Installing Industrial piping system is a large enterprise in itself. It is not just the simple pipes but a wide range of fittings, valves and other special components that are used in various fields of application and completes the entire piping package. The variety of pipe components that are available these days are perfectly suitable for building an entire plant on any range of dimension or structure. Generally speaking, these piping systems are a network of pipes, fittings and valves that are designed to carry fluid from one location to another. There are different types of piping systems like steam piping, refinery piping, milk piping and many more. Highly specialised engineering and design services are employed in manufacturing the modern piping systems.
Talking about technological advancement, let us have a look at the Induction Bending Technology used profusely in the piping system.
Induction bending technology is a technique used to heat steel locally by induction. The heat results in formation of heat band that grows in the shape of bent. To get a proper radius out the created structure, the shape is held by clamp at one stand pivoted on a free arm. The shape that is formed is passed through an inductor, an accurate drive system that creates hot bend and set the structure in the desired radius.
Get an idea of some of the characteristics of induction bends.
- There is not any requirement of bending die for preparing bends like detoured conduits or pipes with multiple bends.
- Induction bending ensures that the bend radius and the angle may not be affected by spring-back and the dimensional stability should be maintained.
- Small radius pipes prepared using high pressure steams could be manufactured under controlled conditions like the heating or cooling temperature.
How the induction bending technology works?
Within the induction bending technology a straight pipe is put over machine bed where the heating coil is located around pipe present at one end. The heating coil then helps in creating a narrow and enclosing heated band around the material. After reaching the required temperature, the pipe is pushed through an inductor to give a shape of bend. As the material passes through the coil, it is simultaneously cooled by a controlled cooling system.
Why is Induction Bending technology advantageous?
- It is a cost efficient method. Working with a straight material is much better than using standard component of bends such as elbows etc. These standard components cannot be welded easily as against the bend which could be produced faster.
- These bends can easily replace the elbows with their larger bends and reduced friction.
- The induction bending technology helps in reducing the number of welds in a system, creating less complexity.
- Unlike cold formation methods, induction bending helps in reducing the deformity of the material and keeps the cross-section radius intact even if there is a bent on it.
- It limits wall thinning, ripping and ovality.
- Lubricants are not required in this process hence this is a cleaner and tidier one than others.
- The bends that are created do not require any additional dies or mandrels.
- There is even lower use of non-destructive testing which leads to cost reduction. Thus the fabrication time as well as fabrication cost is greatly reduced.
- Bends are not easily available as are the straight pipes. Thus, using a straight pipe reduces the time than it takes to search for a bend one.
There are different types of bends that are present in market?
- Short & Long Radius: The elbows are categorized as short and long radius and the main difference between them is length and curvature. A short radius gives the pipe a narrower and sharper turn while in longer radius, there is a broader and a blunter view. A longer radius pipes gives less friction to the flowing fluid and a lower pressure drop.
- Miter bends: This type of bend is developed by cutting pipe ends at some angle and joining the ends. A true miter bend is of 90 degree which is created by cutting two pipes at 45 degrees.
The Variety of Applications of Induction Bending Technology
- Petrochemical: Petrochemical industries are utilizing the induction bends for a long time to transport petrol or diesel from one location to another.
- Chemical industries:Induction bending has been successfully used in transportation of chemical fluids from one place to another with no issues over leakage or any material reaction.
- Power Generation industries: Conventional power generation industries such as hydro, electric or tidal power and nuclear power generation.
- Compressor and pump stations: The petrol and diesel pump stations make use of induction bends for easier and faster transportation of fluids. The pressure points of the pipes at appropriate angles helps in safer flow of the chemical.