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INDUCTION BENDING PROCESS

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Uniform Heating
Induction heating allows for precise control over the heating process, ensuring a uniform temperature distribution throughout the pipe wall. This minimizes thinning and ovality, resulting in more uniform bend.
Uniform Heating
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Predictable Deformation
With controlled temperature profiles, the deformation of the material during bending becomes predictable. This enables precise shaping according to desired specifications, resulting in consistent bend angles and dimensions.
Predictable Deformation
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Consistent Mechanical Properties
Induction heating allows for precise control over the heating process, ensuring a uniform temperature distribution throughout the pipe wall. This minimizes thinning and ovality, resulting in more uniform bend.
Consistent Mechanical Properties
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Multiple Radius Capability
Unlike traditional bending methods that may require different dies or mandrels for different radius. However, the induction bending process allows for the creation of bends with multiple radius using a single setup. This flexibility in design is advantageous for applications requiring complex bends.
Multiple Radius Capability
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Automation and Documentation
The induction bending process highly automated, reducing manual labour and minimizing the risk of human error. Additionally advanced technological features allow for precise control and monitoring of the bending process. Documentation of quality, accuracy, and control parameters further enhances transparency and accountability in the manufacturing process which is monitored by the software Pipe Tracking System.
Automation and Documentation
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Uniform Heating
Uniform Heating
Induction heating allows for precise control over the heating process, ensuring a uniform temperature distribution throughout the pipe wall. This minimizes thinning and ovality, resulting in more uniform bend.
Slide
Vertical Line
Predictable Deformation
Predictable Deformation
With controlled temperature profiles, the deformation of the material during bending becomes predictable. This enables precise shaping according to desired specifications, resulting in consistent bend angles and dimensions.
Slide
Vertical Line
Consistent Mechanical Properties
Consistent Mechanical Properties
Induction heating allows for precise control over the heating process, ensuring a uniform temperature distribution throughout the pipe wall. This minimizes thinning and ovality, resulting in more uniform bend.
Slide
Vertical Line
Multiple Radius Capability
Multiple Radius Capability
Unlike traditional bending methods that may require different dies or mandrels for different radius. However, the induction bending process allows for the creation of bends with multiple radius using a single setup. This flexibility in design is advantageous for applications requiring complex bends.
Slide
Vertical Line
Automation and Documentation
Automation and Documentation
The induction bending process highly automated, reducing manual labour and minimizing the risk of human error. Additionally advanced technological features allow for precise control and monitoring of the bending process. Documentation of quality, accuracy, and control parameters further enhances transparency and accountability in the manufacturing process which is monitored by the software Pipe Tracking System.

PROCESS OVERVIEW

Preparation Preparation
Setup Setup
Heating Heating
Bending Bending
Cooling Cooling
Post-Bend Processing Post-Bend Processing
Finishing Finishing

Preparation

Material Selection Choose the appropriate pipe material based on the required specifications and application (e.g., carbon steel, stainless steel, alloy steel).

Inspection Inspect the pipe for any defects or impurities that may affect the bending process.

Setup

Bending Machine Set up the induction bending machine, ensuring it is calibrated and ready for the specific pipe dimensions and bending angle required.

Heating Coil Install the induction heating coil at the desired bending point on the pipe.

Heating

Induction Heating The induction coil generates a magnetic field that heats the pipe locally at the bending point to a specific temperature, usually between 800-1100°C (1472-2012°F), making the material pliable.

Temperature Control Use pyrometers or infrared sensors to monitor and control the temperature precisely to avoid overheating and maintain the pipe’s integrity.

Bending

Bending Arm A bending arm or die pushes or pulls the heated section of the pipe to the desired angle. The bending is gradual to avoid any abrupt deformation.

Support and Alignment Ensure the pipe is adequately supported and aligned during the bending process to prevent any sagging or misalignment.

Cooling

Controlled Cooling Once the desired bend is achieved, the pipe is cooled either by air or water spray. Controlled cooling helps maintain the mechanical properties and prevent any warping or distortions.

Natural Cooling In some cases, the pipe is allowed to cool naturally to room temperature.

Post-Bend Processing

Heat Treatment (if required) Depending on the material and application, post-bend heat treatment may be necessary to relieve residual stresses and ensure desired mechanical properties.

Inspection and Testing In some cases, the pipe is allowed to cool naturally to room temperature.

Finishing

Surface Treatment Apply surface treatments such as coating or painting to protect against corrosion.

Final Inspection Conduct a final inspection to ensure the pipe meets all specifications and quality standards.

PROCESS OVERVIEW

Preparation Preparation
Setup Setup
Heating Heating
Bending Bending
Cooling Cooling
Post-Bend Processing Post-Bend Processing
Finishing Finishing

Preparation

Material Selection Choose the appropriate pipe material based on the required specifications and application (e.g., carbon steel, stainless steel, alloy steel).

Inspection Inspect the pipe for any defects or impurities that may affect the bending process.

Setup

Bending Machine Set up the induction bending machine, ensuring it is calibrated and ready for the specific pipe dimensions and bending angle required.

Heating Coil Install the induction heating coil at the desired bending point on the pipe.

Heating

Induction Heating The induction coil generates a magnetic field that heats the pipe locally at the bending point to a specific temperature, usually between 800-1100°C (1472-2012°F), making the material pliable.

Temperature Control Use pyrometers or infrared sensors to monitor and control the temperature precisely to avoid overheating and maintain the pipe’s integrity.

Bending

Bending Arm A bending arm or die pushes or pulls the heated section of the pipe to the desired angle. The bending is gradual to avoid any abrupt deformation.

Support and Alignment Ensure the pipe is adequately supported and aligned during the bending process to prevent any sagging or misalignment.

Cooling

Controlled Cooling Once the desired bend is achieved, the pipe is cooled either by air or water spray. Controlled cooling helps maintain the mechanical properties and prevent any warping or distortions.

Natural Cooling In some cases, the pipe is allowed to cool naturally to room temperature.

Post-Bend Processing

Heat Treatment (if required) Depending on the material and application, post-bend heat treatment may be necessary to relieve residual stresses and ensure desired mechanical properties.

Inspection and Testing In some cases, the pipe is allowed to cool naturally to room temperature.

Finishing

Surface Treatment Apply surface treatments such as coating or painting to protect against corrosion.

Final Inspection Conduct a final inspection to ensure the pipe meets all specifications and quality standards.

ADVANTAGES

  • Precision Allows for accurate and consistent bends.
  • Strength Maintains the structural integrity of the pipe.
  • Versatility Can handle a variety of materials and pipe sizes.
  • Efficiency Faster and more cost-effective compared to traditional bending methods.

TYPES OF BEND

  • Quarter 90° bend
  • Angle bend (0-180°)
  • S-bend/offset bend
  • Curved tube up to 813

MATERIAL CAPABILITIES

  • Pipe diameter 114.3mm ("4”) to 2032mm ("80”)
  • Material thickness Up to 60mm
  • Materials Carbon steel, alloy steel, stainless steel, and more.

PRODUCTION BEND

Product Range

Pipe Diameter

4 inch to 80 inch

Thickness

6.35mm to 60mm

Bending Radius

2D≤R≤10D

Bending Angle

0 to 90 degrees

Max. Arc Length

18 Meters

Grade

API 5L X-80

SAFETY MEASURES AT PLANT

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