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Piping Systems
Bilfinger Piping Technologies GmbH

Custom made bends
Inductive and cold bending
PIPING
SYSTEMS
Custom made bends 1

Piping Systems
Contents
Page
3 5 Application areas
6 Materials
7 Manufacturing know-how
8 9 Production program
n Technical data
n Bending program

10 Benefit: less buttwelds
12 13 Bend geometry
14 Activities after bending

n Heat treatment
n End preparation
n Spool fabrication
n Surface preparation
n Packing
15 Tests and certificates
16 Cold bending
18 19 Locations, contacts
2 Custom made bends

Piping Systems
Application areas
n Conventional and
nuclear power stations
n Chemical and
petrochemical industry
n Compressor stations
n Offshore and onshore plants
n Hydraulic plants
n Industrial plants
n Steel producing industry
n Public utilities
Custom made bends 3

Piping Systems
Application areas
The pipe structure Snake

Pier is a masterwork of
engineering. The 112 meters
long pedestrian bridge is
supported by a pipe snake
consisting of 59 various
seamless pipe bends
Induction-bends
made from centrifugally
casted pipes
New building of the

power plant
Neurath BoA 2&3 Cold
reheat line
Material:
OD 762 x 31 WT, 16 Mo3
4 Custom made bends

Piping Systems
New building of the power

plant Niederaussem
Hot Reheat Line,
ID 720 x 48 MWT
Material:
X11CrMoWVNb9-1-1
Induction-bends for the new

building of the power plant
Neurath BoA 2&3
Main Steam,
ID 355 x 96 MWT
Material:
X10CrWMoVNb9-2
Turbine hall of the new

nuclear power plant
Olkiluoto 3 (Finland)
Custom made bends 5

Piping Systems
Materials
n Normal carbon steels
n Fine grain steels
n Low temperature steels
n Steels for pipelines, including

thermo mechanically treaten steel
n Steels for hydrogen service
n Heat resistant steels
n Stainless and acid

resistant steels
n Stainless Duplex and

Superduplex Steels
n Centrifugally cast pipes,

Ni-alloy basis
n Cu and Cu-alloy pipes
n High temperature steels
n Case hardening and quenched and

tempered steels
Fabrication of austenitic piping in white environment
6 Custom made bends

Piping Systems
Manufacturing know-how
The schematics give a visual impression of

the major activities of the manufacturing
process and quality control of custom made
steel bends fabricated by Bilfinger Piping
Technologies. Our manufacturing and test
procedures will be customised to suit the
specific application, materials and clients
specification.
N b
D Z B
a
N
Incoming inspection of base pipe Measuring and marking Induction bending Dimensional check
Heat treatment Dimensional check Hardness test Cutting off ring specimens
Destructive testing Cleaning Non-destructive testing Non-destructive testing

(weld seam) (bend)
BHR12
34567
Machining of weld bevel Non-destructive testing (pipe ends) Labeling
WD mm Temp. Korrosionsschutz
Temp. Corrosion Protection Material
Certificate
Ummantelung
Coating
Anstrich
Painting
Final inspection Corrosion protection Documentation Pipe bends, ready for shipment
Custom made bends 7

Piping Systems
Induction bends
TECHNICAL DATA
Minimum pipe OD 48.3 mm

Maximum pipe OD 870.0 mm
Min. pipe wall thickness tmin. 4.0 mm
Max. pipe wall thickness tmax 120.0 mm
(larger wall thicknesses upon agreement)
Minimum bending radius Rmin. 100.0 mm
Maximum bending radius Rmax 4600 mm
Maximum bending angle at
bending radius > 300 mm 180
Straight inlet and intermediate pipe
length at complex (multiple) bends 460/600/1050 mm*
Required straight pushing length 1150/2350mm*
*shorter lengths upon agreement
BENDING PROGRAM BASED ON RMIN
The following chart indicates the minimum

possible bending radii over the pipe wall
thickness and diameter, for ferritic and
austenitic materials.
BENDING OPTIONS
inch mm Bending radii 1.2 x D 10 x D
34 860.0
32 813.0
00
46
00
00
40
28 711.0
30
00
24 610.0 20
00
20 508.0 15
00
16 406.4 10
500
Outside diameter
12* 323.9
8* 219.3 300
200
4* 114.3
1.9 48.3
4 6 8 10 11 12 14 16 18 20 24 30 40 50 60 70 80 100 120
Minimum wall thickness (mm)
*Nominal bore (DN)
For austenitic materials the minimum possible radius is 1.3 x D
8 Custom made bends

Piping Systems
R/D RATIO
The bending radii shown in the chart

Bending options are the minimum s
b Da
possible ones limited by the manufacturing B
process. However, those are not the B B Di
optimum bending radii. b b
s s
In the following table one can see that at
larger R/D ratios and at fixed center-to-end
Da Da
dimensionsBthe stretched straight
B length of
sa
the bend decreases. b b
sa sa Di Di
A
Sys =
s s B
Sys =
Consequently, if the R/D ratio is increased
si Rm Da
Au =
then: Di
Inn =
n less pipe is required A Da Da s
Wa =
sa
Wa =
n TheA
wall thinning in the
A
extrados zone Bo
sa and the wallsthickening
a in the intrados si si D
i A =
Systemma Di A = Systemma
center to end dimension
si = Wa
Bo
zone will decrease B =
Systemma B = Systemma
Rm = Mit
a Da =
AuendurchmesserDa = Auendurchmesser
outside diameter outside diameter
= Bie
n material costs will decrease Rm Rm
Di =
InnendurchmesserDi = Innendurchmesser
inside diameter inside diametera = Ge
n pressure loss will be lesst s =
Wanddicke des sRohrs = Wanddicke
pipe wallthickness
des Rohrs pipe wallthicknessb = Ge
n flow conditions improve sa =

Wanddicke
an der
sa = Wanddicke
wallthicknessanextrados
der wallthickness extrados
A Bogenauenseite Bogenauenseite
si si
A = Systemma A = center stoi end
Systemma = dimension
Wanddicke
center sto
an der = dimension
i end Wanddicke
wallthicknessanintrados
der wallthickness intrados
B = Systemma B = center
Systemma Bogeninnenseite
to end dimension Bogeninnenseite
a a Da = Auendurchmesser Da = outsideRdiameter
m = Mittlerer outside
Auendurchmesser Rm
Biegeradius = Mittlerer
mean bending
diameter Biegeradius
radius mean bending radius
Rm Rm
Di = Innendurchmesser Di = inside = Biegewinkel
Innendurchmesser
diameter = Biegewinkel
inside diameter bending angle bending angle
s = Wanddicke des Rohrs
s = pipe a =desGerader
Wanddicke
wallthickness Rohrs Schenkela = Gerader
tangent length
pipe wallthickness Schenkel tangent length
sa = Wanddicke
an der
sa = b =anextrados
wallthickness
Wanddicke Gerader
der Schenkelb = extrados
wallthickness Gerader
tangent length
Schenkel tangent length
Bogenauenseite Bogenauenseite
si = Wanddicke an der si = wallthickness
Wanddicke anintrados
der wallthickness intrados
Bogeninnenseite Bogeninnenseite
a a Rm = Rm =
Mittlerer Biegeradius mean
Mittlerer
bending
Biegeradius
radius mean bending radius
= Biegewinkel = bending
Biegewinkel angle bending angle
a = Gerader Schenkel a = tangent
Gerader length
b = Gerader Schenkel b = tangent
Gerader length
CALCULATING OF NECCESSARY PIPELENGTH FOR INDUCTION BENDS
Examples for calculating the total straight length

example N 1.0 2.0 3.0 4.0
outside diameter mm 323.9 323.9 323.9 323.9
wall thickness mm 20.0 20.0 20.0 20.0
bending angle Degree 90 90 90 90
bending radius mm 490 970 1460 1945
radius/OD-ratio 1.5 3.0 4.5 6.0
center to end dimension A mm 2000 2000 2000 2000
center to end dimension B mm 2000 2000 2000 2000
tangent length a mm 1510 1030 540 55
tangent length b mm 1510 1030 540 55
total straight length incl. squashing mm 885 1646 2385 3147
total straight length mm 3905 3706 3465 3257
squashing in % 15 8 4 3
Custom made bends 9

Piping Systems
Material
EXAMPLE 1
Conventional design:
9 buttwelds (left)
Using complex (multiple)

bends: 3 buttwelds (right)
EXAMPLE 2
Conventional design:
6 buttwelds (left)
Using flange ends and

integral reducer: no buttweld
required (right)
n High accuracy of shape

n Custom made individual bends
n Less buttwelds by using
complex bends
n Materials for all applications
10 Custom made bends

Piping Systems
Custom made bends 11

Piping Systems
Bend geometry
Custom made bends from steel pipes have

a high accuracy of shape. Bending with
induction heat input is an advanced
procedure using a highly automated and
continuous forming process. During the
process the pipe will be pushed into a
narrow zone which is heated by a ring
shaped inductor. The bending force will be
applied axially to the pipe, the front end of
which is fixed in a swivel-arm. During the
bending process the bending arm will move
around its axis on a circular arc with the
specified radius. Through the applied axial
force the pipe follows the set circular path.
WALL THICKNESS
During the bending process the pipe

wall thickness at the bend extrados will
decrease, the same at the bend intrados
will increase. The percentage amount of
difference between the wall thickness of the
finished bend and that of the actual wall
thickness of the prepipe depends mainly on
the ratio of bending radius to pipe outside
diameter (R/D). The following chart gives
guidelines of the changes in the wall
thickness when using our bending
machines.
CHANGE OF WALL THICKNESS AT BENDING
20
% Reduction
max. reduction
10
10
min. increase
20
% Increase
30
40
Air
Water
50
60
0 1 2 3 4 5 6 7 8 9 10 11
R/D ratio

Piping Systems
Our bending technology guarantees

moderate wall thickness reductions.
The calculation conditions of accepted
international norms and standards
applicable for straight seamless pipes
without wall thickness allowance will
be complied with. When specifying the
required minimum wall of the pipe one
has to consider the wall thinning in
addition to other allowances (e.g. scaling
and blastcleaning).
OVALITY
The chart shows the expected ovalities.

The achievable values depend among
other factors on the ratio of diameter to
wallthickness.
We are in the position to achieve

considerably better ovality values than
the limit figures in the VGB rules.
TOLERANCES
Our dimensional tolerances are in

accordance with:
n EN 13480-4 and
n PFI-Standard ES-3 (PFI = Pipe Fabrication
Institute Springdale, PA 15144)
ACHIEVABLE OVALITY IN CONNECTION WITH R/D AND D/WT RATIO
10
9
8
7 8
0D
Ovality in %
6 /S
4
5 0D
/S
4 2
0D
/S
3 10
D/S
2
1
0
0 1 2 3 4 5 6 7 8 9 10 11
R/D ratio

Piping Systems
Shop fabrication after bending
HEAT TREATMENT SURFACE PREPARATION
Induction bends may be heat treated after The finished bends upon clients request can
bending, as per requirements of material be blastcleaned, acid-cleaned, coated with
and application. We have furnaces with temporary corrosion protection or painted.
accurate temperature control up to 1200 C.
After the heat treatment the options of
cooling with air or quenching with water PACKING
are available.
Our Bilfinger Piping Technologies Packing
END PREPARATION Guidelines can be made available to the
client to help in their decision of packing.
The finished bends will be delivered as per Packing can of course take place in our
clients specification either with plain ends works, if required we also offer seaworthy
or with welding bevels. packing.
SPOOL FABRICATION
We also offer assembly of multiple bends

to spools with welded stubs, stop blocks,
flanges, etc.

Piping Systems
Tests and certificates
All destructive and non-destructive tests APPROVALS

can be performed in our own laboratory in
the factory. In the case of special tests we We are in possession of all national
co-operate closely with approved testing and international approvals for the
institutes. Representatives of the most manufacturing of all types of high
important Third Party institutes are present pressure piping components:
every day at our works. TV Technical Inspection Authority
AD-2000
PED
TRD
DIN 18800 / EN 1090
DVGW
ASME
EN ISO 3834-2
The Bilfinger Piping Technologies

Quality System is certified by:
DIN/ISO 9001 / EN 29 001 / SCC
KTA 1401
AVS D100 / 50
IAEA50-C-Q
EN ISO 14001
Currently we are holding the following

ASME Symbol Stamps:
ASME S / PP / U / U2

Piping Systems
Cold bending
The Bilfinger Piping Technologies manu

facturing portfolio is supplemented with a
CNC cold bending machine which is suitable
for bends between 10 and 168.3 mm pipe
outside diameter and a maximum bending
radius of 820 mm. We guarantee our cold
bends with R/D ratios larger than 3.0 wall
thickness reduction smaller than 20 % and
ovalities better than the VGB guidelines.
The next table indicates the options of

standard cold bending.
STANDARD BENDING PROGRAM OF COLD BENDS
Pipe OD mm Available tools average bending radii
10.0 20
12.0 25
13.5 500
14.0 30
16.0 30 50 150
17.2 40 55 80
20.0 40 60
21.3 40 60 80 90 135
22.0 45 65
25.0 45 50 75
26.9 40 60 80 90 100 150
30.0 30 60 90 100
31.8 100 110 130 140 150 170
33.7 70 90 100 110 120 134 220 167
35.0 70 150
38.0 50 80 100 120 140 150 170 210 250
42.4 85 120 150 180 230 250
44.5 120 150 240
48.3 90 100 125 145 160 170 190 200 280
51.0 60 150 200 230
57.0 110 120 175 240
60.3 100 150 180 200 240 250 400
63.5 190 200 250
70.0 100 140 200 280 320
73.0 250 465 560 650 740
76.1 110 160 190 230 260 305
88.9 270 320 360 450
101.6 330 400
108.0 310
114.3 295 350 400 450 760
126.0 300 400 457
139.7 420 500
168.3 600 675 820

Piping Systems

13 Essen-Nord
42
Essen-
Piping Systems 224 Altenessen
Our location in Essen Essen-

Vogelheim
42
e
stra
irch
13 Essen-Nord an nisk
Wo l b
42 Joh
ecks
Essen- Gewerbegebiet
224 Altenessen Teilungsweg
224
trae
Essen- eg
Vogelheim n gsw
Teilu

Shop Essen
Wolbeckstr. 25
45329 Essen
e
Germany stra
i s k irch
Telephone +49 201 ann
3645-0
Wo l b
Joh
Fax +49 201 3645-232
ecks
Gewerbegebiet
info.piping@bilfinger.com
Teilungsweg
224
trae
eg
n gsw
Teilu

Piping Systems
Our location in Dortmund
e
Stra
te ner
Mar Gewerbegebiet 45
Alter eg Dortmund
llw
Hellweg He
Kesselb
Dorstfeld
Pla
Martener
ne
orn
ten
g Kreuz
lwe
fel
Hel Dortmund-West
ds
tra
r
te
Al
e
Bo 40 Dortmund
ru Dorstfeld
ss B1
ia
-
41 Dortmund
Kley
st
ra
e
ae
rstr
Hauert
Dortmund Kley bo
45 nna
B re

Shop Dortmund
Alter Hellweg 33
44379 Dortmund
Germany
Telephone +49 231 6182-0
Fax +49 231 6182-341

Piping Systems
Piping Systems

Europaallee 1
46047 Oberhausen
Germany
Phone +49 208 4575-10
Fax +49 208 4575-5111
www.piping.bilfinger.com

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Piping Systems

Bilfinger Piping Technologies GmbH

Custom made bends

Inductive and cold bending

Custom made bends 1

14 Activities after bending

15 Tests and certificates

2 Custom made bends

n Offshore and onshore plants

n Steel producing industry

Custom made bends 3

The pipe structure Snake

New building of the

4 Custom made bends

New building of the power

Induction-bends for the new

Turbine hall of the new

Custom made bends 5

n Normal carbon steels

n Fine grain steels

n Low temperature steels

n Steels for pipelines, including

n Steels for hydrogen service

n Heat resistant steels

n Stainless and acid

n Stainless Duplex and

n Centrifugally cast pipes,

n Cu and Cu-alloy pipes

n High temperature steels

n Case hardening and quenched and

Fabrication of austenitic piping in white environment

6 Custom made bends

The schematics give a visual impression of

Destructive testing Cleaning Non-destructive testing Non-destructive testing

Machining of weld bevel Non-destructive testing (pipe ends) Labeling

Custom made bends 7

Minimum pipe OD 48.3 mm

BENDING PROGRAM BASED ON RMIN

The following chart indicates the minimum

inch mm Bending radii 1.2 x D 10 x D

8 Custom made bends

The bending radii shown in the chart

n flow conditions improve sa =

CALCULATING OF NECCESSARY PIPELENGTH FOR INDUCTION BENDS

Examples for calculating the total straight length

Custom made bends 9

Using complex (multiple)

Using flange ends and

n High accuracy of shape

10 Custom made bends

Custom made bends 11

Custom made bends from steel pipes have

During the bending process the pipe

CHANGE OF WALL THICKNESS AT BENDING

12 Custom made bends

Our bending technology guarantees

The chart shows the expected ovalities.

We are in the position to achieve

Our dimensional tolerances are in

ACHIEVABLE OVALITY IN CONNECTION WITH R/D AND D/WT RATIO

Custom made bends 13

Shop fabrication after bending

HEAT TREATMENT SURFACE PREPARATION

We also offer assembly of multiple bends

14 Activities after bending

n Offshore and onshore plants

n Steel producing industry

n Normal carbon steels

n Fine grain steels

n Low temperature steels

n Steels for pipelines, including

n Steels for hydrogen service

n Heat resistant steels

n Stainless and acid

n Stainless Duplex and

n Centrifugally cast pipes,

n Cu and Cu-alloy pipes

n High temperature steels

n Case hardening and quenched and

n flow conditions improve sa =