Heads and cones. Shell plates, heads and cones from one source. voestalpine Grobblech GmbH

Transcription

1 Heads and cones Shell plates, heads and cones from one source voestalpine Grobblech GmbH

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3 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 3

4 The market Our strengths voestalpine Grobblech is the world s only producer of carbon steel, low-alloyed steel and clad plates with integrated production of heads and cones. We supply shell plates, heads and cones for boiler and pressure vessel manufacture from a single source. Heads and cones can be processed of carbon steel, low-alloyed steel or clad plates. 4

5 Typical fields of application We deliver heads and cones to the following industries: oil and gas industry refineries chemical industry petrochemical industry transport industry power plants energy industry Our heads and cones are used in: coke drums reactors heat exchangers separators columns compressors storage tanks special tank wagons 5

6 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. 6

7 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 Thickness Alternative dimensions on request. max. 10,000 mm max. 160 mm 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 Thickness Alternative dimensions on request. max. 10,000 mm max. 120 mm 7

8 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 Width Length Weight per plate 7-20 mm 1,500-3,800 mm* max. 18,000 mm max mt *alternative dimensions on request Dimensions for heads Thickness Diameter 7-20 mm 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

9 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 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 Überwachungsvereine (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 technical 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 production 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. 9

10 Production of heads «Hydraulic press with a press force of 3,500 mt «Walking beam furnace 10

11 Dishing press» Flanging machine» 11

12 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 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. 12

13 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 Unalloyed structural steels EN S275 JR+AR, JR+N, J0+AR, J0+N, J2+AR, J2+N S355 JR+AR, JR+N, J0+AR, J0+N, J2+AR, J2+N K2+AR, K2+N S275N, NL Fine-grain steels, normalizing rolled, normalized (furnace) EN S355N, NL 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 upon request. 13

14 Pressure vessel steels Steel group Standard Steel grade P235, 265, 295, 355GH Non alloyed 16Mo3, 20MnMoNi4-5 and alloyed EN creep resistant steels 13CrMo4-5, 10CrMo CrMoV9-10 P275 NH, NL1, NL2 Fine grain steels for pressure vessels EN P355 NH, NL1, NL2 P460 NH, NL1, NL2 12Ni14 Ni-alloyed steels EN X12Ni5 X7Ni9 X8Ni9 (S)A 203 Grade D, E (S)A 387 Grade11 Class2 (S)A 387 Grade12 Class2 Steels for pressure vessels ASTM / ASME (S)A 387 Grade22 Class2 (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). 14

15 Materials for clad heads and cones Clad heads and cones are made of roll-bonded clad plates made by voestalpine Grobblech. Base materials We offer the same steel grades as for heads and cones of carbon steels (see pages 13 and 14). Alternative base materials on request. Claddings We offer ferritic and austenitic stainless steels, nickel and nickel-based alloys, copper and copper-nickel-alloys as well as titanium as cladding materials. Stainless steels and heat-resistant steels Special steels, non-ferrous metals and alloys Comparable grades ASTM Type EN material number EN / DIN / SEW Standard EN material number Grade Comparable ASTM A240 / ASME SA240 type B 409 UNS N08800 Alloy SEW 470 B 625 UNS N08904 Alloy 904 L B 709 UNS N08028 Alloy EN X6Cr13 410S B 625 UNS N08926 Alloy X5CrNi B 463 UNS N08020 Alloy DIN B 424 UNS N08825 Alloy DIN X2CrNi L B 443 UNS N06625 Alloy DIN X6CrNiTi B 575 UNS N06022 Alloy C DIN X6CrNiNb B 575 UNS N06455 Alloy C DIN B 575 UNS N10276 Alloy C DIN X5CrNiMo B 575 UNS N06059 Alloy DIN EN X2CrNiMo L X6CrNiMoTi Ti B 333 UNS N10665 Alloy B DIN B 168 UNS N06600 Alloy DIN B 127 UNS N04400 Alloy DIN X2CrNiMo L Mod Mo> X3CrNiMo L Mod Mo>2.5 B 162 UNS N02200 Alloy B 162 UNS N02201 Alloy DIN DIN X2CrNiMoN LN Mod Mo>2.5 B 152 UNS C12200 CW 024 A X2CrNiMo L B 171 UNS C70600 Alloy CuNi 90/10 CW 352 H EN X2CrNiMoN LMN SEW X 15 CrNiSi B 171 UNS C71500 Alloy CuNi 70/30 CW 354 H B 265 Grade 1 Titanium Grade B 265 Grade 2 Titanium Grade DIN

16 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 single-piece heads: diameter: max. 3,700 mm* thickness: max. 160 mm Heads single-piece heads: diameter: max. 6,500 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 with weld seam *from 3,400-6,500 mm with weld seam 16

17 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 17

18 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. 18

19 Dimensions Single-piece heads and cones Hot- or cold-pressed: s = mm Ø 1,000 - Ø 3,700 mm Hemispherical heads = Ø 1,000 - Ø 3,000 mm Wall thickness [mm] Dished and flanged: s = 5-65 mm Ø 1,500 - Ø 6,500 mm Outer diameter [mm] Multi-piece heads and cones crowns and segments Hot- or cold-pressed Hemispherical heads Ø 3,000 - Ø 10,000 mm Wall thickness [mm] Semi-elliptical heads, elliptical heads 2:1 / 1.9:1, torispherical heads Ø 3,700 - Ø 10,000 mm Outer diameter [mm] 19

20 Delivery program Hot- and cold-pressed heads; crowns and segments Semi-elliptical heads (ASME 2:1) Torispherical heads (ASME) Standard-type dished heads Elliptical heads 1.9:1 (NFE) Hemispherical heads Flat heads Outer diameter [mm] Wall thickness [mm] min. max. min. max. min. max upon request upon request upon request upon request ) ) ) 3) ) ) 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. 20

21 Dished and flanged heads Semi-elliptical heads (ASME 2:1) Torispherical heads (ASME) Standard-type dished heads Elliptical heads 1.9:1 (NFE) Flat heads Outer diameter [mm] Wall thickness [mm] min. max. min. max Heads with weld seam flange height (h) 150 mm max. 21

22 Head geometry The following data describe the head geometry and are required in the customer order. Hi h Di Da s ri Semi-elliptical heads (2:1) elliptical heads (1.9:1) Di inner diameter or Da outer diameter Ri inner radius unless ri knuckle radius standardized s nominal or minimum wall thickness Hi inner height h flange height edge design Hi h Dk Di Da s ri Semi-elliptical heads (multi-piece, 2:1) elliptical heads (1.9:1) Di inner diameter or Da outer diameter Ri crown radius unless ri knuckle radius standardized H inner height h flange height Dk crown diameter + number of segments edge design (segments, crown, wall) Hi h Di Da s ri Torispherical heads Di inner diameter or Da outer diameter Ri inner radius unless ri knuckle radius standardized s nominal or minimum wall thickness H inner height h flange height edge design Hi h Dk Di Da s ri Torispherical heads (multi-piece) Di inner diameter or Da outer diameter Ri crown radius unless ri knuckle radius standardized s nominal or minimum wall thickness Hi inner height h flange height Dk crown diameter + number of segments edge design (segments, crown, wall) Hi h Di Da Ri s ri Standard-type dished heads Di inner diameter or Da outer diameter Ri inner radius unless ri knuckle radius standardized s nominal or minimum wall thickness Hi inner height h flange height s Dished discs D diameter Ri inner radius s nominal or minimum wall thickness edge design D Hi h Di Da s ri Flat heads Di inner diameter or Da outer diameter ri knuckle radius s nominal or minimum wall thickness Hi flange height + radius edge design 22

23 h 2 H Hi Ri s Hemispherical heads Di inner diameter or Da outer diameter Ri inner radius = Hi s nominal or minimum wall thickness edge design Di Da Hi h Ri s Hemispherical heads with cylindrical flange Di inner diameter or Da outer diameter Ri inner radius s nominal or minimum wall thickness Hi inner height (radius + flange height) h flange height edge design Di Da Hi Ri s Hemispherical heads with negative flange Di inner diameter or Da outer diameter s nominal or minimum wall thickness Hi radius flange h negative flange edge design h Di Dk s Ri s Hemispherical heads (multi-piece) Di inner diameter or Da outer diameter Ri inner radius s nominal or minimum wall thickness Dk crown diameter + number of petals edge design (petals, crown, flange) design with negative flange is also possible Di Da r 1 r 2 D2 D1 s h 1 Cones D1 diameter D2 diameter r1 knuckle radius r2 knuckle radius H height s nominal or minimum wall thickness h1 flange height h2 flange height angle edge design 23

24 Tolerances Single-piece heads and cones Multi-piece heads and cones Diameter 1) 2) acc. to applicable standard acc. to applicable standard voestalpine standard ±0.3 % D voestalpine standard ±0.2 % D acc. to applicable standard acc. to applicable standard Height 1) voestalpine standard +1.5 % D/-0, voestalpine standard +1.5 % D/-0 max. 38 mm max. 38 mm Shape acc. to applicable standard radius deviation of crown and segments special shapes upon request 3 mm/m from the template acc. to applicable standard acc. to applicable standard Ovality 1) voestalpine standard 1 % D, voestalpine standard 1 % D, max. 30 mm max. 30 mm Flatness voestalpine standard for flat heads 3 mm/m deviation from measuring rod Weld gap Edge base material clad material weld gap ±2 mm 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 > mm -0/+2 mm t > 25 mm -0/+3 mm taper angel ( 3) ±3 root radius for U/DU groove 3) ±1 mm strip back of cladding bevel angel ( 4) ±4 depth of preparation (h2) radius (r) depth (x) 4) of removal into carbon steel +2/-0 mm ±1.5 mm +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 24

25 References Year Project Destination Product Material 2008 UHDE Sorfert Project Algeria Heads A 516 Grade70 / A 387 Grade11 Class2 / A 387 Grade22 Class INA Refinery Croatia Clad Heads A 516 Grade70 / A 387 Grade22 Class L / 316 L / 410 S 2008 ALFA LAVAL Saudi Arabia Heads A 387 Grade11 Class Corinth Refinery Greece Multi-piece heads P355 NL Styrenics Italy Heads A 516 Grade Valero - New Orleans USA Heads A 387 Grade22 Class Haldor Topsoe Italy Heads A 387 Grade11 Class Neste Oil Finland Multi-piece heads A 387 Grade22 Class PCS Nitrogen Trinidad Trinidad Multi-piece heads A 387 Grade11 Class ALFA LAVAL Novoil Italy Heads A 387 Grade11 Class Buzzard Enhancement USA Clad heads P355NL2 + Alloy 904L 2007 / 2008 Revap Brasil Heads, multi-piece and clad heads A 516 Grade70 / A 387 Grade11 Class Pearl GTL Qatar Multi-piece heads 20 MnMoNi Pearl GTL Qatar Heads 20 MnMoNi Voyageur Upgrader Canada Clad Heads A 387 Grade12 Class S 2005 Methanol Hainan China Heads A 387 Grade11 Class Kashagan Offshore Oilfield Kazakhstan Heads and clad heads A 516 Grade70 + Alloy Linde BOC Process Plants LLC USA Clad heads A 387 Grade11 Class PTA Aker Kvaerner Mexico Clad heads A 516 Grade L 2004 BAPCO Bahrain Heads A 516 Grade70 25

26 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 26

27 For information about welding please choose a Brand BÖHLER WELDING Welding consumables for high demanding industries T-PUT welding solutions at its best UTP Welding solutions for nickel based alloys and competence in repair & maintenance SOUDOKAY Strip cladding and cored wire overlaying solutions We are the World of Welding Solutions. 27

28 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 highquality 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 Linz, Austria T. +43/50304/ F. +43/50304/ [email protected]