niras as · as the pipe moves forward it experiences compression in the intrados of the bend...
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Niras ASLocation: Bø in Telemark, Norway
World wide supplier of induction bending
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Why use induction bending?
Geometry
Induction bending allow designers more freedom
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Why use induction bending?
Flow
Designing piping systems with smooth arcs, no welds and larger radii, reduces turbulence and pressure drop and increase the effectivity of the system.
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Why use induction bending?
Reduce number of welds *Cost saving designs*
Traditional6 welded joints
Induction spool0 welded joints
Induction bends1 welded joint
Induction bends2 welded joints
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Induction bending
Basic principle
The principle behind induction bending is to heat up a small cross section of a pipe or profile to such an extent that plastic deformation can be performed by applying relatively small forces.
The work piece is forced forward through the induction coil while guided by a rotating arm.
Only applying heat to a small section allow high level of control and prevents the pipe or profile from collapsing.
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Induction bending
Induction heating
An induction coil with alternating current is used to introduce an electromagnetic force field around a work piece.
The magnetic field induces an electric current(eddy-current) at the surface of the work piece.
Resistance in the work piece causes the current to generate heat.
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Induction bending
Heat zone
The physical bending of the pipe or profile is done within a controlled heated zone.
The width of the zone is controlled by the air-, induction- and quench spools.
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Induction bending
Temperature control
The temperature of the heated zone is controlled by pyrometers.
Examples of temperature ranges:Carbon steels (870 – 930 °C)Duplex / Super Duplex (1050 – 1120 °C)Nickel alloys (1050 – 1100 °C)
Pyrometers
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Induction bending
Cooling
Cooling is provided by the air spool and primarily the quench spool(water).
Rate of cooling is essential to control material properties in most iron based alloys.
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Induction bending
The bending machine:
The bending arm grips the pipe in neutral position and rotates around a fixed point as the pipe is pushed forward.
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Induction bending
Intrados/extrados:
As the pipe moves forward it experiences compression in the intrados of the bend causing material build up and thickening of the pipe.
At the same time the extrados of the pipe experience tension. The tension causes the material to stretch and results in wall thinning.
Full scale pressure testing has shown that in spite of the thinner wall in extrados the pipe will fail in the unaffected portion of the pipe and not in the bent area.
Intrados- compression Extrados- tensionMaterial build up Wall thinning
• Large radii- small effect• Small radii- bigger effect
Calculator:http://www.niras.no/downloads.html
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Induction bending
Qualification and testing:
The induction bending process can be qualified and parameters locked, equal to a welding qualification, to ensure equal properties for each bend.
1. Qualification testing2. Production testing 3. Batch testing
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Induction bending
Specifications
• NORSOK M-630, • DNV OS-F101, • ISO 15590-1, ISO 13628-15• TR 1120• Customer/company specifications
Test regime has major cost impact
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Post bending
PBHT:Post Bend Heat Treatment
Applicable for most carbon steels and heavy-wall CRA’s
- Solution annealing- Normalizing- Quenching - Tempering
Capacity: 3.75 MTTemp. range: 580 – 1150 °CWorking zone: 5800 X 2300 X 1000Qualification: NORSOK M-650/API 5L
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Post bending
Surface finish:
Sand blasting
Pickling and passivation of CRA’s
HNO3 (Nitric acid) HF (Hydrofluoric acid) Citric acid
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Materials
Alloys for bending
All electrically conductive materials can be induction bent.
Suitable for induction bending:• All types of steel• Aluminium • Copper• Nickle alloys• Etc.
If properties can be maintained or enhanced after bending depends on the original condition of the material.
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Design
Profiles
Pipe Dimensions: 16 mm and up(Niras max. OD is 18inches)
Profile dimensions: Maximum 300 x 600 mm R up to 22 000 mmAngle: 0° - 300°
Selection of profiles
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Design
Niras design criteria
http://www.niras.no/downloads.htmlIf in doubt please contact us
Commonly used
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Design
Some examples
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IBP example front page
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IBP example test scope
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Case study
Burst testing:
In collaboration with Telemark University Collage, Niras investigated the effect of induction bending on fracture location in burst testing.
Material grades investigated were Duplex (UNS S31803) and Grade 316 (UNS S31600).
All tests performed showed fracture in the tangent.