ENGINEER’S STAMP: CONTRACTOR’S STAMP:

4 Minor Update Zhao Kloos 27.03.2019

3 General Update Proetzl Kloos 30.10.2015
2 General Update Neumann Schutter 05.08.2010
1 General Update Neumann Casalini 14.11.2006
0 Issue for Tender Documents Kosikova Bangert August 2004
B Issue for Draft Tender Kosikova Bangert August 2004
A For approval Rupietta Bangert July 2003
REV DESCRIPTION PREPARED CHECKED DATE

SALINE WATER CONVERSION CORPORATION

KINGDOM OF SAUDI ARABIA

SWCC WATER TRANSMISSION SYSTEMS

ILF CONSULTING ENGINEERS

LOCATION: TITLE:

Specification M04
FACTORY MADE BENDS FOR MAINLINES

SCALE: DOCUMENT No.: REV:

Q C 1 0 - H - 0 4 4 4
SUBCONTRACTOR:
Sheet 1 of 10
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LIST OF CONTENTS

1 SCOPE 3
2 CODES AND STANDARDS 3
3 GENERAL 3
3.1 Environmental Conditions 3
3.2 Definitions 4
3.3 Abbreviations 4
3.4 Conflicting Requirements, Exceptions 4
4 TECHNICAL REQUIREMENTS 5
4.1 Manufacturing Process 5
4.2 Design of Bends 6
4.3 Material 6
5 INSPECTION, TESTING AND CERTIFICATION 7
5.1 General 7
5.2 Visual and Dimensional Inspection 8
5.3 Material Tests 8
6 PRESERVATION, MARKING AND SHIPPING 9
6.1 Preservation 9
6.2 Marking 9
6.3 Shipping and Loading 9
7 DOCUMENTATION 10
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1 SCOPE

This Specification covers the minimum technical requirements for the

manufacture and testing of uncoated factory-made pipeline bends of carbon steel
materials for mainlines of water transmission systems designed in accordance
with ASME B31.4.

2 CODES AND STANDARDS

The latest edition of the following codes and standards shall establish the
minimum standards for the work.
ASME B16.49 Factory-Made, Wrought Steel, Buttwelding Induction Bends for
Transportation and Distribution Systems
API 5L Specification for Line Pipe
EN 10204 Metallic products: Types of inspection documents
ISO 10893-9 Non-destructive testing of steel tubes – Part 9: Automated
ultrasonic testing for the detection of laminar imperfections in
strip/plate used for the manufacture of welded steel tubes
ISO 9001 Quality management systems - Requirements

Besides the a.m. codes and standards the Contractor shall observe the following
specification:
G02 General Description of Project and Works
G03 Project Execution
L01 Pipeline Construction
M01 Steel Pipes for Mainlines

3 GENERAL

3.1 Environmental Conditions

The environmental conditions, operating conditions, product data, etc. under

which the bends shall operate are defined in the project description and pipe
laying specification.
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3.2 Definitions

The terms “Contractor“, “Engineer“, etc. used in this specification shall have the
meaning defined in the General and Special Conditions of Contract.

3.3 Abbreviations

ANSI American National Standards Institute

API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
EN European Standard
CE Carbon equivalent
HB Brinell Hardness
ISO International Organization for Standardization
NPS Nominal Pipe Size
MPI Magnetic Particle Examination
RT Radiographic Examination
UT Ultrasonic Examination
SMYS Specified Minimum Yield Strength

3.4 Conflicting Requirements, Exceptions

The Contractor shall notify the Engineer of any conflict between this specification,
the related Codes and Standards and any other specifications included as part of
the Contract Documents applicable to the line bends.
Any exceptions to this specification and referenced documentation shall be raised
by the Contractor and approved by the Engineer in writing.
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4 TECHNICAL REQUIREMENTS

4.1 Manufacturing Process

4.1.1 Induction Bends

Bends generally up to NPS of 48 Inch shall be produced by induction bending of
prefabricated steel pipes.
The metal temperature prior to and during bending shall be accurately
determined using an optical pyrometer and temperature chart recorder. The data
shall be recorded for each bend and shall be made available for review by the
Engineer.
For induction bends the requirements of ASME B16.49 and the amendments of
this specification shall apply.

4.1.2 Bends Made from Forgings

Where the induction bending equipment is not capable to accommodate the
required diameter or wall-thickness the bends may be produced by welding of
two forged half-shells.
The welding and non-destructive examination requirements shall be as per
specification M01 Steel Pipes for Mainlines, doc. no. QC10-H-041. The weld joint
efficiency factor shall be 1.0.
Except for the manufacturing process the requirements of ASME B16.49 and this
specification shall apply analogously for the bends made from half-shells.

4.1.3 Pre-Production Documentation

Contractor shall submit the fabrication/production drawing and a detailed bending
procedure for Engineer’s approval prior to commencement of production.
Procedure shall describe the sequence of operations and details of the
equipment to be used for heating and bending of the pipe, temperature control,
water quenching, post bending heat treatment, inspection and testing
accompanied as a minimum with the following information:
- material (chemical composition, mechanical properties and Material Mill
Certificate)
- maximum allowable working pressure
- maximum hydrostatic test pressure
- wall thickness with tolerances
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- dimensions: internal diameter, length, radius etc. including tolerances

- design of welding seams (if produced of two half-shells)
- qualified welding procedures and supporting procedure qualification records
(if produced of two half-shells)
- design of welding ends with specification of machining and tolerances
- details on heat treatment
- calculation of wall thickness
4.2 Design of Bends

The design wall thickness of the bend shall be determined in accordance with the
fundamental requirement that the final bend wall thickness, at any point on the
bend circumference, will not be less than the nominal wall thickness of the
connecting line pipe at the given location.
Contractor is required to demonstrate compliance with the above mentioned
requirements by means of calculations.
The minimum bending radius shall be 5D (D=nominal outside diameter of the
bend) for bends to be used for pipelines with scraper operation. For pipelines
which do not require scraper operation radius of the bends is subject to detailed
pipeline design but shall not be less than 1.5D.
The bends shall be furnished with tangent ends. The length shall be 1D.

4.3 Material

4.3.1 Starting Materials

The material used for the manufacture of bends shall be carbon steel pipe,
cylinders or forgings which are produced according to recognized standards such
as API, ASTM and ASME etc.
In order to achieve good field welding properties of the finished bend the max.
carbon content of the starting material shall be limited to 0.20 %.
The use of thermo-mechanically processed material which will receive a
considerable decrease of strength properties during hot forming shall be
considered as not preferred and will require explicit approval.
All starting material shall be certified by material test certificate according to
EN 10204 type 3.1 or equivalent.
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4.3.2 Material for Bends Containing Welds

The longitudinal weld seams of pipes or cylinders used for bending shall be
placed at a minimum of 5 deg from the neutral axis of the bend in order to
achieve a minimum offset for field welding in the instance when two or more
bends will be welded together in the same plane.

4.3.3 Material Properties

Unless otherwise specified the material properties of the finished bend shall be in
accordance with the grades listed in ASME B16.49, which are equivalent to the
most common line pipe material grades.
The material properties shall be determined as outlined in ASME B16.49 and
unless otherwise specified also the indicated acceptance criteria for fracture
toughness and hardness shall apply.

5 INSPECTION, TESTING AND CERTIFICATION

5.1 General

The Contractor shall operate a Quality Management System in compliance with

requirements of ISO 9001.
The bends shall be inspected and tested in accordance with this specification and
also shall meet the requirements of ASME B16.49.
The Contractor shall submit a manufacturing procedure, a quality plan and a
detailed Inspection and Test Plan before start of production for approval by the
Engineer.
All procedures for testing shall also be subject to the approval of the Engineer or
its representative prior to fabrication of the bends.
All procedures for testing shall be available for review by an Inspector approved
by the Engineer.
Measuring and test equipment, as well as qualification of inspection and test
personnel, shall be in accordance with the requirements of the applicable Codes
and Standards.
The extent of inspection and testing is different for manufacturing procedure
qualification and regular bend production as outlined in the following sections.
The finished bends shall be furnished with material test certificates according to
EN 10204 type 3.2, showing all chemical analysis required, the final heat
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treatment condition as well as the results of mechanical tests and other

information listed in the appropriate section of ASME B16.49.

5.2 Visual and Dimensional Inspection

Each bend shall be visually inspected regarding dimensions, materials and

workmanship by an inspector approved by the Engineer. The results of this
inspection shall be fully in accordance with ASME B16.49.

5.3 Material Tests

5.3.1 Manufacturing Procedure Qualification Tests

The Manufacturing Procedure Qualification Tests are to be performed by the
Contractor in order to prepare the Procedure Qualification Report.
These qualification bends shall be produced for each diameter and wall-
thickness. For other essential variables the regulation of ASME B16.49 shall
apply.
After visual and dimensional inspection and acceptance, in addition to the test
requirements of ASME B16.49 each qualification bend shall be subject to the
following tests:
1. Hydrostatic Test to 95% SMYS and held for a period of 5 minutes.
2. Ultrasonic test of the welding seam including a distance of 50 mm adjacent
to the weld seam. Where the mother pipe has been cut back, the weld seam
shall be subject to radiographic examination up to a distance of 200mm
from the bevelled end. Where the bend has been produced from two half-
shells, the entire length of the weld seam shall be radiographed in lieu of
UT.
3. Magnetic particle inspection of the complete bend area.

5.3.2 Production Tests

After visual and dimensional inspection and acceptance, in addition to the test
requirements of ASME B16.49 the production bends shall be subject to the
following tests:
1. 10% of the bends for each diameter and wall thickness, equally distributed
according to the progress of production, shall be subjected to hydrostatic
test at 95% SMYS and held for a period of 5 minutes.
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2. Each bend shall be subjected to ultrasonic test of the welding seam

including a distance of 50 mm adjacent to the weld seam. Where the mother
pipe has been cut back, the weld seam shall be subject to radiographic
examination up to a distance of 200 mm from the bevelled end. Where the
bend has been produced from two half-shells, the entire length of the weld
seam shall be radiographed in lieu of UT.
3. Magnetic particle inspection of the complete bend area.
4. The machined bevel at the welding ends of each bend shall be subjected to
magnetic particle inspection. An area of 50 mm from the bend end shall be
checked for laminations by means of ultrasonic testing in accordance with
ISO 10893-9 applying Acceptance Level U2 for edges.

6 PRESERVATION, MARKING AND SHIPPING

6.1 Preservation

The bare surfaces of the bend shall be painted outside with a removable varnish
as temporary corrosion protection during transportation.
The bare ends of each bend shall be protected by bevel protectors of a type to be
approved by the Engineer.
6.2 Marking

The marking shall have the minimum information as required by ASME B16.49.
The marking shall have at least a distance of 150 mm to the bend end.
Further marking details like colour coding etc. shall be applied upon mutual
agreement between Contractor and Engineer.
For each item the series of bend numbers shall be different i.e. any one-bend
number shall not be used more than once for the complete project.

6.3 Shipping and Loading

The Contractor shall submit detailed loading-, stacking- and shipping procedures
for approval by Engineer.
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7 DOCUMENTATION

Documentation to be provided by the Contractor shall include

 the pre-production documentation as per 4.1.3
 manufacturing procedure, quality plan, inspection and test plan as per 5.1
 procedure qualification report as per 5.3.1
 methods and procedures for preservation, marking, loading, stacking,
shipping as per clause 6.
 all test and inspection certificates
 any other documentation which may be required as per ASME B16.49
 ISO 9001 certificate.