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INFRASTRUCTURE GROUP
SPECIFICATION
INDUCTION BENDS
TO
DNV OS-F101
REV
ISSUE
PREPARED BY
For use
Dean Hewitt
REVIEWED BY
APPROVED BY
ISSUE DATE
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DATE ISSUED
PREPARED
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APPROVED
COMMENTS
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TABLE OF CONTENTS
1.
INTRODUCTION ..4
2.
3.
MATERIALS .....5
4.
5.
6.
7.
8.
9.
10.
11.
12.
INSPECTION ...11
13.
SHIPMENT ...12
14.
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1. INTRODUCTION
1.1 Scope
This document defines minimum quality and technical requirements for
Induction Bends to DNV OS-F101 used in offshore pipelines.
Contractor shall obtain Company written approval for any deviations from the
requirements of this document or specifications, standards and drawings
referenced herein or elsewhere in the Contract.
This document and the codes, specifications and referenced documents listed
in 1.2 below are not intended to be all-inclusive. The requirements set forth
do not relieve Contractor of his responsibility to perform all services in a safe
manner, to meet applicable codes and standards, to comply with government
regulations or to supply a product capable of performing its intended service.
1.2 Codes, Specifications, And References
The latest editions of all applicable codes, specifications and references shall
define the minimum requirements applicable to the subject work and no
statement contained in this Specification shall be construed as limiting the
work to such minimum requirements.
Wherever conflicts or omissions between codes, specifications and contract
occur, the most onerous condition shall apply. Contractor is responsible for
reviewing the list below and informing the Company of any omissions. All
conflicts shall be formally brought to the attention of the Company.
Applicable Codes
ASNT-TC-1A
DNV OS-F101
Company Specifications
84501-9230-2L-022
84501-9230-2L-046
84501-9230-2L-008
84501-9230-2L-042
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be made to expendable extensions of the bend that are to be cut off prior to
finishing.
5.4 No stoppage shall be allowed during the bending process.
6. HEAT TREATMENT
6.1 Post bend heat treatment shall be applied as necessary to meet specifications.
Consideration shall be given to the manufacturing process of the pipe (e.g.,
TMCP, Q&T, normalized). When practical the pipe manufacturer should be
involved in the selection of specific pipes to be bent and in advising of post
bend heat treatment conditions if applicable.
6.2 If post bend heat treatment is used, temperature ranges specified in approved
heat treating procedure(s) shall be measured during all heat treatment.
Thermocouples attached to representative bend sections shall confirm actual
metal temperature.
7. MANUFACTURING PROCEDURE SPECIFICATION
7.1 A manufacturing procedure specification (MPS) shall be established for each
grade, pipe size and bending radius in the order. Tests bends and production
bends shall be made in accordance with the procedure. The MPS shall
contain the following items as a minimum:
Sequence of operations.
Equipment to be used.
The MPS for the mother pipe for bends. The mother pipe for bends shall
be made in accordance with project line pipe specifications listed in
Section 1.2, as appropriate.
Allowable variation of
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8. NON-DESTRUCTIVE EXAMINATION
8.1 All techniques and procedures for Radiography, Magnetic Particle Inspection
(MT), Dye-Penetrant Inspection (PT) and Ultrasonic Testing (UT) to be used
by Supplier shall be submitted in writing to Company for approval prior to
starting production and shall comply with the requirements of DNV OS-F101,
Appendix D. All non-destructive examination shall be performed on bends in
the final heat-treated condition and after hydrostatic testing and shall be in
compliance with one of the appropriate standards listed in DNV OS-F101
Appendix D, Article B100, 2000.
8.2 Technicians performing non-destructive inspection shall be qualified to the
requirements of SNT-TC-1A, Level II.
8.3 Completed induction bends shall be inspected as per DNV OS-F101, Section 7,
G800. Bends shall be free from cracks and other injurious defects. All
bevelled faces shall also meet the above criteria when tested by MT or Dye
Penetrant Inspection (PT) methods.
8.4 All bends shall be subject to one hundred percent (100%) Visual Inspection as
per DNV-OS-F101, Section 7, G800. Acceptance criteria shall be in
accordance with the relevant line pipe specification.
8.5 Minor surface defects shall be removed by grinding provided the remaining wall
thickness is not less than the minimum specified wall thickness and a smooth
transition exists between the ground area and the original contour, i.e. no
stress risers. Defect removal shall be confirmed by MT. Defect removal that
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results in less than specified minimum wall thickness shall result in bend
rejection.
8.6 Longitudinal surface defects, score marks, etc. shall be investigated by UT
examination, to confirm orientation and depth, and reported to Company prior
to any attempted repair or removal by grinding. Company may at its
discretion reject the bend.
8.7 No weld repairs shall be permitted.
8.8 Surface hardness measurements using an approved hardness tester shall be
performed on all finished bends as per DNV-OS-F101, Section 7, G800, at the
following locations:
Each tangent
Outside of bend
Inside of bend
8.9 Each bend outer radius shall be subject to UT examination for transverse defects
before shipment. This examination shall be made with an angle probe along
a 150-mm band on the outer bend radius. Defects in excess of those
specified the project line pipe specifications listed in Section 1.2, as
appropriate, shall be rejected. Cracks, regardless of depth, shall be rejected.
8.10
8.11
All longitudinal weld seams shall be UT inspected over their entire length.
Acceptable limits shall be in accordance with the project line pipe
specifications listed in Section 1.2.
8.12
All linepipe bends, if cut from original pipe delivered length, shall be one
hundred percent (100%) RT examined for the end 300 mm. Acceptance
criteria shall be to DNV OS -F101 Appendix D Table D-4.
9. DIMENSIONAL TOLERANCES
9.1 Dimensional tolerances shall meet the requirements of the relevant line pipe
specification and the following. In case of conflict, the tolerances contained in
this specification shall govern.
9.2 Minimum internal diameter of each bend shall be guaranteed by passing a
gauging plate, consisting of two circular parallel concentric plates, through the
completed bend. Minimum gauging plate thickness shall be 6.0 mm. The
gauging plate shall be required to pass completely through the bend without
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9.3 Maximum percent ovality shall be determined by measuring the bend outside
diameter, and is defined as maximum outside diameter minus minimum
outside diameter, divided by nominal pipe diameter and multiplied by 100.
Maximum percent ovality shall not exceed three percent (3%). Ovality at the
ends of each bend shall be equal to nominal inside diameter +/- 5.0 mm i.e.
the inside diameter at the pipe ends (within 100 mm of the pipe end) shall be
within 5.0 mm of nominal as measured with a rod gauge.
9.4 Bend radius shall be measured and shall be within 1% of that specified.
9.5 Angular bend tolerance shall be +/- zero point five degrees (0.50 O), determined
by intersecting tangent centerlines, measured by appropriate equipment.
9.6 Out-of-plane bend angle tolerance shall not exceed 10-mm deviation from a flat
base.
9.7 The inside diameter of each end of each bend shall be measured within 100 mm
of the pipe end and shall meet the tolerance requirement of the appropriate
linepipe specification listed in Section 1.2.
9.8 Bends shall have tangents at both ends with minimum length 1000-mm, unless
noted otherwise in the Purchase Order. Bend ends shall be bevelled in
accordance with the project line pipe specifications listed in Section 1.2, as
appropriate. Where required, tapered transitions shall have minimum one in
four slope. The pipe end face shall be perpendicular with the axis of the pipe
within 1.5 mm as measured with a square.
9.9 Supplier shall not accept pipe for bending of less than nominal wall thickness.
The allowable thickness after bending shall be defined in the Basis of Design
and shall be stated in the Purchase Order. Thicker walled pipe may be
required for bend production to achieve a minimum wall thickness that is
compatible with that of the adjoining pipe.
10. MARKINGS AND COATINGS
10.1
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10.2
Induction bends shall be abrasive blasted to remove loose scale and other
foreign material after all required heat treatment has been performed.
10.3
All induction bends shall be externally coated with a Company approved, high
build, two-pack epoxy or Company approved equivalent.
10.4
All bevelled ends shall be suitably protected against damage during transit.
Ends shall be coated with a weldable primer such as Deoxaluminite, or
Company approved equal, that can be easily removed with solvent and that
will prevent weld preparation rusting for a period of at least twelve (12)
months under exposed field conditions.
11.2
11.3
Each tangent
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b.
c.
Acceptance criteria
11.5
11.6
The bend weld seam, if applicable, shall be one hundred percent (100%) RT
examined. Acceptance criteria shall be as DNV OS-F101 Appendix D Table D4.
12. INSPECTION
12.1
12.2
12.3
After production has started on the order, Supplier shall notify Company
inspectors at least twenty-four (24) hours in advance of any changes in
production schedules.
12.4
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13. SHIPMENT
13.1
13.2
Timber blanks or metal end bevel protectors shall be used to protect end
bevels. Bends shall be lifted and stacked in strict accordance with Project
Specification for Handling, Storage and Transportation of Line Pipe.
14.2
Supplier shall submit to Company for approval the following documents prior
to commencement of work:
Procedure Qualification
Shop Drawings
Supplier shall submit to Company for approval a data book containing all
relevant documents including:
Mill Certificates
Certified Drawings
Storage Procedures
Calibration Certificates
All certificates shall be in the English language and use metric units of
measure.
Supplier and Company Representative shall visibly sign
certificates.