Twin booster bending machine processes 90-meter-long tubes

The CNC 60 DB Twin booster bending machine from Schwarze-Robitec with two bending heads bends up to 90-meter-long tubes into tube serpentines for boiler construction. (Courtesy: Schwarze-Robitec)

Russian boiler manufacturer Krasny Kotelshchik bends 90-meter-long tubes into bending membrane walls consisting of numerous 180° single bends. Modern power plant construction requires powerful machines that can bend challenging materials according to strict specifications. The large dimensions require particular structures in the bending process. Germany-based tube bending machine manufacturer Schwarze-Robitec designed the CNC 60 DB Twin booster bending machine for the Russian company complete with a 90-meter-long tube magazine and a supporting table with a 10-meter radius. The machine was recently put into operation.

Modern power plants continuously supply the exact amount of electricity required in the grid. The higher the process temperatures are, the higher the level of efficiency. Constantly starting up and shutting down the power plants leads to extreme fluctuations in temperature. This is something that the pipe lines made of high-strength or resistant materials must be able to withstand. In addition, there are high-pressure conditions inside to contend with. Boiler and power plant manufacturers aim to maximize the surface area to ensure the highest level of heat transfer. Tubes, therefore, need to be bent in narrow radii and must fulfill strict tolerance specifications in terms of wall thinning and ovality.

Illustration: The tube systems are laid out on the supporting table during the bending process. The tubes are directed to the bending machine from the 90-meter-long magazine. (Illustration courtesy: Schwarze-Robitec)

Tube bending machine manufacturer Schwarze-Robitec was able to fulfill these requirements for its Russian client Krasny Kotelshchik. As one of the leading Russian companies for boiler and thermal power plant construction, Krasny Kotelshchik manufactures fired steam boilers and waste-heat boilers in Taganrog, southern Russia. More than 80 percent of power plants in Russia and the CIS countries are equipped with heat-exchange equipment from Krasny Kotelshchik.

A sophisticated design for a sophisticated bending task, the CNC 60 DB Twin from Schwarze-Robitec bends tubes with an outside diameter of up to 63.5mm and with a wall thickness of up to 5mm. The booster bending machine is designed for continuous year-round use.