Custom made bends 1
Power SystemsBilfinger Piping Technologies GmbH
Bilfinger PiPing Technologies gmBh
––––––
Custom made bends––––––
inducTive and cold Bending
Contents
Page
3 – 5 application areas
6 materials
7 manufacturing know-how
8 – 9 Production program n technical data n bending program 10 benefit: less buttwelds
12 – 13 bend geometry
14 activities after bending n Heat treatment n end preparation n spool fabrication n surface preparation n Packing
15 tests and certificates
16 Cold bending
18 – 19 Locations, contacts
Custom made bends 2
Power SystemsBilfinger Piping Technologies GmbH
application areas
n Conventional and nuclear power stations
n Chemical and petrochemical industry
n Compressor stations
n offshore and onshore plants
n Hydraulic plants
n Industrial plants
n steel producing industry
n Public utilities
Custom made bends 3
Power SystemsBilfinger Piping Technologies GmbH
application areas
The pipe structure “snake Pier” is a masterwork of engineering. The 112 meters long pedestrian bridge is supported by a “pipe snake” consisting of 59 various seamless pipe bends
induction-bends made from centrifugally casted pipes
new building of the power plant neurath Boa 2&3 – cold reheat linematerial: od 762 x 31 WT, 16 mo3
Custom made bends 4
Power SystemsBilfinger Piping Technologies GmbH
new building of the power plant niederaussem hot reheat line, id 720 x 48 mWTmaterial: X11crmoWvnb9-1-1
induction-bends for the new building of the power plant neurath Boa 2&3main steam, id 355 x 96 mWTmaterial: X10crWmovnb9-2
Turbine hall of the new nuclear power plant olkiluoto 3 (finland)
Custom made bends 5
Power SystemsBilfinger Piping Technologies GmbH
materials
n normal carbon steels
n Fine grain steels
n Low temperature steels
n steels for pipelines, including thermo mechanically treaten steel
n steels for hydrogen service
n Heat resistant steels
n stainless and acid resistant steels
n stainless duplex and superduplex steels
n Centrifugally cast pipes, ni-alloy basis
n Cu and Cu-alloy pipes
n High temperature steels
n Case hardening and quenched and tempered steels
fabrication of austenitic piping in white environment
Custom made bends 6
Power SystemsBilfinger Piping Technologies GmbH
manufacturing know-how
the schematics give a visual impression of the major activities of the manufacturing process and quality control of custom made steel bends fabricated by bilfinger Piping technologies. our manufacturing and test procedures will be customised to suit the specific application, materials and client’s specification.
7
N
N
D Z B
a
b
Incoming inspection of base pipe Measuring and marking Induction bending Dimensional check
Heat treatment Dimensional check Hardness test Cutting off ring specimens
Destructive testing Cleaning
BHR1234567
Labeling
WD · mm Temp. KorrosionsschutzTemp. Corrosion Protection
AnstrichPainting
UmmantelungCoating
MaterialCertificate
Final inspection Corrosion protection Documentation Pipe bends, ready for shipment
Non-destructive testing (weld seam)
Non-destructive testing (bend)
Machining of weld bevel Non-destructive testing (pipe ends)
Custom made bends 7
Power SystemsBilfinger Piping Technologies GmbH
Induction bends
Technical daTa
minimum pipe od 48.3 mmmaximum pipe od 870.0 mmmin. pipe wall thickness tmin. 4.0 mmmax. pipe wall thickness tmax 120.0 mm(larger wall thicknesses upon agreement)minimum bending radius Rmin. 100.0 mmmaximum bending radius Rmax 4600 mmmaximum bending angle at bending radius > 300 mm 180°straight inlet and intermediate pipe length at complex (multiple) bends 460/600/1050 mm*Required straight pushing length 1150/2350mm**shorter lengths upon agreement
Bending oPTions
4Minimum wall thickness (mm)
Bending radii 1.2 x D – 10 x D
*Nominal bore (DN) For austenitic materials the minimum possible radius is 1.3 x D
10
Ou
tsid
e di
amet
er
6 8 11 12 14 16 18 20 24 30 40 50 60 70 80 100 120
inch mm
34 860.0
32 813.0
28 711.0
24 610.0
20 508.0
16 406.4
12* 323.9
8* 219.3
4* 114.3
1.9 48.3
200300
500
1000
15002000300040004600
Bending Program Based on rmin
the following chart indicates the minimum possible bending radii over the pipe wall thickness and diameter, for ferritic and austenitic materials.
Custom made bends 8
Power SystemsBilfinger Piping Technologies GmbH
r/d raTio
the bending radii shown in the chart “bending options” are the minimum possible ones limited by the manufacturing process. However, those are not the optimum bending radii.
In the following table one can see that at larger R/d ratios and at fixed center-to-end dimen sions the stretched straight length of the bend decreases.
Consequently, if the R/d ratio is increased then:n less pipe is requiredn the wall thinning in the extrados zone
and the wall thickening in the intrados zone will decreasen material costs will decreasen pressure loss will be lesstn flow conditions improve
A = Systemmaß center to end dimensionB = Systemmaß center to end dimensionDa = Außendurchmesser outside diameterDi = Innendurchmesser inside diameters = Wanddicke des Rohrs pipe wallthicknesssa = Wanddicke an der wallthickness extrados Bogenaußenseitesi = Wanddicke an der wallthickness intrados BogeninnenseiteRm = Mittlerer Biegeradius mean bending radiusα = Biegewinkel bending anglea = Gerader Schenkel tangent lengthb = Gerader Schenkel tangent length
a
A
sa
si Rm
α
Bb
s
Di
Da
A = Systemmaß center to end dimensionB = Systemmaß center to end dimensionDa = Außendurchmesser outside diameterDi = Innendurchmesser inside diameters = Wanddicke des Rohrs pipe wallthicknesssa = Wanddicke an der wallthickness extrados Bogenaußenseitesi = Wanddicke an der wallthickness intrados BogeninnenseiteRm = Mittlerer Biegeradius mean bending radiusα = Biegewinkel bending anglea = Gerader Schenkel tangent lengthb = Gerader Schenkel tangent length
a
A
sa
si
Rm
α
B
b
s
Di
Da
A = Systemmaß center to end dimensionB = Systemmaß center to end dimensionDa = Außendurchmesser outside diameterDi = Innendurchmesser inside diameters = Wanddicke des Rohrs pipe wallthicknesssa = Wanddicke an der wallthickness extrados Bogenaußenseitesi = Wanddicke an der wallthickness intrados BogeninnenseiteRm = Mittlerer Biegeradius mean bending radiusα = Biegewinkel bending anglea = Gerader Schenkel tangent lengthb = Gerader Schenkel tangent length
a
A
sa
si
Rm
α
B
b
s
Di
Da
A = Systemmaß center to end dimensionB = Systemmaß center to end dimensionDa = Außendurchmesser outside diameterDi = Innendurchmesser inside diameters = Wanddicke des Rohrs pipe wallthicknesssa = Wanddicke an der wallthickness extrados Bogenaußenseitesi = Wanddicke an der wallthickness intrados BogeninnenseiteRm = Mittlerer Biegeradius mean bending radiusα = Biegewinkel bending anglea = Gerader Schenkel tangent lengthb = Gerader Schenkel tangent length
a
A
sa
si
Rm
α
B
b
s
Di
Da
A = Systemmaß center to end dimensionB = Systemmaß center to end dimensionDa = Außendurchmesser outside diameterDi = Innendurchmesser inside diameters = Wanddicke des Rohrs pipe wallthicknesssa = Wanddicke an der wallthickness extrados Bogenaußenseitesi = Wanddicke an der wallthickness intrados BogeninnenseiteRm = Mittlerer Biegeradius mean bending radiusα = Biegewinkel bending anglea = Gerader Schenkel tangent lengthb = Gerader Schenkel tangent length
a
A
sa
si
Rm
α
B
b
s
Di
Da
calculaTing of neccessarY PiPelengTh for inducTion Bends
Examples for calculating the total straight length
example N° 1.0 2.0 3.0 4.0
outside diameter mm 323.9 323.9 323.9 323.9
wall thickness mm 20.0 20.0 20.0 20.0
bending angle Degree 90 90 90 90
bending radius mm 490 970 1460 1945
radius/OD-ratio 1.5 3.0 4.5 6.0
center to end dimension A mm 2000 2000 2000 2000
center to end dimension B mm 2000 2000 2000 2000
tangent length a mm 1510 1030 540 55
tangent length b mm 1510 1030 540 55
total straight length incl. squashing mm 885 1646 2385 3147
total straight length mm 3905 3706 3465 3257
squashing in % 15 8 4 3
Custom made bends 9
Power SystemsBilfinger Piping Technologies GmbH
material
n High accuracy of shape n Custom made individual bendsn Less buttwelds by using complex bendsn materials for all applications
eXamPle 2
conventional design: 6 buttwelds (left)
Using flange ends and integral reducer: no buttweld required (right)
eXamPle 1
conventional design: 9 buttwelds (left)
using complex (multiple) bends: 3 buttwelds (right)
)
Custom made bends 10
Power SystemsBilfinger Piping Technologies GmbH
Custom made bends 11
Power SystemsBilfinger Piping Technologies GmbH
bend geometry
Custom made bends from steel pipes have a high accuracy of shape. bending with induction heat input is an advanced procedure using a highly automated and continuous forming process. during the process the pipe will be pushed into a narrow zone which is heated by a ring shaped inductor. the bending force will be applied axially to the pipe, the front end of which is fixed in a swivel-arm. during the bending process the bending arm will move around its axis on a circular arc with the specified radius. through the applied axial force the pipe follows the set circular path.
Wall ThicKness
during the bending process the pipe wall thickness at the bend extrados will decrease, the same at the bend intrados will increase. the percentage amount of difference between the wall thickness of the finished bend and that of the actual wall thickness of the prepipe depends mainly on the ratio of bending radius to pipe outside diameter (R/d). the following chart gives guidelines of the changes in the wall thickness when using our bending machines.
change of Wall ThicKness aT Bending
20
10
0
10
20
30
40
50
600
R/D ratio
min. increase
max. reduction
Air
1 2
% In
crea
se%
Red
uct
ion
3 4 5 6 7 8 9 10 11
Water
Custom made bends 12
Power SystemsBilfinger Piping Technologies GmbH
our bending technology guarantees mode rate wall thickness reductions. the calculation conditions of accepted international norms and standards applicable for straight seamless pipes without wall thickness allowance will be complied with. When specifying the required minimum wall of the pipe one has to consider the wall thinning in addition to other allow ances (e.g. scaling and blastcleaning).
ovaliTY
the chart shows the expected ovalities. the achievable values depend – among other factors – on the ratio of diameter to wallthickness.
We are in the position to achieve considerably better ovality values than the limit figures in the VGb rules.
Tolerances
our dimensional tolerances are in accordance with:n en 13480-4 andn PFI-standard es-3 (PFI = Pipe Fabrication
Institute springdale, Pa 15144)
achievaBle ovaliTY in connecTion WiTh r/d and d/WT raTio
10
9
8
7
6
5
4
3
2
1
00
R/D ratio1 2
Ova
lity
in %
3 4 5 6 7 8 9 10 11
≤ 10 D/S
≤ 20 D/S
≤ 40 D/S
≤ 80 D/S
Custom made bends 13
Power SystemsBilfinger Piping Technologies GmbH
shop fabrication after bending
heaT TreaTmenT
Induction bends may be heat treated after bending, as per requirements of material and application. We have furnaces with accurate temperature control up to 1200 °C. after the heat treatment the options of cooling with air or quenching with water are available.
end PreParaTion
the finished bends will be delivered as per client’s specification either with plain ends or with welding bevels.
sPool faBricaTion
We also offer assembly of multiple bends to spools with welded stubs, stop blocks, flanges, etc.
surface PreParaTion
the finished bends upon client’s request can be blastcleaned, acid-cleaned, coated with temporary corrosion protection or painted.
PacKing
our bilfinger Piping technologies Packing Guidelines can be made available to the client to help in their decision of packing. Packing can of course take place in our works, if required we also offer seaworthy packing.
Custom made bends 14
Power SystemsBilfinger Piping Technologies GmbH
tests and certificates
all destructive and non-destructive tests can be performed in our own laboratory in the factory. In the case of special tests we co-operate closely with approved testing institutes. Representatives of the most important third Party institutes are present every day at our works.
Power SystemsBilfinger Piping Technologies GmbH
aPProvals
We are in possession of all national and international approvals for the manufacturing of all types of high pressure piping components:tÜV technical Inspection authorityad-2000PedtRddIn 18 800 / en 1090dVGWasmeen Iso 3834-2
the bilfinger Piping technologies Quality system is certified by:dIn/Iso 9001 / en 29 001 / sCCKta 1401aVs d100 / 50Iaea50-C-Qen Iso 14001
Currently we are holding the following asme symbol stamps:asme s / PP / u / u2
Custom made bends 15
Power SystemsBilfinger Piping Technologies GmbH
Cold bending
the bilfinger Piping technologies manu-facturing portfolio is supplemented with a CnC cold bending machine which is suitable for bends between 10 and 168.3 mm pipe outside diameter and a maximum bending radius of 820 mm. We guarantee our cold bends with R/d ratios larger than 3.0 wall thickness reduction smaller than 20 % and ovalities better than the VGb guidelines.
the next table indicates the options of standard cold bending.
sTandard Bending Program of cold Bends
Pipe OD mm Available tools – average bending radii
10.0 20
12.0 25
13.5 500
14.0 30
16.0 30 50 150
17.2 40 55 80
20.0 40 60
21.3 40 60 80 90 135
22.0 45 65
25.0 45 50 75
26.9 40 60 80 90 100 150
30.0 30 60 90 100
31.8 100 110 130 140 150 170
33.7 70 90 100 110 120 134 220 167
35.0 70 150
38.0 50 80 100 120 140 150 170 210 250
42.4 85 120 150 180 230 250
44.5 120 150 240
48.3 90 100 125 145 160 170 190 200 280
51.0 60 150 200 230
57.0 110 120 175 240
60.3 100 150 180 200 240 250 400
63.5 190 200 250
70.0 100 140 200 280 320
73.0 250 465 560 650 740
76.1 110 160 190 230 260 305
88.9 270 320 360 450
101.6 330 400
108.0 310
114.3 295 350 400 450 760
126.0 300 400 457 139.7 420 500
168.3 600 675 820
Custom made bends 16
Power SystemsBilfinger Piping Technologies GmbH
Custom made bends 17
Power SystemsBilfinger Piping Technologies GmbH
our location in essen
bilfinger Piping technologies GmbHshop essenWolbeckstr. 2545329 essenGermanytelephone +49 201 3645-0Fax +49 201 [email protected] Gewerbegebiet
Teilungsweg224
Teilungsweg
Johanniskirchstraße
Wolb
eckstraße
42
42
13 Essen-Nord
224Essen-
Altenessen
Essen-Vogelheim
Gewerbegebiet Teilungsweg
224
Teilungsweg
Johanniskirchstraße
Wolb
eckstraße
42
42
13 Essen-Nord
224Essen-
Altenessen
Essen-Vogelheim
Custom made bends 18
Power SystemsBilfinger Piping Technologies GmbH
bilfinger Piping technologies GmbHshop dortmundalter Hellweg 3344379 dortmundGermanytelephone +49 231 6182-0Fax +49 231 [email protected]
our location in dortmund
Gewerbegebiet Alter
Hellweg
41 DortmundKley
DortmundDorstfeld
Kreuz Dortmund-West
Dortmund Dorstfeld
B 1
45
45
40
Dortmund Kley
Martener
Hellweg
Hellweg
Alter
straße
Borussia-
Kesselb
orn
Martener Straße
Planeten
feldstraße
Brennaborstraße Hauert
Custom made bends 19
Power SystemsBilfinger Piping Technologies GmbH
Custom made bends 20
Power SystemsBilfinger Piping Technologies GmbH
Power systems
Bilfinger Piping Technologies GmbH Wolbeckstr. 2545329 EssenGermanyTelephone +49 201 3645 0Fax +49 201 3645 [email protected]