Pipe Bending BES-CO-05-009-03

Issuing Organisation Rev: 3 / 17.11.2011

PTS Sheet 1 / 10

PIPE BENDING
BES-CO-05-009

Preparer Date Name/Position

Gino De Landtsheer / Piping Expert,
17.11.2011
PTS

Issuer Date Name/Position

Gino De Landtsheer / Piping Expert,
17.11.2011
PTS

Process owner Date Name/Position

17.11.2011 Filip Goovaerts / Specs PTS

3 3-yearly general update

2 Reason for the next revision
1 Approved
Rev. Description

A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena
 BES-CO-05-009-03 Rev: 3 / 17.11.2011 Sheet 2 / 10

TABLE OF CONTENTS

1 GENERAL .........................................................................................................................3
1.1 Validity ...............................................................................................................................3
1.2 Review Schedule ...............................................................................................................3
1.3 Group Amendment to the Borealis Engineering Specification ............................................3
1.4 Objective and Scope..........................................................................................................3
2 APPLIED STANDARDS ....................................................................................................3
2.1 Standards and Regulations................................................................................................3
2.1.1 European Directives ..........................................................................................................4
2.1.2 Applicable Design Codes ...................................................................................................4
2.1.3 Borealis Reference Documents .........................................................................................4
2.1.4 Standards ..........................................................................................................................4
3 BASIC DESIGN REQUIREMENTS ...................................................................................5
3.1 General..............................................................................................................................5
3.2 Types of Bending ...............................................................................................................5
3.2.1 Cold Bending .....................................................................................................................5
3.2.2 Hot Bending .......................................................................................................................6
3.2.3 High Frequency Induction Bending (HFIB) .........................................................................6
3.3 Bending Procedures ..........................................................................................................6
3.4 Heat Treatment Procedures...............................................................................................7
3.4.1 General..............................................................................................................................7
3.4.2 For Ferritic Steels with the exception of the Quenched and Tempered Grades ..................7
3.4.3 For Quenched and Tempered Ferritic Steels .....................................................................7
3.4.4 Carbon Steel, Mo (0.3, 0.5) Steel Piping ............................................................................7
3.4.5 Cr-Mo Steel Piping.............................................................................................................8
3.4.6 Austenitic Cr-Ni Alloy Steel Piping .....................................................................................8
3.5 Tolerances .........................................................................................................................8
4 INSPECTION AND TESTING ............................................................................................9
4.1 Non-Destructive Testing ....................................................................................................9
4.2 Inspection ..........................................................................................................................9
5 ATTACHMENTS ............................................................................................................. 10

A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena.
 BES-CO-05-009-03 Rev: 3 / 17.11.2011 Sheet 3 / 10

1 GENERAL
1.1 Validity
This specification is valid for all BOREALIS Sites.

1.2 Review Schedule

This specification shall be reviewed at least every three years.

1.3 Group Amendment to the Borealis Engineering Specification

This Borealis Engineering Specification shall consist of the ‘BES-CO-00-001; Group
Amendment to the Borealis Engineering Specifications’ which are incorporated herein and
made part here of by reference.

Content for info: General Definitions, Abbreviations, Objective and Scope, Language, Unit
System, CE-Marking, PED / ATEX / Quality Assurance / Quality Control, General Basic
Design Requirements.

1.4 Objective and Scope

This specification and its appendices cover the minimum technical requirements for the
detailed engineering and design of ferrous pipe bending.

Bending of non-ferrous pipe is outside the scope of this specification.

Bending of thermoplastic piping is covered by the ‘BES-CO-05-304; Thermoplastic Piping

Bending’ specification.

Bending of pipe shall comply with ASME B31.3, PED, national standards and rules and
this specification.

MANUFACTURER is responsible to ensure that all requirements of the regulating

authorities are fulfilled. However, CONTRACTOR shall supply all necessary
documentation regarding inspection, NDT, etc. to fulfil the PED requirements.

2 APPLIED STANDARDS
It shall be CONTRACTOR’s responsibility to be, or to become, knowledgeable of the
requirements of the referenced Codes and Standards.

When an edition date is not indicated for a code or standard, the latest edition in force at
the time of CONTRACTOR’s commitment shall apply.

Intermediate changes or updates/revisions of applied codes, standards, regulations or

laws during the course of the project shall be brought to COMPANY’s attention. Possible
implications for the works shall be discussed.

2.1 Standards and Regulations

The design and engineering shall satisfy all laws and regulations of the national and/or
local authorities of the country in which the EQUIPMENT AND MATERIALS will be
located.

The international codes and standards, to the extent specified herein, form a part of this
specification and shall be followed. Some codes or standards (e.g. Euro codes) are still
under development and their final number and identification are given below. If the
referenced code is not yet available, it’s preceding pre-code, draft code or relevant
national codes covering the same subject shall be followed.

A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena.
 BES-CO-05-009-03 Rev: 3 / 17.11.2011 Sheet 4 / 10

In case of conflict, the order of precedence shall be:

1. National and/or local Laws and Regulations applicable at the location of the site.
2. European Directives
3. Applicable Design Codes
(ASME BVPC, ASME B31.3, AD2000, BS 5500, EN 13445, EN 13480, etc.)
4. Project specific CATALOGUE DATA SHEETS from the LICENSOR
5. COMPANY specifications
Project Specification
Local Amendment
Common Engineering Specification
6. Reference to international standards (API, NFPA, etc.)

The more stringent of two conflicting regulations/standards will prevail.

In all cases CONTRACTOR shall inform COMPANY of any deviation from the
requirements in the specifications, which is considered to be necessary in order to comply
with national and/or local laws and regulations.

Deviations from this specification are subject to written approval by COMPANY. After this
approval these specifications are integral part of the contract.

The standards and codes as listed in 2.1.1, 2.1.2, 2.1.3 and 2.1.4 shall be followed.

2.1.1 European Directives

EU 97/23/EC Directive of the European Parliament and of the Council on the
(2009) Approximation of the Laws of the Member States Concerning
Pressure Equipment.
Pressure Equipment Directive (PED) for pressure containing
equipment and assemblies

2.1.2 Applicable Design Codes

ASME B31.3 American Society of Mechanical Engineers:
(2010) Process Piping
ASME BPVC Boiler & Pressure Vessel Code, Section V:
Sec V Non-destructive Examination
(2010)
ASME BPVC Boiler & Pressure Vessel Code, Section VIII:
Sec VIII Div 1 & Div 2 Rules for Construction of Pressure Vessels
(2010)
AD 2000 Technical Rules for Pressure Vessels:
(2007) AD Merkblätter, AD2000 Merkblatt HP 100 R
CEN EN 13480 Metallic Industrial Piping
Part 1, 2, 3, 4, 5 and 6 Part 1: General
(Part 1 5: 2002) Part 2: Materials
(Part 6: 2004) Part 3: Design and Calculation
Part 4: Fabrication and Installation
Part 6: Additional Requirements for Buried Piping
CEN/CR ISO 15608 Welding – Guidelines for a metallic material grouping system
(2005)

2.1.3 Borealis Reference Documents

BES-CO-00-001 Group Amendment to the Borealis Engineering Specifications
BES-CO-05-007 Pipe Classes ASME
2.1.4 Standards
ASTM A106/A106M Standard Specification for Seamless Carbon Steel Pipe for

A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena.
 BES-CO-05-009-03 Rev: 3 / 17.11.2011 Sheet 5 / 10

(2010) High-Temperature Service

ASTM A333/A333M Standard Specification for Seamless and Welded Steel Pipe for
(2011) Low-Temperature Service
ASTM E112 Standard Test Methods for Determining Average Grain Size
(2010)
EN 473 Non-destructive testing - Qualification and Certification of NDT
(2008) Personnel – General Principles

3 BASIC DESIGN REQUIREMENTS

3.1 General
Sufficient modularity should ensure that in the event of failure, fast component
replacement is facilitated, to avoid prolonged plant outage. Hence, to obtain the economic
advantages offered through maximum standardisation.

The application of bending and the extent of its use shall be agreed with COMPANY in an
early stage of the project.

The piping design shall incorporate the required bending radius. The bending radius shall
be indicated on the isometrics.

The bending radius shall be 1.5 x DN, 3 x DN or 5 x DN, unless specified otherwise in the
pipe material specification. Other bending radii shall be subject to approval by COMPANY.

The bending shall comply with code requirements regarding strain, wall thickness, etc.
The strength increase of cold bent pipe shall not be included in the pipe wall thickness
calculation.

Welding shall not be performed in the plastically deformed zone nor closer than 2 times
the wall thickness, minimum 30mm, to this zone, unless properly qualified on cold formed
material.

All bending shall be done according to approved procedures. These procedures shall be
reviewed and approved by COMPANY before any bending is performed.

Local heating by manually operated gas torches shall not be applied.

The use of water for cooling or quenching is not permitted unless specified in the bending
procedure.

If the pipe contains a longitudinal weld, this weld shall not be located in a zone ± 40° from
the bend tensile axis.

Weld repairs of cracks in pipe bends shall not be permitted.

Bends intended for use in pipes that require pigging shall be checked for correct bore and
radii to allow the passage of the pig.

3.2 Types of Bending

3.2.1 Cold Bending

This is bending at a temperature well below the final heat treatment temperature of both
ferrite and austenitic materials.

A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena.
 BES-CO-05-009-03 Rev: 3 / 17.11.2011 Sheet 6 / 10

Cold bending of austenitic Cr-Ni alloys is defined as bending carried out at temperatures
below 425°C. These alloys shall not be heated in the temperature range 425 - 950°C.

Cold bending of Carbon Steel shall not be used in sodium hydroxide or high pH service.

Cold pipe bending, normally up to DN 50 (NPS 2) shall be done in pipe bending machines
or presses, using formers. For sizes larger than DN 50 (NPS 2), approval of COMPANY is
required.

However, special cold bending technology, using mandrels, conducted according to

COMPANY approved procedures can be applied up to DN 250 (NPS10).

3.2.2 Hot Bending

This is bending at a specified elevated temperature. Heat shall be applied uniformly
before bending.

The hot forming / bending temperatures are shown in ‘Attachment 2; Hot Bending
Temperature and Post Bend Heat Treatment’.

Water-cooling at any time during bending shall not be applied.

3.2.3 High Frequency Induction Bending (HFIB)

This is a hot bending process, using machines in which the pipes are passed through an
induction coil where, successively, a narrow band of pipe material is rapidly heated to the
required bending temperature using the high frequency induction method.

The adjacent pipe is kept cool by water and/or air jets, thus providing the necessary
support for the heated area without the need for mandrels. It shall be ensured that the
bending temperature is uniform over the complete circumference of the bend.

The equipment used for high frequency induction bending shall be calibrated and the
calibration certificates shall be presented to COMPANY’s representative before the start
of bending.

The proposed hot bending process shall be pre-qualified by a test bend for each material
and tube diameter. The test bends shall be inspected mechanically and in a non-
destructive way. These pre-qualifications shall be included in the bending procedure to be
submitted to COMPANY’s representative for approval.

Previous production records, which include mechanical and non-destructive testing, can
also be used as a pre-qualification.

3.3 Bending Procedures

Bending procedures shall, as a minimum, include the following information (covered by
pre-qualifications) about:

Material
Diameter
Wall thickness
Operating sequence
Forming process and machinery used
Production parameters, which shall at least cover:
o Width of heated band
Heating rate and method
Bending temperature range

A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena.
 BES-CO-05-009-03 Rev: 3 / 17.11.2011 Sheet 7 / 10

Cooling rate, cooling method and coolant flow rate

Production bending speed
Method of temperature measurement and recording
Bend dimensions and tolerance
Non-destructive examination procedures
Non-destructive testing procedures
Post forming
Heat treatment after forming
Fabrication procedure qualification testing
Production control procedure
Calibration of equipment and tolerances

3.4 Heat Treatment Procedures

3.4.1 General
Heat treatment shall be applied as specified in ASME B31.3 and paragraphs below.

3.4.2 For Ferritic Steels with the exception of the Quenched and Tempered Grades
(Material group 7.1 as per CEN/CR ISO 15608; Welding – Guidelines for a metallic
material grouping system)

A normalising heat treatment shall be applied, if the cold straining is more than 5%, or
when the hardness increase in Vickers or Brinell is more than 100, unless local
regulations are more stringent.

Stress relieving temperature shall be at least 10°C below the tempering temperature as if
tempering was applied.

3.4.3 For Quenched and Tempered Ferritic Steels

(Material group 7.1 as per CEN/CR ISO 15608; Welding – Guidelines for a metallic
material grouping system)

An appropriate stress relieving heat treatment shall be applied if the cold straining is more
than 5%, or when the hardness increase in Vickers or Brinell is more than 100, unless
local regulations are more stringent.

Stress relieving temperature shall be at least 10°C below the tempering temperature.

3.4.4 Carbon Steel, Mo (0.3, 0.5) Steel Piping

(Material group 1 & 2 as per CEN/CR ISO 15608; Welding – Guidelines for a metallic
material grouping system)

Pipes made of these materials may be bent under hot or cold condition.

For hot formed bends, upon which the final forming operation is completed at a
temperature above 900°C and below 950°C, need no heat treatment provided the
hardness does not exceed a certain value (e.g.: below HV 200 for ASTM A 106/A 333
GR6, 0.3Mo and 0.5Mo steel and HV 180 for St35/St37).
When hot bending is carried out, outside the temperature range given above or when
hardness values are too high, a separate normalising heat treatment at 900-950°C is
required. When not operating within the creep range a stress relieving temperature of
approximately 600°C is sufficient.

The grain size after bending and possible heat treatment shall not be increased. Grain
size shall be determined according to ASTM E112. Replica can be used.

A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena.
 BES-CO-05-009-03 Rev: 3 / 17.11.2011 Sheet 8 / 10

3.4.5 Cr-Mo Steel Piping

(Material group 4, 5, 6 as per CEN/CR ISO 15608; Welding – Guidelines for a metallic
material grouping system)

Cr-Mo steel piping may be bent under hot or cold condition.

To facilitate cold bending, the pipe may nevertheless be heated. The heating shall be
uniformly applied and carefully controlled.

The temperature shall not exceed the maximum temperature limit of post weld heat
treatment as indicated in ASME B31.3 and at least be 10°C below the tempering
temperature.

For hot bending the pipe shall be heated to a temperature between 870-920°C.

After cooling the following heat treatments shall be carried out unless otherwise agreed by
COMPANY:

Normalising at a temperature appropriate for the material concerned, or as specified by

material VENDOR, followed by cooling in still air
Heat treatment at a temperature as indicated in ASME B31.3 and at least 10°C below
the tempering temperature

These heat treatments can be combined with the heat treatment required after completion
of welding.

The maximum hardness shall be below HV 248.

3.4.6 Austenitic Cr-Ni Alloy Steel Piping

(Material group 8 as per CEN/CR ISO 15608; Welding – Guidelines for a metallic material
grouping system)

Bends in austenitic Cr-Ni and Cr-Ni-Mo steel pipes shall normally be made only in the cold
condition. Cold bends are not allowed without solution annealing, where Chloride Stress
Corrosion Cracking (CSCC) is possible.
In exceptional cases, the application of heat during bending is permitted only if approved
by COMPANY’s representative and when followed by solution annealing at 1040-1120°C.
The cooling rate after solution annealing shall be according to the material specification.

High Frequency Induction Bending (HFIB) can be applied for low carbon grades according
to COMPANY approved procedures.

3.5 Tolerances
Tolerances: see EN13480-4 paragraph 7.4 and 7.5.

The tolerances on the maximum flattening and the maximum decrease of wall thickness
shall not exceed the allowance in the code.
Wall thicknesses shall be calculated in accordance with ASME B31.3 – paragraph 304.1.2
(3a-b) to define the internal pressure design thickness for the straight pipe.

The minimum required thickness of the bend after bending shall be determined in
accordance with the equations defined in ASME B31.3 – paragraph 304.2.1 (3c-d-e).

A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena.
 BES-CO-05-009-03 Rev: 3 / 17.11.2011 Sheet 9 / 10

4 INSPECTION AND TESTING

4.1 Non-Destructive Testing
Radiography procedures shall be in accordance with requirements of ASME Boiler and
Pressure Vessel Code, Section VIII, Division I and ASME B31.3.

All NDT testing such as radiography, liquid penetrant inspection, magnetic particle
inspection etc. shall be in accordance with ASME V, ASME VIII, Div. 1 and ASME B31.3,
but also fulfil the requirement in EN 13480.

Personnel performing manual or semi-automatic NDT and interpretation of these results

shall be certified according to EN 473, EN13480-5: 2002 paragraph 8.4.3 (latest issue to
be used), or equivalent. These personnel shall have at least a level 1 certification.

Preparation of NDT procedures and execution of all NDT shall be carried out under the
responsibility of Level 3 personnel and shall be performed by personnel holding at least
Level 2 qualifications (acc EN 473 or equivalent).

The test report shall show the name of the examiner and his qualification level.

In case of ferritic steel piping and all bends - except unalloyed carbon steel - shall be
magnetic particle tested (MT).

All cold bends, in unalloyed carbon steel piping, with service temperatures equal or above
400°C or ASME ratings 900 lbs (PN100) and higher regardless of service temperature,
shall be subjected to magnetic particle examination.

In case of duplex and austenitic chromium-nickel alloy steel piping, all bends shall be
liquid penetrant tested (PT).

4.2 Inspection
Pipe bends manufactured by CONTRACTOR shall be thoroughly visual inspected for
cracks and surface imperfections.

Bends shall not be wrinkled, cracked, scratched, gouged die marked or buckled and shall
not be excessively scaled. Creased or corrugated bends are not permitted under any
circumstances.

If any doubt exists about the presence of cracks and laminations CONTRACTOR shall
apply a magnetic particle or liquid penetrate examination to show the absence of subject
surface defects.

All bends shall be checked against tolerances specified in this specification.

Any defects revealed by any of the examinations performed shall be reworked and
retested.

All items indicating irremediable defects, excessive repairs, improper fabrication or

showing no accordance with the requirements of this specification shall be subject to
rejection, even if the conditions are discovered after acceptance at CONTRACTOR’s shop
or revealed during field test. All costs related to the repairs and/or re-fabrication shall be
for CONTRACTOR’s account.

A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena.
 BES-CO-05-009-03 Rev: 3 / 17.11.2011 Sheet 10 / 10

For low alloy carbon steels and stainless steels, all materials and welds (longitudinally
welded pipes) shall be verified by means of Positive Material Identification (PMI) for Ni, Cr
and Mo content.

5 ATTACHMENTS
Attachment 1; Pipe bending – Parameters for design
Attachment 2; Pipe bending – Hot Bending Temperature and Post Bending Heat
Treatment table

A print of this document is only valid at the date of printing. For reference, use the actual version available on Borena.