Gas trunk lines, crude export lines and large water transmission systems increasingly use pipe of 48 inches and above. Bending at this scale is not simply a bigger version of bending a 12-inch pipe.

Controlling the heat band

Induction bending heats a narrow ring of the pipe to around 1,000 °C while the pipe is pushed through the coil. On a large-diameter, heavy-wall pipe, keeping that band uniform all around the circumference takes more power and tighter control of push speed. Small variations show up as uneven wall thinning or ovality, so temperature and speed are logged continuously for the full arc.

Heavy walls

Large-bore lines often run with thick walls, and our lines handle walls up to 60 mm. Thicker walls hold more heat, so quench, cooling and post-bend heat treatment are planned bend by bend to reach the required properties through the full thickness.

Handling and machine capacity

An 80-inch bend can weigh many tonnes. Clamps, arms, cranes and the laydown area all have to match. Line 2 at Pipetec covers 24″ to 80″, so pipeline-scale bends have their own line while Line 1 continues with 4″ to 36″ work.

Inspection at scale

Large bends need the same proof as small ones: ultrasonic testing of the bent zone, magnetic particle inspection of the transitions, hardness, ovality and wall-thinning surveys. Doing this in an on-site laboratory keeps the bend in the chain of custody and avoids moving it for testing.

Getting it to site

Oversize cargo needs route planning, permits and heavy-lift transport. From KEZAD, bends can go by road to Saudi Arabia and Oman, or by sea through Khalifa Port with re-export papers for Iraq, Africa and beyond.

Until recently, bends above 48 inches for GCC projects were usually imported. Making them in Abu Dhabi shortens the supply chain for some of the region’s largest pipelines.