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PROJECT PACKAGE ORIGINATOR DISCIPLINE
TYPE
UNIT SERIAL REV Page 2 of 11
RAPID P0005 TYM CON MST 2000 0002 0 Date: 25-Jan16
REVISION HISTORY
CONTENTS
1.0 Scope 4
Attachment
Attachment 1: PFI Standard ES-24 (Pipe Bending Methods, Tolerances, Process and
Material Requirement)
Document Number BA1129
DOC.
PROJECT PACKAGE ORIGINATOR DISCIPLINE
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RAPID P0005 TYM CON MST 2000 0002 0 Date: 25-Jan16
1.0 Scope
This method statement shall be applied to fabrication and inspection of High Frequency
Induction Bend Pipe at Shop and Site to be used for RAPID SCC Project.
Mechanical
Property Test
(Initial)
Post Bend
Heat
Treatment (*)
1. Visual inspection will be carried-out on mother pipe to check for any defect.
2. Material Grade, Outside Diameter, Wall Thickness & Length will also be checked
1. Bending Method
The pipe will be clamped at the location which will make the straight tangent portion where
the bend is to be made. Local induction heating will be applied from the outside surface
area to be bent.
The pipe is pushed forward at a constant speed so that bending stress is concentrated on
the heated zone and is cooled just after bending. Therefore, the pipe is continuously
deformed in a desired way to produce the desired bend.
2. Bending Conditions
a. Bending Temperature
- CS/LT : 800 – 1050 oC
- P91 : 900 – 1100 oC
Note: Temperature will be measured on outer radius of bend by an optical
pyrometer and/or emission type pyrometer.
b. Cooling Method
- CS/LT : Water spray cooling and/or forced air cooling
- P91 : Forced air cooling
Note: Cooling water or air pressure: 0.1 – 6.0 kgf/cm2 (0.01-0.59MPa)
c. Bending Speed : 0.2 – 3.0 mm/s
Document Number BA1129
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PROJECT PACKAGE ORIGINATOR DISCIPLINE
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RAPID P0005 TYM CON MST 2000 0002 0 Date: 25-Jan16
d. Heating coil no. (including width of heating coil) will be controlled for each material and
size (OD, WT) and bend radius
e. In case of longitudinal welded pipe, weld seam shall be located along compression
side between the neutral axes.
6.3 Post Bend Heat Treatment shall be he applied to P91 bends as follows;
a. PBHT Method: Gas Furnace
b. Type of Heat Treatment and Condition
1. Normalizing and tempering will be carried-out after bending. Tempering
temperature shall be 765 oC and higher.
2. Heat Treatment condition will follow mother piping material (ASTM A335).
c. Atmospheric cooling outside furnace after heat treatment will be performed
d. Furnace atmosphere and material temperature will be recorded with thermocouples
and chart recorders.
After post bend heat treatment, blast cleaning by garnet or similar acceptable material will be
carried out on external and internal surface of bend to remove the mill scale. (Internal
surface: as far as possible)
1. Ovality (Flattening)
a. Ovality will be measured by a caliper on bend portion
b. Measuring Point : 3 points on bend portion ((Figure-2 ②,③,④))
c. Tolerance:
: Max 8% (For internal pressure)
Max 3% (For external pressure)
P91 : Max 5%
d. Frequency:
CS/LT : Each production bend
P91 : Each production bend
e. Calculation Formula : {(Max.O.D – Min.O.D) ÷ Nom.O.D} ×100 (%)
Document Number BA1129
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RAPID P0005 TYM CON MST 2000 0002 0 Date: 25-Jan16
2. Wall Thickness
3. Bending Angle
i. All waved shapes shall blend into the pipe surfaces in a gradual manner.
ii. The maximum vertical height of any wave, measured from the average height of
two adjoining crests to the valley, shall not exceed 3% of the nominal pipe size.
(Note 1)
iii. The minimum ratio of the distance between crests as compared to the height
between crests and the included valley should be 12 to 1. (Note 2)
The maximum hardness of steel pipes after bending shall not exceed the following
1. Training will be carried-out by High Frequency Induction Bending (HFIB) Specialist for
Operators who will work as part of the bending crew.
2. Certification will be issued by HFIB Company (DHF- Dai-Ichi Frequency Co. Ltd) to
qualified crew after training
3. Only certified Operators shall operate the HFIB machine
1. Since several kind of materials may be subject to bending, utmost care shall be
considered as to the segregation and traceability
2. Traceability shall be as per piping project specification
Inspection requirements as outlined in this Method Statement are summarized in the High
Frequency Induction Bend ITP. Inspections are to be carried-out at either Shop or Site
wherever applicable, and the frequency of inspection and corresponding report formats shall
be as per ITP. Please refer to document number RAPID-P0005-TYM-PIP-ITP-2000-0001.
Document Number BA1129
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RAPID P0005 TYM CON MST 2000 0002 0 Date: 25-Jan16
Prepared by
Pipe Fabrication Institute Engineering Committee
Copyright by
WEB SITE
www.pfi-institute.org
PFI Standard ES-24
(Revised September 2008)
METRIC CONVERSIONS
The conversion of quantities between systems of units involves a determination of the number of
significant digits to be retained. All conversions depend upon the intended precision of the original quantity
and are rounded to the appropriate accuracy.
Pipe sizes together with applicable wall thicknesses are not shown with metric equivalents.
The SI (metric) values where included with the customary U.S. values in this Standard are the rounded
equivalents of the U.S. values and are for reference only.
Metric units were derived utilizing the following conversion factor:
T
3.2 Unless otherwise specified by the governing code,
EN Dn
TA
NG the bending procedure, including the
heating/cooling cycle and post bend heat
treatment, is determined by the pipe material,
R
diameter, wall thickness, bend radius and the
BEND INTRADOS
required properties after bending. Because of the
many variables involved, the bending procedure
should be determined by the fabricator.
FIGURE 2.1
PFI Standard ES-24
(Revised September 2008)
4. Welds in Bends
4.1 In some instances it is not practical to utilize
pipe of sufficient length to satisfy the required
arc length of the bend. When it becomes
necessary to join lengths of pipe resulting in a
circumferential butt weld in the arc of a pipe
bend, the following practices should be
FIGURE 3.5.1 considered:
ROTARY DRAW BENDING
4.1.1 Pipes to be welded should be selected to
3.5.2 RAM BENDING:
provide the best uniformity possible at the
In ram bending, the pipe is held by two
mating ends. Pipe wall thickness shall not be
supporting dies and a force is applied by
less than the design minimum plus bend
means of a hydraulic ram to a forming shoe
thinning allowance (see section 7.0).
located at the center of the workpiece. The
supporting dies rotate on their mounting pins 4.1.2 End preparation for welding shall be in
so that they follow the pipe and maintain accordance with the qualified welding
external support throughout the operation. procedure to be used. Internal counterboring
should be avoided wherever possible.
During fit-up of the joint, the pipes should
be rotated or aligned as necessary to provide
the least amount of I.D. and/or O.D.
mismatch and the best transition across the
weld.
4.1.3 The welding procedure must be qualified in
accordance with the governing Code for the
thermal exposures, (if any) excepted in
bending and heat treatment.
FIGURE 3.5.2
RAM BENDING 4.1.4 After completion of the circumferential butt
weld, but before bending, the O.D. and I.D.
3.5.3 ROLL BENDING: (where accessible) of the weld should be
In roll bending, three forming rolls of ground to remove excess weld reinforcement
approximately the same diameter arranged in a and blended smoothly into the base metal.
pyramid are used. The two fixed rolls oppose 4.1.5 It is good practice to examine the
the adjustable center roll. The pipe is passed circumferential butt weld by radiography
through the rolls with the position of the prior to and after bending, whether or not
adjustable roll controlling the bend radius. such radiography is required by the
applicable Code.
PFI Standard ES-24
(Revised September 2008)
6.2 Since there are occasions when buckles cannot be 6.5 To determine what bends can be produced with a
avoided, the following restrictions should apply: satisfactory degree of quality, the Pipe
Fabrication Institute has conducted studies on
(a) All wave shapes shall blend into the pipe carbon steel and low alloy steel hot bends to
surface in a gradual manner. determine minimum recommended bend radii for
various ratios of outside diameters to wall
(b) The maximum vertical height of any wave, thickness. The resulting bending range
measured from the average height of two determined by these studies for each of the
adjoining crests to the valley, shall not exceed bending processes is shown in Figure 6.5.1 and
3% of the nominal pipe size. (See Figure 6.2, 6.5.2.
Note 1)
(c) The minimum ratio of the distance between
crests as compared to the height between
crests and the included valley should be 12 to
1. (See Figure 6.2, Note 2)
PFI Standard ES-24
(Revised September 2008)
TABLE 7.2.1
FURNACE BENDING
7.3 Since the start of the bend is somewhat dependent place which results in more footage of straight pipe
on factors not completely within the control of the being required than that determined from the
bender, some additional length must be added to developed length. To provide for this compression
insure that overall center-to-end dimensions can be the purchaser of induction bends should add 5% to
met. To compensate for this factor, the purchaser the theoretical arc length. The compression of the
should add 6 inches to the total of the required material may leave a hump, or bump, at the
straight tangent lengths. beginning of the bend on the inside radius which is
not detrimental to the bend.
7.4 Because induction heated bends are produced
under pressure, a compression of the material takes
Nominal pipe size 1" thru 2" 2½" thru 3½" 4" thru 48"
Pulling End 6" 8" 2D (10" min)
Holding End 6" 8" 1.5D (10" min)
Tangent Between Bends (Tm) 6" 9" 1D (12" min)*
*Note: 9" min for 4" pipe. 10" min for 5" pipe.
TABLE 7.5.1
MINIMUM TANGENT LENGTHS FOR FURNACE BENDS
TABLE 7.5.3
MINIMUM TANGENT LENGTHS FOR COLD BENDING
PFI Standard ES-24
(Revised September 2008)
9.1 The Pipe Bend Order Form, (Form 9.1), provides Radius of Bend---------------- 1% of Dim “C”
the recommended information required for the Degree of Bend --------------- 0.5 Degree
purchase pipe bends. Plane of Bend -----------------1.0 Degree
9.2 The applicability and acceptance criteria of each Flat Plane of Bend------------ 1% of Dim “C”
field, as defined by the Pipe Bend Order Form, Linear Dimensions ----------- 1/8”, 12” & under
shall be determined by the applicable codes, 3/16”, over 12”
specifications and fabrication requirements. Ovality in Bent Area --------- 8% of Diameter
after Bend
Ovality at End Prep.---------- ASME B16.9
Lineal
Dimension
Lineal Tangent
Dimension Length
Radius of
Bend (Dim C) Plane of Bend
(Angle between
Two Bend Planes)
Ovality Tolerence :
Minor The difference
Dia. between the major
and minor axis (percent)
Tangent Line
Flat Plane
Nom. Major
of Bend
Dia. Dia.
Degree of
Bend
Ovality
(2 x size)
Tangent Line
Elevation
Figure 9.3
Tolerences
"A" TANG LENGTH
"A"
END
T.L.
PREP "A"
"E"
UT 1
UT 2
"C" RAD
"E"
"B"
UT 3
T.L.
"D"
FORM 9.1
PIPE BEND ORDER FORM