fabrication of components at dillinger huette heavy fabrication · 2015. 12. 10. · 2 service...

1

New Generation of New Generation of CrMo(VCrMo(V))-- SteelSteel Grades for the use in Grades for the use in Petrochemical ReactorsPetrochemical Reactors

DILLINGER HÜTTE GTS

1Dillinger Huette, Pressure Vessel Colloquium, Sept. 16 and 17, 2009

Fabrication of Components

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Fabrication of Components Fabrication of Components at at

Dillinger HütteDillinger HütteHeavy Fabrication DivisionHeavy Fabrication Division

Jean-Paul BERNARD Rudolf J. CAWELIUSSales Divison-Manager Technical [email protected] [email protected]





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1 Introduction

2 Service Philosophy of the Dillinger Hütte’s Heavy Fabrication

3 Some Aspects on Forming of Heavy Plates

4 Components made at Dillinger Hütte’s Heavy Fabrication

4.1 Pre-Fabrication Shop- Oxy-Cutting of Cut-to-Shape Sections - Edge-Milling of Plates - Roll-Bending of Plates for Storage-Tanks

4.2 Pressing Shop- Cold Formed Spherical Segments - One-Piece Heads (unwelded)- Multi-Segment Heads- Taylor-Made Pressings

4.3 Roll-Bending and Welding of heavy Section Shell Coursesan Alternative to Forgings

5 Conclusion

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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:

• 410 mm in Thickness• 5.200 mm in Width• about 40 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





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DILLINGER HÜTTE’sHEAVY FABRICATION

develops Solutions for the Application of thick and heavy Plates - produced by our Mill-in close Contact to our Customer!

2. Service-Philosophy:

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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.

3 Enlarging the Plate Customer’s Product Range in providing ready-for-assembly “Packages” of heavy Components that theycannot 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.

2 Plates and prefabricated Sub-Assemblies from one Hand.

2. Service-Philosophy:





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Forming of Heavy Plates - Overview

3.1 Cold Forming

3.2 Warm Forming (below Tempering resp. PWHT Temperatur)

3.3 Hot Forming (above the upper critical Temperature Ar3)

3. Some Aspects on Forming of Heavy Plates

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• ASME VIII-1, UG-79 (a) and• ASME VIII-2, AF-110 (Ed. 2007: 6.1.2.1)

• Forming Shell Sections and Heads:All materials for shell sections and heads shall be formed to the requiredshape by any process that will not unduly impair the mechanicalproperties of the material.





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• European Pressure Equipment DirectivePED 97/23CEAnnex 1, Sect. 3:

• 3.1.1. Preparation of the component partsPreparation of the component parts (e.g. forming and chamfering) mustnot give rise to defects or cracks or changes in the mechanicalcharacteristics likely to be detrimental to the safety of the pressureequipment. (See Guidelines: 5/3,6/14,6/3)

• 3.1.4. Heat treatmentWhere there is a risk that the manufacturing process will change thematerial properties to an extent which would impair the safety of thepressure equipment, suitable heat treatment must be applied at theappropriate stage of manufacture.

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3.1. Cold Forming to consider

• the actual Y.S. before Forming starts• the Increase in Y.S. while Cold Forming• the Degradation in Formability

Influence of Cold Forming on Y.S. and T.S.

450

500

550

600

650

700

0 2 4 6 8 10Cold Deformation [%]

Rm

, Rp0

.2 [N

/mm

²]

Rp0,2 Q+TRp0,2 Q+T+SRm Q+TRm Q+T+S

PWHT

DIROS 500Q+T





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Influence of Cold Deformation on Yield and Tensile StrengthSteel Grade 13CrMo4-5 (SA 387-11-2) N+T

200

250

300

350

400

450

500

550

600

650

700

0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5

Cold Deformation [%]

Rm

, Rp0

.2 [N

/mm

²]

Rp0,2 Q+TRp0,2 Q+T+SRm Q+TRm Q+T+S

PWHT

-1

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Influence of Cold Deformation on ElongationSteel Grade 13CrMo4-4 (SA 387-11-2) N+T

14,0

15,0

16,0

17,0

18,0

19,0

20,0

21,0

22,0

23,0

24,0

25,0

0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5


Elon

gatio

n [%

]

N+TN+T+S

PWHT

-1





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Influence of Cold Deformation on Yield StrengthSteel Grade 10CrMo9-10 (SA 387-22-2) N+T

300

350

400

450

500

550

600

650

700

0 1 2 3 4 5 6 7 8 9 10


Yiel

d St

reng

th [N

/mm

²]

N+TN+T+S

PWHT

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0,0

1,0

2,0

3,0

4,0

5,0

6,0

7,0

8,0

9,0

10,0

11,0

12,0

0 1 2 3 4 5 6 7 8 9 10


Elon

gatio

n w

ithou

t Str

ictio

n (%

)

N+TN+T+S

PWHT

Influence of Cold Deformation on Elongation without StrictionSteel Grade 10CrMo9-10 (SA 387-22-2) N+T





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Einfluß der Kaltumformung aufStreckgrenze und Zugfestigkeit

450

500

550

600

650

700

0 1 2 3 4 5 6 7 8 9 10

Umformgrad [%]

Rm

, Rp0

.2 [N

/mm

²]

Rp0,2 Q+T

Rp0,2 Q+T+S

Rm Q+T

Rm Q+T+S

PWHT

DIROS 500Q+T

Cold Deformation

Influence of Cold Deformation on Yield Strength and Tensile StrengthDIROS 500 S ( similar to SA533-B-2 / 20MnMoNi4-5) Q+T

Rp0.2

Rm

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0

1

2

3

4

5

6

7

8

9

10

11

12

0 1 2 3 4 5 6 7 8 9 10


Elon

gatio

n w

ithou

t Str

ictio

n [%

]

Q+TQ+T+S

PWHT

Influence of Cold Deformation on Elongation without StrictionSteel Grade DIROS 500S (similar to 20MnMoNi4-5, SA533B2 )





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Cold Deformation (%)

4 Forming

General Trend of the Influence of cold Deformation on mechanical Properties

Elon

gatio

n, T

ensi

leSt

reng

th, Y

ield

Stre

ngth

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Influence of Cold Deformation and subsequent PWHTon Toughness

Av

4 Forming





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4 Forming

3.2. Warm Forming

• to reduce the Y.S. before Forming

SA 302 Grade B (16Mo3), normalised

DIROS 500 ( SA 533 B2 ; 20MnMoNi4-5) Q+T

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Hot Tensile Test for several Steel Grades

SA 387 Grade 11 Class 2 (13CrMoSi5-5), Q+T

10CrMo9-10 (SA 387 Grade 22 Class 2), N+T





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HP = 20.39 = 730°C/90MinHP = 21.11 = 730°C/90min + 710°C/24hrs

Hot Tensile Test for several Steel Grades

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Concept of the Hollomon Parameter (HP)

Time [h]

Tem

pera

ture

[°C

]

+ t +

holding

“ T “Holding

Temperature[°C]

[HP = T (+ 273) log ( T (+ 273)

2,3 * Kh ( 20 - log Kh )

heating

“ Kh “heating rate

[°C/h]

2,3 * Kc ( 20 -log Kc )

T (+ 273) ) + 20 ] * 10 -3

cooling

“ Kc “cooling rate

[°C/h]

“ t “Holding time

[h]*

*) holding time starts whenreaching temperatureover whole thicknessHP=T(20+log t)

Please see: www.heavyplate.com „Steel-Processing“





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Concept of the Hollomon Parameter (HP)• HP combines all relevant parameters of the heat treatment in one

value

• HP is mainly influenced by following parameters:• HP increases with higher temperature / holding time• HP increases with lower heating- / cooling rate

• HP is applicable for tempering and PWHT heat treatment(s)

• HP characterises also combinations of tempering and PWHT

• Different heat treatments with the same HP have the same metallurgical effect on the material

• Increasing HP results in an increased metallurgical effect on the material

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Hollomon-Parameter as Result of different Heat Treatment Cycles

Tempering PWHT 1 PWHT 2 HP total

700°C/300 Miuntes 20.15700°C/250 Minutes 670°C/180 Minutes 20.15680°C/250 Minutes 680°C/540 Minutes 20.16700°C/90 Minutes 680°C/300 Minutes 680°C/180 Minutes 20.16680°C/60 Minutes 680°C/300Minutes 670°C/600 Minutes 20.16

For more Information: www.heavyplate.com





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Influence of Hollomon Parameter on the mechanical Properties(Av typical for Steel grades in the delivery condition N+T, N+AC+T or Q+T )

0

100

200

300

400

500

600

700

0 2 4 6 8 10 12 14 16

Hollomon Parameter

Av, R

mu.

Rp0

.2

Av after

Rp0.2before

Condition 1Before PWHT

Condition 2After PWHT

Rmafter

Rmbefore

Av before

Rp0.2after

A v, R

p0.2

, RM

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Tensile strength in dependence of HP for CrMo and CrMoV steels

500

600

700

800

900

1000

1100

19,00 19,20 19,40 19,60 19,80 20,00 20,20 20,40 20,60 20,80 21,00 21,20 21,40

Rm

[MPa

]

400

HP

12CrMo 910 acc. EN 10028-2:2003

CrMoV: acc.ASTM Code Cases

2151 and 2098-2

2,25CrMoV, t/42,25CrMoV, t/23CrMoV, t/43CrMoV, t/212CrMo 910

HP 20,8: Tempering+705 °C/10h


thickness: 200 mmcondition: N+AC+T





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Yield strength for CrMo and CrMoV steels

19,2 19,4 19,6300

400

500

600

700

800

900

1000

19 19,8 20 20,2 20,4 20,6 20,8 21 21,2 21,4HP

Rp0

2 [M

Pa]

12CrMo 910 acc. EN10028-2:2003

2¼CrMoV, t/42 ¼ CrMoV, t/23CrMoV, t/43CrMoV, t/212CrMo 910 (2¼CrMo)

CrMoV acc. ASTM Code Cases 2151 and 2098-2



thickness: 200 mmcondition: N+AC+T

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HP

0

50

100

150

200

250

300

350

400

19,00 19,20 19,40 19,60 19,80 20,00 20,20 20,40 20,60 20,80 21,00 21,20 21,40

Cha

rpy-

V-tr

ansv

erse

,A

vm

ean

[J]

2¼CrMoV, t/4

3CrMoV, t/4

12CrMo 910 (2¼CrMo)

test temperature: -60°C

CH-V-results vs HP compared between CrMo and CrMoV steels

thickness: 200 mmcondition: N+AC+T test location: t/4





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4 Forming

3.3. Hot Forming

• to reduce Y.S. for forming( above upper critical temperature Ar3: Y.S. less than 100MPa )

Important:

• to apply appropriate Forming Parameters andPost-Forming Heat Treatment

• to restore the mechanical Properties after Hot Forming

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4. Components made atDillinger Hütte‘s

Heavy Fabrication





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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

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Development of Production Facilitiesfollowing the Capability of the Plate Mill

1960 1965 1970 1975 1980 1985 1990 1995 2000 2005

4300 mm4500 mm

5200 mm

3600 mm

450 MPa

1000 MPa

120 mm

420 mm

12 t

40 t

Plate width

Plate weight

Plate thickness

Yield strength

Dishing2 250 t - press

Blanks < 4 000 mmUnit weight < 12 t

1966Edge-preparingMilling machine19 000 x 63 mm

Unit weight < 25 t

1981Roll-bending

3 500 t - machine4 300 x 100 mm (cold)

Unit weight < 30 t

1983Edge-preparingMilling machine25 000 x 120 mmUnit weight < 40 t

2004Dishing

2 500 t - pressBlanks < 5 600 mmUnit weight < 25 t

1993Roll-bending

8 600 t - machine4 300 x 200 mm (cold)

Unit weight < 80 t

2002

Fit for future





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4.1 Pre-Fabrication Shop

Main Equipment

Edge Milling Machine

Roll Bending Machine

CNC Oxy-Cutting Machine

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Component of a Tool for Manufacturing of Tyres

120 mm in Thickness / 5.200 mm in Diameter

Cut to Shape Plates





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Bearing Device for Cement Mills

220 mm in Thickness / 15 t in Weight

Cut to Shape Plates

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Cut-racks for jack-up rigs





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Cut Racks 7“ thick made of DILLIMAX 690E

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Some Types of Cut Racks 7“ thick ready for Shipment





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Chord for a Jack-Up Rig 2“ thick, 3.5m Length

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Machinery

Stationary Milling Station

Mobile milling station

Spare Profile-Milling Heads

Edge-Milling of Plates

2 milling Stations,each one fitted withone Profile Milling-Head

Power: 180 kW 2 x 90 kW

Principle: high-speed millingLength: 120 mManufacturer: LINSINGER (A)





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• Thickness range: ≤ 120 mm• Width: 1.360 mm to 5.000 mm• Length: 4.300 mm to 25.000 mm• Plate weight: ≤ 40 mt• Output: 150.000 t / a• Tapering: yes• De-cladding: yes• CNC process: yes• Shape profiling: yes

Delivery programmeU-Y combi-edge

U-edge

Double Y-edge

Edge-Milling of Plates

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Working process: sequence 1plate being positioned and clamped on the carrying table

Mobile milling station 1

Stationary milling station 2

Plate

Bot

tom Top

Plate-edge machining





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Working process: sequence 2plate being machined at the top side ( first transverse edge ) by the mobile milling unit 1



Plate

Bot

tom Top


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Working process: sequence 3plate being machined at both longitudinal edges by the milling stations 1 and 2, the carrying table being moved towards



PlateB

otto

m Top






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Working process: sequence 4plate being machined at the bottom side: the mobile milling unit 1 runs along the “second” transverse edge



Plate

Bot

tom Top


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Machining process of an annular plate






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αh

The milling equipment is designed to deal with trapezoidal and annular plates

Shape-profiled plate


Processing requirements:• h ≤ 300 mm and α ≤ 6°• Outskirt of the blank to be flame-cut-to-shape• Every segment edge can be equipped with different edge-

preparation

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Shape profiling

αhh





preparation

α





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hα





preparation

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Roll-Bending of Storage-Tank Plates

To supply Plates with machined Weld-Edge Bevelsroll-bend to Radius-on request protected with a Shop-Primer-shipped ready for use at the Site.

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Com

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for Flat Bottom Tanks

Roll-Bending of Storage-Tank Plates





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2500t Press

2250t Press

4000t Press

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Petals for spherical tanks

Always more than a plate, never more than a part





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Cold Dishing of a spherical Segment (Steel Grade SA537Cl2, 94mm thick) using large Forming Tools

Pressing shop

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Progressive and homogeneous Forming Process (1)

Pressing shop





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Progressive and homogeneous Forming Process (2)

Pressing shop

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Weld Edge Preparation

Pressing shop





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Spherical Segments ready for Dispatch

Pressing shop

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Shipping of spherical Segments at the Dillinger Harbour

Pressing shop





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Erection on Side

Pressing shop

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One-Piece Heads (unwelded)

Hot-Forming of Dished Heads( Heat-Treatment of the Heads after Forming if required )

elliptical heads ID <= 4500mmthickness up to 200m

hemispherical ID <=3700mmthickness up to 200mm

flanged only ID<= 4700mmthickness up to 100mm

Pressing shop





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Forming Die (Shapecorresponding to thetheoretical inside Shapeof the Dished End)

Circular Blank, cut fromthe initial Plate

DrawingRing

-- Sketch Ifirst contact between die and blank on the crown area of thehead (the initial plate thickness in this area remains nearlyunchanged)

Pressing shop

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Pressing shop





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-- Sketch IIwith progressive deep drawing the blank will be streched in theradial direction between drawing ring and die; thethinnest part of a dished end is located approximately in thetransition area between crown and knuckle portion (not in theknuckle area!)

Pressing shop

33





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Pressing shop





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the blank diameter will be reduced to the diameter of the end; thethickness of the blank will increase in the area of the (straight) flangeto about 1.1 x initial plate thickness ( about 1.2 x min. thickness of thedished end )

Pressing shop

34





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Pressing shop





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Hemispherical Head at an intermediate Stage of Hot-Forming

Pressing shop

35





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Hemispherical HeadwhileWater-Quenching

Pressing shop





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Semi-elliptical heads

One-piece design,unwelded,hot pressed• OD ≤ 4.500 mm• Thickness ≤ 200 mm• Weight ≤ 22 t

Traces fromCouplant ofUT ThicknessCheck

Pressing shop

36





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One piece design,unwelded,hot pressed with machined flange area• ID = 4.200 mm• Thickness = 120 mm• Steel Grade P 460 NL1

Pressing shop





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Pressing shop

80 mm Thickness / 4.450 mm Diameter

37





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Hemi-spherical head in one-piece design, seamless: ID 3.520 mm x 70 mm

Pressing shop





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Hemispherical Head 190mm thick cut back for a forged Skirt-RingSteel Grade SA 387-22-2 (N+AC+T)

Pressing shop

38





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Hemispherical Heads ID= 1650mm; smin=170mmPressing shop





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End Dome of ARIANE V Space Rocket Side Booster

39





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Flued out Nozzle section for a storage sphere made of steel grade P460QH





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Flanged only Head with an oval Shape(with a straight Intersection; Steel Grade P460NH)

Pressing shop

40





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Hemispherical Heads made out of TMCP steel (X80 Type) hot formed

Pressing shop





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0

5

10

15

20

0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8Distance from the Cap (centre of the crown) (m)

Col

d D

efor

mat

ion

(%)

Crown

Knuckle

straight flange

Cold Deformation on an elliptical dished Head(ID=2500 mm; S=12 mm; h1=55 mm)(CETIM Inf. No. 133, 4.1998; page 15 to 34)

Some Aspects on Forming of HeadsForming of Heads

41





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Max. Deformation evaluated on different types and dimension of dished headsType of Dimension maximum Deformation (%)

Dished Head measured calculated per ASME VIII-1 calculated per EN13445-4 75t/Rf (1-Rf/Ro) ln(Df/De)x100

mm % % %

elliptical ID1500x11 23.0 3.0 23.0ID1600x16 26.0 4.0 23.0

hemispherical ID 508x10 45.0 3.0 45,0ID 455x50 55.0 16.5 52.5

dollar plate/ ID1735x16 3.5 0.7 3.0spherical crown ID1300x10 12.0 1.0 14.5

torispherical ID1600x16 13.0 7.5 18.0ID1900x8 16.5 3.0 17.0

(Cortin, Marez, Rigal: Chaudronnerie-Tolerie-Tuyauterie Industrielle, Feb. 1991)

Forming of Heads





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Max. cold Deformation (%) on dished Heads in relation to Diameter and Hight of the straight Flange( CETIM Inf. No. 133, 4.1998; page 15 to 34)

h1 Hight of thestraight Flange

Forming of Heads

42





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A Cack occured while the Cold-Flanging of this Head

Forming of Heads





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Thermal Buffer

Rolling direction

Test piece removed from material allowance at the skirt area

Process control: check of mechanical properties

Testing of Heads

43





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Removal of Production Test Pieces

Tested Area

Testing of Heads





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Tested area

Tested area

Testing of Heads

44





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Hemispherical HeadsID=3000mm; smin=84mmSteel Grade SA 542 D 4a

LT-HP 20,8

509 513 525 539 530 541 508 531634 634 640 655 653 657 634 652

0

100

200

300

400

500

600

700

plate 1 plate 2 plate 3 plate 4 head 1 head 2 head 3 head 4

Rp0,2 (MPA) Rm (MPA)

HP 21,2

476 468 488 482 475 486 464 486

610 599 610 608 612 618 602 617

0

100

200

300

400

500

600

700

plate 1 plate 2 plate 3 plate 4 head 1 head 2 head 3 head 4

Rp0,2 (MPA) Rm (MPA)

Yiel

d/ T

ensi

leSt

reng

th (M

Pa)





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Hemispherical HeadsID=3000mm; smin=84mmSteel Grade SA 542 D 4a

45





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Hemispherical HeadID=3009mm; smin=93mmSteel Grade SA 542 D 4a

Belleli 105,1 mm

538 559 532 515 485 477

668 647 631 606 601658

0100200300400500600700800

plate petal 1 plate petal 1 plate petal 1

20,5 20,8 21,1

Rp0,2 Rm

Headhead

Head Head





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Head

Hemispherical HeadID=3009mm; smin=93mmSteel Grade SA 542 D 4a

Step-Cooling Test

46





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Multi-Segment Dished Heads

To improve the Fabrication of Dished Heads to largerDiameter and/or Wall Thickness.

Pressing shop





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PP-Reactor

Transition pieces

Cones

Heads

Always more than a plate, never more than a part

47





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Multisegment Headmade out in Crown and Petals

Pressing shop





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Welding of a Multi-Segment Hemispherical Head

48





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Multi-Segment Hemispherical Heads IR=1800mm, t=145mm

Steel GradeSA542D4a(CrMoV)

Weld EdgePreparationby Oxy-Cutting

Pressing shop





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Segments withnarrow-gapWeld-EdgePreparation

Multi-Segment Hemispherical Heads IR=1800mm, t=145mm

Steel GradeSA542D4a(CrMoV)

Pressing shop

49





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Multi-Segment Heads made of Steel Grade SA 542 D 4aID=4066mm; smin=52mm

Winkels-HP 20,8

552 532 524 519 503 529 515

678 651 645 639 629 650 637

0

100

200

300

400

500

600

700

800

plate 1 petal 1 petal 2 petal 3 petal 4 petal 5 petal 6

Rp0,2 Rm

Winkels-HP 21,1

512 502 498 486 480 486 487

645 630 621 619 608 613 616

0

100

200

300

400

500

600

700

800


Rp0,2 Rm

Winkels-HP 20,8

544487 514 524 493 499 514

675 622 642 651 625 631 640

0

100

200

300

400

500

600

700

800


Rp0,2 Rm

Winkels-HP 21,1

489 480 498 496 479 477 490

633 619 633 632 616

477

625

0

100

200

300

400

500

600

700

800


Rp0,2 Rm

Yiel

d/ T

ensi

leSt

reng

th (M

Pa)

Petals





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Winkels-HP 20,8

546 522 511

676 649 638

0

100

200

300

400

500

600

700

800

plate 1 crown-plate 1

crown-plate 2

Rp0,2 Rm

Winkels-HP 21,1

487 487 483

629 622 616

0

100

200

300

400

500

600

700

800

plate 1 crown-plate 1

crown-plate 2

Rp0,2 Rm

Yiel

d/ T

ensi

leSt

reng

th (M

Pa)

Multi-Segment Heads made of Steel Grade SA 542 D 4aID=4066mm; smin=52mm

Crown Plates

50





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Taylor made Pressings

Forming (hot or cold) of heavy Plate Segments following theDesign of the Vessel Manufacturer

Pressing shop





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Some Hemispherical Heads and a Cone whileTrial Assembling

51





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Some Types ofTori-Cones





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Top of a Cowper made out of SegmentsSteel Grade 16Mo3 (SA 302 Gr B)

52





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Manufacturer: SCHIESS FRORIEP

High-efficient NC-driven equipmentsuitable for the workpiece format:- Diameter ≤ 6.000 mm- Height ≤ 2.650 mm- Weight ≤ 60 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

Machining shop

Machinery: 60 t vertical lathe





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Machining of a circular Blank for Tube Sheet

Machining shop

MechanicalTesting ofInitial PlateconsideringASMERequirements

53





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Machining of a 56t forged Shell (Manufacturer: SAARSCHMIEDE)

Machining shop





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Weld-edge preparation and tapering of a flat head into a ladle bottom

Machining shop

Before Machining After Machining

54





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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

Machining shop





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3.3 Roll-Bending and Welding Shop

55





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Roll-Bending and Welding of Shell Courses

Heavy Wall Shell Courses made out ofHeavy Platesan Alternative to Forgings

Roll-Bending and Welding Shop





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4,3m 4 Roller Roll-Bending Machine (2002)

Manufacturer: Haeusler860 to Weight

3 inter-changeable Top Roller

880mm; 1200mm; 1500mm Diameter

Acceptance Test in our Work-ShopCold-Rolling of a Shell-CourseID=2000mm; 4,3m Length, 120mm Thick

Actual Yield Strength 700MPa


56





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240mm thick Shell Plate for a Boiler Drum while Cold-RollingSteel Grade SA516-70

ID = 3517mmL = 2400mmWeight: 54to






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Cold Rolling of a Shell CourseID=7032mmThickness=142mm

Steel Type SA 533 Type B Class 2 (Q+T)made of 2 Shell Platesfor a GTL Reactor


57





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Shell Course ID=7032mm; Thickness = 142mm





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Cold Forming of a Welded Plate

Steel Grade SA 516 Grade 70Wall 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)

58





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SA 516 Grade 70 - Welding of the Plate Material





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3 Tests for Cold Rolling:

3% strain: Rf = 1917mm5% strain: Rf = 1150mm7% strain: Rf = 821mm

⎟⎟⎠

⎞⎜⎜⎝

⎛−⋅

⋅=

0

150%RR

RtStrain f

f

Rf = main radius after formingRo = original mean radius (equal to infinity for a

flat plate)t = normal thickness of plate = 115mm

direction of testspecimen: tangential to the shell sectiondirectiontesting condition:- without PWHT- PWHT 610+/-10°C, 160 Min.- PWHT 610+/-10°C, 640 Min.

( = 4 cycles)

Weld Seam

59





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Base Metal





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Yield Strength – 3% - 5% - 7% Cold Deformation3% Cold Deformation Formed Section

200

250

300

350

400

450

500

Inside/Top t/4 t/2 3/4t Outside/Bottom

Location

Yiel

d St

reng

th (M

Pa)

7% Cold Deformation Formed Section

200

250

300

350

400

450

500


Yiel

d St

reng

th (M

Pa)


200

250

300

350

400

450

500


Location

Yiel

d St

reng

th (M

Pa)

FS, without PWHT FS,PWHT 160min FS,PWHT 640min

60





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500510520530540550560570580590600


Location

Tens

ile S

tren

gth

(MPa

)

FS, without PWHT FS,PWHT 160min FS,PWHT 640min

Tensile Strength – 3% -5% -7% Cold Deformation


500510520530540550560570580590600


Location

Tens

ile S

tren

gth

(MPa

)


500510520530540550560570580590600


Location

Tens

ile S

tren

gth

(MPa

)

3% Cold Deformation 5% Cold Deformation

7% Cold Deformation





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25

27

29

31

33

35

37

39


Location

Elon

gatio

n A

5 (%

)

FS, without PWHT FS,PWHT 160min FS,PWHT 640min7% Cold Deformation Formed Section

25

27

29

31

33

35

37

39


Location

Elon

gatio

n A

5 (%

)

3% Cold deformation Formed Section

25

27

29

31

33

35

37

39


Location

Elon

gatio

n A

5 (%

)

Elongation A5 – 3% -5% -7% Cold Deformation

3% Cold Deformation 5% Cold Deformation

7% Cold Deformation

61





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3% Cold Deformation, Formed Section, without PWHT

0

20

40

60

80

100

120

140

160

180

200

220

240

-80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40

Temperatur [°C]

Av [J

]

Tope/4e/23e/4Bottom

3% Cold Deformation, Formed Section, PWHT = 600 °C/160'

0

20

40

60

80

100

120

140

160

180

200

220

240

-80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40

Temperatur [°C]

Av

[J]

Tope/4e/23e/4Bottom


0

20

40

60

80

100

120

140

160

180

200

220

240

-80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40

Temperatur [°C]

Av [J

]

Tope/4e/23e/4Bottom

3% Cold Deformation, Formed SectionWithout PWHT

3% Cold Deformation, Formed SectionPWHT 600°C / 160 Minutes






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0

20

40

60

80

100

120

140

160

180

200

220

240

-80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40

Temperatur [°C]

Av

[J]

Top


0

20

40

60

80

100

120

140

160

180

200

220

240

-80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40

Temperatur [°C]

Av [J

]

Tope/4e/23e/4Bottom


0

20

40

60

80

100

120

140

160

180

200

220

240

-80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40

Temperatur [°C]

Av

[J]

Top


5% Cold Deformation, Formed SectionWithout PWHT


62





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0

20

40

60

80

100

120

140

160

180

200

220

240

-80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40

Temperatur [°C]

Av

[J]

Tope/4e/23e/4Bottom


0

20

40

60

80

100

120

140

160

180

200

220

240

-80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40

Temperatur [°C]

Av [J

]

Tope/4e/23e/4Bottom


0

20

40

60

80

100

120

140

160

180

200

220

240

-80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40

Temperatur [°C]

Av [J

]

Tope/4e/23e/4Bottom

7% Cold Deformation, Formed Section,PWHT 600°C / 640 Minutes

7% Cold Deformation, Formed Section,PWHT 600°C / 160 Minutes

7% Cold Deformation, Formed Section,Without PWHT





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Weld Seam

63





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0

50

100

150

200250

300350

400450

-80 -60 -40 -20 0 20

Test Temperature [ °C]

Av

aver

age

[J]

WM ,inside, without PWHT cyclesWM ,quater thickness inside, without PWHT cyclesWM ,half thickness, without PWHT cyclesWM ,quater thickness outside, without PWHT cyclesWM ,outside, without PWHT cycles

050

100150200250300350400450

-80 -60 -40 -20 0 20


Av a

vera

ge [

J]

WM ,inside, 1 PWHT cyclesWM ,quater thickness inside, 1 PWHT cyclesWM ,half thickness, 1 PWHT cyclesWM ,quater thickness outside, 1 PWHT cyclesWM ,outside, 1 PWHT cycles

050

100150200250300350400450

-80 -60 -40 -20 0 20Test Temperature [ °C]

Av

aver

age

[J]

WM ,inside, 4 PWHT cyclesWM ,quater thickness inside, 4 PWHT cyclesWM ,half thickness, 4 PWHT cyclesWM ,quater thickness outside, 4 PWHT cyclesWM ,outside, 4 PWHT cycles 3% Cold Deformation

Impact Test Weld Metal





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050

100150200250300350400450

-80 -60 -40 -20 0 20


Av a

vera

ge [

J]


050

100150200250300350400450


Av

aver

age

[J]


050

100150200250300350400450

-80 -60 -40 -20 0 20


Av

aver

age

[J]


5 % Cold DeformationImpact Test Weld Metal

64





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050

100150200250300350400450

-80 -60 -40 -20 0 20


Av

aver

age

[J]


050

100150200250300350400450

-80 -60 -40 -20 0 20


Av a

vera

ge [

J]


050

100150200250300350400450

-80 -60 -40 -20 0 20


Av

aver

age

[J]


7 % Cold DeformationImpact Test Weld Metal





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050

100150

200250

300

350

400

450

-80 -60 -40 -20 0 20


Av

aver

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[J]


050

100150200250300350400450

-80 -60 -40 -20 0 20


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ge [

J]


050

100150200250300350400450

-80 -60 -40 -20 0 20


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J]

WM ,inside, without PWHT cyclesWM ,quater thickness inside, without PWHT cyclesWM ,half thickness, without PWHT cyclesWM ,quater thickness outside, without PWHT cyclesWM ,outside, without PWHT cyclesWeld Metal

Cold FormedWithout PWHT

Impact Test

3% Cold Formed

7% Cold Formed

5% Cold Formed

65





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100150200250300350400450

-80 -60 -40 -20 0 20


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ge [

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HAZ ,inside, without PWHT cyclesHAZ ,quater thickness inside, without PWHT cyclesHAZ ,half thickness, without PWHT cyclesHAZ ,quater thickness outside, without PWHT cyclesHAZ ,outside, without PWHT cycles

050

100150200250300350400450

-80 -60 -40 -20 0 20


Av

aver

age

[J]

HAZ ,inside, 1 PWHT cyclesHAZ ,quater thickness inside, 1 PWHT cyclesHAZ ,half thickness, 1 PWHT cyclesHAZ ,quater thickness outside, 1 PWHT cyclesHAZ ,outside, 1 PWHT cycles

050

100150200250300350400450

-80 -60 -40 -20 0 20


Av

aver

age

[J]


3% Cold DeformationImpact Test HAZ





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050

100150200250300350400450

-80 -60 -40 -20 0 20


Av a

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ge [

J]


050

100150200250300350400450

-80 -60 -40 -20 0 20


Av

aver

age

[J]


0

50

100

150

200

250

300

350

400

450

-80 -60 -40 -20 0 20


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J]


5 % Cold DeformationImpact Test HAZ

66





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050

100150200250300350400450

-80 -60 -40 -20 0 20


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050

100150200250300350400450

-80 -60 -40 -20 0 20


Av

aver

age

[J]


050

100150200250300350400450


Av

aver

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[J]

HAZ ,inside, 4 PWHT cyclesHAZ ,quater thickness inside, 4 PWHT cyclesHAZ ,half thickness, 4 PWHT cyclesHAZ ,quater thickness outside, 4 PWHT cyclesHAZ ,outside, 4 PWHT cycles 7 % Cold Deformation

Impact Test HAZ





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050

100150200250300350400450

-80 -60 -40 -20 0 20


Av

aver

age

[J]


050

100150200250300350400450

-80 -60 -40 -20 0 20


Av

aver

age

[J]


050

100150200250300350400450

-80 -60 -40 -20 0 20


Av

aver

age

[J]


HAZCold FormedWithout PWHT

Impact Test

3% Cold Formed 5% Cold Formed

7% Cold Formed

67





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Preparation of the longitudinal joint by milling: U-groove being milled

Profile-milling head


68





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Typical weld edge-preparation of the longitudinal joint

No scale

Inside

Outside

Shel

l thi

ckne

ss T

α ≅ 40 °

h ≥ 40 mm (T - H)G

rove

H ≤

165

mm

β ≅ 18 °

U-grove

Ri = 7 mm

Cylindrical shell-courses






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SAW Narrow Gap Welding Equipment for 1 to 3 Electrodes


69





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Grinding flush of theWeld Reinforcementusing a Farros Blatter Grinding Machine





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Shell Course Welding from Inside


70





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Cold-forming process

Shell-course fitted with 2 longitudinal weld-joints

Insider Diameter = 3.517 mm

Thickness = 240 mm

Length = 2.400 mm

Weight = 54 t

SA 516 grade 70 N






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Heating for Water-Quenching of a Shell Course 200mm thickDesign Code AD2000

Steel Grade 12CrMo9-10 (SA 387-22-2) Q+T

71





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Options for Water quenching of a Shell-Course(Shell Axis either vertical or horizontal)






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ID = 5.334 mm x 197mm x 2.600mm, cold-formed, SA516 Gr 70, unit weight ca. 39 t

Cylindrical Shell in Halve Section


72





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Halve-Shell, warm rolled from ISR TemperatureSteel Grade SA 542 D 4a





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Shell Course made of 2 Halves Cold Rolled, Tack-Welded and Braced

Steel GradeS460Q

for an Off-ShoreRigg


73





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Shell-Course Di=1430mm; smin=104mm; L=3500mm;Unit Weight 14,5to; Steel Grade P500QL2

for a SeparatorDesign Code PD5500

Impact Test Temp. -50°C





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PD 5500

Cold Deformation in the present case; 6,8%.

Considering the Shift of the Impact Test Transition Curveafter cold Forming a subsequent Water-Quenching has beenapplied..

74





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WPS for the temporary Welding of the Long-Seam forWater-Quenching





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Shell-Course and Test Plates beforeWater-Quenching

75





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Water-Quenching of the Shell-Course





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WPS for Removal of the temporary Weld Metal andfinal Welding of the Weld-Seam

76





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Hardness Test Of

Weld Seams

Influence of the Test Methodon Test Results in theHeat Affected Zone





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Hardness Test OfWeld Seams

77





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Hardness Test OfWeld Seams





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Influence of Test Method on the Test Result ofHardness Testing in the HAZ

Steel Grade P460NIndentation # Test

Method

Diagonal respDiameter ofIndentation

mm

78





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Diameter of theindentation

Steel Type: SA 533 B 2 ; as welded (Stud Weld)

Influence of Test Method on the Test Result ofHardness Testing in the HAZ





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Excerpt from EXXON BP 5-1-1Hardness Test OfWeld Seams

79





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Calculation of Welding Parameters: Ceq

Analysis of SA 516 Gr 70

Please see: www.heavyplate.com „Steel-Processing“





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Analysis ofSA 516 Gr 70ASME II-A, Ed 2007Mn <=1,60%

Calculation of Welding Parameters: Ceq

80





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Calculation of Welding Parameters: Pre-Heat Temp.T8/5





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SAW 1 Wire 4mmFilling Passes

Calculation of Welding Parameters: Pre-Heat Temp.Cooling Time

81





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Maximum Hardness Values as per EN 288-3





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Calculation of Welding Parameters: HardnessInfluence of a PWHT

t8/5 for some WeldingProcesses:TIG 3.5secGTAW 3-12secSMAW 5-12secSAW 10-40secESW >50sec

82





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Advantages of DILLINGER HÜTTE GTS

withHEAVY FABRICATION

• efficient heavy Plate Manufacturer ( Quality Program,Dimensions, complementary Services )

• compentent Partners in one Company at your Disposal forall your Questions about Heavy Plates and their Processingprepared to follow the expectations of our customers

4. Conclusion





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Many Thanks for your Attention !

fabrication of components at dillinger huette heavy fabrication · 2015. 12. 10. · 2 service...

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