AWS Profile EN IR

AWS Schäfer 50 years of experience in manufacturing of pipe forming machines

AWS Schäfer Induktion Bending Machines

• Variable bending radius. The proposed technology enables manufacturing of elbows with different radiuses within the length of the pipe, including radii less than 1.5 x D, using only one set of tooling for the same diameter pipes. Bending radius can be anything from 1.5 to 40 DN

• Bending can be performed with preservation of some straight sectionslength both before bending area and behind, as well as in between. Itreduces the number of welds in the system and prevents welding oncritical points (tangential), which can not be avoided in the manufacture of assemblywelding units

• High quality of elbow, low wall thinning and ovality, high performance

• Minimal required set of tools does not require large amounts of the expensive stamping equipment as in the manufacture of stamped elbows.

• CNC system based on an industrial PC in combination with Hydraulic power and thanks to a special algorithm of coordinated movements of the inductor and the pipes for great quality with minimal human intervention

The advantage of the induction bending

Induction bents with large radius for oil & gas pipelines

Induction bents with tight radiusfor gas pump station

Induction bents made of heat resistant steelfor nuklear power plants and oil refineries

Induction bents for steel bridges

Bending of reqtangual pipies

Bending of beams

Induction bents for steel construction

Induction bents for steel construction

Unit bent

Unit welded

Induction bents without welding joints

Stamped elbow of two pieces Ø 1020 x 32 mm R= 1,5 X D, 90°

Induction bent Ø 1020 x 32 mm R= 1,5 X D, 90°

At least 17 different manufactoring processes

Costs intensive manufactoring process

High amount of specialist is required

Pressure keeping 2,0 of nominal

Delivery time 1 pc. approx. 7-10 days.

Only 5 different manufactoring processes

Low costs manufactoring process

Low amount of specialist is required

Pressure keeping 3,0 of nominal

Delivery time 1 pc.approx. 0,5 day. ( at least 6,5 days faster than stamped technology)

Induction bents vs stamped technology

Export potential for induction bentsOil & Gas

Pipe diameter Ø 57 mm – 1660 mm

Pushing force up to 5000 kN

Bending moment up to 10.000 kNm

Wall thickness 4 mm till 120 mm

Radius from 1,0 x D till 10 m

Bending speed 3-150 mm/min

S355 - P92,

austenitic steel

ferrititc steel

Technical Specifications

Over 30 pcs. Induction BendingMachines built.

T – Forming Machines

Steel T-fittings with diameter from 57 mm till 1020 mm ( or due to customers specifications) made of austenitic and ferritic grades of steel

Elbows with small radius with diameterfrom 57 till 1020 mm made of austenitic and ferritic grades of steel

Reducers with diameter from 57 mm till 1020 mm made of austenitic and ferritic grades of steel

AWS Machines For Tees

Machine Closing Filling with water

Horizontal cylinder advance

Control water pressureHolding cylinder controlled

Pressure releasePress open part removal

T – Forming Process

SHFC 40 - 2014

New Generation Type: SHFC

1. Pipe stock 2. Pipe cutting 3. Sand blasting/Cleaning/Brushing

4. Lubrication 5. Hydroforming 6. Heat treatment

7. Cutting off the cap 8. End preparing 9. Marking

T-Fitting Production Line

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100

Most cost effective production method

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Ho

t fo

rmin

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Hy

dro

form

ing

Cost comparison with hot formingtechnology

Advantages of Hydroforming

Proposal for creation of high-efficiency, highly effective and flexible production of pipeline fittings which guaranties:

Reduction of a work cycle of manufacture of a product - cost price advantage

Increasing mechanical characteristics of a tee at the expense of a cold hardening and the subsequent heat treatment

High efficiency,

Manufacturing of products according to all standards like DIN, ANSI, Gost

Minimal production time, in comparison with other technologies

100 % repeatability of the sizes and properties of dimensions

Less influence of the human factor on the basic processes, as a consequence of the high quality output

The minimum requirement of the highly skilled personnel

One Machine = Three Functions:

1. Pipe Clading

2. Pipe Calibration

3. Hydro Static Testing

AWS Bi-Metal/Clad Pipe Technologies

Modern oil production conditions have changed significantly. The development of new oil fields takes place in the more inaccessible areas with unfavorable geological and climatic conditions for all kinds of work (drilling, construction, maintenance of bore hole) and without production and social infrastructure. Oil downstream in well-developed regions is associated with other complications: most of the bore holes are open to 20-40 years ago, characterized by a decrease in production rate, high water content and increased corrosion of downhole equipment.

The most vulnerable in respect of corrosion are drilling tubing. Active ingredients contained in the upstreaming fluids such as hydrogen sulfide (H2S), carbon dioxide (CO2), oxygen (O2) initiate corrosion on the inner surface of the tubing and substantially reduce their operating life resurses.Operational time drill pipes on some fields do not exceed 1 year. Exploitation of these bore holes is extremely difficult due to the increase in the number of failures in the downhole tubing end equipment. The maintenance of the down hole tubing creates costs and consequently leads to an increase oil price.Researches on nature of pipe metal damage clearly points to the fact that most of the defects is corrosion origin. Thus increasing the service life of the tubing can be achieved by increasing their corrosion resistance.


A traditional method against corrosion used is the addition of inhibitors into the media transportation, for example glycerin or other mostly organic compounds. Due to the expenditure necessary for the injection plant, the waste disposal, the continuous breakdown susceptibility, with its maintenance costs as well as the possible dangers to the environment, this method is normally only used on high productive oil and gas fields.In foreign practice to avoid corrosion damages tubes of different groups of stainless steel and corrosion-resistant alloys austenite stainless steels, high-alloy stainless steels , solid solution nickel-based alloys, ferritic stainless steels , martensitic stainless steels , duplex stainless found wide application. In general these steels and alloys however have a high market price and provide very low strength values when compared with low alloys, so-called ‘black steels’. As a result, high pressures can only be handled if very heavy/ thick walled pipe is used which increases the material cost considerably.

In order to, at least partially balance out this apparent disadvantage, the utilization of so-called clad pipe is recommended. These clad pipes are provided with an approx. 3 mm thick lining made from stainless steels or alloys, thus ensuring corrosion protection. The outside pipe is made from normal high tensile ferrite steels. The AWS Schäfer Technology for clad pipes can be used for production:1. New drilling clad pipes2. Repairing of used drilling pipes by cladding.


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2 3

ToolCladding inner pipe to outer

OuterPipe

Inner Pipe

High pressure for tight connection Finished clad pipe


Process description Hydroforming

The AWS machine is equipped with a two-part tooling featuring two axial horizontal cylinders on each pipe end.

The pipe is inserted into the lower tool half and the tooling is closed.

The pipe ends of inner pipe are sealed by the axial stamps and the pipe is filled by the forming liquid.

The forming liquid generates pressure and expands the inner pipe into the internal surface of outer pipe giving a tight mechanical connection

Finally the tooling is opened and the clad pipe is ejected.

Examples: Pipe Calibration


Examples: Drill Pipes Cladded


Inside corrosion resistant stainless steel pipe

Outside pressure resistant carbon steel

SHFC 240 Pipe Length 6 m


SHFC 320 Pipe Length 12 m SHFC 380 Pipe Length 12 m


Outer Diameter Wallthickness

4" 8.56 mm

6" 10.97 mm

8" 17.7 mm

10" 15.09 mm

12" 17.48 mm

14" 19.5 mm

16" 20.0 mm

20" 20.0 mm

Pipe Diameter Wall Thickness Ratio

Outer Pipe Material Inner Pipe MaterialType Yield

(MPa)Norm

X42 290 API 5L

X52 359 API 5L

X60 414 API 5L

X65 448 API 5L

X70 483 API 5L

X80 552 API 5L

L 360QB 360 DIN EN 10208-2

L 415QB 415 DIN EN 10208-2

L 450QB 450 DIN EN 10208-2

L 485QB 485 DIN EN 10208-2

UNS Type Cr M o N i N PRE

S41000 410 12 — 0,5 — 12

S32100 321 18 — 9,0 — 18

S31603 316L 17 2,5 11,0 — 24

S31703 317L 18 3,0 11,0 0,05 29

N08904 904L 21 5,0 25,0 0,10 39

N08825 Alloy 825 22 3,0 40,0 — 32

N06625 Alloy 625 22 9,0 60,0 — 52

N06059 Alloy 59 23 16,0 59,0 — 75

C70600 CuNi10Fe — 10,0 — —

C71500 CuNi30Fe — — 30,0 —

N08926 Alloy 926 20 6,5 25,0 0,20 45

N08367 Alloy 367 20 6,5 24,0 0,22 45

PRE: Value for pre resistance corossion, (0 - Protection for Steel)

Pipe Material Combinations

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Economical production with AWS Cladding

standard pipe

metallurgical clad

pipe

mechanical clad

pipe

%

Production cost overview

High Quality In Repeatability, In Roundness, In Tolerances

Cost Effective And Flexible Production

Corrosion Protection

Abrasive Protection

Life Time 10 x Higher Then Carbon Steel Pipes

Advantages of AWS Cladding Machines

AWS Schäfer Technologie GmbH

Oberhausenerstr. 8

57234 Wilnsdorf, GermanyKonstantin ZimmerTel.: 0049 2739 87003-28Fax.: 0049 2739 87003-10E-Mail: [email protected] Internet: www.aws-schaefer.de

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Thank you for your attention

AWS Profile EN IR

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