Custom Made Pipe Bends

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


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


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


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


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


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


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


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

A

sa

si

Rm

α

B

b

s

Di

Da


a

A

sa

si

Rm

α

B

b

s

Di

Da


a

A

sa

si

Rm

α

B

b

s

Di

Da


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


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




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



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



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.



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.


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



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





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



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





Power systems

Bilfinger Piping Technologies GmbH Wolbeckstr. 2545329 EssenGermanyTelephone +49 201 3645 0Fax +49 201 3645 [email protected]

Documents

Custom Made Pipe Bends