Over the last 80–90 years, the pipeline bending
process has developed from rudimentary press bending techniques to the advanced
induction bending processes available today. This article provides an overview
of the current techniques available for bending pipeline in the workshop, and
what is in store for the future.
Many pipe bending methods are available, with considerable
overlaps in capacity. Deciding on a suitable option ultimately depends on
quantity and the quality required. All the processes have been described below
with a suggested range/suitability, etc. While some companies have quite
successfully developed processes that exceed the ranges suggested below, having
processes outside of these ranges is not common.
Press bending (hot or cold) Pipe size range: 0.5–60 inches Radius range: 10D+
Despite the fact that this is the oldest method of bending, it
is still used for some jobs. Two fixed dies/tools hold the pipe and another
presses against the pipe to form a bend and, with multiple ‘hits’ on the pipe,
it is possible to bend to various radii. There is often a considerable amount
of deformation with this process, which greatly increases as the radii become
tighter.
This process has also been linked with sand packing and forming,
a process that is rarely used now due to the cost. Sand is packed into the
pipe, which is subsequently heated to between 800°C and 1,100°C, and then
pressed into shape. This was usually on a metal bed with the pipe subsequently
jacked into position.
Rotary draw bending (cold) Pipe size range: 0.5–6 inches Radius range: 5D–10D
This process wraps the pipe around a former die. This method is
limited in radius to that of the die radius. It is a very quick process;
however, due to the tooling cost and its very limited application, it is rarely
used for applications above 6 inches nominal bore (168 mm outer diameter). As
there is no internal support, the quality of the bend is poor for tighter
radii, and thicker pipe is generally used to counter the ovality effect.
Mandrel bending (cold) Pipe size range: 0.5–6 inches Radius range: 1D–10D
This process is similar to rotary draw bending, however, the
pipe is supported internally using a mandrel. The mandrel is a hardened steel
rod, often designed with linkages, to allow it to curve with the bend. This
prevents ovality and rippling of the internal wall. As with rotary draw
bending, the radii is limited to the former die, so it is generally limited to
6 inches and under. When linked to a CNC unit it is a very efficient process
for multiple bends on the same pipe and large batches.
Three-roller bending (cold) Pipe size range: 0.5–26 inches Radius range: 5D+ Three
rollers drive the pipe through the formers. Depending upon the machine style,
either the front/centre roll or the two lower rollers will move to increase
press.
This method has an infinite range of radii and is generally a
quick and economic process. It is the best process for radii 7D and above with
a three-roller mandrel, and 10D+ without a three-roller mandrel. It is possible
to bend in multiple axes and multiple radii per bar with this process. Water
filling and sand packing is also still used by some companies to support the
section during bending to give a better end result.
Induction bending (hot) Pipe size range: 0.5–88 inches Radius range: 3D–20D
(large radii attachments are available but not common)
Induction bending is generally the most common process for
pipelines due to the quality of the bend. The pipe is heated at one point using
an induction coil; the bending temperature will depend upon the material grade,
but generally it is between 800°C and 1,100°C. The high frequency-induced
current creates a heat band within the electrically resistant material, which
then conducts though the section to create a uniform temperature both inside
and out.
The pipe is held in a press, clamped to a pivot arm, and then
gradually pushed through the induction coil. The material is as low as 10 per
cent of the strength of the metal at room temperature at the induction coil
area due to the heating, and therefore yields at this point. The radius of the
pipe is determined by the pivot arm position.
To retain the cross section, the pipe is immediately quenched in
water after bending. This creates cold sections adjacent to the heat band,
which supports the heat-softened section. Thicker pipe is often air-cooled.
The bending temperature is monitored throughout the bending
process, and controlled using the bending speed and power input.
Challenges associated with pipeline bending
The main challenges with pipe bending are naturally cost and
lead time. As the world’s energy requirements grow, and resources become more
expensive and scarce, the need for a more efficient pipeline bending method
increases. In terms of cost, the reduction of welds has always been considered;
it has not always been a cheap option to create multiple bends due to their
set-up and transportability.
The future of bending technology Over the last 20 years, computer-controlled
CNC machines have been developed, and are now generally commonplace in the
workshop. CNC machines calculate the bending para-meters based on data inputted
by the operator on the required shape.
These days, intelligent cold bending machines are able to
calculate the ‘spring back’ or bending characteristics of a pipe during
bending, enabling the computer to alter the roll or tool setting to give the
same bend on differing pipe strengths. Combined mandrel and roller machines
that are able to bend in three dimensions to multiple radii and angles very
quickly are also available now.
In the near future, a number of new developments will be seen,
including:
· Multi-axis induction
bending machines, which will be able to create three- imensional induction
quality bends in a single operation.
· Greater control of
bending processes with instant material analysis, which then controls the
bending parameters.
· Mandrel benders which
are able to bend to multiple radii without the need for expensive tooling, as
they will use adaptive tooling.
Pipes bends are often described as bent to a certain ‘D’ (e.g. 3D or 5D). This relates to the centreline radius of the bend in relation to the diameter of the pipe. For example, 24 inch diameter pipe bent to 3D would have a 72 inch centreline radius (CLR), (24 inches x 3 = 72 inches), 8 inch pipe to 5D (8 inches x 5 = 40 inch CLR).
As the world’s energy requirements grow, and resources become
more expensive and scarce, the need for a more efficient pipeline bending
method increases.
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