PETRONAS TECHNICAL STANDARDS

DESIGN AND ENGINEERING PRACTICE

TECHNICAL SPECIFICATION

PIPELINE BENDS

PTS 20.144
APRIL 1991
 PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication,
of PETRONAS OPUs/Divisions.

They are based on the experience acquired during the involvement with the design, construction,
operation and maintenance of processing units and facilities. Where appropriate they are based
on, or reference is made to, national and international standards and codes of practice.

The objective is to set the recommended standard for good technical practice to be applied by
PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical
plants, marketing facilities or any other such facility, and thereby to achieve maximum technical
and economic benefit from standardisation.

The information set forth in these publications is provided to users for their consideration and
decision to implement. This is of particular importance where PTS may not cover every
requirement or diversity of condition at each locality. The system of PTS is expected to be
sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to
their own environment and requirements.

When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the
quality of work and the attainment of the required design and engineering standards. In
particular, for those requirements not specifically covered, the Principal will expect them to follow
those design and engineering practices which will achieve the same level of integrity as reflected
in the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his
own responsibility, consult the Principal or its technical advisor.

The right to use PTS rests with three categories of users :

1) PETRONAS and its affiliates.

2) Other parties who are authorised to use PTS subject to appropriate contractual
arrangements.
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with
users referred to under 1) and 2) which requires that tenders for projects,
materials supplied or - generally - work performed on behalf of the said users
comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with
users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury
or death) suffered by any company or person whomsoever as a result of or in connection with the
use, application or implementation of any PTS, combination of PTS or any part thereof. The
benefit of this disclaimer shall inure in all respects to PETRONAS and/or any company affiliated
to PETRONAS that may issue PTS or require the use of PTS.

Without prejudice to any specific terms in respect of confidentiality under relevant contractual
arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by
users to any company or person whomsoever and the PTS shall be used exclusively for the
purpose they have been provided to the user. They shall be returned after use, including any
copies which shall only be made by users with the express prior written consent of PETRONAS.
The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe
custody and PETRONAS may at any time require information satisfactory to PETRONAS in order
to ascertain how users implement this requirement.
TITLE: PIPELINE BENDS

The specification contained herein sets out the standard requirements and procedures to be complied
with by CONTRACTORS carrying out work directly or indirectly for PETRONAS.

For a given project, the Contract Documents related thereto may specify requirements and
procedures which deviate from or qualify those set out in this standard specification.

The CONTRACTOR shall be responsible for identifying any and all such deviations and qualifications
and ensuring that the work 's completed in strict accordance therewith.
REVISION REGISTER

REVISION NO. DATE DETAILS OF REVISION

1 - ORIGINAL ISSUE

2 9/83 ENTIRE DOCUMENT

3 12/83 ENTIRE DOCUMENT

4 5/85 ENTIRE DOCUMENT

5 3/91 ENTIRE DOCUMENT, INCLUDING

- Restricted to induction bending

- All welding requirements removed

- Referenced to Petronas linepipe

specs.

- Title changed

6 5/92 - Cold bending and non induction

bending specificaly excluded

- Added criteria on workmanship and

finish.
CONTENTS

1. SCOPE

2. REFERENCES

3. MATERIALS

4. BEND MANUFACTURE

4.1 Manufacture

4.2 Heat Treatment

4.3 Tangents and Bends Ends

4.4 Test Bend

4.5 Wall Thinning

5. DIMENSIONAL TOLERANCES

6. WORKMANSHIP AND FINISH

7. INSPECTION, TESTING AND REPAIRS

7.1 Test Bends

7.2 Production Bends

7.3 Repairs

8. DOCUMENTATION

8.1 Procedures

8.2 Materials and Testing

8.3 Identification

FIGURE NO. 1 LOCATION OF TEST SPECIMENS

FIGURE NO. 2 OUT-OF-ROUNDNESS MEASUREMENTS

FIGURE NO. 3 OUT-OF-PLANE MEASUREMENTS

FIGURE NO. 4 HARDNESS SURVEY REQUIREMENTS

1. SCOPE

This specification defines the minimum technical requirements for the fabrication, inspection
and testing of pipeline bends from straight pipe. Within this specification “shall” is used to
indicate a provision is mandatory.

2. REFERENCES

The latest edition of the following codes and specifications are applicable where referenced in
this specification.

(a) PETRONAS Technical Standards (PTS)

L-2-2/3 "Line Pipe for Use in Oil and Gas Operations Under Non-Sour Conditions"

L-3-2/3 "Line Pipe for Use in Oil and Gas Operations Under Sour Conditions"

(b) British Standards (BS)

BS 427 "Method for Vickers Hardness Tests Part 1 : Testing of Metals

BS 6072 "Method for Magnetic Particle Flaw Detection"

(c) American Petroleum Institute

API 5L " Specification for Line Pipe"

3. MATERIALS

The pipe used for the production of bends shall conform to the requirements of PETRONAS
Technical Standard PTS L-2-2/3 or PTS L-3-2/3 with the surface bare.

The wall thickness of the pipe shall be such that during the bending process the wall thinning
does not exceed the limits specified in Section 4.5.

4. BEND MANUFACTURE

4.1 Manufacture

Bends shall be manufactured by the induction bending process. Use of heating methods other
than induction heating shall not be permitted. Cold bending shall not be permitted

For non seamless pipe, the seam shall be positioned on the bend neutral axis during the
bending operation.

Once the bending operation has commenced any stoppage shall not be permitted until the
entire bend has been completed.

No girth welds are permitted in the bend.

The bends shall be mill varnished on completion.

4.2 Heat Treatment

The heat treatment procedure shall be such that the physical and mechanical properties of
the finished bends shall be in accordance with the original line pipe specification.

4.3 Tangents and Bends Ends

All bends shall be provided with straight tangents on each end. Tangent length shall be 1.5
times nominal pipe diameter unless otherwise stated.

Weld bevels shall be prepared on all ends before application of heat treatment. Bevelled
ends shall have the bevel angle and root face in accordance with the requirement of API 5L
for plain end pipe. All ends shall be fitted with metallic bevel protectors.

4.4 Test Bend

One additional bend for each “heat lot” shall be manufactured for test purposes. For the
purpose of this specification a “heat lot” is defined as bends of the same diameter, wall
thickness, mill heat number and bend forming parameters, excluding bend angle i.e bends
with all parameters equal except bend angle may be considered as the same “heat lot”.

The test bend angle shall be equal to or greater than the largest bend angle in the heat lot.

The bend shall be subjected to the examination and testing specified in Section 7.1 after the
bend has undergone the final heat treatment. Location of test specimens are indicated on
Figure No. 1.

4.5 Wall Thinning

Wall thinning of the bends as a result of the bending process shall not exceed 4% for 10D
bends, 8% for 5D bends and 13% for 3D bends. The final wall thichness for the bends shall
comply with the tolerance stated in Section 5.

5 DIMENSIONAL TOLERANCES

(a) Wall Thickness : The wall thickness at any location on the finished bend
shall not be less than the specified minimum wall
thickness of the initial straight pipe.

(b) Inside Diameter at ends
: The maximum internal diameter shall not be more than
1.5mm larger than specified, and the minimum inside
diameter shall not be more than 1.5mm smaller than
specified , measures with an internal gage, or a
measuring tape at each end of the bend or tangent.

(c) Ovality : Ovality measured as the difference between maximum

and minimum outside diameter shall not exceed 2% of the
nominal pipe outside diameter in the body of the bend.

Refer to Figure No.2 for details.

 (d) Bend Radius : The radius of the bend shall be within ± 1% of the
specified value.

(e) Squareness : The ends of all bends shall be cut square to the axis of
the bend, with a tolerance of ± 2mm.

(f) Out of Plane : Out of plane measured as shown in Figure No.3 shall not
exceed.

Alpha
x10mm
90
Where “Alpha” is the required bend angle.

(g) Bend Angle : The bend included angle shall be within ± 0.5 degrees of
the specified values.

(h) Length : The overall bend length including tangents shall be

± 50mm of the intended length.

7. INSPECTION, TESTING AND REPAIRS

7.1 Test Bends

7.1.1 General

Prior to production the test bend shall undergo the following bending procedure
qualification tests. All test procedures and results shall be in accordance with the
mother pipe specification.

Any change in the production procedures or parameters, or in chemical composition,

material properties, or source of supply of the bend starting material, after the first
test bend has been produced will require another test bend to be produced and
tested.

7.1.2 Tensile Test

One transverse tensile test and one longitudinal tensile test shall be performed on
specimens taken from the inner and outer radius of each test bend.

For seam welded pipe, a cross weld tensile test specimens shall be taken from the
weld and tested.

7.1.3 Charpy V-Notch Impact Test

Two sets of three Charpy V-Notch impact test specimens shall be taken from each of
the inner and outer radii. For seam welded pipe, two additional sets shall be taken
transverse to the longitudinal axis, and the notch line shall be cut through the pipe
thickness.
6. WORKMANSHIP AND FINISH

a) All finished bends shall be free of cracks grooves, dents, laminations and other detrimental
surface defects. Local buckles are not premitted except as defined below.

b) Local buckles on the inside radius of the bend, caused by the induction bending process,
shall be subject to the following restrictions (see Figure 2) :

- All buckles shall be wave shaped and shall blend smoothly in the pipe surface.

- The maximum vertical height (H) of any buckle measured from ‘crest ‘ to ‘ trough ‘
shall not exceed 2 % of the nominal pipe outside diameter, or a maximum of 10mm.

- The minimum ratio of the distance between crests (L) and the height (H) shall be 12
to 1

- A buckle occuring at the transition of bend to tangent length shall have a taper angle
with the longitudinal axis of less than 14 °.

c) The ovality tolerances as specified in 5(c) shall not be exceeded by the cross sections
containing local buckles.
7. INSPECTION, TESTING AND REPAIRS

7.1 Test Bends

7.1.1 General

Prior to production the test bend shall undergo the following bending procedure
qualification tests. All test procedures and results shall be in accordance with the
mother pipe specification.

Any change in the production procedures or parameters, or in chemical composition,

material properties, or source of supply of the bend starting material, after the first
test bend has been produced will require another test bend to be produced and
tested.

7.1.2 Tensile Test

One transverse tensile test and one longitudinal tensile test shall be performed on
specimens taken from the inner and outer radius of each test bend.

For seam welded pipe, a cross weld tensile test specimens shall be taken from the
weld and tested.

7.1.3 Charpy V-Notch Impact Test

Two sets of three Charpy V-Notch impact test specimens shall be taken from each of
the inner and outer radii. For seam welded pipe, two additional sets shall be taken
transverse to the longitudinal axis, and the notch line shall be cut through the pipe
thickness.

Sets of the three Charpy V-Notch impact test specimens shall be taken from the
seam weld from the mid-thickness position (one set for each position).

Typical test piece locations are shown in Figure No.1.

7.1.4 Hardness Tests

One full wall-thickness macro-section shall be taken from the inner and outer radii
and shall be hardness tested in accordance with BS 427 Part 1. The number and
location of the indentation shall be as shown in Figure No. 4.

For seam welded pipe an additional cross-weld macro-section shall be taken and
tested as shown in Figures 1 and 4.

7.1.5 Hydrogen Induced Cracking Test

For sour service conditions, a stepwise cracking test shall be performed on a

specimen taken from the inner radius at the stop of bending location. The details of
specimen preparation, test method and evaluation procedure shall be in accordance
with Appendix VI of PETRONAS Standard Specification L-3-2/3
7.2 Production Bends

7.2.1 General

All production bends shall be non-destructively examined as specified below after final heat
treatment. Testing methods and limits of rejection/acceptance shall be in accordance with the
mother pipe specification. The qualification level for ultrasonic testing inspector shall be ASNT
level II or equivalent.

7.2.2 Visual Inspection

A visual inspection of the bends shall be carried out after they have been fabricated.

After the bends have been transported to the designated location(s), a final visual check shall
be performed.

7.2.3 Dimension Checks

Dimensional control checks on each bend shall be carried out during the process of
manufacturing the bends. The results of such checks shall be within the tolerances specified
in Section 5 and 6.

7.2.4 Wall Thickness Inspection

The wall thickness of the curved section of the bend shall be measured using an ultrasonic
compression wave technique. Measurements shall be taken at spacings of 150 mm along the
longitudinal axis and circumferentially for each bend. Additional measurements shall be made
at positions where internal and/or external dressing by grinding has been carried out,
including arc strikes and ground repairs. These measurements shall be sufficiently closely
spaced to ensure that the minimum wall thickness is universally exceeded.

7.2.5 Inspection of Weld Ends

A 100 mm wide circumferential band at the free ends of tangents shall be ultrasonically tested
for linear indications.

7.2.6 Magnetic Particle Inspection

Both the outer and inner (if accessible) surfaces of each bend shall be 100% magnetic
particle tested in accordance with BS 6072 using wet particles on completion of dressing,
machining and grinding. Surface indications such as cracks, slivers and laminations shall be
cause for repair or rejection in accordance with the mother pipe specification.
7.2.7 Radiography and Ultrasonic Inspection for Weld Seams

The full length of all weld seams of the bends shall be radiographed after bending. Rejection
criteria shall be as for the mother pipe. If it is found that radiographs are difficult to interpret at
the bend portion due to the existing curvature, ultrasonic inspection shall be performed on the
weld seams at such locations.

7.2.8 Hydrostatic Testing

All completed bends shall be hydrostatically tested to the test pressures which result in hoop
stresses equal to 95 percent of the specified minimum yield strength of the bends based on
their nominal wall thickness less the allowance for local thinning as stated in Section 4.5. The
hydrostatic test pressure shall be maintained for a minimum of three minutes.

7.2.9 Gauging of Bends

Each production bend shall be tested with a gauging plate pulled through the bend in such a
way as to maintain the plate perpendicular to the pipe longitudinal axis at all times. The plate
diameter shall be 95% of the nominal inside diameter for pipe sizes of 12-inch or less, and
97.5% for larger diameter. The plate shall pass freely through the bend without damage or
indentation.

7.3 Repairs

Repair of defects in the body of the bend by welding shall not be permitted. Defects in the
body may be repaired by grinding provided the final thickness after grinding is greater than
the specified minimum wall thickness. All repairs shall be examined by magnetic particle
inspection to ensure complete removal of the defect.

8. DOCUMENTATION

8.1 Procedures

The written procedures shall include in detail the equipment, materials, a step by step
description of the bending process and inspection. It shall as a minimum cover the following:-

(a) Bending procedure detailing:

- sequence of operation

- induction bending temperature

- bending speed (mm/min)

- cooling method (medium used, pressure, type and number of nozzles, etc.)

- temperature measurement and calibration

- bend radius control

- bend angle control

- pipe diameter control

 - wall thickness control

- chemical analysis

- material type and grade

(b) Heat treatment procedure

(c) Details of gauging pig.

(d) Dimensional control procedure

(e) Hydrotest procedure

(f) Complete and detailed description of method, technique, equipment and procedures
for all non-destructive testing. The magnetic particle testing procedure shall contain
detailed information concerning the prevention of arc burns from yokes or prods and
of any subsequent demagnetizing treatment.

(g) Bend Manufacture Procedure Qualification including all mechanical testing.

(h) Testing and inspection procedures for all phases of the WORK with a detailed
inspection plan which shall indicate:

• A flowchart illustrating each manufacturing point affecting the quality of the

product and goods and its relative location in the procedure cycle where
conformance of characteristics shall be verified.

• The characteristics to be inspected at each inspection point from procedural

approvals through incoming inspection to shipping inspection.

• Copies of specific forms used to record the results of each inspection.

(i) Proposed repair procedure.

(j) Proposed handling and storage of finished bends with identification system and
tracking methods, short and long term storage arrangements as well as other relevant
information.

(k) Close out and material reconciliation

(l) Safety procedure.

8.2 Materials and Testing

Documentation necessary to show that the material, method of manufacture and testing
conform to the requirements of the specification shall be submitted at the appropriate stages
of the work.

The relevant documentation shall include, but not to be limited to:

(a) Material Certificates for pipe before and after bending.

(b) Manufacturing procedure qualification records.

(c) NDT test reports and operator qualification Certificate.

(d) Mechanical test reports.

(e) Heat Treatment reports.

 (f) Bending equipment and test equipment calibration Certificates.

(g) Dimensional check reports.

(h) Hydrostatic test records.

(i) Weight of completed bend.

(j) Repair report.

The reports shall reference the bend they apply to by quoting the bend number, heat number,
test number and type of steel.

All reports shall be signed to signify compliance with the requirements of the specification.

8.3 Identification

A material control record shall be maintained of receipt, issue, return or disposal of all bend
material supplied by COMPANY which shall reference the identifying number stencilled on the
body of the pipe.

Certificate documents accompanying the bend material shall be preserved and returned with
the final material control record.

Each bend shall be clearly paint-marked with the following information on the outside of the
bend:

- Manufacture's name or trade mark.

- Bend reference number (serial number, etc.)

- Heat number

- Grade or material (X52, etc.)

- Size, wall thickness, bending radius, angle

- Inspection stamp

The paint marks shall be placed within a frame of white paint.

The reference number of any bends which have been totally rejected shall not be used again
for replacement or new bends.

All bend marking shall be inspected prior to dispatch and any bends not correctly marked
shall be rejected until identity is verified and the bend correctly marked.
FIGURE 1: LOCATION OF TEST SPECIMENS INDUCTION BENDS
FIGURE 2: OVALITY AND LOCAL BUCKLES MEASUREMENTS
FIGURE 3: OUT OF PLANE MEASUREMENTS
FIGURE 4: HARDNESS SURVEY REQUIREMENTS