MORE THAN PLATES Prefabricated parts and services for hydropower plants Patrick A. REGNERY Dipl.-Ing., Dipl.-Wirt.-Ing, IWE Heavy Fabrication Division
Content 1. The Heavy Fabrication Division - profile & developments 2. Prefabricated parts and Services - foundry - plate trimming shop (cut-to-shape facility & weld-edge milling machine) - roll bending machine and welding shop - press shop - complementary processing steps and services 3. References 4. Summary 2
Year 1930: Dillinger Hütte - Delivery Programm for welded penstocks 3
History - begining of the 20th century: welded penstocks for power plants e.g. 1898 Salanfe-Wallis, CH / 1912 Leiwen-Dhron, D / 1924 Walchensee, D 4
Heavy Fabrication Division - today Rolling mill Steel plant Sintering plant Coking plant (ZKS) Heavy Fabrication Blast furnaces (ROGESA) 5
Foundry Grey Cast steel: iron: equipment Slag pots up for to the 80 Iron mt piece and Steel weight Industry (up to 45 m 3 ) 6
Product mix of the Heavy Fabriction Division Foundry products Cut-to-shape plates Weld-edged-prepared plates and plates rolled to radius Longitudinally welded shell courses (cold or hot formed) Dished heads (one piece) - hemisperical heads - torisperical & elliptical heads - heads, flanged only Multi-segment sections, also for special application - ready for assembly Welded components 7
Cut-to-shape plates by conventional cutting (ESAB) NC-flame cutting: plates up to 410 x 5400 x 23000 mm; plate weight up to 72 mt 8
Cut-to-shape plates Gear rack: cutting profiled with parts enhanced for jack-up waviness rigs up tolerances 210 mm thickness, S690Q 9
Plate edge milling machine (Linsinger) Mobile Milling Station Spare Profile-Milling Heads Stationary Milling Station 10
Plate edge milling Machine design: Milling Stations: 2, each equipped with one profile-milling head Milling power: 2 x 90 kw (connecting power: 480 kw) Total length: 120 m Principle: high-speed milling Cutting speed: up to 1,000 mm/min depending on plate thickness and weld-edge geometry Plate sizes: Thickness: 120 mm Width: 5,000 mm Length: 25,000 mm Weight: 40 mt 11
Plate-edge milling shape-profiled plates Milling of annular or trapezoidal shaped plates Processing requirements: h 300 mm and 6 Each weld-edge can be machined individually 12
Plate edge milling - tolerance requirements 13
Plate edge milling tolerance requirements Tolerances: macroscopic on the plate and microscopic on the weld-edges 0,5 h 0,5 mm a,5 mm Option: tapering or off-set of cladding 14
Plate edge milling types of joint geometrie U-edge V-U-combi-edge DV-edge 15
Plate edge milling quality control, marking and coating Individual control, marking and coating of the weld-edges 16
Plate edge milling customer oriented fabrication and dispatch Deliveries just-in-time for specific projects 17
Cut-to-shape plates, weld-edge-prepared and formed e.g. for storage tanks or gas carriers 18
Roll bending and welding shop 8,600 mt 4-roll-bending machine 8,600 mt - Four Roller Bending-Machine (installed 2002, by Häusler, CH) Shell course: 7,032mm; thickness 142mm; steel grade: SA 533-B cl. 2 (Q+T) 19
Roll bending and welding shop Cans for the Hydro Electrical Power Plant Vianden, Luuxemburg Thickness: 16 50 mm; 4,500 mm; length: up to 3,000 mm 20
Roll bending and welding shop Cold-rolled Shell course: A516-70; thickness: 240 mm; diameter: 3,500 mm; length: 2,600 mm 21
Roll bending and welding shop Shell course half section: S516-70; thickness: 197 mm (cold rolled!) 22
Welding eqipmment preparation of the longitudinally joint by milling Longitudinally joint preparation of a 240 mm thick shell course 23
Welding equipment Welding processes: SMAW SAW TIG Sub-merged-arc welding with 1, 2 or 3 wires 24
Press shop 2,500 t-hydraulic press and further hydraulic presses 25
Press shop one piece heads Hemispherical Flat dished head, heads flanged (single only piece): (single): up to up to 3.750 Ø 4700 mm mm; and p up to to 100 200 mm thickness 26
Press shop multi-segment sections for special application 27
Press shop - tailor-made sections for special applications Richard Serra, Steel sculpture Canyon 28
Heat treatment of shell courses Shell Water course: quenching 12CrMo9-10 (SA 387-22-2) Q+T ; thickness: 200 mm 29
Heat treatment of heads and/or segments Charging Water quenching of a hemisperical head: 2.985 mm; thickness: 173 mm; unit weight: 26 t 30
Machining Vertical lathe: Diameter: 6,000 mm Height: 2,650 mm Pieces: 60 mt 31
Weld-edge preparation and/or cut-outs Weld-edge preparation by manual oxy-cutting 32
Weld-edge preparation and/or cut-outs Ellipticall Weld-edge cut-out preparation by robot 33
Packages with weld-edge preparation ready for assembly 34
Shipment Transport by lorry waggon 35
Shipment Transport by barge 36
Certification and accreditation ISO 9001: Quality Managememt System EN ISO 14001:2005 Environment OHSAS 18001:1999 HSE ASME Stamps S, U & U2 Manufacturer License PR of China 37
References - Hydro Electrical Power Plants Cut-to-shape ring segments for the HEPP Rio Madeira and Jirau, Brasil: S355J0+N; thickness 305 150 mm; unit weight 21 19 mt 38
References - Hydro Electrical Power Plants Source: photo with kindly permission of Voith Siemens Hydro Shell course half sections for the HEPP Rio Madeira and Jirau, Brasil 39
References - Hydro Electrical Power Plants Components for the river-run power plants Rio Madeira & Jirau, Brasil Bulb nose: 9.692 mm; thickness: 25 mm thick 40
Our philosophy Plate customers can take advantage of our complementary expertise and comprehensive service Under our guiding motto More than just plates! => Packages out of one source! 41
We are constantly investing in our high-skilled labour and state-of-the-art technology, in order to be able to provide you with The Dillinger Heavy Fabrication Division a wide range of added-value parts, not just plates unique products - going even beyond today s requirements comprehensive services By providing valuable support with our expertise, our aim is to enable you to focus on your core business your partner dedicated to the Hydro Power Industry ready for challenging projects! to enhance your productivity respectively your capacity 42
The Heavy Fabrication Division - your partner - dedicated to the offshore wind power industry ready for challenging projects! Thank you for your attention. 43