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Pipe bending is a process wherein the pipe to be bend
is heated to a specified temperature by high frequency induction heating coil and
bending is done in hot condition. The pipe is clamped at the forward end by the
radius arm clamp. The tail end of the pipe is locked in the pushing carriage clamp.
The pushing carriage moves on the main track as it is fitted with a chain, which
is driven by a DC Motor at a fixed constant speed through a gearbox.
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When current is supplied through high frequency current
transformer to the coil, heating of pipe starts. The heating temperature is strictly
controlled depending upon the material of the pipe and its wall thickness. When
the specified temperature is attained, the DC Motor is started at a preset speed
which drives the pushing carriage in the forward direction. As a result the pipe
begins to advance being bent simultaneously.
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Immediately after the bending process, quenching will
follow. The Radius Arm is designed so that the pipe will be bent by the same distance
as the one between the center of a pair of rollers and the axis point of the arm.
The arm rotates in natural mode around the pivotal point. The heated portion begins
to transform its elasticity due to the difference of strength between the heated
and unheated portion of the pipe.
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BRIEF DESCRIPTION OF PIPE BENDING MACHINE :- |
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Pipe Bending Machine consists of the following: |
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1. Hydraulic system.
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2. Induction heating unit. |
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3. DC drive system for constant movement of pipe during bending. |
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4. Water cooling system for quenching. |
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5. Optical pyrometer for temperature monitoring. |
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6. Air cooling system. |
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7. The mechanical system. |
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1) HYDRAULIC SYSTEM:-
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The hydraulic system consists of a power pack and is designed for 10,000 PSI Psi
working pressure. |
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It consists of total of twelve cylinders
and are used as follows: |
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Two cylinders for clamping the pipe
on pushing carriage. |
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Two cylinders for clamping the pipe
on forward carriage. |
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Four cylinders for fixing the pivot
base in pivot track. |
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Four cylinders for fixing the forward
carriage on radius arm. |
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The hydraulic system is equipped with special type of return valve. |
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2) PIPE HEATING UNIT:-
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The Pipe Bending Machine is equipped with 500 KW,
1 KHZ power supply; a matching transformer kept on a matching transformer stand
which can be moved in three direction viz. forward/reverse; up/down and left/right
direction and so the air, induction and water quench coils are concentric. |
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3) DC DRIVE
SYSTEM:- |
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DC drive system consists of a DC motor
and a gearbox. The DC motor is run with a DC drive. The DC motor is fitted with
a taco generator to have a precise speed control. The pushing is controlled with
a chain mechanism, DC motor & gear assembly in forward and reverse direction. |
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4) WATER COOLING
SYSTEM FOR QUENCHING:- |
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There are three water cooling circuits
in the machine. De-mineralized water circulation is used for cooling the induction
furnace. DM water is stored in a water tank, circulates in the induction furnace
and returns back to the DM water tank. The DM water is maintained under specific
temperature with the help of a heat exchanger. Quenching and simultaneously cooling
of the pipe is done with the help of another raw water line. Raw water is sprinkled
continuously on the pipe from the water coil adjoining the induction coil. |
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5) OPTICAL
PYROMETER:- |
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It consists of a temperature sensor
fitted in the vicinity of heating area and is focused on the heated zone. The digital
monitor is fitted on the operators console for the constant monitoring of the temperature
of the pipe recorder. Temperature recorder records temperature maintained during
the bend manufacturing. |
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6) AIR COOLING SYSTEM
:- |
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Air cooling system is used to divert
the quenching water away from the induction coil and the heated zone to have uniform
heating of the pipe. |
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7) MECHANICAL SYSTEM:-
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The mechanical system consists of
a Pushing Carriage, Forward Carriage, Radius Arm, Pivot Base, Pivot Track, Chain,
Gear box etc. |
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PRODUCT RANGE:-
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MAX. PIPE SIZE
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42” (1066 MM OD)
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MIN. PIPE SIZE
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8” (219 MM OD)
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WALL THICKNESS
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8 - 40MM (MAX. 30MM FOR 42” PIPE DIA)
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MAX. PIPE LENGTH
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16Mtr.
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MAX. BEND RADIUS
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6400 MM
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MIN. BEND RADIUS
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750 MM
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FEED SPEED
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0—250 MM/MIN.
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BEND ANGLE
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0—180°
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MAX. ARC LENGTH
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9500 MM
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Application Area |
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Induction
bent steel pipes are mainly employed in the following application area |
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Piping system in conventional and
nuclear power stations
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Turbine piping
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Oil and gas pipelines and compressor
stations
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Chemical and petrochemical process
engineering
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Riser bends for off shore platforms
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Building and bridge construction
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