Brochure Head&Cones E

Heads and conesShell plates, heads and cones from one source

voestalpine Grobblech GmbH

www.voestalpine.com/grobblech

2

3Shell plates, heads and cones from one source

Customer benefits of a package supplierAdvantages 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

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Our strengthsvoestalpine Grobblech is the worlds only pro-

ducer 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.

5Typical 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

6Single-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.

7Clad 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.

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.

8Yield Tensile

strength strength

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

Steel grade Standard T=20C T=20C

P460 NL2 mod. VdTV 531 460 630 - 725

Heads and shell plates for LPG tank wagons

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

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 heads

Thickness 7 - 20 mm

Diameter 1,500 - 3,500 mm*

*alternative dimensions on request

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 berwachungs-

vereine (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.

Quality assurance

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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10

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 treatmentHeat 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 weldingEdges 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 headsThe 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 headsAll 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 10025-2S275 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 10025-3S355N, 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 Standard Steel grade

Non alloyedP235, 265, 295, 355GH

and alloyed EN 10028-216Mo3, 20MnMoNi4-5

creep resistant steels13CrMo4-5, 10CrMo9-10

13CrMoV9-10

Fine grain steelsP275 NH, NL1, NL2

for pressure vesselsEN 10028-3 P355 NH, NL1, NL2

P460 NH, NL1, NL2

12Ni14

Ni-alloyed steels EN 10028-4X12Ni5

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 materialsWe offer the same steel grades as for heads and

cones of carbon steels (see pages 13 and 14).

Alternative base materials on request.

Stainless steels and heat-resistant steels

Special steels, non-ferrous metals and alloys

CladdingsWe offer ferritic and austenitic stainless steels,

nickel and nickel-based alloys, copper and

copper-nickel-alloys as well as titanium as

cladding materials.

Standard

EN material

numberGrade

Comparable ASTM A240

/ ASME SA240 type

EN

10088

1.4000 X6Cr13 410S

1.4301 X5CrNi18-10 304

1.4306 X2CrNi19-11 304L

1.4541 X6CrNiTi18-10 321

1.4550 X6CrNiNb18-10 347

1.4401 X5CrNiMo17-12- 2 316

1.4404 X2CrNiMo17-12-2 316L

1.4571 X6CrNiMoTi17-12-2 316Ti

1.4432 X2CrNiMo18-14-3 316L Mod Mo>2.5

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

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

1.4438 X2CrNiMo18-15-4 317L

1.4439 X2CrNiMoN17-13-5 317LMN

SEW 470 1.4828 X 15 CrNiSi 20 12

ASTM Type

Comparable grades

EN material

numberEN / DIN / SEW

B 409 UNS N08800 Alloy 800 1.4876 SEW 470

B 625 UNS N08904 Alloy 904 L 1.4539

EN 10088B 709 UNS N08028 Alloy 28 1.4563

B 625 UNS N08926 Alloy 926 1.4529

B 463 UNS N08020 Alloy 20 2.4660 DIN 17744

B 424 UNS N08825 Alloy 825 2.4858 DIN 17744

B 443 UNS N06625 Alloy 625 2.4856 DIN 17744

B 575 UNS N06022 Alloy C 22 2.4602 DIN 17744

B 575 UNS N06455 Alloy C 4 2.4610 DIN 17744

B 575 UNS N10276 Alloy C 276 2.4819 DIN 17744

B 575 UNS N06059 Alloy 59 2.4605 DIN 17744

B 333 UNS N10665 Alloy B 2 2.4617 DIN 17744

B 168 UNS N06600 Alloy 600 2.4816 DIN 17742

B 127 UNS N04400 Alloy 400 2.4360 DIN 17743

B 162 UNS N02200 Alloy 200 2.4066

DIN 17740

B 162 UNS N02201 Alloy 201 2.4068

2.0070 DIN 1787

B 152 UNS C12200 CW 024 A

EN 1652B 171 UNS C70600 Alloy CuNi 90/10 CW 352 H

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

B 265 Grade 1 Titanium Grade 1 3.7025

DIN 17850

B 265 Grade 2 Titanium Grade 2 3.7035

35,000 kN Press Dishing press

Flanging machine

HeadsHeads and cones

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

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

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

*from 3,400 - 3,700 mm with weld seam

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

*from 3,400 - 6,500 mm with weld seam

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

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Forming processes

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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

Korbbogenbden (DIN 28013)

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

Klpperbden (DIN 28011)

Hemispherical heads 3,000 / 160

Halbkugelbden

Standard-type dished heads 6,500 / 65

Normalgewlbte Bden

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

Flachbden

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

Gewlbte 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

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.

max. diameter / max. thickness [mm]

pressed

Torispherical heads (ASME) 10,000 / 160

Klpperbden (DIN 28011)

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

Korbbogenbden (DIN 28013)

Hemispherical heads 10,000 / 160

Halbkugelbden

Cones 10,000 / 160

Kegel

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Dimensions

Outer diameter [mm]

Wall

thic

kness [

mm

]

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

Hot- or cold-pressed

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

Dished and flanged:s = 5 - 65 mm 1,500 - 6,500 mm

Outer diameter [mm]

Wall

thic

kness [

mm

]

Single-piece heads and cones

Multi-piece heads and cones

min. max. min. max. min. max.

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Delivery program

Hot- and cold-pressed heads; crowns and segments

Outer diameter [mm]Wall thickness [mm]

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

Hemispherical heads

Semi-elliptical heads (ASME 2:1)Torispherical heads (ASME)Standard-type dished headsElliptical heads 1.9:1 (NFE)

Flat heads

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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Flat heads

Semi-elliptical heads (ASME 2:1)Torispherical heads (ASME)Standard-type dished headsElliptical heads 1.9:1 (NFE)

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

Wall thickness [mm]

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.

Dished and flanged heads

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Da

Di

ri

Hi

h

s

Semi-elliptical heads (2:1)elliptical heads (1.9:1)Di inner diameter orDa outer diameterRi inner radius unless ri knuckle radius standardized s nominal or minimum wall thickness Hi inner heighth flange heightedge design

Dk

ri

Di

Da

Hi

h

s

ri

s

Hi

h

DiDa

Dk

ri

DiDa

s

Hi

h

ri

Da

Di

Ri

h

Hi

s

D

s

ri

s

DaDi

hHi

Semi-elliptical heads (multi-piece, 2:1)elliptical heads (1.9:1)Di inner diameter orDa outer diameterRi crown radius unlessri knuckle radius standardizedH inner heighth flange heightDk crown diameter + number of segmentsedge design (segments, crown, wall)

Torispherical heads Di inner diameter orDa outer diameterRi inner radius unlessri knuckle radius standardizeds nominal or minimum wall thicknessH inner heighth flange heightedge design

Standard-type dished headsDi inner diameter orDa outer diameterRi inner radius unlessri knuckle radius standardizeds nominal or minimum wall thicknessHi inner heighth flange height

Dished discsD diameterRi inner radiuss nominal or minimum wall thicknessedge design

Flat headsDi inner diameter orDa outer diameterri knuckle radiuss nominal or minimum wall thicknessHi flange height + radiusedge design

Torispherical heads (multi-piece)Di inner diameter orDa outer diameterRi crown radius unlessri knuckle radius standardizeds nominal or minimum wall thicknessHi inner heighth flange heightDk crown diameter + number of segmentsedge design (segments, crown, wall)

Head geometry

The following data describe the head geometry and are required in the customer order.

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Hemispherical headsDi inner diameter orDa outer diameterRi inner radius = His nominal or minimum wall thicknessedge design

s

Ri

DiDa

Hi

s

Ri

Di

Da

Hi

h

s

Ri

Di

Hi

h

Hemispherical heads with negative flangeDi inner diameter orDa outer diameters nominal or minimum wall thicknessHi radius flangeh negative flangeedge design

s

Ri

DiDa

Dk

s

D2

D1

r 1

r 2

h 2

h 1

s H

Hemispherical heads (multi-piece)Di inner diameter orDa outer diameterRi inner radius s nominal or minimum wall thicknessDk crown diameter + number of petalsedge design (petals, crown, flange)design with negative flange is also possible

ConesD1 diameterD2 diameterr1 knuckle radiusr2 knuckle radiusH heights nominal or minimum wall thicknessh1 flange heighth2 flange height angleedge design

Hemispherical heads with cylindrical flange Di inner diameter orDa outer diameterRi inner radius s nominal or minimum wall thicknessHi inner height (radius + flange height)h flange heightedge design

Tolerances

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

Diameter1) 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

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

max. 38 mm max. 38 mm

Shapeacc. 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

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

max. 30 mm max. 30 mm

Flatnessvoestalpine standard for flat heads

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

root radius for U/DU groove3) 1 mm

strip back of cladding

bevel angel (4) 4

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

radius (r) 1.5 mm

depth (x)4) of removal into carbon steel +1/-0 mm

Shape control by automatic laser measurement

1) Alternative dimensions on request

2) Generally the diameter tolerance is measured on

the circumference and calculated as D = U/(D diameter, U circumference)

3) Possible up to diameter of 2,200 mm

4) Our standard is 0.5 mm

clad material

base material

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References

Year Project Destination Product Material

2008 UHDE Sorfert Project Algeria HeadsA 516 Grade70 / A 387 Grade11

Class2 / A 387 Grade22 Class2

2008 INA Refinery Croatia Clad HeadsA 516 Grade70 / A 387 Grade22

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

2007 / 2008 Revap Brasil Heads, multi-piece and clad headsA 516 Grade70 / A 387 Grade11

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 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

27

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For information about welding please choose a Brand

T-PUT welding solutions at its best www.t-put.com

UTPWelding solutions for nickel based alloys and competence in repair & maintenance www.utp.de

SOUDOKAYStrip cladding and cored wire overlaying solutions www.soudokay.com

We are the World of Welding Solutions.

www.boehlerweldinggroup.com

voestalpine Grobblech GmbHvoestalpine-Strae 34020 Linz, AustriaT. +43/50304/15-9260F. +43/50304/[email protected] www.voestalpine.com/grobblech

Janu

ary

2009

Edi

tion

High-quality materials are the basis for our products. We strive to be the best partner forour 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 customersDedication to professionalismReliabilityPartnerships based on trustResponsibility for satisfactory project completion

Technically More Advanced. Successful Together.voestalpine The Partner You Can Trust.