 - Ø 3,700 mm
Hemispherical heads = Ø 1,000 - Ø 3,000 mm

Dished and flanged:


s = 5 - 65 mm
Ø 1,500 - Ø 6,500 mm
Wall thickness [mm]

Outer diameter [mm]

Multi-piece heads and cones

Hot- or cold-pressed
crowns and segments

Hemispherical heads
Ø 3,000 - Ø 10,000 mm

Semi-elliptical heads,
elliptical heads 2:1 / 1.9:1,
Wall thickness [mm]

torispherical heads
Ø 3,700 - Ø 10,000 mm

Outer diameter [mm]

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Delivery program

Hot- and cold-pressed heads; crowns and segments

Semi-elliptical heads (ASME 2:1)


Torispherical heads (ASME)
Hemispherical heads Flat heads
Standard-type dished heads
Elliptical heads 1.9:1 (NFE)

Wall thickness [mm]


Outer diameter [mm]
min. max. min. max. min. max.

600 - 900 upon request upon request upon request upon request

1000 6 100 10 100 6 60


1100 6 100 10 100 6 60
1200 6 100 10 100 6 60
1300 6 100 10 100 6 60
1400 6 100 10 100 6 60
1500 8 160 12 160 8 80
1600 8 160 12 160 8 80
1700 8 160 12 160 8 80
1800 8 160 12 160 8 80
1900 8 160 12 160 8 80
2000 8 160 12 160 8 80
2100 10 160 15 160 10 80
2200 10 160 15 160 10 80
2300 10 160 15 160 10 80
2400 10 160 15 160 10 80
2500 10 160 15 160 10 80
2600 10 160 15 160 10 80
2700 10 160 15 160 10 80
2800 10 160 15 160 10 80
2900 10 160 15 160 10 80
3000 10 160 15 160 10 80
3100 10 160 15 160 2) 10 80
3200 10 160 15 160 10 80
3300 10 160 3) 15 160 10 80
3400 10 160 15 160 10 80
3500 10 160 15 160 10 80
3600 10 160 15 160 10 80
3700 10 160 1) 3) 15 160
3800 10 160 15 160
3900 10 160 15 160
4000 10 160 15 160
4500 10 160 15 160
5000 10 160 15 160
5500 10 160 15 160
6000 10 160 15 160
6500 10 160 15 160
7000 10 160 2) 15 160
8000 10 160 15 160
9000 10 160 15 160
10000 10 160 15 160

1) Wall thickness < 65 mm cold production; > 65 mm multi-piece design 2) Multi-piece design 3) Heads with weld-seam (only cold production is
possible for flat heads). Flange height (h) 150 mm max.; greater wall thicknesses or flange heights upon request. Wall thickness (s) of clad heads 90 mm max.

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Dished and flanged heads

Semi-elliptical heads (ASME 2:1)


Torispherical heads (ASME)
Flat heads
Standard-type dished heads
Elliptical heads 1.9:1 (NFE)

Wall thickness [mm]


Outer diameter [mm]
min. max. min. max.

1500 5 25 5 25
1600 5 25 5 25
1700 5 25 5 25
1800 5 25 5 25
1900 5 25 5 25
2000 5 25 5 25
2100 5 60 5 40
2200 5 60 5 40
2300 5 60 5 40
2400 5 60 5 40
2500 5 60 5 40
2600 5 60 5 40
2700 5 60 5 40
2800 5 60 5 40
2900 5 60 5 40
3000 5 60 5 40
3100 5 60 5 40
3200 5 60 5 40
3300 5 60 5 40
3400 5 65 5 40
3500 5 65 5 40
3600 5 65 5 40
3700 5 65 5 40
3800 5 65 5 40
3900 5 65 5 40
4000 5 65 5 40
4100 10 65 10 40
4200 10 65 10 40
4300 10 65 10 40
4400 10 65 10 40
4500 10 65 10 40
5000 10 65 10 40
5500 10 65 10 40
6000 10 65 10 40
6500 10 65 10 40

Heads with weld seam flange height (h) 150 mm max.

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Head geometry
The following data describe the head geometry and are required in the customer order.
Semi-elliptical heads (2:1)
elliptical heads (1.9:1)

s
Di inner diameter or
Da outer diameter
Ri inner radius unless
Hi

ri ri knuckle radius standardized


s nominal or minimum wall thickness
h

Di Hi inner height
Da h flange height
edge design

Dk Semi-elliptical heads (multi-piece, 2:1)


elliptical heads (1.9:1)
s

Di inner diameter or
Da outer diameter
Ri crown radius unless
Hi

ri ri knuckle radius standardized


H inner height
h

h flange height
Di Dk crown diameter + number of segments
Da edge design (segments, crown, wall)

Torispherical heads
s

Di inner diameter or
Da outer diameter
Hi

Ri inner radius unless


ri ri knuckle radius standardized
h

s nominal or minimum wall thickness


Di
Da H inner height
h flange height
edge design

Dk Torispherical heads (multi-piece)


s

Di inner diameter or
Da outer diameter
Ri crown radius unless
ri knuckle radius standardized
Hi

ri s nominal or minimum wall thickness


Hi inner height
h

Di h flange height
Da Dk crown diameter + number of segments
edge design (segments, crown, wall)

Standard-type dished heads


Di inner diameter or
s

Da outer diameter
Ri inner radius unless
Hi

Ri

ri knuckle radius standardized


ri
s nominal or minimum wall thickness
Di
Hi inner height
h

Da
h flange height

Dished discs
s

D diameter
Ri inner radius
s nominal or minimum wall thickness
edge design
D

Flat heads
Di inner diameter or
s

Da outer diameter
ri knuckle radius
Hi

ri
h

s nominal or minimum wall thickness


Di Hi flange height + radius
Da edge design

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Hemispherical heads
Di inner diameter or
s Da outer diameter
Ri inner radius = Hi
s nominal or minimum wall thickness
Hi

edge design
Ri

Di
Da

Hemispherical heads with cylindrical flange


Di inner diameter or
s Da outer diameter
Ri inner radius
Hi

s nominal or minimum wall thickness


Hi inner height (radius + flange height)
Ri h flange height
h

edge design

Di
Da

Hemispherical heads with negative flange


Di inner diameter or
s Da outer diameter
s nominal or minimum wall thickness
Hi

Hi radius – flange
h negative flange
edge design
Ri
h

Di

Dk
Hemispherical heads (multi-piece)
s

Di inner diameter or
Da outer diameter
Ri inner radius
s
s nominal or minimum wall thickness
Dk crown diameter + number of petals
edge design (petals, crown, flange)
design with negative flange is also possible
Ri

Di
Da

D2
Cones
r2
D1 diameter
h2

D2 diameter
r1 knuckle radius
r2 knuckle radius
s H height
H

s nominal or minimum wall thickness


h1 flange height
h2 flange height
h1

r1 ␣ angle
edge design
D1

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Tolerances

Single-piece heads and cones Multi-piece heads and cones

acc. to applicable standard acc. to applicable standard


Diameter1) 2)
voestalpine standard ±0.3 % D voestalpine standard ±0.2 % D

acc. to applicable standard acc. to applicable standard

Height1) voestalpine standard +1.5 % D/-0, voestalpine standard +1.5 % D/-0

max. 38 mm max. 38 mm

acc. to applicable standard radius deviation of crown and segments


Shape
special shapes upon request 3 mm/m from the template

acc. to applicable standard acc. to applicable standard

Ovality1) voestalpine standard 1 % D, voestalpine standard 1 % D,

max. 30 mm max. 30 mm

voestalpine standard for flat heads


Flatness
3 mm/m deviation from measuring rod

Weld gap weld gap ±2 mm

Edge tolerances for edge preparation (flame cut & machined)

bevel angel (␣1, ␣2) ±2°

depth of preparation (h1) +2/-0 mm

thickness of root face (c) ±1 mm

thickness after tapering (t) t > 5 - 10 mm -0/+1 mm

t > 10 - 25 mm -0/+2 mm

t > 25 mm -0/+3 mm

taper angel (␣3) ±3°


clad material
root radius for U/DU groove 3) ±1 mm
base material

strip back of cladding

bevel angel (␣4) ±4°

depth of preparation (h2) +2/-0 mm

radius (r) ±1.5 mm

depth (x) of removal into carbon steel


4) +1/-0 mm

1) Alternative dimensions on request


2) Generally the diameter tolerance is measured on

the circumference and calculated as D = U/π

(D – diameter, U – circumference)
3) Possible up to diameter of 2,200 mm
4) Our standard is 0.5 mm

Shape control by automatic laser measurement

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References

Year Project Destination Product Material


A 516 Grade70 / A 387 Grade11
2008 UHDE Sorfert Project Algeria Heads
Class2 / A 387 Grade22 Class2

A 516 Grade70 / A 387 Grade22


2008 INA Refinery Croatia Clad Heads
Class2 + 304L / 316 L / 410 S

2008 ALFA LAVAL Saudi Arabia Heads A 387 Grade11 Class2

2008 Corinth Refinery Greece Multi-piece heads P355 NL2

2008 Styrenics Italy Heads A 516 Grade70

2008 Valero - New Orleans USA Heads A 387 Grade22 Class2

2008 Haldor Topsoe Italy Heads A 387 Grade11 Class2

2008 Neste Oil Finland Multi-piece heads A 387 Grade22 Class2

2008 PCS Nitrogen Trinidad Trinidad Multi-piece heads A 387 Grade11 Class2
2008 ALFA LAVAL Novoil Italy Heads A 387 Grade11 Class2

2008 Buzzard Enhancement USA Clad heads P355NL2 + Alloy 904L

A 516 Grade70 / A 387 Grade11


2007 / 2008 Revap Brasil Heads, multi-piece and clad heads
Class2 + 347

2007 Pearl GTL Qatar Multi-piece heads 20 MnMoNi 4-5

2007 Pearl GTL Qatar Heads 20 MnMoNi 4-5

2006 Voyageur Upgrader Canada Clad Heads A 387 Grade12 Class2 + 410S

2005 Methanol Hainan China Heads A 387 Grade11 Class2

2005 Kashagan Offshore Oilfield Kazakhstan Heads and clad heads A 516 Grade70 + Alloy 825

2004 Linde BOC Process Plants LLC USA Clad heads A 387 Grade11 Class2

2004 PTA Aker Kvaerner Mexico Clad heads A 516 Grade70 + 304L

2004 BAPCO Bahrain Heads A 516 Grade70

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Clients and partners

International sales organization

Being close to the customer is about more than just physical presence – it’s about really being there when the he or she
needs you. voestalpine Eurostahl GmbH supports its customers in their efforts to meet ever harder challenges as and
when they need it. As a reliable partner, voestalpine Eurostahl opens the door for customers to the full range of voestalpine
products and services. As the company’s international sales organization, voestalpine Eurostahl is the direct link
between customers and the producing companies. Sales and distribution subsidiaries and representatives in twenty
countries speak the voestalpine language and guarantee hassle-free, one-stop customer access to competent support
and solutions.

All foreign offices and contact partners are listed at www.voestalpine.com/eurostahl

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We are the World of Welding Solutions.

27
January 2009 Edition
Technically More Advanced. Successful Together.
voestalpine – The Partner You Can Trust.

High-quality materials are the basis for our products. We strive to be the best partner for
our customers and want to provide them with the best-possible solution. We focus our
expertise on two aspects: personal contact with dedicated, competent employees and high-
quality technically sound methods, products and services.

The companies in the voestalpine Steel Division pledge the following:


Understanding for the business of our customers
Dedication to professionalism
Reliability
Partnerships based on trust
Responsibility for satisfactory project completion

voestalpine Grobblech GmbH


voestalpine-Straße 3
4020 Linz, Austria
T. +43/50304/15-9260
F. +43/50304/55-9260
grobblech@voestalpine.com
www.voestalpine.com/grobblech

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