Reducing cost of choosing pipe bend
Firstly let us know what is pipe bend?
Pipe bend is also called induction bending. Induction bending is a controlled method of bending a pipe by using high frequency induction power to apply local heating.
Initially used to harden steel on the surface, the induction technique used when used for pipe bending basically consists of induction coils placed around the pipe to be bent.The induction coil heats the narrow circumferential portion of the pipe to temperatures between 850 and 1100 degrees Celsius (depending on the material to be formed).When the correct bending temperature range is reached, the pipe moves slowly through the induction coil and the bending force is applied through the fixed radius arm.
How to manufacture induction pipe bend?
By making a straight pipe through the induction bending machine in a factory to form induction pipe bend. The machine uses induction coils to heat the narrow band of the piping material.
The front end of the pipe is clamped on the pivot arm. When the pipe is pushed over the machine, a bend is produced with the desired radius of curvature. The heating material just outside the induction coil is quenched with water jet on the outer surface of the pipe.
Due to the unheated pipes on both sides, the thermal expansion of the narrow heating portion of the pipe is limited, which results in shrinkage of the diameter during cooling. The induction bending process also results in wall thickening on the inner arc and thinning on the outer arc.
The severity of thickening/thinning depends on the bending temperature, which is driven by the speed of the induction coil, the position of the induction coil relative to the pipe (closer to the inner or outer arc), and other factors. Most inductive bends are made with tangent ends (straight lines) and are not affected by the induced bending process.
Making a field weld or connecting a pipe cutting part to an unaffected tangent end allows an assembly similar to that obtained when the straight part of the pipe is welded together. Inductive bends are made with a standard bend angle (e.g. 45°,90°, etc.) or can be customized to a specific bending angle. It is also possible to produce a composite bend (out-of-plane) bent in a single pipe joint. A function that specifies the diameter of the bend radius. For example, the common bending radii for induction bending are 3d,5d and 7D, where D is the nominal pipe diameter.
Benefits of Induction pipe bend:
The large radius allows for smooth flow.
Cost-effective, straight materials cost less than standard parts such as elbows, and bends can be produced faster than standard parts that can be welded.
Where applicable, the elbow can be replaced with a larger radius elbow, which can then reduce friction, wear and pump energy. Inductive bending reduces the number of welds in the system.
It eliminates welds at the critical point (tangent) and increases the ability to absorb pressure and stress.
Induction bending is stronger than elbow with uniform wall thickness. Less nondestructive testing of welds, such as X-ray inspection, can save costs.
The elbows and the standard bent inventory can be greatly reduced. Faster access to basic materials. Straight pipes are easier to obtain than elbow tubes or standard parts, and elbows are almost always cheaper and faster to produce.
A limited number of tools are required (no thorns or spindles are required for cold bends). Induction bending is a clean process. The process does not require lubrication and the water required for cooling is recycled.
If a pipe is bent with a tangent length (tangent bend), it means that the bend has a straight tube length at the end. Typically, the heat-sensing pipe bends should have some straight lengths, the length of which can be customized to the piping system design. The tangent length will make the elbow easier to weld with the pipe.
Long bending radii and tangential straight tube lengths reduce the number of weld points in the piping system, saving work and costs. The most conventional elbow is 30 degrees, 45 degrees, 90 degrees, bending radius of 3D, 5D,7D,10D, where "D" indicates the nominal diameter of the bend.