Custom made bends - Bilfinger

piping.bilfinger.com

Custom made bends - Bilfinger

Bilfinger Piping Technologies GmbH

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Custom made bends

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Piping Systems

Bilfinger Piping Technologies GmbH

Inductive and cold bending

PIPING

SYSTEMS

Custom made bends 1


Piping Systems

Bilfinger Piping Technologies GmbH

Contents

Page

3 – 5 Application areas

6 Materials

7 Manufacturing know-how

8 – 9 Production program

• Technical data

• Bending program

10 Benefit: less buttwelds

12 – 13 Bend geometry

14 Activities after bending

• Heat treatment

• End preparation

• Spool fabrication

• Surface preparation

• Packing

15 Tests and certificates

16 Cold bending

18 – 19 Locations, contacts

2

Custom made bends


Piping Systems

Bilfinger Piping Technologies GmbH

Application areas

• Conventional and

nuclear power stations

• Chemical and

petrochemical industry

• Compressor stations

• Offshore and onshore plants

• Hydraulic plants

• Industrial plants

• Steel producing industry

• Public utilities

Custom made bends 3


Piping 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

4

Custom made bends


Piping 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 5


Piping Systems

Bilfinger Piping Technologies GmbH

Materials

• Normal carbon steels

• Fine grain steels

• Low temperature steels

• Steels for pipelines, including

thermo mechanically treaten steel

• Steels for hydrogen service

• Heat resistant steels

• Stainless and acid

resistant steels

• Stainless Duplex and

Superduplex Steels

• Centrifugally cast pipes,

Ni-alloy basis

• Cu and Cu-alloy pipes

• High temperature steels

• Case hardening and quenched and

tempered steels

Fabrication of austenitic piping in white environment

6

Custom made bends


Piping 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 client’s

specification.

D

N

N

Z

a B 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

Non-destructive testing

(weld seam)

Non-destructive testing

(bend)

BHR12

34567

Machining of weld bevel

Non-destructive testing (pipe ends)

Labeling

WD · mm

Temp. Korrosionsschutz

Temp. Corrosion Protection

Ummantelung

Coating

Material

Certificate

Anstrich

Painting

Final inspection Corrosion protection Documentation Pipe bends, ready for shipment

Custom made bends 7


Piping Systems

Bilfinger Piping Technologies GmbH

Induction bends

TECHNICAL DATA

Minimum pipe OD

48.3 mm

Maximum pipe OD

870.0 mm

Min. pipe wall thickness t min.

4.0 mm

Max. pipe wall thickness t max

120.0 mm

(larger wall thicknesses upon agreement)

Minimum bending radius R min.

100.0 mm

Maximum bending radius R max

4600 mm

Maximum 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 PROGRAM BASED ON R MIN

The following chart indicates the minimum

possible bending radii over the pipe wall

thickness and diameter, for ferritic and

austenitic materials.

BENDING OPTIONS

inch

mm

Bending radii 1.2 x D – 10 x D

34 860.0

Outside diameter

32 813.0

28 711.0

24 610.0

20 508.0

16 406.4

12* 323.9

8* 219.3

4* 114.3

4600

4000

3000

2000

1500

1000

1.9 48.3

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

500

300

200

8

Custom made bends


Piping 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

process. However, those are not the B

optimum bending radii.

B

b

B

b

b

s

Da

Di

a

A

In the following table one can see that at

larger R/D ratios and at fixed center-to-end

s

s

dimen sions Bthe stretched straight B length of

D a

D a

the bend decreases.

b

b

D i

D i

s a s a

A = Sys

s

s

Consequently, if the R/D ratio is increased

B = Sys

si

Rm

Da = Au

then:

Di = Inn

• less pipe is required

A

D a

D a

s = Wa

sa = Wa

• The wall thinning in the extrados zone

A

A

Bo

and the wall sthickening in the intrados s i s i si = Wa

a D i A = Systemmaß

D i A = Systemmaß center to end dimension center to end dimension Bo

zone will decrease

B = Systemmaß B = Systemmaß center to end dimension center to end dimension

Rm = Mit

a

α = Bie

• material costs will decrease

R R

D a = Außendurchmesser D a = Außendurchmesser

outside diameter outside diameter

m m

D D a = Ge

i = Innendurchmesser i = Innendurchmesser inside diameter inside diameter

• pressure loss will be lesst

b = Ge

s = Wanddicke des s Rohrs = Wanddicke pipe wallthickness des Rohrs pipe wallthickness

• flow conditions improve

α s a = Wanddicke α an der s a = Wanddicke wallthickness an extrados der wallthickness extrados

Bogenaußenseite Bogenaußenseite

A = Systemmaß A = center Systemmaß sto i end = dimension

Wanddicke center an der sto i end = dimension

Wanddicke wallthickness an intrados der wallthickness intrados

B = Systemmaß B = center Systemmaß to end dimension

Bogeninnenseite center to end dimension

Bogeninnenseite

a

a

D a = Außendurchmesser

R m = Mittlerer outside Biegeradius R m diameter = Mittlerer mean bending Biegeradius

mean bending radius

R R

D a = Außendurchmesser outside diameter

m m

D i = Innendurchmesser D i = inside Innendurchmesser diameter α = Biegewinkel inside diameter α = Biegewinkel bending angle bending angle

s = Wanddicke des Rohrs s = pipe Wanddicke wallthicknessa = des Gerader Rohrs Schenkel pipe wallthickness

a = Gerader tangent length Schenkel tangent length

α s a = Wanddicke α an der s a = wallthickness Wanddicke b = an extrados Gerader Schenkel wallthickness b = extrados Gerader tangent length Schenkel tangent length

Bogenaußenseite Bogenaußenseite

s i = Wanddicke an der s i = wallthickness Wanddicke an intrados der wallthickness intrados

Bogeninnenseite Bogeninnenseite

a

R m = Mittlerer Biegeradius R m = mean Mittlerer bending Biegeradius

mean bending radius

α = Biegewinkel α = bending Biegewinkel angle bending angle

a = Gerader Schenkel a = tangent Gerader length Schenkel tangent length

b = Gerader Schenkel b = tangent Gerader length Schenkel tangent length

sa

α

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


Piping 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)

• High accuracy of shape

Custom made individual bends

• Less buttwelds by using

complex bends

• Materials for all applications

10

Custom made bends


Piping Systems

Bilfinger Piping Technologies GmbH

Custom made bends 11


Piping 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.

CHANGE OF WALL THICKNESS AT BENDING

% Increase % Reduction

20

10

0

10

20

30

40

50

max. reduction

min. increase

Air

Water

60

0

1 2

3 4 5 6 7 8 9 10 11

R/D ratio

12

Custom made bends


Piping Systems

Bilfinger 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:

• EN 13480-4 and

• 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

Ovality in %

6

5

4

3

2

1

0

0

≤ 40 D/S

≤ 20 D/S

≤ 10 D/S

≤ 80 D/S

1 2 3 4 5 6 7 8 9 10 11

R/D ratio

Custom made bends 13


Piping Systems

Bilfinger 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.

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.

SPOOL FABRICATION

We also offer assembly of multiple bends

to spools with welded stubs, stop blocks,

flanges, etc.

14

Custom made bends


Piping 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:

TÜV Technical Inspection Authority

AD-2000

PED

TRD

DIN 18 800 / 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


Piping Systems

Bilfinger Piping Technologies GmbH

Cold bending

The Bilfinger Piping Technologies manufacturing

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

16

Custom made bends


Piping Systems

Bilfinger Piping Technologies GmbH

Custom made bends 17


42

13 Essen-Nord

Piping Systems

Bilfinger Piping Technologies GmbH

224

Essen-

Altenessen

Essen-

Our location in Vogelheim

42

42

13 Essen-Nord

Johanniskirchstraße

Wolbeckstraße

224

Essen-

Altenessen

224

Gewerbegebiet

Teilungsweg

Essen-

Vogelheim

Teilungsweg

Bilfinger Piping Technologies GmbH

Shop Essen

Wolbeckstr. 25

45329 Essen

Germany

Telephone +49 201 3645-0

Fax +49 201 3645-232

info.piping@bilfinger.com

Gewerbegebiet

Teilungsweg

224

Johanniskirchstraße

Wolbeckstraße

Teilungsweg

18

Custom made bends


Piping Systems

Bilfinger Piping Technologies GmbH

Our location in Dortmund

Martener Straße

Kesselborn

Gewerbegebiet

Alter

Hellweg

45

Hellweg

Dortmund

Dorstfeld

Martener

Planetenfeldstraße

Alter

Hellweg

40

Kreuz

Dortmund-West

B 1

Dortmund

Dorstfeld

Borussia-

41 Dortmund

Kley

straße

Dortmund Kley

45

Brennaborstraße

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


Piping Systems

Bilfinger Piping Technologies GmbH

Piping Systems

Bilfinger Piping Technologies GmbH

Europaallee 1

46047 Oberhausen

Germany

Phone +49 208 4575-10

Fax +49 208 4575-5111

info.piping@bilfinger.com

www.piping.bilfinger.com

20

Custom made bends

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