QAP No. : P.

013828 D 11013 207

Date: 22.04.2019 Revision: 00

QUALITY ASSURANCE PLAN
HOT INDUCTION BEND Prepared : MK
Checked : RP /SG
Approved : NC / SKH

Min Scope of Inspection

Ref. Standard/
Sr. ACTIVITY number of Procedure/Acceptance criteria Document type
Specification Client / TPIA (By EPC
test Maf. Remarks
Consultant Contractor)

Hot induction bends shall be fabricated from carbon

steel line pipe (LSAW) of grade API 5L X70 PSL2 as
PTS P.011947 M 11097 per API 5L &
1 Material Each pipe Test Certificate P R R
016 Clause No. 4 Standard Specification for Longitudinal Seam
Submerged Arc Welded (LSAW) Linepipe, latest
revision of tender documents.

As per Owner's specification for line pipes and MTC,

Pipe receiveing Report shall be reviewed. Pipes with
2 Inspection of Bare Pipes PTS Linepipe Each pipe Inspection Report P RW W
positive wall thickness shall be used for fabrication of
bends.
the longitudinal seam shall be located in the plane of
PTS P.011947 M 11097 minimum deformation or neutral axis. Acceptable
3 Weld Position -- -- P RW W
016Clause No. 5.5 tolerance on location of the longitudinal weld seam shall
be ± 5°

4 Chemical Composition PTS Linepipe 1 Per heat Inspection Report P R R

Hot induction bends shall be fabricated from carbon
Tensile tests (YS, UTS, YS/UTS, %EL, RA, steel line pipe (LSAW) of grade API 5L X70 PSL2 as
5 Bend etc. as applicable ) PTS Linepipe 1 Per heat per API 5L & Inspection Report P RW W
(remark : marking transfer by TPIA) Standard Specification for Longitudinal Seam
Submerged Arc Welded (LSAW) Line pipe, latest
Charpy-test at as per Mat. Spec. (Impact
revision of tender documents.
6 Energy & Shear Area) PTS Linepipe 1 Per heat Inspection Report P RW W
(remark : marking transfer by TPIA)
7 Forming of Bends

As per Approved
7.1 Temperature Each bend As per Approved Manufacturing Procedure Manufacturer's Report P RW RW
Manufacturing Procedure

As per Approved To be frozen after Test bend result . Variation allowed

7.2 Speed Each bend Manufacturer's Report P RW RW
Manufacturing Procedure ±2.2mm/minute

As per Approved Heating coil configuration. Induction heating frequency

7.3 Heating Each bend Manufacturer's Report P RW RW
Manufacturing Procedure (tolerance ±20%)

LAYING AND ASSOCIATED WORKS FOR HMEL CONNECTIVITY PIPELINE PROJECT Page 1 of 6
 QAP No. : P.013828 D 11013 207

Date: 22.04.2019 Revision: 00

QUALITY ASSURANCE PLAN
HOT INDUCTION BEND Prepared : MK
Checked : RP /SG
Approved : NC / SKH

Min Scope of Inspection

Ref. Standard/
Sr. ACTIVITY number of Procedure/Acceptance criteria Document type
Specification Client / TPIA (By EPC
test Maf. Remarks
Consultant Contractor)

Instant cooling with air & water jet distributed

uniformly across the circumference to heated Parameter
As per Approved annular Zone
7.4 Cooling Each bend Manufacturer's Report P RW RW
Manufacturing Procedure • Coolant flow rate & pressure variation allowed is ±
10%.
• Coolant temperature variation allowed is ±15° C

± 1% of Nominal Bending Radius (where nominal

PTS P.011947 M 11097
7.5 Bend Radius Each bend radius shall be 6D). Manufacturer's Report P RW RW
016 Clause No. 5.13

As per Approved
7.6 Pyrometer Setting Each bend Temperature against speed record chart Manufacturer's Report P RW RW
Manufacturing Procedure

Post Bending Heat Treatment/ Stress Relieving

As per Approved Bends shall be supplied in as bend condition i.e without
8 (Loading & Unloading shall be witnessed by -- -- P RW W
Manufacturing Procedure post bend heat treatment
TPIA, Power failure log shall be maintained)

Cold forming or sizing without subsequent heat

As per Approved
9 Sizing (Internal Exterenal) Each bend treatment is permitted provided the induced permanent Log book P RW W
Manufacturing Procedure
strain does not exceed 1.5 %.

By 2 gauging plates of diameter equal to 95% of the

PTS P.011947 M 11097
10 Pig Gauge Trial Each bend nominal internal diameter of the pipe, connected rigidly Inspection Report H RW W
016 Clause No. 7.1.g
together at a distance equal to 500 mm.

11 NON DESTRUCTIVE TEST

Circumferentially 25 mm wide band at each end

As per Approved including end preparation shall be ends for lamination
11.1 Manual Ultrasonic Testing on Bend ends Each bend Inspection Report H RW W
Manufacturing Procedure and inclusion.
Acceptance as per line pipe specification.

The complete seam welds of all finished fabricated

As per Approved from welded pipes shall be 100% inspected by X-Ray R (X-Ray film
11.2 X-Ray of Weld seam Each bend Inspection Report H R (X-Ray film review)
Manufacturing Procedure method. review)
Acceptance as per line pipe specification.

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 QAP No. : P.013828 D 11013 207

Date: 22.04.2019 Revision: 00

QUALITY ASSURANCE PLAN
HOT INDUCTION BEND Prepared : MK
Checked : RP /SG
Approved : NC / SKH

Min Scope of Inspection

Ref. Standard/
Sr. ACTIVITY number of Procedure/Acceptance criteria Document type
Specification Client / TPIA (By EPC
test Maf. Remarks
Consultant Contractor)

- On the Extrados & Intrados to include the area

encompassed 30° either side of the line passing through
Magnetic Particle Testing on Bend Body & PTS P.011947 M 11097 the plane of the bend.
11.3 Each bend Inspection Report H RW W
Weld 016 Clause No. 7.1 f - All Bevel Ends
- Acceptance in accordance with WI for MPI / ASME
Sec. VIII Appendix 6.

PTS P.011947 M 11097

12 Repair Each bend No repair by welding is allowed on any part of bends. Repair Report H RW W
016 Clause No. 5.9

13 VISUAL & DIMENSION INSPECTION

PTS P.011947 M 11097

13.1 Bend Angle Each bend ± 0.50 from the specified angle Inspection Report H RW W
016 Clause No. 4.13

Minimum wall thickness shall be equal to

t min= 0.95 (tactual - ∆t)
where:
t actual = Actual wall thickness of pipe used for bending
∆t = 0.35 mm for a wall thickness < 10 mm 0.5 mm for
a wall
thickness ≥ 10 mm
PTS P.011947 M 11097
13.2 Wall Thickness 016 Clause No. 5.14 Each bend Inspection Report H RW W
Wall thickness shall be measured along both the inside
and outside radii of bend between and including the
start and stop points of the bend arc, at interval
approximately equal to pipe diameter or 300 mm
whichever is less. Wall thickness shall be measured
ultrasonically after bending at the same locations as
measured before bending. In addition the wall thickness
of the tangents shall also be measured.

At End: 3.0 mm max (Out-of-roundness over a length

PTS P.011947 M 11097 of 100 mm from the end)
13.3 Out of Roundness Each bend Inspection Report H RW W
016 Clause No. 5.15
At Body: 5.0 mm max

LAYING AND ASSOCIATED WORKS FOR HMEL CONNECTIVITY PIPELINE PROJECT Page 3 of 6
 QAP No. : P.013828 D 11013 207

Date: 22.04.2019 Revision: 00

QUALITY ASSURANCE PLAN
HOT INDUCTION BEND Prepared : MK
Checked : RP /SG
Approved : NC / SKH

Min Scope of Inspection

Ref. Standard/
Sr. ACTIVITY number of Procedure/Acceptance criteria Document type
Specification Client / TPIA (By EPC
test Maf. Remarks
Consultant Contractor)

± 1% of Nominal Bending Radius (where nominal

PTS P.011947 M 11097
13.4 Bend Radius Each bend radius shall be 6D). Inspection Report H RW W
016 Clause No. 5.13

Off-Plane of bends shall not exceed (θ/ 90) X 10 mm,

PTS P.011947 M 11097
13.5 Off-Plane (Plane of bends) Each bend where θ is the bend angle in degree or the tolerance limit Inspection Report H RW W
016 Clause No. 5.16
specified in MSS-SP-75, whichever is less.

PTS P.011947 M 11097 Each bend

13.6 Tangent Length 500 mm or 1pipe OD whichever is more. Inspection Report H RW W
016 Cl no 5.6 & Both ends

Bends shall be supplied with Plane ends.

Bevel Angle- 30. (+ 5°, -0°)
13.7 End Preparation -- Each bend Inspection Report H RW W
Root Face - 1.6 mm (± 0.8 mm)
Squareness- 1.6 mm Max

Both ends of all bends shall be suitably protected to

PTS P.011947 M 11097
13.8 End Protection Each bend avoid any damage during transit by means of metallic or -- P RW M
016 Clause No. 8.4
high impact plastic bevel protectors.
14 WORKMANSHIP
Bulges dent and flat areas shall not appear within
100mm front end of the bend. For the remaining part
these deviations from the original contour of the pipe
Each Bend ,
14.1 Bend Irregularities -- are permitted provided these deviations do not exceed Inspection Report H RW RW
If any
6.0 mm. The same shall not extend (in any direction)
over a distance of more than 25% of nominal diameter of
the bend.

External and internal reinforcements of longitudinal

14.2 End Flushing -- Each bend welds shall be ground flush for a distance of 100 mm Inspection Report H RW RW
from the ends of the Standard bend.
15 Manufacturing Procedure Qualification Test

On minimum Bend wall thickness at Pressure as per

15.1 Hydrostatic Test Test Bend Inspection Report H RW W
MTC of mother pipe with holding time of 15 Miniutes.

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 QAP No. : P.013828 D 11013 207

Date: 22.04.2019 Revision: 00

QUALITY ASSURANCE PLAN
HOT INDUCTION BEND Prepared : MK
Checked : RP /SG
Approved : NC / SKH

Min Scope of Inspection

Ref. Standard/
Sr. ACTIVITY number of Procedure/Acceptance criteria Document type
Specification Client / TPIA (By EPC
test Maf. Remarks
Consultant Contractor)

A) Tensile Test Inspection Report H RW W

As per Line pipe specification.
B) Crossweld Tensile Test Inspection Report H RW W

- at -20°C, for Base/Weld/HAZ - 35J/cm²(Avg.),

C) Charpy V-Notch
28J/cm²(Ind.).
- Base Material - 2 sets of 3 specimen per lot Inspection Report H RW W
15.2 PTS Test Bend - at 0°C, for Base - 100J/cm²(Avg.), 80J/cm²(Ind.),
- Weld & HAZ - 1 sets of 3 specimen per lot
- at 0°C, for Weld/HAZ - 40J/cm²(Avg.), 32J/cm²(Ind.)

D) Hardness Test Shall not exceed 300 HV 10 Inspection Report H RW W

E) Guided Bend Test As per API 5L Inspection Report H RW W
F) Metallographic Test Grain size shall be 7 or finer Inspection Report R RW W
G) Chemical Test As per Line pipe Specification Inspection Report H R R

Package shall be marked legibly with suitable marking

Each bend ink to indicate the following:
on the a) Order Number
PTS P.011947 M 11097
16 Marking inside b) Package Number -- P RW M
016 Clause No. 9.5
surface at c) Manufacturer’s Name
one end d) Size (Inches) and Wall thickness (mm)
e) Radius of bend (mm)

One coat of anti rust paint shall be applied on outer

PTS P.011947 M 11097
17 Coating Each Bend sarface of bends. Type of paint shall be as agreed upon -- P RW M
016 Clause No. 9.3
with the company.

PTS P.011947 M 11097 All documention shall be done as per specification MTC / Test Reports /
18 Documentation /Certification -- P R R
016Clause No. 10 P.011947 M 11097 016 Clause 10 IRN

LEGEND:
R : Review RW: Random Witness M: Monitor W:Witness
RT:Radiographic test
TPIA: Third Party Inspection Agency Control Authority : Owner/Engineer or their Authorised Inspection Agency
(*) Tests to be specified by the vendor for approval of Owner/Owenr's representative while submission of QAP.
Note: 1 The Above Testing and acceptance criteria are minimum requirements, however, manufacturer shall ensure and also comply to the additional requirements as per Technical specifications.

LAYING AND ASSOCIATED WORKS FOR HMEL CONNECTIVITY PIPELINE PROJECT Page 5 of 6
 QAP No. : P.013828 D 11013 207

Date: 22.04.2019 Revision: 00

QUALITY ASSURANCE PLAN
HOT INDUCTION BEND Prepared : MK
Checked : RP /SG
Approved : NC / SKH

Min Scope of Inspection

Ref. Standard/
Sr. ACTIVITY number of Procedure/Acceptance criteria Document type
Specification Client / TPIA (By EPC
test Maf. Remarks
Consultant Contractor)

2 The supplier shall submit their own detailed QAP prepared on the basis of above for approval of Owner/Owner's representative and TPIA.
3 Supplier shall submit Calibration certificates of all Instruments/Equipment to be used for Inspection and Testing with relevant procedures and updated standards for TPIA review/Approval.
4 TPIA will have to Inspect all manufacturing activities on each day or as specified above.
5 TPIA along with Owner/Owner's Representative shall review/approve all the documents related to QAP/Quality manuals/Drawings etc.submitted by supplier.
6 Manufacturer shall submit detailed production and inspection schedule.
7 Certification requirements to comply with EN 10204 - 3.2.to be issues by TPIA appointed by manufacturer.
8 Vendor has to submit detailed QAP for Bend Manufacturing Procedure Qualifiacation Production Test and Routine production seperately.
9 Heat treatment start and stop temperature chart shall be witnessed & signed by TPIA. Power failure log book / sheet shall be maintained
10 In case of conflict between purchase specification, contract documents and QAP, more stringent conditions shall be applicable.

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