CUTTING

&
EDGE PLANNING
PROCEDURE FOR MARKING, CUTTING AND CHECKING OF
SHELL PLATES

SHELL
PLATE
K1

5U
SA 516 GR

9262 /

4 UNITS
70 24357

NI
K2

TS
3

ROLLING DIR.

3 UNITS
L
TOLERANCE
• L - + 1 mm / M, Max. 3 mm., & W - + 1 mm / M, Max. 3 mm
• K1 - K2 = + 1 mm / M, Max. + 5 mm
• IDENTIFICATION MARKING TO ROLLING DIRECTION.
• L - NOMINAL CIRCUMFERENCE = MEAN DIA. X 
 = 3.1415926535897932384626433832792………...
 GENERAL WEP

WHEN JOINING PLATES OF DIFFERENT THICKNESS

T1 T2
FORMING
 ROLLING DEPENDS

Provide necessary allowance ( 1.5 to 2 times the

thickness)
• Gas cut
• Wastage of the material
• increased cycle time
Edge breaking to remove out peak out
Not feasible for all the thickness
Pressure required is more
 ROLLING
THE PROCESS OF STRETCHING BEYOND THE YIELD
POINT OF THE METAL

METHODS
 PINCH ROLLING
 PYRAMID ROLLING
 COLD ROLLING
 WARM ROLLING
 HOT ROLLING
 NORMAL ROLLING
 PINCH ROLLING
 BENDING AT THE PLATE ENDS
 BOTTOM ROLLER SHIFTED FROM CENTRE TO EITHER
LEFT OR RIGHT

 PRESSURE APPLIED > NORMAL ROLLING PRESSURE

 PYRAMID ROLLING
NORMAL ROLLING

TOP
ROLLER

BOTTOM BOTTOM
ROLLER ROLLER
 COLD ROLLING

ROLLING AT NORMAL ROOM TEMPERATURE

WARM ROLLING

PLATE HEATED BELOW ITS CRITICAL TEMPERATURE

BEFORE ROLLING .

WHY?
 PLATE THICKER THAN THE CAPACITY OF THE ROLLING M/C
 PLATE MATERIAL HAS HIGHER YIELD POINT
 HOT ROLLING

PLATE HEATED BEYOND UPPER CRITICAL TEMP.

BEFORE ROLLING .

WHY?
 PLATE THICKER THAN THE CAPACITY OF THE ROLLING M/C

 PLATE MATERIAL HAS HIGHER YIELD POINT

 NORMAL ROLLING

PLATE PLACED BETWEEN TOP AND BOTTOM

ROLLERS AND PRESSURE APPLIED SLOWLY ON
TOP ROLLER TO ROLL THE REQUIRED DIAMETER.
CHECKING SHELL OVALITY AND CIRCUMFERENCE

OVALITY = ID max - ID min

ACTUAL THK.
= 0.5 % of Nominal ID

I/D CHECK IN HP PLANE

D/

P
M
4

TE
TE
M

4
D/
P

PEAK OUT PEAK IN

 TEMPLATES
 TO CHECK THE INSIDE DIAMETER
 MADE OUT OF 3-4MM THICKNESS PLATES
 D/4 TO D/8 TEMPLATES

D/4
 PEAK IN / PEAK OUT

ID Allowed gap
WHY? Pick in /
out
< 152 0.8 MM
OVER / UNDER BENDING DURING < 305 1.2
EDGE BREAKING OPERATION MM <
457 1.6 MM
< 610 2.4
MM <
914 3.2 MM
PRECAUTIONS < 1219
4.0 MM
 PROPER CARE < 1524 4.8
MM <
 RE ROLLING 1905 5.6 MM
< 2133
6.4 MM
 SKEW
 Rollers not aligned

 Plate edges not kept parallel to roller axis plate

diagonals not checked
 SKEW

15 TO 20MM AND LOW THICKNESS

 SKEW
HIGH THICKNESS
 SKEW

TURN BUCKLES
 PRECAUTIONS
 PROPER DEVELOPMENT & MARKING OF CONE

 CHECK THE DIAGONALS

 EDGE BREAKING WITH CARE ( D/4 LENGTH )

 KEEP SUITABLE RADIUS GAUGE (HANDY)

 ENSURE THE GENERATOR LINE OF THE CONE IS

PARALLEL TO THE TOP ROLLER

 TO AVOID FLARE, INCREASE PREISURE SLOWLY

 GOOD ENGINEERING PRACTICES
( FOR ROLLING )

 Check diagonals of the plates to be rolled.

 Stamp identification mark on the outer surface of

the width so that, when the plate is rolled in to a
shell the identification mark can be seen from
outside.

 Identification mark should be stamped parallel to

the width of the plate
 GOOD ENGINEERING PRACTICES
( FOR ROLLING )
 Always pain rolling direction with an arrow on the
plate to be rolled

 Remove burrs, dust, dirt from the edges of the plate

before it is fed in to rolling machine

 While edge breaking a very long plate, hold one

end of such plate with crane while other end is
being edge broken
 While edge breaking a very long plate, hold one end
of such plate with crane while other end is being
edge broken.
 GOOD ENGINEERING PRACTICES
( FOR ROLLING )

 Always refer capacity chart of a particular rolling

machine before attempting any bending/rolling on
that machine
 Check alignment of the rollers, before rolling is
attempted.
 Ensure that required templates are available before
rolling is taken up.
 Before taking up s.s plate for rolling, the rollers
must be thoroughly cleaned with wire brush.
 TOLERANCES ON CIRC. OF SHELLS, D’ENDS , CONES &
BELLOWS

• THE REQUIRED CIRCUMFERENCE SHALL BE COMPUTED

BY THE FOLLOWING METHOD.

REQUIRED CIRCUMFERENCE = ( ID + 2T ) * PIE

WHERE,I.D = INSIDE DIA. AS SPECIFIED IN DRAWINGS
T = ACTUAL THICKNESS MEASURED AT ENDS
PIE = VALUE OBTAINED FROM CALCULATOR

• MEASURE THE ACTUAL CIRCUMFERENCE ON THE JOB.

• ONLY CALIBRATED TAPES SHOULD BE USED FOR MEASUREMENT.
• COMPARE THESE TWO VALUES OF CIRCUMFERENCE AND CHECK THE
ACCEPTABILITY BASED ON BELOW GIVEN TOLERANCE CHART.