WHAT PIPELINERS

NEED TO KNOW
O
ABOUT
INDUCTION BENDS
Barry Crouch
Inductabend Pty Ltd
Melbourne Australia
Inductabend - APIA Conference

Introduction
Presentation Contents
What are induction bends & specifications?
Why are induction bends required?
What
Wh t types
t
off bends
b d are available
il bl
How are they made?
Affects
Aff
on di
dimensions.
i
Material properties & the role of chemistry
What
h can go wrong
What to think about to get it right

Inductabend - APIA Conference

What are Induction Bends?

Factory made hot

hot bends from mother
mother pipe
pipe
Bending machine
El
Electric
i iinduction
d i h
heating
i
Mother pipe changes shape during bending
at radius
to angle
g

Test certified
Piggable
Inductabend - APIA Conference

Specifications
Pipeline Induction Bends
ISO 1559015590-1
ASME B6.49
DNV OS F101
Inductabend - APIA Conference

Why Do Pipeliners Need Induction

Bends?
B d?

Obstacles
Change direction, grade & elevation
rope the
h pipeline
i li string
i 250D
cold
cold--field bend pipe joints 40D
use an iinduction
d i b
bend
d 3D
D
use a fitting

Inductabend - APIA Conference

What kinds of Induction Bends are

Available
A il bl to Pi
Pipeliners?
li
?

Diverse Industries

construction &

Wide Variety
y of Materials

mining, power generation, processing,

pipelines

all grades carbon, stainless & alloy steels, CrCr-Ni alloys, titanium &
clad pipe

Pipe Types seamless & welded

(HFW SAWL & SAWH)

(HFW,
Inductabend - APIA Conference

How are Induction Bends Made?

Bare straight mother pipe

Bending machine & induction heating
S l
Selected
d process parameters

Aff t the
Affect
th pipe
i shape
h

speed, temperature & cooling

Radius, angle - cause ovality, wall thinning

Affect Material Properties

Strength, hardness, toughness

Inductabend - APIA Conference

I d ti Bending
Induction
B di M
Machine
hi
3
4

Fb

le
g
n
a

Fb
2

Inductabend - APIA Conference

P=Push Force
Fb=Bend
b
d Roll
ll Force
R=Bend Radius
1. Pusher
1
2. Bend roll
3. Heat transformer
4. Induction coil
5. Bend clamp
6. Bend arm
7. Pipe

Induction Bending Machine

Inductabend - APIA Conference

Induction Bending Machine

Inductabend - APIA Conference

10

What Size Pipes Can Be Bent?

Internationally

over 1600mm diameter & over 150mm wall

Australia - Inductabend
currently
l
to 900 di
dia & 100mm wall
ll
Radii
100mm to 12,500mm bend arm
Longer radii using specialised techniques

Inductabend - APIA Conference

11

How Does Induction

Heating/Bending Work?
Induction heating creates a plastic hinge
Coolingg Water
Spray
a

Induction Coil

s
o
d

Mo ement
Movement

Int
r

Ex
tr

s
o
d
a

Zone of
Induction
Heating

Inductabend - APIA Conference

12

How Does Induction

Heating/Bending Work?
Induction Coil
Cooling Water
S
Spray

Pyrometer
Aim

Wall
Thinning

Temperature
Contours
Bend
Tensile
Strain

O
M
I

Plastic Zone

INDUCTION COIL & EXTRADOS WALL

Inductabend - APIA Conference

13

Inductabend - APIA Conference

14

Inductabend - APIA Conference

15

Inductabend - APIA Conference

16

Inductabend - APIA Conference

17

M hi C
Machine
Capacity
it
100

WA
ALL THICK
KNESS

90

Unsuitable - too stiff

80

R = 3D
R = 5D

70

60
50

40

A =Carbon steel @ 875 C

B =Carbon steel @ 950 C
C =Carbon steel @ 1050 C

Suitable

30
20

10
200

300

Unsuitable - wrinkles
400 500
600
700 800
900
PIPE DIAMETER

TYPICAL INDUCTION PIPE BENDING CAPACITY DIAGRAM

Inductabend - APIA Conference

18

How Does Induction Bending Affect

Dimensions?
8
7
OVA
ALITY %

UNSUITABLE
FOR BENDING

5
4

UNSTABLE

110
90
70
50
30
10

2
1

SUITABLE

5 6
R/D

D/T

10

TYPICAL SUITABILITY & OVALITY

Inductabend - APIA Conference

19

% THINNIN
NG ( T / T X 100)

How Does Induction Bending Affect

Wall Thickness?
30%
25%
20%
15%
10%
5%
1

10

R/D

TYPICAL WALL THINNING

Inductabend - APIA Conference

20

How Does Induction Bending

Aff
Affect
High
Hi h Strength
S
h Line
Li pipe?
i ?

High strength carbon steel line pipe

Chemistry
wall thickness
seamless
welded ((HFW,, SAWL,, SAWH))

Sensitive to temperature
p
& coolingg rate
hotter temperature stronger & harder
faster cooling
g stronger
g & harder

Inductabend - APIA Conference

21

Temperature - Hardness
Hardneess HV10

300

EXAMPLE HFW PIPE

DN500 Wall 12.7 API 5LX70
CEQ0.36
SPEED: 50MM/MIN
COOLING:WATER
OUTSIDE SURFACE

250

O
M
I

INSIDE SURFACE

O
M
I

200

150
900

950

1000

Temperature C
Inductabend - APIA Conference

1050
22

Temperature - Strength
STRENGTH VS INDUCTION BENDING TEMPERATURE

YIELD STR
RENGTH & TEN
NSILE STRENGT
TH
Mpa

900
800
700
600
500
400
300
800

850

900

950

1000

1050

1100

1150

1200

TEMPERATURE C

Inductabend - APIA Conference

23

Chemistry CEQ - Strength

STRENGTH VS CEQ

YIE
ELD& TENSIL
LE STRENGTH
H MPa

900
800
700
600
500
400
300
0.2

0.22

0.24

0.26

0.28

0.3

0.32

0.34

0.36

0.38

CEQ %

Inductabend - APIA Conference

24

What Can Go Wrong With Hot

B d
Bends

Mother pipe condition & defects

Cracks, slivers, inclusions, gouges & dents
Lack of fusion
Lack of chemistry
Diameter
Di
t SAWL & SAWH
Surface contamination

Inductabend - APIA Conference

25

Inductabend - APIA Conference

26

Inductabend - APIA Conference

27

What Can Go Wrong With Hot

Bends?
B d?

Process Parameters
Speed
Temperature
p
Cooling
Start/Stop
p procedure
p
Dimensions radius, angles, thinning, ovality
Wrinkles & bumps
p
Process interruptions
Air draught

Inductabend - APIA Conference

28

What Do Pipeliners Need To Do To

Get It Right The First Time On
On-time?

Plan
Consider bends in the FEED
Read the standards
Talk to the bender
Consider
C id pipe
i chemistry
h i t iin li
light
ht off pipe
i ttype
and wall thickness
Ch
Choose
suitable
it bl maximum
i
h
hardness
d
Understand mother pipe actual wall
thi k
thickness
Inductabend - APIA Conference

29

Cont/.

select single
g heat bare pipe
p p for bendingg
Allow for a contingency of mother pipe
Allow for suitable straight
g tangent
g
ends
Show bend angles as angle of deflection
Allow time to qualify, production bend & coat
Consider transport & storage logistics
Consider coating systems
Utilise compact compound hot bends
Plan, plan and more planning
Inductabend - APIA Conference

30

Inductabend - APIA Conference

31

Inductabend - APIA Conference

32