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SPECIFICATION FOR PREFABRICATED HOT-BEND

02 FINAL APPROVED MK AN MM 89.12 -

01 IFA MK BM BM 89.10 -
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PURPOSE OF
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Table of Contents

CONTENTS..............................................................................................................................................
.................................................................................................................................................PAGE
1- INTRODUCTION
2. SCOPE
3. DEFINITIONS
4. REFERENCES
5. ORDER OF PRECEDENCE
6. MATERIALS
7- MANUFACTURE
8- INSPECTION AND TESTS


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9- TEST CERTIFICATES
10- MARKING, PACKING AND SHIPMENT
11- MATERIAL TRACEABILITY
12- DOCUMENTATION
13- QUALITY ASSURANCE


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1- INTRODUCTION

Iranian Gas Engineering & Development Company (I.G.E.D.C) has intended to

perform gas transmission pipeline and gas compressor stations for transferring of
110 MMSCMD of natural gas to be fed from South Pars phases 22 ~ 24 from
Assalouyeh to Bazargan.

Design of a new 56" gas transmission pipeline from Assalouyeh to Bazargan has
been described under this EPC Contract.
2- Scope

This specification gives minimum technical specifications and general requirements

for purchasing the prefabricated bends for use in mentioned project and shall be
read in conjunction with that document.
3- Definitions

Client: Iranian Gas Engineering & Development Company (IGEDC).

MC: Ghods Niroo Consulting Engineers.

CONSULTANT: Haraz Rah Consulting Engineers.

CONTRACTOR: Gharargah Khatam-AL-Anbia.Niroo Goostar Institute.



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4- REFERENCES
Throughout this Specification the following standards/codes are referred to. These
referenced documents shall, to the extent specified herein, form a part of this specification.
For undated references, the latest edition of the referenced documents (including any
supplements and amendments) applies.
ASTM (AMERICAN SOCIETY FOR TESTING AND MATERIALS)

ASTM A370 Standard Methods and Definitions for Mechanical Testing of

Products

ASTM E112 Standard Test Methods for Determining Average Grain Size

BSI (BRITISH STANDARDS INSTITUTION)

BS EN 10160 Ultrasonic Testing of Steel Flat Product of Thickness Equal or Greater

Than 6 mm (Reflection Method)

IPS (IRANIAN PETROLEUM STANDARDS)

IPS-E-PI-140 Engineering Standard for Onshore Transportation Pipelines

IPS-M-PI-190(2) Material and Equipment Standard for Line Pipe

API American Petroleum Institute

API 5L Specification for Line Pipe

API 1104 Specification for Welding Pipeline and Related Facilities

ASME - American Society of Mechanical Engineers

ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other
Liquids


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ASME B31.8 Gas Transmission and Distribution Piping Systems

ASME B16.5 Pipe Flanges, and Flanged Fittings NPS through NPS 24

ASME B16.9 Factory Made Wrought Steel Butt welding Fittings

ASME B16.25 Butt Welding Ends

ASME B16.49 Factory-Made Wrought Steel Butt welding Induction Bends for
Transportation and Distribution Systems

5- ORDER OF PRECEDENCE
In case of conflict between the requirements of this specification and the referenced
codes, standards, and specifications, the following precedence shall apply:

Purchase Order,

This specification,

Project's Specification for Line Pipe

Project's Other Specifications,

Iranian Petroleum Standards,

Other internationally recognized codes and standards.

6- MATERIALS
6.1 General

Bends shall be fabricated from carbon steel seamless line pipe or SAW line pipe
conforming to Project's Gas Pipeline Data Sheet IGAT6-D-PL-PI-DSH-0001 and
Specification for Pipes IGAT6-D-PL-ME-SPC-0002.


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The wall thickness of the line pipe to be bent shall be selected to ensure that the minimum
thickness after bending is equal to the design requirements including corrosion allowance.
Supplier shall provide, with his tender details for the amount of wall thinning expected for
each bend and the straight pipe wall thickness required to ensure the design wall
thickness requirements are met.

Heat treatment procedure adopted shall be such that the finished bends achieve the
required mechanical property requirements of the Project's Specification for Line Pipe.
Heat treatment of bends shall be carried out as per the procedure established during the
bend manufacturing procedure qualification and as approved by the Purchaser.

Mechanical testing of test bends performed during the bend manufacturing procedure
qualification as per this specification shall ensure that all bends made according to the
qualified bending procedure have the required mechanical properties; and destructive
testing of production bends is not required. However, Purchaser reserves the right to
require destructive testing whenever production bending parameters or heat treatment
parameters deviate from those established in the qualified procedures.

6.2 Chemical Composition and Properties

Chemical composition of long radius bends, as determined by product analysis shall be

suitable for fluid composition attached to purchase order or shall be as per Project's
Specification for Pipes IGAT6-D-PL-ME-SPC-0002. Supplier shall propose suitable
chemical composition for each medium in his quotation in case of deviation from
mentioned specification.


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7- MANUFACTURE
7.1 General

Material grade, bend size, bend radius and bend angle shall be as indicated in the
Purchase Order. Unless specified otherwise, the bending radius for bends shall be
minimum five (5) times the nominal outside diameter (5D).

Bends shall be manufactured by high frequency induction heating and forming method
only with the qualified bending procedure qualification. The manufacturer shall maintain
continuous records of the forming conditions for each bend. Cold or hot working of the
bends to meet the dimensional requirements after bending or final heat treatment shall not
be performed without the prior approval of the purchaser.

The pipe material shall be inspected prior to bending and shall be free of surface defects,
such as cracks, gouges, nicks, scratches, abrasions, or similar marks and any buckles or
similar damage.

Prior to bending, the pipe surface shall be cleaned. The pipe shall be visually inspected to
assure removal of all contaminants.

Before bending, the wall thickness shall be measured on each length of pipe. Hot
induction bends shall be manufactured from line pipe with positive wall thickness
tolerance.

For bends required to be manufactured from the LSAW line pipe, the longitudinal seam
shall be located in the plane of minimum deformation (bend neutral axis). Acceptable
tolerance on location of the longitudinal weld seam shall be 5. (See Figure 2)

Bends shall not have any circumferential joint.

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



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The bending temperature shall be in the range of 1500 to 1675 F (815 to 913C). When
the bending temperature is reached, the bending moment shall be applied. The metal
temperature prior to and during bending shall be accurately determined using an optical
pyrometer. The temperature data shall be recorded for each bend and shall be provided
to the client's representative at his request.

The bend area shall be immediately cooled after bending.

If bending temperatures, bending rate, cooling medium volume, or heat treatment

temperature departs from the qualified manufacturing procedure, then the bend shall be
discarded and another bend shall be made in its place.

Any interruption to the bending process shall result in the rejection of the bend.

Cold or hot working of the bends to meet the dimensional tolerances after bending or final
heat treatment shall not be permitted.

Bulges, dents and flat areas shall not appear within 100 mm from end of the bend. For the
remaining part of the bend these deviations from the original contour of the pipe are
permitted provided these deviations do not exceed 2.0% of nominal outside diameter of
the pipe. The same shall not extend (in any direction) over a distance of more than 25%
of nominal outside diameter of the pipe. A gouge, groove or notch in the pipe wall shall not
be of depth greater than 5% of nominal wall thickness

All bends shall be provided with a tangent length at the ends. Tangent length shall be 500
mm or pipe outside diameter whichever is the greater.

The excess weld material at the inside of the bend shall be removed over a distance of
100 mm at both ends.

Unless otherwise specified in the Purchase Order, the bevels at the ends shall be as per
Project's Specification for Line Pipe.


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7.2 Bend Manufacturing Procedure Qualification

Prior to start of production bending, Manufacturer shall demonstrate the suitability of the
proposed manufacturing procedures for producing pipe bends that meet the requirements
of this specification, by mechanical testing the test bends in accordance with this
specification.

Test bends shall be made by using the pipe specified in this specification. One test bend
is required per heat lot where a heat lot is deemed to include all bends of the same
diameter, wall thickness, material grade, mill heat number and bend forming parameters
(excluding bend angle). The test bend shall be bent to a radius of 5D and an angle of 90.

All bending shall be performed in accordance with the Suppliers written procedures,
which shall be qualified prior to production for each pipe size (diameter), thickness, grade
and heat of material combination for the tightest bend radius required. The Supplier shall
submit a bend manufacturing procedure to purchaser for approval, which shall include the
following:

Description of induction heating and bending equipment.

Fabrication sequences

Anticipated bending temperature and temperature control during bending and

expected temperature profile across the pipe wall.

Width of heating band

Rate of bending and approximate bending load.

Estimated quenching or cooling rate in the bender.

Cooling method and type of coolant



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Dimensions of the finished bend and their tolerances.

Details of post-bending heat treatment.

NDT procedures

Transport and packing procedure.

7.3 Tolerances

The finished bends shall conform to the following dimensional tolerances in addition to
MSS SP-75 requirements. However the ends of the finished pipe bend shall meet the
dimensional tolerances of the IPS-M-PI-190(2).

Bend Angle 0.5

Bend Radius 1% of bending nominal radius.

7.4 Wall Thickness

The Manufacturer shall check the wall thickness of the pipe ultrasonically before bending
along both the inside and outside radii, at approximately 15 degree intervals or 300 mm
whichever is less. The wall thickness shall be measured ultrasonically after bending at the
same locations measured before bending. These measurements shall be taken at four
equally spaced locations around the pipe circumference at both welding ends of the bend.

The measured wall thickness at any place in the pipe measured during the inspection shall
not deviate from the nominal wall thickness by more than the tolerances specified in the
following table:

Tolerance
Wall Thickness, t (mm)
Minus Plus
t 7 0.35 mm 10%


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7< t 10 5% 10%
10 < t 0.5 mm 10%
7.5 Ovality

Ovality in any plane along the finished bend shall not exceed 2%. Ovality shall be
calculated using the following formula:

2 OD max OD min
Ovality
OD nom

Where ODmax = Maximum Outside Diameter

ODmin = Minimum Outside Diameter
ODnom = Nominal Outside Diameter

The measurements shall be made over the circumference of the bend either at distances
approximately equal to pipe diameter or 300 mm whichever is less. Minimum three
measurements shall be taken for each bend.

7.6 Off Plane

Off plane of bends shall not exceed (/90) x 10 mm, where is the bend angle in degree
or the tolerance limit specified in MSS SP-75 whichever is less. The measurement shall be
in accordance with MSS SP-75.

7.7 Wrinkles

The bends shall be fabricated to achieve a smooth surface on the inside of the bend.
Wrinkles depth shall not exceed 5mm high measured from 'valley' to 'crest' and shall not
be more than 1/50th of the distance between the adjoining crests.


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8- INSPECTION AND TESTS

8.1 General

The Manufacturer shall perform all inspection and tests as per the requirements of this
specification and MSS SP-75 prior to shipment, at his works. Such inspection and tests
shall be as a minimum, the following:

A) Verify that the unfinished product arriving at Manufacturer's shop is in full

compliance with the line pipe specification and IPS-M-PI-190(2).

B) Visual Inspection.

C) Dimensional and tolerances check as per MSS SP-75 and requirements of this
specification.

D) The non-destructive inspection on the finished bend shall be carried out as given
below. Detailed NDT procedure shall be approved by Purchaser prior to its use.

All seam welds of bends fabricated from LSAW pipes shall be fully
radiographed and acceptance limits shall be as specified in the applicable line
pipe specification referred in Clause 4.0 of this specification.

The full circumference of both ends of each bend after beveling shall be
ultrasonically tested for laminations over a length of 25 mm and acceptance
limits shall be as specified in the applicable line pipe specification referred in
this specification.

E) A check shall be performed on each bend by passing a gauging pig consisting of

two discs having a diameter equal to 97% of the nominal internal diameter of the
pipe, connected rigidly together at a distance equal to bend ID. Details of the
gauging pig, including its dimensions shall be approved by Purchaser.


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8.2 Purchaser Inspection

Purchaser's Inspector reserves the right to perform stage wise inspection and witness
tests on all bends at the Manufacturer's works, prior to shipment.

Manufacturer shall give reasonable notice of time and shall provide without charge
reasonable access and facilities required for inspection to the Purchaser's Inspector.
Inspection and tests performed or witnessed by Purchaser's Inspector shall in no way
relieve the Manufacturer's obligation to perform the required inspection and tests. Under
no circumstances shall any action of the Purchaser's Inspector relieve the Manufacturer of
his responsibility for ensuring the quality of the bends.

8.3 Test Bend

All finished test bends shall be subjected to following mechanical testing to confirm that
the pipe bends manufactured meets all mechanical property requirements of Project
specifications referred in Project's Specification for Line Pipe.

The test specimen shall be taken from the formed portion of the bend (Fig.1). For the
following tests, number of specimens, specimen orientation with respect to longitudinal
axis of the unformed pipe, test procedure and acceptance criteria shall be in accordance
with the Project's Specification for Line Pipe.

8.4 Tensile Test

One tensile test shall be conducted on the base material of finished bend, which has been
subjected to all mechanical and heat treatment operations, for each heat of steel used, to
establish yield strength, ultimate tensile strength and elongation. The specimen shall be
taken one at inside radius and one at outside radius of the bend.


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8.5 Fracture Toughness Test

Charpy-V-notch test temperature shall be the same as specified in the project pipe
specifications. One set of three transverse specimens shall be taken from the outside
radius and one set from the inside radius of the bend.

8.6 Guided Bend Test

In case of bends fabricated from LSAW pipes, one face and one root guided bend weld
test shall be performed.

8.7 Hardness Test

Hardness testing shall be performed on a test ring removed from the middle of the bend.
Four specimens shall be prepared one from each quadrant. In case of bends fabricated
from LSAW pipes, one specimen shall have the longitudinal weld seam in the middle.
Hardness shall be checked for base metal, weld metal and HAZ to IPS-M-PI-190(2).

9- TEST CERTIFICATES

The Manufacturer shall submit the following certificates, in accordance with EN10204 3.1B:

A) Pipe used for fabrication of bends, test certificates of chemical analysis, mechanical
tests, NDT, heat treatment, dimensional inspection and hydrostatic test carried out.

B) Test bends, test certificates of mechanical carried out.

C) Test certificates of non-destructive test inspection for bends.

D) Records of heat treatment for bends.

E) Certified reports of dimensional tolerance for bends.

F) Certificates of all other tests as required in this specification.



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The certificates shall be valid only when signed by Purchasers Inspector. Only those bends
which have been certified by Purchasers Inspector shall be dispatched from Manufacturers
works.

10-MARKING, PACKING AND SHIPMENT

Packing, marking and shipping shall be agreed between supplier and purchaser before
signing the purchase order.

All bends shall be marked as per MSS SP-75.

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

A coat of antirust paint shall be applied on the bends for protection during transit and
storage. The type of paint shall be as agreed upon with the Purchaser.

Both ends of all bends shall be suitably protected to avoid any damage during transit by
means of metallic or high impact plastic bevel protectors.

Packaging shall be marked legibly with suitable indelible marking ink to indicate the
following:

A) Project name

B) Client' Name

C) Purchase Order number and Item Number

D) Manufacturer's name

E) Inspection agency name or logo

F) Unique bend identification number



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G) Outside diameter and wall thickness (mm)

H) API 5L material grade

I) Radius of bend (mm) and bend angle

Bends shall be handled and stored in accordance with API 5L1 and 5LW and in a manner to
prevent any damage to the bends, including beveled ends and coating if applicable. Bends shall
be handled with nylon slings. Bends shall be secured for shipping with wood separators and on
wood pallets.

11-MATERIAL TRACEABILITY

The CONTRACTOR shall ensure that material is fully traceable throughout the production
process. A unique identification number shall be assigned to each bend. This shall be traceable
to the original material certificates and identification number.

12-DOCUMENTATION

After placement of order, the manufacturer shall submit the bend manufacturing procedure
including manufacturing, inspection, testing procedures, Quality Control Manual and Quality
Plans.

The Bend Manufacturing Procedure shall detail the following, as a minimum:

A) Sequence of operation;

B) Induction forming process including bending temperature, temperature control, bending

rate, cooling rate and cooling procedure;

C) Temperature measurement and calibration;

D) Post bend heat treatment;

E) Dimensional control procedure;



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F) Pipe material used for bend manufacture;

G) Pipeline wall thinning calculation;

H) NDT procedures;

I) Quality Assurance and Quality Control;

J) Test procedures.

Upon successful completion of the bend manufacturing procedure qualification, Manufacturer

shall submit the qualified procedure to Purchaser for approval. Regular production of bends shall
commence only after the bend manufacturing procedure has been qualified and approved by
Purchaser.

Prior to shipment, the Manufacturer shall submit test certificates and documentation as specified
in this specification.

Documents shall be in the English language only.

13-QUALITY ASSURANCE

The Manufacturer shall operate a Quality System meeting the requirements of the relevant Part
of ISO 9000.

The Manufacturers Quality system shall be subject to Purchaser approval prior to commitment
to the Purchase Order. The Purchaser reserves the right to conduct a Quality Audit at the
Manufacturers facilities at any stage during manufacture.


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APPENDIX I Figures

INNER

FIG 1 - Test specimen location



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5D MIN.

Fig 2 Location of weld seam