Heads and cones

Shell plates, heads and cones from one source

voestalpine Grobblech GmbH www.voestalpine.com/grobblech

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

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

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

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 Diameter Thickness max. 3,400 mm max. 160 mm flanged max. 3,400 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 Diameter Thickness 3,400 - 3,700 mm max. 160 mm flanged 3,400 - 6,500 mm max. 65 mm

Alternative dimensions on request.

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

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 VdTV 531.

Dimensions for plates

Thickness Width Length Weight per plate 7 - 20 mm 1,500 - 3,800 mm* max. 18,000 mm max. 11.7 mt
*alternative dimensions on request

Dimensions for heads

Thickness Diameter 7 - 20 mm 1,500 - 3,500 mm*
*alternative dimensions on request

Yield strength Rp0,2 min. [MPa] Steel grade P460 NL2 mod. Standard VdTV 531 T=20C 460

Tensile strength Rm [MPa] T=20C 630 - 725

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 berwachungsvereine (VdTV) (Union of Technical Inspection Groups) and by the Technischer berwachungsverein Industrie Service GmbH (=TV-Sd) (former Technical Inspection Group Bavaria): AD-Merkblatt W0 / TRD 100 EG-Druckgerterichtlinie 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.

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 Unalloyed structural steels EN 10025-2 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 10025-3 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 91802 upon request.

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Pressure vessel steels

Steel group Non alloyed and alloyed creep resistant steels EN 10028-2 Standard Steel grade P235, 265, 295, 355GH 16Mo3, 20MnMoNi4-5 13CrMo4-5, 10CrMo9-10 13CrMoV9-10 Fine grain steels for pressure vessels EN 10028-3 P275 NH, NL1, NL2 P355 NH, NL1, NL2 P460 NH, NL1, NL2 12Ni14 Ni-alloyed steels EN 10028-4 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).

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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
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

EN material

ASTM

Type

EN / DIN / SEW number

B 409 UNS N08800

Alloy 800

1.4876

SEW 470

EN material Standard number

Comparable ASTM A240 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 10088
1.4404 X2CrNiMo17-12-2 316L

B 333 UNS N10665

Alloy B 2

2.4617

DIN 17744

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

single-piece heads: diameter: max. 3,700 mm* thickness: max. 160 mm multi-piece heads: diameter: max. 10,000 mm thickness: max. 160 mm

Heads
single-piece heads: diameter: max. 6,500 mm* thickness: max. 65 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

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Shapes of single-piece heads and cones

max. diameter / max. thickness [mm] pressed Semi-elliptical heads (ASME) Korbbogenbden (DIN 28013) 3,700 / 160 flanged 6,500 / 65

Torispherical heads (ASME) Klpperbden (DIN 28011)

3,200 / 160

6,500 / 65

Hemispherical heads Halbkugelbden

3,000 / 160

Standard-type dished heads Normalgewlbte Bden

6,500 / 65

Flat heads Flachbden

3,600 / 80

6,500 / 40

Dished discs / spherical segments Gewlbte Scheiben/Kugelsegmente

4,000 / 160

6,500 / 65

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) Klpperbden (DIN 28011) 10,000 / 160

Semi-elliptical heads (ASME) Korbbogenbden (DIN 28013)

10,000 / 160

Hemispherical heads Halbkugelbden

10,000 / 160

Cones Kegel

10,000 / 160

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 1,000 - 3,700 mm Hemispherical heads = 1,000 - 3,000 mm Dished and flanged: s = 5 - 65 mm 1,500 - 6,500 mm Wall thickness [mm]

Outer diameter [mm]

Multi-piece heads and cones

Hot- or cold-pressed crowns and segments Hemispherical heads 3,000 - 10,000 mm Semi-elliptical heads, elliptical heads 2:1 / 1.9:1, torispherical heads 3,700 - 10,000 mm

Wall thickness [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) Standard-type dished heads Elliptical heads 1.9:1 (NFE) Outer diameter [mm]

Hemispherical heads

Flat heads

Wall thickness [mm] min. upon request 6 6 6 6 6 8 8 8 8 8 8 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 100 100 100 100 100 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 3) 160 160 160 160 160 160 160 160 160 160 160 160 160 2) 160 160 160
1) 3)

max.

min. upon request 10 10 10 10 10 12 12 12 12 12 12 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15

max.

min. upon request

max.

600 - 900 upon request 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 3100 3200 3300 3400 3500 3600 3700 3800 3900 4000 4500 5000 5500 6000 6500 7000 8000 9000 10000

100 100 100 100 100 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 2) 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160

6 6 6 6 6 8 8 8 8 8 8 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

60 60 60 60 60 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80

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

Flat heads

Outer diameter [mm]

Wall thickness [mm] min. max. min. max.

1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 3100 3200 3300 3400 3500 3600 3700 3800 3900 4000 4100 4200 4300 4400 4500 5000 5500 6000 6500 Heads with weld seam flange height (h) 150 mm max.

5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 10 10 10 10 10 10 10 10 10

25 25 25 25 25 25 60 60 60 60 60 60 60 60 60 60 60 60 60 65 65 65 65 65 65 65 65 65 65 65 65 65 65 65 65

5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 10 10 10 10 10 10 10 10 10

25 25 25 25 25 25 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40

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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) 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 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

Di Da

Dk

Hi

ri

Di Da

s
ri

ri
Di Da

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

Hi

Dk

Hi

s
ri

Di Da

Hi

Ri

ri

Di h Da

ri
Di Da

Flat heads Di inner diameter or Da outer diameter ri knuckle radius s nominal or minimum wall thickness Hi flange height + radius edge design

Hi

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

Hi

Ri

Di Da

Ri

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

Hi h

Di Da

Ri
h

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

Hi

Di

Dk

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

Ri

Di Da

D2

r2
h2

r1

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

D1

h1

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Tolerances
Single-piece heads and cones Diameter1) 2) acc. to applicable standard voestalpine standard 0.3 % D acc. to applicable standard Height1) voestalpine standard +1.5 % D/-0, max. 38 mm Shape acc. to applicable standard special shapes upon request acc. to applicable standard Ovality1) voestalpine standard 1 % D, max. 30 mm Flatness Weld gap Edge voestalpine standard for flat heads 3 mm/m deviation from measuring rod weld gap 2 mm tolerances for edge preparation (flame cut & machined) bevel angel (1, 2) depth of preparation (h1) thickness of root face (c) thickness after tapering (t) t > 5 - 10 mm t > 10 - 25 mm t > 25 mm taper angel (3) clad material base material strip back of cladding bevel angel (4) depth of preparation (h2) radius (r) depth (x) of removal into carbon steel
4)

Multi-piece heads and cones acc. to applicable standard voestalpine standard 0.2 % D acc. to applicable standard voestalpine standard +1.5 % D/-0 max. 38 mm radius deviation of crown and segments 3 mm/m from the template acc. to applicable standard voestalpine standard 1 % D, max. 30 mm

2 +2/-0 mm 1 mm -0/+1 mm -0/+2 mm -0/+3 mm 3

3)

root radius for U/DU groove

1 mm

4 +2/-0 mm 1.5 mm +1/-0 mm

1) 2)

Alternative dimensions on request Generally the diameter tolerance is measured on the circumference and calculated as D = U/ (D diameter, U circumference)

3) 4)

Possible up to diameter of 2,200 mm Our standard is 0.5 mm

Shape control by automatic laser measurement

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References

Year
2008

Project
UHDE Sorfert Project

Destination
Algeria

Product
Heads

Material
A 516 Grade70 / A 387 Grade11 Class2 / A 387 Grade22 Class2

2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2007 / 2008 2007 2007 2006 2005 2005 2004 2004 2004

INA Refinery ALFA LAVAL Corinth Refinery Styrenics Valero - New Orleans Haldor Topsoe Neste Oil PCS Nitrogen Trinidad ALFA LAVAL Novoil Buzzard Enhancement Revap Pearl GTL Pearl GTL Voyageur Upgrader Methanol Hainan Kashagan Offshore Oilfield Linde BOC Process Plants LLC PTA Aker Kvaerner BAPCO

Croatia Saudi Arabia Greece Italy USA Italy Finland Trinidad Italy USA Brasil Qatar Qatar Canada China Kazakhstan USA Mexico Bahrain

Clad Heads Heads Multi-piece heads Heads Heads Heads Multi-piece heads Multi-piece heads Heads Clad heads Heads, multi-piece and clad heads Multi-piece heads Heads Clad Heads Heads Heads and clad heads Clad heads Clad heads Heads

A 516 Grade70 / A 387 Grade22 Class2 + 304L / 316 L / 410 S A 387 Grade11 Class2 P355 NL2 A 516 Grade70 A 387 Grade22 Class2 A 387 Grade11 Class2 A 387 Grade22 Class2 A 387 Grade11 Class2 A 387 Grade11 Class2 P355NL2 + Alloy 904L A 516 Grade70 / A 387 Grade11 Class2 + 347 20 MnMoNi 4-5 20 MnMoNi 4-5 A 387 Grade12 Class2 + 410S A 387 Grade11 Class2 A 516 Grade70 + Alloy 825 A 387 Grade11 Class2 A 516 Grade70 + 304L 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 its 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 companys 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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For information about welding please choose a Brand

BHLER WELDING Welding consumables for high demanding industries

www.boehlerwelding.com

T-PUT welding solutions at its best

www.t-put.com

UTP Welding solutions for nickel based alloys and competence in repair & maintenance

www.utp.de

SOUDOKAY Strip cladding and cored wire overlaying solutions

www.soudokay.com

We are the World of Welding Solutions.

27

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-Strae 3 4020 Linz, Austria T. +43/50304/15-9260 F. +43/50304/55-9260 [email protected] www.voestalpine.com/grobblech

January 2009 Edition