Sie sind auf Seite 1von 20

Power Systems

Bilfinger Piping Technologies GmbH

Bilfinger Piping Technologies GmbH

Custom made bends

Inductive and cold bending

Custom made bends

Power Systems
Bilfinger Piping Technologies GmbH

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

18 19

Custom made bends

Cold bending
Locations, contacts

Power Systems
Bilfinger 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

Power Systems
Bilfinger 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 line
Material:
OD 762 x 31 WT, 16 Mo3

Custom made bends

Power Systems
Bilfinger Piping Technologies GmbH

New building of the power


plant Niederaussem
Hot Reheat Line,
ID 720 x 48 MWT
Material:
X11CrMoWVNb9-1-1

Induction-bends for the new


building of the power plant
Neurath BoA 2&3
Main Steam,
ID 355 x 96 MWT
Material:
X10CrWMoVNb9-2

Turbine hall of the new


nuclear power plant
Olkiluoto 3 (Finland)

Custom made bends

Power Systems
Bilfinger 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

Power Systems
Bilfinger 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 clients
specification.

N
D

Z
N

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

Non-destructive testing
(weld seam)

Non-destructive testing
(bend)

BHR12
34567

Machining of weld bevel

WD mm

Non-destructive testing (pipe ends)

Temp. Korrosionsschutz
Temp. Corrosion Protection
Ummantelung
Coating

Labeling

Material
Certificate

Anstrich
Painting

Final inspection

Corrosion protection

Documentation

Pipe bends, ready for shipment

Custom made bends

Power Systems
Bilfinger Piping Technologies GmbH

Induction bends
TECHNICAL DATA
Minimum pipe OD
Maximum pipe OD
Min. pipe wall thickness tmin.
Max. pipe wall thickness tmax
(larger wall thicknesses upon agreement)
Minimum bending radius Rmin.
Maximum bending radius Rmax
Maximum bending angle at
bending radius > 300 mm
Straight inlet and intermediate pipe
length at complex (multiple) bends
Required straight pushing length

48.3 mm
870.0 mm
4.0 mm
120.0 mm
100.0 mm
4600 mm
180
460/600/1050 mm*
1150/2350mm*

*shorter lengths upon agreement

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.

Outside diameter

BENDING OPTIONS

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

00

860.0
46

34

Bending radii 1.2 x D 10 x D

00

mm

40

inch

00

30

00

20

00

15

00

10

500

300
200

4 6 8 10 11 12 14 16 18 20 24 30 40 50 60 70 80 100 120
Minimum wall thickness (mm)

*Nominal bore (DN)


For austenitic materials the minimum possible radius is 1.3 x D

Custom made bends

Power Systems
Bilfinger Piping Technologies GmbH

R/D RATIO
The bending radii shown in the chart
Bending options are the minimum
possible ones limited by the manufacturing
B
process. However, those are not the
optimum bending radii.

si
Rm

Rm

A
B
Da
Di
s
sa

=
=
=
=
=
=

si

Rm

a
b

=
=
=
=

sa

b
s
Da
Di

si
A

Da
si D
i

Rm

Systemma
A =
Systemma
B =
Da =
Auendurchmesser
Di =
Innendurchmesser
Wanddicke des Rohrs
s =
Wanddicke
an der
sa =

Bogenauenseite
si =
Wanddicke an der
Bogeninnenseite
Rm =
Mittlerer Biegeradius
Biegewinkel =
Gerader Schenkel
a =
Gerader Schenkel
b =

Da

sa

Consequently, if the R/D ratio is increased


then:
n less pipe is required
wall thinning in the
extrados zone
n The
A
A
and the wallsthickening
in the intrados si
a
zone will decrease
n material costs will decrease
n pressure loss will be lesst
n flow conditions improve
si

sa

Da
Di

In the following table one can see that at


larger R/D ratios and at fixed center-to-end
dimensionsBthe stretched straight
B length of
the bend decreases.
b

sa

Rm
Da

Di

A
B
Da
Di
s
sa

Sys
Sys
Au
Inn
Wa
Wa
Bo
si = Wa
Systemma
center to end dimension
center to end dimension
Bo
Systemma
center to end dimension
center to end dimension
Rm = Mit
= Bie
Auendurchmesser
outside diameter
outside diameter
Innendurchmesser
inside diameter
inside diametera = Ge
b = Ge

Di A =
Systemma
Systemma
B =
Da =
Auendurchmesser
Rm
Di =
Innendurchmesser
Wanddicke des sRohrs
= Wanddicke
pipe wallthickness
des Rohrs pipe wallthickness
Wanddicke
an der
wallthickness
anextrados
der
wallthickness extrados
sa = Wanddicke

Bogenauenseite
Bogenauenseite
stoi end
sto
= dimension
Wanddicke
an der
= dimension
Wanddicke
wallthickness
anintrados
der
wallthickness intrados
center
Systemma
center
i end
Bogeninnenseite
Bogeninnenseite
center
Systemma
to end dimension
center to end dimension
Rm
Rdiameter
Biegeradius
= Mittlerer
mean bending
Biegeradius
radius mean bending radius
outside
Auendurchmesser
diameter
m = Mittlerer outside
= Biegewinkel
= Biegewinkel
bending angle
bending angle
inside
Innendurchmesser
diameter
inside diameter
a =desGerader
a = Gerader
tangent length
Schenkel
tangent length
pipe
Wanddicke
wallthickness
Rohrs Schenkel
pipe wallthickness
b =anextrados
Gerader
Schenkel
b = extrados
Gerader
tangent length
Schenkel
tangent length
wallthickness
Wanddicke
der
wallthickness
Bogenauenseite
wallthickness
Wanddicke anintrados
der
wallthickness intrados
Bogeninnenseite
mean
Mittlerer
bending
Biegeradius
radius mean bending radius
bending
Biegewinkel
angle
bending angle
tangent
Gerader length
Schenkel
tangent length
tangent
Gerader length
Schenkel
tangent length
A
B
Da
Di
s
sa

=
=
=
=
=
=

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

1.5

3.0

4.5

6.0

radius/OD-ratio
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

15

squashing in %

=
=
=
=
=
=

Custom made bends

Power Systems
Bilfinger Piping Technologies GmbH

Material
EXAMPLE 1
Conventional design:
9 buttwelds (left)
Using complex (multiple)
bends: 3 buttwelds (right)
)

EXAMPLE 2
Conventional design:
6 buttwelds (left)
Using flange ends and
integral reducer: no buttweld
required (right)

n High accuracy of shape


n Custom made individual bends
n Less buttwelds by using

complex bends
n Materials for all applications

10

Custom made bends

Power Systems
Bilfinger Piping Technologies GmbH

Custom made bends

11

Power Systems
Bilfinger 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.

% Reduction

CHANGE OF WALL THICKNESS AT BENDING


20
max. reduction

10
0
10

min. increase

% Increase

20
30
40

Air
Water

50
60
0

12

Custom made bends

6
R/D ratio

10

11

Power Systems
Bilfinger Piping Technologies GmbH

Our bending technology guarantees


moderate 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 allowances (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 and
n PFI-Standard ES-3 (PFI = Pipe Fabrication
Institute Springdale, PA 15144)

ACHIEVABLE OVALITY IN CONNECTION WITH R/D AND D/WT RATIO


10
9

Ovality in %

8
7

0D

/S

5
4

10

0D

/S

0D

/S

D/S

1
0
0

5
6
R/D ratio

10

11

Custom made bends

13

Power Systems
Bilfinger Piping Technologies GmbH

Shop fabrication after bending


HEAT TREATMENT

SURFACE PREPARATION

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.

The finished bends upon clients request can


be blastcleaned, acid-cleaned, coated with
temporary corrosion protection or painted.

END PREPARATION
The finished bends will be delivered as per
clients 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.

14

Custom made bends

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.

Power Systems
Bilfinger 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.

APPROVALS
We are in possession of all national
and international approvals for the
manufacturing of all types of high
pressure piping components:
TV Technical Inspection Authority
AD-2000
PED
TRD
DIN 18800 / EN 1090
DVGW
ASME
EN ISO 3834-2
The Bilfinger Piping Technologies
Quality System is certified by:
DIN/ISO 9001 / EN 29 001 / SCC
KTA 1401
AVS D100 / 50
IAEA50-C-Q
EN ISO 14001
Currently we are holding the following
ASME Symbol Stamps:
ASME S / PP / U / U2

Custom made bends

15

Power Systems
Bilfinger 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
10.0
12.0
13.5
14.0
16.0
17.2
20.0
21.3
22.0
25.0
26.9
30.0
31.8
33.7
35.0
38.0
42.4
44.5
48.3
51.0
57.0
60.3
63.5
70.0
73.0
76.1
88.9
101.6
108.0
114.3
126.0
139.7
168.3

16

Custom made bends

Available tools average bending radii


20
25
500
30
30
40
40
40
45
45
40
30
100
70
70
50
85
120
90
60
110
100
190
100
250
110
270
330
310
295
300
420
600

50
55
60
60
65
50
60
60
110
90
150
80
120
150
100
150
120
150
200
140
465
160
320
400
350
400
500
675

150
80
80

90

135

75
80
90
130
100

90
100
140
110

100

150

150
120

170
134

120
180

140
230

145
230
240
200

100
150
240
125
200
175
180
250
200
560
190
360

400
457
820

220

167

150
250

170

210

250

160

170

190

200

280

240

250

400

280
650
230
450

320
740
260

305

450

760

Power Systems
Bilfinger Piping Technologies GmbH

Custom made bends

17

13 Essen-Nord

42

EssenAltenessen

224

Power Systems
Bilfinger Piping Technologies GmbH

Our location in Essen


EssenVogelheim

42

Joh

n
Teilu

18

Custom made bends

trae

n
Teilu

ecks

Teilungsweg

Wo l b

Bilfinger Piping Technologies GmbH


Shop Essen
Wolbeckstr. 25
45329 Essen
e
Germany
stra
irch
k
s
i
Telephone +49 201
3645-0
ann
Joh
Fax +49 201 3645-232
Gewerbegebiet
info.piping@bilfinger.com

224

Gewerbegebiet
Teilungsweg

gsw

eg

trae

EssenVogelheim

224

ecks

EssenAltenessen

224

an

stra

Wo l b

13 Essen-Nord

42

irch
nisk

gsw

eg

Power Systems
Bilfinger Piping Technologies GmbH

Our location in Dortmund

te
Mar

ner

Stra

He

llw

eg

Dortmund
Dorstfeld

tra

ia

ds

ss

Kreuz
Dortmund-West

fel

ru

te

ten

orn
Al

lwe

ne

Martener
Hel

Bo

45

Pla

Kesselb

Gewerbegebiet
Alter
Hellweg

40

B1

Dortmund
Dorstfeld

st

41 Dortmund
Kley
ra

Dortmund Kley

45

B re

bo
nna

rstr

ae

Hauert

Bilfinger Piping Technologies GmbH


Shop Dortmund
Alter Hellweg 33
44379 Dortmund
Germany
Telephone +49 231 6182-0
Fax +49 231 6182-341
info.piping@bilfinger.com

Custom made bends

19

Power Systems
Bilfinger Piping Technologies GmbH

Power Systems
Bilfinger Piping Technologies GmbH
Wolbeckstr. 25
45329 Essen
Germany
Telephone +49 201 3645 0
Fax +49 201 3645 111
info.piping@bilfinger.com
www.piping.bilfinger.com
20

Custom made bends