OIL & GAS DEVELOPMENT COMPANY LIMITED

DEVLOPMENT OF BHAMBRA & THAL

WELLHEAD FACILITY
Doc. No. :
2378-SP-004 Specifications for Induction Bends Revision No.1

TABLE OF CONTENTS

1.0 SCOPE ........................................................................................................................... 2

2.0 CODES, STANDARDS AND REFERENCE DOCUMENTS ..................................... 2
3.0 PROCESS OF MANUFACTURE................................................................................. 3
4.0 MANUFACTURE OF PRODUCTION BENDS .......................................................... 5
5.0 INSPECTION AND TESTING ..................................................................................... 7
6.0 DIMENTIONAL REQUIREMENTS ............................................................................ 9
7.0 MARKING, PACKING AND SHIPMENT ................................................................ 10
8.0 DOCUMENTATION .................................................................................................. 11

Specifications for Induction Bends Page 1

 OIL & GAS DEVELOPMENT COMPANY LIMITED

DEVLOPMENT OF BHAMBRA & THAL

WELLHEAD FACILITY
Doc. No. :
2378-SP-004 Specifications for Induction Bends Revision No.1

1.0 SCOPE

1.1 This Specification defines the minimum requirements for the manufacturing, marking,
inspection, testing and shipment of long radius bends made from longitudinally
submerged arc welded (LSAW) carbon steel API 5L Gr. X42, PSL 2 line pipes for use
in onshore gas pipeline systems.

2.0 CODES, STANDARDS AND REFERENCE DOCUMENTS

The manufacturer shall perform work in accordance with the latest edition of the
following codes, standards and specifications:

2.1 CODES & STANDARDS

ASME B 16.49 Factory Made wrought steel butt welded Induction Bends for
Transportation and Distribution System

ASME Sec. V Method for non-destructive examination

BS EN 10204 Metallic Products-Types of inspection documents

ANSI 31.8 Gas transmission and distribution piping system

BS 427 Part I Methods for Vickers hardness Test – Testing of metals

MSS-SP-75 Specification for high test wrought weld fitting

API-5L Specification for Line pipe

API-5L 1 Recommended practice for rail road transportation of line pipes

API-RP 5LW Recommended practice for transportation of line pipe on

barges and marine vessels

ASNT-TC-1A Personnel Qualification and Certification in Non-destructive

testing

The Contractor / Sub contractor / Vendor shall be in possession of all the above
referred Codes, Standards and Specifications. All such documents shall be made
readily available to all personnel involved in executing the work, including Employer.

Specifications for Induction Bends Page 2

 OIL & GAS DEVELOPMENT COMPANY LIMITED

DEVLOPMENT OF BHAMBRA & THAL

WELLHEAD FACILITY
Doc. No. :
2378-SP-004 Specifications for Induction Bends Revision No.1

Alternative codes and standards, at least equivalent to those listed above, may be
substituted, but approval from Employer will be required for any such substitution.

3.0 PROCESS OF MANUFACTURE

3.1 MANUFACTURING PROCEDURE SPECIFICATION

The Contractor / Sub contractor / Vendor shall submit a manufacturing procedure

specification (MPS) which shall meet all the requirements of these specifications. The
MPS shall include but not limited to a complete and detailed procedure for the
manufacture of high frequency induction bends and shall include all proposed
operations, in the correct sequence, together with all appropriate parameters and
methods by which the Contractor / Sub contractor / Vendor proposes to monitor the
parameters as listed below:

i. Name of Bend Manufacturer;

ii. Sequence of operations;
iii. Description of equipment and instrumentation;
iv. Bending speed (mm/min);
v. Bending load;
vi. Bending temperature;
vii. Dimensional Control Procedure;
viii. Hydrostatic Testing Procedure;
ix. Quench variables (including flow rate);
x. Heat treatment procedure;
xi. Mechanical testing and inspection procedures;
xii. Non-destructive testing and inspection procedures;
xiii. Handling, transport and storage;
xiv. Making details.

3.2 MANUFACTURING PROCEDURE QUALIFICATION

Contractor / Sub contractor / Vendor shall perform the manufacturing Procedure

Qualification to demonstrate that the MPS will produce bends with the requirements

Specifications for Induction Bends Page 3

 OIL & GAS DEVELOPMENT COMPANY LIMITED

DEVLOPMENT OF BHAMBRA & THAL

WELLHEAD FACILITY
Doc. No. :
2378-SP-004 Specifications for Induction Bends Revision No.1

set forth in this specification. Test bends shall be provided by Contractor / Sub
contractor / Vendor for qualification of the MPS. Employer reserves the right to select
the test bends.

Once the bending operation has commenced any stoppage shall not be permitted
until the entire bend is completed. Post bend heat treatment shall be applied over the
entire bend and tangent lengths.

3.2.1 Test Bends

One additional bend for each heat, nominal diameter and wall thickness shall be
made by the Contractor / Sub contractor / Vendor for test purposes.

The following examinations and mechanical tests shall be performed on the test bend
in compliance with the methods and requirements of specifications. All tests shall be
performed on a bend after final heat treatment. The result of all tests shall be in
accordance with the requirements of this Specification.

i. The bend shall be non-destructively tested in accordance with 5.2 of this

specification.
ii. The dimensions of the bends shall meet the requirements of section 6.0 of this
specification.
iii. The bend shall be hydrostatically tested in accordance with Section 5.1 of this
specification.
iv. Tensile tests shall be performed in accordance with API-5L on transverse and
longitudinal specimens one each taken from the inner and outer radius and from the
stop and start transition areas of the bend. Tensile properties shall be in accordance
with specification.
v. One transverse weld tensile test shall be performed by the Contractor / Sub
contractor / Vendor to determine the yield and tensile strengths. Such test shall be
performed as per API-5L.
vi. One sets of three Charpy V-notch impact test specimens shall be taken from each of
the inner and outer radii and from the stop and start transition areas of the bend. Test

Specifications for Induction Bends Page 4

 OIL & GAS DEVELOPMENT COMPANY LIMITED

DEVLOPMENT OF BHAMBRA & THAL

WELLHEAD FACILITY
Doc. No. :
2378-SP-004 Specifications for Induction Bends Revision No.1

temperatures and impact energy shall be in accordance with project specification for
Welded Line Pipe and specification for Welding of Pipeline.
vii. Four sets of three Charpy V-notch impact test specimens shall be taken from the
following locations :
_ Centre of the weld
_ Fusion line
_ 2 mm from fusion line
_ 5mm from fusion line
viii. One full wall macro section taken parallel to the longitudinal axis of the bend shall be
removed from the inner and outer radii and from the stop and start transition areas in
the body of the bend. The macro sections shall be polished and Vickers hardness
tested in accordance with BS 427 Part 1. The hardness survey shall be carried out as
per project specification for Welded Line Pipe. The maximum hardness shall be as
per specifications.
ix. Guided bend test shall be conducted in accordance with the requirements of API- 5L
as specified in project specification for Welded Line Pipe.

Failure of any of the qualification tests shall be caused for rejection of the MPS and
all induction bends produced to it. Employer reserves the right to require re-
qualifications in the case of any changes to the Employer approved MPS or
interruptions in the production of induction bends.

4.0 MANUFACTURE OF PRODUCTION BENDS

4.1 Induction bends shall be manufactured in accordance with the Employer approved
MPS. Any deviations from the MPS or deviation from the bend forming parameters
used for the Manufacturing Procedure Qualification test bend shall be cause for
rejection or the performance of additional test bends for re-qualification of the MPS at
Contractor / Sub contractor / Vendor expenses.

4.1.1 All induction bends shall be manufactured by hot bending from the line pipe of same
grade that of mainline by using high frequency induction heating and forming.
Contractor shall ensure that the thickness at any section of the bend shall be 5%

Specifications for Induction Bends Page 5

 OIL & GAS DEVELOPMENT COMPANY LIMITED

DEVLOPMENT OF BHAMBRA & THAL

WELLHEAD FACILITY
Doc. No. :
2378-SP-004 Specifications for Induction Bends Revision No.1

more than the specified minimum thickness of the pipeline as per corresponding /
applicable location class.

4.1.2 Bends manufactured by induction bending shall be subject to post bend heat
treatment.

4.1.3 All bending shall be manufactured by using a type of bending equipment approved by
the Employer.

4.1.4 The longitudinal weld seam shall be located at approximately 10º from the neutral
zone, measured from the outside of the bend as indicated in figure-A

4.1.5 The Contractor / Sub contractor / Vendor shall, at no additional expense to the
Employer, furnish and use an internal bending mandrel to achieve smooth and
undistorted bends.

4.1.6 All bends having a difference between the maximum and minimum diameters in
excess of 2.5% of the nominal outside diameter of the pipe, or having buckles, shall
be rejected.

4.1.7 The minimum wall thickness of the pipe after bending shall not be less than the
specified nominal wall thickness of the pipeline.

4.1.8 All bends shall be provided with a tangent length at the ends. In case the angle of the
bend is less than or equal to 45 degree, the tangent length shall be 500mm and for
bend angle greater than 45 degree the tangent length shall be 1000mm.

4.1.9 The Contractor / Sub contractor / Vendor shall supply all the bends with machined
bevel at both ends in accordance with API-5L.

4.1.10 Bend angle and bend radius shall be as indicated in the Material / Purchase
Requisition. All bends shall be non-destructively examined in accordance with the
requirements of Section 5.2 of this specification.

Specifications for Induction Bends Page 6

 OIL & GAS DEVELOPMENT COMPANY LIMITED

DEVLOPMENT OF BHAMBRA & THAL

WELLHEAD FACILITY
Doc. No. :
2378-SP-004 Specifications for Induction Bends Revision No.1

4.1.11 Each bend shall be tested using a gauging pig consisting of 2 gauging plates. The
diameter of the gauging plates shall be 95% of the nominal internal diameter. The
gauge plates shall be mounted 500mm apart on each end of the gauging pig. Details
of the gauging pig shall be submitted to the Employer for approval.

4.1.12 Bends shall not have any circumferential joints.

4.1.13 No repair by welding is allowed on any part of the bends.

4.1.14 Maximum allowable ripple in any section of the bend shall not exceed 0.75% of the
outside diameter of the pipe.

4.1.15 When bending, the longitudinal axis of the pipe shall not be deflected more than 8 x
D in any length along the pipe axis equal to the outside diameter of the pipe.

4.1.16 Any bend that is buckled or gouged by the bending operation shall be rejected.

5.0 INSPECTION AND TESTING

It is mandatory to perform all inspection and tests and certify as per the requirement
of this specification prior to shipment at his works.

5.1 HYDROSTATIC TESTING

5.1.1 All induction bends shall be hydrostatically tested at the Sub contractor / Vendor’s
works in accordance with the requirements of API-5L. The test pressure shall be as
per project specification for Welded Line Pipe with a hold time of 15 minutes.

5.1.2 The Contractor / Sub contractor / Vendor shall submit hydrostatic test pressure
calculations to the Employer.

5.1.3 All pressure gauges hydrostatic used for measurement for hydrostatic testing of
bends shall be calibrated against a dead weight tester to the satisfaction of the
Employer before and after the test all pressure gauges used shall have an upper
range of 1.5 to 3 times the minimum test pressure.

Specifications for Induction Bends Page 7

 OIL & GAS DEVELOPMENT COMPANY LIMITED

DEVLOPMENT OF BHAMBRA & THAL

WELLHEAD FACILITY
Doc. No. :
2378-SP-004 Specifications for Induction Bends Revision No.1

5.1.4 All hydrostatic pressure test shall be chart recorded. The identification no. of the
induction bends being tested shall be clearly recorded on the hydrostatic pressure
charts.

5.1.5 Orientation of the longitudinal weld seam of the pipe bends shall be such that any pin
hole leak in the seam area shall be clearly visible to hydrostatic testing operators and
inspection personnel.

5.2 NON-DISTRUCTIVE EXAMINATION

5.2.1 Contractor / Sub contractor / Vendor shall submit a detailed procedure for all non-
destructive tests to be performed on the bend. The NDT procedure shall, as a
minimum, include the following:

i. Equipment Details and Calibration Techniques

ii. Qualification of NDT operators (shall be minimum ASNT-TC-1A level 2)
iii. Scanning Techniques (100% coverage)
iv. Examination Techniques
v. Testing evaluation method
vi. Preparation of Reports

5.2.2 All bends shall be subject to non-destructive testing in accordance with the
requirements of project specification for Welded Line Pipe.

5.2.3 All tests shall be performed on all bends that have passed the hydrostatic testing.

5.2.4 The surface of the bends to be examined shall be clean and smooth, free from dirt,
paint or any other foreign matter which would affect/influence the results of testing.

5.2.5 The entire outer surface of each bend and bevels shall be inspected for laminations
and cracks by Magnetic Particle Inspection in accordance with ASME Section V,
article 7.

5.2.6 The Contractor / Sub contractor / Vendor shall ultrasonically examine all weld areas
of all induction bends for defects and shall be witnessed.

Specifications for Induction Bends Page 8

 OIL & GAS DEVELOPMENT COMPANY LIMITED

DEVLOPMENT OF BHAMBRA & THAL

WELLHEAD FACILITY
Doc. No. :
2378-SP-004 Specifications for Induction Bends Revision No.1

5.2.7 Acceptance levels for MPI and UT inspections shall be in accordance with project
specification for Welded Line Pipe.

5.2.8 Residual Magnetism

Contractor / Sub contractor / Vendor shall use a digital or analogue gauss meter with
directional pro with an accuracy of  0.1 Gauss to determine the residual magnetism
of the induction bend.

No residual magnetism in either longitudinal or transverse direction to the pipe axis

shall be greater than 20 Gauss.

Demagnetization shall be applied if the magnetic measurement is greater than the

acceptable limit i.e. 20 Gauss.

The method of degaussing shall be included in the Manufacturing Procedure

Specification by the Sub contractor/Vendor.

5.2.9 Surface Finish

Any irregularities in the surface contour of the bend caused by the bending operation
shall be rejected.

Contractor / Sub contractor / Vendor shall include a description of how surface

irregularities shall be avoided and the methods proposed to inspect such
irregularities in the MPS.

6.0 DIMENTIONAL REQUIREMENTS

All induction bends shall be of a minimum radius equal to eight times outside the
diameter. The bend angle shall be as per the relevant data sheets.

All bends shall be supplied to the dimensional tolerances specified in this

specification and relevant data sheets.

Specifications for Induction Bends Page 9

 OIL & GAS DEVELOPMENT COMPANY LIMITED

DEVLOPMENT OF BHAMBRA & THAL

WELLHEAD FACILITY
Doc. No. :
2378-SP-004 Specifications for Induction Bends Revision No.1

7.0 MARKING, PACKING AND SHIPMENT

7.1 All bends shall be marked complying with the requirements of API-5L

7.2 The original pipe number and bend suffix shall be marked by die stamping at both
ends on the bevel of all bends. No die stamping shall be permitted on any other part
of the bend.

7.3 As a minimum for each bend the following markings are stenciled at both ends
internally with indelible paint.

i. Pipe original individual identification number and bend suffix heat number and
original pipe number.
ii. Purchase order/Item number
iii. Bend angle
iv. Heat number
v. Certifying Agency’s name
vi. API-5L material grade
vii. Specified wall thickness, outside diameter, bend angle, bend radius
viii. heat treatment
ix. Measured weight
x. Any other information required by API-5L.
xi. Stamp of Certifying Agency

7.4 All loose and foreign material i.e. rust, grease etc. shall be removed from inside and
outside of the bend.

7.5 A coat of antirust paint shall be applied on the bends for protection during transit and
storage.
7.6 Both ends of the bends shall be suitably protected to avoid any damage during transit
by means of metallic or high impact plastic bevel protectors.

Specifications for Induction Bends Page 10

 OIL & GAS DEVELOPMENT COMPANY LIMITED

DEVLOPMENT OF BHAMBRA & THAL

WELLHEAD FACILITY
Doc. No. :
2378-SP-004 Specifications for Induction Bends Revision No.1

7.7 Package shall be marked legibly with indelible marking ink to indicate the following:

a. Order Number
b. Package Number
c. Manufacturer’s Name
d. Size (Inches) and wall thickness (mm)
e. Radius of bend(mm) and bend angle.

8.0 DOCUMENTATION

Documentation relating to the supply of goods shall be provided by the Contractor /

Sub contractor / Vendor. All documents shall be reviewed by Contractor’s Quality
team and approved by the Employer.

Full certification of the procedure and results of bending, inspection and testing shall
be provided by the Contractor / Sub contractor / Vendor and certified by Employer.

Certificates shall be provided by Contractor / Sub contractor / Vendor in accordance

with applicable codes and standards and shall be approved by Employer.

Certification shall cover all results required by this specification. All certificates shall
be marked with sufficient information to enable full traceability to the items it
represents and the relevant specifications and procedures.

Specifications for Induction Bends Page 11

 OIL & GAS DEVELOPMENT COMPANY LIMITED

DEVLOPMENT OF BHAMBRA & THAL

WELLHEAD FACILITY
Doc. No. :
2378-SP-004 Specifications for Induction Bends Revision No.1

FIGURE-A

ORIENTATION OF WELD SEAM FOR INDUCTION BENDS.

ORIENTATION OF WELD SEAM FOR INDUCTION BENDS.

10°

WELD HERE

BEDDING PLANE

OR HERE

BEND

10°

Specifications for Induction Bends Page 12