1. Tube Bending

2. Objectives At the end of this training you will be able to: 1.Explain the key features of the tube bender 2.Layout tubing to make bends 3.Use the tube bender to make a variety of bends 4.Diagnose problems with tube bends 5.Design tube runs for safety and maintenance

3. TurnPro Indexing Handle Tube Bender Features Makes bends greater than 90° in a single operation Eliminates crossed handles No assembly and reassembly of bender handles Durable Construction – Suitable for heavier wall tubing – Vise mountable 1/4, 3/8, 1/2 in. (6, 8, 10, 12 mm) sizes Training available

4. TurnPro Indexing Handle Tube Bender Tube Lock Hook Alignment Marks Bend Angle Marks Indexing Lever Handle Indexing Trigger Bender Die Roller Housing Die Radius Indicator

5. Tube Selection and Preparation

6. DescriptionMaterialHardnessStandard Carbon Steel Soft Annealed, Seamless 72 HRB (130 HV) or lessASTM A179 304 Stainless Steel Fully-annealed, seamless or welded and drawn 90 HRB (200 HV) or lessASTM 269 or A213 316Stainless Steel Fully-annealed, seamless or welded and drawn 90 HRB (200 HV) or lessASTM 269 or A213 Selecting Tubing

7. Tube OD Approx Bend Radius Carbon Steel Wall Thickness Min/Max Stainless Steel Wall Thickness Min/Max 1/4 9/160.028/0.065 3/40.028/0.065 3/815/160.035/0.0650.035/0.083 1/21 1/20.035/0.083 Selecting Tubing

8. Tube OD Approx Bend Radius Carbon Steel Wall Thickness Min/Max Stainless Steel Wall Thickness Min/Max 615150.8/1.5 8241.0/1.5 10241.0/1 51.0/2.0 12381.0/2.21.0/2.0 Selecting Tubing

9. Selecting & Handling Tubing Check for – Clean – No scratches or gouges – Out of round ends – Burr – Seams Handling – Dragging – Capping – Uncoiling – Cutting Tube Cutter Sharp saw Cutting wheel – deburr

10. Tube Installation Bend Allowance T - Tube OD L - Length of straight tube required R – Bend Radius

11. Bend Allowance - Fractional Tubing T Tube ODR Bend RadiusL 1/4 9/1613/16 3/815/16 1/21 1/21 3/16 Tube Installation

12. Bend Allowance – Metric Tubing Tube ODR Bend RadiusL 61521 82423 102425 123831 Tube Installation

13. Laying Out & Bending Tubing

14. Layout Sequential Layout Example 3 in.

15. Layout Sequential Bend Method 1.Add the lengths or all section together to estimate the overall length of tubing required for the job. 2.Mark the starting point (reference mark) for your project. – Remember to make all marks completely around the tube. 3.Measure from the reference mark to the vertex of the first bend. – The vertex is the point where the center lines of the two legs of the angle meet. 4.Bend the tube. 5.Using the vertex of the previous bend as the reference mark, mark the vertex for the next bend the next bend. 6.Repeat steps 3 and 4 for the next bend

16. Sequential Layout Reference Mark Vertex 3 in. 1.Add the lengths or all section together to calculate the overall length of tubing required for the job.

17. Sequential Layout 2.Mark the starting point (reference market) for your project. Remember to make all marks completely around the tube. Reference Mark

18. Sequential Layout 3.Measure from the reference mark to the vertex of the first bend. The vertex is the point where the center lines of the two legs of the angle meet. Reference Mark 3 in. Vertex

19. Reference Mark Align Vertex Mark With L 90° Bends – Reference Left

20. Sequential Layout 4.Bend the tube.

21. Reference Mark 90° Bends – Reference Left Bend until 90 meets 0

22. Layout Vertex New Reference Vertex 3 in. 5.Measure and mark the next segment.

23. Sequential Layout Tip – Mark the vertex of the next bend to help alignment

24. Vertex 1 45° Bends Vertex Mark 30° Alignment

25. Bend until 45 meets 0 45° Bends

26. Sequential Layout Vertex 6.Bend the tube

27. Bend Calculations

28. Layout Calculations Offset Calculations 3.5 x 1.414 = 4.494 or approx. 5 in. ? 3.5

29. Offset Bend Angle Offset Bend Allowance 22 ½2.613 30302.000 45451.414 60601.1541.154 Layout Calculations Offset Calculations

30. Layout Calculations Offset Calculations 3.50 x 1.414 = 4.949 or approx. 5 in. Solution 3.5 5

31. Layout Calculations 3 in. 3.5 in. Reference Mark 1/4 in. OD Tubing Adjustment (Gain) Calculations Original Calculation 11 1/2 in.

32. Layout Calculations Adjustment (Gain) Calculations

33. Layout Calculations Reference Mark 3 in. 6 3/16 in. 3 in. in. Adjustment (Gain) Calculations 3 in. + 3.5 in. – 5/16 in. = 6 3/16 in. 6 3/16 in. + 3 in. – 5/16 in. = 8 7/8 3.5 in. New Calculation 9 1/2 in. – (2 x 5/16) = 8 7/8 in.

34. More Bending

35. Bends Greater than 90°

36. Bend until 0 meets 180, then a little more for spring back

37. Right Reference Bends 3 in. Reference Mark 9 in. Tubing

38. Align Vertex Mark with R Reference Right Bends

39. 90° Bends – Reference Right

40. Changing Planes 90°

41. Multi-Plane Bends 2 1/2 in. 4 in. 30° x 30° 90° 2 1/2 in.

42. Multi-Plane Bends 15° 30° 45° 60° 75° 90° 15° 30° 45° 60° 75° 90° Bend Direction 0°

43. Multi-Plane Bends Bend Direction 15° 30° 45° 60° 15° 30° 45° 60° 75° 90° 75° 90° 0°

44. Multi-Plane Bends 15° 30° 45° 60° 15° 30° 45° 60° 75° 90° 75° 90° 0°

45. Multi-Plane Bends 15° 30° 45° 60° 15° 30° 45° 60° 75° 90° 75° 90° 0°

46. Imperfect Bends Common causes of imperfect bends May be caused by: Not having the mandrel forward far enough in the tube Bending thin wall tubes without a mandrel Trying to bend too short a radius Bending smaller diameter tubing in a larger radius block. Sometimes produced when thin wall tube is bent without a support mandrel. May be caused by the tube slipping in the bender. A kinked bend may also result from the use of non-annealed tubing.

47. Installing Tube Runs

48. Avoid creating ladders Run tubing close to the wall Use support hangers every 3 – 5 ft. Support valves, transmitters etc, independent of the tubing Run tubing vertically when possible

49. Installing Tube Runs Stagger Connections

50. Installing Tube Runs

51. Installing Tube Runs Avoid straight line connections whenever possible

52. Installing Tube Runs Avoid straight line connections whenever possible

53. Installing Tube Runs Bend up staggers for easier access and maintenance

54. Expansion

55. Installing Tube Runs

56. Installing Tube Runs

57. Installing Tubing Runs

58. Installing Tube Runs

59. Installing Tubing Runs

61. Final Exercise

62. Tube Bender Training 1 3/8 6 18 6 150° 15°/90° 30° 15° 2 3/4 2 1/2 Final Exercise 1 2 3 4 5 6 7

63. Vertex #Distance toBend°Rotation°Direction Reference0 11 3/830°0° 2615°90°Left 32 ½150°90°Right 418150°0° 52 3/42 3/4 15°90°Right 6630°90°Left 71 3/8

64. A Better Hook Overall Length – 9 in. 3/4 1 1/4 1 1/2 1 1/4 60° 45° Quantity 500

65. Thanks